Compliant polishing tools are utilized incomprehensibly as a part of vehicle and aviation businesses to clean complex surfaces and structures. The major advantages of using coated abrasive tools are that they are compliant and their geometry conforms to the surface of the workpiece. Though they have been used for finishing operations for a long time, not much work has been done to understand the effect of compliance on the distribution of forces in the contact area of such tools. Such understanding would help to reduce the trial and error operations involved and thereby reducing rework and cost.
The objectives of this study are as follows:
1) Study the effect of tool (rubber pad and abrasive cloth) compliance on contact pressure distribution and material removal of commonly used compliant polishing tools
2) The tool compliance is in turn studied by conducting material characterization; along with the geometry of the workpiece, other machining parameters are the key variables in this study
3) Design and analyze an active complaint finishing tool
The document discusses various hardness testing methods including indentation hardness tests like Brinell, Vickers and Rockwell as well as microhardness tests. It provides details on the procedure, equipment, and applications of each test. The Brinell test uses a 10mm steel or carbide ball indenter under a load of 500-3000kg. The Vickers test uses a diamond pyramid indenter under 1-120kg load. The Rockwell test uses steel ball or diamond cone indenters with minor and major loads. Microhardness tests can apply loads as low as 1g using Vickers or Knoop indenters to test thin materials. Durometers also measure hardness of plastics and rubbers using conical steel indent
Surface Quality Improvement Using Modified Tool Clamping In Boring OperationsIJRES Journal
Boring operations are challenging owing to limited process performance due to inherent tool overhang and resulting vibrations. The tool vibrations can be suppressed with insertion of suitable damping methodology. The present work adopts a method suitable for machine operators, where in insertion of packing sheets at the boring tool support has been suggested. Insertion of number of layers causes frictional phenomenon to dissipate the exciting energy thereby damping the vibrations. Substantial improvement of surface quality of the internally machined surfaces has been noticed in the experiments
Experimental Investigation and Analysis of Extrusion of Lead from Round Secti...IOSR Journals
Abstract : An experimental investigation has been done on the changes of die angle, area reduction in dies,
loading rate on the final extruded products, extrusion pressures of lead of circular cross sections of different
length. The proposed method is successfully adapted to the extrusion of the equilateral triangular section from
round billet through converging dies of different area reductions. Computation of extrusion pressure at various
area reductions and finite element analysis of different parameters (stress, strain, velocity) both in dry and wet
condition.
Keywords - Converging dies, Extrusion of the equilateral triangular section, Extrusion Pressure
Application of Roller Burnishing Process for Final Machining Of Cilindrical S...IOSR Journals
This document discusses the roller burnishing process for final machining of cylindrical surfaces. Roller burnishing is an economical process that improves surface roughness and induces compressive residual stresses in the surface layer through plastic deformation. It can achieve a roughness of less than 0.1 mm and hardness increases of up to 10 HRC. The process results in a smoothed surface with no chips or coolant waste. It can be performed on standard machine tools and provides advantages over other finishing processes such as reduced cycle times, cleaner production, and improved part integrity and fatigue resistance through compressive residual stresses.
This document discusses a study on the influence of particle size gradation on shear parameters for cohesionless soil. Laboratory direct shear tests were performed on sand samples with different particle size gradations (coarse, medium, fine mixes) and relative densities (30-90%). The results showed that the angle of internal friction increased with increasing particle size and relative density. Specifically, samples with coarser grains had internal friction angles ranging from 36-42 degrees, while finer grained samples ranged from 28-34 degrees. The shear strength parameters were thus found to depend on both the particle size gradation and relative density of the cohesionless soil samples.
Shear properties of composite materials and ASTM standardsKaustubh Garud
This document discusses different test methods for determining the shear properties of composite materials, including in-plane shear properties and interlaminar shear strength. It describes tests such as the shear test (ASTM D3518), off-axis test, Iosipescu shear test (ASTM D5379), and rail shear method (ASTM D4255) for measuring in-plane shear modulus and strength. It also covers the short-beam shear test (ASTM D2344) for evaluating interlaminar shear strength between laminates using three-point bending of a short beam specimen. Calculations for determining shear stress and strain from the test results are also presented.
The document discusses the ring compression test method for determining the coefficient of friction between a die and workpiece. It investigates the friction factors of aluminum rings under dry and lubricated conditions. The key findings are:
1) Lubrication reduces interface friction coefficients compared to dry conditions.
2) Friction coefficients decrease with reductions in ring height and outer radius but increase with increases in inner radius.
3) Molybdenum disulfide and zinc stearate provide the lowest friction, while dry conditions provide the highest, according to experimental, theoretical and analytical analyses.
This document outlines test methods for assessing the particle size and shape of aggregates used in concrete from an Indian Standard published in 1963. It includes procedures for sieve analysis to determine particle size distribution, and tests for materials finer than 75 microns, flakiness index, elongation index, and angularity number. The goal is to assist in evaluating the quality of aggregates used in concrete construction in India by testing relevant properties. Maximum sample weights and sieve sizes are provided for different tests.
