Engineering and Technology Journal

The manufacturing industry heavily relies on deep drawing due to its remarkable ability to produce intricate symmetrical and asymmetrical shapes with accuracy and efficiency. This research aimed to create a deep drawing tool capable of producing a pentagonal cup measuring 41mm in diameter and 30mm in height. This was achieved by conducting numerical simulations and experimental tests using two different methods. The first method involved converting an 80mm diameter circular blank into a pentagonal cup through a drawing operation, while the second method involved redrawing a cylindrical cup into a pentagonal shape. The study also analyzed the impact of these methods on the drawing load, stress/strain distributions, and thickness distributions. The finite element method software, ANSYS 20, was employed for numerical simulations. The results showed that the first method had a significantly higher punch load than the second method. However, the pentagonal cup produced using the first method had a greater thickness reduction towards the cup wall curvature compared to those produced using the second method. Therefore, the second method was considered ideal for manufacturing a pentagonal cup because it resulted in a lower degree of thinning at the cup curvature and a more uniform distribution of thickness, stress, and strain. In conclusion, this research highlights the importance of deep drawing in the manufacturing industry and emphasizes the need to choose the appropriate forming method to achieve optimal results.

This study examines the effects of reinforcing PMMA acrylic resin with different Nanoparticle types: Silica (SiO2) (67.8nm), Titania (TiO2) (57.3nm), and Talc powders (TP) (80.1nm). This was done by using the ultrasonic mixing method for dispersing the nano-powder in the matrix and using them at three different proportions (0. 5, 1, and 1.5%) to improve the properties of PMMA composite materials for medical applications. The characteristic functional groups associated with Nano-ceramic particles and PMMA in the composite specimens were confirmed by FT-IR spectroscopy. Also, this research investigates some mechanical properties, including (tensile strength, compression strength, elastic modulus, hardness, and surface roughness), some physical properties (density and water absorption), and biological properties (antibacterial activity). The experimental work was performed on prepared specimens that may be employed for cartilaginous joint applications. The results revealed that all mechanical properties enhanced as the nanoparticles concentration was increased till it reached a maximum of 1.5%. The proportion of tensile strength and elastic modulus enhancement for 1.5% of (SiO2, TiO2, and Talc) is equal to (66.5%, 47.55% and 59.38%), (261.5, 315.38 and 388.4%), respectively. The compressive strength of composites increased by (49.3, 36.66, and 40.5%) for 1.5% (SiO2, TiO2, and Talc). The physical properties manifested that the increased content of reinforcing nanoparticles led to the raised water absorption, while the density values of PMMA nanocomposite decreased. Additionally, the biological results elucidated that the increased concentration led to the increased antibacterial activity of nanocomposite. Furthermore, the results concluded that adding 1.5% of SiO2 to a PMMA matrix improves the properties obtained.

Present-day industrial need high surface engineering quality since it deals with many material properties that are applied in modern applications. Autocatalytic plating of material surfaces enhances their mechanical and chemical properties. This study used electroless plating to create (NiP-TiC-SiC) nanocomposite coatings on alumina ceramic under various time and temperature deposition conditions to get the best performances of nanocomposite coatings. Different coating morphologies have been created, as seen in (FESEM) images. The (EDX) results show that the (NPs) were effectively integrated and that the main elements of the coating are nickel and phosphorus. The (XRD) pattern validates the existence of metallic nickel and the phases (NiP, Ni2P, and Ni3P). The hydrophobic properties of the (NiP-TiC-SiC) NCCS generated at (95℃ for 30 minutes) increased to (127.26°). The corrosion behavior was studied via the electrochemical method, which was done in the (3.5 wt%) NaCl at (25℃) and the results showed that the addition of (TiC) together with (SiC) nanoparticles shows a significant enhancement in the polarization resistance, the maximum polarization resistance value was obtained for (NiP-TiC-SiC) prepared at (60 minutes 85⁰C) and it is equal to (56.31419 kΩ.cm).

