An Application of SMED Methodology

Single Minute Exchange of Dies (SMED) mainly focuses on recognition of internal and external activities. It is concerned particularly with transferring internal activities into external ones in as many numbers as possible, by also minimizing the internal ones. The validity of the method and procedures are verified by an application a Styrofoam manufacturing process where setup times are critical for time reduction. Significant time savings have been achieved with minimum investment. Further, the issues related with employer safety and ergonomics principles during die exchange are noted.

Dry Sliding Wear Behavior of Epoxy-Rubber Dust Composites

Composite pins of rubber dust collected from tyre retreading centres of trucks, cars and buses etc.and epoxy with weight percentages of 10. 15, and 20 % of rubber (weight fractions of 9, 13 and 17 % respectively) have been prepared in house with the help of a split wooden mould. The pins were tested in a pin-on-disc wear monitor to determine the co-efficient of friction and weight losses with varying speeds, loads and time. The wear volume and wear rates have also been found out for all these three specimens.. It is observed that all the specimens have exhibited very low coefficient of friction and low wear rates under dry sliding condition. Out of the above three samples tested, the specimen with 10 % rubber dust by weight has shown lowest wear rates. However a peculiar result i.e decreasing trend has been obtained with 20% reinforcement of rubber in epoxy while rubbed against steel at varying speeds. This might have occurred due to high surface finish of the disc and formation of a thin transfer layer from the composite

Cross-Industry Innovations–Systematic Identification of Ideas for Radical Problem Solving

Creativity is often based on an unorthodox recombination of knowledge; in fact: 80% of all innovations use given knowledge and put it into a new combination. Cross-industry innovations follow this way of thinking and bring together problems and solution ideas from different industries. Therefore analogies and search strategies have to be developed. Taking this path, the questions where to search, what to search and how to search have to be answered. Afterwards, the gathered information can be used within a planned search process. Identified solution ideas have to be assessed and analyzed in detail for the success promising adaption planning.

A Detailed Experimental Study of the Springback Anisotropy of Three Metals using the Stretching-Bending Process

Springback is a significant problem in the sheet metal forming process. When the tools are released after the stage of forming, the product springs out, because of the action of the internal stresses. In many cases the deviation of form is too large and the compensation of the springback is necessary. The precise prediction of the springback of product is increasingly significant for the design of the tools and for compensation because of the higher ratio of the yield stress to the elastic modulus. The main object in this paper was to study the effect of the anisotropy on the springback for three directions of rolling: 0°, 45° and 90°. At the same time, we highlighted the influence of three different metallic materials: Aluminum, Steel and Galvanized steel. The original of our purpose consist on tests which are ensured by adapting a U-type stretching-bending device on a tensile testing machine, where we studied and quantified the variation of the springback according to the direction of rolling. We also showed the role of lubrication in the reduction of the springback. Moreover, in this work, we have studied important characteristics in deep drawing process which is a springback. We have presented defaults that are showed in this process and many parameters influenced a springback. Finally, our results works lead us to understand the influence of grains orientation with different metallic materials on the springback and drawing some conclusions how to concept deep drawing tools. In addition, the conducted work represents a fundamental contribution in the discussion the industry application.

Multistage Condition Monitoring System of Aircraft Gas Turbine Engine

Researches show that probability-statistical methods application, especially at the early stage of the aviation Gas Turbine Engine (GTE) technical condition diagnosing, when the flight information has property of the fuzzy, limitation and uncertainty is unfounded. Hence the efficiency of application of new technology Soft Computing at these diagnosing stages with the using of the Fuzzy Logic and Neural Networks methods is considered. According to the purpose of this problem training with high accuracy of fuzzy multiple linear and non-linear models (fuzzy regression equations) which received on the statistical fuzzy data basis is made. For GTE technical condition more adequate model making dynamics of skewness and kurtosis coefficients- changes are analysed. Researches of skewness and kurtosis coefficients values- changes show that, distributions of GTE work parameters have fuzzy character. Hence consideration of fuzzy skewness and kurtosis coefficients is expedient. Investigation of the basic characteristics changes- dynamics of GTE work parameters allows drawing conclusion on necessity of the Fuzzy Statistical Analysis at preliminary identification of the engines' technical condition. Researches of correlation coefficients values- changes shows also on their fuzzy character. Therefore for models choice the application of the Fuzzy Correlation Analysis results is offered. At the information sufficiency is offered to use recurrent algorithm of aviation GTE technical condition identification (Hard Computing technology is used) on measurements of input and output parameters of the multiple linear and non-linear generalised models at presence of noise measured (the new recursive Least Squares Method (LSM)). The developed GTE condition monitoring system provides stageby- stage estimation of engine technical conditions. As application of the given technique the estimation of the new operating aviation engine technical condition was made.

