behnam davoodi - Academia.edu (original) (raw)

Papers by behnam davoodi

Journal of Manufacturing Processes, 2019

Superalloys (nickel and titanium-based alloys) are grouped as difficult-to-cut materials. Therefo... more Superalloys (nickel and titanium-based alloys) are grouped as difficult-to-cut materials. Therefore, due to poor machinability of superalloys, their machining is a great challenge for manufacturing sectors. Surface quality of work part and chip formation morphology are considered as the main machinability attributes in machining superalloys. Although numerous studies have been focused on this context, however, no work was found on the effect of nanoparticles stability on nanofluid performance and consequently on machinability attributes, in principle surface quality and chip formation morphology. In the present study, the importance of nanoparticles stability by adding of surface active agent (surfactant) as additive elements was evaluated. Two kinds of nanoparticles including nano copper-oxide and nano silicon-oxide with different volume fraction were used to prepare nanofluid solution. In addition, surfactant from the group of Sodium Dodecyl Sulfate (SDS) which is appropriate for polar fluid was selected. Scanning Electron Microscope (SEM) images were utilized to analyse the machined surface of the work part. Cutting fluids were prepared in three conditions, including nanofluid with surfactant (reinforced nanofluid), nanofluid without surfactant, and conventional cutting fluid (without nanoparticles). The average surface roughness R a was considered as the surface quality attribute. The recorded values of R a and chip formation morphology indicated that reinforced nanofluid could significantly improve the cutting mechanism as compared with nanofluid without surfactant and conventional fluid. The main reason for this phenomenon can be attributed to high ability of surfactant to disperse nanoparticles in the fluid medium as well as high capability to prevent nanoparticles aggregation. After a short period, the nanoparticles in nanofluid without surfactant attached to other particles and a massive mass (nanoparticles aggregation) was formed which led to quick settling of nanoparticles. By settling of nanoparticles, the environment becomes free of nanoparticles and similar properties and capability as conventional fluid may occur.

Advanced Materials Research, 2011

As respects of usage of widespread machining procedures in producing industrial pieces, optimizat... more As respects of usage of widespread machining procedures in producing industrial pieces, optimization of this procedure is one of most subject that attract researchers intrest. Finite element analysis based techniques are available to simulate cutting processes and offer several advantages including prediction of tool forces, distribution of stresses and temperatures, estimation of tool wear and residual stresses on machined surfaces, optimization of cutting tool geometry and cutting conditions. Success and reliability of numerical models are heavily dependent upon work material flow stress models in function of strain, strain rate and temperatures. In this paper Johnson-Cook material law, owing to its simplicity, has been used for simulating of Aluminum Alloy AA5083. The model parameters are determined by fitting the data from both quasi-static compression tests at law strain rates and machining tests at high strain rates. For calculating deforming parameters in machining being used...

Advanced Materials Research, 2009

In order to simulate manufacturing processes, it is essential to have accurate information about ... more In order to simulate manufacturing processes, it is essential to have accurate information about mechanical behaviour of material for different deformation conditions depending on the type of the process. In finite element (FE) analysis based techniques for simulation, a constitutive equation is needed to model the mechanical behaviour of material. In the case of metal cutting, the Johnson and Cook (JC) flow stress model is the most suitable constitutive equation to be used in simulation since it contains the effects of strain, strain-rate and temperature. It is needed to evaluate the parameters and constants of the JC model to make it applicable in FE simulations. There are several ways to evaluate the parameters of the equation: experimental such as high strain-rate compression tests called “Split Hopkinson Pressure Bar” which is relatively complicated and expensive technique requiring special testing apparatus; and analytical approach based on Oxley’s theory. An integral method c...

Measurement, 2012

ABSTRACT The cutting temperature and temperature distribution along the rake face of cutting tool... more ABSTRACT The cutting temperature and temperature distribution along the rake face of cutting tool and work piece is an essential factor in study of machining processes due to its effect on surface quality, tool life, tolerances, metallurgical behavior and chip-removing rate. Several methods have been introduced to measure temperature during machining, such as the thermocouple technique, infrared camera and metallurgical methods. Each of these methods has some advantages and limitations. In this article, an infrared high-speed sensor with specially designed software has been used to measure the transferred heat to the work piece during high speed machining (HSM) of bronze alloys. The results revealed that this system enhances accuracy and reduces the number of tests required.

