In recent years Gas Metal Arc Welding (GMAW) technology has expanded its functionalities in vario... more In recent years Gas Metal Arc Welding (GMAW) technology has expanded its functionalities in various areas which have further motivated its usage in several emerging manufacturing industries. There are several issues and challenges associated with this technology, especially in dissimilar metal welding (DMW). One of the predominant challenges is selecting appropriate welding parameters which influence the efficiency of this technology. To explore several modern advancements in this expertise, this paper has done an exclusive survey on various standards of GMAW and its variants for selecting suitable parameters for welding dissimilar nonferrous metals. This review summarizes various experimental and numerical results along with related illustrations to highlight the feasibility of welding dissimilar nonferrous metals using traditional GMAW and investigations on advanced GMAW processes such as cold metal transfer (CMT) and pulsed GMAW (P-GMAW). Simulation and modeling of nonferrous DMW...
2020 Advances in Science and Engineering Technology International Conferences (ASET)
Use of aluminum components has increased during the last decade due to the light weight requireme... more Use of aluminum components has increased during the last decade due to the light weight requirements. With the intention to improve the strength, retaining the desirable properties of aluminium, particularly its lightness and corrosion resistance, many alloys have been developed. A390 is such an aluminum alloy, which is light weight and having good wear properties. A composite is a multiphase material and having better properties. A390 alloys and silicon carbide particulates were used to fabricate particulate reinforced aluminium metal matrix composites. Squeeze casting is a fabrication technique where solidification of liquid metal is promoted under applied hydrostatic pressure. In this work, A390- Silicon carbide composites of different weight fraction of silicon carbide were fabricated by squeeze casting and gravity casting through stir casting route. Squeeze castings were done at 50 MPa and 100 MPa squeeze pressures. Specimens of the composites were prepared and characterized through microstructural and wear analysis, tensile and hardness tests. The test results obtained for squeeze casting and gravity casting composites were compared and the effect of squeeze pressure was studied.
2022 14th International Conference on Computer Research and Development (ICCRD), 2022
Distortion is one of the predominant challenges concerning the quality and efficiency of a welded... more Distortion is one of the predominant challenges concerning the quality and efficiency of a welded joint. It has been shown that distortion is significantly influenced by the weld sequence. In this context, Weld Sequence Optimization (WSO) is ideal for avoiding bottlenecks in the design stage, repairing, and overall capital expenditure in a manufacturing industry. Generally, the weld procedures are determined through experienced welders and in some cases, a plan of experimentation may be necessary. The current research is based on practical testing, computational simulations, and Artificial Neural Networks (ANN). Experiments are carried out using Gas Metal Arc Welding and the Finite Element Model (FEM) has been performed by MSc Simufact Welding software as well as it is validated by high-intensity experiments. The objective of the present research is to create and evaluate a useful method providing real-time predictions of distortion as well as WSO using hot-encoding. The generated optimal sequence from Neural network (NN) models is evaluated by performing the confirmatory test. The findings revealed that the proposed ANN method can significantly predict and optimize weld sequences for reducing distortion.
This study aims to perform comparative analyses in modeling serrated chip morphologies using trad... more This study aims to perform comparative analyses in modeling serrated chip morphologies using traditional finite element and smoothed particles hydrodynamics methods. Although finite element models are being employed in predicting machining performance variables for the last two decades, many drawbacks and limitations exist with the current finite element models. The problems like excessive mesh distortions, high numerical cost of adaptive meshing techniques, and need of geometric chip separation criteria hinder its practical implementation in metal cutting industries. In this study, a mesh free method, namely, smoothed particles hydrodynamics, is implemented for modeling serrated chip morphology while machining AISI H13 hardened tool steel. The smoothed particles hydrodynamics models are compared with the traditional finite element models, and it has been found that the smoothed particles hydrodynamics models have good capabilities in handling large distortions and do not need any g...
