Showing papers in "Journal of The Institution of Engineers : Series C in 2017"

Finite Element Simulation of Temperature and Strain Distribution during Friction Stir Welding of AA2024 Aluminum Alloy

Abstract: Friction Stir Welding (FSW) is a solid state joining process and is handy for welding aluminum alloys. Finite Element Method (FEM) is an important tool to predict state variables of the process but numerical simulation of FSW is highly complex due to non-linear contact interactions between tool and work piece and interdependency of displacement and temperature. In the present work, a three dimensional coupled thermo-mechanical method based on Lagrangian implicit method is proposed to study the thermal history, strain distribution and thermo-mechanical process in butt welding of Aluminum alloy 2024 using DEFORM-3D software. Workpiece is defined as rigid-visco plastic material and sticking condition between tool and work piece is defined. Adaptive re-meshing is used to tackle high mesh distortion. Effect of tool rotational and welding speed on plastic strain is studied and insight is given on asymmetric nature of FSW process. Temperature distribution on the workpiece and tool is predicted and maximum temperature is found in workpiece top surface.

Wear Behaviour of Al-6061/SiC Metal Matrix Composites

Abstract: Aluminium Al-6061 base composites, reinforced with SiC particles having mesh size of 150 and 600, which is fabricated by stir casting method and their wear resistance and coefficient of friction has been investigated in the present study as a function of applied load and weight fraction of SiC varying from 5, 10, 15, 20, 25, 30, 35 and 40 %. The dry sliding wear properties of composites were investigated by using Pin-on-disk testing machine at sliding velocity of 2 m/s and sliding distance of 2000 m over a various loads of 10, 20 and 30 N. The result shows that the reinforcement of the metal matrix with SiC particulates up to weight percentage of 35 % reduces the wear rate. The result also show that the wear of the test specimens increases with the increasing load and sliding distance. The coefficient of friction slightly decreases with increasing weight percentage of reinforcements. The wear surfaces are examined by optical microscopy which shows that the large grooved regions and cavities with ceramic particles are found on the worn surface of the composite alloy. This indicates an abrasive wear mechanism, which is essentially a result of hard ceramic particles exposed on the worn surfaces. Further, it was found from the experimentation that the wear rate decreases linearly with increasing weight fraction of SiC and average coefficient of friction decreases linearly with increasing applied load, weight fraction of SiC and mesh size of SiC. The best result has been obtained at 35 % weight fraction and 600 mesh size of SiC.

Optimization of Magneto-Rheological Damper for Maximizing Magnetic Flux Density in the Fluid Flow Gap Through FEA and GA Approaches

Abstract: A magneto rheological (MR) fluid damper offers cost effective solution for semiactive vibration control in an automobile suspension. The performance of MR damper is significantly depends on the electromagnetic circuit incorporated into it. The force developed by MR fluid damper is highly influenced by the magnetic flux density induced in the fluid flow gap. In the present work, optimization of electromagnetic circuit of an MR damper is discussed in order to maximize the magnetic flux density. The optimization procedure was proposed by genetic algorithm and design of experiments techniques. The result shows that the fluid flow gap size less than 1.12 mm cause significant increase of magnetic flux density.

Optimization of Surface Roughness Parameters of Al-6351 Alloy in EDC Process: A Taguchi Coupled Fuzzy Logic Approach

Abstract: This paper investigates the application of Taguchi method with fuzzy logic for multi objective optimization of roughness parameters in electro discharge coating process of Al-6351 alloy with powder metallurgical compacted SiC/Cu tool. A Taguchi L16 orthogonal array was employed to investigate the roughness parameters by varying tool parameters like composition and compaction load and electro discharge machining parameters like pulse-on time and peak current. Crucial roughness parameters like Centre line average roughness, Average maximum height of the profile and Mean spacing of local peaks of the profile were measured on the coated specimen. The signal to noise ratios were fuzzified to optimize the roughness parameters through a single comprehensive output measure (COM). Best COM obtained with lower values of compaction load, pulse-on time and current and 30:70 (SiC:Cu) composition of tool. Analysis of variance is carried out and a significant COM model is observed with peak current yielding highest contribution followed by pulse-on time, compaction load and composition. The deposited layer is characterised by X-Ray Diffraction analysis which confirmed the presence of tool materials on the work piece surface.

