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Article
Publication date: 20 August 2019

G. Yoganjaneyulu, Y. Phaneendra, V.V. Ravikumar and C. Sathiya Narayanan

The purpose of this paper is to investigate the void coalescence and corrosion behaviour of titanium Grade 4 sheets during single point incremental forming (SPIF) process with…

Abstract

Purpose

The purpose of this paper is to investigate the void coalescence and corrosion behaviour of titanium Grade 4 sheets during single point incremental forming (SPIF) process with various spindle rotational speeds. The development of corrosion pits in 3.5 (%) NaCl solution has also been studied during SPIF process.

Design/methodology/approach

In this current research work, the void coalescence analysis and corrosion behaviour of titanium Grade 4 specimens were studied. A potentio-dynamic polarization (PDP) study was conducted to investigate the corrosion behaviour of titanium Grade 4 processed samples with various spindle speeds in 3.5 (%) NaCl solution. The scanning electron microscope and transmission electron microscope analysis was carried out to study the fracture behaviour and corrosion morphology of processed samples.

Findings

The titanium Grade 4 sheets obtained better formability and corrosion resistance by increasing the CNC spindle rotational speeds. In fact that, the significant plastic deformation affects the corrosion rate with various spindle speeds were recorded.

Originality/value

The spindle rotational speeds and vertical step depths increases then the titanium Grade 4 sheets showed better formability, void coalescence and corrosion behaviour as the same is evidenced in forming limit diagram and PDP curves.

Details

Anti-Corrosion Methods and Materials, vol. 66 no. 6
Type: Research Article
ISSN: 0003-5599

Keywords

Article
Publication date: 29 August 2019

G. Yoganjaneyulu, V.V. Ravikumar and C. Sathiya Narayanan

The purpose of this paper is to investigate the strain distribution, stress-based fracture limit and corrosion behaviour of titanium Grade 2 sheets during single point incremental…

Abstract

Purpose

The purpose of this paper is to investigate the strain distribution, stress-based fracture limit and corrosion behaviour of titanium Grade 2 sheets during single point incremental forming (SPIF) process, with various computerized numerical control (CNC) spindle rotational speeds and step depths. The development of corrosion pits in 3.5 (%) NaCl solution has also been studied during the SPIF process.

Design/methodology/approach

A potentiodynamic polarization (PDP) study was performed to investigate the corrosion behaviour of titanium Grade 2 deformed samples, with various spindle rotational speeds in 3.5 (%) NaCl solution. The scanning electron microscope (SEM) and transmission electron microscope (TEM) analysis was carried out to study the fracture behaviour, dislocation densities and corrosion morphology of deformed samples.

Findings

The titanium Grade 2 sheets exhibited better strain distribution, fracture limit and corrosion resistance by increasing the CNC spindle rotational speeds, tool diameters and vertical step depths (VSD). It was recorded that varying the spindle speed affected plastic deformation which in turn affected corrosion rate.

Research limitations/implications

In this study, poor corrosion rate was observed for the as-received condition, and better corrosion rate was achieved at maximum speed of 600 rpm and 0.6 mm of VSD in the deformed sheet. This indicates that corrosion rate improved with increase in the plastic deformation. The EDS analysis report of corroded surface revealed the composition to be mainly of titanium and oxides.

Practical implications

This study discusses the strain distribution, stress-based fracture limit and corrosion behaviour by using titanium Grade 2 sheets during SPIF process.

Social implications

This study is useful in the field of automobile and industrial applications.

Originality/value

With an increase in the spindle rotational speeds and VSD, the titanium Grade 2 sheets showed better strain distribution, fracture limit and corrosion behaviour; the same is evidenced in fracture limit curve and PDP curves.

Article
Publication date: 6 November 2017

Rajkumar D, Ranjithkumar P, M.P. Jenarthanan and Sathiya Narayanan C

The purpose of this paper is to develop a statistical model for delamination and thrust forcing during drilling of carbon-fibre reinforced polymer (CFRP) composites using response…

Abstract

Purpose

The purpose of this paper is to develop a statistical model for delamination and thrust forcing during drilling of carbon-fibre reinforced polymer (CFRP) composites using response surface methodology (RSM) to determine the input parameters (drill speed, drill diameter and feed rate) that influences the output response (delamination and thrust force) in the machining of CFRP composite using solid carbide drill cutter.

Design/methodology/approach

Three factors, three levels central composite face centred (CCFC) design, is used to conduct the experiments on CFRP by carbide drill. The whole quality evaluation (delamination) was done by video measuring system to measure the width of maximum damage of the machined CFRP composite. The thrust forces during drilling are measured using digital multi-component cutting force (Make: IEICOS, Model: 652) dynamometer. The “Design Expert 7.0” is used to analyse the data collected graphically. An analysis of variance is carried out to validate the model and for determining the most significant parameter.