The document discusses various hardness testing methods including indentation hardness tests like Brinell, Vickers and Rockwell as well as microhardness tests. It provides details on the procedure, equipment, and applications of each test. The Brinell test uses a 10mm steel or carbide ball indenter under a load of 500-3000kg. The Vickers test uses a diamond pyramid indenter under 1-120kg load. The Rockwell test uses steel ball or diamond cone indenters with minor and major loads. Microhardness tests can apply loads as low as 1g using Vickers or Knoop indenters to test thin materials. Durometers also measure hardness of plastics and rubbers using conical steel indent
Surface Quality Improvement Using Modified Tool Clamping In Boring OperationsIJRES Journal
Boring operations are challenging owing to limited process performance due to inherent tool overhang and resulting vibrations. The tool vibrations can be suppressed with insertion of suitable damping methodology. The present work adopts a method suitable for machine operators, where in insertion of packing sheets at the boring tool support has been suggested. Insertion of number of layers causes frictional phenomenon to dissipate the exciting energy thereby damping the vibrations. Substantial improvement of surface quality of the internally machined surfaces has been noticed in the experiments
Experimental Investigation and Analysis of Extrusion of Lead from Round Secti...IOSR Journals
Abstract : An experimental investigation has been done on the changes of die angle, area reduction in dies,
loading rate on the final extruded products, extrusion pressures of lead of circular cross sections of different
length. The proposed method is successfully adapted to the extrusion of the equilateral triangular section from
round billet through converging dies of different area reductions. Computation of extrusion pressure at various
area reductions and finite element analysis of different parameters (stress, strain, velocity) both in dry and wet
condition.
Keywords - Converging dies, Extrusion of the equilateral triangular section, Extrusion Pressure
Application of Roller Burnishing Process for Final Machining Of Cilindrical S...IOSR Journals
This document discusses the roller burnishing process for final machining of cylindrical surfaces. Roller burnishing is an economical process that improves surface roughness and induces compressive residual stresses in the surface layer through plastic deformation. It can achieve a roughness of less than 0.1 mm and hardness increases of up to 10 HRC. The process results in a smoothed surface with no chips or coolant waste. It can be performed on standard machine tools and provides advantages over other finishing processes such as reduced cycle times, cleaner production, and improved part integrity and fatigue resistance through compressive residual stresses.
This document discusses a study on the influence of particle size gradation on shear parameters for cohesionless soil. Laboratory direct shear tests were performed on sand samples with different particle size gradations (coarse, medium, fine mixes) and relative densities (30-90%). The results showed that the angle of internal friction increased with increasing particle size and relative density. Specifically, samples with coarser grains had internal friction angles ranging from 36-42 degrees, while finer grained samples ranged from 28-34 degrees. The shear strength parameters were thus found to depend on both the particle size gradation and relative density of the cohesionless soil samples.
Shear properties of composite materials and ASTM standardsKaustubh Garud
This document discusses different test methods for determining the shear properties of composite materials, including in-plane shear properties and interlaminar shear strength. It describes tests such as the shear test (ASTM D3518), off-axis test, Iosipescu shear test (ASTM D5379), and rail shear method (ASTM D4255) for measuring in-plane shear modulus and strength. It also covers the short-beam shear test (ASTM D2344) for evaluating interlaminar shear strength between laminates using three-point bending of a short beam specimen. Calculations for determining shear stress and strain from the test results are also presented.
The document discusses the ring compression test method for determining the coefficient of friction between a die and workpiece. It investigates the friction factors of aluminum rings under dry and lubricated conditions. The key findings are:
1) Lubrication reduces interface friction coefficients compared to dry conditions.
2) Friction coefficients decrease with reductions in ring height and outer radius but increase with increases in inner radius.
3) Molybdenum disulfide and zinc stearate provide the lowest friction, while dry conditions provide the highest, according to experimental, theoretical and analytical analyses.
This document outlines test methods for assessing the particle size and shape of aggregates used in concrete from an Indian Standard published in 1963. It includes procedures for sieve analysis to determine particle size distribution, and tests for materials finer than 75 microns, flakiness index, elongation index, and angularity number. The goal is to assist in evaluating the quality of aggregates used in concrete construction in India by testing relevant properties. Maximum sample weights and sieve sizes are provided for different tests.
DEFORMATIONAL BEHAVIOR OF THE FLAT SLIDING LAYER OF THE SPHERICAL BEARINGIAEME Publication
Analysis of the friction properties of modified PTFE is performed, the functions
describing the change in the friction coefficient depending on the pressure level with a
maximum error from the experiments results less than 1% are proposed in the work.
The influence of friction on the deformation behavior of the flat sliding layer of the
spherical bearing on a periodicity cell model is considered. The geometrical
configuration of the flat sliding layer with truncated spherical hole for the lubricant is
considered. The periodicity cell includes one hole for lubrication. A series of
numerical experiments for three options for the thickness of the sliding layer from 4 to
8 mm with a recess for the lubricant, in the unfavorable case the absence of lubricant
is performed. The pattern of geometric configuration hole change with increasing
pressure level is established. It was found that an increase of the antifriction layer
thickness leads to a less significant deformation of the sliding layer thickness and the
spherical hole. The sliding layer with a thickness of 8 mm has the smallest level
minimum stress intensity and the material volume with the maximum stress intensity is
minimal for this variant of the sliding layer thickness compared to other variants. The
maximum integral stiffness of the 8 mm sliding layer decreased slightly by 1.74 and
1.5% on contact without and with lubricant respectively.
This document describes the procedure for conducting a tensile test to determine the tensile splitting strength of a material according to BS 1881 standards. Specimens are placed between hardboard packing strips and steel loading pieces and loaded continuously in a testing machine until failure. The tensile splitting strength is calculated using the maximum load at failure, specimen dimensions, and material density.
Cutting force and surface roughness in cryogenic machining of elastomerIAEME Publication
This document summarizes research on cryogenic machining of elastomers. Experiments were conducted to analyze the effects of rake angle, cutting speed, and feed rate on cutting force and surface roughness under ambient and cryogenic conditions. The results showed that cutting forces were higher for cryogenic machining but decreased with increasing rake angle. Cryogenic machining produced significantly lower surface roughness than ambient machining, especially at high rake angles and cutting speeds, due to increased material rigidity at lower temperatures.
