International Journal of Mechanical, Industrial and Aerospace Sciences

Modeling and Simulation of Delaminations in FML Using Step Pulsed Active Thermography

Year: 2013 Volume: 7 Issue: 4 709 - 718 Pages

Abstract: The study focuses to investigate the thermal response of delaminations and develop mathematical models using numerical results to obtain the optimum heat requirement and time to identify delaminations in GLARE type of Fibre Metal Laminates (FML) in both reflection mode and through-transmission (TT) mode of step pulsed active thermography (SPAT) method in the type of nondestructive testing and evaluation (NDTE) technique. The influence of applied heat flux and time on various sizes and depth of delaminations in FML is analyzed to investigate the thermal response through numerical simulations. A finite element method (FEM) is applied to simulate SPAT through ANSYS software based on 3D transient heat transfer principle with the assumption of reflection mode and TT mode of observation individually. The results conclude that the numerical approach based on SPAT in reflection mode is more suitable for analysing smaller size of near-surface delaminations located at the thermal stimulator side and TT mode is more suitable for analysing smaller size of deeper delaminations located far from thermal stimulator side or near thermal detector/Infrared camera side. The mathematical models provide the optimum q and T at the required MRTD to identify unidentified delamination 7 with 25015.0022W/m2 at 2.531sec and delamination 8 with 16663.3356 W/m2 at 1.37857sec in reflection mode. In TT mode, the delamination 1 with 34954W/m2 at 13.0399sec, delamination 2 with 20002.67W/m2 at 1.998sec and delamination 7 with 20010.87 W/m2 at 0.6171sec could be identified.

Modal Analysis of Machine Tool Column Using Finite Element Method

Year: 2013 Volume: 7 Issue: 4 699 - 708 Pages

Authors:
Migbar Assefa

Abstract: The performance of a machine tool is eventually assessed by its ability to produce a component of the required geometry in minimum time and at small operating cost. It is customary to base the structural design of any machine tool primarily upon the requirements of static rigidity and minimum natural frequency of vibration. The operating properties of machines like cutting speed, feed and depth of cut as well as the size of the work piece also have to be kept in mind by a machine tool structural designer. This paper presents a novel approach to the design of machine tool column for static and dynamic rigidity requirement. Model evaluation is done effectively through use of General Finite Element Analysis software ANSYS. Studies on machine tool column are used to illustrate finite element based concept evaluation technique. This paper also presents results obtained from the computations of thin walled box type columns that are subjected to torsional and bending loads in case of static analysis and also results from modal analysis. The columns analyzed are square and rectangle based tapered open column, column with cover plate, horizontal partitions and with apertures. For the analysis purpose a total of 70 columns were analyzed for bending, torsional and modal analysis. In this study it is observed that the orientation and aspect ratio of apertures have no significant effect on the static and dynamic rigidity of the machine tool structure.

Kinematic Analysis and Software Development of a Seven Degree of Freedom Inspection Robot

Year: 2013 Volume: 7 Issue: 4 691 - 698 Pages

Abstract: Robots are booming as an essential substituent in the field of inspection. In hazardous environments like nuclear waste disposal, robots are really a necessitate one. In a view to meet such demands, this paper presents the seven degree of freedom articulated inspection robot. To design such a robot the kinematic analysis of seven Degree of freedom robot which can inspect the hazardous nuclear waste storage tanks is done. The effective utilization of universal joints for arms and screw jack mechanisms at the base gives the higher order of degree of freedom to the newly designed robot. The analytical method of deriving the manipulator forward as well as inverse kinematics is explained elaborately using the Denavit-Hartenberg Approach for the purpose of calculating the robot joints, links and end-effector parameters. The comparison of the geometric and the analytical approach is stated. The self-developed kinematic model gives the accurate positions of the end effector. The Graphical User Interface (GUI) is developed in Visual Basic language for the manipulation of kinematic results easily. This software gives the expected position of the end-effector accurately at short time compared to manual manipulations.

Parametric Study on Grindability of GFRP Laminates Using Different Abrasives

Year: 2013 Volume: 7 Issue: 4 685 - 690 Pages

Abstract: A study on grindability of chopped strand mat glass fiber reinforced polymer laminates (CSM GFRP) have been carried out to evaluate the significant parameters on wheel performance. Performance of Aluminum oxide and c-BN wheels during grinding of CSM GFRP laminate was evaluated in terms of grinding force and surface roughness during grinding. The cubic Boron Nitride wheel experiences higher tangential grinding forces components and lower normal force component than Aluminum oxide grinding wheels. In case of surface finish, Aluminum oxide grinding wheels outdo the cubic Boron Nitride grinding wheels.

Keywords:
Grinding
glass fiber reinforced polymer laminates
grinding force
surface finish.

