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Design and Analysis of Piercing Tool with Special Purpose Hydraulic Press
Prabhakar Purushothaman,
Prashanth Thankachan
Issue:
Volume 1, Issue 3, November 2016
Pages:
31-37
Received:
26 August 2016
Accepted:
19 September 2016
Published:
10 October 2016
DOI:
10.11648/j.ajmie.20160103.11
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Abstract: The modern manufacturing industries are highly focused towards increasing productivity with very less investment on new tooling and machines. This paper discusses about design of press tool with press to be setup in line production, were component usually transferred stage by stage for performing sequence of operation. Deep drawing is the metal forming operation used to form cups from flat sheet metal, in order to assemble the component holes are required and usually produced by secondary operation using piercing tool. The below sections describe about the design of piercing tool for deep drawn component with hydraulic press for piercing operation. The design challenges involve understanding and identification of various uncertainties involved in process and troubleshooting them through virtual prototyping by using FEM and other simulation software and facilitate the design that supports risk free manufacturing environment, with minimum overall cost of production.
Abstract: The modern manufacturing industries are highly focused towards increasing productivity with very less investment on new tooling and machines. This paper discusses about design of press tool with press to be setup in line production, were component usually transferred stage by stage for performing sequence of operation. Deep drawing is the metal for...
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Assessment of Electrical Characteristics of Conductive Woven Fabrics
Sandra Varnaitė-Žuravliova,
Julija Baltušnikaitė-Guzaitienė,
Lina Valasevičiūtė,
Rasa Verbienė,
Aušra Abraitienė
Issue:
Volume 1, Issue 3, November 2016
Pages:
38-49
Received:
10 September 2016
Accepted:
22 September 2016
Published:
14 October 2016
DOI:
10.11648/j.ajmie.20160103.12
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Abstract: Electroconductive textiles can not be considered as homogenous structures, because fabrics consist of conductive and nonconductive yarns, interlaced to each other. Such distribution of yarns results in anisotropic current distribution, when voltage is applied. The aim of investigations was investigate current and temperature distributions in conductive textiles, which can be used in many applications, such as protective textiles, e-textiles, heating textiles etc. It was found that the Ohm's law is valid for such type of textiles and temperature increases increasing voltage applied. The amount of current passing through the conductive yarn depends mainly on the conductivity of it. The length of conductive yarn also influences values of current and temperature. It was concluded that current passes through yarns with silver coated filaments more homogeneously than in yarns with metal fibres, because of continuous coating. Also it was noticed, that there exists a maximum voltage which can be fed to the conductive yarns, without damaging it.
Abstract: Electroconductive textiles can not be considered as homogenous structures, because fabrics consist of conductive and nonconductive yarns, interlaced to each other. Such distribution of yarns results in anisotropic current distribution, when voltage is applied. The aim of investigations was investigate current and temperature distributions in conduc...
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Evaluation and Monitoring of Condition of Turbo Generator on the Example of Thermal Power Plant Ugljevik 1x300 MW
Zdravko N. Milovanovic,
Aleksandar N. Milasinovic,
Darko M. Knezevic,
Jovan B. Skundric,
Svetlana R. Dumonjic-Milovanovic
Issue:
Volume 1, Issue 3, November 2016
Pages:
50-57
Received:
15 September 2016
Accepted:
26 September 2016
Published:
15 October 2016
DOI:
10.11648/j.ajmie.20160103.13
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Abstract: The every complex technical system brings high potential risk of possible failures and breakdowns which can seriously endanger surrounding environment. Causes of harmful events are of stochastic nature because they depend upon number of both distinct and accidental factors. Preventive measures can in certain way be used to plan activities for controlling and possible respond regarding that group of factors. Methods of monitoring which are in use are in the same time used as a techniques for evaluation of incurred damages together with identifying its major causes (root causes). Defining system for periodic analyzing and remote monitoring of relevant parameters of turbo generators also include adequate technique for collecting, storing and analyzing significant amount of data. Organization of the data has impact on quality of evaluation of present state and also on planning of stoppages of power plant and predicting of remaining life span of the machine. This type of management has increase in availability and reliability of machines as a result. Inside this paper, the presentation of the algorithm of two year lasting monitoring of turbo generator in TPP Ugljevik of installed power of 300 MW, together with supporting results of conducted diagnostics is given.