Machining and rolling processes are used to produce threads. The thread rolling process is more c... more Machining and rolling processes are used to produce threads. The thread rolling process is more considered by the producers because of necessity to threads with high quality and strength in different industries. Other advantages of this process are producing without chips and wasting of material with high rate of manufacturing. Because of indicated geometry and small sizes of the threads studying on them is difficultly. As for increasing demands to accuracy, speed and optimization of manufacturing process the regard to the finite elements simulations of processes has been increased by the investigators. At this article making threads on St37 steel pipes has been done. For studying microhardness, texture of material and strength of threads made by thread rolling some tests were design and done. Then the results compared with process simulation results in ABAQUS commercial code and the results got by machining threading process. The results showed that the hardness and strength is sig...

WIT transactions on engineering sciences, 2005

In order to facilitate the characterization of materials at high strain rate and high temperature... more In order to facilitate the characterization of materials at high strain rate and high temperature, this paper introduces a very simple technique for using the traditional Split Hopkinson Pressure Bar (SHPB) system at elevated temperatures, with a different geometry for the specimen. This particular specimen is used to avoid a complicated SHPB system at an elevated temperature, and to keep things as simple as possible. The limitations of the compression SHPB in use at high temperatures, the need for extra computations and the requirement for additional equipment may be reasons why there is such a scarcity of reliable flow stress data for various materials at high temperatures in the literature. In the layout of the high temperature test set up at our laboratory, in addition to the conventional compression SHPB, an induction coil heater is used as the heating system and a simple holder is used to hold the specimen at the correct position during the test. The thermal behaviour of the new specimen will make it possible to bring the cold bars in contact with the heated specimen manually and without using cumbersome mechanisms, increasing the likelihood that the experiments will be successfully carried out at the desired temperatures. This simple, easy, and practical, system has been used to test metallic materials at high temperature and high strain rates.

Journal de Physique IV (Proceedings), 2006

In order to facilitate characterization of materials at high strain rate and high temperature, th... more In order to facilitate characterization of materials at high strain rate and high temperature, this paper introduces a technique for using the traditional Split Hopkinson Pressure Bar (SHPB) system at elevated temperature, with a different geometry for the specimen. This particular specimen is used to avoid a complicated SHPB system at an elevated temperature, and to keep things as simple as possible. The limitations of the compression SHPB in use at high temperatures, the need for extra computations and the requirement for additional equipment may be reasons why there is such a scarcity of reliable flow stress data for various materials at high temperatures in the literature. In order to identify the constitutive equation, an inverse analysis method is used from a reduced finite element simulation of the specimen compression. This simple, easy, practical experimental system and inverse analysis technique, have been used to study a AA5083 aluminium alloy at high temperature and high strain rates.

Super alloys, are metal with high toughness and low thermal conductivity that they have low machi... more Super alloys, are metal with high toughness and low thermal conductivity that they have low machinability. Sever tool wear and unsuitable surface roughness in machining of these materials are the main challenges for machining process. In this study, the effect of the cutting fluid types under minimum quantity coolinglubrication method on work piece surface roughness and tool wear in machining of A286 super alloy were studied and their results were compared with wet and dry methods. For this purpose, vegetable based lubricant and nanoparticles in minimum quantity lubrication along with cryogenic cooling were used. The results of surface roughness survey under Ra criterion showed that using of vegetable-based lubricant with nano silicon oxide under minimum quantity lubrication and cooling with liquid nitrogen are caused the surface roughness decreased 30-75% compare to dry condition and 15-64% decreased compare to wet lubrication. Also due to very low surface roughness variations comp...

Due to the wide applications of aluminum alloy in numerous industrial sectors and products, signi... more Due to the wide applications of aluminum alloy in numerous industrial sectors and products, significant attention has been paid by many researchers to improve the production and manufacturing aspects of aluminium alloys and related products. One of the main concerns in this regard is the cutting tool life when machining aluminium alloys. This work aims to present the capability and performance of a new strategy of life improvement in the tungsten carbide inserts by creating micro-textured grooves on their surface. For this purpose, the laser was used to create the different morphologies of textures on the insert surfaces. The grooves were created with different distances in parallel to the cutting edge on the tool rake face. The effects of fabricated grooves on the tool wear attributes were discussed in three directions, including the main edge (x-direction), side edge (y-direction), and radial (in the direction of 45 degrees) and the effect of these grooves/textures on the surface ...

