Applied Mechanics and Materials Vol. 899

Abstract: External fixator has played an important role in repairing fractured ankle bone. This surgery is done due to the several factors which are the bone is not normal position or has broken into several pieces. The external fixator will help the broken bone to grow and remodel back to the original appearance. However, there are some issues regarding to the stability of this fixation. Improper design and material are the major factor that decreased the stability since it is related to the deformation of the external fixator to hold the bone fracture area. This study aims to design a stable structure for constructing delta frame ankle external fixator to increase the stability of the fixation. There are two designs of external fixator with two types of material used in this present study. Both external fixators with different materials are analyzed in terms of von Mises stress and deformation by using a conventional Finite Element Analysis software; ANSYS Workbench V15. The result obtained shows the Model 1 with stainless steel has less stress and deformation distributions compared to the Model 2. Hence, by using Model 1 as the external fixator, the stability of the fixation can be increased.

Abstract: Nowadays, running is said to be one of the common activities that be practiced by various people especially athletes. Back then, there were some researchers report that most of the injuries among athletes involves lower hip bodies. It is due to some factors such as body and foot posture during running activity, selection shoe and style of running. Hence, this research is about to design and develop an insole monitoring system using ESP 32 development board and FSR sensor for the purpose of force distribution detection on runner’s foot. The development of smart insole is to countermeasure the risk of injury to the athletes. This system includes (ESP 32) development board which act as a microcontroller that interfaced with a Wi-Fi module and force sensing resistance (FSR) sensor to detect the force distribution of runner’s foot in (kg) unit. The system able to detect the foot force distribution acts by the runner and transmits the output data of the FSR sensor through the application which called Blynk. The experiments had done through two methods which are jogging and running. The force monitoring data was obtained through the Blynk Application via Wi-Fi. The design and development of insole monitoring system has successfully done and implemented on the runner.

Abstract: In an initiative to reveal the property of welded joint, investigation and assessment of the welding parameters in friction stir spot welding (FSSW) was carried out. In this study, the AA5052-H112 sheets with 2mm thickness was welded using cylindrical tool pin profile under different combinations of main process parameters i.e. spindle speed, tool depth, and dwell time. The fatigue test under cyclical load condition was performed to investigate the dynamic behavior of the welded joint. Failure mode analysis on the fracture of the weld joint after fatigue test was took also consideration. Finally, results from the test were evaluated using analysis of variance (ANOVA) to deter-mine statistically significant factors and associated percentage contribution together with the generation of main effects plots. From ANOVA results, dwell time had the highest influence on fatigue load with a PCR of 52.8%, followed by the spindle speed 37.1%, and then tool depth 6%.

Abstract: This study deals with the fatigue life assessment of the transverse fillet weld and transverse fillet weld on weld fatigue specimen of the offshore steel S460G2+M with a thickness of 10 mm. These specimens were joined using gas metal arc welding (GMAW) with ER80S-N1 filler metal of 1.0 mm in diameter and mixed gases of 80% Ar + 20% CO2 as the consumables. Upon the welding completion, some of the fatigue specimens are treated using high-frequency mechanical impact device called pneumatic impact treatment (HFMI/PIT). The treatment procedure uses 90Hz of frequency, 6 bars of pneumatic pressure and 2 mm pin radius with aims to enhance the lifespan of the specimen. These fatigue specimens are classified in as-welded and HFMI/PIT. The fatigue test was conducted to all fatigue specimens until failure using a 250KN Instron fatigue machine with a constant amplitude loading, a stress ratio of 0.1 and stress loading from 55% to 75% of the yield strength of the base material. The fatigue data were evaluated based on the International Institute of Welding (IIW) evaluation procedures. Further, the fatigue life comparison between the as-welded and HFMI/PIT of both fatigue specimens also with the FAT class recommendation of the IIW for transverse fillet weld is plotted in the S-N curve diagram. Based on the assessment, it is found that the HFMI/PIT fatigue specimens attained higher fatigue life than the as-welded of both fatigue specimens. The most significant of fatigue life improvement after the HFMI/PIT is the HFMI/PIT transverse fillet weld. These treated welds obtained 256 MPa of FAT class which is 79 % higher than FAT class recommended by the IIW for the transverse fillet weld. Besides, the multi-pass welds on the groove weld of the transverse fillet weld on welds are found to contribute to a lower fatigue life of this specimen due to the existing weld defects on the fractured surface of the groove weld.