Abstract: The every complex technical system brings high potential risk of possible failures and breakdowns which can seriously endanger surrounding environment. Causes of harmful events are of stochastic nature because they depend upon number of both distinct and accidental factors. Preventive measures can in certain way be used to plan activities for contr...
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Development of Flux Bounded Tungsten Inert Gas Welding Process to Join Aluminum Alloys
A. V.Santhana Babu,
P. Ramesh Narayanan,
S. V. S. Narayana Murty
Issue:
Volume 1, Issue 3, November 2016
Pages:
58-63
Received:
5 September 2016
Accepted:
23 September 2016
Published:
17 October 2016
DOI:
10.11648/j.ajmie.20160103.14
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Abstract: Tungsten Inert Gas (TIG) welding process is normally used to join aluminum alloys because of its simplicity. However its penetration capability is limited. To improve penetration capability of TIG process to join aluminum alloys, Flux Bounded TIG (FBTIG) was developed. This paper consolidates the developments that took place in FBTIG process specifically in the selection of flux, flux gap, flux particle size, current polarity, weld bead depth enhancement achieved in the investigations and characterisation of the welds in terms of its tensile strength and corrosion resistance.
Abstract: Tungsten Inert Gas (TIG) welding process is normally used to join aluminum alloys because of its simplicity. However its penetration capability is limited. To improve penetration capability of TIG process to join aluminum alloys, Flux Bounded TIG (FBTIG) was developed. This paper consolidates the developments that took place in FBTIG process specif...
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Effect of Milling Parameters on Surface Roughness and Dry Friction: An Experimental and Modeling Study
Issue:
Volume 1, Issue 3, November 2016
Pages:
64-69
Received:
18 September 2016
Accepted:
28 September 2016
Published:
27 October 2016
DOI:
10.11648/j.ajmie.20160103.15
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Abstract: Aquantitative relationship is demonstrated between the coefficient of static friction and the milling process parameters. Different levels of surface roughness are obtained by varying the spindle speed, depth of cut and feed which is followed by measurement of surface roughness using stylus profile meter. The corresponding coefficients of static friction are measured for all specimens using inclined plane method. The surface roughness (Ra) value is found to increase with increase in feed rate and depth of cut and vice-versa. The surface roughness is found to marginal decrease with increasing spindle speed. The coefficient of static friction is found to decrease with increasing Ra values.
Abstract: Aquantitative relationship is demonstrated between the coefficient of static friction and the milling process parameters. Different levels of surface roughness are obtained by varying the spindle speed, depth of cut and feed which is followed by measurement of surface roughness using stylus profile meter. The corresponding coefficients of static fr...
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Application of Response Surface Methodology for Study of Fluxes Effects in Fusion of Ashes from Mineral Coal
Jonas Matsinhe,
Geraldo Martins,
Dominges Macuvele,
Rela Riella,
Nivadlo Kuhuen,
Uamusse Miguel,
Mohammad Aljaradin
Issue:
Volume 1, Issue 3, November 2016
Pages:
70-73
Received:
8 September 2016
Accepted:
12 October 2016
Published:
31 October 2016
DOI:
10.11648/j.ajmie.20160103.16
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Abstract: The present study uses RSM (Response Surface Methodology) to verify the fusibility of bottom ash from coal industry, and efficient flux between, calcium oxide (CaO), lithium oxide (Li 2O) and sodium oxide (Na2O). The bottom ashes, have demonstrated the possibility to be used in the development of glass-ceramics, and glassy materials, due to the presence of high concentrations of aluminum silicates. Different oxides agents were added to enhance the manufacturing process. However, selecting the best combination between these agents is a need. After using this RSM methodology it was found that the mixture of 50% by mass of sodium and lithium oxide the most significant for reducing the melting and softening temperature.
Abstract: The present study uses RSM (Response Surface Methodology) to verify the fusibility of bottom ash from coal industry, and efficient flux between, calcium oxide (CaO), lithium oxide (Li 2O) and sodium oxide (Na2O). The bottom ashes, have demonstrated the possibility to be used in the development of glass-ceramics, and glassy materials, due to the pre...