A Review of Variable Slicing in Fused Deposition Modeling

Abstract: The paper presents a literature survey in the field of fused deposition of plastic wires especially in the field of slicing and deposition using extrusion of thermoplastic wires. Various researchers working in the field of computation of deposition path have used their algorithms for variable slicing. In the study, a flowchart has also been proposed for the slicing and deposition process. The algorithm already been developed by previous researcher will be used to be implemented on the fused deposition modelling machine. To demonstrate the capabilities of the fused deposition modeling machine a case study has been taken. It uses a manipulated G-code to be fed to the fused deposition modeling machine. Two types of slicing strategies, namely uniform slicing and variable slicing have been evaluated. In the uniform slicing, the slice thickness has been used for deposition is varying from 0.1 to 0.4 mm. In the variable slicing, thickness has been varied from 0.1 in the polar region to 0.4 in the equatorial region Time required and the number of slices required to deposit a hemisphere of 20 mm diameter have been compared with that using the variable slicing.

Optimization of Straight Cylindrical Turning Using Artificial Bee Colony (ABC) Algorithm

Abstract: Artificial bee colony (ABC) algorithm, that mimics the intelligent foraging behavior of honey bees, is increasingly gaining acceptance in the field of process optimization, as it is capable of handling nonlinearity, complexity and uncertainty. Straight cylindrical turning is a complex and nonlinear machining process which involves the selection of appropriate cutting parameters that affect the quality of the workpiece. This paper presents the estimation of optimal cutting parameters of the straight cylindrical turning process using the ABC algorithm. The ABC algorithm is first tested on four benchmark problems of numerical optimization and its performance is compared with genetic algorithm (GA) and ant colony optimization (ACO) algorithm. Results indicate that, the rate of convergence of ABC algorithm is better than GA and ACO. Then, the ABC algorithm is used to predict optimal cutting parameters such as cutting speed, feed rate, depth of cut and tool nose radius to achieve good surface finish. Results indicate that, the ABC algorithm estimated a comparable surface finish when compared with real coded genetic algorithm and differential evolution algorithm.

Three-Dimensional Finite Element Based Numerical Simulation of Machining of Thin-Wall Components with Varying Wall Constraints

Abstract: Control of part deflection and deformation during machining of low rigidity thin-wall components is an important aspect in the manufacture of desired quality products. This paper presents a comparative study on the effect of geometry constraints on the product quality during machining of thin-wall components made of an aerospace alloy aluminum 2024-T351. Three-dimensional nonlinear finite element (FE) based simulations of machining of thin-wall parts were carried out by considering three variations in the wall constraint viz. free wall, wall constrained at one end, and wall with constraints at both the ends. Lagrangian formulation based transient FE model has been developed to simulate the interaction between the workpiece and helical milling cutter. Johnson–Cook material and damage model were adopted to account for material behavior during machining process; damage initiation and chip separation. A modified Coulomb friction model was employed to define the contact between the cutting tool and the workpiece. The numerical model was validated with experimental results and found to be in good agreement. Based on the simulation results it was noted that deflection and deformation were maximum in the thin-wall constrained at one end in comparison with those obtained in other cases. It was noted that three dimensional finite element simulations help in a better way to predict the product quality during precision manufacturing of thin-wall components.

