The Experts below are selected from a list of 570 Experts worldwide ranked by ideXlab platform
M. Bouazara - One of the best experts on this subject based on the ideXlab platform.
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Optimization of Casting Design Parameters on Fabrication of Reliable Semi-Solid Aluminum Suspension Control Arm
Journal of Materials Engineering and Performance, 2017Co-Authors: Kh. A. Ragab, A. Bouaicha, M. BouazaraAbstract:The semi-solid casting process has the advantage of providing reliable mechanical aluminum parts that work continuously in dynamic as control Arm of the Suspension system in automotive vehicles. The quality performance of dynamic control Arm is related to casting mold and gating system designs that affect the fluidity of semi-solid metal during filling the mold. Therefore, this study focuses on improvement in mechanical performance, depending on material characterization, and casting design optimization, of Suspension control Arms made of A357 aluminum semi-solid alloys. Mechanical and design analyses, applied on the Suspension Arm, showed the occurrence of mechanical failures at unexpected weak points. Metallurgical analysis showed that the main reason lies in the difficult flow of semi-solid paste through the thin thicknesses of a complex geometry. A design modification procedure is applied to the geometry of the Suspension Arm to avoid this problem and to improve its quality performance. The design modification of parts was carried out by using SolidWorks design software, evaluation of constraints with ABAQUS, and simulation of flow with ProCast software. The proposed designs showed that the modified Suspension Arm, without ribs and with a central canvas designed as Z, is considered as a perfect casting design showing an increase in the structural strength of the component. In this case, maximum von Mises stress is 199 MPa that is below the yield strength of the material. The modified casting mold design shows a high uniformity and minim turbulence of molten metal flow during semi-solid casting process.
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Fatigue Characteristics and Quality Index of A357 Type Semi-Solid Aluminum Castings Used for Automotive Application
Journal of Materials Engineering and Performance, 2015Co-Authors: M. Bouazara, A. Bouaicha, Kh. A. RagabAbstract:The present work aims to investigate the fatigue characteristics of automotive lower Suspension Arm made of semi-solid A357 aluminum castings using metallurgical and analytical approaches. The fatigue life calculations of analytical model are used to identify and introduce the model parameters based on the Suspension Arm material followed by analyzing the load-number of cycles fatigue curve. The critical stress areas capable of initiating cracks during fatigue tests are detected using ABAQUS software followed by the installation of strain gages on the Suspension Arm to calculate maximum stress. The fatigue experiments are carried out to compare the results of the analytical method with the experimental endurance curves traced by lower Suspension Arm samples. Microstructure characteristics of the semi-solid A357 under T6 heat treatment conditions are examined using scanning electron microscope. The results show that the fatigue life and the quality index of alloys investigated are affected by casting technique, castings design, microstructural characterization, and heat treatment condition.
Kh. A. Ragab - One of the best experts on this subject based on the ideXlab platform.
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Optimization of Casting Design Parameters on Fabrication of Reliable Semi-Solid Aluminum Suspension Control Arm
Journal of Materials Engineering and Performance, 2017Co-Authors: Kh. A. Ragab, A. Bouaicha, M. BouazaraAbstract:The semi-solid casting process has the advantage of providing reliable mechanical aluminum parts that work continuously in dynamic as control Arm of the Suspension system in automotive vehicles. The quality performance of dynamic control Arm is related to casting mold and gating system designs that affect the fluidity of semi-solid metal during filling the mold. Therefore, this study focuses on improvement in mechanical performance, depending on material characterization, and casting design optimization, of Suspension control Arms made of A357 aluminum semi-solid alloys. Mechanical and design analyses, applied on the Suspension Arm, showed the occurrence of mechanical failures at unexpected weak points. Metallurgical analysis showed that the main reason lies in the difficult flow of semi-solid paste through the thin thicknesses of a complex geometry. A design modification procedure is applied to the geometry of the Suspension Arm to avoid this problem and to improve its quality performance. The design modification of parts was carried out by using SolidWorks design software, evaluation of constraints with ABAQUS, and simulation of flow with ProCast software. The proposed designs showed that the modified Suspension Arm, without ribs and with a central canvas designed as Z, is considered as a perfect casting design showing an increase in the structural strength of the component. In this case, maximum von Mises stress is 199 MPa that is below the yield strength of the material. The modified casting mold design shows a high uniformity and minim turbulence of molten metal flow during semi-solid casting process.