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Design Optimization of Pico-satellite Frame for Computational Analysis and Simulation
Anselm Chukwuemeka Okolie,
Spencer O. Onuh,
Yusuf T. Olatunbosun,
Matthew S. Abolarin
Issue:
Volume 1, Issue 3, November 2016
Pages:
74-84
Received:
20 September 2016
Accepted:
8 October 2016
Published:
31 October 2016
DOI:
10.11648/j.ajmie.20160103.17
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Abstract: In this research work, a structural optimization methodology is applied to generate a Frame model that meets CubeSat Design Standards. The frame is further subjected to software simulation that encapsulates worst case launch scenarios. The validity of the frame design has been demonstrated by quasi-static and modal analyses, with the results being verified analytically using direct stiffness approach. All subsystems in this study were modelled as remote masses at their Centre of Gravity (C.G) positions, considering their Moments of Inertia (M.I). The mass location analysis was done for a presumed internal configuration with the subsystems arranged such that the Centre of Gravity (C.G) and Moment of Inertia (M.I) values satisfy the launch vehicle constraints. The mass of the proposed structure has been reviewed to meet design mass requirements of a picosatellite structure as a subsystem with a mass less than 20 per cent of overall design mass of 1.33kg. The frame is modelled to bear the on-board electronics without transferring significant load to these delicate electronics that represent different subsystems. The failure analysis of the final structure design indicates very infinitesimal resultant displacement of 1.573 x 10-2mm which is far less than a millimetre and a Factor of safety of 2.06. The minimum natural frequency for the first mode of free vibration of the final design structure obtained to be 199.32 Hz indicating very high structural stiffness. The worst-case harmonic and random vibration analyses have been performed on the frame-PCBs assembly. The maximum structural responses- displacement and stress- at critical points on the Printed Circuit Boards (PCBs) yielded 3.733 x 10-4mm and 98666.7N/m2 respectively for harmonic excitation. and 1.715 x 10-1mm and 33090298N/m2 respectively for random vibration. The peak stress values compared to material yield stress indicate that the subsystems would remain safe under severe launch loading conditions.
Abstract: In this research work, a structural optimization methodology is applied to generate a Frame model that meets CubeSat Design Standards. The frame is further subjected to software simulation that encapsulates worst case launch scenarios. The validity of the frame design has been demonstrated by quasi-static and modal analyses, with the results being ...
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Experimental Studies of Compression Ignition Diesel Engine UsingCNG and Pongamia Biodiesel in a Dual Fuel Mode
Noel D,
Shashikant Kushnoore,
Nitin Kamitkar,
Satishkumar M
Issue:
Volume 1, Issue 3, November 2016
Pages:
85-90
Received:
15 September 2016
Accepted:
28 September 2016
Published:
1 November 2016
DOI:
10.11648/j.ajmie.20160103.18
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Abstract: The rapid depletion of energy resources and continuous increasing cost of petroleum based fuels with their pollution from diesel engine to environment has caused an interest to search for new alternate fuels such as vegetable oils, gaseous fuel. The main objective of this work is to evaluate performance and emission characteristics using CNG (compressed natural gas) and POME (Pongamia oil methyl ester) in a dual fuel mode where pongamia biodiesel used as a pilot fuel to ignite CNG gas. The engine tests were carried out for neat pongamia biodiesel, CNG flow rates of 0.3 kg/hr and 0.6 kg/hr with pongamia biodiesel in a dual fuel mode and obtained results are compared with diesel. In a dual fuel mode CNG flow rate of 0.6 kg/hr gives similar performance compared to diesel. The brake thermal efficiency for 0.6 kg/hr CNG-POME is 26.7% against 28.6% diesel at 75% of the load. In a dual fuel mode CO, CO CORR and hydro carbon emissions are higher at low load and at full load with increase in percentage of CNG CO, CO CORR and HC emissions are completely reduced to a certain extent. In a dual fuel mode CO2 emission, smoke and NOx emission also reduced compared to diesel and pongamia biodiesel. From comparison of all tested fuels CNG flow rate of 0.6 kg/hr with biodiesel is optimum having lower emissions with very little reduction in brake thermal efficiency.
Abstract: The rapid depletion of energy resources and continuous increasing cost of petroleum based fuels with their pollution from diesel engine to environment has caused an interest to search for new alternate fuels such as vegetable oils, gaseous fuel. The main objective of this work is to evaluate performance and emission characteristics using CNG (compr...