Findings

The response surface model is used to predict the input factors influencing the delamination and thrust force on the drilled surfaces of CFRP composite at different cutting conditions with the chosen range of 95 per cent confidence intervals. The analysis on the influences of the entire individual input machining parameters on the delamination and thrust force has been carried out using RSM. This investigation revealed that the drill diameter is the eminent factor which affects the responses.

Originality/value

In all, 0.3, 0.4 and 0.5 mm holes have been successfully made on CFRP using vertical machining center, whereas the previous researchers have not drilled hole size less than 1 mm in CFRP using vertical machining center.

Details

Pigment & Resin Technology, vol. 46 no. 6
Type: Research Article
ISSN: 0369-9420

Keywords

Article
Publication date: 25 October 2020

Munmun Bhaumik and Kalipada Maity

In this research, electro discharge machining (EDM) of Ti-5Al-2.5Sn titanium alloy is performed taking gap voltage, pulse on time, peak current and duty cycle as process…

Abstract

Purpose

In this research, electro discharge machining (EDM) of Ti-5Al-2.5Sn titanium alloy is performed taking gap voltage, pulse on time, peak current and duty cycle as process parameters. The purpose of this paper is to find out the optimal process parameters setting for getting higher machining efficiency.

Design/methodology/approach

For experimental design, a face-centered central composite design (FCCCD)-based response surface methodology (RSM) is used. Multi-objective optimization like grey relational analysis (GRA) is adopted to achieve the higher machining efficiency by means of lower radial overcut (ROC), surface roughness (Ra), tool wear rate (TWR) and higher material removal rate (MRR). For the statistical study, analysis of variance (ANOVA) has been carried out.

Findings

The result shows that gap voltage, peak current and pulse on time are the most efficient parameters for the responses. An optimal parameter setting has been obtained for achieving higher machining efficiency. For validation of the study, confirmation experiment has been performed at optimal parameters setting.

Originality/value

Optimum parameter level for higher machining performance of Ti-5Al-2.5Sn Titanium alloy has been achieved machined by copper electrode during EDM operation.

Details

World Journal of Engineering, vol. 18 no. 1
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 16 April 2020

Alagappan K M, Vijayaraghavan S, Jenarthanan M P and Giridharan R

The purpose of this paper is to identify the ideal process parameters to be set for the drilling of hybrid fibre-reinforced polymer (FRP) (kenaf and banana) composite using…

Abstract

Purpose

The purpose of this paper is to identify the ideal process parameters to be set for the drilling of hybrid fibre-reinforced polymer (FRP) (kenaf and banana) composite using High-Speed Steel drill bits (5, 10, 15 mm) coated with tungsten carbide by means of statistical reproduction of the delamination factor and machining force using Taguchi–Grey Relational Analysis.

Design/methodology/approach

The contemplated process parameters are Feed, Speed and Drill Diameter. The trials were carried out by taking advantage of the L-27 factorial design by Taguchi. Three factors, the three level Taguchi Orthogonal Array design in Grey Relational Analysis was used to carry out the trial study. Video Measuring System was used to identify the damage around the drill region. “Minitab 18” was used to examine the data collected by taking advantage of the various statistical and graphical tools available. Examination of variance is used to legitimize the model in identifying the most notable parameter.

Findings

The optimised set of input parameters were found out successfully which are as follows: Feed Rate: 450 mm/min, Cutting Speed: 3,000 rpm and Drill Diameter of 5 mm. When these values are fed in as input the optimised output is being obtained. From ANOVA analysis, it is apparent that the Speed (contribution of 92.6%) is the most influencing parameter on the delamination factor and machining force of the FRP material.

Originality/value

Optimization of process parameters on drilling of natural fibres reinforced in epoxy resin matrices using Taguchi–Grey Relational Analysis has not been previously explored.

Details

Multidiscipline Modeling in Materials and Structures, vol. 16 no. 5
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 26 July 2021

Zhong Li, Xiaojia Yang, Jing Liu, Zhiyong Liu, Xiaogang Li and Yan Tingting

The purpose of this paper is to determine the failure reasons and failure mechanism of the commercially pure titanium air conditioning condenser.

Abstract

Purpose

The purpose of this paper is to determine the failure reasons and failure mechanism of the commercially pure titanium air conditioning condenser.

Design/methodology/approach

In this paper, chemical analysis, metallographic observation, visual examination and scanning electron microscope examination, corrosion products analysis and working conditions analysis were adopted for determining the reasons for the failure of the condenser.

Findings

The results indicated that TA2 titanium pipe perforation failure is caused by the synergistic effect of crevice corrosion and deposit corrosion. The corrosion processes can be divided into three steps.

Originality/value

This research is an originality study on the failure case of a commercially pure titanium air conditioning condenser. This study makes up for the shortage of titanium alloy failure cases and also gives the result of the failure reason and failure mechanism for titanium, which has an engineering significance.