A control methodology based on a nonlinear control algorithm and optimization technique is presen... more A control methodology based on a nonlinear control algorithm and optimization technique is presented in this paper. A controller called “the robust integral of the sign of the error” (in short, RISE) is applied to control chaotic systems. The optimum RISE controller parameters are obtained via genetic algorithm optimization techniques. RISE control methodology is implemented on two chaotic systems, namely, the Duffing-Holms and Van der Pol systems. Numerical simulations showed the good performance of the optimized RISE controller in tracking task and its ability to ensure robustness with respect to bounded external disturbances.
Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used i... more Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with...
Currently, most companies that conduct business in both domestic and global markets are facing gr... more Currently, most companies that conduct business in both domestic and global markets are facing growing international competition and recognize the importance of reducing manufacturing lead time, for example, companies in the machining industry. In general, machining can be performed manually, automatically or by Computer Numerical Control (CNC). The optimization of tool routing path operation in machining can lead to significant reduction in non-productive machining time. This paper focuses on the development of the Ant Colony Optimization (ACO) algorithm for use in searching for the optimal tool routing path and the relationship with its control parameter values. The simulation of a machining operation is conducted in MATLAB with incremental positioning axis movement based on the Travelling Salesman Problem (TSP). The results indicate that the relationship between the travelled distance of the ant and the ant's control parameters are significant in increasing the hole drilling ...
In this study we present an approach of hypothetical reasoning for action decision of Automated G... more In this study we present an approach of hypothetical reasoning for action decision of Automated Guided Vehicle (AGV) in Autonomous Decentralized in Flexible Manufacturing Systems (AD-FMS). The AD-FMS is characterized as being online, in realtime mode and of a short-term nature that responds to frequent changing of the production order. The decentralized control in AD-FMS enables to solve dynamically some typical task of production system without using a fixed centralized control system. We adopt a hypothetical reasoning approach that will decide the conceivable next action from the competition hypothesis. Simulation results show that the efficiency of AGV in AD-FMS increased.
Currently, most companies that act on both domestic and global markets experience a growing inter... more Currently, most companies that act on both domestic and global markets experience a growing international competition and recognize the importance to reduce manufacturing lead time. One of the industries that has to face this globalization challenges is the machining industry. In general, machining can be done manually or automatically, better known as Computer Numerical Control (CNC). It is reported that tool movement and tool switching time in machining process take most of the total time in a manufacturing process. Optimization of tool path operation can lead to significant reduction in non-productive machining time. This paper focuses on the development of Ant Colony Optimization (ACO) model by using Matlab® software. In searching for the optimize tool path for machining operation in incremental positioning axis movement is based on the Travelling Salesman Problem (TSP) principles. Results shows that with the increasing of the hole drilling operation and also its trail evaporati...
In machining operations, repositioning the cutting tool requires airtime motion of the cutting to... more In machining operations, repositioning the cutting tool requires airtime motion of the cutting tool. Minimizing the airtime motion during pocket machining in mass production is important for increasing the efficiencies of the machining process. This paper presents an optimization of airtime motion during contour parallel offset machining by minimizing the tool retraction based on Ant Colony Optimization (ACO). Optimization of the tool retraction is modelled as an application of the Travelling Salesman Problem (TSP). To evaluate the performance of ACO, its result for the length of the non-productive tool path is compared with that of conventional computer-aided manufacturing (CAM) software. It is found that the ACO method produces a non-productive tool path length that is approximately 60% shorter than the conventional method.
This study aims to utilize Tagushi design in quality improvement for construction industry. A com... more This study aims to utilize Tagushi design in quality improvement for construction industry. A comparison between full factorial and Tagushi design is conducted experimentally. The experiment investigates the effect of four major factors and their interactions on concrete compression strength. The factors are; percentage of recycled aggregates, percentage of dune sand, amount of steel fiber in concrete mixture and test time. Two types of design of experiments (DOE) have been done to test different concrete mixtures by using different combinations of the mentioned four factors. The collected data has been studied using full factorial and Taguchi “Robust” designs. Also, Minitab software results have been obtained and analyzed. Based on full factorial design, it was found that all factors were significant, whereas the interactions between factors were significant only for two-way interaction. The three-way and four-way interactions were insignificant. On the other hand, Taguchi analysis...