DCC3113 DETERMINATION OF AGGREGATE IMPACT VALUE.YASMINE HASLAN
This document summarizes a laboratory report on determining the aggregate impact value of samples according to Malaysian Public Works Department (JKR) standards. The experiment involved subjecting aggregate samples to impact blows using a test machine and sieve. The percentage of fines passing through a 2.36mm sieve was calculated to determine the aggregate impact value. Sample 1 had a 17% impact value and Sample 2 was 15%, both below the JKR requirement of 20%, indicating the aggregates have medium toughness and resistance to crushing. The results show the aggregates met the JKR specifications and the experiment was successfully conducted.
Introduction on aggregate crushing value apparatusAbhishek Sagar
The principle mechanical properties required in road stones are
Satisfactory resistance to crushing under the roller during construction.
Adequate resistance to surface abrasions under traffic.
This document outlines a procedure to determine the aggregate impact value (AIV) of road construction aggregates. The AIV test involves compacting a sample of aggregates, subjecting it to 15 blows from a hammer, and calculating the percentage of fines generated that pass through a 2.36mm sieve. An AIV below 10% indicates an aggregate is exceptionally strong for road surfacing, while above 35% is too weak. The summarized experiment found an AIV of 15.82% for a tested sample, indicating it is sufficiently strong.
Experimental Study Of The FrictionalPproperties Of FrictionKEVSER CARPET
This study characterized the frictional properties of various friction spun yarns made from different fibers. The yarns were tested using a capstan method to measure friction force at different tensions. The results showed that friction is influenced by factors like fiber type, tension applied, spinning speed, and core element characteristics. Friction decreased with increasing tension, as higher tensions resulted in smoother yarn surfaces. Faster spinning speeds and thinner core elements also reduced friction. Understanding these frictional properties provides insight into how yarn structure affects performance.
Extrusion is a manufacturing process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section. A brief and concise review of the contributions made by the previous researchers in the area of extrusion process has been presented. Steel material and aluminium alloys are mostly used by researchers as die and billet material in extrusion process. FEM modeling of extrusion process is carried out by employing axisymmetric conditions in most cases. Meshing of the work piece is generally done by using axisymmetric quadrilateral elements. Experimental set-up and tools utilized in formation of extrusion process are presented and discussed. FEM results are presented in terms of variation of punch stroke, punch force.
This document summarizes a laboratory experiment conducted by civil engineering students at MUST to determine the crushing strength of a concrete aggregate sample. The experiment involved:
- Compacting an aggregate sample into a steel cylinder and subjecting it to a gradually increasing load in a compression testing machine according to British Standard 812.
- Sieving the crushed sample and calculating the aggregate crushing value (ACV) as the percentage of sample passing a 2.36mm sieve.
- The sample was found to have an ACV of 14.87%, indicating a "normal" quality aggregate suitable for use in road construction according to the standard.
This document provides an overview of mechanical and non-destructive testing methods for composite materials. It discusses various mechanical tests including hardness, tensile, compression, impact, and fatigue tests. It also discusses non-destructive testing methods such as visual inspection, liquid penetrant, magnetic particle, eddy current, ultrasonic, and radiographic testing. The document provides details on procedures and purposes for many of the most common tests used to evaluate composite material properties and identify defects.
Sieve Analysis of Fine & Coarse Aggregate | Jameel AcademyJameel Academy
This report summarizes the results of a sieve analysis test performed on samples of fine and coarse aggregates. Sieve analysis was used to determine the particle size distribution of each aggregate by separating particles via sieves with decreasing size openings. For the fine aggregate, the average size was found to be 0.6mm. For the coarse aggregate, the maximum size was found to be 13.2mm. While the calculations and procedures appeared to be performed correctly, the results did not fully meet specification limits, indicating the aggregates may not be suitable for the intended construction purpose without further processing or testing.
This lab report summarizes a compression test experiment conducted to determine the mechanical properties of a metal alloy sample. The experiment involved compressing the sample between two plates using a universal testing machine while measuring stress and strain. The results showed the stress-strain curve for the material and identified its maximum compression strength. The objective was to learn how materials behave under compressive loads and determine properties like elastic modulus, yield point, and ultimate strength.
This lab report summarizes a compression test experiment conducted to determine the mechanical properties of a metal alloy sample. The experiment involved compressing the sample between two plates using a universal testing machine while measuring stress and strain. The results showed the stress-strain curve for the material and identified its maximum compression strength. The objective was to learn how materials behave under compressive loads and determine properties like elastic modulus, yield point, and ultimate strength.
Hardness is a material's resistance to plastic deformation from external forces. There are several common hardness tests used to measure this property, including Brinell hardness testing, Rockwell hardness testing, and Vickers hardness testing. Brinell hardness testing involves indenting a material's surface with a hard steel or tungsten carbide ball under a heavy load and measuring the diameter of the indentation. The Brinell hardness number depends on the applied load and resultant indentation size. Rockwell hardness testing directly provides a hardness value based on measuring the depth of indentation from both a minor and major applied load. Vickers hardness testing uses a diamond-tipped indenter to make a square-shaped indentation, and the hardness value is calculated
Testing mechanical properties of textile compositesfaizanali353
This document outlines various mechanical tests conducted on textile composites, including Brinell hardness testing, tensile strength testing, compressive strength testing, fracture toughness testing, and fatigue testing. Brinell hardness testing involves applying a load to a steel ball pressed into the material surface. Tensile strength testing uses a universal tester to pull specimens until failure. Compressive strength testing employs a combined loading fixture according to ASTM standards. Fracture toughness is evaluated using mixed-mode bending. Fatigue testing cyclically loads materials to induce cracking and failure over time. Standard test methods and procedures are described for each technique.
This document summarizes a sieve test experiment conducted on fine aggregate to determine its grain size distribution. The experiment involved sieving 500g of dry fine aggregate through various sized sieves, weighing the material retained on each sieve, and calculating the percentage passing and retained. The results were plotted on a grading curve and compared to BS standards to evaluate the quality of the aggregate sample. In conclusion, the experiment was successfully performed and the fineness modulus calculated. The aggregate sample fell within the acceptable range specified by standards.
