Abstract: The closed form study deals with elastic stress analysis of annular bi-material discs with variable thickness subjected to the mechanical and thermomechanical loads. Those discs have many applications in the aerospace industry, such as gas turbines and gears. Those discs normally work under thermal and mechanical loads. Their life cycle can increase when stress components are minimized. Each material property is assumed to be isotropic. The results show that material combinations and thickness of profiles play an important role in determining the responses of bi-material discs and an optimal design of those structures. Stress distribution is investigated and results are shown as graphs.
Abstract: In this study, thermo elastic stress analysis is performed on a cylinder made of laminated isotropic materials under thermomechanical loads. Laminated cylinders have many applications such as aerospace, automotive and nuclear plant in the
industry. These cylinders generally performed under thermomechanical loads. Stress and displacement distribution of the laminated cylinders are determined using by analytical method both thermal and mechanical loads. Based on the results, materials combination plays an important role on the stresses distribution along the radius. Variation of the stresses and displacements along the radius are presented as graphs. Calculations program are prepared using MATLAB® by authors.
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.
Abstract: Metal matrix composites consists of a metallic matrix combined with dispersed particulate phase as reinforcement. Aluminum alloys have been the primary material of choice for structural components of aircraft since about 1930. Well known performance characteristics, known fabrication costs, design experience, and established manufacturing methods and facilities, are just a few of the reasons for the continued confidence in 7XXX Al alloys that will ensure their use in significant quantities for the time to come. Particulate MMCs are of special interest owing to the low cost of their raw materials (primarily natural river sand here) and their ease of fabrication, making them suitable for applications requiring relatively high volume production. 7XXX Al alloys are precipitation hardenable and therefore amenable for thermomechanical treatment. Al–Zn alloys reinforced with particulate materials are used in aerospace industries in spite of the drawbacks of susceptibility to stress corrosion, poor wettability, poor weldability and poor fatigue resistance. The resistance offered by these particulates for the moving dislocations impart secondary hardening in turn contributes strain hardening. Cold deformation increases lattice defects, which in turn improves the properties of solution treated alloy. In view of this, six different Al–Zn–Mg alloy composites reinforced with silica (3 wt. % and 5 wt. %) are prepared by conventional semisolid synthesizing process. The cast alloys are solution treated and aged. The solution treated alloys are further severely cold rolled to enhance the properties. The hardness and strength values are analyzed and compared with silica free Al – Zn-Mg alloys. Precipitation hardening phenomena is accelerated due to the increased number of potential sites for precipitation. Higher peak hardness and lesser aging time are the characteristics of thermo mechanically treated samples. For obtaining maximum hardness, optimum number and volume of precipitate particles are required. The Al-5Zn-1Mg with 5% SiO2 alloy composite shows better result.
Abstract: This paper subsidizes to the discussion of Six Sigma in the Aerospace Industry. The main aim of this report is to study the literature review of Six Sigma emphasizing on the aerospace industry. The implementation of Six Sigma stages are studied and how the improvement cycle ‘Define, Measure, Analyze, Improve and Control cycle’ (DMAIC) and the design process is ‘Define, Measure, Analyze, Design and Verify cycle’ (DMADV) is used. The focus is also done by studying how the implementation of Six Sigma on an aerospace company has brought a positive effect to the company.
Abstract: The use of a conventional air plasma-sprayed thermal barrier coating (TBC) and a porous, functionally graded TBC as a thermal insulator for Al7075 alloy was explored. A quench test at 1200°C employing fast heating and cooling rates was setup to represent a dynamic thermal condition of an aerospace component. During the test, coated samples were subjected the ambient temperature of 1200°C for a very short time. This was followed by a rapid drop in temperature resulting in cracking of the coatings. For the conventional TBC, it was found that the temperature of the Al7075 substrate decreases with the increase in the ZrO2 topcoat thickness. However, at the topcoat thickness of 1100 µm, large horizontal cracks can be observed in the topcoat and at the topcoat thickness of 1600 µm, the topcoat delaminate during cooling after the quench test. The porous, functionally graded TBC with 600 µm thick topcoat, on the other hand, was found to be as effective at reducing the substrate temperature as the conventional TBC with 1100 µm thick topcoat. The maximum substrate temperature is about 213°C for the former and 208°C for the latter when a heating rate of 38°C/s was used. When the quench tests were conducted with a faster heating rate of 128°C/s, the Al7075 substrate heat up faster with a reduction in the maximum substrate temperatures. The substrate temperatures dropped from 297 to 212°C for the conventional TBC and from 213 to 155°C for the porous TBC, both with 600 µm thick topcoat. Segmentation cracks were observed in both coating after the quench test.
