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The aim of the present study is to facilitate the machining process of cast steel (HSS)through cooling and lubricating by compressed air with liquid in three directions andconsisting of (oil, soap, carbolic acid, and sculpture) and was compared with the lubricantprocess in one direction and at different cutting speeds (2.08, 6.25, 10.4, and 14.16 m/sec).The Auto Desk Inventor programme is used to simulate the cutting process by applyingcutting forces to the tool's shear surface. The interface equipment is used to measurecutting tool strains by the response of a strain gauge and the Arduino equipment to measurecutting tool temperature. In addition, the tool strain equations were used assuming that thecutting tool is fixed between the two walls (fixing region and surface of the workpiece) toget the best results at the same speed. The results refer to the lubricant in three directions,which is better than one direction due to decreasing cutting tool strain, reaction of cuttingforce on the shear surface of the cutting tool, and cutting tool temperature. Theexperimental results show that a cutting speed of 10.4 m/sec is the best for the cuttingprocess. Furthermore, the numerical results are converged with practical results in a smallcorrection factor (0.428), preventing the tool from vanishing.

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Abstract: Sheet metal is widely used in industry and in different production processes. The present work aims to reduce the bending force in the air-die bending process. Different mild steel sheet thicknesses (0.5, 0.75, 1, and 1.25 mm) were considered, and two techniques were proposed. The first technique involves an annealing process, while the second one considers cutting a rectangular hole along the bending line. The bending stress was calculated using Autodesk inventor software. The results revealed that the annealing process can provide significant ductility improvement and hence bending force reduction, and that annealing time is an important factor that influences ductility development. Moreover, cutting a hole along the bending line could reduce the bending stress and consequently the bending force. The study also reported that increasing the thickness beyond a specific value could result in a reduction in bending force instead of an increase, which is attributed to a temperature increase in the sheet and bending tool.

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Abstract: For this time being; one of the main approaches in mass production is to control both quality and raw material consuming by smart design and analysis method. Estimating and controlling the main design parameters which effects on the productivity and quality, with design sensitivity analysis to control and optimize the geometry topology is the important key for any efficient manufacturing process. This article introduces a work relating to manufacturing process of a rubber pad which used in many industrial applications like automobile and aerospace by using finite element analysis. An efficient model has been created for solving this manufacturing process by using FEM. Commercial software (ABAQUS/CAE) has been adopted in this research for developing a standard design based on finite element analysis. This analysis will includes estimating and finding the effects of updating and modifying the geometry according to stresses concentration, thereby finding and specifying the main effecting parameters to estimate and determine the appropriate geometry design. One of the main objectives is to alter or modify the geometry to minimum or lowering axial stresses values, which help for increasing the service life. Study of design sensitivity is very important in improving any design through analysis process. It has been found from simulation results that effects of radius influence on stress generation is more than the effects of changing in rubber thickness. This analysis will also provide important information’s to ensure that the values of strains and stresses will not exceed the maximum range and rest in acceptable limits. Simulation results can be used to validate the experimental results and establish a new design formula through comparison. It has been found that a good relation between simulation results and experimental results. In order to increase the stiffness of the unit; steel parts are normally used and attached with rubber in many structural applications to bond and support the structure. The bonding between steel part and rubber will be stronger than the rubber material and will be very efficient with good suitability to attach during molding process.

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Abstract- Nowadays; any manufacturing process for mass production like forming process requires high precision tools (punch and die) for re-shaping the metal to a new product. During forming process; there are a lot of defects will appears in the products due to sever friction forces between the contact surfaces. The dislocation of particles due these forces will generates huge amount of stresses and strain hardening which consider the main causes of these defects. The present work is focus on analysis the process of forming a thin sheet of metal theoretically and practically. The main approach of this work is to analysis and estimates the main effecting parameters on this manufacturing process theoretically and experimentally. ANSYS (R18) software has been adopted for analysis this process to find and estimate the main parameters that effects on the product quality. Specially the values of stresses and strain hardening which has the main cause of defects like wrinkling and cracks. Theoretical analysis focuses on the onset of metal distortion depending on the values of stress concentrations, while the empirical part focused on the microstructure behaviour of metal before and after the forming process. For this purposes; thin square aluminium blank is adopted by means of drawing die as a square cup. In simulation process; the blank distortion in many directions has measured in terms of von-mises stresses distribution, strain hardening and total deformation measurements. This research will enhance the knowledge about these types of manufacturing technology and help the researchers that working in this fields.

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Abstract Purpose – The purpose of this paper is to investigate the effect of graphene platelets (GPLs) on the low-speed contact between a mass and surface of a multi-layer polymer beam. Design/methodology/approach – This problem is primarily organized by first-order shear deformation beam theory and nonlinear Hertz rule. GPLs are distributed along the beam thickness direction. The Halpin–Tsai micromechanics model is applied for computing the effective Young’s modulus of the GPLs/polymer composites. In the formulation process, the principle of conservation of energy is first used and the histories of results are extracted using the separation of variables and Runge–Kutta method. Findings – In comparing the responses with the available data, a good agreement is observed. The effects of the weight fraction and distribution pattern on the impact response of polymer beam reinforced with GPLs are studied. Results show that contact force is increased, contact time and beam recess are decreased with increasing of weight fraction of GPLs. Also, among the different distribution patterns, the contact force depended on value of GPLs at the point of contact.