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Experimental Study and Numerical Simulation of Sheet Hydroforming Process for Aluminum Alloy AA5652
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 Abstract   

Lightweight materials is used in the sheet metal hydroforming process,  because it can be adapted to the manufacturing of complex structural components into a single body with high structural stiffness. Sheet hydroforming has been successfully developed in industry such as in the manufacturing of the components of automotive.The aim of this study is to simulate the experimental results ( such as the amount of pressure required to hydroforming process, stresses, and strains distribution)  with results  of finite element analyses (FEA)  (ANSYS 11)  for aluminum alloy (AA5652) sheets with  thickness (1.2mm) before heat treatment (BHT) and after heat treatment (AHT) respectively in the circular die with cavity equals to (20mm) . The comparison of results by these two approaches show the same tendency that an improvement formability, also  the plastic deformation is greatly enhanced AHT for same metal.

 Keyword : sheet hydroforming , stress and strain distribution, aluminum alloy, forming limit diagram.

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Publication Date
Sat Dec 02 2023
Journal Name
Journal Of Engineering
Simulation and Experimental Investigation of Performance and Flow Behavior for Steam Ejector Refrigeration System
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The ejector refrigeration system is a desirable choice to reduce energy consumption. A Computational Fluid Dynamics CFD simulation using the ANSYS package was performed to investigate the flow inside the ejector and determine the performance of a small-scale steam ejector. The experimental results showed that at the nozzle throat diameter of 2.6 mm and the evaporator temperature of 10oC, increasing boiler temperature from 110oC to 140oC decreases the entrainment ratio by 66.25%. At the boiler temperature of 120oC, increasing the evaporator temperature from 7.5 to 15 oC increases the entrainment ratio by 65.57%. While at the boiler temperature of 120oC and

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Publication Date
Mon Dec 18 2017
Journal Name
Al-khwarizmi Engineering Journal
Effect of Magnesium Addition on Corrosion Resistance of Aluminum -17%Silicon Alloy
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The electrochemical behavior of Al-17%Si alloy is investigated in 3.5wt% NaCl solution. Many alloys with addition of the different wt% magnesium metal of  1wt%, 2%, 3wt% ,4.5wt% ,and 9wt% were prepared by gravity die casting . The microstructures of prepared alloys were examined by optical and SEM microscopes. Corrosion behavior was investigated by using potentiostat instrument under static potentials test and corrosion current was recorded to determine corrosion resistance of all prepared samples. It was found that the addition of Mg metal improves the corrosion resistance of Al-17%Si alloy in 3.5%NaCl solution. The alloy containing 1%Mg shows less corrosion rate than the others while the alloys containing 4.5%Mg, 9%Mg content have

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Publication Date
Mon Jan 29 2024
Journal Name
Polymer Bulletin
An experimental study to investigate the effect of aluminum nanorod-reinforced epoxy matrix nanocomposites
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Publication Date
Sun Dec 01 2019
Journal Name
Al-khwarizmi Engineering Journal
Modeling of Bending Properties of Stainless Steel 304 Sheets Welded by Tungsten Inert Gas Welding Process
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In this research, the effects of both current and argon gas pressure on the bending properties of welded joints were studied. Using the possible ranges of welding gas pressures and currents, Tungsten inert gas welding (TIG) of stainless steel (304) sheet was used to obtain their influence on the maximum bending force of the (TIG) welded joints. Design of experiment (DOE) ‘version 10' was used to determine the design matrix of experiments depending on the used levels of the input factors. Response surface methodology (RSM) technique was used to obtain an empirical mathematical model for the maximum bending force as a function of welding parameters (Current and Argon gas pressure). Also, the analysis of variance (ANOVA) was used to verif

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Publication Date
Sat Oct 01 2011
Journal Name
Journal Of Engineering
THE INFLUENCE OF TOOL GEOMETRY OF FRICTION STIR WELDS ON MECHANICAL PROPERTIES AND MICROSTRUCTURE OF 2218-T72 ALUMINUM ALLOY
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Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt. This process uses a nonconsumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the weld quality. In this investigation an attempt
has been made to understand the effect of tool pin profile and rotation diameter on microstructure and mechanical properties in aluminum alloy (2218-T72). Five different tool pin profiles (straight cylindrical, threaded cylindrical, triangular, square, and threaded cylindrical with flat), with three different rotation
d

