Excellence in Research and Innovation for Humanity

International Science Index

Commenced in January 1999 Frequency: Monthly Edition: International Paper Count: 28

Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering

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  • 28
    A Comparative Study on the Dimensional Error of 3D CAD Model and SLS RP Model for Reconstruction of Cranial Defect

    Rapid Prototyping (RP) is a technology that produces models and prototype parts from 3D CAD model data, CT/MRI scan data, and model data created from 3D object digitizing systems. There are several RP process like Stereolithography (SLA), Solid Ground Curing (SGC), Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), 3D Printing (3DP) among them SLS and FDM RP processes are used to fabricate pattern of custom cranial implant. RP technology is useful in engineering and biomedical application. This is helpful in engineering for product design, tooling and manufacture etc. RP biomedical applications are design and development of medical devices, instruments, prosthetics and implantation; it is also helpful in planning complex surgical operation. The traditional approach limits the full appreciation of various bony structure movements and therefore the custom implants produced are difficult to measure the anatomy of parts and analyze the changes in facial appearances accurately. Cranioplasty surgery is a surgical correction of a defect in cranial bone by implanting a metal or plastic replacement to restore the missing part. This paper aims to do a comparative study on the dimensional error of CAD and SLS RP Models for reconstruction of cranial defect by comparing the virtual CAD with the physical RP model of a cranial defect.

    Novel Use of a Quality Assurance Tool for Integrating Technology to HSE

    The product development process (PDP) in the Technology group plays a very important role in the launch of any product. While a manufacturing process encourages the use of certain measures to reduce health, safety and environmental (HSE) risks on the shop floor, the PDP concentrates on the use of Geometric Dimensioning and Tolerancing (GD&T) to develop a flawless design. Furthermore, PDP distributes and coordinates activities between different departments such as marketing, purchasing, and manufacturing. However, it is seldom realized that PDP makes a significant contribution to developing a product that reduces HSE risks by encouraging the Technology group to use effective GD&T. The GD&T is a precise communication tool that uses a set of symbols, rules, and definitions to mathematically define parts to be manufactured. It is a quality assurance method widely used in the oil and gas sector. Traditionally it is used to ensure the interchangeability of a part without affecting its form, fit, and function. Parts that do not meet these requirements are rejected during quality audits. This paper discusses how the Technology group integrates this quality assurance tool into the PDP and how the tool plays a major role in helping the HSE department in its goal towards eliminating HSE incidents. The PDP involves a thorough risk assessment and establishes a method to address those risks during the design stage. An illustration shows how GD&T helped reduce safety risks by ergonomically improving assembling operations. A brief discussion explains how tolerances provided on a part help prevent finger injury. This tool has equipped Technology to produce fixtures, which are used daily in operations as well as manufacturing. By applying GD&T to create good fits, HSE risks are mitigated for operating personnel. Both customers and service providers benefit from reduced safety risks.

    Machining of FRP Composites by Abrasive Jet Machining Optimization Using Taguchi

    Abrasive Jet Machining is an Unconventional machining process in which the metal is removed from brittle and hard material in the form of micro-chips. With increase in need of materials like ceramics, composites, in manufacturing of various Mechanical & Electronic components, AJM has become a useful technique for micro machining. The present study highlights the influence of different parameters like Pressure, SOD, Time, Abrasive grain size, nozzle diameter on the Metal removal of FRP (Fiber Reinforced Polymer) composite by Abrasive jet machining. The results of the Experiments conducted were analyzed and optimized with TAGUCHI method of Optimization and ANOVA for Optimal Value.

    Vibration, Lubrication and Machinery Consideration for a Mixer Gearbox Related to Iran Oil Industries

    In this paper, some common gearboxes vibration analysis methods and condition monitoring systems are explained. In addition, an experimental gearbox vibration analysis is discussed through a critical case history for a mixer gearbox related to Iran oil industry. The case history also consists of gear manufacturing (machining) recommendations, lubrication condition of gearbox and machinery maintenance activities that caused reduction in noise and vibration of the gearbox. Besides some of the recent patents and innovations in gearboxes, lubrication and vibration monitoring systems explained. Finally micro pitting and surface fatigue in pinion and bevel of mentioned horizontal to vertical gearbox discussed in details.

