Professional Documents
Culture Documents
PREFACE
A.Muralidhar
P.Praveen Raj
Organizing Secretaries
Dr. P. RAMAMOORTHY
PRINCIPAL
THANTHAI PERIYAR GOVERNMENT INSTITUTE OF
TECHNOLOGY
VELLORE
MESSAGE
P.RAMAMOORTHY
MESSAGES
MESSAGES
ADVISORY COMMITTEE
1. Dr. V. Ganesan ,
Professor, IITM, Chennai.
2. Dr. K. Jayachandran,
Professor (Retd), Anna University, Chennai.
3. Dr. C. Jebaraj,
Professor, Anna University,Chennai.
4. Dr. S. Gowri,
Professor, Anna University,Chennai.
5. Dr. G. Thanigaiarasu,
Professor, Anna University,Chennai.
6. Prof. G. Vedagiri,
Principal, SBC College of Engineering,Arni.
7. Dr. A. Elayaperumal,
Asst.Professor, Anna University,Chennai.
9. Dr. K. Sankaranarayanasamy,
Professor & Head, NIT, Tiruchirappalli.
ORGANIZING COMMITTEE
THANTHAI PERIYAR
GOVERNMENT INSTITUTE OF TECHNOLOGY,
BAGAYAM, VELLORE – 632 002.
TAMIL NADU.
The Department of Mechanical Engineering was established in the year 1990 since the
college was started. Right from its inception, the department has progressed with a vision and
a strong commitment in developing competent, carrier oriented programs and providing
excellent training to the students. The department of Mechanical Engineering offers the
following courses which are affiliated to Anna University.
B. E. (Mechanical Engineering)
B. E. (Mechanical Engineering, Part-time)
M. E. (Manufacturing Engineering)
The Department has excellent Laboratory facilities for carrying out laboratory
experiments and research activities. The following are the laboratories under the Mechanical
Engineering Department:
Extension Activities
The department organizes a number of activities like conducting Faculty Development
Programmes, national level workshops and conferences and regular departmental seminars for
the benefit of the staff and students.
Placements
Several leading companies are visiting the campus every year and recruited many of
our students. Some of the prominent companies that have already recruited our students are:
ELGI Equipments, UCAL Systems, Wipro Technologies, TCS, Infosys, Robert Bosch,
Renault-Nissan, CTS, Caparo, Titan and U.S Technologies etc.
Faculty Members
The department has excellent, experienced and highly qualified faculty members to
impart knowledge and training to the students and they have to their credit a record number of
publications in national and international journals and conference proceedings.
INVITED LECTURE
Dr.N.S.Parthasarathy
Director AU-FRG
Anna University, Chennai.
INVITED LECTURE
Dr.G.Subba Rao,
Dean-Academic,
SCSVMV University
TECHNICAL PAPERS
DESIGN
Low-Velocity
Machine
• Tup or dart Style – B
• Dead weight
• Self locking
• Guide path
• Rebound stopper
• Specimen holder
• Height adjustment
• Mass adjustment
Table 2
Tup and Specimen holder Inner dimension
Dimensions in mm (in)
Sl. Geomet Specimen
No. ry Tup Holder Inside
Diameter
Style – 15.86
1 78.0 (3.00)
A (0.625)
Style – 12.7
2 38.1 (1.50)
B (0.500)
Style –
Style – C 3 38.1 (1.5) 127.0 (5.00)
C
Style – 20.0
4 40.0 (1.57)
E (.787)
Failure
The presence of any crack or split, created by
the impact of the falling tup that can be seen by
the naked eye under normal laboratory lighting
conditions.
up and down (to the required height) the metal From the raw material, to be use in the
wire with drum was provided. application the standard size of required
number should be make it ready.
Table
The table must with stand the entire load as 2. Calculate the mean failure of the specimen
well as the weight. That was taken in account
to decide the no. of specimen to be test.
the table was constructed. It has a hollow box.
With door provided to accommodate all the
accessories. The bottoms of the table to leveling 3. Selection of trials
bolts are provided. Top of the table SH, pillar, When the approximate mean failure for a
GP were mounted. Inside the box all driving given sample is known, 20 specimens will
mechanism were incorporated. usually yield sufficiently precise results. If
not 30 specimens must be selected.
Specimen Holder (SH)
Specimen holder assembly shown in Fig 3 As 4. Selection of tup or intender
per standard each tup the specimen dimensions
The intender or tup selection depends upon
are varied. The SH which is the large in
dimension permanently mounted on the tester the application.
table. The remaining all the specimen holders
are kept as accessories. Depends upon the 5. Selection of specimen holder.
requirement the other specimen holder can Depends upon the tup selection the
directly attached to the SH. appropriate specimen holder must be
selected.
For easy clamping and unclamping between
the top and bottom specimen holder pen coil
helical spring was attached. It serves two 6. Calculation of energy level
purposes namely: top plate entire load cannot Energy level = mgh J (Nm)
transfer to the specimen, while unclamping the m=mass of the FFW (kg)
top plate move upward automatically without g=9.81m/s2
any external load. h=SB from the specimen top surface (m)
For ensure the accessories top specimen 7. The energy level can be adjusted by
holders the locaters are provided.
changing the mass, to change the velocity
the falling height should be adjusted.
Figure 3 Specimen Holder 11. Raise the FFW in its position by rotating the
drum until the FFW locked by the plunger.
IV. PROCEDURE
1. Specimen preparation
12. Remove the specimen from the SH and plates subjected to drop weight impacts”,
insert the next specimen. Composites Science and Technology 66
(2006) 61–68
13. Repeat the step 6 to 9.
[3] Othman R and Barton D.C. (2007) ‘Failure
V. CONCLUSION initiation and propagation characteristics of
honeycomb sandwich composites’ Journal
The present fabricated tester itself by varying of Composite Structures.
the guide pipe diameter and the free falling
weight the energy level can be increased. [4] Richardson M.O.W. and Wisheart M.J.,
(1996) ‘Review of low-velocity impact
Using the fabricated tester impact load properties of composite materials’, Comp
applied to the specimen, the top surface Part A 27, pp. 1123–1131.
damages are absorbed by naked eye.
[5] Tomasz Lendze, Rafał Wojtyra, Laurent
The internal damages are inspecting by the Guillaumat, Christine Biateau’ (2006) ‘Low
Scanning Acoustic Microscope (SAM). Velocity Impact Damage In Glass/Polyester
Composite Sandwich Panels’ Advances In
VI. SCOPE Materials Science, Vol. 6, No. 1 (9).
• Data extraction.
• Increasing of Velocity.
• Increasing of Energy level
• Etc.
REFERENCES
IV.MODELING OF THE MECHANISM
PART Figure 2. Geneva Mechanism Parts
C. Modeling of Geneva or Star Wheel
In Fig. 4 Inputs for the Geneva wheel
Crank wheel radius
Crank wheel depth
Pin radius
Number of slots
Angle between the slots
the reciprocator option is needed in
animation controller
Figure 4. Star/Geneva Wheel inputs To see the simulation replay option
is needed
IX. ASSEMBLY OF MAIN
MODEL
Existing Mechanism New Hybrid
Mechanism
No use of pulley
Evangelos, for arm motion
Papadopoulos and
Georgios Patsianis 's
mechanism they are
using a pulley to No chance for
Figure 5. Main Model
give a arm motion. pain because
there is a stepby
Some time the step motion. It
motion of this will be slow in
mechanism can be motion
is very useful for side arm motion without
painful for suffering
pain because it gives a stepbystep
people.
motion. This is a type of hybrid
CONCLUSION
mechanism. In this hybrid mechanism
The developed mechanism is well suited Geneva mechanism is the main part to
to help people are suffering from muscle give stepbystep motion. The modeling of
atrophy especially, such a device can be Geneva mechanism is programmed by
used together with physical therapy in programming tool of visual basic 6.0
order to accelerate the recovery process. interfacing with the modeling software
In present time many existing equipment solidworks 2005.The simulation this
does not have a property to shift the center mechanism is also done by solidworks
of rotation of limb. They directly give the software in assembly mode. By this
side arm motion. This kind of mechanism interfacing we can save time and reduce
the complexity of Geneva mechanism. So mechanism and four bar mechanism so it
it is a combination of the Geneva is known as a Hybrid mechanism.
REFERENCES
[1] Evangelos Papadopoulos and [2] Varadarajan Vidya, Palani
Georgios Patsianis (2007)‘Design of Kumaresan (2000), ‘Design of a
Mechanism for the Shoulder Joint’ Micromachined Geneva Wheel as a
Nation Technical university, Athens, Mechanism to Obtain Intermittent
Greece. Motion from a Contantly Rotating
Source’, University of California,
Berkeley
Motion Assist – Consideration of the
[3] E.J.McCormick, Ed., ‘Human Factor Effect of Bi Articular Muscles’,
Engineering’, 3rd ed. New York: Proceedings of IEEE International
McGrawHill, 1970. Conferenceon Robotics and
Automation,New Orleans.
[4] Kazuo Kiguchi Toshio Fuduka, ‘a
3dof Exoskeleton for Upper Limb
REFERENCES
[1] J. Argyris, M. De Donno, F.L. Litvin
(June 1999) “Computer program in
Visual Baisc language for simulation of
meshing and contact of gear drives and
its application for design of worm gear
drive” The University of Illinois at
Chicago, USA.
Introduction to Ansys
Co
Load(kg Hc No Smoke
s.no emission
) emission(ppm) emission(ppm) %
%
1 0 0.24 2797 77 2
2 3 0.18 2451 170 1
3 6 0.18 2310 236 1
4 9 0.15 2113 282 3
5 12 0.13 1995 322 4
Table 2 emission reading for conventional piston
Time
Brake
taken Total Brake
specific
for (10 Brake fuel mean Brake
L fuel Exhaust
cc) of Torque powe consup effective Thermal
s.no rpm oad consupt temperat
fuel (t)nm r (bp) tion(tf pressure efficiency
kg ion ure c
consum kw c)kg/h (bmep) bte %
(bsfc)k
ption r kpa
g/kw-hr
sec
1
1 0 66 0 0 0.48 0 0 168
550
1
2 3 58 4.44 0.697 0.5462 0.7832 83.34 10.44 207
500
1
3 6 53 8.89 1.396 0.5977 0.4281 166.92 19.10 242
500
1
4 9 49 13.34 2.095 0.6405 0.3057 250.51 26.51 272
500
1
5 12 44 17.80 2.796 0.72 0.2575 334.33 31.77 306
500
Table 3 performance reading for air gap insulated piston
s.no Load(kg) Co emission % Hc emission(ppm) No emission(ppm) Smoke %
ABSTRACT
Slider crank mechanism is a well was tested on a no: of numerical examples,
known application in an engine which is some of them are outlined in this work.
widely used to convert reciprocating to
rotary motion and composed of three Keywords: Computer Aided design, Crank,
important parts i.e., crank is a rotating Slider, Connecting Rod, Visual Basic 6.0,
disc, slider which slides inside the tube and Solid works.
connecting rod which joins the parts
together.The best examples of crank slider INTRODUCTION
–Mechanism are steam train and cylinder Modern trends in the design of
of an internal combustion engine. mechanisms emphasize economical design
analysis
Computer Aided Design software is By means of computer aided design
developed for generating slider crank – techniques .Computer-aided design (CAD)
mechanism by inputting configuration is the use of a wide range of computer-based
values using object oriented programming tools that assist engineers and other design
approach of visual basic and visualizing the professionals in their design activities. This
model in 3D modeling software[Solid has however over the last 20 years been
Works]. overtaken by 3D parametric feature based
modeling. Components are created using
The software graphical features Solid modeling are assembled into a 3D
were used to give a visual interpretation of representation of the final product, this is
the solutions. The software effectiveness called as Bottom-up Design.
Mechanism is the arrangement of [c]. Diameter of the piston Dp
connected parts in a machine in order to
accomplish desired force and motion DESIGN CALCULATIONS:
transmission, which is considered to be an [a]. length of the connecting rod :
assembly of mechanical items designed to Lc = 4.5* Dc
achieve a specific purpose with in a machine. [b]. Diameter of the crank pin:
There are clearly an infinite number of Dcp = 0.5* Dc
mechanisms available, but concentrated on [c]. Diameter of the large boss:
specific one is slider- crank mechanism. The Dlb = 1.8 *Dc
piston, cylinder, crank and connecting rod [d]. Diameter of the small boss:
combination is known as a Slider-Crank Dsb = 0.9*Dc
Mechanism.The purpose of this is to convert [e].Diameter of the big end of
the linear motion of the piston to rotational the connecting rod :
motion of the crankshaft. One common Dbc = 1.5* Dlb
application of the mechanism is in IC [f]. Diameter of the small end of
Engines. The connecting rod :
Dsmc = 0.45* Dbc
A. MECHANISM DESIGN: The creation of a [g]. Diameter of the wrist pin:
scheme for the assembly of a machine. His Dwp = 0.5*Dsmc
involves [h]. Diameter of the cylinder:
1. Conception of an arrangement of dc = 2*Dp
components or elements or parts which will
accomplish the desired purpose. SLIDER CRANK MODEL
2. Definition of the geometry of each part.
And INTRODUCTION TO VISUAL BASIC
3. Processing Visual basic is the event – driven
programming language and integrated
Slider-crank mechanism, (a) Mechanism, development environment from
(b) Graph of mechanism. R = pin joint; P = Microsoft for its COM programming model,
sliding joint which is also considered a relatively easy to
In this slider crank linkage learn and use Programming language.
mechanism, the crank is in pure rotation and
the piston is In pure translation [which moves INTERFACING VB WITH SOLIDWORKS:
back and forth in a straight line] Automation via the SolidWorks
Principal parts of slider-crank mechanism Simulation API can greatly enhance
productivity and help designers and
This watermark does not appear in the Engineer’s quickly pre-process or post-
registered version - process information external to the user-
http://www.clicktoconvert.com interface capabilities.
Simple software package can be designed that
MECHANISM DESIGN allows this type of mechanism design. Such a
package would require a simple user front end
The components of mechanism Crank, and easy to understand API. Users should be
Connecting rod, Piston, wrist pin and allowed to fully integrate the
Cylinders are designed using relevant design Software package into their own code with
equations. the ability to either choose to specify an input
This watermark does not appear in the
INPUT PARAMETERS: registered version -
[a]. Diameter of the crank shaft Dc http://www.clicktoconvert.com
[b]. Radius of the crank Rc
THEORY AND PROBLEMS OF MACHINE
ACKNOWLEDGMENT DESIGN Hall * Holomenko A.R, Laughtin
HG
I, sreekala.D wish to thank Dr. Kingsley Jeba
Singh, professor and also MECHANICAL ENGINEERING DESIGN S
Thanks to S. Karppudiayan, Sr. Lecturer. higley Je, Mischke CR, 6th Edu.New York,
McGraw Hill 2001
MICROSOFT DEVELOPER NETWORK,
REFERENCES Help for Visual basic6.0
MACHINARY AND MECHANISM Robert
l. nordon
A. Contact line
Inner and outer gear is always in contact through
contact points (P). The number of contact points equal
to the number of outer lobes.