This paper is concerned with the optimization of the tool path in a production line consisting of... more This paper is concerned with the optimization of the tool path in a production line consisting of two machine tools. Existing computer – numerical control (CNC) time estimation methods are based either for a single machine or a single operation. As current methods don’t illustrate the necessity of the multiple operations with more than one machine, this paper presents a new method for CNC machining time estimation which predicts the optimal tool path sequence with minimal time for a 2M production line. The optimized sequence is determined by employing the most reliable hybrid method i.e., Genetic Algorithm (GA). Attention was focusing on the hole making operations where a hole may need multiple cutting tools to get the process finished. Each of the machines can do certain set of operations. So the non-productive time between two machines should be minimized and it is obtained by this intelligent sequence optimizer. This proposed technique is developed on a modified travel salesman p...
In this work, squeeze stir casting was used to produce recycled Aluminum Metal Matrix Composites ... more In this work, squeeze stir casting was used to produce recycled Aluminum Metal Matrix Composites (MMC’s) plates. Scrap Aluminum Alloy Wheel (SAAW) was used as a matrix and alumina as reinforcement. The produced recycled MMC plate was subjected to abrasive and sliding wear using a Two-body abrasion tester and Pin-on-Disc tester with a load of 20 N. To improve the wear resistance of the recycled MMC, graphite (1% to 4%) and SiC (3% and 6%) were added to alumina, and the results were compared. The results showed that the addition of graphite and SiC to alumina decreased the wear rate and frictional forces compared to using alumina alone as reinforcements. Also, wear rates and frictional forces further reduced by increasing the percentage of graphite to 4%, whereas increasing the SiC content increased the wear. Scanning Electron Microscopy (SEM) analysis and microstructure analysis was conducted on these samples. These results confirmed that graphite and alumina exhibited better bonding...
In recent years Gas Metal Arc Welding (GMAW) technology has expanded its functionalities in vario... more In recent years Gas Metal Arc Welding (GMAW) technology has expanded its functionalities in various areas which have further motivated its usage in several emerging manufacturing industries. There are several issues and challenges associated with this technology, especially in dissimilar metal welding (DMW). One of the predominant challenges is selecting appropriate welding parameters which influence the efficiency of this technology. To explore several modern advancements in this expertise, this paper has done an exclusive survey on various standards of GMAW and its variants for selecting suitable parameters for welding dissimilar nonferrous metals. This review summarizes various experimental and numerical results along with related illustrations to highlight the feasibility of welding dissimilar nonferrous metals using traditional GMAW and investigations on advanced GMAW processes such as cold metal transfer (CMT) and pulsed GMAW (P-GMAW). Simulation and modeling of nonferrous DMW...
2020 Advances in Science and Engineering Technology International Conferences (ASET)
Use of aluminum components has increased during the last decade due to the light weight requireme... more Use of aluminum components has increased during the last decade due to the light weight requirements. With the intention to improve the strength, retaining the desirable properties of aluminium, particularly its lightness and corrosion resistance, many alloys have been developed. A390 is such an aluminum alloy, which is light weight and having good wear properties. A composite is a multiphase material and having better properties. A390 alloys and silicon carbide particulates were used to fabricate particulate reinforced aluminium metal matrix composites. Squeeze casting is a fabrication technique where solidification of liquid metal is promoted under applied hydrostatic pressure. In this work, A390- Silicon carbide composites of different weight fraction of silicon carbide were fabricated by squeeze casting and gravity casting through stir casting route. Squeeze castings were done at 50 MPa and 100 MPa squeeze pressures. Specimens of the composites were prepared and characterized through microstructural and wear analysis, tensile and hardness tests. The test results obtained for squeeze casting and gravity casting composites were compared and the effect of squeeze pressure was studied.