Finite Element Method Based Modeling for Prediction of Cutting Forces in Micro-end Milling

Abstract: Micro-end milling is one of the widely used processes for producing micro features/components in micro-fluidic systems, biomedical applications, aerospace applications, electronics and many more fields. However in these applications, the forces generated in the micro-end milling process can cause tool vibration, process instability and even cause tool breakage if not minimized. Therefore, an accurate prediction of cutting forces in micro-end milling is essential. In this work, a finite element method based model is developed using ABAQUS/Explicit 6.12 software for prediction of cutting forces in micro-end milling with due consideration of tool edge radius effect, thermo-mechanical properties and failure parameters of the workpiece material including friction behaviour at tool-chip interface. Experiments have been performed for manufacturing of microchannels on copper plate using 500 µm diameter tungsten carbide micro-end mill and cutting forces are acquired through a dynamometer. Predicted cutting forces in feed and cross feed directions are compared with experimental results and are found to be in good agreements. Results also show that FEM based simulations can be applied to analyze size effects of specific cutting forces in micro-end milling process.

An Approach to Maximize Weld Penetration During TIG Welding of P91 Steel Plates by Utilizing Image Processing and Taguchi Orthogonal Array

Abstract: P-91 is modified 9Cr–1Mo steel. Fabricated structures and components of P-91 has a lot of application in power and chemical industry owing to its excellent properties like high temperature stress corrosion resistance, less susceptibility to thermal fatigue at high operating temperatures. The weld quality and surface finish of fabricated structure of P91 is very good when welded by Tungsten Inert Gas welding (TIG). However, the process has its limitation regarding weld penetration. The success of a welding process lies in fabricating with such a combination of parameters that gives maximum weld penetration and minimum weld width. To carry out an investigation on the effect of the autogenous TIG welding parameters on weld penetration and weld width, bead-on-plate welds were carried on P91 plates of thickness 6 mm in accordance to a Taguchi L9 design. Welding current, welding speed and gas flow rate were the three control variables in the investigation. After autogenous (TIG) welding, the dimension of the weld width, weld penetration and weld area were successfully measured by an image analysis technique developed for the study. The maximum error for the measured dimensions of the weld width, penetration and area with the developed image analysis technique was only 2 % compared to the measurements of Leica-Q-Win-V3 software installed in optical microscope. The measurements with the developed software, unlike the measurements under a microscope, required least human intervention. An Analysis of Variance (ANOVA) confirms the significance of the selected parameters. Thereafter, Taguchi’s method was successfully used to trade-off between maximum penetration and minimum weld width while keeping the weld area at a minimum.

Finite Element Simulations of Micro Turning of Ti-6Al-4V using PCD and Coated Carbide tools

Abstract: The demand for manufacturing axi-symmetric Ti-6Al-4V implants is increasing in biomedical applications and it involves micro turning process. To understand the micro turning process, in this work, a 3D finite element model has been developed for predicting the tool chip interface temperature, cutting, thrust and axial forces. Strain gradient effect has been included in the Johnson–Cook material model to represent the flow stress of the work material. To verify the simulation results, experiments have been conducted at four different feed rates and at three different cutting speeds. Since titanium alloy has low Young’s modulus, spring back effect is predominant for higher edge radius coated carbide tool which leads to the increase in the forces. Whereas, polycrystalline diamond (PCD) tool has smaller edge radius that leads to lesser forces and decrease in tool chip interface temperature due to high thermal conductivity. Tool chip interface temperature increases by increasing the cutting speed, however the increase is less for PCD tool as compared to the coated carbide tool. When uncut chip thickness decreases, there is an increase in specific cutting energy due to material strengthening effects. Surface roughness is higher for coated carbide tool due to ploughing effect when compared with PCD tool. The average prediction error of finite element model for cutting and thrust forces are 11.45 and 14.87 % respectively.

