No abstract

Digital image processing (DIP), is the use of a digital computer to process digital images through an algorithm. In this work DIP used to perform crack/defect Detection and geometry measurements in terms of angle, length, and width by building a MATLAB code. In this research, the test of tensile were applied on two flat samples, the two flat samples are painted in a speckle pattern on the tested surface to use DIP features. The DIP gives a low-cost optical, and an appropriate technique to detect crack/defect as well as geometry measurements with the load increment in terms of angle, length and width without any contact with the tested surfaces. The tests directed for both of flat Aluminum alloy and Copper alloy specimens. In order to guarantee the efficiency of the planned DIP systems, the comparison is considered between the test results of this technique with the measurements gained by actual physical by using calibrated digital vernier calliper (IP 54) to measure the length of the crack with 0-300 mm range and 0.01 mm resolution. The DIP obtained percentage of accuracy varies from (97) % to (99) % by comparison with the measurements gained by actual physical way.

DIC program developed to obtain the full-field measurements of displacement, strain, and stress around the crack/defect. In the present work, the tensile test is conducted for two different flat specimens, which were painted by speckle pattern to allow using features of DIC system for strain measurements. Two defected/cracked copper and aluminum samples have been investigated. The experimental rig was especially designed and manufactured to perform the tensile test. A comparison between the results of the technique investigated with the results obtained from open source software (Ncorr & GOM), results obtained from the finite element analysis using (ANSYS) software using, and the exact and analytical solutions. The results achieved by the proposed DIC technique have agreement with other methods. The experiments conducted for two flat Aluminum and Copper plates. The DIP percentage of accuracy varies from (97) % to (99) % with the actual physical measurements. The obtained DIC percentage of accuracy as minimum and maximum were (88) % and (95) % with ANSYS software.

The request depending on electrochemical machining (ECM) technique has progressed in a large scale according to different points of view such that; cost or energy consuming, environment protection, reliable performance etc. This work aims to predict and optimize ECM process parameters for important, economic and applicable material (6061 aluminum) by employing L9 Taguchi method as a design of experiment (DOE) approach. This has led to experimental designing, developing a mathematical model and optimizing the entire ECM operation. This was carried out by controlling the chosen process variables (voltage, flow rate speed and electrolyte concentration) in order to optimize and predict the responses namely material removal rate (MRR) and dissolution rate. ANOVA, 3D contour graphs and perturbation plots have been employed to identify the analysis of variance of each response as well as to show the significant model terms. The process parameters i.e. voltage, flow rate speed and electrolyte concentration have been ranged to be 15-25V, 8-12 l/min and 3.36-7 % respectively. In both cases of MRR and dissolution rate the voltage parameter has seen to be the prominent factor that affects the responses so as to investigate highest value of MRR and dissolution rate, 0.477 g/min and 2.149 mm/min, respectively. This has been confirmed due to the results obtained from the ANOVA analysis which shows maximum F-valu for the voltage in the MRR and dissolution rate such that; 921.91 and 1608.34 respectively. But, still there was a considerable enhancement in the MRR and dissolution rate due to the increment in the flow rate speed and electrolyte concentration. Model validation has been carried out and thus the results invistigated that all the considered models were adequate since the residuals in prediction of each response were ignored, because the residuals were semi-matched with the diagonal line. Optimizations of responses were performed in this work numerically by using two types of criteria (restricted and non-restricted). According to these criteria, important increment in the MRR can be obtained which reaches 37%. A considerable enhancement has been obtained in the dissolution rate due to the comparison between the two criteria which results in increment by around 11% as well.