1
pump. This area can be found out by two methods The chamber area can be calculated as,
namely Integral Derivative method and Derivative
1 1
Integral method. But derivative integrative method V1( ) H re2 d H ri 2 d
2 2
The delivery flow rate per revolution of outer The sample was tested in the standard performance
rotor can be expressed as, test rig and tested for flow performance at different
N
dV j speeds. Fig. 10 shows the layout of the test rig.
QN d d
0 j 1
(14)
E. Design Parameters
Table I
Design Parameters
Description Symbol Unit values
Number of teeth in outer
N - 8
gear
Radial distance ofK the mm 37.5105
centers of outer gear teeth
V. RESULTS & DISCUSSIONS shows the variation in chamber area calculated by
Derivative Integral method
Abstract
This paper presents the results of attempt to explain why a component has failed
investigations carriedout to study the stress during operation. However, the more important
concentration and crack propagation in aspect of studying fracture mechanics is to be
pressure vessel steel. Finite element method able to accurately predict service life of a part,
is used to calculate fracture parameters and so that disastrous failures can be prevented.
crack propagation. This paper includes, Fracture Mechanics is proving to be a powerful
study on stress distribution during crack and important tool for both defects assessment
propagation. FEA package and the fracture-safe design of components and
ABAQUS is used to study the crack structures.
propagation.
This is particularly true for situations
KEYWARDS: FEA, Fracture mechanics, Stress where unscheduled plant breakdown cannot be
Concentration & Crack propagation. tolerated or where the potential hazard of a
failure is such that the highest possible
INTRODUCTION standards of structural integrity are required.
Such areas include electrical power generation,
Fracture mechanics is the study of flaws by fossil fuel or nuclear means military
in engineering materials. This involves projects, where high design stresses are used to
characterizing a material’s ability to resist crack maximize performance
onset and propagation, as well as understanding
how propagation occurs. The important aspect STRESS CONCENTRATION
of this field is failure analysis, where engineers
If there is a geometrical discontinuity in pressure vessel steel (STE 460) and it is
a body, such as a hole or a crack, results in non- assumed to be isotropic with elastic plastic
uniform stress distribution at the vicinity of the behavior. Chemical Composition are given in
discontinuity. The stress near the discontinuity the Table 1
will be higher than the average stress and drops
off rapidly with distance away from the TABLE 1 CHEMICAL COMPOSITION
discontinuity (Inglis, 1913).
C 0.20
Stress concentration plays major role in Mn 1.70
initiation of crack in many of the structural and Si 0.80
engineeringcomponents. Many methods are P 0.025
available for experimental and analytical S 0.015
estimation of stress concentration factor. Cr 1.50
Though experimental methods provide actual Ni 2.50
Values, they are expensive and time consuming. Mo 0.70
Few analytical equations have been evaluated Nbc 0.06
on the basis of Linear Elastic Fracture Tic 0.05
Mechanics (LEFM) and semi empirical Vc 0.12
approach. These equations predict the stress Zrc 0.15
concentration with acceptable accuracy level
(i.e., with a variation of ± 10%) In recent years The properties of the material are:
Finite Element Method (FEM) has emerged as Young’s modulus (E): 2.1 X 105 N/mm2
one of the accurate and reliable numerical tools Poisson’s Ratio (υ): 0.3
in stress analysis. Hence stress concentrations Stress-strain data for isotropic plastic behavior
could be reliable and accurately estimated using are given in the Table 2
FEM In this juncture the present study aims at TABLE 2 STRESS – STRAIN DATA
investigating the stress distribution during crack
Propagation. True Stress (MPa) True Strain
Abstract i.INTRODUCTION
With the increase in number of
For the urban transportation and to tackle the
vehicles on road, there is shortage of parking
parking problem the foldable frame is used in the
space anticipated in the near future even
vehicle. The parking space is much reduced by using
inside educational and other organizational
these foldable frame vehicles. The wheel base is much
campuses. Changing the vehicle wheel track
reduced as the parking space needed for each vehicle
according to the vehicle speed increases the
is reduced. Thus each vehicle contributes to the lesser
vehicle performance.
space for parking. The wheel track is also much
reduced for contribution of allotting less problem to
I wish to propose a solution to this by
parking. Thus this concept is much suitable for the city
introducing a concept of “foldable vehicle”. In this
car. The overall size of the vehicle can also be reduced
vehicle the wheel track and wheel base can be changed
for stalking more number of cars.
in addition to the vehicle height.
Micro mobility vehicle is designed to use
This “Foldable Frame Vehicle” (FFV), is a
inside the educational centre, research centre,
three wheeler with electric propulsion through a hub
hospitals, and production assembly units for easy
motor. This product is designed to specifically address
mobility. The ground clearance of the vehicle is low
the problems related to parking space requirements.
.For this reason the vehicle speed is set to maximum of
With this concept, the effective reduction in parking
30KMPH.The desired maximum speed is sufficient to
space (occupying volume) is expected to be around
use them in the campus. The mentioned speed satisfied
80% in comparison to a conventional 100 cc to 250 cc
the requirement to use in the industries as the preferred
motor bikes in the Indian market. Similarly in
speed of vehicles inside the industries is less than
comparison to a human powered bicycle, the expected
30kmph.
reduction is around 86% With this, I wish to introduce
the concept of “stacked parking”
For the easy transportation with less movable
parts the electrical drive is preferred. The battery is
The frame has been designed with optimal
used as the power source. The maintenance free
cross section for strength to weight ratio. The material
battery is used for this purpose. The vehicle speed
used selected is standard aluminum alloy used in
control is by the rheostat control placed in the handle
design of bicycle frames. The weight of the FFV is
bar. The power variation is send to the hub motor.
kept in a range such that it can be carried around after
Thus the speed of the motor is controlled and hence
folding.
the vehicle speed. Battery is placed in the handle
section so that during folding process the battery falls
The vehicle stalking box is designed to use the
on the base plate. Thus the battery finds the better
parking volume efficiently. The stalk box can be
place in between two folding component .the analysis
designed for various number of vehicle requirement.
is made on the frame considering battery weight.
The vehicle folding factor plays a vital role in using
the stalking board more efficiently.
As the vehicle is run by electric power the
vehicle is eco friendly. This makes the vehicle well
Other features have also been considered for safe and
suit to use in the research centre and eligible for
“emission free” (on site) operation. The design is as
pollution free transportation in the campus.
per the vehicle safety regulation.
The various methods of parking are
• Conventional parking in ground for that operation also. Finally, it's a good idea to tow
the bike on the trailer at a variety of speeds and over
• Stalking the cars by reducing their sizes different surfaces to understand how the trailer
while parking handles.
• Multi floor building for parking of The work is coordinated and supervised by
vehicle in corresponding floor Professor William J. Mitchell says the foldable vehicle
should be parked in a certain manner, so that if one
• Parking at any convenient floor(shopping vehicle is driven out the next vehicle should fill the
maal) same place. The "City Car" project is collaboration
between the MIT Media Laboratory and the new MIT
Design Lab Massachusetts Institute of Technology had
There are various possibilities to fold the vehicle proposed the same.
• Electric rear hub motor (1 HP) The wheel track of the vehicle can be varied as
per the requirement. In additional to the foldable
• Front wheel assembly components the wheel track (distance between the
front wheels) can be changed as per the requirement.
• Electrical control module Distance between Wheels can be arranged and placed
in the position. The tandem tubular frame paves the
• Lithium battery way for easy variation in the wheel track. These
arrangements are possible only in the vehicle rest
• Side stand for parking condition. The wheel base (the distance between the
front and rear wheel) can also changed as per the
design. The base frame has the clamp to hold the two
IV. LOADS ON FRAMES base frame segments of various sizes.
• Weight of the vehicle and passengers The specification for the vehicle is given in a
commercial vehicle format. The battery details are
• vertical loads when the vehicle comes taken out from the manufacturer. The hub motor is of
across a bump or hollow, which results diameter10 inch and 3 inch tyre width. Drum brake
in longitudinal torsion due to one lifted assembly unit is attached to the wheel.
(or lowered) with the other wheels at the
usual road level
IX. CONCLUSION for the vehicle for ensuring the safer design.
The foldable frame for the micro The light weight material can be used for
mobility vehicle is designed as per the handling the vehicle and folding in the stalking
requirement. The electric vehicle gives the free box is proposed for stalking the vehicle if it is
operation even in case of the fossil fuel used in large number.
shortage. The static structural analysis is done
X.SCOPE FOR FUTURE WORKS Vehicle Parking System”, National Central
In my design the foldable parts are very University, Taiwan.
less as two third of vehicle side is reduced. This [9] Katherine L. Eveleth - EDS Corp,“Parking
can be improved by using a different design Management Systems –The City of
concept to further reduced size. The lighter Chicago:a Case Study” Document Number:
materials like aluminum, fiber reinforcement 941007.
can be preferred. The frame has been [10] Terry D. Day,J. Travis Garvey,Engineering
structurally analyzed for static conditions with Dynamics Corporation ‘Applications and
sequential loading. This can be done for Limitations of 3-Dimensional Vehicle
dynamic conditions. The suggestion of Rollover Simulation’
modification to reduce resonance can be given. [11] United states patent ‘Foldable Handle Bar
References Stem of a Skate Board’
[8] Li-Der Chou, Chun-Cheng Sheu, Home-
Way Chen,“Design and Prototype,
Implementation of A Novel Automatic
Shih has also shown that dn usually varies Table 1: Composition of the specimen
between0.4 to 0.8 for elastic perfectly plastic
materials (N=∞) dn=1, which is obtained by Specimens were fabricated with three
extrapolation. It is required to examine the different notch angles, viz. 30◦, 45◦ and 60◦. The
effect of the specimen geometry and a/W ratio specimens, shown in Fig. 1, had the design
on the factor dn, which can address in plain recommended by ASTM Standard E399-05 for
constrain effects. three-point-bend specimens, except that they
We have taken a rectangular bar with contained a straight-face notch terminated by a
angular notch, since [16]notches in structural semicircular tip instead of a sharp crack. The
components give rise to localized stress ratio of notch depth to specimen width[15] (a /
W) was more than 0.45 for all specimens. The independent of specimen configuration and
other actual dimensions match the nominal ones crack length.
to within the accuracy of the measurements CMOD is found out for various loads of
(0.03 mm). 30º notch angled specimen and it is given.
Fig. 1.1- Typical Lubrication System [A] 2.1 THE FINITE ELEMENT METHOD
4 0 13 2438.8 1 13
5 0 14 2744.1 1 14
6 0 15 2790.4 1 15
7 0.53195E-03
Table 5.4 – Natural Frequency Values
8 0.98903E-03
9 0.25534E-02
10 0.36218E-02 The different mode shapes obtained are given
below
11 37669E-02
12 0.71921E-02
13 83.369
14 85.776
15 439.10
Table 5.3 – Free- Free Modal frequency values
5.5 FIXED MODAL ANALYSIS
After completing the free-free modal
analysis, the forced model analysis is done.
Here the boundary conditions are given. Bolted
holes are arrested in all degree of freedom. And
an acceleration of 10 g is been provided. And Fig. 5.1 – 1st Mode shape (Frequency 352.343Hz)
then the modal analysis is done. The following
table gives the different frequencies of the
system. Since the working range is from 40 Hz,
the frequencies are also obtained above 40Hz.
The results and the mode shapes obtained are
given in the following pages.
Fig. 5.2 – 6th Mode shape (Frequency 1447 Hz)
A. Equation of motion
REFERENCE
F Equi-
Where, dP/d valent
V2 – Destination Volume to be filled, m3 P1 P2 Cd low
t flow
R – Gas Constant, K / kg/K area
Path Dia.
T 2 – Temperature of the destination volume, <no
Ba bar/ mm
m3 Bar unit 2 mm
r sec
dP / dt – rate of pressure change bar/ sec >
γ – Gas Constant for medium (1.4 for air) Apply 10.1 1 36 0.65 55.5 8.41
P1 – Signal Pressure, bar Releas 1.
7.5 11.6 0.95 94.5 10.95
With pipe friction also considered as standard e 3
friction,
Aeffetive Our valve is considered as two Relay Valves
Cd =
Ageometrical in Series for “Apply” path and in “Release”
The ratio is obtained from standard Pipe path, it is just one Valve.
friction
Values. C. CONCEPT OF EQUIVALENT FLOW
AREAS:
In dynamic analysis of flow through a
valve, we consider the orifices as equivalent The observed Values in actual column
to Resistors in electrical circuit. To estimate denote values found out by experimental
the resistance to flow path, we create an observations of the model under standard
equivalent flow diameter to the system which testing conditions. With this comparison, we
is calculated as below. By this approach, we conclude that the formula has concurrence
assume the whole flow path as an equivalent within 10 % of the experimental value.
to a circular pipe with diameter equivalent to Hence, re-design process can be carried out
equivalent flow diameter. based on the value calculated by the formula.
1/Aeq3 = 1 / A13 +1 / A23 +1 / A33 +….. By accounting for same amount of errors,
we started re-designing the component for the
Where new corrected Equivalent flow diameters.
A1 - Area at the first cross section
A2 - Area at the second cross section TABLE IV
A3 - Area at the first cross section COMPARISON OF VALUES OF
And so on… EQUIVALENT FLOW DIAMETER
TABLE 7.1
TABLE SHOWING COMPARISON OF
RESPONSE TIMES
REFERENCES
1. S.V.Natarajan, S.C.Subramanian,
S.Darbha, K.R.Rajagopal, “A Model of
Relay Valve Used in an Air Brake
System,” Nonlinear analysis: Hybrid
systems 1 (2007) 430-442.
2. Acarman T. and Ozguner U. (2000)
‘Pneumatic brake system modeling for
systems analysis,’ SAE Paper 2000-01-
3414.
3. W.B. Browner, Jr., E. Eisler,” On the
compressible flow through an orifice”,
Journal of Fluid Engineering, Vol
115,December 1993 pp 660 -664.
4. Khan Y., Kulkarni P. and Youcef-Toumi
K. (1994) ‘Modeling, experimentation and
simulation of a brake apply system,
Journal of Dynamic Systems,
Measurement and Control, vol. 116, pp.
111–122.
5. Yahya S.M. (2004) ‘Fundamentals of
Compressible Flow’, New Age
International Publishers
6. Krishna Chaitanaya. S, “Theoretical and
Experimental Analysis for prediction of
response time in Air Brake Valves”, Anna
Univerity M.E. Thesis , 2007.
7. Kumaravel.B, “Modeling and Simulation
of a Relay Valve in Air Brake Circuit”,
Anna Univerity M.E. Thesis, 2008.
8. Various Design Guidelines of Wabco Tvs
India Limited, Chennai
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
Therefore, in the three hybrid damping these patches in response to the structural
treatments described, three distinct damping vibration deforms the viscoelastic damping layer
augmentation mechanisms were analyzed. In the across its thickness and dissipates the vibration
SPN, the augmentation results from the energy energy in the form of heat. Here two varities of
dissipation in the shunted electric circuitry APDT has been shown.APDT-1 consists of a
whereas in the ACLD treatments, the viscoelastic layer and piezoelectric layer.APDT-2
augmentation is attributed to the enhanced shear consists of two piezoelectric layer and one
and Compressional deformations of the visco- viscoelastic layer.
elastic layers, respectively.