An Exploratory Analysis for the Selection and Implementation of Advanced Manufacturing Technology by Fuzzy Multi-criteria Decision Making Methods: A Comparative Study

Abstract: Advanced Manufacturing Technologies (AMTs) offer opportunities for the manufacturing organizations to excel their competitiveness and in turn their effectiveness in manufacturing. Proper selection and evaluation of AMTs is the most significant task in today’s modern world. But this involves a lot of uncertainty and vagueness as it requires many conflicting criteria to deal with. So the task of selection and evaluation of AMTs becomes very tedious for the evaluators as they are not able to provide crisp data for the criteria. Different Fuzzy Multi-criteria Decision Making (MCDM) methods help greatly in dealing with this problem. This paper focuses on the application of two very much potential Fuzzy MCDM methods namely COPRAS-G, EVAMIX and a comparative study between them on some rarely mentioned criteria. Each of the two methods is very powerful evaluation tool and has beauty in its own. Although, performance wise these two methods are almost at same level, but, the approach of each one of them are quite unique. This uniqueness is revealed by introducing a numerical example of selection of AMT.

ANN–PSO Integrated Optimization Methodology for Intelligent Control of MMC Machining

Abstract: Metal Matrix Composites (MMC) show improved properties in comparison with non-reinforced alloys and have found increased application in automotive and aerospace industries. The selection of optimum machining parameters to produce components of desired surface roughness is of great concern considering the quality and economy of manufacturing process. In this study, a surface roughness prediction model for turning Al-SiCp MMC is developed using Artificial Neural Network (ANN). Three turning parameters viz., spindle speed (N), feed rate (f) and depth of cut (d) were considered as input neurons and surface roughness was an output neuron. ANN architecture having 3–5–1 is found to be optimum and the model predicts with an average percentage error of 7.72 %. Particle Swarm Optimization (PSO) technique is used for optimizing parameters to minimize machining time. The innovative aspect of this work is the development of an integrated ANN–PSO optimization method for intelligent control of MMC machining process applicable to manufacturing industries. The robustness of the method shows its superiority for obtaining optimum cutting parameters satisfying desired surface roughness. The method has better convergent capability with minimum number of iterations.

Numerical Simulation of 3D Thermo-Elastic Fatigue Crack Growth Problems Using Coupled FE-EFG Approach

Abstract: In this work, finite element method (FEM) and element free Galerkin method (EFGM) are coupled for solving 3D crack domains subjected to cyclic thermal load of constant amplitude. Crack growth contours and fatigue life have been obtained for each of the considered numerical examples. Thermo-elastic problems are decoupled into thermal and elastic problems . Firstly, the unknown temperature field is obtained by solving heat conduction equation, then, it is used as the input load in the elastic problem to calculate the displacement and stress fields. The geometrical discontinuity across crack surface is modelled by extrinsically enriched EFGM and the remaining part of the domain is approximated by standard finite element method. At the crack interface, a ramp function based interpolation scheme has been implemented. This coupled approach combines the advantages of both EFGM and FEM. A linear successive crack increment approach is used to model crack growth. The growing crack surface is traced by level set function. Standard Paris law is used for life estimation of the three-dimensional crack models. Different cases of planar and non-planar crack problems have been solved and their results are compared with the results obtained using extended finite element method to check accuracy, efficiency and robustness of the coupled FE-EFG approach implemented in this study.

Optimisation of Double Pipe Helical Tube Heat Exchanger and its Comparison with Straight Double Tube Heat Exchanger

Abstract: Optimization of double pipe helical coil heat exchanger with various optimizing parameters and its comparison with double pipe straight tube are the prime objectives of this paper. Numerical studies were performed with the aid of a commercial computational fluid dynamics package ANSYS FLUENT 14. In this paper the double pipe helical coil is analysed under turbulent flow conditions for optimum heat exchanger properties. The parameters used for optimization are cross-sectional shape and taper angles. Optimization analysis is being carried out for finding best cross sectional shape of heat exchanger coils by using rectangular, square, triangular and circular cross-sections. The tapered double pipe helical coil is then analysed for best heat transfer and pressure drop characteristics by varying the angle of taper. Finally, an optimum coil on the basis of all the analysis is selected. This optimized double pipe helical coil is compared with double pipe straight tube of equivalent cross-sectional area and length as that of unwounded length of double pipe helical coil.