Complex geometry components can be produced using FDM-based additive manufacturing (AM). In this study, the compressive and tensile strength were investigated, considering variations in layer thickness (0.2, 0.25, and 0.3 mm), density (40%, 60%, and 80%), and infill pattern (tri-hexagon, zig-zag, and gyroid). The experiment was designed using the Taguchi technique and carried out on a commercial FDM 3D printer, involving nine specimens with different processing settings. The compression standard ASTM D695 and tension standard ASTM D638-02a were used for evaluation. The results indicated that infill density significantly impacted compressive and tensile strength, contributing to 65% and 60% of the variations. Based on the S/N ratio analysis, the optimal parameters for achieving high compressive and tensile strength were 80% infill density, a Gyroid infill pattern, and a layer thickness of 0.3 mm. With these settings, the maximum compression strength reached 45.23 MPa, and the maximum tensile strength was 44.03 MPa. Regression prediction modeling proved to be a powerful tool for predicting the compression and tensile strengths of PLA samples and optimizing the 3D printing process. Accurate and reliable predictions can be achieved by carefully selecting relevant features, preprocessing the data, training, and evaluating the model. These predictions can greatly assist in process design and manufacturing, with a percentage error of approximately 2.79% for compression strength and 3.35% for tensile strength.

In this study, two different types of polymers—Polyamide (PA) type (6) and Polyvinylpyrrolidone (PVP) type (K30), each added separately with a different weight fraction (0%, 2%, 4%, 6%) to Polymethylmethacrylate (PMMA) heat-cured resin as blend matrix—have been blended with heat-cured PMMA resin to develop the PMMA resin properties used for prosthesis complete denture. Sisal and coconut powder, two natural powders, were added separately to the polymer blend matrices with varying weight fractions (2%, 4%, 6%) to create composite specimens. Testing for density, water absorption, thermal conductivity, FTIR, and DSC were included in this study. The results show that adding reinforcing powders and polymer blends increases density, water absorption, and thermal conductivity, except PA powder, which lowers density values. The ultimate thermal conductivity and the most negligible density value were (0.289 W/m. k and 1.182 gm/cm3), respectively, for (PMMA-6% PA). The highest water absorption value was (1.007%)for (PMMA-2% PA-6% coconut). According to FTIR and DSC tests, the miscibility between blend constituents is good, and no additional materials are formed in specimens. These findings lead to the conclusion that one of the promising composite materials that can be used for improving some physical properties of a denture base, and they are, is composed of a blended matrix and natural materials reinforcement. The materials which are used in this search are an introduction to future research in the applications of dental and other applications

An effort has been made to improve the formability of (1006) AISI steel alloy sheets in deep drawing of square-shaped parts with flat bases through hydroforming. To achieve this goal, the manufacturing process involved the use of a newly developed experimental setup for sheet hydroforming with a die, which was created by the researchers. The key design features of this setup aimed for simplicity and modularity, allowing for potential utilization with oil pressures of up to 100 MPa. The obtained results were compared with those of conventional deep drawing. Both processes were examined under specific conditions to form identical cups up to the full depth of the provided die. Indicators of formability considered for comparison included the minimum possible corner radius, the maximum achievable depth without failure, and the maximum percentage of thinning at the corners. This study demonstrates that hydroforming can enhance the formability of low-carbon steel alloy sheets by improving the flow of metal into the die cavity and reducing thinning at critical regions, when compared to conventional deep drawing processes. In conventional deep drawing, only 70% of the full depth could be achieved before failure due to high local deformations resulting in significantly higher thinning at the corners.

The effect of calcium carbonate nanoparticles (CaCO3) on the mechanical and thermal properties of various polymers was investigated in this review. The results were compared to scholarly research published between 2002-2022. Different polymers were evaluated, including Polypropylene (PP), High-density polyethylene (HDPE), Polyvinyl chloride (PVC), Low-density polyethylene (LDPE), Polyethylene (PE), and natural rubber (NR). Through this work, the effect of CaCO3 nanoparticles that act as fillers in polymeric materials has been reviewed. It can be concluded that mechanical and thermal properties can be decreased, increased, or unchanged by increasing and decreasing the fillers to obtain optimal results. It is reasonable to conclude that most papers with nano-CaCO3 showed improvements in appreciable mechanical and thermal properties. In general, the term "surface modification of inorganic fillers" refers to the coating of the fillers with organic materials, which can be done by physical and chemical interactions between the modifiers and the fillers. The reviewed articles revealed that modification of CaCO3 nanoparticles with surface pre-treatment fillers caused enhancement of the mechanical properties of the polymeric matrix twice and prevented the agglomeration of particles in the matrix. Various mixing methods have been used, the most significant being a twin screw extruder, mechanical stirrer, and two-roll mill.