In this paper, we introduce a new class of
hybrid damping treatments which is the Active
piezoelectric damping treatment (APDT). The
APDT is a modified active version of the
magnetic constrained layer damping (MCLD)
treatment [6]. In the APDT, the compression Fig 1 APDT-1
damping of the visco-elastic layer is controlled
using piezoelectric actuators which have high
control authority as compared to that of the
piezoelectric fibers used in the APDC treatment.
Therefore, the APDT could present a viable and
practical means for controlling high amplitudes of
vibration of massive structures. The proposed
Fig 1a APDT-2
APDT is also an active version of the passive
Compressional damping treatment that has been
successfully employed and analyzed by Douglas 3.0 PERFORMANCE OF ACTIVE
and Yang [7], In the passive Compressional PIEZOELECTRIC DAMPING TREATMENT
damping treatment, the viscoelastic layer is
In this section, the experimental
sandwiched between the base structure and an
performance of the APDT has been determined.
elastic layer. Damping is generated by virtue of
The performance of the APDT configurations are
the relative transverse deflection between the
determined at different control gains. The
base structure and the elastic layer. Liu and Wang
obtained characteristics are compared with those
[8] proposed the use of a hybrid constraining
of conventional passive constrained layer
layer viz., partly active _PZT_ and partly passive
damping (PCLD) treatments which are APDT
(Al2O3). It is, therefore, the purpose of this paper
with zero control gain or APDT operating in their
is to demonstrate the effectiveness of the APDT
open-loop mode.
by analyzing the layer thickness variation and
optimum placement position of APDT patch as an Five systems have been studied (Fig. 2) viz.
active Compressional damping treatment in System 1: Beam
controlling the vibration of beams experimentally. System 2a: Beam-single APDT-1
2.0 CONCEPT OF APDT System 2b: Beam-double APDT-1
The concept of the APDT can best be System 3: Beam-single APDT-2
understood by considering the configuration System 4: Beam-double APDT-2
shown in Fig. 1. In this configuration, a
viscoelastic damping layer is sandwiched 4.0 BEAM PROPERTIES
between two piezoelectric patches. Activation of
Organized By the Department of Mechanical Engineering,
Thanthai Periyar Government Institute of Technology
92
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
Four aluminum beams are used as test articles in actuator are listed in Table 1.Both of the APDT
this study same as used by A Baz [2]. The first patches are placed near the fixed end of the beam
beam is tested as bare beam. The second beam is with an offset of 0.0047 m (3/16 in).
provided with a piezoelectric+VEM patch at the
top of the beam. The third beam is provided with
single APDT at the top .The fourth beam is
provided with two APDT.The properties of the
beam, VEM damping polymer, and piezoelectric
*ISD 112 is visco elastic manufactured by the amplitude and frequency content of the
Cephas Medical Private Ltd Company, Chennai vibrations. The sensor signal is utilized also to
(http://www.tradeindia.com) generate the necessary control action using a
**SP-5H is manufactured by sparkler ceramics derivative controller. The resulting output
PvtLtd.India(http://www.sparklerceramics.com signal is sent to activate the piezoelectric layer
). The viscoelastic damping layer sheet has of the APDT patch. Figure 3a shows p the
density=1230 kg/m3. The elastic modulus of the experimental set up.
viscoelastic material is represented by a
complex number: E=E’ (1+iη) where E’ is the
storage modulus, η is the loss factor of the
material and i= .
TABLE: 2
Gain 10 20 30
System 2a 2b 3 4 2a 2b 3 4 2a 2b 3 4
Tip Before 1.7 1. 1. 1.4 1.6 1.6 1. 1. 2 1.4 1. 1.1
displacement control 6 8 4 2 2
at resonance After 1.1 0. 0. 0.4 1.0 0.9 0. 0. 1. 0.8 0. 0.7
(mm) Control 8 6 7 3 4 6
% 35.2 50 66 7 3 43.7 50 75 30 42.8 50 36.36
Reduction 9 1.4 7.5 5 5
6.0 REFERENCES
During the Function Analysis, Phase of the The following steps are involved in
Job Plan function is identified that the implementation of Value Engineering
describes the work being performed within shown in Figure 3.1
the scope of the project under study. Figure 3.1 Steps involved in
These functions are described using two Implementation of VE
words, active verb/measurable noun
pairings, for example one function of a V. CHOOSING A PRODUCT (OR)
hammer is to apply force. Function PRODUCT FAMILY
analysis can be enhanced through the use Engineering components with
of a graphical mapping tool known as the optimum use of material, easy
Function Analysis System Technique manufacturability and customer
(FAST) The value engineering is applied satisfaction is a direction where Value
using a process known as the “Job Plan.” Engineering is found to be very useful. It
The purpose of the Job Plan is to guide us would be highly creditable to implement
through the process of identifying and the concept of value engineering in the
focusing on key project functions in order front axle Front axle of the vehicle is one
to create new ideas that will result in value of the major and very important
improvements component and needs good robust design
as this part experiences the worst loading
A.STAGES INVOLVED conditions of the whole vehicle. The
A value study generally encompasses three current design of the front axle which has
stages shown in Figure 1.1 no failures at the field has been decided to
1. Pre – Study activity take up through value engineering
2. Execution Job Plan Technique methodology for achieving cost effective
3. Documentation and Implementation robust front axle without affecting its
Figure 1.1 Value Engineering Process function and aesthetics.
Flow Diagram
Job Plan process flow illustrated in Figure VI. INFORMATION PHASE
1.1.Each of the Job Plan phases must be As a first step it is necessary to obtain all
performed in sequence because each phase available information regarding the
provides information and understanding existing front axle. Get all pertinent
necessary for the successful execution of information on costs, quantities, technical
the next phase. As the team gains drawings, specification, operation sheets,
additional knowledge about the project, a marketing surveys, reliability and warranty
previous phase may be revisited. information, manufacturing methods and a
set of parts (or) pre assembly.
III. OBJECTIVES
The Objective of this project is to reduce A.Study of Current Design
the cost of the front axle without affecting
The study of current design to be done on The first step is to begin to develop the
the following characteristics, Type of the two word technique, which is difficult
front axle, Volue, Wheel track, Wheel enough. For this Figure 3.2 shows the
base, Front axle weight, Total vehicle Details of front axle its function, cost Part
weight, Kingpin inclination, castor and Name: Front Axle Present cost: Rs. 2500/
camber angle, Turning circle radius and Unit
steering type used Operation and Performance:
Front axle supports the front end of
B.Bench Marking the vehicle along with front tyres and the
Bench marketing is usually called steering in connection which can steer and
competitive analysis. This should be a way gives stability to the entire vehicle. The
to measure our standing Vs competition Front axle consists of 12 types of
and to identify short comings. Every components (22) Figure 3.2 Details of
designer should be familiar with Front axle Start the function definition
competitive products, design, operation process by looking at the functions of the
and cost. The Table 3.2 explains the entire assembly and then define the
comparison between existing design and functions of each piece in the assembly.
other leading manufacturers front axle The functions of the front axle assembly
assembly. From the comparison chart we are screened in Table 3.4 to eliminate the
found that existing design is superior to all duplication Table 3.4 Function
other manufacturer when compared in Identification of front axle
weight and section modulus (ie: based on
front axle section type). It also gives the DETERMINE SCOPE – IDENTIFY
comparative inputs from customer and FUNCTIONS
service aspects of the front axle. From the Assembly / Components name: FRONT
study advantages and disadvantages of the AXLE
existing design of front axle given below. What does the product do? What is the
level of the function?
Advantages: Support the front end & to steer the
- Better front end stability vehicle
- Suitable for heavier haulage loading SL.NO. FUNCTIONS ORDER REF.
- Increased ground clearance REMARKS
- Lesser turning circle which leads to fuel 1. Maintain stability BASIC
saving & time saving 2. Allow articulation SECONDARY
- Easy serviceability 3. mount front tyres SECONDARY
4. maintain balance (on uneven surface)
Disadvantages: SECONDARY
- Less gap between tyre and front axle 5. Ensure manuverability BASIC
leads to 6. Adequate track width SECONDARY
stone struck or mud struck 7. Guide spindles SECONDARY
8. control toe - out SECONDARY
C.Function Identification 9.controlcamber/caster/KPI
The next phase is to define the functions of SECONDARY
the product. This is quite difficult because 10.Support front weight platform
it requires an indepth analysis of what the SECONDARY
product does rather than what it is. For 11. Resist corrosion SECONDARY
successful product improvement a 12. protect center pin SECONDARY
“function” must be carefully defined from 13. support FES SECONDARY
the aspect of total life cycle cost, so that 14. Control wheel base SECONDARY
associated costs can be properly assigned.
15. Maintain high ground clearance ask WHY that function is performed. This
SECONDARY line of logic is read from right to left. A
16. lesser turning SECONDARY FAST model, reading
17. Reduce tyre ware SECONDARY from left to right, starts with the goal, and
18.Support steering geometry ends at the beginning of the “system” that
SECONDARY will achieve that goal. model “which
19. Aesthetics Good BASIC gives process of creating model. The
20. control rigidity ( vehicle ) customer sensitivity functions can be
SECONDARY identified as well as opportunities for
21. visibility Good SECONDARY significant cost improvements in design
22. Absorb thrust SECONDARY and manufacturing process
23. Easy steering SECONDARY
24.sealing avoid mud entry SECONDARY E.Cost Function Worth Analysis
25. ensure steering stopper SECONDARY From cost details provided for the
26. Prevent lifting SECONDARY individual components, for arriving the
27.Maintain center of gravity cost function worthiness the educated
SECONDARY opinion must be used. In some cases data
28.Support front end loader may be available to help in the decision or
SECONDARY team members may analyze the cost
29 Support front dozer SECONDARY function worthiness of each item for
30 Support front reaper SECONDARY arriving the value gap. For example In the
31 support toe hook SECONDARY front axle, - the cup spindle can be
32 Support front transfer box integrated with spindle housing (Intricacy
SECONDARY forging ) - Stopper can be integrated with
After the function screening, find the basic cup spindle (Simple forging) In option I ie
function, the basic function is the one upon the integration of parts cup spindle and
which all other functions depend. Read spindle housing the cost may go up in
down the list and put “Basic” in the order view of forging cost. When we go for
reference column. In the case of front axle option II integration of cup spindle with
three are basic functions and rests of them stopper the cost will come down in view of
are secondary functions. All the secondary the savings through forging. (minor
functions are subject to modification or component) Likewise the team analyzed
elimination depending on their cost and the each component assembly. After
value. Secondary function makes the basic identifying the desired functions of each
function work better. item, the team established the worth
components, depending on its essential
D.Construction of Function Analysis function. While establishing the
System Technique worthiness, the definition of value ie., the
Model lowest price one has to pay for reliable
The FAST model has a horizontal function was used as the basis.
directional orientation described as the
HOW – WHY dimension. This dimension VII. CREATIVE PHASE
is described in this manner because HOW One outcome of a value study is a
and WHY questions are asked to structure “shopping list” of alternative ideas to
the logic of the systems function. Starting achieve value improvement. Lateral
with a function, we ask HOW that function thinking is encouraged during this phase to
is performed to develop a more specific produce as many ideas as possible, even
approach. This line of questioning and those ideas that may seem unworkable or
thinking is read from left to right. To unreasonable. Generating ideas and
abstract the problem to a higher level, we
options is encouraged by Asking the analysed functions for its worthiness on
following questions while doing the brain the basic of function and cost wise. The
storming: creative phase generated a broad array of
- How else may the required function be ideas that provide a wide variety of
performed? possible alternative ways to perform the
- What else will perform the required function to improve the value of the front
function? axle assembly. Further FEA analysis to be
- What will the alternatives cost? done on the alternate ideas in comparison
There are several ways to structure the with existing design, a focused list of
study to facilitate idea generation. The concepts that warrant quality, time to
method depends upon the study and the develop into value based solutions that can
nature of the project. In project terms be implemented in to the front axle design
various parts of the project will need to be for its enhanced performance in the field.
specifically targeted for idea generation.
Front axle assembly is a single product REFERENCES
that is being considered, then the front axle [1] Bharat .R (1994) “Value engineering
will need to be analysed component-by- -A new concept in reducing cost of burn
comonent or aspect-by-aspect. During this care.” Department of burns and plastic
phase , the hidden cost areas, identified survey.
earlier ,were subjected to brainstorming, to
find but alternative ways of accomplishing [2] Jim Dimsey (2002) “QFD to Direct
the functions. Criticisms and evaluation Value Engineering in the Design of a
are avoided and even wild ideas were Brake System” Hayes Brake, LLC
noted down in line with basic VE
principles. During this session, a large [3] Jun Matsuo (1968) “Value engineering
number of ideas were generated for each for manufacture of
item to perform the same function. Help large products,” for forgings and castings
was taken from the experts in the similar engineering
design and vendors were contacted to
contribute alternative ideas. In all 42 ideas section. Japan steel works, Muroran plant.
were generated for items of front axle [4] Kimio Ogawa (1965) “An approach to
assembly, further evaluation of ideas. product planning through value
engineering-Value engineering that creates
VIII. CONCLUSION the worthwhile product” Victor Company
Value engineering study on front axle of Japan.
assembly done after studying the existing
design in detail. From the characteristics of [5] Richard Park (1999) “Value
existing two design the value engineering engineering – a plan for invention”,
done on the more volume and widely R.J.Park and associates Inc, Birmingham,
accepted robust look design and this has Michigan
been bench marked against some
manufacturers for its characteristics [6] Ross Edward Bates & Catherine
customer and service inputs which gives a Simpson (2001) “Value Engineering of
clear cut picture of where the existing Car Park Ventilation Systems” Building
design of front axle stands . During the Simulation Ltd
function identification & analysis phase
provides a more comprehensive [7] Theodore C. Fowler, CVS (1976) “24
understanding of the front axle by Principles that guarantee an effective value
focussing on what the front axle does or program- Function analysis system
must do rather than what it is, also technique for product and services.”
A Study on Failure Analysis of Knee Replacement
D.Balaji
M.E (CAD/CAM), Department of Mechanical Engineering.,
Arunai Engineering College, Tiruvannamalai -606603.