Mathematical Modelling of Solidification in a Curved Strand During Continuous Casting of Steel

Abstract: A two dimensional fluid flow, heat transfer and solidification model has been developed for a curved shape continuous steel slab caster. The strand has been divided in various sections depending upon cooling conditions in the mold and Secondary Cooling Zone (SCZ). The model was validated against the experimental results reported in the literature for solid shell thickness in the mold. CFD software ANSYS Fluent has been used for solving the differential equations of heat transfer and fluid flow. Surface temperature distribution has been predicted while; the thickness of solid shell formed in the mold and SCZ has been calculated by finding the liquid fraction of steel within the domain. Process parameters such as, casting speed and cooling rate has been varied to analyse their effects on metallurgical length and solid shell thickness at the mold exit. The analysis was based on keeping the shell thickness between 10 and 14 mm at mold exit and metallurgical length less than the cut-off length but having complete solidification after the straightening zone.

A Comparative Study on Automotive Brake Testing Standards

Abstract: Performance testing of automotive brakes involves determination of stopping time, distance and deceleration level. Braking performance of an automobile is required to be ensured for various surfaces like dry, wet, concrete, bitumen etc. as well as for prolonged applications. Various brake testing standards are used worldwide to assure vehicle and pedestrian safety. This article presents methodologies used for automotive service brake testing for two wheelers. The main contribution of this work lies in comparative study of three main brake testing standards; viz. Indian Standards, Federal Motor Vehicle Safety Standards and European Economic Commission Standards. This study shall help the policy makers to choose the best criteria out of these three while formulating newer edition of testing standards.

Dynamic Testing of a Pre-stretched Flexible Tube for Identifying the Factors Affecting Modal Parameter Estimation

Abstract: Experimental modal analysis is the primary tool for obtaining the fundamental dynamic characteristics like natural frequency, mode shape and modal damping ratio that determine the behaviour of any structure under dynamic loading conditions. This paper discusses about a carefully designed experimental method for calculating the dynamic characteristics of a pre-stretched horizontal flexible tube made of polyurethane material. The factors that affect the modal parameter estimation like the application time of shaker excitation, pause time between successive excitation cycles, averaging and windowing of measured signal, as well as the precautions to be taken during the experiment are explained in detail. The modal parameter estimation is done using MEscopeVESTM software. A finite element based pre-stressed modal analysis of the flexible tube is also done using ANSYS ver.14.0 software. The experimental and analytical results agreed well. The proposed experimental methodology may be extended for carrying out the modal analysis of many flexible structures like inflatables, tires and membranes.

Parametric Optimization of Wire Electrical Discharge Machining of Powder Metallurgical Cold Worked Tool Steel using Taguchi Method

Abstract: Wire Cut EDM is an unconventional machining process used to build components of complex shape. The current work mainly deals with optimization of surface roughness while machining P/M CW TOOL STEEL by Wire cut EDM using Taguchi method. The process parameters of the Wire Cut EDM is ON, OFF, IP, SV, WT, and WP. L27 OA is used for to design of the experiments for conducting experimentation. In order to find out the effecting parameters on the surface roughness, ANOVA analysis is engaged. The optimum levels for getting minimum surface roughness is ON = 108 µs, OFF = 63 µs, IP = 11 A, SV = 68 V and WT = 8 g.

Design and Development of Gas Carburettor for a Gasifier-Engine System

Abstract: This work presents a novel design of a gas-carburettor for SI engine operated on producer gas in single fuel mode. For geometrical modelling of carburettor, the ANSYS workbench is used, while RNG k-e turbulence model in conjunction with species transport model is employed for numerical simulations. This carburettor design was fabricated, the operations were performed to ensure load following flexibility of gas carburettor. CFD model for gas carburettor gives realistic predictions for qualitative trends of pressure drop at different load conditions.