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Fatigue Characteristics and Quality Index of A357 Type Semi-Solid Aluminum Castings Used for Automotive Application
Journal of Materials Engineering and Performance, 2015Co-Authors: M. Bouazara, A. Bouaicha, Kh. A. RagabAbstract:The present work aims to investigate the fatigue characteristics of automotive lower Suspension Arm made of semi-solid A357 aluminum castings using metallurgical and analytical approaches. The fatigue life calculations of analytical model are used to identify and introduce the model parameters based on the Suspension Arm material followed by analyzing the load-number of cycles fatigue curve. The critical stress areas capable of initiating cracks during fatigue tests are detected using ABAQUS software followed by the installation of strain gages on the Suspension Arm to calculate maximum stress. The fatigue experiments are carried out to compare the results of the analytical method with the experimental endurance curves traced by lower Suspension Arm samples. Microstructure characteristics of the semi-solid A357 under T6 heat treatment conditions are examined using scanning electron microscope. The results show that the fatigue life and the quality index of alloys investigated are affected by casting technique, castings design, microstructural characterization, and heat treatment condition.
Nawar A. Kadhim - One of the best experts on this subject based on the ideXlab platform.
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Effect of Nitriding Cold Roled and Shot Peening on Automotive Component Fatigue Life
Applied Mechanics and Materials, 2013Co-Authors: Nawar A. Kadhim, N. Nik Abdullah, Sureena Abdullah, A. K. ArrifinAbstract:The finite element modeling and analysis have been performed to investigate the effects of nitriding, cold rolled and shot peening on fatigue life of an automotive lower Suspension Arm component which fabricated of SAE1045 steel. The finite element analysis (FEA) results indicate a great effect for all surface finish parameters on fatigue life. It shows that nitriding increased the fatigue life of the component better than shot peening, while cold rolled effect was between them. In a nut shell, nitriding can be considered as the best surface treatment to improve the fatigue life of the automotive lower Suspension Arm which fabricated of SAE1045 steel.
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Effective strain damage model associated with finite element modelling and experimental validation
International Journal of Fatigue, 2012Co-Authors: Nawar A. Kadhim, Shahrir Abdullah, Ahmad Kamal AriffinAbstract:Abstract An efficient computational effort is required for sufficient analysis during component design stage to avoid expensive modifications during the later stages of the manufacturing process. A combination of the effective strain damage (ESD) model based FORTRAN code with finite element software was proposed to predict fatigue life under random loadings. The ESD model parameters were extracted from the experimental and finite element analysis representing the strain history for the most damaging node in an automobile lower Suspension Arm. The ESD model provides reliable fatigue life prediction under random loadings with only 12% minimum difference comparing to the experimental estimations.
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Experimental and Analytical Durability Assessment of SAE 1045 Steel under Service Loadings
Applied Mechanics and Materials, 2012Co-Authors: Nawar A. Kadhim, Ahmad Kamal Ariffin, Shahrum Abdullah, N. NikabdullahAbstract:Durability assessment of automotive lower Suspension Arm has been studied under service loadings. The fatigue tests were conducting for the SAE 1045 steel based strain-controlled. To specify the material mechanical properties of the used material, a fatigue test under constant amplitude loading has been carried out then the results were provided for the finite element code. The finite element fatigue life were evaluated and compared with the experimental results. The accuracy and efficiency of the numerical models are demonstrated. This tool cannot be considered as a powerful alternative prior to the further experimental process. Instead, suitable fatigue prediction models under service loadings need to be developed.