    A Design of the Organic Rankine Cycle for the Low Temperature Waste Heat

    A presentation of the design of the Organic Rankine cycle (ORC) with heat regeneration and superheating processes is a subject of this paper. The maximum temperature level in the ORC is considered to be 110°C and the maximum pressure varies up to 2.5MPa. The selection process of the appropriate working fluids, thermal design and calculation of the cycle and its components are described. With respect to the safety, toxicity, flammability, price and thermal cycle efficiency, the working fluid selected is R134a. As a particular example, the thermal design of the condenser used for the ORC engine with a theoretical thermal power of 179 kW was introduced. The minimal heat transfer area for a completed condensation was determined to be approximately 520m2. 

    ED Machining of Particulate Reinforced MMC’s

    This paper reports the optimal process conditions for machining of three different types of MMC’s 65vol%SiC/A356.2; 10vol%SiC-5vol%quartz/Al and 30vol%SiC/A359 using PMEDM process. MRR, TWR, SR and surface integrity were evaluated after each trial and contributing process parameters were identified. The four responses were then collectively optimized using TOPSIS and optimal process conditions were identified for each type of MMC. The density of reinforced particles shields the matrix material from spark energy hence the high MRR and SR was observed with lowest reinforced particle. TWR was highest with Cu-Gr electrode due to disintegration of the weakly bonded particles in the composite electrode. Each workpiece was examined for surface integrity and ranked as per severity of surface defects observed and their rankings were used for arriving at the most optimal process settings for each workpiece. 

    Design and Manufacture of Non-Contact Moving Load for Experimental Analysis of Beams

    Dynamic tests are an important step of the design of engineering structures, because the accuracy of predictions of theoretical–numerical procedures can be assessed. In experimental test of moving loads that is one of the major research topics, the load is modeled as a simple moving mass or a small vehicle. This paper deals with the applicability of Non-contact Moving Load (NML) for vibration analysis. For this purpose, an experimental set-up is designed to generate the different types of NML including constant and harmonic. The proposed method relies on pressurized air which is useful, especially when dealing with fragile or sensitive structures. To demonstrate the performance of this system, the set-up is employedfor a modal analysis of a beam and detecting crack of the beam.The obtained results indicate that the experimental set-up for NML can be an attractive alternative to the moving load problems.

    Performance Study of Cascade Refrigeration System Using Alternative Refrigerants

    Cascade refrigeration systems employ series of single stage vapor compression units which are thermally coupled with evaporator/condenser cascades. Different refrigerants are used in each of the circuit depending on the optimum characteristics shown by the refrigerant for a particular application. In the present research study, a steady state thermodynamic model is developed which simulates the working of an actual cascade system. The model provides COP and all other system parameters e.g. total compressor work, temperature, pressure, enthalpy and entropy at different state points. The working fluid in low temperature circuit (LTC) is CO2 (R744) while Ammonia (R717), Propane (R290), Propylene (R1270), R404A and R12 are the refrigerants in high temperature circuit (HTC). The performance curves of Ammonia, Propane, Propylene, and R404A are compared with R12 to find its nearest substitute. Results show that Ammonia is the best substitute of R12.

    Residual Stress in Ground WC-Co Coatings

    High velocity oxygen fuel (HVOF) spray technique is one of the leading technologies that have been proposed as an alternative to the replacement of electrolytic hard chromium plating in a number of engineering applications. In this study, WC-Co powder was coated on AISI1045 steel using high velocity oxy fuel (HVOF) method. The sin2ψ method was used to evaluate the through thickness residual stress by means of XRD after mechanical layer removal process (only grinding). The average of through thickness residual stress using X-Ray diffraction was -400 MPa.