On Discretization of Second-order Derivatives in Smoothed Particle Hydrodynamics

Discretization of spatial derivatives is an important issue in meshfree methods especially when the derivative terms contain non-linear coefficients. In this paper, various methods used for discretization of second-order spatial derivatives are investigated in the context of Smoothed Particle Hydrodynamics. Three popular forms (i.e. "double summation", "second-order kernel derivation", and "difference scheme") are studied using one-dimensional unsteady heat conduction equation. To assess these schemes, transient response to a step function initial condition is considered. Due to parabolic nature of the heat equation, one can expect smooth and monotone solutions. It is shown, however in this paper, that regardless of the type of kernel function used and the size of smoothing radius, the double summation discretization form leads to non-physical oscillations which persist in the solution. Also, results show that when a second-order kernel derivative is used, a high-order kernel function shall be employed in such a way that the distance of inflection point from origin in the kernel function be less than the nearest particle distance. Otherwise, solutions may exhibit oscillations near discontinuities unlike the "difference scheme" which unconditionally produces monotone results.

Machining Parameters Optimization of Developed Yttria Stabilized Zirconia Toughened Alumina Ceramic Inserts While Machining AISI 4340 Steel

An attempt has been made to investigate the machinability of zirconia toughened alumina (ZTA) inserts while turning AISI 4340 steel. The insert was prepared by powder metallurgy process route and the machining experiments were performed based on Response Surface Methodology (RSM) design called Central Composite Design (CCD). The mathematical model of flank wear, cutting force and surface roughness have been developed using second order regression analysis. The adequacy of model has been carried out based on Analysis of variance (ANOVA) techniques. It can be concluded that cutting speed and feed rate are the two most influential factor for flank wear and cutting force prediction. For surface roughness determination, the cutting speed & depth of cut both have significant contribution. Key parameters effect on each response has also been presented in graphical contours for choosing the operating parameter preciously. 83% desirability level has been achieved using this optimized condition.

Simulation of Fluid Flow and Heat Transfer in the Inclined Enclosure

Mixed convection in two-dimensional shallow rectangular enclosure is considered. The top hot wall moves with constant velocity while the cold bottom wall has no motion. Simulations are performed for Richardson number ranging from Ri = 0.001 to 100 and for Reynolds number keeping fixed at Re = 408.21. Under these conditions cavity encompasses three regimes: dominating forced, mixed and free convection flow. The Prandtl number is set to 6 and the effects of cavity inclination on the flow and heat transfer are studied for different Richardson number. With increasing the inclination angle, interesting behavior of the flow and thermal fields are observed. The streamlines and isotherm plots and the variation of the Nusselt numbers on the hot wall are presented. The average Nusselt number is found to increase with cavity inclination for Ri ³ 1 . Also it is shown that the average Nusselt number changes mildly with the cavity inclination in the dominant forced convection regime but it increases considerably in the regime with dominant natural convection.

Vibration Suppression of Timoshenko Beams with Embedded Piezoelectrics Using POF

This paper deals with the design of a periodic output feedback controller for a flexible beam structure modeled with Timoshenko beam theory, Finite Element Method, State space methods and embedded piezoelectrics concept. The first 3 modes are considered in modeling the beam. The main objective of this work is to control the vibrations of the beam when subjected to an external force. Shear piezoelectric sensors and actuators are embedded into the top and bottom layers of a flexible aluminum beam structure, thus making it intelligent and self-adaptive. The composite beam is divided into 5 finite elements and the control actuator is placed at finite element position 1, whereas the sensor is varied from position 2 to 5, i.e., from the nearby fixed end to the free end. 4 state space SISO models are thus developed. Periodic Output Feedback (POF) Controllers are designed for the 4 SISO models of the same plant to control the flexural vibrations. The effect of placing the sensor at different locations on the beam is observed and the performance of the controller is evaluated for vibration control. Conclusions are finally drawn.