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Dynamic Analysis of an Automobile Lower Suspension Arm Using Experiment and Numerical Technique
New Trends and Developments in Automotive System Engineering, 2011Co-Authors: S. Abdullah, Nawar A. Kadhim, A.k. Ariffin, M. HosseiniAbstract:All machines, vehicles and buildings are subjected to dynamic forces that cause vibration. Most practical noise and vibration problems are related to resonance phenomena where the operational forces excite one or more modes of vibration. Modes of vibration that lie within the frequency range of the operational dynamic forces always represent potential problems. Mode shapes are the dominant motion of a structure at each of its natural or resonant frequencies. Modes are an inherent property of a structure and do not depend on the forces acting on it. On the other hand, operational deflection shapes do show the effects of forces or loads, and may contain contributions due to several modes of vibration. Modal analysis is an efficient tool for describing, understanding, and modelling structural dynamics (Sitton, 1997). The dynamic behaviour of a structure in a given frequency range can be modelled as a set of individual modes of vibration. The modal parameters that describe each mode are: natural frequency or resonance frequency, (modal) damping, and mode shape. The modal parameters of all the modes, within the frequency range of interest, represent a complete dynamic description of the structure. By using the modal parameters for the component, the model can subsequently be used to come up with possible solutions to individual problems (Agneni & Coppotelli, 2004). Published studies have demonstrated the different purposes from performing modal analysis. Initially, Wamsler & Rose (2004) found the mode shapes and study the dynamic behavior of structure in automotive applications. Gibson (2003), presented a comparison of actual dynamic modal test data to the analytically predicted mode shapes and natural frequencies for a missile and its launcher structure that was created in MSC.Patran/MSC.Nastran. Then Guan et al. (2005) evaluated the modal parameters of a dynamic tire then carried out the dynamic responses of tire running over cleats with different speeds. In other study, Leclere et al. (2005) performed modal analysis on a finite element (FE) model of engine block and validated the experimental results. Hosseini et al. (2007) performed experimental modal analysis of crankshaft to validate the numerical results. In particular, studies using a computational model to estimate component fatigue have been actively developed because of the low cost and time savings associated with the estimation (Yim & Lee, 1996; Lee et al., 2000; Kim et al., 2002; Jung et al., 2005). Recently, Choi et al.
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Fatigue Failure Behaviour Study of Automotive Lower Suspension Arm
Key Engineering Materials, 2011Co-Authors: Nawar A. Kadhim, Ahmad Kamal Ariffin, Shahrum Abdullah, S. M. BedenAbstract:Fatigue life of automotive lower Suspension Arm has been studied under variable amplitude loadings. In simulation, the geometry of a sedan car lower Suspension Arm has been used. To obtain the material monotonic properties, tensile test has been carried out and to specify the material mechanical properties of the used material, a fatigue test under constant amplitude loading has been carried out using the ASTM standard specimens. Then, the results used in the finite element software to predict fatigue life has been evaluated later to show the accuracy and efficiency of the numerical models which they are appreciated. The finite element analysis tool is therefore proved to be a good alternative prior to the further experimental process. The predicted fatigue life from the simulation showed that Smith-Watson-Topper model provides longer life than Morrow and Coffin-Manson models. This is due to the different consideration for each strain-life model during life calculations.