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Publication Date
Mon Jan 29 2018
Journal Name
Iraqi Journal Of Science
Diagnostics of Magnesium-Aluminum alloy plasmas produced by laser induced breakdown spectroscopy
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In this work, the Al-Mg alloys plasma plume that produced under vacuum (10-1 torr) by Nd:Yag Laser was studied. the plasma spectra were analyzed by comparing the atomic lines of Al and Mg lines with standard lines. The effect of laser energies on spectral lines produced by laser ablation were investigated using optical
spectroscopy .several plasma characteristics like electron temperature, electron density, Debye’s length, plasma frequency and number of particles in the ‘‘Debye’s Sphere’’ were calculated in vacuum .The results show the electron temperature and electron density increase in magnesium, aluminum and magnesium :aluminum alloy
targets . It was found that the lines intensities at

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Publication Date
Fri Jul 21 2023
Journal Name
Journal Of Engineering
EXPERIMENTAL AND NUMERICAL STRESS ANALYSIS OF INVOLUTE SPLINED SHAFT
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In this study, the induced splined shaft teeth contact and bending stresses have been investigated numerically using finite element method(Ansys package version 11.0) with changing the most effecting design parameter,(pressure angle, teeth number, fillet radius and normal module), for internal and external splined shaft. Experimental work has been achieved using two dimensional photoelastic techniques to get the contact and bending stresses; the used material is Bakelite sheet type “PSM-4”.
The results of numerical stress analysis indicate that, the increasing of the pressure angle and fillet radius decrease the bending stress and increase the contact stress for both internal and external spline shaft teeth while the increasing of

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Publication Date
Thu Sep 08 2022
Journal Name
Al-khwarizmi Engineering Journal
Performance Prediction in EDM Process for Al 6061 Alloy Using Response Surface Methodology and Genetic Algorithm
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The Electric Discharge (EDM) method is a novel thermoelectric manufacturing technique in which materials are removed by a controlled spark erosion process between two electrodes immersed in a dielectric medium. Because of the difficulties of EDM, determining the optimum cutting parameters to improve cutting performance is extremely tough. As a result, optimizing operating parameters is a critical processing step, particularly for non-traditional machining process like EDM. Adequate selection of processing parameters for the EDM process does not provide ideal conditions, due to the unpredictable processing time required for a given function. Models of Multiple Regression and Genetic Algorithm are considered as effective methods for determ

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Publication Date
Fri Sep 30 2011
Journal Name
Al-khwarizmi Engineering Journal
Studying the Effect of Addition Particles of Alumina (Al2O3) and Zirconia (ZrO2), on Some Mechanical Properties for Matrix Composites (Al-Si-Mg) Alloy
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This study is concerned with the effect of adding two kinds of ceramic materials on the mechanical properties of (Al-7%Si- 0.3%Mg) alloy, which are zirconia with particle size (20μm > P.S ≥ 0.1μm) and alumina with particle size (20μm > P.S ≥ 0.1μm) and adding them to the alloy with weight ratios (0.2, 0.4, 0.6, 0.8 and 1%). Stirring casting method has been used to make composite material by using vortex technique which is used to pull the particles to inside the melted metals and distributed them homogenously.

After that solution treatment was done to the samples at (520ºC) and artificial ageing at (170ºC) in different times, it has been noticed that the values of hardness is increased with the aging time of the o

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Publication Date
Sat Jan 01 2022
Journal Name
Journal Of The Mechanical Behavior Of Materials
Molding and simulation sedimentation process using finite difference method
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Abstract<p>The goal of this research is to develop a numerical model that can be used to simulate the sedimentation process under two scenarios: first, the flocculation unit is on duty, and second, the flocculation unit is out of commission. The general equation of flow and sediment transport were solved using the finite difference method, then coded using Matlab software. The result of this study was: the difference in removal efficiency between the coded model and operational model for each particle size dataset was very close, with a difference value of +3.01%, indicating that the model can be used to predict the removal efficiency of a rectangular sedimentation basin. The study also revealed</p> ... Show More