Journal of Materials and Manufacturing

Study on burr formation, tool wear and surface quality in machining Al6063

Aamer Sharif — 2022-12-22

Drilling plays significant role in machining process for assembly operations. High-quality holes are possible with appropriate tools machine setup and proper selection of drilling process parameters. The significant issues in drilling are burrs formation, surface quality and tool wear, which impacts the final product's quality. This study examines the influences of process parameters on burr formation, surface roughness and tool wear. The work piece material selected is Al6063 which is commonly used in construction was drilled using different feed rates and spindle speed. The result shows that surface roughness and burr formation improve with increased spindle speed and decreased feed rate. Adhesion wear is more significant near the nose of the tool and less at cutting edges. Analysis of variance investigated that spindle speed has a high impact on surface roughness with a percentage contribution of 63.56 % than feed rate of 33.62 %.

Effect of material type, cutout shape and temperature on stress and deformation analyses of thin plates

Savas Evran — 2022-12-22

In this numerical and statistical paper, the effect of material type, cutout shape and temperature on von Mises stress and total deformation analysis of plates was examined using numerical and statistical methods. Each plate was analyzed under clamped boundary conditions. The areas of the cutouts were taken equal. Numerical calculations were conducted by Taguchi L₈ orthogonal array with three control factors using finite element software ANSYS Workbench. Material type, cutout shape, and temperature of plates were selected as control factors. Effects and the optimum levels of control factors were identified using analysis of signal/noise ratio. Also, meaningful control factors were obtained using analysis of variance. According to results obtained from this study, stress and deformation of plates with cutouts in the form of circular shapes is smaller compared to plates with cutouts in the form of square shapes. Compared to magnesium alloy, aluminum alloy leads to an increase in stress and a decrease in deformation of plates due to temperature increase. In addition, the applied temperature increase provides an increase in the stress and deformation values of the plates. The strongest control factors on stress outcomes are found to be cutout shape with 79.09% effect, temperature with 9.76% effect, and material property with 5.78% effect, respectively. Significant control factors on deformation outputs are obtained as temperature with 56.87% effect, cutout shape with 32.46% effect, and material property with 8.86% effect, respectively. This numerical and statistical study can be used as a reference paper for experimental and numerical studies in the thermal field.

Jig design and manufacturing for adhesive thickness control in adhesive joints

Berkant Şentürk — 2022-12-22

Adhesives and adhesive bonding is a material group and joining technique with a long history. There are many parameters that affect performance in the bonded joints. Factors such as the type of adhesive, the force applied to the joints, the shape of the joint, the surface preparations, the material to have adhered, the working conditions, and the adhesive thickness change the characteristics of the process (adhesion). Researchers use different methods to keep or change the adhesive thickness. In this study, an apparatus was designed and manufactured, which allows for keeping the adhesive thickness constant during sample preparation by focusing on the adhesive thickness in single lap joints. As a result of the tests, it was determined that the adhesive thickness was 0.2 mm in the joints obtained using this apparatus.

Performance comparison of Genetic Algorithm and Artificial Bee Colony Algorithm in optimizing controller parameters of a flexible manipulator

Sezgin Eser — 2022-12-22

Optimization is about finding the most suitable solution among all feasible solutions. For this purpose, many metaheuristic algorithms have been developed. Genetic Algorithm (GA) and Artificial Bee Colony (ABC) Algorithm are two popular algorithms developed for this purpose. Metaheuristic algorithms are also used in the optimization of controller parameters for flexible manipulators. In this study, parameter optimization was performed with GA and ABC Algorithms for a flexible manipulator controller. For the first comparison, the optimizations are repeated with different number of cycles, and for the second comparison, the simulations are repeated with different search space boundaries. Obtained results were compared over transient responses, maximum end point oscillations and required maximum torque values.

Synthesis and characterization of spherical FeNi3 metallic nanoparticles based on sodium dodecyl sulfate

Ozlem Altintas Yildirim — 2022-12-22

In this work, the metallic FeNi₃ nanoparticles with spherical structure have been synthesized in the presence of sodium dodecyl sulfate (SDS) using the hydrothermal method at 180 °C for 2 hours. The structural and morphological of the FeNi₃ metallic nanoparticles were characterized by X-ray diffraction (XRD), Fourier transforms infrared spectra (FTIR), scanning electron microscopy (SEM), and energy dispersion spectrum (EDS). As a result of XRD, the obtained metallic nanoparticles were observed to be single-phase pure stoichiometric FeNi₃ metallic nanoparticles with a face-centered cubic crystal structure. In the FTIR analysis, the peak obtained at 478.3 cm^-1 was a characteristic Fe-Ni peak. The SEM-EDS images obtained in the microstructure analysis showed that the FeNi₃ metallic nanoparticles produced were 169.33 nm in size and had a spherical morphology. The hydrothermal method used in the study is known to be very effective in producing metallic nanoparticles. In addition, the use of sodium dodecyl sulfate as an anionic surfactant and the realization of the reaction in ethanol/water environments reveal the innovative aspect of the study.

J-V and C-V characteristic of CdS/CdTe solar cell modelled by SCAPS-1D program

Sami Dursun — 2022-12-22

In this spectacular work, we have theoretically modelled and experimentally produced a CdS/CdTe thin film heterojunction solar cell using some physical parameters of CdS thin film at 150 nm thickness and a 2.4 eV band gap. The photovoltaic (PV) characteristics of simulated solar cell PV have been determined based on a variety of variables. A spike-like conduction band offset has been formed between CdS and CdTe semiconductors. The PV performance has been negatively impacted (the variation of PV parameters for N_t variation in 10¹⁰-10¹⁸ cm^-3) by some increases in operating temperature, Auger electron recombination coefficient and interface defect density (Nt). It has been observed and interpreted that the efficiency of solar cell is increased as the donor defect density (N_D) in CdS thin film increases. However, as N_D is increases, the capacitance is slightly decreased, and the voltage built in (V_bi) is also slightly increased. However, the conversion efficiency of solar cell is unaffected by this reduction in capacitance.