Details

Anti-Corrosion Methods and Materials, vol. 68 no. 4
Type: Research Article
ISSN: 0003-5599

Keywords

Article
Publication date: 10 October 2023

Pawan Bishnoi and Pankaj Chandna

This paper aims to optimize the single-point incremental forming process variables for realizing higher formability in Inconel 625 components and to plot the forming limit diagram…

Abstract

Purpose

This paper aims to optimize the single-point incremental forming process variables for realizing higher formability in Inconel 625 components and to plot the forming limit diagram for Inconel 625 aviation-grade superalloy.

Design/methodology/approach

The formability of Inconel 625 components has been measured in terms of major strain, minor strain and minimum sheet thickness. Response surface methodology with desirability function analysis has been used to achieve maximum formability. The finite element analysis has been conducted at optimal parametric setting.

Findings

The derived forming limit diagram proves that the maximum forming limit for Inconel 625 is 57.5° at the optimal parametric setting, achieved with desirability of 0.995. The outcomes of finite element analysis conducted at optimal parametric setting show excellent agreement with confirmation experiment results.

Practical implications

Inconel 625 superalloy is frequently used in aircraft and other high-performance applications for its superior strength.

Originality/value

It has been suggested that to enhance formability, higher tool rotation speed, minimum step-size, larger tooltip diameter and higher wall angle must be used. Wall angle is the governing parameter among all the parameters.

Details

Aircraft Engineering and Aerospace Technology, vol. 96 no. 1
Type: Research Article
ISSN: 1748-8842

Keywords

Article
Publication date: 5 August 2014

K. Balamurugan, A.P. Abhilash, P. Sathiya and A. Naveen Sait

Friction welding (FW) is a solid state joining process. Super austenitic stainless steel is the preferable material for high corrosion resistance requirements. These steels are…

Abstract

Purpose

Friction welding (FW) is a solid state joining process. Super austenitic stainless steel is the preferable material for high corrosion resistance requirements. These steels are relatively cheaper than austenitic stainless steel and it is expensive than nickel base super alloys for such applications. The purpose of this paper is to deal with the optimization of the FW parameters of super austenitic stainless steel using artificial neural network (ANN) simulation and particle swarm optimization (PSO).

Design/methodology/approach

The FW experiments were conducted based on Taguchi L-18 orthogonal array. In FW, rotational speed, friction pressure, upsetting pressure and burn-off length are the important parameters which determine the strength of the weld joints. The FW trials were carried out on a FW machine and the welding time was recorded for each welding trial from the computerized control unit of the welding machine. The left partially deformed zone (L.PDZ) and right partially deformed zone (R.PDZ) were identified from the macrostructure and their values are considered for the output variables. The tensile test was carried out, and the yield strength and tensile strength of the joints were determined and their fracture surfaces were analyzed through scanning electron microscope (SEM).

Findings

The tensile test was carried out, and the yield strength and tensile strength of the joints were determined and their fracture surfaces were analyzed through SEM. An ANN was designed to predict the weld time, L.PDZ, R.PDZ and tensile strength of the joints accurately with respect to the corresponding input parameters. Finally, the FW parameters were optimized using PSO technique.

Research limitations/implications

There is no limitations, difficult weld by fusion welding process material can easily weld by FW process.

Originality/value

The research work described in the paper is original.

Details

Multidiscipline Modeling in Materials and Structures, vol. 10 no. 2
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 18 April 2019

Isam Tareq Abdullah and Sabah Khammass Hussein

The purpose of this paper is to join a sheet of the AA7075 with the high-density polyethylene (HDPE) by a lap joint using friction spot processing and investigate the temperature…

Abstract

Purpose

The purpose of this paper is to join a sheet of the AA7075 with the high-density polyethylene (HDPE) by a lap joint using friction spot processing and investigate the temperature distribution of joint during this process using the finite element method (FEM).

Design/methodology/approach

A semi-conical hole was manufactured in the AA7075 specimen and a lap joint configuration was prepared with the HDPE specimen. A rotating tool was used to generate the required heat to melt the polymer by the friction with the AA7075 specimen. The applied tool force moved the molten polymer through the hole. Four parameters were used: lower diameter of hole, rotating speed, plunging depth and time. The results of shear test were analyzed using the Taguchi method. A FEM was presented to estimate the temperature distribution of joint during the process.

Findings

All specimens failed by shearing the polymer at the lap joint region without dislocation. The specimens of the smallest diameter exhibited the highest shear strength at the lap joint. The maximum ranges of temperature were recorded at the contact region between the rotating tool and the AA7075 specimen. The tool plunging depth recorded the highest effect on the generated heat compared with the rotating speed and plunging time.

Originality/value

For the first time, the AA7075 sheet was joined with the HDPE sheet by friction spot processing. The temperature distribution of this joint was simulated using the FEM.

Details

International Journal of Structural Integrity, vol. 10 no. 4
Type: Research Article
ISSN: 1757-9864

Keywords

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