9.0 References
Abstract
In the modern automotive
I. Introduction
world, research in motor vehicle is an
ongoing process. The trend in general Nowadays the automobile field is
seems to be incremental improvements emerged and developed with the help of
of existing technology. However electronics control. Automobile manufacturers
electronic control is being introduced in continue to incorporate more and more
more areas of the vehicle. Since technological features into their automobiles. One
automobiles are getting several design such emerging feature is wireless access. The
changes in time to time manner, by this wireless communication used in automobile for
enormous development proper and various applications is referred by the name
continuous monitoring of engine “Auto Telematics” [1]. Telematics is a
parameter is necessary nowadays. For combination of telecommunication and
efficient monitoring of engine informatics. It often describes vehicle systems
parameter several methods are being that combine GPS and cellular technologies with
followed, in which the remote engine onboard electronics. They can include safety,
parameter monitoring is carried out by communication, vehicle diagnostic and
using wireless technologies. In this entertainment features. Telematics is typically not
paper various wireless communications an onboard autonomous navigation system and
used in automobile are discussed and AM/FM radio.
the system used for wireless engine data The parts of the Telematics are,
management system are described. In • Vehicle (cell phone, GPS, vehicle
this system, the parameters are data),Wireless interface,Back-office
continuously measured from the engine systems
with the help of sensors. The transmitter
Some of the services offered in Telematics are,
transmits the signals from various
• Automatic Notification of Air Bag
sensors to the remote receiver unit with
Deployment.
the help of GSM. At the receiver end the
graphical user interface (GUI) is to be • Stolen Vehicle Location Assistance -
developed by using VB programming to If your car is stolen, an advisor can
monitor the vehicle parameters. In this use the on-board GPS to track the
paper described about the wireless car.
engine data management system of
• Vehicle Diagnostics – It can receive
vehicle.
information about the status of
systems like the engine, air bag and
Index Terms— wireless communication, anti-lock brakes.
GSM, engine
• The module checks these systems
on a daily / weekly / monthly
basis,and then automatically sends a
message to Telematics System.
II. LITERATURE REVIEW There are several automotive
applications uses wireless
Today’s motor vehicles contain an
communications, that may be inter -
increasing number of microcontrollers
vehicle communication or vehicle to road
providing electronic control of a range of
side communication. Looking to in vehicle
systems, including engine management,
communication the application system
breaking, steering and airbag safety
uses GSM devices and computers. Based
systems. There are lots of research is going
on this previous literature collections, in
on in automotive electronics.
this paper described the problem and its
A. Automotive Diagnostic System solution methodology.
The automotive diagnostics system is III. problem description
build by utilizing a collection of wireless In this paper gives a solution methodology to
sensor nodes collecting data from the car. develop a wireless system that to be transmitting
All persons who interact with a vehicle various engine parameters from vehicle to remote
require a unique set of data about its station and remotely monitor the performance of
operations [5]. For example, drivers are the vehicle.
interested to know healthy of the car. On IV. solution methodology
the other hand mechanics are interested to
know about current operational state of The Solution methodology has various stages to
numerous components. develop a system. This is represented by the
block diagram at fig. 1.
B. Automobiles and wireless
communication
The display of engine parameters and
their control has been implemented using a
bidirectional wireless system. Some of the
systems use wireless communication such
as Bluetooth (IEEE 802.15.1) [2], ZigBee
(IEEE 802.15.4), Ultra Wide Band
(UWB/IEEE 802.15.3a) and Wi-Fi (IEEE
802.11a/b/g) [2]. All these technologies are
used for wireless real-time control systems
found in automotive systems. The
comparison chart shown in Table 1 [2].
Table 1 Comparison between wireless
Fig. 1 Methodology
communications
Range Mobility • Creating a data base having collection
Wi-Fi Up to 1000 <100 mph of sensor signals.
802.11p feet • The measured quantity of engine
Wi MAX Up to 30 <75-93 mph parameters to be transmitted through
802.16e miles GSM.
MBWA Up to 9 <155 mph
802.20 miles • Develop the graphical user interface
3G Typically 1- 310 mph at (GUI) to monitor the vehicle
parameters for received signal.
5 miles 144 Kbps
75 mph at 384 A. Parameters to be monitored:
Kbps • Engine Temperature
6 mph at 2
Mbps • Engine Speed
• Fuel Level
Engine Temperature: The resistance value is varied by a contact sliding
The engine coolant temperature will give the over a resistor.
engine temperature. Coolant temperature
measurement is carries out by a simple thermistor B. Data Acquisition Unit:
- in many cases the same sensor may be used for The signals from all sensors are
the operation of the temperature gauge and to collected through data acquisition circuit.
provide information to the fuel control system. The data acquisition unit consists of an
The temperature sensor is shown in fig. 2. analog to digital converter (ADC) and
The engine coolant temperature sensor is a microcontroller (8051). The output from
negative temperature coefficient (NTC) the data acquisition unit is connected to the
GSM MODULE.
The connection between data
acquisition unit and GSM module is
established by a small interfacing circuit,
which is shown in fig. 4.
C. Data Transmission Through GSM:
The communication establishment
Fig. 2 Temperature Sensor between Personal Computer and server
thermistor. It is fitted in to the water jacket close
to the thermostat or bypass coolant circuit
passages. The sensor measures the engine coolant
temperature and provides a signal voltage to the
ECU. The normal running engine coolant
temperature is maintained at about 90 c, which
gives an engine temperature where clean
combustion is possible.
Engine Speed:
Crank shaft sensor is used to get information on Fig. 4. Interfacing Circuit with
engine speed. This will often be the same sensor side is carried out by GSM/GPRS module.
that is used for the speedometer. The inductive The GPRS services reflect the GSM
services with an exception that the GPRS
have a tremendous transmission rate.
Services such as the internet,
videoconferencing and on –line chatting is
smoothly possible. GPRS is a packet-
based data bearer service for GSM and
Fig. 3 Inductive speed TDMA networks, which provides both
sensor
speed sensor used in automobile is shown in fig. standards with a way to handle higher-data
3. speeds and transition to 3G. At the receiver
If not several types are available, the most end, the GSM module has a RS 232 port
common producing a pulsed signal the frequency through which, the module can be
of which is proportional to the vehicle speed. The connected to the personal computer.
signal from the sensing unit is counted by number D. Graphical User Interface:
of pulses. And it is divided by four to get the In the receiver end, the user interface is
speed in revolution per minute (RPM). to be developed through VB programming.
Fuel Level: It gives a representation of vehicle front
Fuel level is measured by using a variable resistor panel, showing vehicle parameters like
that is moved by a float. The position of the float sensor values. The fig 5 shows the main
is determined by how much fuel is in the tank.
page of vehicle information system. This • The automobile engine
page contains current sensor values. performance to be monitored,
when the vehicle is moving
The main page has a button for trend condition.
window. The trend window gives data • To prevent the accident.
value based on daily report and also • It helps the motor vehicle crash
weekly report. investigation.
• Easy to trace the vehicle position in
the globe.
• Mal practices in the vehicle can be
avoided. Such as fuel theft, etc..,
References
CONTENTS: EXPLANATION:
Sensing Unit:
1) Introduction Sensint unit senses the weight and
2) Construction sends the data to control unit. This may
consist of sensors, weighting machine.
3) Explanation of the components Control Unit:
4) Working of Electromagnetic This plays a major role in the working
of the car. This controls the working of
engine the engine. This selects and sends the
required initial current and voltage so that
5) Analytical salvation there is high torque initially. The voltage
6) Our project details and ampere can be changed by nob but the
initial voltage and ampere cannot be
7) Areas to be concentrated changed/lowered if same load is placed.
The required initial (V&A) can be selected
8) Ways to increase the efficiency from a microprocessor.
9) Problems to be solved Battery:
The battery is the heart of the setup.
10) Conclusion This supplies current to the whole setup.
11) Reference This must be charged frequently by putting
anything like flywheel,etc.
When the supply is given to the
electromagnet-A side, then the
Electromagnatic engine: piston gets attracted towards it.
This is the working part in our project When the supply is given to the
which is the reason for moving of the car. electromagnet-B side, then the
piston gets attracted towards it.
But when one electromagnet is
working other is operated in off
condition.
This gives a to and fro motion and
this can be used for any work.
ANALYTICAL SOLVATION:
Since
Torque α B * I
Ns= 120*(f/p)
By this equation we can tell that by increasing the frequency of changing the poles we
can increase speed
Where
B- magnetic flux
n- constant
µo- Permittivity – Constant
Therefore:
BαI
Force= B * I * L
Where
L- Length of piston – constant
I – Current passing through the electromagnet
Force α B * I * L
Since,
BαI
Therefore,
Force α I^2
We know that
Torque = B * I * A
Where
A- Area of piston – constant
Since,
BαI
Finally,
Torque α I^2
Thus by increasing the current the torque can be increased and the graph will be as shown.
B α (µo * n * I)
can avoid some loss. Since the thickness
OUR PROJECT DETILS: of the wire plays a major role in the copper
In our project we have constructed loss so by using the conductor of less
a relay circuit to give the supply thickness must be used.
manually. Control Unit:
This unit is so complicated because
Then in a our engine we gave the the designing is not so simple. This is so
load as spring and piston weight. as the storage of data i.e the storage of
voltage and ampere for the initial moving.
We constructed like that the piston This can be done successfully by
has to move against the spring and undertaking a testing based on weight for
the piston initially. So we are only the electromagnetic engine for which the
able to move with a very few circuit is to be designed. One must also be
length. careful in determining the maximum load
which is to be applied for that particular
For this we need a battery or an electromagnetic engine.
autotransformer and rectifier
Piston:
Since we faced many problems The piston determines the speed of
during this project and all that is the vehicle however the power is supplied.
needed to this project is the proper The piston should be made of Mild steel
discussion and the way of doing. and it should be of light weight. We can
also use any magnetic material having less
AREAS TO BE CONCENTRATED: magnetic loss.
Electro Magnet:
Here the magnet is very important WAYS TO INCREASE THE MAGNETIC
so the windings must be very FLUX:
sophisticated. The wire which are winded If you see the capacitor it will have an
must be coated with so insulin so that we oil paper. This arrangement is so used to
increase the storage. This can also be used
in the magnetic materials or The major role in this project is the
electromagnets to increase the magnetic concentration of losses during the
flux. So by implementing this oil paper or working. This can be minimized by
any oil material we can surely increase the adding some of the materials which
flux of the electromagnet. decreases the losses in the magnetic usage.
V. OPERATING MODES
Figure 1 Layout of Hybrid Electric Vehicle
A. Electric motor mode
M-PMDC motor, M.C-Motor Controller,
E-Engine, G-Gearbox, FT-Fuel Tank, and
When starting, by using a control device
A-Alternator.
keeps the gasoline engine stopped. The
electric motor alone transmits power via
In the fig 1 the vehicle is fitted with a two
the final drive reduction drive for moving
stroke 145.45 CC single cylinder SI engine
auto-rickshaw. The vehicle operates in
with a maximum power of 7hp. The
“Battery” mode up to 20 kmph to help in
fuel savings, during the initial period is Tv (t) = mv*g*cr*rw + 1/2 ρ*cd*Af *ωv (t)2*
high torque required. rw3
--------- (1)
B. Engine mode
With the wheel speed
When the electric motor drives auto- ωv (t) = v (t)/rw --------- (2)
rickshaw at maximum speeds, a control
device starts the gasoline engine. The The drive power demand becomes,
engine is accelerated to high speed by Pv (t) = Tv (t) ωv (t) --------- (3)
accelerating cable. Engine is start after few
minutes. It’s changed to engine mode for it VII. EXPERIMENTAL RESULTS AND
connected 35 to 40 kmph. Engine normal DISCUSSIONS:
operating time CO2 emission is less
compare to starting, stopping and idling The hybrid electric auto rickshaw is
time. tested in chassis dynamometer, it is drive
by two mode namely battery mode and
C. Engine/charging mode engine mode. The vehicle performance
tests are conducted and plots Maximum
While auto-rickshaw is running at cruises speed, acceleration test by distance mode
speed 35 to 45 kmph alternator is engaged and speed mode.
in engine and the electric power is stored
in the battery controlled by a control
device. The vehicle runs at low speed the
electric motor is turn to generator function
by regenerative braking. At the same time,
the control device regulates the load of the
electric motor/generator according to the
state of the engine.
PROBLEM SPECIFICATION
During braking the kinetic energy
of the moving vehicle is converted into
thermal energy through friction in the
brakes which results in increase of
temperature in brake components.
High temperature that generate
inside the drum induces thermal stresses
and brake fade and reduces the strength of
the drum. Hence thermal analysis of brake
drum becomes essential to study the
feasibility of using MMC brake drum
applications.
BRAKE LINING:
It is friction material fitted on the DIMENSIONS OF THE BRAKE DRUM
surface of the brake shoe. At the time of
braking the kinetic energy is transformed Outer diameter - 0.47 m
into heat energy. Brake liner absorbs the Inner diameter - 0.395 m
heat making it to wear. Depth - 0.187 m
Depth of rib - 0.048 m
Rib diameter - 0.486 m
Hole diameter - 0.022 m
Hub diameter - 0.223 m
Outer edge champher - 45 x 0.005 m
Inner edge champher - 45 x 0.01 m
Eight holes with centre
Distance - 0.115 m
LITERATURE SURVEY
Over the past three decades the
composite industry has undergone many
developments in the processes and
applications. Some of the papers which
deal with composite materials and their
applications in automobile field are
reviewed below:
High density , rigorous machining
N.NATARAJAN, S.VIJAYARANJAN and due to imprecise casting and
AND I.RAJENDRAN Manufactured and substantial production cycle times
tested a metal matrix composite brake
are few of the drawbacks in
drum and the thermal analysis under
single, continuous and repeated braking utilizing cast iron in brake drum.
conditions were carried out.
G.WITHERS, P.MURIE, Hence composite materials are
R.ZHENG Developed low cost aluminium invaluable in eliminating such
matrix composite using fly ash micro shortcomings.
spheres by solidification processing. The
materials were successfully squeeze cast Aluminium alloy composites are
into automotive brake drums that were becoming potential engineering
defect free and heat treatable. materials offering excellent
J.BIENIAS , M.WALCZAK , combination of properties such as
B.SUROWSKA Studied the
microstructure and corrosion behavior of High specific strength, High
aluminium fly ash composites.
specific stiffness, Low coefficient
K.SUGANUMA,
T.FUJITA,N.SUZUKI AND K.NIHARA of thermal expansion and wear
developed a metal matrix composite resistance.
reinforced with a new aluminium borate
whisker. This aluminium borate whisker COMPOSITE FABRICATION
has been established by a Japanese Composites are fabricated by adding
chemical company. ceramic particles to a molten aluminium
P.ROHATGI studied the various alloy and then casting that liquid metal
automotive applications of cast aluminium ceramic mixture into near-net-shape
matrix composites. The various components.
applications include drive shafts , disc After the ceramic was well distributed the
brake rotors, brake drums, brake calipers, composite alloy was poured into ingot
connecting rods, piston and engine block moulds and solidified.The ingots were
cylinder line for automotive and rail shipped to a casting plant.There they were
vehicle applications. remelted and squeezed cast to net shape
D.R.HERLING , G.J. GRANT AND component such as brake drum.
W.HUNT developed low cost aluminium
metal matrix composites. The stiffness, MATERIALS CONSIDERED IN THIS
wear resistance and temperature PROJECT
capabilities of the matrix alloys can be Two composite materials are
considerably increased by introducing considered in this project.
ceramic particles and this makes light 1. ALUMINIUM METAL MATRIX
alloys such as aluminium and magnesium COMPOSITE WITH SILICON
most suitable candidates as metal matrices. CARBIDE(SiC) AS
REINFORCEMENT
COMPOSITE MATERIALS.
Cast iron has been utilized in brake
drum and rotors throughout the 2. ALUMINIUM METAL MATRIX
history of automobile COMPOSITE WITH FLY ASH AS
REINFORCEMENT.
manufacturing.
