Omar Suliman Zaroog

Taguchi design optimization of machining parameters on the CNC end milling process of halloysite nanotube with aluminium reinforced epoxy matrix (HNT/Al/Ep) hybrid composite

Abstract This paper introduces the application of Taguchi optimization methodology in optimizing the cutting parameters of end-milling process for machining the halloysite nanotubes (HNTs) with aluminium reinforced epoxy hybrid composite material under dry condition. The machining parameters which are chosen to be evaluated in this study are the depth of cut (d), cutting speed (S) and feed rate (f). While, the response factors to be measured are the surface roughness of the machined composite surface and the cutting force. An orthogonal array of the Taguchi method was set-up and used to analyse the effect of the milling parameters on the surface roughness and cutting force. The result from this study shows that the application of the Taguchi method can determine the best combination of machining parameters that can provide the optimal machining response conditions which are the lowest surface roughness and lowest cutting force value. For the best surface finish, A1–B3–C3 (d = 0.4 mm, S = 1500 rpm, f = 60 mmpm) is found to be the optimized combination of levels for all the three control factors from the analysis. Meanwhile, the optimized combination of levels for all the three control factors from the analysis which provides the lowest cutting force was found to be A2–B2–C2 (d = 0.6 mm, S = 1000 rpm, f = 40 mmpm).

Impact Resistance Performance of Kenaf Fibre Reinforced Concrete

This paper investigate the performance of kenaf fibre mesh reinforced concrete (KFMRC) with varied kenaf fibre mesh reinforcement content for the concrete slab of 300mm × 300mm size reinforced with different mesh diameter at constant spacing with varied slab thickness subjected to low impact projectile test. A self-fabricated drop-weight impact test rig with a steel ball weight of 1.236 kg drop at 0.40 m height has been used in this research work. The main variables for the study is to find the relationship of the impact resistance against the amount of mesh reinforcement and slab thickness. A linear relationship has been established between first and ultimate crack resistance against kenaf fiber diameters by the experiment. The linear relationship has also been established between the service (first) crack and ultimate crack resistance against the slab thickness. The threshold (highest) values for service crack and ultimate crack is 47.9 N/mm2 and 130.58 N/mm2 respectively observed and computed for 50 mm slab with 7 mm diameter mesh.

Impact Resistance Behaviour of Light Weight Rice Husk Concrete with Bamboo Reinforcement

This paper investigate the performance of lightweight rice husk concrete (LWRHC) with varied bamboo reinforcement content for the concrete slab of 300mm × 300mm size reinforced with varied slab thickness subjected to low impact projectile test. A self-fabricated drop-weight impact test rig with a steel ball weight of 1.236 kg drop at 0.65 m height has been used in this research work. The main variables for the study is to find the relationship of the impact resistance against the amount of bamboo reinforcement and slab thickness. A linear relationship has been established between first and ultimate crack resistance against bamboo diameters and slab thickness by the experiment. The linear relationship has also been established between the service (first) crack and ultimate crack resistance against the bamboo reinforcement diameter and slab thickness. 5% RH content exhibit better first and ultimate crack resistance up to 1.80 times and up to 1.72 times respectively against 10% RH content.

Residual Stress Relaxation and Surface Hardness of a 2024-t351 Aluminium Alloy

Abstract For design it is generally important to consider the residual stress relaxation. In the study for this contribution, 2024 T351 Aluminium alloy specimens were shot peened at three different shot peening intensities, followed by fatigue tests for two loads. Fatigue tests were divided into two stages. The residual stresses and micro-hardness were measured at initial and after each cyclic load for the three shot peening intensities and the two aforementioned sets of loads. The results showed that the residual stresses and micro-hardness of the specimens were decreased. Moreover, the relaxation depended on the fatigue load amplitude. Residual stress relaxation reached 54% of the initial residual stress while the micro-hardness relaxation reached 39% of the initial micro-hardness. Most of the residual stress relaxation occurred during the first cycle. The relaxation of the initial residual stress is severe when there is low shot peening intensity and high applied load, and the reduction of the micro-hardness is depending on the residual stress relaxation.

Relationship between Compressive Residual Stress Relaxation and Microhardness Reduction after Cyclic Loads on Shotpeened ASTM A516 Grade 70 Steel

Shot peening process is a cold performed function to enhance the mechanical properties which is widely used in many industries. This process introduces compressive residual stress which was proven to increase the fatigue life, geometry stability and corrosion resistance. However, the benefit of the residual stress is still unstable due to the relaxation during the operation. This paper will study on the trend of the relaxation of residual stress against cyclic loading as well as the change in the hardness. The material used in this study is carbon steel ASTM A516/ SA 516 Grade 70. Shot peening process with steel shots was applied to the samples to introduce compressive residual stress in the samples. Cyclic load was applied to samples after shot peening process with low load of 52Mpa (20% of Yield Strength) and high load of 208Mpa (80% of Yield Strength). The measurement of residual stress using X-Ray diffraction and hardness test was done on the samples to study the trend of the relaxation of residual stress and the change in hardness values. The result shows that more relaxation of residual stress occurs if the applied cyclic load is higher. The change of hardness trend is found non-sequenced in this study due to random coverage of shot peening.