Simulation of Magnetic Field Assisted Finishing (MFAF) Process Utilizing Smart MR Polishing Tool

Abstract: Magnetic field assisted finishing process is an advanced finishing process. This process is capable of producing nanometer level surface finish. In this process magnetic field is applied to control the finishing forces using magnetorheological polishing medium. In the current study, permanent magnet is used to provide the required magnetic field in the finishing zone. The working gap between the workpiece and the magnet is filled with MR fluid which is used as the polishing brush to remove surface undulations from the top surface of the workpiece. In this paper, the distribution of magnetic flux density on the workpiece surface and behaviour of MR polishing medium during finishing are analyzed using commercial finite element packages (Ansys Maxwell® and Comsol®). The role of magnetic force in the indentation of abrasive particles on the workpiece surface is studied. A two-dimensional simulation study of the steady, laminar, and incompressible MR fluid flow behaviour during finishing process is carried out. The material removal and surface roughness modelling of the finishing process are also presented. The indentation force by a single active abrasive particle on the workpiece surface is modelled during simulation. The velocity profile of MR fluid with and without application of magnetic field is plotted. It shows non-Newtonian property without application of magnetic field. After that the total material displacement due to one abrasive particle is plotted. The simulated roughness profile is in a good agreement with the experimental results. The conducted study will help in understanding the fluid behavior and the mechanism of finishing during finishing process. Also, the modelling and simulation of the process will help in achieving better finishing performance.

Numerical Simulation of Flow Through Equilateral Triangular Duct Under Constant Wall Heat Flux Boundary Condition

Abstract: The force convective heat transfer in an equilateral triangular duct of different wall heat flux configurations was analysed for the laminar hydro-dynamically developed and thermally developing flow by the use of finite volume method. Unstructured meshing was generated by multi-block technique and set of governing equations were discretized using second-order accurate up-wind scheme and numerically solved by SIMPLE Algorithm. For ensuring accuracy, grid independence study was also done. Numerical methodology was verified by comparing results with previous work and predicted results showed good agreement with them (within error of ±5 %). The different combinations of constant heat flux boundary condition were analysed and their effect on heat transfer and fluid flow for different Reynolds number was also studied. The results of different combinations were compared with the case of force convective heat transfer in the equilateral triangular duct with constant heat flux on all three walls.

Comparison of Customer Preference for Bulk Material Handling Equipment through Fuzzy-AHP Approach

Abstract: In the present study, customer’s perception has played one of the important roles for selection of the exact equipment out of available alternatives. The present study is dealt with the method of optimization of selection criteria of a material handling equipment, based on the technical specifications considered to be available at the user end. In this work, the needs of customers have been identified and prioritized, that lead to the selection of number of criteria, which have direct effect upon the performance of the equipment. To check the consistency of selection criteria, first of all an AHP based methodology is adopted with the identified criteria and available product categories, based upon which, the judgments of the users are defined to derive the priority scales. Such judgments expressed the relative strength or intensity of the impact of the elements of the hierarchy. Subsequently, all the alternatives have ranked for each identified criteria with subsequent constitution of weighted matrices. The same has been compared with the normalized values of approximate selling prices of the equipments to determine individual cost-benefit ratio. Based on the cost-benefit ratio, the equipment is ranked. With same conditions, the study is obtained again with a Fuzzy AHP concept, where a fuzzy linguistic approach has reduced the amount of uncertainty in decision making, caused by conventional AHP due to lack of deterministic approach. The priority vectors of category and criteria are determined separately and multiplied to obtain composite score. Subsequently, the average of fuzzy weights was determined and the preferences of equipment are ranked.