A. Bouaicha - One of the best experts on this subject based on the ideXlab platform.
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Optimization of Casting Design Parameters on Fabrication of Reliable Semi-Solid Aluminum Suspension Control Arm
Journal of Materials Engineering and Performance, 2017Co-Authors: Kh. A. Ragab, A. Bouaicha, M. BouazaraAbstract:The semi-solid casting process has the advantage of providing reliable mechanical aluminum parts that work continuously in dynamic as control Arm of the Suspension system in automotive vehicles. The quality performance of dynamic control Arm is related to casting mold and gating system designs that affect the fluidity of semi-solid metal during filling the mold. Therefore, this study focuses on improvement in mechanical performance, depending on material characterization, and casting design optimization, of Suspension control Arms made of A357 aluminum semi-solid alloys. Mechanical and design analyses, applied on the Suspension Arm, showed the occurrence of mechanical failures at unexpected weak points. Metallurgical analysis showed that the main reason lies in the difficult flow of semi-solid paste through the thin thicknesses of a complex geometry. A design modification procedure is applied to the geometry of the Suspension Arm to avoid this problem and to improve its quality performance. The design modification of parts was carried out by using SolidWorks design software, evaluation of constraints with ABAQUS, and simulation of flow with ProCast software. The proposed designs showed that the modified Suspension Arm, without ribs and with a central canvas designed as Z, is considered as a perfect casting design showing an increase in the structural strength of the component. In this case, maximum von Mises stress is 199 MPa that is below the yield strength of the material. The modified casting mold design shows a high uniformity and minim turbulence of molten metal flow during semi-solid casting process.
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Materials Performance and Design Analysis of Suspension Lower-Arm Fabricated from Al-Si-Mg Castings
Key Engineering Materials, 2016Co-Authors: Khaled Ragab, A. Bouaicha, Mohamed Bouazara, Hatem MradAbstract:The diversity of physical and mechanical properties of aluminum alloys leads to develop a variety of manufacturing processes including the semi-solid casting process. Fatigue failure is considered the most common problem occurred in automotive engineering applications by which the vehicle components, mainly Suspension system parts, fail under conditions of dynamic loading. It is well known that the fatigue life of aluminum castings, mainly A357, is very sensitive to casting design as well as to casting defects and microstructure constituents. The fatigue characteristics of automotive lower Suspension Arm made of semi-solid A357 aluminum castings have been investigated using metallurgical and analytical approaches. The critical stress areas capable of initiating cracks during fatigue tests are detected by using fatigue experimental design for real part materials by the installation of strain gages on the Suspension Arm to calculate maximum stress; further more, analytical approach is applied using modelling software. Microstructure characteristics of the semisolid A357 under T6 heat treatment conditions are examined using scanning electron microscope. The results show that using the SEED casting technology (Swirled Enthalpy Equilibration Device) has an efficient effect on the mechanical and metallurgical characteristics of real part materials that are also affected by castings design.
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Fatigue Characteristics and Quality Index of A357 Type Semi-Solid Aluminum Castings Used for Automotive Application
Journal of Materials Engineering and Performance, 2015Co-Authors: M. Bouazara, A. Bouaicha, Kh. A. RagabAbstract:The present work aims to investigate the fatigue characteristics of automotive lower Suspension Arm made of semi-solid A357 aluminum castings using metallurgical and analytical approaches. The fatigue life calculations of analytical model are used to identify and introduce the model parameters based on the Suspension Arm material followed by analyzing the load-number of cycles fatigue curve. The critical stress areas capable of initiating cracks during fatigue tests are detected using ABAQUS software followed by the installation of strain gages on the Suspension Arm to calculate maximum stress. The fatigue experiments are carried out to compare the results of the analytical method with the experimental endurance curves traced by lower Suspension Arm samples. Microstructure characteristics of the semi-solid A357 under T6 heat treatment conditions are examined using scanning electron microscope. The results show that the fatigue life and the quality index of alloys investigated are affected by casting technique, castings design, microstructural characterization, and heat treatment condition.
Ahmad Kamal Ariffin - One of the best experts on this subject based on the ideXlab platform.
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Effective strain damage model associated with finite element modelling and experimental validation
International Journal of Fatigue, 2012Co-Authors: Nawar A. Kadhim, Shahrir Abdullah, Ahmad Kamal AriffinAbstract:Abstract An efficient computational effort is required for sufficient analysis during component design stage to avoid expensive modifications during the later stages of the manufacturing process. A combination of the effective strain damage (ESD) model based FORTRAN code with finite element software was proposed to predict fatigue life under random loadings. The ESD model parameters were extracted from the experimental and finite element analysis representing the strain history for the most damaging node in an automobile lower Suspension Arm. The ESD model provides reliable fatigue life prediction under random loadings with only 12% minimum difference comparing to the experimental estimations.