2022 14th International Conference on Computer Research and Development (ICCRD), 2022
Distortion is one of the predominant challenges concerning the quality and efficiency of a welded... more Distortion is one of the predominant challenges concerning the quality and efficiency of a welded joint. It has been shown that distortion is significantly influenced by the weld sequence. In this context, Weld Sequence Optimization (WSO) is ideal for avoiding bottlenecks in the design stage, repairing, and overall capital expenditure in a manufacturing industry. Generally, the weld procedures are determined through experienced welders and in some cases, a plan of experimentation may be necessary. The current research is based on practical testing, computational simulations, and Artificial Neural Networks (ANN). Experiments are carried out using Gas Metal Arc Welding and the Finite Element Model (FEM) has been performed by MSc Simufact Welding software as well as it is validated by high-intensity experiments. The objective of the present research is to create and evaluate a useful method providing real-time predictions of distortion as well as WSO using hot-encoding. The generated optimal sequence from Neural network (NN) models is evaluated by performing the confirmatory test. The findings revealed that the proposed ANN method can significantly predict and optimize weld sequences for reducing distortion.
This study aims to perform comparative analyses in modeling serrated chip morphologies using trad... more This study aims to perform comparative analyses in modeling serrated chip morphologies using traditional finite element and smoothed particles hydrodynamics methods. Although finite element models are being employed in predicting machining performance variables for the last two decades, many drawbacks and limitations exist with the current finite element models. The problems like excessive mesh distortions, high numerical cost of adaptive meshing techniques, and need of geometric chip separation criteria hinder its practical implementation in metal cutting industries. In this study, a mesh free method, namely, smoothed particles hydrodynamics, is implemented for modeling serrated chip morphology while machining AISI H13 hardened tool steel. The smoothed particles hydrodynamics models are compared with the traditional finite element models, and it has been found that the smoothed particles hydrodynamics models have good capabilities in handling large distortions and do not need any g...
A control methodology based on a nonlinear control algorithm and optimization technique is presen... more A control methodology based on a nonlinear control algorithm and optimization technique is presented in this paper. A controller called “the robust integral of the sign of the error” (in short, RISE) is applied to control chaotic systems. The optimum RISE controller parameters are obtained via genetic algorithm optimization techniques. RISE control methodology is implemented on two chaotic systems, namely, the Duffing-Holms and Van der Pol systems. Numerical simulations showed the good performance of the optimized RISE controller in tracking task and its ability to ensure robustness with respect to bounded external disturbances.
Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used i... more Electric discharge machining (EDM) is one of the most efficient manufacturing technologies used in highly accurate processing of all electrically conductive materials irrespective of their mechanical properties. It is a non-contact thermal energy process applied to a wide range of applications, such as in the aerospace, automotive, tools, molds and dies, and surgical implements, especially for the hard-to-cut materials with simple or complex shapes and geometries. Applications to molds, tools, and dies are among the large-scale initial applications of this process. Machining these items is especially difficult as they are made of hard-to-machine materials, they have very complex shapes of high accuracy, and their surface characteristics are sensitive to machining conditions. The review of this kind with an emphasis on tool and die materials is extremely useful to relevant professions, practitioners, and researchers. This review provides an overview of the studies related to EDM with...
Currently, most companies that conduct business in both domestic and global markets are facing gr... more Currently, most companies that conduct business in both domestic and global markets are facing growing international competition and recognize the importance of reducing manufacturing lead time, for example, companies in the machining industry. In general, machining can be performed manually, automatically or by Computer Numerical Control (CNC). The optimization of tool routing path operation in machining can lead to significant reduction in non-productive machining time. This paper focuses on the development of the Ant Colony Optimization (ACO) algorithm for use in searching for the optimal tool routing path and the relationship with its control parameter values. The simulation of a machining operation is conducted in MATLAB with incremental positioning axis movement based on the Travelling Salesman Problem (TSP). The results indicate that the relationship between the travelled distance of the ant and the ant's control parameters are significant in increasing the hole drilling ...
In this study we present an approach of hypothetical reasoning for action decision of Automated G... more In this study we present an approach of hypothetical reasoning for action decision of Automated Guided Vehicle (AGV) in Autonomous Decentralized in Flexible Manufacturing Systems (AD-FMS). The AD-FMS is characterized as being online, in realtime mode and of a short-term nature that responds to frequent changing of the production order. The decentralized control in AD-FMS enables to solve dynamically some typical task of production system without using a fixed centralized control system. We adopt a hypothetical reasoning approach that will decide the conceivable next action from the competition hypothesis. Simulation results show that the efficiency of AGV in AD-FMS increased.
