Laminar flowmeter for mechanical ventilator: Manufacturing challenge of Covid-19 pandemic.

The rapid and sudden attack of the covid-19 pandemic has emerged the urgent need for pulmonary resuscitation devices (ventilators). The airflow sensor is a main element in the ventilator. Sensing very low airflow rates is an essential requirement to meet the least significant bit of the analogue to digital converter included in the ventilator. This short communication describes the fabrication and test of five flow sensors using basic and the 3D printing techniques to overcome the severe challenge arising from the pandemic under strict quarantine. The principle of these five flow sensors is based on Fleisch pneumotachograph technology, which creates a pseudo-laminar flow within a bundle of capillary tubes. Amongst the five tested sensors, those fabricated by 3D printing technique were the most accurate and reliable. Results show that the 3D printed sensor of 33 trapezoidal capillary tubes and displaced pressure taps meet the requirement of sensing flowrates with less resistance to patient at exhalation and more linearity figure. The experimental data were correlated using a sophisticated MMF correlation with an R-squared factor of 0.9999 and a percentage error of 1.68%.

Experimental Investigation of Load-Bearing Capacity in EN AW-2024-T3 Aluminum Alloy Sheets Strengthened by SPIF-Fabricated Stiffening Rib.

The aluminum strength-to-weight ratio has become a highly significant factor in industrial applications. Placing stiffening ribs along the surface can significantly improve the panel's resistance to bending and compression in aluminum alloys. This study used single-point incremental forming (SPIF) to fabricate stiffening ribs for 1 mm and 3 mm thick aluminum alloy EN AW-2024-T3 sheets. A universal compression machine was used to investigate sheet deformation. The resulting deformation was examined using non-contact digital image correlation (DIC) based on several high-resolution cameras. The results showed that deformation progressively escalated from the edges toward the center, and the highest buckling values were confined within the non-strengthened area. Specimens with a larger thickness (3 mm) showed better effectiveness against buckling and bending for each applied load: 8 kN or 10 kN. Additionally, the displacement from the sheet surface decreased by 60% for sheets 3 mm thick and by half for sheets 1 mm thick, which indicated that thicker sheets could resist deformation better.

Analysis of Surface Texture and Roughness in Composites Stiffening Ribs Formed by SPIF Process.

Studying roughness parameters and the topography of stiffening ribs in composite sandwich structures is important for understanding these materials' surface quality and mechanical properties. The roughness parameters describe the micro-geometry of the surface, including the average height deviation, roughness depth, and waviness. The topography of the surface refers to the spatial arrangement and distribution of features such as bumps, ridges, and valleys. The study investigated the roughness parameters under three scenarios based on two SPIF process parameters: tool rotational speed(N) and feed rate (f). The vertical step was held constant at 0.4 mm across all scenarios. In scenario A, the process parameters were set at f = 300 mm/min and n = 300 rpm; in scenario B, f = 1500 mm/min and n = 3000 rpm; and in scenario C, f = 1500 mm/min and n = 300 rpm. The experimental research topography analyses revealed that the surface roughness of the stiffened ribs was highly dependent on the SPIF process parameters. The highest feed rate and tool rotational speed produced the smoothest surface texture with the lowest maximum height (Sz) value. In contrast, the lowest feed rate and tool rotational speed resulted in a rougher surface texture with a higher maximum height (Sz) value. Furthermore, the contour plots generated from the topography analyses provided a good visual representation of the surface texture and roughness, allowing for a more comprehensive analysis of the SPIF process parameters. This study emphasizes optimizing the SPIF process parameters to achieve the desired surface quality and texture of stiffened ribs formed in Litecor® panel sheets.

Effects of Noncontact Shoulder Tool Velocities on Friction Stir Joining of Polyamide 6 (PA6).

In this study, the effects of the traverse and rotational velocities of the noncontact shoulder tool on the heat generation and heated flux during the friction stir joining of high-density polyamide 6 (PA6) polymer were investigated. The computational fluid dynamics (CFD) method was employed to simulate the thermomechanical phenomena during the friction stir joining (FSJ) process of PA6. A developed model was used to consider the void formation and thermochemical properties of PA6. The surface and internal heat flow, material flow, and geometry of the joint were simulated, and an experimental study evaluated the simulation results. The simulation results indicated that the stir zone formed was smaller than regular joints with a noncontact shoulder tool. Despite the polymer's traditional FSJ, heat generation and material flow do not differ significantly between advancing and retreating sides. On the other hand, the surface flow is not formed, and the surface temperature gradient is in a narrow line behind the tool. The material velocity increased at higher rotational speed and lower transverse velocity and in the stir zone with more giant geometry forms. The maximum generated heat was 204 °C, and the maximum material velocity was predicted at 0.44 m/s in the stir zone, achieved at 440 rpm and 40 mm/min tool velocities.