Arabian Journal for Science and Engineering, 2021

Journal of Modern Processes in Manufacturing and Production, 2019

Johnson cook constitutive equation was utilized to model the 10100 copper alloy wires at the cold... more Johnson cook constitutive equation was utilized to model the 10100 copper alloy wires at the cold wire drawing process. Johnson cook parameters were determined using several quasi-static tensile tests at different strain rates. The wire drawing experiments carried out at seven drawing conditions with two areal reductions and four drawing speeds caused the strain rate ranged from 37 to 115 s-1. Wire Drawing forces were measured using a load cell connected to the die. Analytical and finite element with VUHARD subroutine solutions were implemented to calculate the drawing forces using the Johnson cook parameters as well. Results showed that the Johnson cook model with parameters determined from a quasi-static condition was not able to predict the material behavior at the wire drawing process with a moderate strain rate. Inverse analysis using the Newton- Raphson method to minimize the objective function was carried out to modify the Johnson cook parameters. Updated Johnson cook paramet...

Journal of Central South University, 2020

In the present study, the effect of reduction of cutting fluid consumption on the surface quality... more In the present study, the effect of reduction of cutting fluid consumption on the surface quality and tool wear was studied. Mathematical models were developed to predict the surface roughness using response surface methodology (RSM). Analysis of variance (ANOVA) was used to investigate the significance of the developed regression models. The results showed that the coefficient of determination values (R 2) for the developed models was 97.46% for dry, 89.32% for flood mode (FM), and 99.44% for MQL, showing the high accuracy of fitted models. Also, under the minimum quantity lubrication (MQL) condition, the surface roughness improved by 23%−44% and 19%−41% compared with dry and FM, respectively, and the SEM images of machined surface proved the statement. The prepared SEM images of tool rake face also showed a considerable decrease in adhesion wear. Built-up edge and built-up layer were the two main products of the adhesion wear, and energy-dispersive X-ray spectroscopy (EDX) analysis of specific points on the tool faces helped to discover the chemical compositions of adhered materials. By changing dry and FM to MQL mode, dominant mechanism of tool wear in machining aluminum alloy was significantly decreased. Breakage wear that led to early failure of cutting edge was also controlled by MQL technique.

Mechanics & Industry, 2020

Johnson-Cook constitutive equation was utilized to model the 10100 copper and AA 1100 aluminum wi... more Johnson-Cook constitutive equation was utilized to model the 10100 copper and AA 1100 aluminum wires at the cold wire drawing process. Initial Johnson cook parameters were determined through quasi-static tensile tests at different strain rates. Analytical and finite element with VUHARD subroutine solutions were implemented to calculate the drawing forces using the Johnson cook parameters. Wire drawing experiments were carried out at different drawing conditions with two areal reductions and four drawing speeds with the strain rate ranged from 37 s−1 to 115 s−1 and wire drawing forces were measured using a load cell connected to the drawing die. Results showed that the Johnson cook model with parameters determined from a quasi-static condition was not able to predict the material behavior at the wire drawing process with a moderate strain rate. In order to modify the initial JC parameters an inverse analysis approach was adopted. An objective function was defined based on analytical ...

Environmental Science and Pollution Research, 2020

Knowing that over two-thirds of lubricant disposals return to the environment with no purificatio... more Knowing that over two-thirds of lubricant disposals return to the environment with no purification process, adequate strategies are demanded to reduce their risks. For this reason, the main focus of the present study is to describe an environment-friendly approach. In the first part, two widely used lubricants (mineral-based and vegetable-based) were introduced, and the reasons for their hazards were investigated. The composition of mineral-based lubricant was characterized by x-ray fluorescence elemental analysis. The result showed the presence of phosphorus, chlorine, and zinc dialkyl dithiophosphate in its composition that many scholars considered them to be the leading risk factor in the chemical composition of mineral-based lubricants. It has been focused on the potential risks of vegetable-based lubricants, which many researchers have identified as a safe lubricant. The Pseudomonas microbe was cultivated in the vegetable-based sample, and the result showed that although vegetable-based lubricants are compatible with humans, bacteria colony can quickly grow there without making any apparent changes that lead to harm to operators in a mysterious way. In the present work, the hypothesis of the safety of unreinforced vegetable-based lubricants has been rejected, and a new window on the environmental issues of vegetable-based lubricants has been presented. In the final, to eliminate environment-human risks and to reduce consumption of lubricant and natural resources to green manufacturing, a comprehensive study on the possibility of completely removing lubricant was performed. The results showed that the machining without lubricant could be replaced with the traditional method.