In the first composite SiC
acts are ceramic inclusions which are MECHANICAL PROPERTIES OF
incorporated in the aluminium metal COMPOSITE MATERIALS
alloy.
In the second composite ADVANTAGES OF COMPOSITE
fly ash acts as inclusions in aluminium MATERIALS
metal matrix.This composite has 1. Composite materials have density
higher stiffness , strength and wear compared to other ferrous
resistance. materials.
The fly ash particles are
obtained as by product of burning of 2. Composite materials have high
black coal in power stations and wear resistance and high thermal
therefore very low in cost. Fly ash is conductivity.
made up of tiny spheres and consists of
3. Composite materials have high
silicon, aluminium, iron and calcium
frictional coefficient .
oxides. The fly ash particles are
collected by electrostatic precipitator 4. Along the length of fiber the
from the exhaust gases in power composite have high strength and
stations. stiffness.
The fly ash particles were incorporated
into AL alloys by mechanical mixing
and casting.
MATERIA ULTIMATE YIELD
L TENSILE STRENGTH( ELONGATION( BRINELL
STRENGTH(MPa)) MPa) %) HARDNES
S
Aluminiu
m MMC
with SiC
278 207 6 80
as
reinforce
ment
Aluminiu
5. FEA AND BRAKE DRUM m MMM
with
327 318 2.5 135
MODELING fly ash as
reinforce
5.1 FINITE ELEMENT METHOD ment
Finite element method is a technique the continuum is not known, let as assume
in which a given domain is represented as that the variation of field variable inside
a collection of simple domains, called the finite element can be approximated by
finite elements. The finite element method a simple function.
differs from the traditional variational These approximating functions (also
methods in the manner in which the called interpolation models) are defined in
approximation functions are constructed. terms of the field variables at the nodes.
In the finite element method, the When field equations for the whole
actual continuum of body of matter like continuum are written, the new unknowns
solid, liquid or gas is represented as an will be the nodal values of the fixed
assemblage of sub-divisions called finite variables. By solving the field equations,
elements of domains. These elements are which are generally in the form of matrix
considered to be interconnected at equations, the approximating functions
specified joints or nodal points. The nodes define the field variable throughout the
usually lie on the element boundaries assemblage of elements.
where adjacent elements are considered to 5.2 ANSYS PACKAGE
be connected. Since the actual variation of ANSYS is a general purpose
the field variables (like displacement, finite element modeling package for
temperature, pressure or velocity) inside numerically solving a wide variety of
mechanical problems. ANSYS – Finite
element analysis software enables specify a table of temperatures along with
engineers to perform the following tasks: the corresponding values of film
Build compute models or coefficient at each temperature.
transfer CAD models of 5.4.1 TYPES OF THERMAL
structures, products, ANALYSIS
components or system ANSYS supports two types of
Apply operating loads or thermal analysis:
other design performance 1. A steady-state thermal analysis
conditions. determines the temperature
Study physical responses, distribution and other thermal
such as stress levels, quantities under steady-state
temperature distribution or loading conditions. A steady-
the impact of state loading condition is a
electromagnetic situation where heat storage
fields.Optimize a design effect varying over a period of
early in the design stage 5.3 time can be ignored.
TYPES OF ANALYSIS 2. A transient thermal analysis
The analysis types used in determines the temperature
ANSYS, whether the problem is linear or distribution and other thermal
nonlinear are: quantities under conditions that
Static/dynamic structural vary over a period of time.
analysis
Thermal analysis 5.4.2 TYPES OF THERMAL LOADS
1. Constant Temperature (TEMP)
Fluid analysis
These are DOF constraints usually
Acoustic and Electro- specified at model boundaries to
Magnetic analysis impose a known, fixed
5.4 THERMAL ANALYSIS temperature.
A thermal analysis calculates the 2. Heat flow rate
temperature distribution and related These are concentrated nodal loads,
thermal quantities in a system or used mainly in line-elements
component. Typical thermal quantities of models where we can not specify
interest are: convections and heat fluxes. A
The temperature positive value of heat flow rate
distribution indicates heat flowing into the
The amount of heat lost or node. If both TEMP and HEAT are
gained specified at a node, the temperature
Thermal gradients constraint prevails.
Thermal fluxes 3. Convection (CONV)
The ANSYS program handles all Convections are surface loads
the three primary modes of heat transfer: applied on exterior surfaces of the
conduction, convection and radiation. The model to account for the heat lost
convection effect can be incorporated as a to (or gained from) a surrounding
surface load on conducting solid elements medium. They are available only
or shell elements. The convection film for solids and shells.
coefficient and the bulk fluid temperature 4. Heat Fluxes
at a surface are to be specified; ANSYS Heat fluxes are also surface load.
then calculates the appropriate heat Used when the amount heat
transfer across the surface. If the film transfer across a surface is known,
coefficient depends upon temperature, you or is calculated through a
FLOTRAN CFD analysis. A Older cars and trucks have drum brakes at
positive value of heat flux indicates all four wheels. Newer vehicles using
heat flowing into the element. Heat drum brakes have them only in the rear.
flux is used only with solids and 5.7 DIMENSIONS OF THE BRAKE
shells. An element face may have DRUM
either CONV or HFLUX (but not Outer diameter - 0.47 m
both) specified as a surface load. If Inner diameter - 0.395 m
both are specified on the same Depth - 0.187 m
element face, ANSYS uses what Depth of rib - 0.048 m
was specified last. Rib diameter - 0.486 m
Hole diameter - 0.022 m
5. Heat Generation Rates (HGEN) Hub diameter - 0.223 m
Heat generation rates are applied as Outer edge champher - 45 x 0.005 m
“body loads” to represent heat Inner edge champher - 45 x 0.01 m
generation within an element, for Eight holes with center distance- 0.115m
example by a chemical reaction or
an electric current. Heat generation 5.8 MODELING OF THE BRAKE
rates have units of heat flow rate DRUM
per unit volume. Using the above dimensions,
5.5 FIELDS OF APPLICATION modeling of the brake drum is done. PRO-
Aerospace E Wild fire.2 software is used in modeling
Automotive industries of the brake drum. The modeling can also
Biomedical be done using ANSYS.10 package, but its
Bridges and buildings little difficult when compared to PRO-E.
Heavy Equipments & The modeling of the brake drum is done as
Machinery a single unit i.e. there is no need for any
assembly of components.
MEMS – Micro
Electromechanical Systems
Sporting goods.
3.8*105N/M2
FIG-6.4: STATIC STRESS INDUCED IN
CAST IRON BRAKE DRUM
FOR A HYDRAULIC 7. THERMAL ANALYSIS OF THE
PRESSURE OF 7.6*105 N/M2
BRAKE DRUMS
7.1 BRAKE POWER DEVELOPED IN
A BRAKE DRUM
The brake drum is a structural
component that converts the kinetic energy
of a moving vehicle into thermal energy in
the process of slowing down or stopping
of a vehicle. Cast iron is the dominant
FIG-6.5: STATIC STRESS INDUCED material normally found for this
IN MMC BRAKE
DRUM WITH SILICON application. In vehicles, the drum is used
CARBIDE AS
REINFORCEMENT in rear brakes and disc in front brakes. The
FOR HYDRAULIC
PRESSURE OF 7.6*105 researchers around the world are taking
N/M2
constant effort towards the development of
a new brake system, brake design and
brake material. When the pedal is actuated,
the wheel cylinder piston forces the lining
against the rotating drum. Due to the
friction between the stationary lining and
the rotating drum, a drag force is
FIG-6.6: STATIC STRESS INDUCED IN MMC
developed in a direction opposite to the
WITH FLY ASH AS
REINFORCEMENT FOR A direction of rotation. Therefore, the brake
HYDRAULIC PRESSURE OF power developed in brake drum can be
7.6*105 N/M2
expressed as follows.
BP = 1000 KW
d = 7228 Kg / m3
cd = 419 J / Kg K
d = 11137 cm3
So
T = 1000000 * 5 / 7228 * 419 * 0.011137=148.24 K= 150 K
Similarly for a hydraulic pressure value of 7.6 * 105 N / m2 (BP= 2000KW). We have
T = 2000000 * 5 / 7228 * 419 * 0.011137= 298 K
In the case of MMC brake drum with silicon carbide as reinforcement, for a hydraulic
pressure value of 3.8 * 105 N / m2 and a braking time of 5 sec, we have
T = BP tb / d cd d
BP = 1000 KW
d = 2785 Kg / m3
cd = 970 J / Kg K
d = 11137 cm3
So
T = 1000000 * 5 / 2785 * 970 * 0.011137= 165 K
Similarly for a hydraulic pressure value of 7.6 * 105 N / m2 (BP= 2000KW), we have
T = 2000000 * 5 / 2785 * 970 * 0.011137= 330 K
In the case of MMC brake drum with fly ash as reinforcement, for a hydraulic pressure
value of 3.8 * 105 N / m2 and a braking time of 5 sec, we have
T = BP tb / d cd d
BP = 1000 KW
d = 2300 Kg / m3
cd = 1170 J / Kg K
d = 11137 cm3
So
T = 1000000 * 5 / 2300 * 1170 * 0.011137= 168 K
Similarly for a hydraulic pressure value of 7.6 * 105 N / m2 (BP= 2000KW), we have
T = 2000000 * 5 / 2300 * 1170 * 0.011137= 337 K
Using the above temperature values, coupled field thermal analysis is carried out and
the thermal stresses induced in each of the three materials is found out. The reference
temperature is this case is taken as 273 K.
FIG-7.1: THERMAL STRESS INDUCED IN CAST IRON BRAKE DRUMFOR TEMPERATURE
DIFFERENCE OF 150 K
FIG-7.3: THERMAL STRESS INDUCED IN MMC BRAKE DRUM WITH FLY ASH AS
REINFORCEMENT FOR TEMPERATURE DIFFERENCE OF 168 K
FIG-7.4: THERMAL STRESS INDUCED IN CAST IRON BRAKE DRUMFOR TEMPERATURE
DIFFERENCE OF 298 K
FIG-7.5: THERMAL STRESS INDUCED IN MMC BRAKE DRUM WITH SIC AS REINFOR
CEMENT FOR TEMPERATURE DIFFERENCE OF 330 K
FIG-7.6: THERMAL STRESS INDUCED IN MMC BRAKE DRUM WITH FLY ASH AS
REINFORCEMENT FOR TEMPERATURE DIFFERENCE OF 337 K
From structural analysis, the static stresses induced in the three brake drums namely
cast iron, silicon carbide and fly ash composite brake drums are found out.
Table.8.1 Deflection and static stress values for three materials for a hydraulic pressure
of 3.8 * 105 N/m2
Parameters Cast Iron MMC with Silicon Carbide MMC with Fly Ash
as reinforcement as reinforcement
Deflection(m)
0.473 * 10-5 0.338 *10-5 0.29 * 10-5
Stress
minimum(N/m2) 13391 13391 12334
Stress
maximum(N/m2) 0.259 * 107 0.259 * 107 0.239 107
Table.8.2 Deflection and static stress values for three materials for a hydraulic pressure
of 7.6 * 105 N/m2
Parameters Cast Iron MMC with Silicon Carbide MMC with Fly Ash
as reinforcement as reinforcement
Deflection(m)
105 *10-4 0.676 * 10-5 0.622 * 10-5
Stress
minimum(N/m2) 26782 26782 26430
Stress
maximum(N/m2) 0.519 * 107 0.519 * 107 0.512 * 107
Table.8.3 Deflection and Thermal stress values for three materials for a hydraulic
pressure of 3.8 * 105 N/m2
Parameters Cast Iron MMC with Silicon Carbide MMC with Fly Ash
as reinforcement as reinforcement
Deflection(m)
0.001121 0.001134 0.000462
Thermal stress
minimum(N/m2) 0.714 * 107 0.603 * 107 0.327 * 107
Thermal stress
Maximum(N/m2) 1.05 * 109 0.885 * 109 0.481 * 109
Table.8.4 Deflection and Thermal stress values for three materials for a hydraulic
pressure of 7.6 * 105 N/m2
Parameters Cast Iron MMC with Silicon Carbide MMC with Fly Ash
as reinforcement as reinforcement
Deflection(m)
0.002241 0.002262 0.000918
Thermal stress
minimum(N/m2) 0.143 * 108 0.12 * 108 0.0651 * 108
Thermal stress
Maximum(N/m2) 0.210 1010 0.176 * 1010 0.0955 * 1010
In order to study the improvement of the tubes [3]. Vortex generators can be
heat exchanger surfaces, the present mounted in the fin–tube heat exchangers
numerical study investigates the use of using following two common
oval tubes in place of circular tubes, with configurations, (i) common-flow-down
delta-winglets mounted in front of the oval and (ii) common-flow-up, as proposed by
Pauley and Eaton [4]. Fig. 2 presents a in a common-flow-down configuration in
sectional view of the suggested front of the oval tube. It may be mentioned
arrangement with the delta-winglets placed that the study of low Reynolds number
simulations in the present work is not for often laminar and the Reynolds numbers in
computational simplification. Usually, the the passages are in the range of low and
fin spacing is so small and the mean moderate [5].
velocity range is such that the flows are
The dimensions used are those of a Simulations were carried out and the heat
proposed design. The other winglet of the transfer rates, pressure drop and the flow
first winglet pair is placed symmetrically behavior were analyzed for each and every
about the centreline. case varying the orientation of the winglet.
∂T ∂T ∂T ∂ 2T ∂ 2T ∂ 2T
ρ C p ( u + v + w ) = k 2 + 2 + 2 + φ 1 -4.5
∂x ∂y ∂z ∂x ∂y ∂z
Body force term is neglected as the flow comes under forced convection. So fx, fy,
and fz are zero.
The pressure drop and the average nusselts number for various configurations are
tabulated below.
NON-CONVENTIONAL REFRIGERATION
(MAGNETIC REFRIGERATION)
1. S.VIJAY 2. S.VENKATRAMAN
KONGU ENGINNERING COLLEGE , MECHATRONICS , PERUNDURAI ,
ERODE
EMAIL ID: vijayspn12@gmail.com
KONGU ENGINNERING COLLEGE , MECHATRONICS , PERUNDURAI
,ERODE
EMAIL ID: raman.kongu@gmail.com
Vessel
A fan blows air past this cold fluid into caloric Beds, where it continues to
the freezer to keep the freezer cycle around the loop. However, the
temperature at approximately 0° Magneto caloric beds simultaneously
The heat transfer fluid then gets move up and down, into and out of
heated up to 80°F as it passes the magnetic field.
through the copper plates adjoined by
the magnetized warmer Magneto
Driving Shaft
Pump Electro
Magnets
Cold To
To Hot
Heat Fa
Atmosph Heat
Exchan n
ere Exchan
ger ger
Vessel
Figure below, shows how the temperature of 0oF. Refrigerators
cold air from the freezer is maintain a temperature of 39oF. The
blown into the refrigerator by refrigerator will be insulated with
the freezer fan. The temperature of polyurethane foam, one of the most
the refrigerator section is kept around common forms of insulation
39°F. available. The refrigerator is kept
cool by forcing cold air from the
The typical household freezer into the refrigerator by using
refrigerator has an internal volume of a small fan. The control system for
21 cu.ft, where the freezer represents machining the desired internal
approximately 30% of this volume. temperatures consists of two
Freezers are designed to maintain a thermostats with on/off switches.