    Stress Variation around a Circular Hole in Functionally Graded Plate under Bending

    The influence of material property variation on stress concentration factor (SCF) due to the presence of a circular hole in a functionally graded material (FGM) plate is studied in this paper. A numerical method based on complex variable theory of elasticity is used to investigate the problem. To achieve the material property, variation plate is decomposed into a number of rings. In this research work, Young’s modulus is assumed to be varying exponentially and it is found that stress concentration factor can be reduced by increasing Young’s modulus progressively away from the hole.

    Behavioral Studies on Multi-Directionally Reinforced 4-D Orthogonal Composites on Various Preform Configurations

    The main advantage of multidirectionally reinforced composites is the freedom to orient selected fiber types and hence derives the benefits of varying fibre volume fractions and there by accommodate the design loads of the final structure of composites. This technology provides the means to produce tailored composites with desired properties. Due to the high level of fibre integrity with through thickness reinforcement those composites are expected to exhibit superior load bearing characteristics with capability to carry load even after noticeable and apparent fracture. However, a survey of published literature indicates inadequacy in the design and test data base for the complete characterization of the multidirectional composites. In this paper the research objective is focused on the development and testing of 4-D orthogonal composites with different preform configurations and resin systems. A preform is the skeleton 4D reinforced composite other than the matrix. In 4-D performs fibre bundles are oriented in three directions at 1200 with respect to each other and they are on orthogonal plane with the fibre in 4th direction. This paper addresses the various types of 4-D composite manufacturing processes and the mechanical test methods followed for the material characterization. A composite analysis is also made, experiments on course and fine woven preforms are conducted and the findings of test results are discussed in this paper. The interpretations of the test results reveal several useful and interesting features. This should pave the way for more widespread use of the perform configurations for allied applications.

    Developing a New Vibration Analysis Calculative Method for Esfahan Subway Train and Railways Design, Manufacturing, and Construction

    The simulated mass and spring method evaluation for subway or railways construction and installation systems have a wide application in rail industries. This kind of design should be optimizing all related parameters to reduce the amount of vibration in cities, homelands, historical zones and other critical locations. Finite element method could help us a lot to analysis such applications with an excellent accuracy but always developing some simple, fast and user friendly evaluation method required in subway industrial applications. In addition, process parameter optimization extremely required in railway industries to achieve some optimal design of railways with maximum safety, reliability and performance. Furthermore, it is important to reduce vibrations and further related maintenance costs as well as possible. In this paper a simple but useful simulated mass and spring evaluation system developed for Esfahan subway construction. Besides, some of related recent patent and innovations in rail world industries like Suspension mass tuned vibration reducer, short sleeper vibration attenuation fastener and Airtight track vibration-noise reducing fastener discussed in details.

    Approach of Measuring System Analyses for Automotive Part Manufacturing

    This work aims to introduce an efficient and to standardize the measuring system analyses for automotive industrial. The study started by literature reviewing about the management and analyses measurement system. The approach of measuring system management, then, was constructed. Such approach was validated by collecting the current measuring system data using the equipments of interest including vernier caliper and micrometer. Their accuracy and precision of measurements were analyzed. Finally, the measuring system was improved and evaluated. The study showed that vernier did not meet its measuring characteristics based on the linearity whereas all equipments were lacking of the measuring precision characteristics. Consequently, the causes of measuring variation via the equipments of interest were declared. After the improvement, it was found that their measuring performance could be accepted as the standard required. Finally, the standardized approach for analyzing the measuring system of automotive was concluded.

    A Variable Stiffness Approach to Vibration Control

    This work introduces a new concept for controlling the mechanical vibrations via variable stiffness coil spring. The concept relies on fitting a screw though the spring to change the number of active spring coils. A prototype has been built and tested with promising results toward an innovation in the field of vibration control.