Compressive strength and Flexural of Hardened Concrete | Jameel AcademyJameel Academy
This report details tests conducted to determine the compressive and flexural strength of hardened concrete. The compressive strength was tested on concrete cubes with an average result of 32.8 MPa, meeting the design strength of 24 MPa. The flexural strength was tested on concrete prisms and resulted in 6.4 MPa. While lower than compressive strength as expected, this shows the concrete can resist compression and tension loads required for construction projects. In conclusion, the concrete met design specifications and can be used safely in construction.
This document discusses the effect of preform geometry on material behavior and densification during hot upset forging of sintered AISI 9840 steel powder metal parts. Powder blends were prepared with different compositions and compacted into preforms with varying initial aspect ratios between 0.45-0.92. The preforms were sintered and hot forged to different height strains. Results showed that lower aspect ratio preforms densified more rapidly than higher ratios. Densification curves followed a third order polynomial relationship with height strain. Preform geometry significantly affected the densification curves and Poisson's ratio with density.
This document provides a major project synopsis presentation for an experimental and failure analysis of a CFRP-CFRP (carbon fiber reinforced plastic) single lap adhesive joint. The objectives are to fabricate single lap adhesive joint specimens with CFRP and Araldite AW106 adhesive, varying overlap length and adhesive thickness, and perform tensile testing and ANSYS analysis. The methodology involves a literature review, materials purchasing, specimen fabrication, testing, ANSYS analysis, results comparison, and conclusion. Dimensions, material properties, and validated ANSYS models are presented. The analysis shows maximum stresses at the overlap ends and agrees with reference results.
This document investigates the mechanical properties of a 3D printed elastomer under static loading. It aims to determine material parameters for numerical simulations through experimental testing of tensile and compressive strength. Various tests are conducted to determine the effects of build parameters like printing direction, infill percentage, and layer height. The results will help develop 3D printed elastomeric components and allow for finite element analysis simulations.
This document discusses tack measurement and provides definitions of tack. It describes parameters that affect tack measurement results, including equipment design and test method accuracy. The recommended procedure for tack measurement involves precise control of ink application, roller temperature, and measurement speeds and times. A new method for measuring tack with controlled water application can reveal differences in ink water uptake and release rates.
DEFORMATIONAL BEHAVIOR OF THE FLAT SLIDING LAYER OF THE SPHERICAL BEARINGIAEME Publication
Analysis of the friction properties of modified PTFE is performed, the functions
describing the change in the friction coefficient depending on the pressure level with a
maximum error from the experiments results less than 1% are proposed in the work.
The influence of friction on the deformation behavior of the flat sliding layer of the
spherical bearing on a periodicity cell model is considered. The geometrical
configuration of the flat sliding layer with truncated spherical hole for the lubricant is
considered. The periodicity cell includes one hole for lubrication. A series of
numerical experiments for three options for the thickness of the sliding layer from 4 to
8 mm with a recess for the lubricant, in the unfavorable case the absence of lubricant
is performed. The pattern of geometric configuration hole change with increasing
pressure level is established. It was found that an increase of the antifriction layer
thickness leads to a less significant deformation of the sliding layer thickness and the
spherical hole. The sliding layer with a thickness of 8 mm has the smallest level
minimum stress intensity and the material volume with the maximum stress intensity is
minimal for this variant of the sliding layer thickness compared to other variants. The
maximum integral stiffness of the 8 mm sliding layer decreased slightly by 1.74 and
1.5% on contact without and with lubricant respectively.
This document describes the procedure for conducting a tensile test to determine the tensile splitting strength of a material according to BS 1881 standards. Specimens are placed between hardboard packing strips and steel loading pieces and loaded continuously in a testing machine until failure. The tensile splitting strength is calculated using the maximum load at failure, specimen dimensions, and material density.
Cutting force and surface roughness in cryogenic machining of elastomerIAEME Publication
This document summarizes research on cryogenic machining of elastomers. Experiments were conducted to analyze the effects of rake angle, cutting speed, and feed rate on cutting force and surface roughness under ambient and cryogenic conditions. The results showed that cutting forces were higher for cryogenic machining but decreased with increasing rake angle. Cryogenic machining produced significantly lower surface roughness than ambient machining, especially at high rake angles and cutting speeds, due to increased material rigidity at lower temperatures.
DCC3113 DETERMINATION OF AGGREGATE IMPACT VALUE.YASMINE HASLAN
This document summarizes a laboratory report on determining the aggregate impact value of samples according to Malaysian Public Works Department (JKR) standards. The experiment involved subjecting aggregate samples to impact blows using a test machine and sieve. The percentage of fines passing through a 2.36mm sieve was calculated to determine the aggregate impact value. Sample 1 had a 17% impact value and Sample 2 was 15%, both below the JKR requirement of 20%, indicating the aggregates have medium toughness and resistance to crushing. The results show the aggregates met the JKR specifications and the experiment was successfully conducted.
Introduction on aggregate crushing value apparatusAbhishek Sagar
The principle mechanical properties required in road stones are
Satisfactory resistance to crushing under the roller during construction.
Adequate resistance to surface abrasions under traffic.
This document outlines a procedure to determine the aggregate impact value (AIV) of road construction aggregates. The AIV test involves compacting a sample of aggregates, subjecting it to 15 blows from a hammer, and calculating the percentage of fines generated that pass through a 2.36mm sieve. An AIV below 10% indicates an aggregate is exceptionally strong for road surfacing, while above 35% is too weak. The summarized experiment found an AIV of 15.82% for a tested sample, indicating it is sufficiently strong.