FIG : REFRIGERATOR WITH A FREEZER FAN
The freezer thermostat regulates the temperature by turning the
compressor off when the temperature gets below 0oF. A second thermostat
regulates the fan that cools the refrigerator to 39o
4.0 RESULTS OBTAINED FOR VARIOUS MAGNETIC FIELDS :
REFERENCES:
0.2
PL1 0 50
P1
100 150 200
Piston -0.1
Angle along the ring (Degrees)
Ring
a Fig.5 Ring deformation
D
d Analysis of compression ring under operating
Pb
conditions was carried out to find out the twist
PL2
of the ring at operating conditions i.e. at
Oil Film pressure conditions, compression ring shapes
Up Force were analyzed individually as well as in
assembled condition. The results of Assembly
analysis indicate that displacement of ring also
F Down = π. d.a. (P2+Pb)/2 occurs due to piston load acting on it. All types
FUp = π.d. a. Pb +Fi of compression rings were modeled with an
allowable initial twist of 0.65º within the
groove and were subjected to the pressure load.
Fig.4 Modal of pressure distribution in The results obtained are as follows: All
radial direction compression rings exhibit positive twist during
compression and negative twist during suction
II. ANALYSIS OF RING DEFORMATION stroke. Napier ring exhibits maximum twist
BEHAVIOR USING FEA value than any other cross-section during
Different compression ring cross- compression stroke. The twist values of
sections were analyzed for ring-twist during proposed cross-sections is below the twist value
installation and at operating conditions and the of Napier ring but greater than that of plain
cross-sections with twist less than the existing ring.
cross-section were considered for Prototype
development and experimentation. Fig shows
the twisting behavior under installation III. DOE FOR COMPRESSION RING
The Taguchi method of experimental design N ±2N
is used during initial design and prototype
2nd Ring :17.35 ± 2nd ring : 13
testing to determine optimal settings for the
product and process parameters. Considering 2.3 N ±2N
the results of the experimental design the
products are then designed to minimize any
detrimental effect. The proper choice in the
design phase of parameter settings for both the
product and process can reduce costs and
improve quality. There are several advantages Interactions to be estimated
to experimental design, they are as follows: Taper Angle Tangential tension
1. Identifying the key decision variables
that control the process
2. Development of a new process for Table 2 Control Factors
which historical data is unavailable. Factors Value Factors Value
3. Identifying important factors and their Compressor Manual Compressor 1500 rpm
associated levels that maximize yield Assembly throughout speed
and reduce overall cost.
the
4. Reduces lead time between design and
manufacturing. experiment
Compressor Same Loading 780sloading
To assess the effect of piston ring parameters
such as Running face taper angle, tangential body cycle /30s
tension, bevel angle and bevel height on blow- unloading
by. Thereby a DOE is performed to assess the
significance of these factors on blow-by of the Linear Graph
compressor. Designs of Experiments were
formulated such that Process would be simpler
and contain correlating factors. Therefore two
DOE were performed using L4 orthogonal
array. AXB
A B
Response: Oil carry over and Blow-by Orthogonal Array (No: of replications
Factors and levels
planned: 2)
Table 1 Factors and levels
Table.3 Mean response plot
0.90
Table 5. Annova Results
0.80
Factor Factor Interaction 0.70
A B AXB 1 2
1 1 1 6.8 7 0.50
2 1 2 9.6 10.2
Oil carry
0.30
Q table Target
2 2 1 9 9.4 0.20
0.10
0.00
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
From the mean response plot and Annova
Duration Duration (h)
(hours)
results the following can be inferred:
Fig.6 Oil Carry Over
Factor A i.e. Running face taper angle is the
most significant factor affecting blow-by The oil carry over trend is well within the Q-
variation. Factor B i.e. Tangential tension has
Table limit. Average Oil carry over 0.02 g/h
significant influence on blow-by variation. No
interaction exists between Running face taper
angle and tangential tension. The running face
taper angle value for a ring-pack should be
optimized such that it yields low blow-by. The 6.2
5.4
5.3 5.3
5.26 5.26
Duration (hours)
Design of Experiments a ring-pack with low
blow-by and optimum configuration of running
face taper angle and tangential tension was Fig 7. Blowby
selected for endurance testing. Observed blow-by is within the project limit of
6 litres/ minute
References
8. Hippoliti, R., 1993, “FEM Method For 15. Rice, R. C., ed., 1997, “SAE Fatigue
Design and Optimization of Connecting Design Handbook”, Society of
Rods for Small Two-Stroke Engines,” Automotive Engineers, Warrendale, 3rd
Small Engine Technology Conference, PP. Edition.
217-231.
16. Sarihan, V. and Song, J., 1990,
“Optimization of the Wrist Pin End of an
Automobile Engine Connecting Rod With
9. James R. Dale, 2005, “Connecting Rod an Interference Fit”, Journal of
Evaluation”, Metal Powder Industries Mechanical Design, Transactions of the
Federation, January Edition. ASME, Vol. 112, PP. 406-412.
2Fe + O2 → 2FeO
Abstract Due to corrosion forming cold end airpreheater
Generally in the sugar mills, they tubes are damaged with in few years. To avoid
are using bagasse as the fuel, to burn the corrosion, the atmosphere air is preheated by
bagasse primary and secondary air is the steam preheater from the exhaust steam.
supplied. Forced draught fan supply By increasing the temperature of the
primary air and sail air fan supply atmosphere air prevents the corrosion in air
secondary air. Primary air is sucked by preheater tubes, which is supplied to furnace.
forced draught fan and passed through the Installing the steam preheater in between FD
airpreheater to furnace. In airpreheater fan and APH for increasing the temperature of
the flue gases coming out of economizer are air at the same time pressure drop will occur
further utilized for preheating the due to the number of tubes available in the
atmosphere air before supplying to the steam preheater. To minimize the pressure
furnace. Atmosphere wet air enters into the drop in the steam preheater should increase the
airpreheater, reacts with the metal tubes area of flow between the tubes. Calculate the
causes corrosion. The main aim of this velocity of the atm air and mass flow rate of
project is to avoid the corrosion of cold end air supplied by the forced draught fan. Design
in airpreheater and increase temperature should be effective for above dew point
of the supply air to furnace. To resist the temperature (65∞) to avoid corrosion. The
corrosion, the atmosphere air temperature forced draught fan supply air heated by
is increases up to above dew point exhaust steam.To maintain the pressure of the
temperature (65°C). Air flow analysis takes supply air to furnace, air duct modify depends
place from FD fan to furnace using upon flow velocity.. In air preheater analysis
computational fluid dynamics. calculate the temperature of supply air before
Keywords: Airpreheater, corrosion, installating steam preheater. Boiler efficiency
dewpoint temperature, Computational
fluid dynamics. increases by increase the temperature of the
supply air. The air flow should be analysis
I. INTRODUCTION from forced draught to furnace using
computational fluid dynamics.
Wet air enter into the air preheater, reacts
with the metal tube causes corrosion. The II.FORCED DRAUGHT FAN
main aim of the
Project is to avoid the corrosion of cold end in Fan is to move a mass of gas or
air preheater and increase the temperature of vapour at the desired velocity by the action
the supply air to furnace. of rotor. For achieving this objective there
The principal reaction is is a slight increase in the gas pressure
across the fan rotor. However the main
purpose of fan is to move a gas without an
appreciable increase in its pressure. installed at inlet to the air-preheater.
Axial fan have higher capital cost. They handle cold air, so they have less
Axial fan handles the small volume of maintenance problem, consume less
air. In the centrifugal fan, gases are power capital and operating cost are
accelerated radially through curved or lower is the highest for backward
flat impeller blades from rotor to a curved and lowest for the forward
spiral or volute casing. FD fans are curved blades
.
A. SPECIFICATION
B AIR SPECIFICATION
In steam preheater 3 tones per hour of mass of steam utilized for attain the dew
point temperature. Table II shows temperature difference with number of tons.
B.VARIOUS LOSSES
Computational fluid
dynamics analysis takes place from
forced draught fan to furnace by
using fluent with Air duct is
modeled by gambit which is an
integral division of Fluent. After
modeling the air duct using the
given co-ordinates the model is
meshed using Gambit Mapped
mesh. Quadrilateral cells were
used for this simple geometry
because they can be stretched
easily to account for different size gradients in different
directions. The coupled solver is bases of any CFD problem are the
recommended when dealing with Navier-Stokes equations, which
applications involving high speed define any single-phase fluid flow.
flow. These equations can be simplified by
removing terms describing viscosity
A. COMPUTATIONAL FLUID to yield the Euler equations. These
DYNAMICS equations can be simplified by
removing terms describing viscosity
Computational fluid to yield the Euler equations. Further
dynamics (CFD) is one of the simplification, by removing terms
branches of fluid mechanics that uses describing vorticity yields the full
numerical methods and algorithms to potential equations. Finally, these
solve and analyze problems that equations can be linearized to yield
involve fluid flows. The fundamental the linearized potential equations.
The stability of the chosen
discretization is generally established
numerically rather than analytically
as with simple linear problems. The
Where Q is the vector of
Euler equations and Navier-Stokes
conserved variables, F is the vector
equations both admit shocks, and
of fluxes V is the cell volume, and
contact surfaces. The governing
is the cell surface area. After
equations are solved on discrete
modeling the air duct given co-
control volumes. FVM recasts the
ordinates the model is meshed using
PDE's of the N-S equation in the
Gambit Mapped mesh. Quadrilateral
conservative form and then discretize
cells were used for this simple
this equation. Moreover this method
geometry because they can be
is sensitive to distorted elements
stretched easily to account for
which can prevent convergence if
different size gradients in different
such elements are in critical flow
directions. The coupled solver is
regions. This integration approach
recommended when dealing with
yields a method that is inherently
applications involving high speed
conservative (i.e. quantities such as
flows. The Spalart-Allmaras model
density remain physically
was designed specially for aerospace
meaningful)
applications involving wall-bounded
has been shown to give good results
for boundary layers subjected to
adverse pressure gradients.
Before After
Content modification modification
of air duct of air duct
FIGURE IV VELOCITY
94 mm of 72 mm of
Pressure VARIATION FOR
Hg Hg BEFORE MODIFICATION
drop OF AIR DUCT
Outlet
115.3 ºC 147.7 ºC
temperatur
e of APH
15.11
Air 1.005
0.833
Steam 4.4895
VIII. CONCLUSION
Driving Shaft
Magnetocalori
c Bed
Copper
Plates
Pump Electro
Magnets
Cold To
To Hot
Heat Fa
Atmosph Heat
Exchan n
ere Exchan
ger ger
Vessel
Figure below, shows how the cold air temperature of 39oF. The refrigerator
from the freezer is blown into the will be insulated with polyurethane
refrigerator by the freezer fan. The foam, one of the most common
temperature of the refrigerator forms of insulation available. The
section is kept around 39∞F. The refrigerator is kept cool by forcing
typical household refrigerator has an cold air from the freezer into the
internal volume of 21 cu.ft, where refrigerator by using a small fan. The
the freezer represents approximately control system for machining the
30% of this volume. Freezers are desired internal temperatures consists
designed to maintain a temperature of two thermostats with on/off
of 0oF. Refrigerators maintain a switches.
FIG : REFRIGERATOR WITH A FREEZER FAN
5.0 ADVANTAGES :
9. Very low temperatures of the order of reduced
10. 001K can be obtained.
11. Required pressures are obtained without the aid of a compressor.
12. Does not produce toxic gases and chloro-fluoro carbons, thus reducing
ozone layer depletion.
13. Efficiency and compactness are increased where as power consumption is
reduced.
14. Larger temperature swings that will allow the technology to provide the
Cooling power required for specific markets, such as home refrigerators,
air conditioning, electronics cooling, and fluid chilling can be obtained.
15. The unit runs virtually silent and is vibration free.
16. The magnetic material in the regenerator bed will ever need to be replaced
when changing refrigerant to achieve a different temperature range.
17. When a better magnetic material is developed, the refrigerator will not
need to be redesigned.
6.0 APPLICATIONS:
7.0 REFERENCES:
A textbook on “CRYOGENIC ENGIMEERING” by V.J. Johnson.
Refrigeration and Air-conditioning” by Arora & Domkundwar.
ELECTROMAGNETIC ENGINE
V.Nagakarthik
Kongu Engineering college, erode, Tamilnadu.
ero.naga@gmail.com
Contact No: 9994189874
ABSTRACT: which is also be discussed in this
The transport is the main paper in further….
important sector for our mankind.
This tends us to depend upon the CONTENTS:
10) Introduction
fissile fuels. This in turn increases
11) Construction
the global warming. The mining and 12) Explanation of the components
13) Working of Electromagnetic
other illegal activities against nature
engine
also plays a major role in every 14) Analytical salvation
15) Our project details
increase of global warming. This
16) Areas to be concentrated
can be avoided by using our 17) Ways to increase the efficiency
18) Problems to be solved
renewable energy completely which
10) Conclusion
is available. Renewable energy like 11) Reference
INTRODUCTION:
solar, wind, etc. are well versed to us,
we also know that there vehicles Today the rate of increase of fossile
fuels is so high. This makes increases
available which works on the electric
a dangerous monster called Global
and this power can also be get by warming.. This lets us to search for an
another way for the transport. This can
using solar radiation.
be avoided by using the electric
But in that vehicles we use A.C vehicles. But in that vehicles we use
electric motors to run it. But this paper
series motor run the vehicle. This
is an innovation idea of running the
paper delivers you an innovation engine completely with the help of
Electric power but not with the fuel.
idea of engine which works
completely on electromagnetic
radiation. Here we discuss about the CONSTRUCTION:
construction and working of the
electromagnetic engine which is
done as project in our college. Since
this paper also revels the problems
that are faced during this project
work. We will also discuss about the
areas which are to be concentrated
during the project work. Here the
analytical salvation is also done EXPLANATION:
Sensing Unit: Electromagnatic engine:
Sensint unit senses the weight and This is the working part in our
sends the data to control unit. This project which is the reason for moving
may consist of sensors, weighting of the car.
machine.
Control Unit:
This plays a major role in the
working of the car. This controls the
working of the engine. This selects
and sends the required initial current
and voltage so that there is high torque
initially. The voltage and ampere can
be changed by nob but the initial
voltage and ampere cannot be
changed/lowered if same load is When the supply is given to the
placed. The required initial (V&A) electromagnet-A side, then the
can be selected from a microprocessor. piston gets attracted towards it.
When the supply is given to the
Battery: electromagnet-B side, then the
piston gets attracted towards it.
The battery is the heart of the
But when one electromagnet is
setup. This supplies current to the
working other is operated in off
whole setup. This must be charged
condition.
frequently by putting anything like
flywheel,etc. This gives a to and fro motion
and this can be used for any
work.