    Numerical Study of Laminar Mixed Convection Heat Transfer of a Nanofluid in a Concentric Annular Tube Using Two-Phase Mixture Model

    Laminar mixed Convection heat transfer of a nanofluid with prescribed constant heat flux on the inner wall of horizontal annular tube has been studied numerically based on two-phase mixture model in different Rayleigh Numbers and Azimuth angles. Effects of applying of different volume fractions of Al2O3 nanoparticles in water as a base fluid on hydrodynamic and thermal behaviors of the fluid flow such as axial velocity, secondary flow, temperature, heat transfer coefficient and friction coefficient at the inner and outer wall region, has been investigated. Conservation equations in elliptical form has been utilized and solved in three dimensions for a steady flow. It is observed that, there is a good agreement between results in this work and previously published experimental and numerical works on mixed convection in horizontal annulus. These particles cause to increase convection heat transfer coefficient of the fluid, meanwhile there is no considerable effect on friction coefficient.

    Neural Network Monitoring Strategy of Cutting Tool Wear of Horizontal High Speed Milling

    The wear of cutting tool degrades the quality of the product in the manufacturing processes. The on line monitoring of the cutting tool wear level is very necessary to prevent the deterioration of the quality of machining. Unfortunately there is not a direct manner to measure the cutting tool wear on line. Consequently we must adopt an indirect method where wear will be estimated from the measurement of one or more physical parameters appearing during the machining process such as the cutting force, the vibrations, or the acoustic emission etc…. In this work, a neural network system is elaborated in order to estimate the flank wear from the cutting force measurement and the cutting conditions.

    On the Catalytic Combustion Behaviors of CH4 in a MCFC Power Generation System

    Catalytic combustion is generally accepted as an environmentally preferred alternative for the generation of heat and power from fossil fuels mainly due to its advantages related to the stable combustion under very lean conditions with low emissions of NOx, CO, and UHC at temperatures lower than those occurred in conventional flame combustion. Despite these advantages, the commercial application of catalytic combustion has been delayed because of complicated reaction processes and the difficulty in developing appropriate catalysts with the required stability and durability. To develop the catalytic combustors, detailed studies on the combustion characteristics of catalytic combustion should be conducted. To the end, in current research, quantitative studies on the combustion characteristics of the catalytic combustors, with a Pd-based catalyst for MCFC power generation systems, relying on numerical simulations have been conducted. In addition, data from experimental studies of variations in outlet temperatures and fuel conversion, taken after operating conditions have been used to validate the present numerical approach. After introducing the governing equations for mass, momentum, and energy equations as well as a description of catalytic combustion kinetics, the effects of the excess air ratio, space velocity, and inlet gas temperature on the catalytic combustion characteristics are extensively investigated. Quantitative comparisons are also conducted with previous experimental data. Finally, some concluding remarks are presented.

    Plant Layout Analysis by Computer Simulation for Electronic Manufacturing Service Plant

    In this research, computer simulation is used for Electronic Manufacturing Service (EMS) plant layout analysis. The current layout of this manufacturing plant is a process layout, which is not suitable due to the nature of an EMS that has high-volume and high-variety environment. Moreover, quick response and high flexibility are also needed. Then, cellular manufacturing layout design was determined for the selected group of products. Systematic layout planning (SLP) was used to analyze and design the possible cellular layouts for the factory. The cellular layout was selected based on the main criteria of the plant. Computer simulation was used to analyze and compare the performance of the proposed cellular layout and the current layout. It found that the proposed cellular layout can generate better performances than the current layout. In this research, computer simulation is used for Electronic Manufacturing Service (EMS) plant layout analysis. The current layout of this manufacturing plant is a process layout, which is not suitable due to the nature of an EMS that has high-volume and high-variety environment. Moreover, quick response and high flexibility are also needed. Then, cellular manufacturing layout design was determined for the selected group of products. Systematic layout planning (SLP) was used to analyze and design the possible cellular layouts for the factory. The cellular layout was selected based on the main criteria of the plant. Computer simulation was used to analyze and compare the performance of the proposed cellular layout and the current layout. It found that the proposed cellular layout can generate better performances than the current layout. 

