Taguchi-Based Surface Roughness Optimization for Slotted and Tapered Cylindrical Products in Milling and Turning Operations

The research follows a systematic approach to optimize the parameters for parts machined by turning and milling processes. The quality characteristic chosen is surface roughness since the surface finish plays an important role for parts that require surface contact. A tapered cylindrical surface is designed as a test specimen for the research. The material chosen for machining is aluminum alloy 6061 due to its wide variety of industrial and engineering applications. HAAS VF-2 TR computer numerical control (CNC) vertical machining center is used for milling and HAAS ST-20 CNC machine is used for turning in this research. Taguchi analysis is used to optimize the surface roughness of the machined parts. The L9 Orthogonal Array is designed for four controllable factors with three different levels each, resulting in 18 experimental runs. Signal to Noise (S/N) Ratio is calculated for achieving the specific target value of 75 ± 15 µin. The controllable parameters chosen for turning process are feed rate, depth of cut, coolant flow and finish cut and for milling process are feed rate, spindle speed, step over and coolant flow. The uncontrollable factors are tool geometry for turning process and tool material for milling process. Hypothesis testing is conducted to study the significance of different uncontrollable factors on the surface roughnesses. The optimal parameter settings were identified from the Taguchi analysis and the process capability Cp and the process capability index Cpk were improved from 1.76 and 0.02 to 3.70 and 2.10 respectively for turning process and from 0.87 and 0.19 to 3.85 and 2.70 respectively for the milling process. The surface roughnesses were improved from 60.17 µin to 68.50 µin, reducing the defect rate from 52.39% to 0% for the turning process and from 93.18 µin to 79.49 µin, reducing the defect rate from 71.23% to 0% for the milling process. The purpose of this study is to efficiently utilize the Taguchi design analysis to improve the surface roughness.

State Estimation Based on Unscented Kalman Filter for Burgers’ Equation

Controlling the flow of fluids is a challenging problem that arises in many fields. Burgers’ equation is a fundamental equation for several flow phenomena such as traffic, shock waves, and turbulence. The optimal feedback control method, so-called model predictive control, has been proposed for Burgers’ equation. However, the model predictive control method is inapplicable to systems whose all state variables are not exactly known. In practical point of view, it is unusual that all the state variables of systems are exactly known, because the state variables of systems are measured through output sensors and limited parts of them can be only available. In fact, it is usual that flow velocities of fluid systems cannot be measured for all spatial domains. Hence, any practical feedback controller for fluid systems must incorporate some type of state estimator. To apply the model predictive control to the fluid systems described by Burgers’ equation, it is needed to establish a state estimation method for Burgers’ equation with limited measurable state variables. To this purpose, we apply unscented Kalman filter for estimating the state variables of fluid systems described by Burgers’ equation. The objective of this study is to establish a state estimation method based on unscented Kalman filter for Burgers’ equation. The effectiveness of the proposed method is verified by numerical simulations.

Inverse Dynamics of the Mould Base of Blow Molding Machines

This paper deals with the study of devices for displacement of the mould base of blow-molding machines. The displacement of the mould in the studied case is carried out by a linear actuator, which ensures the descent of the mould base and by extension springs, which return the letter in the initial position. The aim of this paper is to study the inverse dynamics of the device for displacement of the mould base of blow-molding machines and to determine its optimum parameters for higher rate of production. In the other words, it is necessary to solve the inverse dynamic problem to find the equation of motion linking applied forces with displacements. This makes it possible to determine the stiffness coefficient of the spring to turn the mold base back to the initial position for a given time. The obtained results are illustrated by a numerical example. It is shown that applying a spring with stiffness returns the mould base of the blow molding machine into the initial position in 0.1 sec.

Static Modeling of the Delamination of a Composite Material Laminate in Mode II

The purpose of this paper is to analyze numerically by the three-dimensional finite element method, using ABAQUS calculation code, the mechanical behavior of a unidirectional and multidirectional delaminated stratified composite under mechanical loading in Mode II. This study consists of the determination of the energy release rate G in mode II as well as the distribution of equivalent von Mises stresses along the damaged zone by varying several parameters such as the applied load and the delamination length. It allowed us to deduce that the high energy release rate favors delamination at the free edges of a stratified plate subjected to bending.