Experimental Study Of The FrictionalPproperties Of FrictionKEVSER CARPET
This study characterized the frictional properties of various friction spun yarns made from different fibers. The yarns were tested using a capstan method to measure friction force at different tensions. The results showed that friction is influenced by factors like fiber type, tension applied, spinning speed, and core element characteristics. Friction decreased with increasing tension, as higher tensions resulted in smoother yarn surfaces. Faster spinning speeds and thinner core elements also reduced friction. Understanding these frictional properties provides insight into how yarn structure affects performance.
Extrusion is a manufacturing process used to create objects of a fixed cross-sectional profile. A material is pushed through a die of the desired cross-section. A brief and concise review of the contributions made by the previous researchers in the area of extrusion process has been presented. Steel material and aluminium alloys are mostly used by researchers as die and billet material in extrusion process. FEM modeling of extrusion process is carried out by employing axisymmetric conditions in most cases. Meshing of the work piece is generally done by using axisymmetric quadrilateral elements. Experimental set-up and tools utilized in formation of extrusion process are presented and discussed. FEM results are presented in terms of variation of punch stroke, punch force.
This document summarizes a laboratory experiment conducted by civil engineering students at MUST to determine the crushing strength of a concrete aggregate sample. The experiment involved:
- Compacting an aggregate sample into a steel cylinder and subjecting it to a gradually increasing load in a compression testing machine according to British Standard 812.
- Sieving the crushed sample and calculating the aggregate crushing value (ACV) as the percentage of sample passing a 2.36mm sieve.
- The sample was found to have an ACV of 14.87%, indicating a "normal" quality aggregate suitable for use in road construction according to the standard.
This document provides an overview of mechanical and non-destructive testing methods for composite materials. It discusses various mechanical tests including hardness, tensile, compression, impact, and fatigue tests. It also discusses non-destructive testing methods such as visual inspection, liquid penetrant, magnetic particle, eddy current, ultrasonic, and radiographic testing. The document provides details on procedures and purposes for many of the most common tests used to evaluate composite material properties and identify defects.
Sieve Analysis of Fine & Coarse Aggregate | Jameel AcademyJameel Academy
This report summarizes the results of a sieve analysis test performed on samples of fine and coarse aggregates. Sieve analysis was used to determine the particle size distribution of each aggregate by separating particles via sieves with decreasing size openings. For the fine aggregate, the average size was found to be 0.6mm. For the coarse aggregate, the maximum size was found to be 13.2mm. While the calculations and procedures appeared to be performed correctly, the results did not fully meet specification limits, indicating the aggregates may not be suitable for the intended construction purpose without further processing or testing.
This lab report summarizes a compression test experiment conducted to determine the mechanical properties of a metal alloy sample. The experiment involved compressing the sample between two plates using a universal testing machine while measuring stress and strain. The results showed the stress-strain curve for the material and identified its maximum compression strength. The objective was to learn how materials behave under compressive loads and determine properties like elastic modulus, yield point, and ultimate strength.
This lab report summarizes a compression test experiment conducted to determine the mechanical properties of a metal alloy sample. The experiment involved compressing the sample between two plates using a universal testing machine while measuring stress and strain. The results showed the stress-strain curve for the material and identified its maximum compression strength. The objective was to learn how materials behave under compressive loads and determine properties like elastic modulus, yield point, and ultimate strength.
Hardness is a material's resistance to plastic deformation from external forces. There are several common hardness tests used to measure this property, including Brinell hardness testing, Rockwell hardness testing, and Vickers hardness testing. Brinell hardness testing involves indenting a material's surface with a hard steel or tungsten carbide ball under a heavy load and measuring the diameter of the indentation. The Brinell hardness number depends on the applied load and resultant indentation size. Rockwell hardness testing directly provides a hardness value based on measuring the depth of indentation from both a minor and major applied load. Vickers hardness testing uses a diamond-tipped indenter to make a square-shaped indentation, and the hardness value is calculated
Testing mechanical properties of textile compositesfaizanali353
This document outlines various mechanical tests conducted on textile composites, including Brinell hardness testing, tensile strength testing, compressive strength testing, fracture toughness testing, and fatigue testing. Brinell hardness testing involves applying a load to a steel ball pressed into the material surface. Tensile strength testing uses a universal tester to pull specimens until failure. Compressive strength testing employs a combined loading fixture according to ASTM standards. Fracture toughness is evaluated using mixed-mode bending. Fatigue testing cyclically loads materials to induce cracking and failure over time. Standard test methods and procedures are described for each technique.
This document summarizes a sieve test experiment conducted on fine aggregate to determine its grain size distribution. The experiment involved sieving 500g of dry fine aggregate through various sized sieves, weighing the material retained on each sieve, and calculating the percentage passing and retained. The results were plotted on a grading curve and compared to BS standards to evaluate the quality of the aggregate sample. In conclusion, the experiment was successfully performed and the fineness modulus calculated. The aggregate sample fell within the acceptable range specified by standards.
Compressive strength and Flexural of Hardened Concrete | Jameel AcademyJameel Academy
This report details tests conducted to determine the compressive and flexural strength of hardened concrete. The compressive strength was tested on concrete cubes with an average result of 32.8 MPa, meeting the design strength of 24 MPa. The flexural strength was tested on concrete prisms and resulted in 6.4 MPa. While lower than compressive strength as expected, this shows the concrete can resist compression and tension loads required for construction projects. In conclusion, the concrete met design specifications and can be used safely in construction.
This document discusses the effect of preform geometry on material behavior and densification during hot upset forging of sintered AISI 9840 steel powder metal parts. Powder blends were prepared with different compositions and compacted into preforms with varying initial aspect ratios between 0.45-0.92. The preforms were sintered and hot forged to different height strains. Results showed that lower aspect ratio preforms densified more rapidly than higher ratios. Densification curves followed a third order polynomial relationship with height strain. Preform geometry significantly affected the densification curves and Poisson's ratio with density.