Aluminum alloy finds strong suitability in automotive, sporting, goods aerospace, and weight reduction industries. Its blend of lightweight attributes and robust strength make it well-suited for crafting lightweight components and structures while upholding overall strength and performance standards. In this research, AA6061-T4 alloy chips underwent a recycling process involving hot extrusion followed by Equal Channel Angular Pressing. The influence of various routes and varied numbers of cycles on microstructure and mechanical characteristics were examined utilizing a die featuring angles of 90° and 20°. Two routes, BC and C, were scrutinized, and the outcomes displayed significant enhancements in properties for the recycled chips after the hot extruded and ECAP techniques. After the fourth run, route BC exhibited a maximum Ultimate tensile strength of 265 MPa, peak yield strength of 149 MPa, and an elongation to failure of 46%. Meanwhile, the corresponding values for route C were 238 MPa, 136 MPa, and 41%, respectively. For two routes, BC and C, every pass led to elevated strength and hardness while also contributing to increased elongation to failure. The microstructures and mechanical characteristics of the ECAPed samples surpassed those of the extruded sample. The routes and pass numbers substantially impacted the microstructures and mechanical properties of the solid-state recycled AA6061-T4 alloy chip specimens. Scanning electron microscopy pictures showcased a honeybee-type pattern following ECAP through route BC, signifying the final stages of grain refinement. At the same time, the initial sample exhibited a fracture tendency with a mix of brittleness and ductility.

Electrical Discharge Machining (EDM) is a non-traditional technique widely used in various industries to remove material using electrical discharges. Finding a suitable electrode material that can resist high temperatures and efficiently remove material from the workpiece is a major difficulty in electrical discharge machining (EDM). Due to their exceptional electrical and thermal properties, composite electrodes of various metals have become extremely popular. In this study, a composite electrode (Cu-1%Cr-0.5%WC-1%Ag) manufactured using the stir casting technique will be utilized to evaluate the electrical discharge machining (EDM) process. The study compares the performance between conventional pure copper electrodes and composite electrode utilization of stainless steel 304L as the workpiece material. The results indicate composite electrodes can increase machining effectiveness and reduce electrode wear. Utilizing a current of 10 A, with a pulse on time of 50μs followed by a pulse off time of 50 μs, reduced the tool wear rate to 0.215 gm/min for the composite electrode. By comparison, it was observed that the copper electrodes displayed a tool wear rate of 0.514 gm/min under the same conditions. While the pure copper electrode had the lowest material removal rate (MRR) at 54.5588 mm3/min, the composite electrode had the greatest MRR at 56.8689 mm3/min. The surface Roughness (SR) of the composite electrode was 3.747μm; this value was lower than that of the pure copper electrode, 3.967μm. As a result, composite electrodes present a potentially viable substitute for traditional EDM electrodes.

Material Extrusion technology is one of the most widely used Additive Manufacturing processes due to its simplicity in use, affordable parts fabricating costs, product durability, and possibility for changing materials. Despite having many advantages, parts manufactured through this technique fall short in strength criteria. The present paper focuses on predicting and optimizing three critical printing parameters in additive manufacturing: printing temperature, extrusion width, and number of shells. A neural network model was built to predict the tensile and compressive strengths and optimize the process parameters for maximum strength. The full factorial design experiments found that higher strength is achieved at higher temperatures, extrusion width, and number of shells. Based on the Analysis of Variance (ANOVA), the most influential parameter on tensile strength was printing temperature with (44.2%). in the other hand, the extrusion width contributed more than others to compressive strength (51.3%). Comparisons between the experimental and the predicted values were illustrated.The mean error between the experimental and neural network models was (0.42%) for tensile strength and (0.45%) for compression strength, with a correlation coefficient equal to (0.996) and (0.992) for the two responses, respectively. The current proposed study demonstrates good agreements between the predicted model values and the experiment outcomes of tensile and compressive strengths.

