International Journal of Mechanical, Industrial and Aerospace Sciences

Modeling and Simulation of a Serial Production Line with Constant Work-In-Process

Year: 2009 Volume: 3 Issue: 5 629 - 637 Pages

Authors:
Mehmet Savsar

Abstract: This paper presents a model for an unreliable production line, which is operated according to demand with constant work-in-process (CONWIP). A simulation model is developed based on the discrete model and several case problems are analyzed using the model. The model is utilized to optimize storage space capacities at intermediate stages and the number of kanbans at the last stage, which is used to trigger the production at the first stage. Furthermore, effects of several line parameters on production rate are analyzed using design of experiments.

Numerical Investigation of Non Fourier Heat Conduction in a Semi-infinite Body due to a Moving Concentrated Heat Source Composed with Radiational Boundary Condition

Year: 2010 Volume: 4 Issue: 11 1299 - 1306 Pages

Abstract: In this paper, the melting of a semi-infinite body as a result of a moving laser beam has been studied. Because the Fourier heat transfer equation at short times and large dimensions does not have sufficient accuracy; a non-Fourier form of heat transfer equation has been used. Due to the fact that the beam is moving in x direction, the temperature distribution and the melting pool shape are not asymmetric. As a result, the problem is a transient threedimensional problem. Therefore, thermophysical properties such as heat conductivity coefficient, density and heat capacity are functions of temperature and material states. The enthalpy technique, used for the solution of phase change problems, has been used in an explicit finite volume form for the hyperbolic heat transfer equation. This technique has been used to calculate the transient temperature distribution in the semi-infinite body and the growth rate of the melt pool. In order to validate the numerical results, comparisons were made with experimental data. Finally, the results of this paper were compared with similar problem that has used the Fourier theory. The comparison shows the influence of infinite speed of heat propagation in Fourier theory on the temperature distribution and the melt pool size.

Performance Analysis of a Flexible Manufacturing Line Operated Under Surplus-based Production Control

Year: 2011 Volume: 5 Issue: 11 2464 - 2470 Pages

Abstract: In this paper we present our results on the performance analysis of a multi-product manufacturing line. We study the influence of external perturbations, intermediate buffer content and the number of manufacturing stages on the production tracking error of each machine in the multi-product line operated under a surplusbased production control policy. Starting by the analysis of a single machine with multiple production stages (one for each product type), we provide bounds on the production error of each stage. Then, we extend our analysis to a line of multi-stage machines, where similarly, bounds on each production tracking error for each product type, as well as buffer content are obtained. Details on performance of the closed-loop flow line model are illustrated in numerical simulations.

Fuzzy Wavelet Packet based Feature Extraction Method for Multifunction Myoelectric Control

Year: 2008 Volume: 2 Issue: 1 79 - 87 Pages

Abstract: The myoelectric signal (MES) is one of the Biosignals utilized in helping humans to control equipments. Recent approaches in MES classification to control prosthetic devices employing pattern recognition techniques revealed two problems, first, the classification performance of the system starts degrading when the number of motion classes to be classified increases, second, in order to solve the first problem, additional complicated methods were utilized which increase the computational cost of a multifunction myoelectric control system. In an effort to solve these problems and to achieve a feasible design for real time implementation with high overall accuracy, this paper presents a new method for feature extraction in MES recognition systems. The method works by extracting features using Wavelet Packet Transform (WPT) applied on the MES from multiple channels, and then employs Fuzzy c-means (FCM) algorithm to generate a measure that judges on features suitability for classification. Finally, Principle Component Analysis (PCA) is utilized to reduce the size of the data before computing the classification accuracy with a multilayer perceptron neural network. The proposed system produces powerful classification results (99% accuracy) by using only a small portion of the original feature set.

Characteristics of Wall Thickness Increase in Pipe Reduction Process using Planetary Rolls

Year: 2011 Volume: 5 Issue: 11 2459 - 2463 Pages

Abstract: In recent years, global warming has become a worldwide problem. The reduction of carbon dioxide emissions is a top priority for many companies in the manufacturing industry. In the automobile industry as well, the reduction of carbon dioxide emissions is one of the most important issues. Technology to reduce the weight of automotive parts improves the fuel economy of automobiles, and is an important technology for reducing carbon dioxide. Also, even if this weight reduction technology is applied to electric automobiles rather than gasoline automobiles, reducing energy consumption remains an important issue. Plastic processing of hollow pipes is one important technology for realizing the weight reduction of automotive parts. Ohashi et al. [1],[2] present an example of research on pipe formation in which a process was carried out to enlarge a pipe diameter using a lost core, achieving the suppression of wall thickness reduction and greater pipe expansion than hydroforming. In this study, we investigated a method to increase the wall thickness of a pipe through pipe compression using planetary rolls. The establishment of a technology whereby the wall thickness of a pipe can be controlled without buckling the pipe is an important technology for the weight reduction of products. Using the finite element analysis method, we predicted that it would be possible to increase the compression of an aluminum pipe with a 3mm wall thickness by approximately 20%, and wall thickness by approximately 20% by pressing the hollow pipe with planetary rolls.

