scholarly journals Influence Mechanism and Optimization Analysis of Technological Parameters for the Composite Prepreg Tape Winding Process

Polymers ◽  
2020 ◽  
Vol 12 (8) ◽  
pp. 1843
Author(s):  
Bo Deng ◽  
Yaoyao Shi ◽  
Tao Yu ◽  
Pan Zhao
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Composite Structures ◽  
Heating Temperature ◽  
Continuous Distribution ◽  
Optimization Analysis ◽  
Parameter Combination ◽  
Influence Mechanism ◽  
Revolving Body

Composite prepreg tape winding technology has proven to be an effective method for manufacturing revolving body composite structures in aerospace field. Process parameters including heating temperature, tape tension and roller pressure have an important impact on the winding products’ mechanical property such as tensile strength. The aim of this study is to investigate the influence mechanism and optimization analysis of parameters for the composite prepreg tape winding process. Firstly, the sensitivity analysis for single parameter had be employed to reveal the influence mechanism of each winding parameter change on tensile strength. Secondly, iso-surfaces analysis for parameter range had be applied to describe the distribution law of parameter with continuous distribution characteristics. Then the coupling analysis for process parameters was carried out employing response surface methodology. The analysis results showed that tape tension has the most significant effect on the winding products’ tensile strength. And the outstanding parameter combination with the heating temperature of 72 °C, tape tension of 307 N and roller pressure of 1263 N was provided by response surface design software via desirability function method. The validation experiments showed that the optimal parameter combination has a positive guiding significance for improving the quality of winding products.

Resistance Welding Process Development and Optimization for Recycled High-Density Polyethylene (HDPE)

2015 ◽  
Author(s):  
Peter F. Baumann ◽  
Lucas Sendrowski
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
High Density Polyethylene ◽  
Heating Temperature ◽  
Base Material ◽  
Heating Time ◽  
High Density ◽  
Hot Plate ◽  
Initial Testing ◽  
Hot Plate Welding

Large recycled high-density polyethylene (HDPE) structural members, difficult to manufacture by extrusion processes, have been created by the hot plate welding of simple plastic lumber sections. Hot plate welding generates better joint strength than any other welding method currently employed in plastic manufacturing. However, to achieve the desired temperature of the thick plate to melt the polymer uniformly, the process needs a high amount of heat energy requiring furnace (or resistance) heating of a considerable mass. A new method which could combine the heating element and a thin plate into one source could be more efficient in terms of heat loss and thus energy used. The premise of this investigation is to replace the hot plate with a very thin piece of high resistance nickel-chromium alloy ribbon to localize the application of heat within a plastic weld joint in order to reduce energy loss and its associated costs. This resistance ribbon method uses electrical current to reach an adequate temperature to allow for the welding of the HDPE plastic. The ribbon is only slightly larger than the welding surface and very thin to reduce the loss of excess heat through unused surface area and thick sides. The purpose of this project was to weld recycled high-density polyethylene (HDPE) using resistance welding and to match the tensile strength results considered acceptable in industry for hot plate welding, that is, equal to or greater than 80% of the base material strength. Information obtained through literature review and previous investigations in our laboratories established welding (heating) temperature and time as testing factors. Designed experimentation considered these factors in optimizing the process to maximize the weld tensile strength. A wide-ranging full-factorial experimental design using many levels was created for the initial testing plan. Tensile strengths obtained after welding under the various condition combinations of weld temperature and time revealed a region of higher strength values in the response surface. After the wide-range initial testing, the two control parameters, heating temperature and heating time, were ultimately set up in a focused Face Centered Cubic (FCC) Response Surface Method (RSM) testing design and the tensile strength response was then analyzed using statistical software. The results obtained indicated a strong correlation between heating time and heating temperature with strength. All welded samples in the final testing set exhibited tensile strength of over 90% base material, meeting the goal requirements. A full quadratic equation relationship for tensile strength as a function of welding time and temperature was developed and the maximum tensile strength was achieved when using 280°C for 60 seconds.