Metal Matrix Composite (MCC) reveals considerably better properties, such as low density, high tensile strength, hardness, and good resistance to wear compared with every alloy or other metal. The current study concentrated upon the assessment of the properties of aluminum matrix composites (AMCs) synthesis with the Al-7075 as a matrix and the MSGNPs that sieved to (35 nm) at different weight fractions percentages as reinforcements using stir-casting method and compared with Al7075/B4C-WC nanocomposites. These experiments aim to select the appropriate type and percentage of reinforcement particles for producing Al-7075 composites with the best mechanical properties. The mechanical properties, as well as the metallurgical features for analyzing the microstructure and the distribution of (MSGNP, SiC-WC) into the composite alloy specimens, have been studied utilizing the mechanical tests and the Optical Microscopy (OM), Scanning Electron Microscope (SEM), Energy Dispersive Spectroscopy (EDS), and X-Ray Diffraction (XRD) SEM pictures. By reviewing the mechanical test results, they manifested that the value of the composite's ultimate strength was enhanced with the additive concentration of nanoglass. The maximum tensile strength was obtained for the sample comprising 4% MSGNP—the composite with 6 wt.% B4C and WC have the highest hardness value, which means the increase of the added composite material beyond 10% will decrease the hardness. The X-ray diffraction (XRD) examination results illustrate the various phases of the two-theta value-generated diffraction patterns for the Al-7075/MSGNP and Al-7075/B4C-WC workpieces materials. These examinations show that the matrix of Al and the clear glass are the two major composite constituents and contain B4C, WC, and aluminum matrix, which are consistent with what was shown by the optical microstructure of the composite. The Al-7075 microstructure analysis also demonstrated a virtuous metallic bonding between the particles of Al and the uniformly dispersed and transparent glass particles at the optimal addition of 8wt%. Such enhancement was ascribed to the reinforcement's sufficiency and the uniform dispersion of MSGNP. Therefore, the addition of 8 wt.% was chosen in the present work.

The industrial development and growth in population activity caused an annual increase in solid wastes over the past decades. The emissions of CO2 from the cement industry are the main source of air pollution. Recycling wastes as cementitious materials conserve the ecosystem in different aspects, e.g., reduction of CO2 footprint. Consequently, the pozzolanic activity of two solid wastes abundantly available in Iraq, steel slag (SS) and waste glass (WG), were evaluated. This study aimed to replace them with ordinary Portland cement. This will achieve a sustainable, eco-efficient, and environmentally friendly construction industry. The Chemical analysis of the wastes by XRF and XRD suggests a possible cementitious capability owing to the amorphous nature of WG and the presence of C3S and C2S in SS. Accordingly, due to international standards, cubic mortars were produced by replacing cement with SS at 50% and WG at 50% and 20%. The effects of such replacements on the compressive strength of mortars were evaluated by comparison with that of the control mortars. WG increases workability and results in a higher strength index (72.8%) than that of SS (48.7%) at similar replacement levels (50%). Subsequently, SS and WG replaced coarse aggregates (CA) and cement, respectively, in concrete. The results revealed positive effects of SS on compressive strength in contrast to WG influence. The compressive strength of concrete cured for 91d increased by about 20% compared to the control sample upon incorporation of 50% SS without any WG.