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Prediction of Fatigue Life of Welded Structures
Issue:
Volume 1, Issue 3, November 2016
Pages:
91-95
Received:
17 September 2016
Accepted:
13 October 2016
Published:
3 November 2016
DOI:
10.11648/j.ajmie.20160103.19
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Abstract: This paper describes the fatigue life computation and comparisons of welded structures made up of high strength steels. Fatigue life of a T-joint two side fillet welded component is computed with four different methods. The methods used for investigation are nominal stress method, effective notch method, structural stress method and simple fracture mechanics method. To investigate the problem using structural stress and effective notch method, a fillet welded plate is modeled in ANSYS software and two-dimensional linear elastic analysis is performed. The fatigue lives obtained with these methods are reported and compared with the results obtained from nominal stress and simple fracture mechanics approach.
Abstract: This paper describes the fatigue life computation and comparisons of welded structures made up of high strength steels. Fatigue life of a T-joint two side fillet welded component is computed with four different methods. The methods used for investigation are nominal stress method, effective notch method, structural stress method and simple fracture...
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Experimental Investigations on Thrust, Torque and Circularity Error in Drilling of Aluminium Alloy (Al6061)
Shashikant Kushnoore,
Noel D.,
Nitin Kamitkar,
Satishkumar M.
Issue:
Volume 1, Issue 3, November 2016
Pages:
96-102
Received:
15 September 2016
Accepted:
2 October 2016
Published:
7 November 2016
DOI:
10.11648/j.ajmie.20160103.20
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Abstract: Aluminium alloy (Al6061) is one of the most important metal for construction of aircraft structures, yacht construction, automotive parts etc. It is a precipitation hardening aluminum alloy, containing magnesium and silicon as its major alloying elements. It has good mechanical properties and exhibits much lighter, more corrosion resistant and good weld ability. In this project work, experimental performance on drilling characteristics such as thrust force, torque and the hole quality of aluminium alloy with carbide drills are studied. The drilling experiments are planned as per full factorial design (FFD) by using L27 standard orthogonal array. The effect of three process parameters, namely drill diameter, spindle speed and feed rate on thrust force and hole quality such as circularity error of the drilled hole are analyzed by developing response surface methodology (RSM) based on second-order mathematical models. The proposed models are tested through analysis of variance (ANOVA) for their adequacy. The parametric analysis based on quadratic model is carried out to study the interaction effects of the process parameters. The optimum parameter levels for thrust force, torque and circularity error are obtained using Taguchi technique of signal to noise ratio. Minitab statistical software is employed for statistical and parametric analysis.
Abstract: Aluminium alloy (Al6061) is one of the most important metal for construction of aircraft structures, yacht construction, automotive parts etc. It is a precipitation hardening aluminum alloy, containing magnesium and silicon as its major alloying elements. It has good mechanical properties and exhibits much lighter, more corrosion resistant and good...
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The Optimal Modeling of an Angular Position of Saw Cylinders in Single-Chamber Two Cylinders Gin
Shuhrat Mamatovich Azizov,
Xamit Tursunovich Axmedhodjaev
Issue:
Volume 1, Issue 3, November 2016
Pages:
103-106
Received:
24 September 2016
Accepted:
19 October 2016
Published:
9 November 2016
DOI:
10.11648/j.ajmie.20160103.21
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Abstract: In work considered process of optimal modelling of an angular position of saw cylinders in single-chamber two cylinders gin. For increase, durability work of saw disks and shaft, by the static analysis of pressure upon saws. That will increase wear resistance and will improve quality indicators of a fiber and seeds it will be accepted an optimum corner of an arrangement saw cylinders of 600 degrees this decreases loading on bottom saw cylinder on 35% of percent and on top saw the cylinder decreases loading on 50% both increases productivity and working capacity saw cylinders several times.
Abstract: In work considered process of optimal modelling of an angular position of saw cylinders in single-chamber two cylinders gin. For increase, durability work of saw disks and shaft, by the static analysis of pressure upon saws. That will increase wear resistance and will improve quality indicators of a fiber and seeds it will be accepted an optimum co...