scholarly journals The Optimum Process Parameter of Dissimilar Metal AA6061 – AISI304 Continuous Drive Friction Welding

2020 ◽  
Vol 55 (2) ◽  
Author(s):  
Totok Suwanda ◽  
Rudy Soenoko ◽  
Yudy Surya Irawan ◽  
Moch. Agus Choiron
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Friction Welding ◽  
Welding Parameters ◽  
Optimum Process ◽  
Dissimilar Metals ◽  
Maximum Tensile Strength ◽  
Friction Pressure ◽  
Welding Processes

This article explains the use of the response surface method to produce the optimum tensile strength for the joining of dissimilar metals with the continuous drive friction welding method. The joining of dissimilar metals is one of the biggest challenges in providing industrial applications. Continuous drive friction welding has been extensively used as one of the important solid-state welding processes. In this study, the optimization of the friction welding process parameters is established to achieve the maximum tensile strength in AA6061 and AISI304 dissimilar joints via the response surface methodology. The effect of continuous drive friction welding parameters, which are friction pressure, friction time, upset pressure, and upset time, are investigated using response surface analysis. The design matrix factors are set as 27 experiments based on Box-Behnken. The 3D surface and the contour is plotted for this model to accomplish the tensile strength optimization. The optimization model of the tensile strength was verified by conducting experiments on the optimum values of the parameters based on the experimental data results. It can be denoted that the optimum process parameters settings were friction pressure = 25 MPa, friction time = 6 seconds, upset pressure = 140 MPa, and upset time = 8 seconds, which would result in a maximum tensile strength of 228.57 MPa.

scholarly journals Optimization of process parameters of friction stir welded AA 5083-O aluminum alloy using Response Surface Methodology

2015 ◽  
Vol 63 (4) ◽  
pp. 851-855 ◽  
Author(s):  
S. Jannet ◽  
P. Koshy Mathews ◽  
R. Raja
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Ultimate Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
Welding Speed ◽  
Rotational Speed ◽  
Strength Analysis ◽  
Aluminum Compound ◽  
Friction Stir

Abstract A methodology was exhibited to create the experimental model for assessing the Ultimate Tensile Strength of AA 5083-O aluminum compound which is broadly utilized as a part of boat building industry by Friction Stir Welding (FSW). FSW process parameters, such as: tool rotational speed, welding speed, and axial force were optimized for better results. FSW was completed considering three-component 3-level Box Behnekn Design. Response surface Methodology (RSM) was implemented to obtain the relationship between the FSW process parameters and ultimate Tensile Strength. Analysis of Variance (ANOVA) procedure was utilized to check the aptness of the created model. The FSW process parameters were additionally streamlined utilizing Response Surface Methodology (RSM) to augment tensile strength. The joint welded at a rotational speed of 1100 rpm, a welding speed of 75 mm/min and a pivotal energy of 2.5 t displays higher tensile strength compared with different joints in comparison with other joints.

scholarly journals Prediction of Tensile Strength of 3D Printed Bronze PLA Part Using Response Surface Modelling

F1000Research ◽  
2021 ◽  
Vol 10 ◽  
pp. 1030
Author(s):  
Chockalingam Palanisamy ◽  
Sugendran Nagarajan
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
Layer Thickness ◽  
Tensile Property ◽  
Process Parameters ◽  
Surface Model ◽  
Tensile Test Specimen ◽  
Input Parameters ◽  
3D Printed ◽  
Tensile Experiment

