Journal of Applied Sciences and Environmental Management
The objective of this study is to predict the percentage dilution in AISI 1020 low carbon steel w... more The objective of this study is to predict the percentage dilution in AISI 1020 low carbon steel welds produced from tungsten inert gas welding using Artificial Neural Networking (ANN) approach. The regression plot showed R = 0.9992 as progress of training, R = 0.99865 as progress of validation and R = 0.85285 as progress of the training test. This led to overall correlation coefficient (R) of 0.90007 which signified that ANN is a robust tool for predicting the percentage of weld dilution. To test the reliability of the trained network, the ANN model was employed to predict its own value of percentage dilution using the same input parameters generated from the central composite design. Based on the observed and the predicted values of percentage dilution, a regression plot of outputs was thereafter generated, and r2 value of 0.9876 was obtained which led to the conclusion that the trained network can be used to predict percentage dilution beyond the limit of experimentation. There wa...
The weld quality of tungsten inert gas (TIG) welded joint has been investigated to identify the m... more The weld quality of tungsten inert gas (TIG) welded joint has been investigated to identify the most economical weld parameters that will bring about optimum properties. Response surface methodology has been used in the optimization of the tungsten inert gas weld of mild steel pipes. Response surface methodology, based on the central composite face centered design was generated for the purpose of optimization of the weld quality.All the process parameters have desirability of 1. Tensile strength response for this solution have a desirability of 0.910595 and the yield strength of 0.59. Result showed that minimizing current and voltage an average tensile strength of 535.452MPa and yield strength of up to 408.74MPa can be achieved, while keeping gas flow rate and electrode diameter within the range of test. It was also deduced that tensile elongation of the TIG weld is not influenced by the process parameters selected for the purpose of this study.
European Journal of Engineering and Technology Research, 2021
The challenges of using locally available materials in Nigeria to meet the tiles demand that will... more The challenges of using locally available materials in Nigeria to meet the tiles demand that will be affordable and compete favourably with imported products will no doubt not only contribute to our Gross Domestic Product but also meet the yearning of the Federal Government on her local content policy. This necessitated this study to aim at the production of ceramic floor tiles with clays modified with naturally occurring materials. An experimental method was adopted to carry out this research work. Different clay samples were purposively gotten from Mbaukwu town, Anambra State, Nigeria. Rice husk, silt, feldspar, quartz was obtained to serve as modifiers. An elaborate nested experimental design, structured as an analytical hierarchy process, and festooned with three base materials, 4-modifiers, and with replications, facilitated the achievement of the production. The nested design was developed to guide in the optimum combination of materials that will give the best yield of tiles....
Tungsten Inert Gas (TIG) welding was used in this paper in order to achieve good weld qualities a... more Tungsten Inert Gas (TIG) welding was used in this paper in order to achieve good weld qualities and geometry. Desired specifications were used as process parameters for the various joints that were welded for investigation. This justifies the aim of this research which is to develop an Adaptive Neuro-Fuzzy Inference System to predict the properties of Tungsten Inert Gas (TIG) Welded joints of mild steel pipeline joint. During the welding process, current, voltage, shielding gas flow rate and electrode diameter were considered as the process parameters while tensile strength and yield strength were taken as responses. Results show that the best prediction by ANFIS for tensile and yield strength resulted to 508.25 MPa and 387.98 MPa respectively. The ANFIS Model was able to predict tensile and yield strength to maximum error of 0.361. From results, ANFIS has demonstrated the efficiency to predict least values for both tensile and yield at lowest percentage error compared to other syst...
Expert Modelling and Prediction of Von Mises Stresses in Carbide Insert Cutting Tool Using Fem (Ansys)
Metal machining operation results in irreversible stripping of a work piece material in order to ... more Metal machining operation results in irreversible stripping of a work piece material in order to achieve a predefined geometry. It comes with various adverse effects on the cutting tool such as abnormal thermal gradient in the form of von mises stresses. These effects can lead to regrinding of the cutting edges, untimely tool’s failure as well as poor surface finish on the work piece. These and many others are cost ineffective to the manufacturing firm. In this research, we aim to show how robust the Finite Element (ANSYS) method is, by comparing its predictive strength to the experimental machining operation. To achieve our goal, we carried out an experimental cutting test using the dry cutting of a cylindrical mild steel bar of 200mm length by 44mm diameter. Carbide insert single point cutting tool was used for the machining operation. The Box-Behnken Design (BBD) of experiment was adopted for this work and seventeen (17) experimental tests were generated for the research. The exp...
NIPES Journal of Science and Technology Research, 2020
Residual stress are stresses that remains in an engineering material, especially metallic materia... more Residual stress are stresses that remains in an engineering material, especially metallic materials, after the original applied load has been removed. Its measurement will help reveal areas in fabricated materials highly stressed. This paper presents a design of a portable residual stress measuring device based on the magnetic barkhausen noise principle. This was achieved by using two permanent magnets, a pickup coil, amplifier and an analogue to digital converter to create the hardware. The software was designed using LabVIEW 2019. After fabrication, measuring experiments on mild steel materials were conducted and the results obtained from using the device for measurement were compared to simulated values (Simufact.Weld 6.0) CAD software. Comparing its results with that obtained from Simulation showed an R 2 value of 77.47% with a strong correlation of 0.831and a P-value of 0.0071 which was less than the 0.05 alpha level taken. This device can be adopted in weld residual stress measurement by artisans and roadside welders for effective minimization of residual stress and failures associated with it.