Accurate And Efficient Global Approximation using Adaptive Polynomial RSM for Complex Mechanical and Vehicular Performance Models

Year: 2010 Volume: 4 Issue: 8 710 - 720 Pages

Abstract: Global approximation using metamodel for complex mathematical function or computer model over a large variable domain is often needed in sensibility analysis, computer simulation, optimal control, and global design optimization of complex, multiphysics systems. To overcome the limitations of the existing response surface (RS), surrogate or metamodel modeling methods for complex models over large variable domain, a new adaptive and regressive RS modeling method using quadratic functions and local area model improvement schemes is introduced. The method applies an iterative and Latin hypercube sampling based RS update process, divides the entire domain of design variables into multiple cells, identifies rougher cells with large modeling error, and further divides these cells along the roughest dimension direction. A small number of additional sampling points from the original, expensive model are added over the small and isolated rough cells to improve the RS model locally until the model accuracy criteria are satisfied. The method then combines local RS cells to regenerate the global RS model with satisfactory accuracy. An effective RS cells sorting algorithm is also introduced to improve the efficiency of model evaluation. Benchmark tests are presented and use of the new metamodeling method to replace complex hybrid electrical vehicle powertrain performance model in vehicle design optimization and optimal control are discussed.

Development of a Low Cost Haptic Knob

Year: 2011 Volume: 5 Issue: 10 2057 - 2060 Pages

Abstract: Haptics has been used extensively in many applications especially in human machine interaction and virtual reality systems. Haptic technology allows user to perceive virtual reality as in real world. However, commercially available haptic devices are expensive and may not be suitable for educational purpose. This paper describes the design and development of a low cost haptic knob, with only one degree of freedom, for use in rehabilitation or training hand pronation and supination. End-effectors can be changed to suit different applications or variation in hand sizes and hand orientation.

Information System for Data Selection and New Information Acquisition for Reconfigurable Multifunctional Machine Tools

Year: 2007 Volume: 1 Issue: 9 528 - 533 Pages

Authors:
Sasho Guergov

Abstract: The purpose of the paper is to develop an informationcontrol environment for overall management and self-reconfiguration of the reconfigurable multifunctional machine tool for machining both rotation and prismatic parts and high concentration of different technological operations - turning, milling, drilling, grinding, etc. For the realization of this purpose on the basis of defined sub-processes for the implementation of the technological process, architecture of the information-search system for machine control is suggested. By using the object-oriented method, a structure and organization of the search system based on agents and manager with central control are developed. Thus conditions for identification of available information in DBs, self-reconfiguration of technological system and entire control of the reconfigurable multifunctional machine tool are created.

Measurement of Convective Heat Transfer from a Vertical Flat Plate Using Mach-Zehnder Interferometer with Wedge Fringe Setting

Year: 2013 Volume: 7 Issue: 12 2407 - 2412 Pages

Abstract: Laser interferometric methods have been utilized for the measurement of natural convection heat transfer from a heated vertical flat plate, in the investigation presented here. The study mainly aims at comparing two different fringe orientations in the wedge fringe setting of Mach-Zehnder interferometer (MZI), used for the measurements. The interference fringes are set in horizontal and vertical orientations with respect to the heated surface, and two different fringe analysis methods, namely the stepping method and the method proposed by Naylor and Duarte, are used to obtain the heat transfer coefficients. The experimental system is benchmarked with theoretical results, thus validating its reliability in heat transfer measurements. The interference fringe patterns are analyzed digitally using MATLAB 7 and MOTIC Plus softwares, which ensure improved efficiency in fringe analysis, hence reducing the errors associated with conventional fringe tracing. The work also discuss the relative merits and limitations of the two methods used.