Journal of the Brazilian Society of Mechanical Sciences and Engineering, 2018

Obtaining high surface quality with minimum tool wear values is one of the most important goals o... more Obtaining high surface quality with minimum tool wear values is one of the most important goals of turning process. Moreover, when it comes to process costs, the volume of material removed is very important and should be considered when optimizing cutting variables. In this work, gray relational analysis was employed with the aim of simultaneously optimizing surface roughness, tool wear and volume of material removed. Cutting speed, feed rate and depth of cut were chosen as process control factors. Optimization results showed that cutting speed of 80 m/min, feed rate of 0.1 mm/rev and depth of cut of 1.5 mm were the optimum set of cutting parameters. Scanning electron microscope images of worn cutting edges revealed that depth-of-cut notch, built-up edge, and adhesion are dominant wear mechanisms. Finally, confirmation test proved the accuracy of the prediction carried out by the optimization process.

International Journal of Machining and Machinability of Materials, 2019

In this work, surface damage mechanisms generated in turning of N-155 iron-nickel-base superalloy... more In this work, surface damage mechanisms generated in turning of N-155 iron-nickel-base superalloy with coated carbide tools were studied. Machined surface of the specimens were precisely examined under scanning electron microscope (SEM), and mechanics of cutting equations were employed to evaluate the cutting condition by measuring the shear strain for each experiment. The experiments were conducted according to L 9 Taguchi standard orthogonal array and cutting speed, feed rate and depth of cut were selected as cutting parameters. The adequate application of signal-to-noise (S/N) quality characteristics as well as analysis of variance (ANOVA) led to determination of the optimal cutting parameters and statistical significance level of each parameter. Experimental results indicated that built-up edge (BUE) and cavity were the predominant surface damage mechanisms. Furthermore, results showed that feed rate was the most effective cutting variable on surface roughness.

The International Journal of Advanced Manufacturing Technology, 2017

Burr formation is considered as a detrimental phenomenon that not only decreases the machined par... more Burr formation is considered as a detrimental phenomenon that not only decreases the machined part surface and assembly quality, but also increases the production cost. To conduct burr removal from machined edges and holes, the costly and non-desirable secondary operation, so-called deburring, is demanded. The complexity and severity of deburring processes depend on several factors, including burr size, location, and the material to be deburred. Due to vast applications of aluminum alloys in numerous manufacturing sectors including automotive and aerospace industries, adequate knowledge of the most widely used deburring processes on aluminum alloys is demanded. However, surprisingly, despite the acute demands by numerous manufacturing sectors, no state of the art was found in the open literature about applicable deburring and edge-finishing methods for aluminum work parts. This lack is intended to be remedied in this work by providing an insight into the most widely used deburring and edge-finishing processes for aluminum work parts. To that end, several deburring classifications were proposed. The main highly used category of deburring techniques is mechanical deburring process which is related to the removal of various kinds of burr shapes and size by means of mechanical abrasion. In fact, mechanical deburring processes are the most widely used techniques due to versatility, flexibility, deburring rate, and acceptable cost. Among mechanical deburring methods, several methods including robotic, CNC, and manual deburring were presented in this work. A brief insight into the application of several other non-classified mechanical deburring processes was also presented. In addition, knowing that an accurate selection of deburring methods is highly dependent to proper understanding of the burr formation, therefore, an overview of burr formation mechanism, morphology, shape, and, in principle, those factors governing burr formation are also presented, followed by experimental, numerical, and analytical models of burr formation morphology and size. Other general concerns, including the use of lubricant and its effects on deburring performance, must be identified. The future demands of precision deburring are challenging, not only for machine tools and deburring tools, but also for high-precision machining researchers. Close collaborations between machine tool builders, CAD/CAM programmers for precision tool path planning, and deburring and edge-finishing R & D community are highly demanded towards the successful movement to the next generation of precision deburring and edge finishing.

Modern Applied Science, 2017

The process of cold forming is considered of the most different industries and the use of such pr... more The process of cold forming is considered of the most different industries and the use of such process in the manufacture of components and small parts has expanded. Therefore, analyzing the behavior of metals in this process to identify and control durability that is the main factor of limiting process has particular importance in industrial forming processes. In this study, cold forming process of aluminum metal has been studied and its effect on its mechanical properties has been evaluated. For this purpose, first modeling piece of aluminum alloy 5083 for cold forming process is carried out and using finite element analysis, mechanical properties of considered piece during cold forming processes are investigated. The results show that by reducing friction, stress and strain during the process will reduce, thereby durability of the piece increases, or in other words, ductile fracture occurs in longer life and higher stresses. The results show that by proper forming operations, it ...