Finite Element Analysis of Cross Rolling on AISI 304 Stainless Steel: Prediction of Stress and Strain Fields

Abstract: Studies on the effect of strain path during rolling has been carried out for a long time, but the same has not been done using Finite Element Analysis (FEA). Change in strain path affects the state variables in the rolled plate like stress, strain, temperature etc. In the current work, Finite Element Analysis for cross rolling of AISI 304 austenitic stainless steel has been carried out by rotating the plate by 90° in between the passes. To analyze stress and strain fields in the material for cross rolling, a full 3D model of work-roll and plate has been developed using rigid-viscoplastic finite element method. The stress and strain fields, considering von-Mises yield criteria, are calculated by using updated Lagrangian method. In addition to these, the model also calculates the normal pressure and strain rate distribution in the plate during cross rolling. The nature of the variations of stress and strain fields in the plate, predicted by the model, is in good agreement with the previously published works for unidirectional rolling.

Effect of Burnishing Parameters on Surface Finish

Abstract: Burnishing is cold working process in which hard balls are pressed against the surface, resulting in improved surface finish. The surface gets compressed and then plasticized. This is a highly finishing process which is becoming more popular. Surface quality of the product improves its aesthetic appearance. The product made up of aluminum material is subjected to burnishing process during which kerosene is used as a lubricant. In this study factors affecting burnishing process such as burnishing force, speed, feed, work piece diameter and ball diameter are considered as input parameters while surface finish is considered as an output parameter In this study, experiments are designed using 25 factorial design in order to analyze the relationship between input and output parameters. The ANOVA technique and F-test are used for further analysis.

Modelling the Peak Elongation of Nylon6 and Fe Powder Based Composite Wire for FDM Feedstock Filament

Abstract: In the present work, to increase the application domain of fused deposition modelling (FDM) process, Nylon6–Fe powder based composite wire has been prepared as feed stock filament. Further for smooth functioning of feed stock filament without any change in the hardware and software of the commercial FDM setup, the mechanical properties of the newly prepared composite wire must be comparable/at par to the existing material i.e. ABS, P-430. So, keeping this in consideration; an effort has been made to model the peak elongation of in house developed feedstock filament comprising of Nylon6 and Fe powder (prepared on single screw extrusion process) for commercial FDM setup. The input parameters of single screw extruder (namely: barrel temperature, temperature of the die, speed of the screw, speed of the winding machine) and rheological property of material (melt flow index) has been modelled with peak elongation as the output by using response surface methodology. For validation of model the result of peak elongation obtained from the model equation the comparison was made with the results of actual experimentation which shows the variation of ±1 % only.

Analytical Modeling for Mechanical Strength Prediction with Raman Spectroscopy and Fractured Surface Morphology of Novel Coconut Shell Powder Reinforced: Epoxy Composites

Abstract: In this paper, an analytical modeling and prediction of tensile and flexural strength of three dimensional micro-scaled novel coconut shell powder (CSP) reinforced epoxy polymer composites have been reported. The novel CSP has a specific mixing ratio of different coconut shell particle size. A comparison is made between obtained experimental strength and modified Guth model. The result shows a strong evidence for non-validation of modified Guth model for strength prediction. Consequently, a constitutive modeled equation named Singh model has been developed to predict the tensile and flexural strength of this novel CSP reinforced epoxy composite. Moreover, high resolution Raman spectrum shows that 40 % CSP reinforced epoxy composite has high dielectric constant to become an alternative material for capacitance whereas fractured surface morphology revealed that a strong bonding between novel CSP and epoxy polymer for the application as light weight composite materials in engineering.