Background - 3D printing is a dynamic process with many process parameters influencing the product, including the type of the material; it is often difficult to understand the combined influence of these parameters.   Purpose - The tensile strength of 3D printed parts is important for the functionality of components. The effects of process parameters on tensile strength must therefore be examined. The objective of this study is to develop a response surface model (RSM) to predict the final quality of a 3D printed bronze part from a different set of input parameters.   Methods - The tensile test specimen was built in a Makerbot 3D printer with bronze polylactic acid (PLA) material. The three controllable input parameters were; thickness of layers, number of shells, and infill density. The three levels of layer thickness were 0.1mm, 0.2mm and 0.3mm. The number of shells was 2, 3 and 4. The infill densities were 20%, 30% and 40%. A tensile experiment tested the strength of the specimens. RSM is a statistical approach for modelling and analyzing how different variables affect the response of interest, and for optimizing it.   Results - The result obtained shows that the specimen with a high layer thickness of 0.3mm and infill density of 40% is the best among all the other parameters. Finally, the regression equation produced was used for random values of layer thickness, the number of shells, and infill density, to see whether the values obtained from the tests fall into the range of experimental data.   Conclusion - Infill density and layer thickness are the two criteria that significantly influence the tensile property. The number of shells has the least influence on the tensile property. However, the best tensile strength is the part printed with higher infill density, a greater number of shells, and higher layer thickness.

Application of Response Surface Methodology to Optimize Quenching Process Parameters of 17Cr2Ni2Mo Steel

2011 ◽  
Vol 411 ◽  
pp. 508-513
Author(s):  
Chun Jing Liu ◽  
Dun Bing Tang ◽  
Hua He
Keyword(s):  
Tensile Strength ◽  
Response Surface ◽  
Process Parameters ◽  
High Performance ◽  
Holding Time ◽  
Austenitizing Temperature ◽  
Operating Variables ◽  
Gear Steel ◽  
Quenching Process ◽  
Fast Development

With fast development of output, light-weighting and high performance of automobile, 17Cr2Ni2Mo steel, as an important vehicle-used gear steel, has to improve properties to fulfill the development. The performance of 17Cr2Ni2Mo steel is affected by quenching process parameters. In order to investigate the effect of austenitizing temperature and holding time on the quenching hardness and tensile strength, the central composite design (CCD) and response surface method (RSM) are applied to optimize the operating variables viz. austenitizing temperature and holding time. Multi-objective optimization developed for the two responses (quenching hardness and tensile strength) indicates the optimum conditions to be 920.46°C of austenitizing temperature and 0 h of holding time, while the values of quenching hardness, tensile strength are not less than 43.47 HRC and 1616.42 MPa. The gear has advantages with mechanical strength and abrasion resistance energy when 17Cr2Ni2Mo steel is produced using the optimum parameters.

scholarly journals Prediction of Optimum Weld Tensile Strength Using Response Surface Methodology

2021 ◽  
Vol 6 (3) ◽  
pp. 81-84
Author(s):  
C. E. Etin-Osa ◽  
L. M. Ebhota
Keyword(s):  
Tensile Strength ◽  
Response Surface Methodology ◽  
Mild Steel ◽  
Tensile Test ◽  
Response Surface ◽  
Process Parameters ◽  
Flow Rate ◽  
Gas Flow ◽  
Experimental Result ◽  
Gas Flow Rate

Metals are often subjected to various types of stresses, usually under tensile stress, quick failure of material can be encouraged especially when poor combinations of process parameters are employed in joining of the material. Tensile strength is regarded as the maximum stress that a material can sustain under tension. The aim of this study is to predict the weld tensile strength of tungsten inert gas (TIG) mild steel welds using Response Surface Methodology (RSM), with the purpose of achieving optimum results. The input parameters considered were current, voltage, and gas flow rate. The TIG welding process was used to join two pieces of mild steel plates, after which tensile test was conducted on the specimen. The experimental result was analyzed using the RSM. Weld Tensile test of 596.218MPa with a desirability value of 95.70% was observed to be the best, resulting from the optimized process parameters of current of 120.00 Amp, voltage of 20.00 volt and gas flow rate of 12.00 L/min.

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