This research is aimed at developing a novel approach for selecting an optimum flux combination f... more This research is aimed at developing a novel approach for selecting an optimum flux combination from a collection of various flux combinations by applying the Nested Random Model, with the stoichiometric characteristics of each of the flux combinations and the desired physical properties taken into consideration. Having been grouped into five batches, each specimen was used to make weld deposits and thereafter machined to determining their Ultimate Tensile Strength (UTS). The average UTS values were applied to the Nested Random Model, and Batch 1 was singled out for further analysis. The UTS of the weld deposit was thereafter subjected to Analysis of Variance (ANOVA), and the specimen which had the highest contribution, designated as flux1(45%NaCl-45%CaCl 2-2%CaF 2-8%3NaFAlF 3) was chosen. The Nested Random Model has been successfully adapted for the development of an optimum flux composition.
A human error is an act of commission or omission which leads to a failure to perform a specified... more A human error is an act of commission or omission which leads to a failure to perform a specified task. This failure could result in damage to property and equipment inevitably creating a hazardous scenario. There are two types of human errors; critical human error which could cause imminent system break down (unplanned breakdown). Secondly, there are latent (asymptomatic) human errors, which would not usually lead to an immediate system breakdown. The inability of employees to operate machines and equipment, and perform routine and thorough maintenance exercises within specified safety regulations in an engineering system could lead to a significant rise in asymptomatic hazard rates, hence this project. The probability density and hazard rate functions were used to determine the hazard rates of the plant studied. The acceptable failure time is the longest time a system is expected to remain functional at 95% confidence level before it fails. From the computations in this study it w...
The production of liquid detergent using locally sourced palm fruit bunch (Elaeis Guineesis) wast... more The production of liquid detergent using locally sourced palm fruit bunch (Elaeis Guineesis) waste saponifier has been investigated. An optimum blend ratio of rubber seed oil to palm kernel oil RSO:PKO 20:80 being constituent elements used for the production of the soap; was obtained using the Duncan Multiple Range Test. The black pigmentation in the oil was removed by bleaching and passing compressed air through it using laboratory grade activated carbon. Saponification values of 130.5 and 126.3 were obtained for the local KOH and laboratory grade respectively. From expert test results, good quality soap was produced using local KOH comparable to laboratory grade KOH.
Bead penetration depth plays a significant role on the quality and integrity of welds, as deeper ... more Bead penetration depth plays a significant role on the quality and integrity of welds, as deeper penetration can improve the strength and load bearing capacity of weldments in service condition. Based on Design of Experiment (DOE), an experimental design matrix having thirteen (13) center points, six (6) axial points and eight (8) factorial points resulting in twenty (20) experimental runs was generated for TIG welding current, voltage, gas flow rate (L/min) and temperature. Maximum bead penetration of 8.44 mm was obtained from the FEM simulation with corresponding input variables of 190 A, 19 V, 18 L/min and 298.44 o C compared to maximum bead penetration of 7.942 mm obtained from the welding experimentation with corresponding input variables of 155 A, 22 V, 15.50 L/min and 278.46 o C. To clearly understand the rate of heat distribution across the as-welded plate, FEM bead penetration profiles were developed using Solid Works (2017 version) thermal transient analysis which revealed that the higher the temperature distribution the wider the Heat Affected Zones (HAZs) which are indications of phase transformations and alterations in mechanical properties of the welded metal which may lead to induced residual stresses if the welding parameters particularly the amperage is not controlled adequately. In addition, there was proximity in the trend of bead penetration from the regression plot where the FEM model had a coefficient of determination (R 2) of 0.9799 while R 2 of 0.9694 was obtained for the welding experimentation, indicating about 97.4% variance which in this context signifies that both bead penetration values can be adopted for real practical scenarios where deep weld bead penetrations are required.
Application Of Artificial Neural Network In Predicting The Weld Quality Of A Tungsten Inert Gas Welded Mild Steel Pipe Joint
International Journal of Scientific & Technology Research, 2014
The weld quality of Tunston inert gas welded joint has been investigated to identify the most eco... more The weld quality of Tunston inert gas welded joint has been investigated to identify the most economical weld parameters that will bring about optimum properties. Artificial neural network, has been used in the prediction and optimization of the Tunston inert gas weld of mild steel pipes. Neural network model was generated using the Levenberg-Marquardt algorithm with feed ward back propagation learning rule. Results show that the generated neural network model was able to predict tensile and yield strength to a mean square error of 34.2.