Automatic Generating CNC-Code for Milling Machine

Year: 2013 Volume: 7 Issue: 12 2607 - 2613 Pages

Abstract: G-code is the main factor in computer numerical control (CNC) machine for controlling the toolpaths and generating the profile of the object’s features. For obtaining high surface accuracy of the surface finish, non-stop operation is required for CNC machine. Recently, to design a new product, the strategy that concerns about a change that has low impact on business and does not consume lot of resources has been introduced. Cost and time for designing minor changes can be reduced since the traditional geometric details of the existing models are applied. In order to support this strategy as the alternative channel for machining operation, this research proposes the automatic generating codes for CNC milling operation. Using this technique can assist the manufacturer to easily change the size and the geometric shape of the product during the operation where the time spent for setting up or processing the machine are reduced. The algorithm implemented on MATLAB platform is developed by analyzing and evaluating the geometric information of the part. Codes are created rapidly to control the operations of the machine. Comparing to the codes obtained from CAM, this developed algorithm can shortly generate and simulate the cutting profile of the part.

Modeling and Optimization of Part Type Selection and Loading Problem in Flexible Manufacturing System Using Real Coded Genetic Algorithms

Year: 2013 Volume: 7 Issue: 4 675 - 684 Pages

Abstract: This paper deals with modeling and optimization of two NP-hard problems in production planning of flexible manufacturing system (FMS), part type selection problem and loading problem. The part type selection problem and the loading problem are strongly related and heavily influence the system’s efficiency and productivity. These problems have been modeled and solved simultaneously by using real coded genetic algorithms (RCGA) which uses an array of real numbers as chromosome representation. The novel proposed chromosome representation produces only feasible solutions which minimize a computational time needed by GA to push its population toward feasible search space or repair infeasible chromosomes. The proposed RCGA improves the FMS performance by considering two objectives, maximizing system throughput and maintaining the balance of the system (minimizing system unbalance). The resulted objective values are compared to the optimum values produced by branch-and-bound method. The experiments show that the proposed RCGA could reach near optimum solutions in a reasonable amount of time.

Visual Inspection of Work Piece with a Complex Shape by Means of Robot Manipulator

Year: 2013 Volume: 7 Issue: 9 1900 - 1903 Pages

Abstract: Inconsistency in manual inspection is real because humans get tired after some time. Recent trends show that automatic inspection is more appealing for mass production inspections. In such as a case, a robot manipulator seems the best candidate to run a dynamic visual inspection. The purpose of this work is to estimate the optimum workspace where a robot manipulator would perform a visual inspection process onto a work piece where a camera is attached to the end effector. The pseudo codes for the planned path are derived from the number of tool transit points, the delay time at the transit points, the process cycle time, and the configuration space that the distance between the tool and the work piece. It is observed that express start and swift end are acceptable in a robot program because applicable works usually in existence during these moments. However, during the mid-range cycle, there are always practical tasks programmed to be executed. For that reason, it is acceptable to program the robot such as that speedy alteration of actuator displacement is avoided. A dynamic visual inspection system using a robot manipulator seems practical for a work piece with a complex shape.

An Evaluation of TIG Welding Parametric Influence on Tensile Strength of 5083 Aluminium Alloy

Year: 2013 Volume: 7 Issue: 11 2333 - 2336 Pages

Abstract: Tungsten Inert Gas (TIG) welding is a high quality welding process used to weld the thin metals and their alloy. 5083 Aluminium alloys play an important role in engineering and metallurgy field because of excellent corrosion properties, ease of fabrication and high specific strength coupled with best combination of toughness and formability. TIG welding technique is one of the precise and fastest processes used in aerospace, ship and marine industries. TIG welding process is used to analyze the data and evaluate the influence of input parameters on tensile strength of 5083 Al-alloy specimens with dimensions of 100mm long x 15mm wide x 5mm thick. Welding current (I), gas flow rate (G) and welding speed (S) are the input parameters which effect tensile strength of 5083 Al-alloy welded joints. As welding speed increased, tensile strength increases first till optimum value and after that both decreases by increasing welding speed further. Results of the study show that maximum tensile strength of 129 MPa of weld joint are obtained at welding current of 240 Amps, gas flow rate of 7 Lt/min and welding speed of 98 mm/min. These values are the optimum values of input parameters which help to produce efficient weld joint that have good mechanical properties as a tensile strength.

Gas Flow into Rotary Valve Intake and Exhaust Mechanism in Internal Combustion Engine

Year: 2013 Volume: 7 Issue: 4 669 - 674 Pages

Abstract: Simple design of a rotary valve system is capable of controlling intake and exhaust gases, which will eliminate the need of known complex mechanisms. The cost of material and production, maintenance, and noise level of the system can be further reduced. The new mechanism enables the elimination of the overlapping of valves work that reduces gas leakage. This paper examines theoretically the gas flow through the holes of a rotary valve design in a small engine. Preliminary results show that the new gas flow has many positive differences than a conventional poppet-valve system. New dependencies on the gas speed enable the finding of better solutions for the geometry of a rotary valve system that will result in a higher efficiency of an internal-combustion engine of the automotive industry.