Abstract: Aerospace vehicles are subjected to non-uniform
thermal loading that may cause thermal buckling. A study was
conducted on the thermal post-buckling of shape memory alloy
composite plates subjected to the non-uniform tent-like temperature
field. The shape memory alloy wires were embedded within the
laminated composite plates to add recovery stress to the plates. The
non-linear finite element model that considered the recovery stress of
the shape memory alloy and temperature dependent properties of the
shape memory alloy and composite matrix along with its source
codes were developed. It was found that the post-buckling paths of
the shape memory alloy composite plates subjected to various tentlike
temperature fields were stable within the studied temperature
range. The addition of shape memory alloy wires to the composite
plates was found to significantly improve the post-buckling behavior
of laminated composite plates under non-uniform temperature
distribution.
Abstract: Today automobile and aerospace industries realise Laser Beam Welding for a clean and non contact source of heating and fusion for joining of sheets. The welding performance is mainly based on by the laser welding parameters. Some concepts related to Artificial Neural Networks and how can be applied to model weld bead geometry and mechanical properties in terms of equipment parameters are reported in order to evaluate the accuracy and compare it with traditional modeling schemes. This review reveals the output features of Titanium and Aluminium weld bead geometry and mechanical properties such as ultimate tensile strength, yield strength, elongation and reduction of the area of the weld using Artificial Neural Network.
Abstract: Metal matrix composites (MMC) are generating
extensive interest in diverse fields like defense, aerospace, electronics
and automotive industries. In this present investigation, material
removal rate (MRR) modeling has been carried out using an
axisymmetric model of Al-SiC composite during electrical discharge
machining (EDM). A FEA model of single spark EDM was
developed to calculate the temperature distribution.Further, single
spark model was extended to simulate the second discharge. For
multi-discharge machining material removal was calculated by
calculating the number of pulses. Validation of model has been done
by comparing the experimental results obtained under the same
process parameters with the analytical results. A good agreement was
found between the experimental results and the theoretical value.
Abstract: Corrugated wire mesh laminates (CWML) are a class
of engineered open cell structures that have potential for applications
in many areas including aerospace and biomedical engineering. Two
different methods of fabricating corrugated wire mesh laminates from
stainless steel, one using a high temperature Lithobraze alloy and the
other using a low temperature Eutectic solder for joining the
corrugated wire meshes are described herein. Their implementation is
demonstrated by manufacturing CWML samples of 304 and 316
stainless steel (SST). It is seen that due to the facility of employing
wire meshes of different densities and wire diameters, it is possible to
create CWML laminates with a wide range of effective densities. The
fabricated laminates are tested under uniaxial compression. The
variation of the compressive yield strength with relative density of the
CWML is compared to the theory developed by Gibson and Ashby for
open cell structures [22]. It is shown that the compressive strength of
the corrugated wire mesh laminates can be described using the same
equations by using an appropriate value for the linear coefficient in the
Gibson-Ashby model.
Abstract: This research contribution propels the idea of collaborating environment for the execution of student satellite projects in the backdrop of project management principles. The recent past has witnessed a technological shift in the aerospace industry from the big satellite projects to the small spacecrafts especially for the earth observation and communication purposes. This vibrant shift has vitalized the academia and industry to share their resources and to create a win-win paradigm of mutual success and technological development along with the human resource development in the field of aerospace. Small student satellites are the latest jargon of academia and more than 100 CUBESAT projects have been executed successfully all over the globe and many new student satellite projects are in the development phase. The small satellite project management requires the application of specific knowledge, skills, tools and techniques to achieve the defined mission requirements. The Authors have presented the detailed outline for the project management of student satellites and presented the role of industry to collaborate with the academia to get the optimized results in academic environment.
Abstract: Titanium alloys like Ti-6Al-2Sn-4Zr-6Mo (Ti-
6246) are widely used in aerospace applications. Component
manufacturing, however, is difficult and expensive as their
machinability is extremely poor. A thorough understanding of the
chip formation process is needed to improve related metal cutting
operations.In the current study, orthogonal cutting experiments have
been performed and theresulting chips were analyzed by optical
microscopy and scanning electron microscopy.Chips from aTi-
6246ingot were produced at different cutting speeds and cutting
depths. During the experiments, depending of the cutting conditions,
continuous or segmented chips were formed. Narrow, highly
deformed and grain oriented zones, the so-called shear zone,
separated individual segments. Different material properties have
been measured in the shear zones and the segments.
Abstract: Defense and Aerospace environment is continuously
striving to keep up with increasingly sophisticated Information
Technology (IT) in order to remain effective in today-s dynamic and
unpredictable threat environment. This makes IT one of the largest
and fastest growing expenses of Defense. Hundreds of millions of
dollars spent a year on IT projects. But, too many of those millions
are wasted on costly mistakes. Systems that do not work properly,
new components that are not compatible with old ones, trendy new
applications that do not really satisfy defense needs or lost through
poorly managed contracts.