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Experimental and Analytical Durability Assessment of SAE 1045 Steel under Service Loadings
Applied Mechanics and Materials, 2012Co-Authors: Nawar A. Kadhim, Ahmad Kamal Ariffin, Shahrum Abdullah, N. NikabdullahAbstract:Durability assessment of automotive lower Suspension Arm has been studied under service loadings. The fatigue tests were conducting for the SAE 1045 steel based strain-controlled. To specify the material mechanical properties of the used material, a fatigue test under constant amplitude loading has been carried out then the results were provided for the finite element code. The finite element fatigue life were evaluated and compared with the experimental results. The accuracy and efficiency of the numerical models are demonstrated. This tool cannot be considered as a powerful alternative prior to the further experimental process. Instead, suitable fatigue prediction models under service loadings need to be developed.
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Fatigue Failure Behaviour Study of Automotive Lower Suspension Arm
Key Engineering Materials, 2011Co-Authors: Nawar A. Kadhim, Ahmad Kamal Ariffin, Shahrum Abdullah, S. M. BedenAbstract:Fatigue life of automotive lower Suspension Arm has been studied under variable amplitude loadings. In simulation, the geometry of a sedan car lower Suspension Arm has been used. To obtain the material monotonic properties, tensile test has been carried out and to specify the material mechanical properties of the used material, a fatigue test under constant amplitude loading has been carried out using the ASTM standard specimens. Then, the results used in the finite element software to predict fatigue life has been evaluated later to show the accuracy and efficiency of the numerical models which they are appreciated. The finite element analysis tool is therefore proved to be a good alternative prior to the further experimental process. The predicted fatigue life from the simulation showed that Smith-Watson-Topper model provides longer life than Morrow and Coffin-Manson models. This is due to the different consideration for each strain-life model during life calculations.
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FEA Based Fatigue Life Estimation of Automotive Component Correlated with Fatigue Data Editing Technique
Advanced Materials Research, 2011Co-Authors: Nawar A. Kadhim, Ahmad Kamal Ariffin, Shahrum Abdullah, S.m. BedanAbstract:A computational approach based on finite element analysis (FEA) for integrated durability assessment in an automotive component is presented. For further time saving related durability evaluation, the objective of this research is to investigate how accurately a road data history can be edited. A road data has been collected using a fatigue data acquisition system. A substantial compression for automotive lower Suspension Arm fatigue damage was performed for the purpose of accelerated fatigue data analysis. FEA was then used to estimate the fatigue life for the original and the edited data using two different strain life models. The original road data has been successfully edited for the purpose of damage predicting using FEA with a big difference in the software spending time for the component fatigue life prediction. As a result, the editing method was shown to be useful for summarising long histories and resulting in significantly shorter analysis with presenting the predicted amount of the fatigue damage as the original histories. As a consequence of application for automotive lower Suspension Arm, this technique can be applied in performing a fatigue history editing, especially in compression of data set.
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Effect of the fatigue data editing technique associated with finite element analysis on the component fatigue design period
Materials & Design, 2011Co-Authors: Nawar A. Kadhim, Shahrir Abdullah, Ahmad Kamal AriffinAbstract:The present study concerns development of accelerated fatigue design time based finite element analysis (FEA) through a combination of the fatigue data editing (FDE) technique and FEA. Country road, pavement and highway fatigue data histories were collected using a fatigue data acquisition system. The component durability was evaluated using both original and editing fatigue data signals. Both signals showed a large difference in the CPU time. Furthermore, the histories were successfully edited by presenting the predicted amount of the fatigue damage as the original histories. As a consequence of application for automotive lower Suspension Arm, this technique can be applied in performing a fatigue history editing, especially in compression of data set. Briefly, design time was saved based on FDE technique associated with FEA.