Simulation of Agri-Food Supply Chains

Year: 2012 Volume: 6 Issue: 5 982 - 987 Pages

Abstract: Supply chain management has become more challenging with the emerging trend of globalization and sustainability. Lately, research related to perishable products supply chains, in particular agricultural food products, has emerged. This is attributed to the additional complexity of managing this type of supply chains with the recently increased concern of public health, food quality, food safety, demand and price variability, and the limited lifetime of these products. Inventory management for agrifood supply chains is of vital importance due to the product perishability and customers- strive for quality. This paper concentrates on developing a simulation model of a real life case study of a two echelon production-distribution system for agri-food products. The objective is to improve a set of performance measures by developing a simulation model that helps in evaluating and analysing the performance of these supply chains. Simulation results showed that it can help in improving overall system performance.

An Advanced Technology for Renovation of Extruding Shafts

Year: 2013 Volume: 7 Issue: 8 1715 - 1718 Pages

Abstract: The paper is concerned with the technological process of renovation of shafts used in industrial manufacturing for extruding of sheet material. In the classical renovation technologies, a chrome based coating is applied to the working surface of the shaft in galvanic baths. The process, however, is known to be exclusively harmful due to the waste cyanide products. In this work, we present an advanced nanotechnology based on nonelectric chemical laying of a nickel coating with included nanoparticles. The technology is environmentally harmless and the new coating features an increased hardness and wear resistance. Results from experimental tests of the nanostructured nickel coating are presented and discussed.

A Study of Various Numerical Turbulence Modeling Methods in Boundary Layer Excitation of a Square Ribbed Channel

Year: 2010 Volume: 4 Issue: 11 1292 - 1298 Pages

Abstract: Among the various cooling processes in industrial applications such as: electronic devices, heat exchangers, gas turbines, etc. Gas turbine blades cooling is the most challenging one. One of the most common practices is using ribbed wall because of the boundary layer excitation and therefore making the ultimate cooling. Vortex formation between rib and channel wall will result in a complicated behavior of flow regime. At the other hand, selecting the most efficient method for capturing the best results comparing to experimental works would be a fascinating issue. In this paper 4 common methods in turbulence modeling: standard k-e, rationalized k-e with enhanced wall boundary layer treatment, k-w and RSM (Reynolds stress model) are employed to a square ribbed channel to investigate the separation and thermal behavior of the flow in the channel. Finally all results from different methods which are used in this paper will be compared with experimental data available in literature to ensure the numerical method accuracy.

Improvements in Material Handling: A Case Study of Cement Manufacturing Plant

Year: 2011 Volume: 5 Issue: 3 721 - 725 Pages

Authors:
A. Pancharya

Abstract: The globalization of the Indian economy has thrown a great challenge to the Indian industries in respect of productivity, quality, cost, delivery etc. Achieving success• the global market has required fundamental shift in the way business is conducted and has dramatically affected virtually every aspect of process industry. The internal manufacturing process and supporting infrastructure should be such that it can compete successfully in global markets with better flexibility and delivery. The paper deals with a case study of a reputed process industry, some changes in the process has been suggested, which leads to reduction in labor cost and production cost.

Modeling of Single-Particle Impact in Abrasive Water Jet Machining

Year: 2007 Volume: 1 Issue: 12 764 - 769 Pages

Abstract: This work presents a study on the abrasive water jet (AWJ) machining. An explicit finite element analysis (FEA) of single abrasive particle impact on stainless steel 1.4304 (AISI 304) is conducted. The abrasive water jet machining is modeled by FEA software ABAQUS/CAE. Shapes of craters in FEM simulation results were used and compared with the previous experimental and FEM works by means of crater sphericity. The influence of impact angle and particle velocity was observed. Adaptive mesh domain is used to model the impact zone. Results are in good agreement with those obtained from the experimental and FEM simulation. The crater-s depth is also obtained for different impact angle and abrasive particle velocities.

Evaluation of Optimal Residence Time in a Hot Rolled Reheating Furnace

Year: 2011 Volume: 5 Issue: 11 2455 - 2458 Pages

Authors:
Dong-Eun Lee

Abstract: To calculate the temperature distribution of the slab in a hot rolled reheating furnace a mathematical model has been developed by considering the thermal radiation in the furnace and transient conduction in the slab. The furnace is modeled as radiating medium with spatially varying temperature. Radiative heat flux within the furnace including the effect of furnace walls, combustion gases, skid beams and buttons is calculated using the FVM and is applied as the boundary condition of the transient conduction equation of the slab. After determining the slab emissivity by comparison between simulation and experimental work, variation of heating characteristics in the slab is investigated in the case of changing furnace temperature with various time and the slab residence time is optimized with this evaluation.