This study makes experimental evaluations of the corrosion and tip tests of CP-Ti joint (commercial pure Ti) implant alloys coated with YSZ nanoceramic. A Taguchi design of experiments (DOE) strategy was used to create a thin adhesive covering utilizing dip coating and electrophoretic deposition techniques. An L9-type orthogonal Taguchi array determined how dip coating and electrophoretic deposition factors, such as temperature, voltage, YSZ concentration, time, and the degree of pulverizing the Ti alloy substrate, affected the deposition yield. The Ti alloys were coated using the optimal settings for the dip coating and electrophoretic deposition procedures as previously described, utilizing the output data from the thickness and adhesion experiments used to optimize the conditions of dip coating and electrophoretic deposition. The optimal conditions for electrophoretic deposition were 60 volts, 7 minutes, 15% concentration, and 400 grit of grinding. The optimal dip coating conditions were 60°C temperature, 10 seconds, 1% concentration, and 250 grit size of Grinding. High-resolution scanning electron microscopy (FE-SEM) images of the coated alloys were employed for the examination. The microstructure and thickness of the coated surfaces were further examined using optical microscopy and atomic force microscopy (AFM). The corrosion resistance of the best-coated Ti alloys was examined using electrochemical techniques such as polarizing (Tafel) and cyclic polarization in simulated bodily fluid (SBF). Using a tip tester, the coatings' adhesive strength was evaluated. The coated CP-Ti alloys were contrasted using the following corrosion-resistant values: Both coating alloys enhanced corrosion resistance in Ringer's solution at 37°C. However, the coated CP-Ti alloy by electrophoretic deposition corroded less quickly than the CP-Ti alloy by dip coating (3.031×10-3 vs 1.042×10-3 respectively).

Hybrid Electrochemical Discharge Machining (ECDM) streamlines the manufacturing process for challenging materials. Tungsten carbide (WC) is widely recognized as a formidable material due to its exceptional hardness and its ability to maintain hardness even at elevated temperatures. This study has conducted a comprehensive investigation of the multi-response optimization of ECDM process parameters to enhance the machining of tungsten carbides, utilizing Grey Relation Analysis (GRA) and Artificial Neural Network (ANN) methods. This optimization's primary objective is to achieve the maximum Material Removal Rate (MRR) and machining depth. The study involved a systematically designed experiment based on the Taguchi design method. Scanning Electron Microscopy (SEM) analysis reveals shallow craters, minimal microcracks, and small melt re-deposits on the machined surfaces, elucidating the smooth surface achieved after ECD machining. The average surface roughness achieved in this study, utilizing Electrochemical Discharge Machining (ECDM) for tungsten, measured at 0.9275 μm. Optimal parameters were determined, including a current of 80 A, a stand-off distance of 0.1 mm, a 30 mm gap, and an electrolyte composed of KCl + KOH for machining tungsten carbide. The results of the Analysis of Variance (ANOVA) indicate that electrolyte concentration has the most significant impact on machining depth and material removal rate (50.55%), followed by the current value (31.32%). Additionally, the ANN results aligned closely with those obtained through GRA. Compositional analysis of the surface using Energy-Dispersive X-ray Spectroscopy (EDS) mapping confirms the presence of oxides and carbon on the machined surface.

Fused deposition modeling (FDM) is an additive manufacturing (AM) technique frequently used to create prototypes and parts with intricate geometrical designs. It is gaining popularity since it enhances products by removing the need for expensive equipment. The materials used, the printing process, and the parameters influence the mechanical properties of printed objects. The quality and functionality of the parts are impacted by FDM process parameters. This study focused on the impact of six parameters on the mechanical and physical properties of samples printed using the FDM machine (Creality Ender-5 Pro). The infill density percentage, infill pattern, layer thickness, shell thickness, number of top/bottom layers, and the percentage of infill overlap have been taken as the process parameters. The compressive strength has been calculated using the ASTM D695 compression test. The results illustrated how printing parameters affected samples' mechanical and physical properties, which were proven by the ultimate compression stress UCS and the percentage of compression average deviation. The analysis of variance shows the significance of infill density (100%) for UCS, while layer thickness (0.15 mm) is significant for compression average percentage deviation. For instance, the increase in the infill density from 20% to 100% shows that the strength climbed from 4 MPa to 56.5 MPa. Similarly, reducing layer thickness from 0.3 mm to 0.15 mm results in a diminished dimensional accuracy deviation from 1.65% to 0.446%, approximately three times less than that of the specimen with a 0.3 mm layer thickness.