This paper investigates and compiles the effective strategies that
aim to end exasperation with low returns and high cost of
Information Technology acquisition for defense; it tries to show how
to maximize value while reducing time and expenditure.
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.
Abstract: Application of flexible structures has been
significantly, increased in industry and aerospace missions due to
their contributions and unique advantages over the rigid counterparts.
In this paper, vibration analysis of a flexible structure i.e., automobile
wiper blade is investigated and controlled. The wiper generates
unwanted noise and vibration during the wiping the rain and other
particles on windshield which may cause annoying noise in different
ranges of frequency. A two dimensional analytical modeled wiper
blade whose model accuracy is verified by numerical studies in
literature is considered in this study. Particle swarm optimization
(PSO) is employed in alliance with input shaping (IS) technique in
order to control or to attenuate the amplitude level of unwanted
noise/vibration of the wiper blade.
Abstract: This paper describes the design process and the realtime validation of an innovative autonomous mid-air flight and landing system developed by the Italian Aerospace Research Center in the framework of the Italian national funded project TECVOL (Technologies for the Autonomous Flight). In the paper it is provided an insight of the whole development process of the system under study. In particular, the project framework is illustrated at first, then the functional context and the adopted design and testing approach are described, and finally the on-ground validation test rig on purpose designed is addressed in details. Furthermore, the hardwarein- the-loop validation of the autonomous mid-air flight and landing system by means of the real-time test rig is described and discussed.
Abstract: The Ministry of Defense (MoD) spends hundreds of
millions of dollars on software to support its infrastructure, operate
its weapons and provide command, control, communications,
computing, intelligence, surveillance, and reconnaissance (C4ISR)
functions. These and other all new advanced systems have a common
critical component is information technology. Defense and
Aerospace environment is continuously striving to keep up with
increasingly sophisticated Information Technology (IT) in order to
remain effective in today-s dynamic and unpredictable threat
environment. This makes it one of the largest and fastest growing
expenses of Defense. Hundreds of millions of dollars spent a year on
IT projects. But, too many of those millions are wasted on costly
mistakes. Systems that do not work properly, new components that
are not compatible with old once, trendily new applications that do
not really satisfy defense needs or lost though poorly managed
contracts.
This paper investigates and compiles the effective strategies that
aim to end exasperation with low returns and high cost of
Information Technology Acquisition for defense; it tries to show how
to maximize value while reducing time and expenditure.
Abstract: This paper describes the design and modeling
procedure of a novel 5-phase segment type switched reluctance motor
(ST-SRM) under simultaneous two-phase (bipolar) excitation of
windings. The rotor cores of ST-SRM are embedded in an aluminum
block as well as to improve the performance characteristics. The
magnetic circuit of the produced ST-SRM is constructed so that the
magnetic flux paths are short and exclusive to each phase, thereby
minimizing the commutation switching and eddy current losses in the
laminations. The design and simulation principles presented apply
primarily to conventional SRM and ST-SRM. It is proved that the
novel 5-phase switched reluctance motor under two-phase excitation
is superior among the criteria used in comparison. The purposed
model is particularly well suited for high torque and weight
constrained applications such as automobiles, aerospace and military
applications.
Abstract: Greenhouse gases (GHG) emissions impose major
threat to global warming potential (GWP). Unfortunately
manufacturing sector is one of the major sources that contribute
towards the rapid increase in greenhouse gases (GHG) emissions. In
manufacturing sector electric power consumption is the major driver
that influences CO2 emission. Titanium alloys are widely utilized in
aerospace, automotive and petrochemical sectors because of their
high strength to weight ratio and corrosion resistance. Titanium
alloys are termed as difficult to cut materials because of their poor
machinability rating. The present study analyzes energy consumption
during cutting with reference to material removal rate (MRR).
Surface roughness was also measured in order to optimize energy
consumption.
Abstract: Topology Optimization is a defined as the method of
determining optimal distribution of material for the assumed design
space with functionality, loads and boundary conditions [1].
Topology optimization can be used to optimize shape for the
purposes of weight reduction, minimizing material requirements or
selecting cost effective materials [2]. Topology optimization has been
implemented through the use of finite element methods for the
analysis, and optimization techniques based on the method of moving
asymptotes, genetic algorithms, optimality criteria method, level sets
and topological derivatives. Case study of Typical “Fuselage design"
is considered for this paper to explain the benefits of Topology
Optimization in the design cycle. A cylindrical shell is assumed as
the design space and aerospace standard pay loads were applied on
the fuselage with wing attachments as constraints. Then topological
optimization is done using Finite Element (FE) based software. This
optimization results in the structural concept design which satisfies
all the design constraints using minimum material.