ANALYTICAL SOLVATION:
Since
Ns=
120*(f/p)
By this equation we can tell that by increasing the frequency of changing the poles
B α (µo * n * we can increase speed
I)
Where
B- magnetic flux
n- constant
µo- Permittivity – Constant
Therefore:
BαI
Thus we also know that
Force= B * I * L
Where
L- Length of piston – constant
I – Current passing through the electromagnet
Force α B * I * L
Since,
BαI
Therefore,
Force α I^2
We know that
Torque = B * I * A
Where
B- Area of piston – constant
Torque α B *
I
Since,
BαI
Finally,
Torque α I^2
Thus by increasing the current the torque can be increased and the graph will be as
shown.
OUR PROJECT DETILS:
In our project we have constructed a relay circuit to give the supply manually.
Then in a our engine we gave the load as spring and piston weight.
We constructed like that the piston has to move against the spring and the
piston initially. So we are only able to move with a very few length.
Since we faced many problems during this project and all that is needed to this
project is the proper discussion and the way of doing.
REFRENCE:
Since this is my won idea I only developed this and I referred so of the webs and
information in the internet
And I asked about the information about this work.
I also referred the 12th books for the analytical solvation of this project.
EXPERIMENTAION RESULTS
Fe 2000
1500
Fl 1000
l
Force( N)
Fb 500
0
Fn m
-500
Fm n
-1000
-180 -160 -140 -120 -100 -80 -60 -40 -20 0 20 40 60 80 100 120 140 160 180
Crank angle (degree)
Fig.3 Fup and Fdown
Fl = P2 x l,Fm= (PL1+PL2)x m/2, Fn= PL2
xn
Fo = Fl +Fm+ Fn , Fl=h (Pe+Pb)
Fig.2 Modal of pressure
distribution in radial direction
Pb
0.4 Napier ring
P2
P2
0.2
Plain ring
Ring 0.1
a
0
D 0 50
P1
100 150 200
d
-0.1
Angle along the ring (Degrees)
Angle along the ring (Degree) Napier Plain Proposed shape1
PL2 Pb
Oil Film
Up Force
Fig.5 Ring deformation
F Down = π. d.a. (P2+Pb)/2 Analysis of compression ring under
FUp = π.d. a. Pb +Fi operating conditions was carried out to find
out the twist of the ring at operating
Fig.4 Modal of pressure distribution in conditions i.e. at pressure conditions,
radial direction compression ring shapes were analyzed
individually as well as in assembled
II. ANALYSIS OF RING condition. The results of Assembly analysis
DEFORMATION BEHAVIOR USING indicate that displacement of ring also
FEA occurs due to piston load acting on it. All
types of compression rings were modeled
Different compression ring cross-sections with an allowable initial twist of 0.65º
were analyzed for ring-twist during within the groove and were subjected to the
installation and at operating conditions and pressure load. The results obtained are as
the cross-sections with twist less than the follows: All compression rings exhibit
existing cross-section were considered for positive twist during compression and
Prototype development and experimentation. negative twist during suction stroke. Napier
Fig shows the twisting behavior under ring exhibits maximum twist value than any
installation condition. Napier ring other cross-section during compression
experiences both positive as well as negative stroke. The twist values of proposed cross-
twist along the ring cross-section sections is below the twist value of Napier
Plain ring does not exhibit any twist pattern ring but greater than that of plain ring.
except for some points. Proposed shape 1
has a positive twist, which is desirable.
Proposed shape 2 experiences positive twist III. DOE FOR COMPRESSION RING
that can be efficient in sealing the
compression chamber. Proposed shape 3 The Taguchi method of experimental design
conforms to the twist pattern of plain ring. is used during initial design and prototype
However, it has higher twist values than testing to determine optimal settings for the
plain ring. product and process parameters. Considering
the results of the experimental design the
products are then designed to minimize any
detrimental effect. The proper choice in the
design phase of parameter settings for both
the product and process can reduce costs and
improve quality. There are several N ±2N
advantages to experimental design, they are
2nd Ring :17.35 2nd ring : 13
as follows:
5. Identifying the key decision ± 2.3 N ±2N
variables that control the process Interactions to be estimated
6. Development of a new process for
which historical data is unavailable. Taper Angle Tangential tension
7. Identifying important factors and
their associated levels that maximize Table 2 Control Factors
yield and reduce overall cost.
8. Reduces lead time between design Factors Value Factors Value
Compresso Manual Compressor 1500 rpm
and manufacturing.
To assess the effect of piston ring parameters r Assembly throughout the speed
such as Running face taper angle, tangential experiment
Compresso Same Loading 780sloading
tension, bevel angle and bevel height on
blow-by. Thereby a DOE is performed to r body cycle /30s
assess the significance of these factors on unloading
blow-by of the compressor. Designs of
Experiments were formulated such that Linear Graph
Process would be simpler and contain
correlating factors. Therefore two DOE were
performed using L4 orthogonal array. AXB
A B
tension has significant influence on blow-by The oil carry over trend is well within the
variation. No interaction exists between
Q-Table limit. Average Oil carry over 0.02
Running face taper angle and tangential
tension. The running face taper angle value g/h
for a ring-pack should be optimized such
that it yields low blow-by. The optimized
value is found to be 1º for first ring and 3º
for second ring, this configuration is used 6.2
Blow-by litres/minute
5.8
Blow by (liters/min)
5.4
5.3 5.3
5.26 5.26
1.00
0.90 V. CONCLUSION
0.80
0.60
0.30
Q table Target for blow-by and oil carry over in
0.20 compression ring bedding-in (worn out)
0.10
condition and the results are observed to be
0.00
0 300 600 900 1200 1500 1800 2100 2400 2700 3000
within the project limit. The effect of ring
Duration Duration (h)
(hours)
parameters like running face taper angle,
Tangential tension, on oil carry over
Fig.6 Oil Carry Over variation were confirmed using Design of
Experiments
REFERENCES
email id:sundar.mtrs@yahoomail.com
chemical reactions take place and lead to In UDS gasifier the volatile products like
generation of producer gas . Producer gas tar are carried out along with producer
derived from biomass contains combustible gas from gasifier. Tar contained in the gas
components i.e. Carbon monoxide, hydrogen can be depositedon
DRYING
and small amount of methane, non- valves ands it will affect
combustible components like co2, nitrogen, the pressure at the end of
dust and condensable tars. Dust particles will compression stroke PRYOLISIS
lead to increase wear and increase
maintenance. Tar content causes coking in • Down Draught
cylinders, sticks in valves, cases can occur System OXIDATION
that require dismantling of engine for
cleaning or complete engine replacement. Calorific value of ags
Dust particles from the hot gases coming out obtained from theUDS is REDUCTION
of gasifier can be removed by passing high, even then it is not used in engine
through cyclone. Sprinkling of water from applications. In DDS the tar have to pass
top of the cyclone causes the condensation of through the oxidation and reduction
tar. zones, hence cracking of tars take place
to make acceptable gas for IC engine.
Three common design of gasifier.
Cross draught system:
• Up Draught System (UDS)
Here the flow of gas is across the gasifier
and it holds a position in STAGES
OF CONVERSION between UDS and
DDS for its merits and demerits.
Transition Phase, 3 turbulent phases, and 4. considerable inert gas presence in the
Termination. It is possible to reduce burn producer gas.
duration through turbulence in phase 2 and 3.
The turbulent burning velocity varies directly It can be seen that highest c.r. that can be
with initial temperature and decreases with used is limited by hydrogen in producer
increase in pressure with higher c.r., the gas. On average, octane number of
burning velocity would reduce by pressure producer gas can be 105.the critical c.r.
alone, but the increase in temperature and and octane number requirement of
reduction in exhaust gas dilution would be producer gas and gasoline operated SI
expected more than compensate for such an engine is presented in graph.
effect. Burning velocity thus would likely
increase. Producer gas stoichiometric mixture is
not comparable with the mixture of all
combustible gases because of higher
amount of nitrogen. Nitrogen presence in
the producer gas increases the ignition
delay and therefore leads to knock
suppression.
from no load condition to full load condition at For obtaining the base line data engine was first
constant rated speed on CNG with compression ratio variatio n of exhaust temp.
.
of 11 and ignition timing of 30° BTDC. The p
m600
performance of the engine in terms of power e
t 500
t 400 Exhaust
capacity and energy efficiency were the main s 300
u 200 temp.
a
parameters. Exhaust gas temperature and fuel h 100
x 0
e
consumption was also measured along with 0 2 4
load. brake power
3. Producer gas and air was adjusted such run on CNG fuel and the load test was
that engine will be operated with performed at the rated speed of the engine.
stoichometric mixture. Experiments were Compression ratio of11 and spark advance of 30°
conducted from full load to no load
was selected for the operation of the engine with
condition. If the speed of the engine is
the CNG. Results are reported bellow.
more producer gas flow rate was
CNG CR-11
O bser and results using CNG at compression ratio of 11 and
Brake
vati 30 Thermal on spark advance of 30°
Efficienc
20
y
10
0 Air Fuel
Ratio
0 2 4
BRAKE POWER
410
400
Temperature
S.A=30
390
SA=35
380
SA=40
370
360
0 2 4
Brake pow er
Brake thermal
efficiency(%)
reported here with the given data. 20
SA=40
SA=35
10
SA=30
Engine test on producer gas 0
0 2 4
As proposed earlier the engine was made to Brake pow er(kw )
run at various ignition timings at each
compression ratio with producer gas as the
fuel. First engine test was performed with the Compression ratio of 13
compression ratio of 11 at three ignition
timings and corresponding reading are By the operation of the engine with the
presented bellow in graphical format. producer gas, tar accumulated and blocked
Similarly pistons were changed with the the piston rings. Before operating the engine
designed one for the compression ratio of 13 with the new piston i.e. piston designed for
and 15 and the experimentation was carried the c.r.0f 13, valves were grinded such that
out. there will be no more leakage through the
valve. Similar procedure for the above
Compression ratio of 11 c.r.was repeated for this c.r. also. Maximum
power obtained 3.181 kw and maximum
With producer gas as fuel and c.r. of 11 brake thermal efficiency of the engine is
experiment was done at various spark 25.64% at brake torque timing of 35° BTDC.
advance (40,35,30) and the graph for With the spark advancement beyond that load
maximum brake thermal efficiency and following capability of the engine is
power output of the engine has been done . decreasing. Maximum exhaust temperature at
Maximum power obtained 3.3 kw that is de- the best efficiency was 400°c.
rating of the engine is 11.4%. Maximum
brake thermal efficiency of the engine is
25.69%, which is 2.9% more than CNG
operation.
500
Exhaust temp. 400 Compression ratio of 15
S.A=30
300
S.A=35
200
S.A=40 With completion of experiment with at c.r. of
100
13, valves were grinded and the piston was
0
0 2 4
replaced with designed one for this c.r.of 15.
Experiments were done at various spark
Brake pow er
advance (32,35) and the graph for maximum
brake thermal efficiency and power output of
the engine has been done . Maximum power
30
obtained 3.181 kW. Maximum brake thermal
25 efficiency of the engine is 28.50%.
20
S .A 30
15 S A 35
S.A 40
10
0
0 1 2 3 4
B rake power
l 30
a
m y 25
r c
e n 20 S.A=32
th ei 15
e ci
k ff 10 S.A=35
a
r e 5
B
0
0 2 4
Brake power
Exhaust Gas temperature
380
375
370
365
360
S.A 32
355
S A 35
350
345
340
335
330
0 2 4
Br ak e the rm al e fficie ancy
380
S.A=25
360
S.A=30
340
S.A=35
320
0 1 2 3
Brake pow er
original c.r. of 16.5, brake thermal efficiency with the load and spark advance where reported.
Variation of exhaust gas with load and spark advance is also presented.
30
25
Brake thermal efficiency
20
CR 11
15 CR 13
CR 15
10 CR16.5
0
0 20 40 60
Spark advance
The figure shows variation in brake thermal efficiency withn the ignition timing at various
compression ratios.the best performance has been obtained with c.r. of 15 although the power
capacity of the engines with combinations (CR=11 SA=40; CR=13 SA =35
AND CR =15 SA=35) is almost the same efficiency is maximum at the c.r of 15 with the ignition
timing of 35° BTDC.
25
20 S.A25
Brake thermal
efficiency
15
S.A=30
10
5 S.A=35
0
0 2 4
Brake pow er
Conclusion
Performance of converted engine under CNG was carried out at c.r of 11 and spark advance of 30
° BTDC. Producer gas operation has been carried out at 11,13 and 15. At each c.r. park advance
has been optimized for best performance of the engine. Results have been analysed to find the
best compression ratio and spark advance for SI producer gas engine.
9. Engine could be successfully operated at all the c.r with comparable power capacities
10. Spark advance reduce with c.r.(35° BTDC for c.r.of 13 and 15 , 40° BTDC for c.r. of 11)
11. Best performance in terms of efficiency has been obtained with c.r. of 15. efficiency I at
this c.r is more than CNG operation with comparable power.
References
Core
model
Typically the convective Heat Transfer Programming PID Algorithm in LabVIEW 8.2
coefficient is greater with forced convection LabVIEW VIs contain three main components
than with natural convection, which results in • Font Panel
improved heating of the product.
In this paper, fan with blower setup is used • Block Diagram
for forced convection. Blower along with air • Icon/Connector Pane
flow sensor is added inside the oven, air flow
sensor is used to find out the flow velocity (1) Virtual Instrumentation is a user
inside the oven. With forced convection, the interface. It can
most important variable is the velocity V and, build the front panel with controls (inputs) and
indicators (outputs)
(2) Block diagram contains the graphical
source code. Front panel object
appears as terminals on the block
(2) diagram.
(3) Icon/Connector pane
Where v is the flow velocity, k is the • Icon: graphical
permeability which depends on distance representation of a VI
between dendritic arms and volume fraction,
η here is the kinematic viscosity, P is • Connector Pane: map of the
pressure, ρL is the liquid density and g is the inputs and outputs of a VI
acceleration due to gravity. • Icons and connector
The relevant dimensionless groups are the panes are necessary to
Nusselt and Prandtl Numbers and the use a VI as sub VI
Reynolds number (Re). In using the Nusselt
1. A sub VI that is
number to calculate the heat transfer inside of another VI
coefficient c h the characteristic length L is
replaced by the hydraulic diameter H D 2. Similar to a
equation. If Re > 2000 the flow is turbulent. function in a text-
based programming the experimental setup (temperature, air flow
language rate).
The PID controller VI consists of four 3. A TRIAC controller is used to control the
Sub VIs: Proportional, integral, ampere rating of the heating coil, fan with
derivative and Sub VIs. The blower setup. It controls the ampere rating by
mathematical algorithm of PID controlling the phase angle of the input pulse.
controller is as follows The control over the phase angle will change
the voltage input and accordingly the ampere
VOUT (t) = Kp e (t) + KI ∫e(t) dt + Kd[de
rating will vary.
(t)/dt]
4. The PID controller in RS Logic PLC
Where e (t) is the error. Kp, ki, kd are
software is used for controlling the TRIAC
coefficients of proportional, integral
controller. Whenever the temperature at the
and derivative actions
bottom portion increases, the current input to
respectively.
the coil is reduced. Since the heat transfer is
SOLUTION METHODOLOGY
through forced convection, higher heat energy
The PID controller in the LabVIEW
distributes to the middle and top trays at that
software is going to be used for
time the bottom tray will also reach the same
controlling the heating coil and blower set
temperature.
up. The block diagram of this controller is
5. Whenever the temperature reaches below
shown in figure.2.
the set value, the current input is increased
accordingly. In the similar fashion, the
uniformity will be maintained throughout the
oven space.