A Search Algorithm for Solving the Economic Lot Scheduling Problem with Reworks under the Basic Period Approach

Year: 2013 Volume: 7 Issue: 6 1266 - 1270 Pages

Abstract: In this study, we are interested in the economic lot scheduling problem (ELSP) that considers manufacturing of the serviceable products and remanufacturing of the reworked products. In this paper, we formulate a mathematical model for the ELSP with reworks using the basic period approach. In order to solve this problem, we propose a search algorithm to find the cyclic multiplier ki of each product that can be cyclically produced for every ki basic periods. This research also uses two heuristics to search for the optimal production sequence of all lots and the optimal time length of the basic period so as to minimize the average total cost. This research uses a numerical example to show the effectiveness of our approach.

Simulation and Experimentation of Multibody Mechanical Systems with Clearance Revolute Joints

Year: 2012 Volume: 6 Issue: 3 710 - 719 Pages

Abstract: Clearance in the joints of multibody mechanical systems such as linkage mechanisms and robots is a main source of vibration, and noise of the whole system, and wear of the joints themselves. This clearance is an inevitable matter and cannot be eliminated, since it allows the relative motion between joint components and make them assemblage. This paper presents an experimental verification of the obtained simulation results of a slider – crank mechanism of one clearance revolute joint. The simulation results are obtained with the aid of CAD and dynamic simulation softwares, which is an effective method of simulation multibody systems with clearance joints and have many advantages. The comparison between both simulation and experimental results shows that the simulation results are so close to the experimental ones which proves the accuracy and efficiency of this method of modeling and simulation of mechanical systems with clearance joints.

Automated Textile Defect Recognition System Using Computer Vision and Artificial Neural Networks

Year: 2008 Volume: 2 Issue: 1 73 - 78 Pages

Abstract: Least Development Countries (LDC) like Bangladesh, whose 25% revenue earning is achieved from Textile export, requires producing less defective textile for minimizing production cost and time. Inspection processes done on these industries are mostly manual and time consuming. To reduce error on identifying fabric defects requires more automotive and accurate inspection process. Considering this lacking, this research implements a Textile Defect Recognizer which uses computer vision methodology with the combination of multi-layer neural networks to identify four classifications of textile defects. The recognizer, suitable for LDC countries, identifies the fabric defects within economical cost and produces less error prone inspection system in real time. In order to generate input set for the neural network, primarily the recognizer captures digital fabric images by image acquisition device and converts the RGB images into binary images by restoration process and local threshold techniques. Later, the output of the processed image, the area of the faulty portion, the number of objects of the image and the sharp factor of the image, are feed backed as an input layer to the neural network which uses back propagation algorithm to compute the weighted factors and generates the desired classifications of defects as an output.

Development of Predictive Model for Surface Roughness in End Milling of Al-SiCp Metal Matrix Composites using Fuzzy Logic

Year: 2012 Volume: 6 Issue: 7 1325 - 1330 Pages

Abstract: Metal matrix composites have been increasingly used as materials for components in automotive and aerospace industries because of their improved properties compared with non-reinforced alloys. During machining the selection of appropriate machining parameters to produce job for desired surface roughness is of great concern considering the economy of manufacturing process. In this study, a surface roughness prediction model using fuzzy logic is developed for end milling of Al-SiCp metal matrix composite component using carbide end mill cutter. The surface roughness is modeled as a function of spindle speed (N), feed rate (f), depth of cut (d) and the SiCp percentage (S). The predicted values surface roughness is compared with experimental result. The model predicts average percentage error as 4.56% and mean square error as 0.0729. It is observed that surface roughness is most influenced by feed rate, spindle speed and SiC percentage. Depth of cut has least influence.

Simultaneous Optimization of Machining Parameters and Tool Geometry Specifications in Turning Operation of AISI1045 Steel

Year: 2011 Volume: 5 Issue: 2 461 - 464 Pages

Abstract: Machining is an important manufacturing process used to produce a wide variety of metallic parts. Among various machining processes, turning is one of the most important one which is employed to shape cylindrical parts. In turning, the quality of finished product is measured in terms of surface roughness. In turn, surface quality is determined by machining parameters and tool geometry specifications. The main objective of this study is to simultaneously model and optimize machining parameters and tool geometry in order to improve the surface roughness for AISI1045 steel. Several levels of machining parameters and tool geometry specifications are considered as input parameters. The surface roughness is selected as process output measure of performance. A Taguchi approach is employed to gather experimental data. Then, based on signal-to-noise (S/N) ratio, the best sets of cutting parameters and tool geometry specifications have been determined. Using these parameters values, the surface roughness of AISI1045 steel parts may be minimized. Experimental results are provided to illustrate the effectiveness of the proposed approach.