This document provides a major project synopsis presentation for an experimental and failure analysis of a CFRP-CFRP (carbon fiber reinforced plastic) single lap adhesive joint. The objectives are to fabricate single lap adhesive joint specimens with CFRP and Araldite AW106 adhesive, varying overlap length and adhesive thickness, and perform tensile testing and ANSYS analysis. The methodology involves a literature review, materials purchasing, specimen fabrication, testing, ANSYS analysis, results comparison, and conclusion. Dimensions, material properties, and validated ANSYS models are presented. The analysis shows maximum stresses at the overlap ends and agrees with reference results.
This document investigates the mechanical properties of a 3D printed elastomer under static loading. It aims to determine material parameters for numerical simulations through experimental testing of tensile and compressive strength. Various tests are conducted to determine the effects of build parameters like printing direction, infill percentage, and layer height. The results will help develop 3D printed elastomeric components and allow for finite element analysis simulations.
This document discusses tack measurement and provides definitions of tack. It describes parameters that affect tack measurement results, including equipment design and test method accuracy. The recommended procedure for tack measurement involves precise control of ink application, roller temperature, and measurement speeds and times. A new method for measuring tack with controlled water application can reveal differences in ink water uptake and release rates.
Analyzing Adhesion of Epoxy/Steel Interlayer in Scratch TestIJERA Editor
The document summarizes a study that investigated how different parameters affect the adhesion strength of epoxy adhesives bonded to zinc-plated mild steel. Scratch tests were performed using two epoxy adhesives and zinc-plated mild steel adherends treated with different surface treatments. A Taguchi experimental design was used to test combinations of surface treatment, adhesive type, blade angle, and adhesive thickness. Results found that surface treatment and thickness were the most influential parameters, affecting scratch force by 52.4% and 19.9% respectively, and scratch energy by 44.0% and 25.6% respectively.
Influence of contact friction conditions on thin profile simulationVan Canh Nguyen
The paper presents the development of the Finite Element model for simulation of thin
aluminium profile extrusion of both solid and hollow shapes. The analysis has shown that the material
flow in simulation is very dependent on the friction model. Experimental and theoretical studies show
that friction traction on the interface between the tool and the deformed material can be represented as
a combination of adhesive friction force and the force that is required to deform surface asperities. In
aluminium extrusion we can clearly distinguish two different areas with respect to friction conditions
such as sticking and sliding and transient zones between them. The lengths of these zones are also
dependent on variation of the choke angle and actual thickness of the profile. To get these values the
material flow problem is to be coupled with the simulation of the tools deformation. A series of
experiments with specially designed tools have been done to investigate how the bearing length and
choke angle may influence the extension of different friction zones and by these means vary the
material flow pattern. The friction models have also been tested with industrial profiles of complex
shapes and have shown good correspondence to reality.
Investigation of Extrusion of Lead experimentally from Round section through ...inventy
ABSTRACT :The changes of die angle, area reduction in dies, loading rate on the final extruded products, extrusion pressures of lead of circular cross sections has been investigated experimentally. The proposed method is successfully adapted to the forward extrusion of the equilateral triangular section from round billet through converging dies of different area reductions. Computation of extrusion pressure at various area reductions and calculations of different parameters (stress, strain etc.) in wet condition.
Keywords - Extrusion of Triangular section, Converging Dies at different area reductions, Friction Factor, Extrusion Pressure
IRJET-Experimental Study on Spring Back Phenomenon in Sheet Metal V- Die BendingIRJET Journal
This document presents an experimental study on the spring back phenomenon in sheet metal V-die bending. The study investigates how factors like angle, sheet thickness, and varying width cross-section affect the amount of spring back that occurs in CRC-D steel sheets. Experiments were conducted using a design of experiments approach based on response surface methodology. 20 bending experiments were performed according to the experimental design matrix. The results show that spring back decreases with increasing angle and first increases then decreases with increasing thickness. Spring back also increases linearly with increasing width. A regression model was developed to predict spring back based on the experimental results.
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Study of Pressure Distribution in Compliant Polishing Tools
1. Seah Kheng Wee, MAE
Presented By
Komanduri Raghava Kumar
School of Mechanical & Aerospace Engineering
5 May, 2017
Study of Pressure Distribution in
Compliant Polishing Tools
1
2. • Introduction
• Project Objective and Scope
• Project Overview
• Literature Review Summary
• Overall Methodology
• Results and Discussions
• Conclusion
• Scope for future work
• Learning Outcomes
2
3. • Polishing is usually carried out in the final stage of production
• Manual polishing takes up to 37-50% of total production time
3
4. • Coated abrasive tools are used extensively in manufacturing industry
• Tools are replaceable and have conformable geometry
• A backing pad provides additional stiffness
• Not much work has been done to understand the effect of compliance on the
pressures distribution in the contact area of coated abrasive tools.
• An appreciation of the development of pressure distributions using FEM can
help to predict the surface profiles produced after polishing.
4
Controllable compliance
Well controlled surface finishImproved performance
5. Project Objective
•Study the effect of tool (rubber pad and abrasive cloth) compliance on contact pressure distribution
•Conduct material characterization to study the tool compliance
•Design and analyze an active complaint finishing tool
Scope
•This project only deals with the circular form of abrasive discs
•The effect of tool compliance on contact pressure distribution is investigated only under static
conditions
•The finite element analysis only deals with the structural component
•Abrasive grains are not modelled because of the inherent complexity
•The fully developed tool integrated with the robot will be able to provide fine polishing for a wide
range of mechanical components
5
6. 6
Tool Simulation
The newly designed active tool is simulated in ABAQUS to analyze the load and pressure
distribution. These results are compared with the experimental results for validation
purposes.
Laboratory Experiments
Several tests like tensile testing, removal of grains, measurements of grains, etc. were carried
out to study material properties. Following this, pressure distribution tests were carried out.