Optimal Peer-to-Peer On-Orbit Refueling Mission Planning with Complex Constraints

On-Orbit Refueling is of great significance in extending space crafts' lifetime. The problem of minimum-fuel, time-fixed, Peer-to-Peer On-Orbit Refueling mission planning is addressed here with the particular aim of assigning fuel-insufficient satellites to the fuel-sufficient satellites and optimizing each rendezvous trajectory. Constraints including perturbation, communication link, sun illumination, hold points for different rendezvous phases, and sensor switching are considered. A planning model has established as well as a two-level solution method. The upper level deals with target assignment based on fuel equilibrium criterion, while the lower level solves constrained trajectory optimization using special maneuver strategies. Simulations show that the developed method could effectively resolve the Peer-to-Peer On-Orbit Refueling mission planning problem and deal with complex constraints.

Active Linear Quadratic Gaussian Secondary Suspension Control of Flexible Bodied Railway Vehicle

Passenger comfort has been paramount in the design of suspension systems of high speed cars. To analyze the effect of vibration on vehicle ride quality, a vertical model of a six degree of freedom railway passenger vehicle, with front and rear suspension, is built. It includes car body flexible effects and vertical rigid modes. A second order linear shaping filter is constructed to model Gaussian white noise into random rail excitation. The temporal correlation between the front and rear wheels is given by a second order Pade approximation. The complete track and the vehicle model are then designed. An active secondary suspension system based on a Linear Quadratic Gaussian (LQG) optimal control method is designed. The results show that the LQG control method reduces the vertical acceleration, pitching acceleration and vertical bending vibration of the car body as compared to the passive system.

Result Validation Analysis of Steel Testing Machines

Structural failures occur due to a number of reasons. These may include under design, poor workmanship, substandard materials, misleading laboratory tests and lots more. Reinforcing steel bar is an important construction material, hence its properties must be accurately known before being utilized in construction. Understanding this property involves carrying out mechanical tests prior to design and during construction to ascertain correlation using steel testing machine which is usually not readily available due to the location of project. This study was conducted to determine the reliability of reinforcing steel testing machines. Reconnaissance survey was conducted to identify laboratories where yield and ultimate tensile strengths tests can be carried out. Six laboratories were identified within Ibadan and environs. However, only four were functional at the time of the study. Three steel samples were tested for yield and tensile strengths, using a steel testing machine, at each of the four laboratories (LM, LO, LP and LS). The yield and tensile strength results obtained from the laboratories were compared with the manufacturer’s specification using a reliability analysis programme. Structured questionnaire was administered to the operators in each laboratory to consider their impact on the test results. The average value of manufacturers’ tensile strength and yield strength are 673.7 N/mm2 and 559.7 N/mm2 respectively. The tensile strength obtained from the four laboratories LM, LO, LP and LS are given as 579.4, 652.7, 646.0 and 649.9 N/mm2 respectively while their yield strengths respectively are 453.3, 597.0, 550.7 and 564.7 N/mm2. Minimum tensile to yield strength ratio is 1.08 for BS 4449: 2005 and 1.15 for ASTM A615. Tensile to yield strength ratio from the four laboratories are 1.28, 1.09, 1.17 and 1.15 for LM, LO, LP and LS respectively. The tensile to yield strength ratio shows that the result obtained from all the laboratories meet the code requirements used for the test. The result of the reliability test shows varying level of reliability between the manufacturers’ specification and the result obtained from the laboratories. Three of the laboratories; LO, LS and LP have high value of reliability with the manufacturer i.e. 0.798, 0.866 and 0.712 respectively. The fourth laboratory, LM has a reliability value of 0.100. Steel test should be carried out in a laboratory using the same code in which the structural design was carried out. More emphasis should be laid on the importance of code provisions.

Design of a Chaotic Trajectory Generator Algorithm for Mobile Robots

This work addresses the problem of designing an algorithm capable of generating chaotic trajectories for mobile robots. Particularly, the chaotic behavior is induced in the linear and angular velocities of a Khepera III differential mobile robot by infusing them with the states of the H´enon chaotic map. A possible application, using the properties of chaotic systems, is patrolling a work area. In this work, numerical and experimental results are reported and analyzed. In addition, two quantitative numerical tests are applied in order to measure how chaotic the generated trajectories really are.