Loop Heat Pipe: Simple Thermodynamic

The LHP is a two-phase device with extremely high effective thermal conductivity that utilizes the thermodynamic pressure difference to circulate a cooling fluid. A thermodynamics analytical model is developed to explore different parameters effects on a Loop Heat Pipe (LHP).. The effects of pipe length, pipe diameter, condenser temperature, and heat load are reported. As pipe length increases and/or pipe diameter decreases, a higher temperature is expected in the evaporator.

Hydrothermal Behavior of G-S Magnetically Stabilized Beds Consisting of Magnetic and Non-Magnetic Admixtures

The hydrothermal behavior of a bed consisting of magnetic and shale oil particle admixtures under the effect of a transverse magnetic field is investigated. The phase diagram, bed void fraction are studied under wide range of the operating conditions i.e., gas velocity, magnetic field intensity and fraction of the magnetic particles. It is found that the range of the stabilized regime is reduced as the magnetic fraction decreases. In addition, the bed voidage at the onset of fluidization decreases as the magnetic fraction decreases. On the other hand, Nusselt number and consequently the heat transfer coefficient is found to increase as the magnetic fraction decreases. An empirical equation is investigated to relate the effect of the gas velocity, magnetic field intensity and fraction of the magnetic particles on the heat transfer behavior in the bed.

Terrain Evaluation Method for Hexapod Robot

In this paper a simple terrain evaluation method for hexapod robot is introduced. This method is based on feet coordinate evaluation when all are on the ground. Depending on the feet coordinate differences the local terrain evaluation is possible. Terrain evaluation is necessary for right gait selection and/or body position correction. For terrain roughness evaluation three planes are plotted: two of them as definition points use opposite feet coordinates, third coincides with the robot body plane. The leaning angle of body plane is evaluated measuring gravity force using three-axis accelerometer. Terrain roughness evaluation method is based on angle estimation between normal vectors of these planes. Aim of this work is to present a simple method for embedded robot controller, allowing to find the best further movement settings.

Magnetohydrodynamic Mixed Convective Flow in a Cavity

A magnetohydrodynamic mixed convective flow in a cavity was studied in this paper. The lower surface of cavity was heated from below whereas other walls of the cavity were thermally isolated. The governing two-dimensional flow equations have been solved by using finite volume code. The effects of magnetic field were studied on flow and temperature field and heat transfer performance at a wide range of parameters, Such as Hartmann (0≤Ha≤100) and Reynolds (1≤Re≤100) numbers. The results showed that as Hartman number increases the Nusselt number, representing heat transfer from the cavity decreases.

Turbine Follower Control Strategy Design Based on Developed FFPP Model

In this paper a comprehensive model of a fossil fueled power plant (FFPP) is developed in order to evaluate the performance of a newly designed turbine follower controller. Considering the drawbacks of previous works, an overall model is developed to minimize the error between each subsystem model output and the experimental data obtained at the actual power plant. The developed model is organized in two main subsystems namely; Boiler and Turbine. Considering each FFPP subsystem characteristics, different modeling approaches are developed. For economizer, evaporator, superheater and reheater, first order models are determined based on principles of mass and energy conservation. Simulations verify the accuracy of the developed models. Due to the nonlinear characteristics of attemperator, a new model, based on a genetic-fuzzy systems utilizing Pittsburgh approach is developed showing a promising performance vis-à-vis those derived with other methods like ANFIS. The optimization constraints are handled utilizing penalty functions. The effect of increasing the number of rules and membership functions on the performance of the proposed model is also studied and evaluated. The turbine model is developed based on the equation of adiabatic expansion. Parameters of all evaluated models are tuned by means of evolutionary algorithms. Based on the developed model a fuzzy PI controller is developed. It is then successfully implemented in the turbine follower control strategy of the plant. In this control strategy instead of keeping control parameters constant, they are adjusted on-line with regard to the error and the error rate. It is shown that the response of the system improves significantly. It is also shown that fuel consumption decreases considerably.

A Finite Element Model for Estimating Young-s Modulus of Carbon Nanotube Reinforced Composites Incorporating Elastic Cross-Links

The presence of chemical bonding between functionalized carbon nanotubes and matrix in carbon nanotube reinforced composites is modeled by elastic beam elements representing covalent bonding characteristics. Neglecting other reinforcing mechanisms in the composite such as relatively weak interatomic Van der Waals forces, this model shows close results to the Rule of Mixtures model-s prediction for effective Young-s modulus of a Representative Volume Element of composite for small volume fractions (~1%) and high aspect ratios (L/D>200) of CNTs.