Correlation between Heat Treatment, Microstructure and Properties of Trip-Assisted Steels

Year: 2013 Volume: 7 Issue: 4 663 - 668 Pages

Abstract: In the present study, two TRIP-assisted steels were designated as A (having no Cr and Cu content) and B (having higher Ni, Cr and Cu content) heat treated under different conditions, and the correlation between its heat treatment, microstructure and properties were investigated. Micro structural examination was carried out by optical microscope and scanning electron microscope after electrolytic etching. Non-destructive electrochemical and ultrasonic testing on two TRIP-assisted steels was used to find out corrosion and mechanical properties of different alter microstructure phase’s steels. Furthermore, micro structural studies accompanied by the evaluation of mechanical properties revealed that steels having martensite phases with higher corrosive and hardness value were less sound velocity and also steel’s microstructure having finer grains that was more grain boundary was less corrosion resistance. Steel containing more Cu, Ni and Cr was less corrosive compared to other steels having same processing or microstructure.

A Source Point Distribution Scheme for Wave-Body Interaction Problem

Year: 2013 Volume: 7 Issue: 12 2603 - 2606 Pages

Abstract: A two-dimensional linear wave-body interaction problem can be solved using a desingularized integral method by placing free surface Rankine sources over calm water surface and satisfying boundary conditions at prescribed collocation points on the calm water surface. A new free-surface Rankine source distribution scheme, determined by the intersection points of free surface and body surface, is developed to reduce numerical computation cost. Associated with this, a new treatment is given to the intersection point. The present scheme results are in good agreement with traditional numerical results and measurements.

Manufacturing of Full Automatic Carwash Using with Intelligent Control Algorithms

Year: 2013 Volume: 7 Issue: 3 522 - 525 Pages

Abstract: In this paper the intelligent control of full automatic car wash using a programmable logic controller (PLC) has been investigated and designed to do all steps of carwashing. The Intelligent control of full automatic carwash has the ability to identify and profile the geometrical dimensions of the vehicle chassis. Vehicle dimension identification is an important point in this control system to adjust the washing brushes position and time duration. The study also tries to design a control set for simulating and building the automatic carwash. The main purpose of the simulation is to develop criteria for designing and building this type of carwash in actual size to overcome challenges of automation. The results of this research indicate that the proposed method in process control not only increases productivity, speed, accuracy and safety but also reduce the time and cost of washing based on dynamic model of the vehicle. A laboratory prototype based on an advanced intelligent control has been built to study the validity of the design and simulation which it’s appropriate performance confirms the validity of this study.

The Effect of Multipass Cutting in Grinding Operation

Year: 2013 Volume: 7 Issue: 3 518 - 521 Pages

Abstract: Grinding requires high specific energy and the consequent development of high temperature at tool-workpiece contact zone impairs workpiece quality by inducing thermal damage to the surface. Finishing grinding process requires component to be cut more than one pass. This paper deals with an investigation on the effect of multipass cutting on grinding performance in term of surface roughness and surface defect. An experimental set-up has been developed for this and a detailed comparison has been done with a single pass and various numbers of cutting pass. Results showed that surface roughness increase with the increase in a number of cutting pass. Good surface finish of 0.26μm was obtained for single pass cutting and 0.73μm for twenty pass cutting. It was also observed that the thickness of the white layer increased with the increased in a number of cutting pass.

Effect of Jet Diameter on Surface Quenching at Different Spatial Locations

Year: 2014 Volume: 8 Issue: 1 46 - 49 Pages

Abstract: An experimental investigation has been carried out to study the cooling of a hot horizontal Stainless Steel surface of 3 mm thickness, which has 800±10 C initial temperature. A round water jet of 22 ± 1 oC temperature was injected over the hot surface through straight tube type nozzles of 2.5- 4.8 mm diameter and 250 mm length. The experiments were performed for the jet exit to target surface spacing of 4 times of jet diameter and jet Reynolds number of 5000 -24000. The effect of change in jet Reynolds number on the surface quenching has been investigated form the stagnation point to 16 mm spatial location.

Robust Control Design and Analysis Using SCILAB for a Mass-Spring-Damper System

Year: 2014 Volume: 8 Issue: 1 43 - 45 Pages

Authors:
Yoonsoo Kim

Abstract: This paper introduces an open-source software package SCILAB [1], an alternative of MATLAB [2], which can be used for robust control design and analysis of a typical mass-spring-damper (MSD) system. Using the previously published ideas in [3,4], this popular mechanical system is considered to provide another example of usefulness of SCILAB for advanced control design.