Literature Review
A detailed study on the mechanics of polishing, types of abrasives, current active compliant
tools, difference between hard and compliant tools, weft and warp yarn in a woven fabric, etc.
7. The Polishing Process
•Polishing is the mechanism that gives the final surface characteristics like roughness, geometry,
tolerances and integrity.
•Some advantages of polishing include:
– Gives a natural appearance with a high gloss and sheen
– Produces a relatively durable finish
– Never requires stripping
– Can be applied with a standard low speed weighted floor machine.
•Different types of polishing
Mechanics of Abrasion
Source: University of Toledo, The Polishing Process, Ohio: University of Toledo, 2017 7
8. Types of Abrasives
•Bonded Abrasives
•Coated Abrasives
•Non-woven Abrasives
8
Source: Federation of European Producers of Abrasives, "Bonded Abrasives,"
Federation of European Producers of Abrasives.
Source: Federation of European Producers of Abrasives, "Coated Abrasives,"
Federation of European Producers of Abrasives.
9. Current Active Compliant Tools
PushCorp Inc supplies compliance force devices on which the clients can mount their own devices.
These gadgets are pneumatic-headed to provide the axial compliance, like ATI's AC instrument.
Hard and Compliant Tools
9
Hard Tools Compliant Tools
A hard tool, like a grinding wheel, is very
stiff and does not conform to the free-form
surface being polished.
A compliant tool can fit the surface profile
and impose favorable pressure (or force) on
the polishing region of the surface.
Currently, a constant force is maintained
using force control in the robot, and
complex components are polished based on
this technique. But constant force will not
assure constant pressure thereby leading to
uneven material removal.
Using the tool with precise compliance is
required to produce uniform material
removal thereby increasing dimensional
accuracy and reducing rework which would
lead to more time and cost.
16. • The effect of tool compliance such as ‘Hard’ and ‘Soft’ on contact pressure
distribution for rubber pad was studied to a very limited extent earlier.
• This project not only aims to provide fine polishing for a wide range of mechanical
components but also explores the scope for future work in this field where simulations
can be fine-tuned to predict the contact pressure more precisely.
• This project primarily focuses on developing the material properties of composite
materials like elastic modulus and poissons ratio which would not only give more
accurate simulation results but also broaden the scope of this project to the usage of
several types of abrasive materials for polishing.
16
17. Tensile Testing
Samples of Y grade and T grade (samples in the X direction and samples in the Y
direction) measuring 250mm by 25mm and samples of 3M120 and 3M60 measuring
70mm by 20mm were cut for tensile testing.
17
19. Abrasive Material Study
The tensile specimens were chemically treated to understand the properties of the
underlying material. Also, the composition of the different fibers in the fabric (called blend
percentage) was found out through certain tests.
19
21. To extract only the cloth out of the abrasive roll, the abrasive roll was boiled in 5-8%
solution of caustic soda for 15-20 mins. As time passed, the chemicals and grains
disintegrated giving the bare cloth.
21
22. Pressure Distribution Study
The ABAQUS assembly was modelled in such a way that the work coupon was fixed. One
half of the tool head was modelled in an incline of 15 degrees with the work coupon. The
abrasive disc which was modelled as a continuum shell element can be seen attached to the
rubber pad. Reference point 2 can be seen at the center of the shaft where a downward
vertical force of 10N is applied.
22
23. The rubber pads were pressed against the titanium work coupons, and the load
displacement curves were captured. The INSTRON machine was programmed in such a
way that the compression would take place till the force reaches 10N. Once the force
reaches 10N, the disc is held against the coupon for 5 seconds. Following this, the disc is
retracted back till the force drops to 0N.
23
24. Once the load displacements curves were obtained, the material properties of the hard and
soft rubber pad were determined by using a trial and error method. The hard pad has a
shore hardness of 80+, and the soft pad has a shore hardness of 40+. Thus, the following
figure was used as a reference to determine the material properties.
24
25. These data points were keyed into the uniaxial stress-strain material properties in
ABAQUS, and the simulation was run. The load displacement plots obtained were
compared to experimental load displacement plots. The material properties corresponding
to the best fit simulation curve were assumed as the material properties of the hard pad
and soft pad respectively.
However, the matching load displacement plots weren’t enough to conclude the material
properties. It was important for the simulation and experimental pressure distribution
values to match as well.
25
Film Type Abbreviation Pressure Range
Extremely Low Pressure 4LW 0.05-0.2 MPa
Ultra-Ultra Low Pressure LLLW 0.2-0.6 MPa
Ultra Low Pressure LLW 0.5-2.5 MPa
Low Pressure LW 2.5-10 MPa
29. Analysis of the Active Compliant Tool Design
Three different design versions were modelled on Solidworks, and their feasibility was
studied accordingly.
29
Design 1
34. Several ABAQUS simulations were done using the final tool design to study the effect of
stiffeners on the contact pressure.
•The young’s modulus of stiffener was given around E=200 MPa
•Load applied was 5N
•The max pressure for retrieved stiffeners was 0.2435 MPa compared with 0.7194 MPa
fully inserted stiffener
•Soft nitrile rubber (Shore A 45 ±5) property was used for the backing pad and tubes.
•For the stiffeners, two different properties were tried.
– HARD NITRILE RUBBER STIFFENER (Shore A 80 ± 5)
– STIFFENER WITH E= 200 MPa
34
36. Tensile Testing
It can be clearly seen that Y, T, 3M120 and 3M60 have different stresses and strains in
both directions. This phenomenon might be due to different cloth thicknesses.
36
37. Abrasive Material Study
The blend percentage test was carried out whose results are as follows.