Abstract: Green manufacturing concept has become a cutting edge in the field of sustainable machining. The prime objective of the philosophy is to find a technique in machining or material removal processes that are environmentally friendly, with minimal wastage, energy efficient and optimal condition for the machining processes. This review paper discusses the significance of textured novel cutting tools, is one of the promising technologies and process. It discusses the Dry Machining process to capture green sustainable manufacturing practices. The study may answer of how it stands among other methods including minimum quantity lubrication and nano fluid lubricant. This paper also presents the importance of advanced manufacturing tools to match the sustainable future needs with an idea of proposed methodology to conduct a research on textured novel cutting tools for sustainable machining.

Abstract: This paper presents the experimental work of the surface roughness, surface topography, elementary analysis and microhardness of wire electro-discharge (WEDM) machining of grade 5 titanium alloy (Ti-6Al-4V). Ti-6Al-4V has wide range of application in alloys due to its superior mechanical properties such as corrosion resistance, high tensile strength and toughness. Based on its great hardness value, conventional machining leads to high rates of tool wear, thus, WEDM is an alternative to manufacture Ti-6Al-4V, in which better surface characteristics can be produced. This work explores the surface integrity of Ti-6Al-4V alloy after WEDM in different input parameter. From the experimental work, good surface integrity can be achieved with low peak current. The scanning electron microscope (SEM) analysis depicted the appearance of craters, crack, recast layer and globule of debris on the machined surface. Within the chemical composition on the machined surface, titanium seizes the highest percentage as there is no alternation of the metallurgical structure of the parent material. The microhardness value gradually increases from the machined surface to the parent material of Ti-6Al-4V due to over-aging of the machined surface and the work hardening during the process.

Abstract: Rice husk and bamboo leaves are types of agricultural wastes that can easily be found around the world. Rice husk contains over 60 % of organic silica while silica bamboo leaves extract consist of more than 70 % silica content. Parameters such as concentration of acid and weight percentage of rice husk and bamboo leaves used during acid leaching method were also compared. In this paper, citric acid (C₆H₈O₇) was used for production of silica from rice husk and bamboo leaves. Samples were characterized using X-Ray Fluorescence (XRF) and Field Emission Scanning Electron Microscope Energy Dispersive X-Ray spectroscopy (FESEM / EDX). The performance of glaze on ceramic will be analyzed by undergoes hardness testing. The result indicates that highest percentage silica of rice husk and bamboo leaves after leaching was on 1.0M.

Abstract: Silicon wafers are a key component in integrated circuits which comprised of various electronic components that are arranged to perform a specific function. Wafer dicing is a mechanical process of removing material from a wafer by synthetic diamonds as abrasive particles. Chipping along the cut line crucial to the wafer dicing operation has been identified by semiconductor manufacturers as a relevant area for improvement. The purposed of this study is to characterize the effect of dicing operation on the optical silicon wafer coating material. The effect of the blade wear and silicon wafer kerf width will be analyzed in this work

Abstract: This study focused on investigation of the effect of process parameter to the tensile strength of a spot welded S235 low carbon steel through simulation and experiment. Resistance spot welding (RSW) is commonly used in joining metal sheets due to its key capabilities, which is time and cost effective as well as high adaptability for automation. However, strength and reliability of a spot welded joint especially in an auto vehicle can be unpredictable. Premature failure of a spot welded joint can be difficult to be predicted but common factors that had been discussed in many research is related with fatigue and residual stress. Process parameter is recognized as one of critical factors affecting the reliability and quality of a spot welded joint. Different type of material and thickness may require different set of parameter to achieve an optimum result. Experimental procedure alone to demonstrate and investigate the effect could be too costly and time inefficient. Therefore, design of experiment and non-linear FEM simulation analysis were used to analyze and validate the result. This study shows the significance of process parameters such as weld current and electrode pressure to the strength of a spot welded joint and accurate setting is needed prior to the welding process to achieve an optimum result.

Abstract: By combining the traditional slip casting technique and existing polymer rotary moulding concept a new process namely Ceramic Slip Rotary Moulding (CSRM) machine was established. The CSRM machine was developed to control parameters such as temperature (heating and cooling), time and speed. It is suitable for producing hollow ceramic products especially for ceramic materials such as fine bone china, which is a soft material used for tableware and art ware products due to its brightness and high strength. This research mainly focuses on the preparation of five different particle sizes of fine bone china measurements; 106 μm, 125 μm, 202 μm, 250 μm, and 300 μm respectively by using the CSRM machine. Different particle sizes of the fine bone china materials were tested to check the accurate and suitable wall thickness by controlling the temperature, speed, time and also the weight of the slip to get the best quality of fine bone china products. The parameters obtained will be the guidelines for the overall test to produce the best hollow fine bone china products.