Resistance Analysis for a Trimaran

Year: 2014 Volume: 8 Issue: 1 34 - 42 Pages

Abstract: Although a lot of importance has been given to resistance analysis for various vessel types, explicit guidelines applied to multihull vessels have not been clearly defined. The purpose of this investigation is to highlight the importance of the vessel’s layout in terms of three axes, the transverse (separation), the longitudinal (stagger) and the vertical (draught) with respect to resistance analysis. When a vessel has the potential to experience less resistance at a particular range of speeds a vast selection of opportunities are made available for both the commercial and leisure market.

Optimal Trailing Edge Flap Positions of Helicopter Rotor for Various Thrust Coefficients to Solidity (Ct/σ) Ratios

Year: 2013 Volume: 7 Issue: 12 2599 - 2602 Pages

Abstract: This study aims to determine change in optimal locations of dual trailing-edge flaps for various thrust coefficient to solidity (Ct /σ) ratios of helicopter to achieve minimum hub vibration levels, with low penalty in terms of required trailing-edge flap control power. Polynomial response functions are used to approximate hub vibration and flap power objective functions. Single objective and multiobjective optimization is carried with the objective of minimizing hub vibration and flap power. The optimization result shows that the inboard flap location at low Ct /σ ratio move farther from the baseline value and at high Ct /σ ratio move towards the root of the blade for minimizing hub vibration.

Keywords:
Helicopter rotor
Trailing-edge flap
Thrust coefficient to solidity (Ct /σ) ratio
Optimization.

An Approach for Optimization of Functions and Reducing the Value of the Product by Using Virtual Models

Year: 2013 Volume: 7 Issue: 3 514 - 517 Pages

Abstract: New developed approach for Functional Cost Analysis (FCA) based on virtual prototyping (VP) models in CAD/CAE environment, applicable and necessary in developing new products is presented. It is instrument for improving the value of the product while maintaining costs and/or reducing the costs of the product without reducing value. Five broad classes of VP methods are identified. Efficient use of prototypes in FCA is a vital activity that can make the difference between successful and unsuccessful entry of new products into the competitive word market. Successful realization of this approach is illustrated for a specific example using press joint power tool.

Chatter Stability Characterization of Full-Immersion End-Milling Using a Generalized Modified Map of the Full-Discretization Method, Part 1: Validation of Results and Study of Stability Lobes by Numerical Simulation

Year: 2013 Volume: 7 Issue: 3 502 - 513 Pages

Abstract: The objective in this work is to generate and discuss the stability results of fully-immersed end-milling process with parameters; tool mass m=0.0431kg,tool natural frequency ωn = 5700 rads^-1, damping factor ξ=0.002 and workpiece cutting coefficient C=3.5x10^7 Nm^-7/4. Different no of teeth is considered for the end-milling. Both 1-DOF and 2-DOF chatter models of the system are generated on the basis of non-linear force law. Chatter stability analysis is carried out using a modified form (generalized for both 1-DOF and 2-DOF models) of recently developed method called Full-discretization. The full-immersion three tooth end-milling together with higher toothed end-milling processes has secondary Hopf bifurcation lobes (SHBL’s) that exhibit one turning (minimum) point each. Each of such SHBL is demarcated by its minimum point into two portions; (i) the Lower Spindle Speed Portion (LSSP) in which bifurcations occur in the right half portion of the unit circle centred at the origin of the complex plane and (ii) the Higher Spindle Speed Portion (HSSP) in which bifurcations occur in the left half portion of the unit circle. Comments are made regarding why bifurcation lobes should generally get bigger and more visible with increase in spindle speed and why flip bifurcation lobes (FBL’s) could be invisible in the low-speed stability chart but visible in the high-speed stability chart of the fully-immersed three-tooth miller.

Transient Three Dimensional FE Modeling for Thermal Analysis of Pulsed Current Gas Tungsten Arc Welding of Aluminum Alloy

Year: 2013 Volume: 7 Issue: 3 494 - 501 Pages

Abstract: This paper presents the results of a study aimed at establishing the temperature distribution during the welding of aluminum alloy plates by Pulsed Current Gas Tungsten Arc Welding (PCGTAW) and Constant Current Gas Tungsten Arc Welding (CCGTAW) processes. Pulsing of the GTA welding current influences the dimensions and solidification rate of the fused zone, it also reduces the weld pool volume hence a narrower bead. In this investigation, the base material considered was aluminum alloy AA 6351 T6, which is finding use in aircraft, automobile and high-speed train components. A finite element analysis was carried out using ANSYS, and the results of the FEA were compared with the experimental results. It is evident from the study that the finite element analysis using ANSYS can be effectively used to model PCGTAW process for finding temperature distribution.