Journal of Applied Sciences and Environmental Management, Jan 2, 2019
In this study, temperature and time dependence analysis was carried out on Tungsten Inert Gas (TI... more In this study, temperature and time dependence analysis was carried out on Tungsten Inert Gas (TIG) Welding of AISI 1020 Low Carbon Steel Plate of 10 mm thickness. The TIG welding parameters deduced from design of experiment for current ranging from 96-213 A, voltage ranging from 16-25 V and gas flow rate ranging from 11-19 L/min was used as input variables for the welding experimentation and simulation using Finite Element Method (FEM) based on Goldak model heat source. There was proximity in the regression plot of temperature outputs for both the experimental and FEM predicted values. The temperature and time dependence transient thermal analysis was simulated for 20 seconds at welding speed of 1.5 mm/s in steps of 2.5 seconds for each heat source and the result revealed that at each increasing step, the heat distribution characterized by intense heat, phase transformation and alteration in mechanical properties gradually formed a spiral transient patterns from the weldment known as Heat Affected Zone (HAZ). Hence the longer the arc heat at a given weldment the wider the HAZ which result in high residual stress build-ups, undercut and other welding defects that hampers the welded component in service condition.
Globally, aluminium and its alloys are generally regarded as materials that are difficult to weld... more Globally, aluminium and its alloys are generally regarded as materials that are difficult to weld. Research is ongoing with a view to finding newer and better ways to repair or weld these alloys. Consequently various mathematical models are currently being adapted to formulate new compositions for aluminium welding fluxes. In this study, a new flux was developed for the welding of high strength aluminium alloy using the Gauss Jordan Row Operation model. By applying this model, an optimum composition of 39% NaCl , 20.5% CaCl2 , 20.5% KCl, 6% CaF2, and 14% 3NaFAlF3, was obtained. The weldment which resulted from the application of this optimum flux was subjected to certain mechanical tests, such as the tensile test, hardness test, and micro-structural analysis. The ultimate tensile strength of the weld was found to be 428 MPa, 0.2% proof stress of 305 MPa, and a Brinell hardness number of 94. These values compare well with published values in literature. Also from the micro-structural analysis, the weld is confirmed to be of good quality. A systematic (step by step) approach has been applied in this research work and found to be very rewarding
Several different processes and models have been adopted for the optimization of weld deposit qua... more Several different processes and models have been adopted for the optimization of weld deposit quality of mild steel joints. These various processes and models have been used continually over the decades to find new ways of improving weld deposit quality, with the ultimate aim of improving the service life of the resulting weld joints. This quest to find ways of improving weld deposit quality has resulted in the use of Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). TOPSIS is one such technique used for solving multi criteria problems. It is based on the concept that the optimal alternative should have the shortest distance from the positive ideal solution, and the farthest distance from the negative ideal solution. From applying the TOPSIS technique, it was found that weldment 9 has the best weld mechanical properties with a Brinell hardness number (BHN) of 216, Ultimate tensile strength (UTS) of 600MPa, Charpy V-notch (CVN) impact energy of 90J, and a percentage elongation of 23%. Also the relationship between the input parameters and the output parameters was examined. It is therefore, concluded that TOPSIS has successfully optimized the input process parameters which has produced the most desired mechanical properties. In this study a step by step approach for the application of the TOPSIS technique is adopted
This study is aimed at investigating the forces responsible for the detachment of molten metal dr... more This study is aimed at investigating the forces responsible for the detachment of molten metal droplets formed at an electrode tip, which imminently and eventually drop into the weld pool during the welding process. The Equations used by Kim and Eagar in 1993 were applied to this study. It was found that the different detaching forces which are the gravitational force, the electromagnetic force, and the drag force, were determined to be 7.154 x 10 -6 N, 0.05N and 1.736N respectively. Whereas, the primary retaining force, which is the surface tension force, was calculated to be 0.0195N. From the findings, since the combination of the detaching forces taken together is greater than the retaining force, detachment of the molten metal droplet must inevitably occur. The combined effect of these forces on the behaviour of molten metal during the droplet detachment process was adequately investigated in this study.
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Papers by Joseph Achebo
resulted from the application of this optimum flux was subjected to certain mechanical tests, such as the tensile test, hardness test, and micro-structural analysis. The ultimate tensile strength of the weld was found to be 428 MPa, 0.2% proof stress of 305 MPa, and a Brinell hardness number of 94. These values compare well with published values in literature. Also from the micro-structural analysis, the weld is confirmed to be of good quality. A systematic (step by step) approach has been applied in this research work and found to be very rewarding
solution. From applying the TOPSIS technique, it was found that weldment 9 has the best weld mechanical properties with a Brinell hardness number (BHN) of 216, Ultimate tensile strength (UTS) of 600MPa, Charpy V-notch (CVN) impact energy of 90J, and a percentage elongation of 23%. Also the relationship between the input parameters and the output parameters was examined. It is therefore, concluded that TOPSIS has successfully optimized the input process parameters which has produced
the most desired mechanical properties. In this study a step by step approach for the application of the TOPSIS technique is adopted