Performance and Emission Characteristics of a Compression Ignition Engine Operating on Blends of Castor Oil Biodiesel–Diesel

Abstract: Diesel vehicles are the nerves and veins of transportation, particularly in developing countries. With the rapid rate of modernization, increasing demand of fuel is inevitable. The exponential increase in fuel prices and the scarcity of its supply from the environment have promoted interest in the development of alternative sources of fuel. In this work, genus Ricinus communis L. was studied in order to delimit their potential as a raw material for biodiesel production. Further, castor oil, ethyl ester were prepared by transesterification using potassium hydroxide (KOH) as a catalyst and tested on a four-stroke, single-cylinder compression ignition engine. The test was carried out at a constant speed of 3000 rpm at different loads. The results represent a substantial decrease in carbon monoxide (CO) emission with an increasing biodiesel percentage. The reduction of CO in B05, B10, B15 and B20 averaged 11.75, 22.02, 24.23 and 28.79 %, respectively, compared to mineral diesel. The emission results of the comparative test indicated that CO, oxygen (O2) and smoke density emissions are found to be lower when the engine is filled with B05, B10, B15 and B20 as compared to mineral diesel, while carbon dioxide (CO2) and nitrogen oxide (NOx) with B05, B10, B15 and B20 are found to increase marginally. Brake thermal efficiency and brake specific fuel consumption decrease and increase respectively in biodiesel with different blends in comparison of mineral diesel.

Overview of Automotive Core Tools: Applications and Benefits

Abstract: Continuous improvement of product and process quality is always challenging and creative task in today’s era of globalization. Various quality tools are available and used for the same. Some of them are successful and few of them are not. Considering the complexity in the continuous quality improvement (CQI) process various new techniques are being introduced by the industries, as well as proposed by researchers and academia. Lean Manufacturing, Six Sigma, Lean Six Sigma is some of the techniques. In recent years, there are new tools being opted by the industry, especially automotive, called as Automotive Core Tools (ACT). The intention of this paper is to review the applications and benefits along with existing research on Automotive Core Tools with special emphasis on continuous quality improvement. The methodology uses an extensive review of literature through reputed publications—journals, conference proceedings, research thesis, etc. This paper provides an overview of ACT, its enablers, and exertions, how it evolved into sophisticated methodologies and benefits used in organisations. It should be of value to practitioners of Automotive Core Tools and to academics who are interested in how CQI can be achieved using ACT. It needs to be stressed here that this paper is not intended to scorn Automotive Core Tools, rather, its purpose is limited only to provide a balance on the prevailing positive views toward ACT.

Analytical and Empirical Modeling of Wear and Forces of CBN Tool in Hard Turning - A Review

Abstract: Machining of steel material having hardness above 45 HRC (Hardness–Rockwell C) is referred as a hard turning. There are numerous models which should be scrutinized and implemented to gain optimum performance of hard turning. Various models in hard turning by cubic boron nitride tool have been reviewed, in attempt to utilize appropriate empirical and analytical models. Validation of steady state flank and crater wear model, Usui’s wear model, forces due to oblique cutting theory, extended Lee and Shaffer’s force model, chip formation and progressive flank wear have been depicted in this review paper. Effort has been made to understand the relationship between tool wear and tool force based on the different cutting conditions and tool geometries so that appropriate model can be used according to user requirement in hard turning.

Numerical Simulation of Hydrogen Air Supersonic Coaxial Jet

Abstract: In the present study, the turbulent structure of coaxial supersonic H2–air jet is explored numerically by solving three dimensional RANS equations along with two equation k–e turbulence model. Grid independence of the solution is demonstrated by estimating the error distribution using Grid Convergence Index. Distributions of flow parameters in different planes are analyzed to explain the mixing and combustion characteristics of high speed coaxial jets. The flow field is seen mostly diffusive in nature and hydrogen diffusion is confined to core region of the jet. Both single step laminar finite rate chemistry and turbulent reacting calculation employing EDM combustion model are performed to find the effect of turbulence-chemistry interaction in the flow field. Laminar reaction predicts higher H2 mol fraction compared to turbulent reaction because of lower reaction rate caused by turbulence chemistry interaction. Profiles of major species and temperature match well with experimental data at different axial locations; although, the computed profiles show a narrower shape in the far field region. These results demonstrate that standard two equation class turbulence model with single step kinetics based turbulence chemistry interaction can describe H2–air reaction adequately in high speed flows.