Sheet metal forming is one of the most commonly used manufacturing processes because millions of different parts are formed daily. In the single-point incremental forming process (SPIF), the change in the thickness of the sheet material is an essential parameter because it is an indicator of the occurrence of failure. In this context, this study investigates the effect of SPIF parameters on the thickness of the Al 2024 alloy used in producing the truncated pyramid. The process parameters were the sheet thicknesses of (1, 1.5, and 2) mm, the step depths of (0.2, 0.4, and 0.6) mm, and the wall angles of (40, 50, and 60) degrees. A full factorial design (L27) was used to design the experimental work, and a non-destructive test method was used to measure the thickness at multiple locations on the fabricated surfaces accurately. The SPIF process was performed on the CNC milling machine by the tool path (G-code) generated in the UGS-NX9 program. The data were statistically analyzed using analysis of variance (ANOVA) to determine the relationship between the SPIF parameters and the thickness changes. The results showed that the optimum value of the thinning ratio in the thickness was achieved with a thickness of 2 mm, a step depth of 0.6 mm, and a wall angle of 40°. In this regard, previous works found that a larger step size led to pronounced thickness reduction. However, this work investigated the minimum reduction in the thickness achieved at a large step size.

Lean Production is a continuous improvement philosophy derived from the Toyota Production System (TPS) aimed at improving the operational efficiency and performance of companies. Although the Lean philosophy has been widely applied in large enterprises, its implementation and adoption in small and medium-sized enterprises (SMEs) has remained relatively underexplored. In this paper, a fuzzy assessment model has been proposed that integrates Fuzzy Decision-Making Trial and Evaluation Laboratory (Fuzzy DEMATEL) and Fuzzy Technique for Order of Preference by Similarity to Ideal Solution (Fuzzy TOPSIS) to aim to investigate the level of implementation and adoption of the lean philosophy in SMEs through five lean dimensions, namely, management, process, supplier, customer, and employee. Fuzzy DEMATEL is used to identify the weight of influence of each lean dimension on SMEs leanness and identify the cause and effect lean dimensions, while Fuzzy TOPSIS is used to investigate and assess the level of adoption of lean philosophy related to these five dimensions in SMEs. The main contribution of this research lies in providing a comprehensive framework for; assessing the level of influence of lean dimensions on SMEs leanness which is an important issue in the improvement process and identifying the level of adoption of lean philosophy in SMEs. The proposed model has been applied in five Iraqi SMEs for producing healthy water and juice. The results show that although the management, employee, and process have the highest weights of influence on SMEs leanness, management, and employee are cause lean dimensions that have a high influence on improving the effect dimensions, process, and customer. The level of adoption of lean philosophy of the assessed SMEs related to the five lean dimensions is in the mid-level so this refers to acceptable implementation of lean philosophy.

ISMF is a potential manufacturing technology that uses progressive deformation to create complicated shapes. ISMF produces sheet metal consecutively using targeted tool movement. This innovative method increases component precision, material waste reduction, and design flexibility. A tool is moved along a set path over a flat metal sheet while twisting forces are applied to get the needed shape. SPIF could be used in the medical equipment, aerospace, automotive, and building industries, but it is only profitable in certain situations because it is slower than other sheet-forming methods. SPIF-based die-less making makes it easier to shape. To make cone-shaped structures with SPIF, the spindle speed (1000, 1500, and 2000 RPM), feed rate (200, 400, and 600 mm/min), tool width (8, 10, and 12 mm), and step-down (0.2, 0.4, and 0.6 mm) at the specimen interface were all changed. For aluminum alloy AA 5010, the maximum thinning (mm) and formability (%) were the important mechanical qualities. The L9 orthogonal array was used for a complete look at these qualities. Making high-quality cones using a computer numerically controlled machine was the aim of this research. (CNC) machine. The important factors affecting engineering and forming quality were studied using the Taguchi and analysis of variance methods. The most influential factor on maximum thinning was the rotational speed followed by the feeding, which is inversely proportional to it. In contrast, the most effective factor on the formability is the feeding followed by the rotational speed, which is directly proportional to it. It was discovered that a spindle speed of 1500 revolutions per minute (RPM), a feed rate of 200 millimeters per minute (mm/min), a tool diameter of 10 millimeters (mm), and a step down of 0.4 millimeters provide the least amount of maximum thinning (mm) and formability (percent).