    An Integrated DEMATEL-QFD Model for Medical Supplier Selection

    Supplier selection is considered as one of the most critical issues encountered by operations and purchasing managers to sharpen the company’s competitive advantage. In this paper, a novel fuzzy multi-criteria group decision making approach integrating quality function deployment (QFD) and decision making trial and evaluation laboratory (DEMATEL) method is proposed for supplier selection. The proposed methodology enables to consider the impacts of inner dependence among supplier assessment criteria. A house of quality (HOQ) which translates purchased product features into supplier assessment criteria is built using the weights obtained by DEMATEL approach to determine the desired levels of supplier assessment criteria. Supplier alternatives are ranked by a distance-based method.

    A Fuzzy Decision Making Approach for Supplier Selection in Healthcare Industry

    Supplier evaluation and selection is one of the most important components of an effective supply chain management system. Due to the expanding competition in healthcare, selecting the right medical device suppliers offers great potential for increasing quality while decreasing costs. This paper proposes a fuzzy decision making approach for medical supplier selection. A real-world medical device supplier selection problem is presented to illustrate the application of the proposed decision methodology.

    Multi-Objective Multi-Mode Resource-Constrained Project Scheduling Problem by Preemptive Fuzzy Goal Programming

    This research proposes a preemptive fuzzy goal programming model for multi-objective multi-mode resource constrained project scheduling problem. The objectives of the problem are minimization of the total time and the total cost of the project. Objective in a multi-mode resource-constrained project scheduling problem is often a minimization of makespan. However, both time and cost should be considered at the same time with different level of important priorities. Moreover, all elements of cost functions in a project are not included in the conventional cost objective function. Incomplete total project cost causes an error in finding the project scheduling time. In this research, preemptive fuzzy goal programming is presented to solve the multi-objective multi-mode resource constrained project scheduling problem. It can find the compromise solution of the problem. Moreover, it is also flexible in adjusting to find a variety of alternative solutions. 

    A CFD Analysis of Flow through a High-Pressure Natural Gas Pipeline with an Undeformed and Deformed Orifice Plate

    This work aims to present a numerical analysis of the natural gas which flows through a high-pressure pipeline and an orifice plate, through the use of CFD methods. The paper contains CFD calculations for the flow of natural gas in a pipe with different geometry used for the orifice plates. One of them has a standard geometry and a shape without any deformation and the other is deformed by the action of the pressure differential. It shows the behavior of natural gas in a pipeline using the velocity profiles and pressure fields of the gas in both models with their differences. The entire research is based on the elimination of any inaccuracy which should appear in the flow of the natural gas measured in the high-pressure pipelines of the gas industry and which is currently not given in the relevant standard.

    Rapid Prototyping Applications in Various Field of Engineering and Technology

    In the product design and development process, the prototyping or model making is one of the important step to finalize a product which helps in conceptualization of a design. Rapid Prototyping (RP) is layer-by-layer material deposition started during early 1980s with the enormous growth in Computer Aided Design and Manufacturing (CAD/CAM) technologies. The edges and surfaces of a complex solid model and their information are used for defining a product which is further manufactured as a finished product by CNC machining. This paper provides a better platform for researchers, new learners and product manufacturers for various applications of RP models. Subsequently it creates awareness among the peoples of recently developing RP method of manufacturing in product design, developments and its applications.