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Influence of Bainitic Transformation on Fatigue Behaviour of Medium Carbon Steel
F. F. Osasere Orumwense,
Okeoghene Henry Emonena,
Segun Afokhainu Agbadua
Issue:
Volume 1, Issue 3, November 2016
Pages:
107-114
Received:
25 September 2016
Accepted:
17 October 2016
Published:
9 November 2016
DOI:
10.11648/j.ajmie.20160103.22
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Abstract: This paper examines the behavior of medium carbon steels subjected to a bainitic transformation. The compositional analysis was performed to ascertain the percentage of carbon in the as-received materials. The specimens were machined to a precise gauge length and exposed to various bainitic transformation temperatures. Fatigue test was also performed with the use of Avery Dennison and bending stress was obtained using the curve supplied with the machine. The medium carbon steel specimens were austenitized at 900°C and then transformed into bainite at 200, 300 and 400°C for one hour and also at 300°C for periods of 20, 40, 60, 80, 100, 120 and 140 minutes to obtain various bainitic transformation microstructures. The results from the machine were converted to Mega Pascal (MPa) and the values used to plot S-N curves and fatigue behavior for the specimens at various bainitic transformation temperatures at different times were established. It was discovered that bainitic transformed medium carbon steel showed improved fatigue behavior.
Abstract: This paper examines the behavior of medium carbon steels subjected to a bainitic transformation. The compositional analysis was performed to ascertain the percentage of carbon in the as-received materials. The specimens were machined to a precise gauge length and exposed to various bainitic transformation temperatures. Fatigue test was also perform...
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Experimental Investigation and Modelling of EWR, Ra and MRR in Electric Discharge Machining of AISI 316 Steel
Alankar Patni,
Ashok Keche,
Hanumant Dharmadhikari
Issue:
Volume 1, Issue 3, November 2016
Pages:
115-122
Received:
5 October 2016
Accepted:
15 October 2016
Published:
14 November 2016
DOI:
10.11648/j.ajmie.20160103.24
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Abstract: The triangular shape graphite electrode materials have been utilized in the electric discharge machining by considering this objective, the parameters discharge current, pulse time, and voltage considered as input parameters and EWR, MRR, and Ra value as output parameters to perform machining on AISI 316 steel in EDM. The experimentation performed on the commercial EDM machine by considering the number of runs which was defined by the DOE Taguchi method. By using regression analysis, the different correlations were formed in between discharge current, pulse time, and voltage i.e. input parameters and EWR, MRR, and Ra value i.e. output parameters. The individual as well as combined correlations are formed in between input and output parameters. The result analysis shows the co-relation between runs and the estimated and experimental values for the different output parameters. The conclusion shows that the final equation for different output parameters would be able to predict EWR with accuracy of 97.09%, MRR with accuracy 99.39%, and Ra with accuracy of 99.51%.
Abstract: The triangular shape graphite electrode materials have been utilized in the electric discharge machining by considering this objective, the parameters discharge current, pulse time, and voltage considered as input parameters and EWR, MRR, and Ra value as output parameters to perform machining on AISI 316 steel in EDM. The experimentation performed ...
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Application of Taguchi Method for Optimum Weld Process Parameters of Pure Aluminum
Makkapati Sahiti,
Madur Raghavendra Reddy,
Budi Joshi,
Boggarapu Nageswara Rao
Issue:
Volume 1, Issue 3, November 2016
Pages:
123-128
Received:
17 October 2016
Accepted:
24 December 2016
Published:
17 January 2017
DOI:
10.11648/j.ajmie.20160103.25
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Abstract: Though many optimization methods have been developed, there is a lack of comparative study regarding the performance of those methods. This paper demonstrates the adequacy as well as the simplicity of the Taguchi method on the selection of optimum process parameters of the MIG welding as well as the TIG welding of pure aluminum by comparing the grey rational analysis results of Joshi and his co-workers. ANOVA results are utilized to identify the optimum weld process parameters (viz. welding current, gas flow and wire feed rate) and estimated the possible optimum ultimate tensile strength of the aluminum weld joint, by means of additive law. The estimates are found to be reasonably in good agreement with test results, when compared to those from the empirical relations of Joshi and his co-workers.
Abstract: Though many optimization methods have been developed, there is a lack of comparative study regarding the performance of those methods. This paper demonstrates the adequacy as well as the simplicity of the Taguchi method on the selection of optimum process parameters of the MIG welding as well as the TIG welding of pure aluminum by comparing the gre...
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