Effect of Sandblasting Process on Mechanical Properties of ASTM A516 Grade 70 Steel

Sandbalsting is a method used for surface treatment and at the same time this process also improves the mechanical properties of the material. ASTM A516 Grade 70 is widely used in industrial sector as it provides very good mechanical properties in tough conditions. The main usage of this material is in moderate and low operating services. This paper focus on the effect of sandblasting process on ASTM A516 Grade 70 on improving the mechanical properties and fatigue life of this material. Samples have been blasted with sand grade SAE G-80. The focus of this paper is the result of the microhardness, tensile and fatigue test before and after the sandblasting process to study the improvement in mechanical properties as well as the fatigue life. The research was extent to the microstructure analysis using SEM to study the change in microstructure after sandblasting process and fatigue test. Result shows that the hardness increases with respect to blasting time. Result also shows 2.3% increment in tensile strength after sandblasting and there is significant increment in fatigue life. Result also shows that the sandblasting process decreases the grain size of the material. It was proven that the sandblasting process will increase the hardness and decrease the grain size of the material with respect to sandblasting time. At the same time, there is a significant improvement in mechanical properties and fatigue life by applying sandblasting process on the tested material.

Time dependent hardness and residual stress reduction in a shot-peened aluminum alloy 2024-T351

Abstract In common engineering practice, the shot-peened aluminum alloy 2024-T351 is often subjected to loading. After time passes, the residual stress induced by shot peening might relax leading to respective metal cracking and failure. For this study, samples were stored for two years and a comparison of the hardness and microstructure before and after two years storage was carreid out. The primary aim of this study was to determine the effect of time on hardness and microstructure of shot-peened sample, thus to calculate the residual stress relaxation depending on time parameter. The results showed that the hardness and the residual stress of the material reduced after two years. The average reduction of the hardness is 20 % and the residual stress reduction ranged at 47 %

The Effect of Thickness and Mesh Spacing on the Impact Resistance of Ferrocement Slab

This paper investigates the effect of the thickness and mesh spacing on the impact of ferrocement for the concrete slab of 300mm x 300mm size reinforced subjected to low impact projectile test. A self-fabricated drop-weight impact test rig with a steel ball weight of 1.236 kg drop at height of 150 mm, 350mm, and 500mm has been used in this research work. The objective of this research is to study the relationship of impact resistance of ferrocement against slab thickness and mesh reinforcement spacing. There is a good linear correlation between impact resistance of ferrocement against slab thickness and its mesh spacing. The first and ultimate crack impact resistance for 40 mm slab are 2.00 times and 1.84 times respectively against the 20 mm slab with the same mesh spacing. The first and ultimate crack impact resistance for 40 mm slab with 20 mm mesh spacing are 2.24 times and 3.70 times respectively against 50 mm mesh spacing with the same slab thickness. The mesh with higher content of reinforcement provides more contribution to the slab resistance as compare with the thickness.

Impact Resistance Behaviour of Banana Fiber Reinforced Slabs

This paper investigate the performance of banana fibre reinforced slabs 300mm × 300mm size with varied thickness subjected to low impact projectile test. A self-fabricated drop-weight impact test rig with a steel ball weight of 1.25 kg drop at 1 m height has been used in this research work. The main variables for the study is to find the relationship of the impact resistance against the BF contents and slab thickness. A linear relationship has been established between first and ultimate crack resistance against BF contents and slab thickness by the experiment. The linear relationship has also been established between the service (first) crack and ultimate crack resistance against the BF contents for a constant spacing for various banana fibre reinforced slab thickness. The increment in BF content has more effect on the first crack resistance than the ultimate crack resistance. The linear relationship has also been established between the service (first) crack and ultimate crack resistance against the various slab thickness. Overall 1.5% BF content with slab thickness of 40 mm exhibit better first and ultimate crack resistance up to 16 times and up to 17 times respectively against control slab (without BF)

The Effect of Mortar Grade and Thickness on the Impact Resistance of Ferrocement Slab

This paper investigate the effect of the thickness and mesh spacing on the impact of ferrocement for the concrete slab of 300mm × 300mm size reinforced subjected to low impact projectile test. A self-fabricated drop-weight impact test rig with a steel ball weight of 1.236 kg drop at height of 150 mm, 350mm, and 500mm has been used in this research work. The objective of this research is to study the relationship of impact resistance of ferrocement against the mortar grade and slab thickness. There is a good linear correlation between impact resistance of ferrocement against the mortar grade and the thickness of ferrocement slab. The first and ultimate crack impact resistance of mortar grade 43 (for 40 mm thick slab with mesh reinforcement) are 1.60 times and 1.53 times respectively against the mortar grade 17 slab (of same thickness with mesh reinforcement). The first and ultimate crack impact resistance for 40 mm thick slab (mortar grade 43 with mesh reinforcement) are 3.55 times and 4.49 times respectively against the 20 mm thick slab (of same mortar grade with mesh reinforcement).