Effects of Underwater Friction Stir Welding Heat Generation on Residual Stress of AA6068-T6 Aluminum Alloy.

This article aims to study water-cooling effects on residual stress friction stir welding (FSW) of AA6068-T6 aluminum alloy. For this reason, the FSW and submerged FSW processes are simulated by computational fluid dynamic (CFD) method to study heat generation. The increment hole drilling technique was used to measure the residual stress of welded samples. The simulation results show that materials softening during the FSW process are more than submerged. This phenomenon caused the residual stress of the joint line in the submerged case to be lower than in the regular FSW joint. On the other hand, the results revealed that the maximum residual stresses in both cases are below the yielding strength of the AA6068-T6 aluminum alloy. The results indicated that the residual stress along the longitudinal direction of the joint line is much larger than the transverse direction in both samples.

Investigating Residual Stresses in Metal-Plastic Composites Stiffening Ribs Formed Using the Single Point Incremental Forming Method.

Low weight and high strength are significant factors in the current decade's spread of composite sandwich materials. Previous studies have proven that forming stiffening ribs in these materials through the Single Point Incremental Forming (SPIF) process is possible and gives encouraging results. On the other hand, knowledge of residual stress (RS) values that form during the manufacturing process is essential, as they may affect the structural integrity of manufactured elements, whether in compression or tension. The investigation of the RS in the composite materials formed by the SPIF process using the XRD method was very limited in the previous studies, so this research aims to apply the X-ray diffraction (XRD) method to determine RS on the part of the LITECOR® sandwich material formed using SPIF. LITECOR® consists of a plastic core between two layers of steel. In this study, three types of LITECOR® were used with differing plastic core thicknesses of 0.8, 1.25, and 1.6 mm, while the steel layers' thickness remained the same at 0.3 mm. The axial and traverse RSs were measured in five positions on both sides of the formed part. It was found that the achieved RSs varied from tensile to compressive along the formed regions. It was found that the residual stress values in both directions were inversely proportional to the thickness of the plastic core. It was noted that the highest RS values were in the unformed base metal, after which the RS was reduced on both sides of the SPIF-formed region, followed by a rise in the RS at the concave of the SPIF-formed region. The maximum measured RS for X-axes was 1041 MPa, whereas, for Y-axes, it was 1260 MPa, both of which were recorded on the back side at a thickness of t = 0.8 mm.

The Effects of Pin Profile on HDPE Thermomechanical Phenomena during FSW.

Friction stir welding (FSW) of polymeric materials has recently attracted significant attention. Herein, we present the effect of the tool pin profile on the FSW of high-density polyethylene (HDPE) joints through joint experimental analysis and thermomechanical simulations. For analysis of pin profile effects on the thermomechanical properties of HDPE joints, frustum (FPT), cubic (CPT), and triangular (TPT) pin shapes were selected in this study. This research investigated the heat generation of the parts of the different tools as well as heat flux (internal and surface). The results revealed that the heat generation in pins with more edges (cubic (96 °C) and triangular (94 °C)) was greater than in pins with a smooth shape (frustum (91 °C)). The higher heat generation caused the heat flux on the surface of the HDPE from the cubic pin profile to be greater than for other joints. Due to the properties of HDPE, higher heat generation caused higher material velocity in the stirring zone, where the velocity of the materials in TPT, CPT, and FPT pins were 0.41 m/s, 0.42 m/s, and 0.4 m/s, respectively. The simulation results show sharp-edged pins, such as triangular and cubic, lead to over-stirring action and internal voids formed along the joint line. Furthermore, the simulation results indicated that the size of the stirred zones (SZs) of the FPT, TPT, and CPT samples were 17 mm2, 19 mm2, and 21 mm2, respectively, which is around three times the corresponding values in the HAZ.