Flow Visualization of Angled Supersonic Jets into a Supersonic Cross Flow

This paper describes Nano-particle based Planar Laser Scattering (NPLS) flow visualization of angled supersonic jets into a supersonic cross flow based on the HYpersonic Low TEmperature (HYLTE) nozzle which was widely used in DF chemical laser. In order to investigate the non-reacting flowfield in the HYLTE nozzle, a testing section with windows was designed and manufactured. The impact of secondary fluids orifice separation on mixing was examined. For narrow separation of orifices, the secondary fuel penetration increased obviously compared to diluent injection, which means smaller separation of diluent and fuel orifices would enhance the mixing of fuel and oxidant. Secondary injections with angles of 30, 40 and 50 degrees were studied. It was found that the injectant penetration increased as the injection angle increased, while the interfacial surface area to entrain the freestream fluid is largest when the injection angle is 40 degree.

Application of Association Rule Mining in Supplier Selection Criteria

In this paper the application of rule mining in order to review the effective factors on supplier selection is reviewed in the following three sections 1) criteria selecting and information gathering 2) performing association rule mining 3) validation and constituting rule base. Afterwards a few of applications of rule base is explained. Then, a numerical example is presented and analyzed by Clementine software. Some of extracted rules as well as the results are presented at the end.

Detached-Eddy Simulation of Vortex Generator Jet Using Chimera Grids

This paper aims at numerically analysing the effect of an active flow control (AFC) by a vortex generator jet (VGJ) submerged in a boundary layer via Chimera Grids and Detached- Eddy Simulation (DES). The performance of DES results are judged against Reynolds-Averaged Navier-Stokes (RANS) and compared with the experiments that showed an unsteady vortex motion downstream of VGJ. Experimental results showed that the mechanism of embedding logitudinal vortex structure in the main stream flow is quite effective in increasing the near wall momentum of separated aircraft wing. In order to simulate such a flow configuration together with the VGJ, an efficient numerical approach is required. This requirement is fulfilled by performing the DES simulation over the flat plate using the DLR TAU Code. The DES predictions identify the vortex region via smooth hybrid length scale and predict the unsteady vortex motion observed in the experiments. The DES results also showed that the sufficient grid refinement in the vortex region resolves the turbulent scales downstream of the VGJ, the spatial vortex core postion and nondimensional momentum coefficient RVx .

Aerodynamic Stall Control of a Generic Airfoil using Synthetic Jet Actuator

The aerodynamic stall control of a baseline 13-percent thick NASA GA(W)-2 airfoil using a synthetic jet actuator (SJA) is presented in this paper. Unsteady Reynolds-averaged Navier-Stokes equations are solved on a hybrid grid using a commercial software to simulate the effects of a synthetic jet actuator located at 13% of the chord from the leading edge at a Reynolds number Re = 2.1x106 and incidence angles from 16 to 22 degrees. The experimental data for the pressure distribution at Re = 3x106 and aerodynamic coefficients at Re = 2.1x106 (angle of attack varied from -16 to 22 degrees) without SJA is compared with the computational fluid dynamic (CFD) simulation as a baseline validation. A good agreement of the CFD simulations is obtained for aerodynamic coefficients and pressure distribution. A working SJA has been integrated with the baseline airfoil and initial focus is on the aerodynamic stall control at angles of attack from 16 to 22 degrees. The results show a noticeable improvement in the aerodynamic performance with increase in lift and decrease in drag at these post stall regimes.

Pseudo-polynomial Motion Commands for Vibration Suppression of Belt-driven Rotary Platforms

The motion planning technique described in this paper has been developed to eliminate or reduce the residual vibrations of belt-driven rotary platforms, while maintaining unchanged the motion time and the total angular displacement of the platform. The proposed approach is based on a suitable choice of the motion command given to the servomotor that drives the mechanical device; this command is defined by some numerical coefficients which determine the shape of the displacement, velocity and acceleration profiles. Using a numerical optimization technique, these coefficients can be changed without altering the continuity conditions imposed on the displacement and its time derivatives at the initial and final time instants. The proposed technique can be easily and quickly implemented on an actual device, since it requires only a simple modification of the motion command profile mapped in the memory of the electronic motion controller.