    Model-Based Control for Piezoelectric-Actuated Systems Using Inverse Prandtl-Ishlinskii Model and Particle Swarm Optimization

    In this paper feedforward controller is designed to eliminate nonlinear hysteresis behaviors of a piezoelectric stack actuator (PSA) driven system. The control design is based on inverse Prandtl-Ishlinskii (P-I) hysteresis model identified using particle swarm optimization (PSO) technique. Based on the identified P-I model, both the inverse P-I hysteresis model and feedforward controller can be determined. Experimental results obtained using the inverse P-I feedforward control are compared with their counterparts using hysteresis estimates obtained from the identified Bouc-Wen model. Effectiveness of the proposed feedforward control scheme is demonstrated. To improve control performance feedback compensation using traditional PID scheme is adopted to integrate with the feedforward controller. 

    Decision Tree Based Scheduling for Flexible Job Shops with Multiple Process Plans

    This paper suggests a decision tree based approach for flexible job shop scheduling with multiple process plans, i.e. each job can be processed through alternative operations, each of which can be processed on alternative machines. The main decision variables are: (a) selecting operation/machine pair; and (b) sequencing the jobs assigned to each machine. As an extension of the priority scheduling approach that selects the best priority rule combination after many simulation runs, this study suggests a decision tree based approach in which a decision tree is used to select a priority rule combination adequate for a specific system state and hence the burdens required for developing simulation models and carrying out simulation runs can be eliminated. The decision tree based scheduling approach consists of construction and scheduling modules. In the construction module, a decision tree is constructed using a four-stage algorithm, and in the scheduling module, a priority rule combination is selected using the decision tree. To show the performance of the decision tree based approach suggested in this study, a case study was done on a flexible job shop with reconfigurable manufacturing cells and a conventional job shop, and the results are reported by comparing it with individual priority rule combinations for the objectives of minimizing total flow time and total tardiness.

    An Aerodynamic Design and Analysis of Motor Cycle Helmet with Anti-Glare Visor

    Motor cycle accidents have been increased for the past two decades. Helmet can protect the vehicle riders from severe injuries during road accident to certain extent. To design a functional helmet, it is important to analyze the shape of the helmet and visor portion. Hence, an attempt has been made for design and analysis of new helmet by considering the drag pressure and anti-glare visor. The drag pressure resistance presses the helmet against the neck portion of the rider. The shape of an aerodynamic helmet can be able to reduce the drag pressure. The spherical shape and a new aerodynamic shape helmets are designed with help of Pro-E software and the drag pressures were calculated and comparison has been made on the basis of drag pressure.

    Stealth Laser Dicing Process Improvement via Shuffled Frog Leaping Algorithm

    In this paper, performances of shuffled frog leaping algorithm was investigated on the stealth laser dicing process. Effect of problem on the performance of the algorithm was based on the tolerance of meandering data. From the customer specification it could be less than five microns with the target of zero microns. Currently, the meandering levels are unsatisfactory when compared to the customer specification. Firstly, the two-level factorial design was applied to preliminarily study the statistically significant effects of five process variables. In this study one influential process variable is integer. From the experimental results, the new operating condition from the algorithm was superior when compared to the current manufacturing condition.

    Solving Transient Conduction and Radiation Using Finite Volume Method

    Radiative heat transfer in participating medium was carried out using the finite volume method. The radiative transfer equations are formulated for absorbing and anisotropically scattering and emitting medium. The solution strategy is discussed and the conditions for computational stability are conferred. The equations have been solved for transient radiative medium and transient radiation incorporated with transient conduction. Results have been obtained for irradiation and corresponding heat fluxes for both the cases. The solutions can be used to conclude incident energy and surface heat flux. Transient solutions were obtained for a slab of heat conducting in slab and by thermal radiation. The effect of heat conduction during the transient phase is to partially equalize the internal temperature distribution. The solution procedure provides accurate temperature distributions in these regions. A finite volume procedure with variable space and time increments is used to solve the transient radiation equation. The medium in the enclosure absorbs, emits, and anisotropically scatters radiative energy. The incident radiations and the radiative heat fluxes are presented in graphical forms. The phase function anisotropy plays a significant role in the radiation heat transfer when the boundary condition is non-symmetric.