37
Sample T
Sample Y
38. Following this, the fiber patterns in the obtained bare cloths were observed.
38
Sample TSample Y Sample 3M60
39. The warp and weft yarn are always perpendicular to each other. It appears that it's at an
angle because of the pattern formed by the particular type of weave. In this case, the
particular type of weave is called TWILL i.e. 2 up/1 down. So the pattern formed by
weaving in the 2/1 configuration makes the yarn look like it is at an angle.
The warp direction is held under high tension during the entire weaving process and hence
the warp yarn is stronger than the weft yarn. Thus, the abrasive rolls Y and T having
different young’s moduli in X and Y directions is justified. In order to ensure that these
results obtained were accurate, tensile testing was done for several samples to ensure
repeatability of results.
39
43. 43
Abrasive Sample Warp Direction
(Higher Stiffness)
Weft Direction
(Lower Stiffness)
Y X direction/0o
direction
Y direction/90o
direction
T X direction/0o
direction
Y direction/90o
direction
3M120 Y direction/0o
direction
X direction/90o
direction
3M60 Y direction/0o
direction
X direction/90o
direction
44. 44
Abrasive Type Area of cross-section
Y Width = 25mm, Thickness = 0.8mm, Area
= 20mm2
T Width = 25mm, Thickness = 0.5mm, Area
= 12.5mm2
3M120 Width = 20mm, Thickness = 0.9mm, Area
= 18mm2
3M60 Width = 20mm, Thickness = 1 mm, Area
= 20mm2
45. 45
Abrasive Roll E1(in MPa) E2(in MPa)
Y 1250 800
T 1100 312.5
3M120 1429 1000
3M60 2778 2500
46. The values of these six material parameters namely E1, E2, v12, G12, G13 and G23 were
keyed into ABAQUS’s composite layout manager for simulation purposes.
46
Abrasive Roll G12 G13 G23
Y 370.37 370.37 296.29
T 217.14 217.14 115.74
3M120 442.743 442.743 370.37
3M60 976.05 976.05 925.92
47. Pressure Distribution Study
The material property curves HT3 for hard pad and ST1 for soft pad gave similar
simulation and experimental load displacement curves. Thus, the stress-strain values
corresponding to the curve HT3 and ST1 were assumed as the uniaxial material properties
of the hard pad and soft pad respectively.
47
49. Contact Area and Contact Pressure comparison for experiment and simulation – Hard Pad
Contact Area and Contact Pressure comparison for experiment and simulation – Soft Pad
49
Type Contact Length (X) Contact Length (Y) Contact
Pressure
Experiment 43.75mm 17.5mm 0.6Mpa
Simulation 59.21mm 20mm 0.096Mpa
Type Contact Length (X) Contact Length (Y) Max. Contact
Pressure
Experiment 43.75mm 13.125mm 0.4Mpa
Simulation 47mm 14mm 0.324Mpa
53. From the above chart, the effect of the backing pad on pressure distribution can be clearly
seen. The pressure distribution results in case of soft pad seem to be better compared to
the pressure distribution results in case of hard pad. As expected, the hard pad gives higher
maximum contact pressure values as compared to soft pad in all the four cases i.e. when
combined with all the different types of abrasive materials.
53
54. • It was understood that the overall stiffness of the abrasive materials varies as
3M60 > 3M120 > Y > T
• In the case of combination with a hard pad, the experimental and simulation load
displacement curves for the different types of abrasive materials varied significantly.
The trends observed in the maximum contact pressure values were
𝑴𝒂𝒙. 𝑪𝑷 (𝒀)>𝑴𝒂𝒙.𝑪𝑷(𝑻)
𝑴𝒂𝒙.𝑪𝑷(𝟑𝑴𝟔𝟎)>𝑴𝒂𝒙.𝑪𝑷(𝟑𝑴𝟏𝟐𝟎)
• In the case of combination with soft pad, the variation between the experimental and
simulation load displacement curves was very less. The experimental load displacement
curves in this case almost seemed to trace the simulation load displacement curves.
The trends observed in maximum contact pressure values were
𝑴𝒂𝒙.𝑪𝑷(𝒀)>𝑴𝒂𝒙.𝑪𝑷(𝑻)
𝑴𝒂𝒙. 𝑪𝑷 (𝟑𝑴𝟔𝟎)>𝑴𝒂𝒙.𝑪𝑷(𝟑𝑴𝟏𝟐𝟎)
54
55. • The rubber backing pad played a vital role in determining the contact pressure values
which in turn affect the material removal rate. The soft pad gave very good results due
to its flexible nature.
• One reason why the results with hard pad were not matching was the bent structure of
the discs. However, this problem did not affect the soft pad results. The soft pad could
conform to the structure of the abrasive discs and thus contribute decently to the
pressure distribution plots.
• The different designs modelled were assessed based on their contact pressure values.
The initial designs were scrapped due to poor control over contact pressure variation.
Another challenge that was posed was the selection of a bearing that could allow both
rotational and translation motion at high RPM (2500rev/min).
• The latest design V3 has been developed keeping in mind the above challenges. At the
same time, several tool simulation results as shown above make this a viable design for
development, printing and industrial use.
55
56. • The best way to minimize the current deviations of the experimental results from the
simulation results would be performing several experimental trials by ensuring that the
abrasive discs are not bent.
• Furthermore, the touch down study was limited to static conditions. Future research
can include repeating a set of experiments in dynamic conditions with a particular rpm.
• The experiments can be repeated on concave and convex surfaces to study the change
in compliance, contact pressure and contact area due to an increase or decrease in
force. The pressure distribution results can be compared with material removal
profiles.
• Pressure distribution simulations (similar to the simulations done in this project) with
the Fujifilm pressure films can be performed for the current active compliant tool
design.
• Consequently, the design can be improved to refine the deviations from experimental
results. Following this, the tool design can be patented and integrated with the robot
for testing, validation, product development and deployment.
56