Currently, most companies that act on both domestic and global markets experience a growing inter... more Currently, most companies that act on both domestic and global markets experience a growing international competition and recognize the importance to reduce manufacturing lead time. One of the industries that has to face this globalization challenges is the machining industry. In general, machining can be done manually or automatically, better known as Computer Numerical Control (CNC). It is reported that tool movement and tool switching time in machining process take most of the total time in a manufacturing process. Optimization of tool path operation can lead to significant reduction in non-productive machining time. This paper focuses on the development of Ant Colony Optimization (ACO) model by using Matlab® software. In searching for the optimize tool path for machining operation in incremental positioning axis movement is based on the Travelling Salesman Problem (TSP) principles. Results shows that with the increasing of the hole drilling operation and also its trail evaporati...
In machining operations, repositioning the cutting tool requires airtime motion of the cutting to... more In machining operations, repositioning the cutting tool requires airtime motion of the cutting tool. Minimizing the airtime motion during pocket machining in mass production is important for increasing the efficiencies of the machining process. This paper presents an optimization of airtime motion during contour parallel offset machining by minimizing the tool retraction based on Ant Colony Optimization (ACO). Optimization of the tool retraction is modelled as an application of the Travelling Salesman Problem (TSP). To evaluate the performance of ACO, its result for the length of the non-productive tool path is compared with that of conventional computer-aided manufacturing (CAM) software. It is found that the ACO method produces a non-productive tool path length that is approximately 60% shorter than the conventional method.
This study aims to utilize Tagushi design in quality improvement for construction industry. A com... more This study aims to utilize Tagushi design in quality improvement for construction industry. A comparison between full factorial and Tagushi design is conducted experimentally. The experiment investigates the effect of four major factors and their interactions on concrete compression strength. The factors are; percentage of recycled aggregates, percentage of dune sand, amount of steel fiber in concrete mixture and test time. Two types of design of experiments (DOE) have been done to test different concrete mixtures by using different combinations of the mentioned four factors. The collected data has been studied using full factorial and Taguchi “Robust” designs. Also, Minitab software results have been obtained and analyzed. Based on full factorial design, it was found that all factors were significant, whereas the interactions between factors were significant only for two-way interaction. The three-way and four-way interactions were insignificant. On the other hand, Taguchi analysis...
This paper is concerned with the optimization of the tool path in a production line consisting of... more This paper is concerned with the optimization of the tool path in a production line consisting of two machine tools. Existing computer – numerical control (CNC) time estimation methods are based either for a single machine or a single operation. As current methods don’t illustrate the necessity of the multiple operations with more than one machine, this paper presents a new method for CNC machining time estimation which predicts the optimal tool path sequence with minimal time for a 2M production line. The optimized sequence is determined by employing the most reliable hybrid method i.e., Genetic Algorithm (GA). Attention was focusing on the hole making operations where a hole may need multiple cutting tools to get the process finished. Each of the machines can do certain set of operations. So the non-productive time between two machines should be minimized and it is obtained by this intelligent sequence optimizer. This proposed technique is developed on a modified travel salesman p...
In this work, squeeze stir casting was used to produce recycled Aluminum Metal Matrix Composites ... more In this work, squeeze stir casting was used to produce recycled Aluminum Metal Matrix Composites (MMC’s) plates. Scrap Aluminum Alloy Wheel (SAAW) was used as a matrix and alumina as reinforcement. The produced recycled MMC plate was subjected to abrasive and sliding wear using a Two-body abrasion tester and Pin-on-Disc tester with a load of 20 N. To improve the wear resistance of the recycled MMC, graphite (1% to 4%) and SiC (3% and 6%) were added to alumina, and the results were compared. The results showed that the addition of graphite and SiC to alumina decreased the wear rate and frictional forces compared to using alumina alone as reinforcements. Also, wear rates and frictional forces further reduced by increasing the percentage of graphite to 4%, whereas increasing the SiC content increased the wear. Scanning Electron Microscopy (SEM) analysis and microstructure analysis was conducted on these samples. These results confirmed that graphite and alumina exhibited better bonding...
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