PID
Blower
CONTROLL AMPLI
with FAN
ER FIER
COMPUTER
CONTROLS
SETUP
CONCLUSION
PID
CONTROLL
AMPLI
HOT AIR
OVEN
Experiments are conducted by placing
ER
FIER eight samples inside the oven to ensure the
Thermocouple
non uniform temperature distribution. The
Thermocouple
Lab VIEW following graphs showed the top plate and
SOFTWARE DAQ
CARD CUM CHASSIS
Air flow sensor
bottom plate having very noticeable
temperature difference. By the above
investigation it is found that there is some
Figure.2: Block diagram of the experimental contradiction arises between LabVIEW and
setup PID controller while working. In order to
overcome this limitations it is preferred to use
1. The ampere rating of the coil, air flow rate LabVIEW alone for the above investigation.
of the blower are taken as parameters which BR – Bottom Right core
control the uniform temperature distribution. MR – Middle Right Core
The cores are prepared and placed in trays BL - Bottom left core
inside the oven from the bottom to top whose ML – Middle Left core
temperatures are monitored using the TR – Top right core
thermocouples placed nearer to them. Blower M2R – Second Middle Right Core
along with air flow sensor is added inside the TL – Top left core
oven. The temperature distribution will be M2L – Second Middle Left Core
analyzed by observing the temperatures of the
cores placed inside.
2. The temperature terminals and the air flow
equipments of the oven considered will be
interfaced with the Lab VIEW 8.2 and system
model is generated in the software to monitor
[15] Chih Peng Huang, Yun Tien Chang and
Yau Tarng Juang (2008) ‘Design of fuzzy
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[17] Hung Ching Lu, Jui Chi Chang and Ming
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[27] Vittorio Romano and Francesco Marra, A Vol.115, pp. 161-166.
numerical analysis of radio frequency [31] Xiancheng Zhan, Jinyou Jiang, Shicheng
heating of regular shaped regular shaped Liu and Gongkuan Yin (1995) ‘Computer
foodstuff, Journal of Food Engineering, controlled heating system and new
Vol 84, pp.449- 457. (2008). computation for reciprocal heating
[28] Weibiao Zhou, Shin-Yee Wong and stability experiment’, International
Jinsong Hua (2007) ‘Designing process Journal of Pharmaceutics, Vol.115, pp.
controller for a continuous bread baking 167-173.
process based on CFD modelling’, [32] Yau-Tarng Juang,Yun-tien Charg and
Journal of food engineering , Vol.81, pp. Chih-Peng Huang,Design of fuzzy PID
523-524. controllers using modified triangular
[29] Weibiao Zhou, Shin Yee Wong and membership functions, Information
Jinsong Hua (2007) ‘CFD modeling of an sciences Vol.178, pp.1325-1333. (2008).
industrial continuous bread baking
process involving U - movement’,
TECHNICAL PAPERS
MANUFACTURING
Design, Fabrication and Analysis of Vision
Assisted Inspection Robot
R.Sivaramakrishnan1, V.G.Umasekar2
1
Madras Institute of Technology/Production Technology, Chennai, India
2
Madras Institute of Technology/Production Technology, Chennai, India
vgu432@yahoo.co.in
Input
Measured Error
Sampl pitch Error
pitch value in
e value in %
in mils mils
in mils
1 3 2.99 -0.10 3.33
Figure 3. Defective IC image 2 4 4.15 +0.15 3.75
3 5 5.3 +0.3 6
4 8 8.74 +0.74 9.25
Distance
measure
tool
robot
place robot
Level - 3 TL FM S JS CM
Figure 1. Manufacturing system selection hierarchy
The same approach of pairwise comparison matrix formation from the data collected through
questioner for the remaining criteria used in decision making process level 2 (Inventory,
Investment, Operating cost, Employee) are used to calculate the relative weights with respect
to the alternatives. The relative weights calculated are listed in the Table 8 for global weight
calculation; the global weight is obtained by multiplying the relative weights of criteria with
respect to alternative performance as explained in the AHP methodology to find out the
suitable manufacturing system.
TABLE VIII
ALTERNATIVE PCM & RW FOR THROUGHPUT CRITERIA
Justification Methodologies
AHP’s ease of use makes it’s a viable [41] Roger N. Wabalickis, “Justification of FMS with the
Analytic Hierarchy Process”, Journal of
method for everyone involved in the Manufacturing Systems, 1987, Vol 3, No 3, p.p.
decision analysis. The respective nature of 175-182.
pairwise comparison and the structure of [42] Vinay Datta, Sambasivarao, K.V., Rambabu Kodali
and Deshmukh, S.G., “Multi-attribute decision
AHP make computerization of the model using the analytic hierarchy process for the
technique attractive and easy. justification of manufacturing systems”, Int. Journal
Selecting a suitable manufacturing of Prod Eco, 1992, Vol 28, p.p. 227 – 234.
[43] Katsundo HItomi, “The Japanese way of
system from the alternatives is a multi- manufacturing and production management”,
criteria decision making problem. In which Technovation, 1985, Vol 3, p.p. 49 – 55.
the objectives are not equally important. [44] Eric Molleman, Jannes Slomp and Samantha
Rolefes., “The evolution of a cellular manufacturing
This paper presented AHP as a decision system – a longitudinal case study”, Int. Journal of
making method that allows the Prod. Eco, 2002, Vol 75, p.p. 305 – 322.
consideration of multi-criteria. This study [45] Charlene A. Yauch, Harold J. Steudel, “Cellular
manufacturing for small businesses: key cultural
shows that cellular manufacturing is the factors that impact the conversion process”, Journal
suitable manufacturing system for the of Operations Management, 2002, Vol 20, p.p. 593 –
617.
3. EXPERIMENTAL RESULTS
Experiments have been carried out on the EDM set-up to predict the influence of
some of the ascendant process parameters on MRR, Tool wear and over cut.
Formulas used
MRR = (initial weight – final weight of work piece)/ (density * time)
Tool wear = (initial weight – final weight of tool) / (density * time)
FIG .2. 20V, 5.5A, 50µsec, 19min FIG.3. 40V, 5.5A, 20µsec, 13min
The table shows that experimental results for copper
S.NO Voltage Current Pulse Mach. MRR Tool wear Over cut(mm)
On time Time (mm3/min) (mm3/min)
1 3.023 0.17 4.032
1 1 1 1
2 3.315 0.29 4.080
1 2 2 2
3 3.980 0.36 4.135
1 3 3 3
4 4.571 0.57 4.218
1 4 4 4
5 5.030 0.36 4.274
2 1 2 3
6 5.896 0.52 4.312
2 2 1 4
7 6.423 0.42 4.326
2 3 4 1
8 6.731 0.68 4.382
2 4 3 2
9 6.981 0.52 4.454
3 1 3 4
10 7.329 0.62 4.478
3 2 4 3
11 7.520 0.74 4.498
3 3 1 2
12 8.152 0.72 4.513
3 4 2 1
13 8.426 0.64 4.542
4 1 4 2
14 8.742 0.72 4.621
4 2 3 1
15 9.213 0.84 4.683
4 3 2 4
16 9.432 0.92 4.652
4 4 1 3
4. OPTIMIZATION
The table shows that S/N ratio for MRR, Tool wear and over cut
S.NO Pulse on Machining For For tool For over
Voltage Current
time Time MRR wear cut
1 1 1 1 1 9.6088 15.3910 -12.1104
2 1 2 2 2 10.4097 10.7520 -12.2132
3 1 3 3 3 11.997 8.8739 -12.3295
4 1 4 4 4 13.2002 4.8825 -12.5021
5 2 1 2 3 14.0314 8.8739 -12.6167
6 2 2 1 4 15.4038 5.6799 -12.6936
7 2 3 4 1 16.1548 7.5350 -12.7217
8 2 4 3 2 16.5616 3.3498 -12.8334
9 3 1 3 4 16.8784 5.6799 -12.9750
10 3 2 4 3 17.3009 4.1521 -13.0217
11 3 3 1 2 17.5244 2.61536 -13.0604
12 3 4 2 1 18.2253 2.85335 -13.0893
13 4 1 4 2 18.5124 3.876401 -13.1449
14 4 2 3 1 18.8344 2.85335 -13.2947
15 4 3 2 4 1 9.288 1.514414 -13.4105
16 4 4 1 3 19.4921 0.724243 -13.3528
18
16
14
S/ N in (dB)
12
1 2 3 4 1 2 3 4
PULSE ON TIME C MACHINING TIME D
20
18
16
14
12
1 2 3 4 1 2 3 4
Signal-to-noise: Larger is better
4
S/ Nin (dB)
2
1 2 3 4 1 2 3 4
PULSE ON TIME C MACHINING TIME D
10
2
1 2 3 4 1 2 3 4
Signal-to-noise: Smaller is better
-12.4
-12.6
-12.8
-13.0
S/ Nin (dB)
-13.2
1 2 3 4 1 2 3 4
PULSE ON TIME C MACHINING TIME D
-12.4
-12.6
-12.8
-13.0
-13.2
1 2 3 4 1 2 3 4
Signal-to-noise: Smaller is better
SUGGESTED OCCURRENCE
EVALUATION CRITERIA
CONCLUSION ACKNOWLEDGEMENT
Failure Mode and Effects Analysis is a In any endeavor, more than one person
specific methodology to evaluate the designs, is responsible for carrying the task to
and to identify failure mode, causes and effects completion. The efforts resulting in this project
of all failure modes in order to improve the are no exception. Many people have contributed
Quality and Reliability of the Centrifugal to the success of this project, either directly or
pumps. indirectly.
The technique of FMEA has been First and foremost, I sincerely thank our
applied to centrifugal pump for the purpose of beloved Correspondent
improving the quality and reliability of the Mr.A.C.SHANMUGAM Ex. M.P. and all the
centrifugal pump. During the process of Members of, for providing all the necessary
application of FMEA technique, the following facilities to complete the course successfully.
observations are made, I wish to express my profuse thanks to
1) Occurrence, Detection, Severity and Risk our beloved Principal, who gave us the
Priority Number for all failure mode of necessary support throughout the course of
study.
I am very much indebted to Department execution", Milwau-kee, WI: ASQC Quality
of Mechanical Engineering, , for their timely Press.
help and support throughout the course of the 2. Bell, D., Cox, L., Jackson, S. & Schaefer, P.,
project. (1992), "Using Causal Reasoning for
No word would be either superlative or Automated Failure Modes & Effects
hyperbolic to praise Department of Mechanical Analysis (FMEA)", IEEE Proceedings
Engineering, whose efficacious advice and Annual Reliability and Maintainability
perpetual inspiration kept my backbone straight Symposium, pp. 343–353.
in times of difficulty. I am much indebted for 3. BenDaya, M. & Raouf, A., (1996), "A
his creative suggestion, technical advice given revised failure mode and effects analysis
during the course of the project. I sincerely owe model",International Journal of Quality &
my deepest sense of gratitude to him. Reliability Management, 13(1),
I express my whole hearted thanks to pp. 43– 47.
my project coordinator, Department of 4. Bluvband, Z. & Zilberberg, E., (1998),
Mechanical Engineering, for his valuable "Knowledge based approach to integrated
guidance, support, and encouragement, which FMEA", ASQ’s 52 nd Annual Quality
helped me in accomplishing this project. Congress Proceedings, pp. 535– 545.
I extend my special thanks to Prof. 5. Bowles, J.B., (1998), "The new SAE
K.BALASUBRMANIAN Ph.D, Vice – FMECA standard", 1998 Proceedings Annual
Principal and Prof.G.SOMASUNDARAM Reliability and Maintainability Symposium,
M.E. HOD in Department of Mechanical pp. 48–53.
Engineering, for giving me valuable 6. Burns D.J. & Pitblado R.M., (1993), "A
suggestions and guidance in bringing out this modified HAZOP methodology for Safety
project successfully. Critical System Assessment", 7th meeting of
Finally, I express my gratitude to the UK Safety Critical Club, Bristol,
all the faculty members of Mechanical February 1993.
Engineering Department, my parents and 7. Gilchrist, W., (1993), "Modelling failure
friends, who have given me their kind modes and effects analysis", International
cooperation and help in completing this project Journal of Quality and Reliability
successfully. Management, 10(5), pp. 16–23.
8. Goble, W.M. & Brombacher, A.C., (1999),
REFERENCES "Using a failure mode, effects and
1. Stamatis, D. H., (1995), Failure mode and
diagnostic analysis (FMEDA) to measure
effect analysis: FMEA from theory to
diagnostic coverage in programmable
electronic systems", Reliability Engineering 1999.
& System Safety. 66(2), pp. 145–148, 9. Goddard, P.L., (2000), "Software FMEA
techniques", 2000
New Machinability Study of GFRP Using Coated Ceramic Cutting Tool
of AB2010 Grade
R.Soundararajan1 A. Naveen Sait2 C.Balaji1 G. Vijay Krishna1
1
Department of Mechanical Engineering, Sri Krishna College of Engg and Tech, Coimbatore, TN, India
2
Department of Mechanical Engineering, Chendhuran College of Engg and Tech, Pudukkottai, TN, India
S/NSR for the CO = 31.3458-0.07426 xV- % deviation of S/N ratio of FWSR = [ 40~
52.243xf+ 29.95 ]
6.39 x d x 100 / [ 29.95 ] = 33.54715 %
With reference to the test condition
number 5, the values for the flank wear % deviation of S/N ratio of FWCPR= [40 ~
when V = 150 m/min , f = 0.15 mm/rev , d = 34.23423 ] x 100/ [ 34.23423] = 16.84213 %
2 mm , based on simple regression is
predicted as The deviations are calculated in a similar
manner for each of the other test conditions
S/NSR for the FW = 31.3458-0.07426 using the above equations. The graphs
x150- depicting the % deviation results obtained
52.243x0.15+ 6.39 x 2 are shown.
= 29.95197
Similarly S/N ratio for the combined
objective by cross product regression is
predicted by the equation
= 34.23423
IX) CONCLUSION
The percentage deviations between
experimental and empirical values of the Thus a study was conducted for the
S/N ratio of flank wear for the test condition glass fibre reinforced plastic material,
number 5 is calculated and presented as, manufactured by hand lay-up process, using
a coated ceramic cutting tool by applying • The simple regression deviates the
Design of Experiments concepts. The combined objective by 33.54715
experiments were conducted as per the % and the cross product regression
developed Taguchi array. Flank wear was model deviates the combined
measured as the response variables for the objective by 16.84213 %.
change in the machining parameters (V, f, • As a result, the cross product
d). The experimental results were then regression model is suggested as
compared with those obtained from the well suited for this particular model.
mathematical regression model developed.
ABSTRACT
Many manufacturers are now critically evaluating their processes to determine their
effectiveness in bringing maximum value to customers. Factory management techniques of
yesterday are being replaced by more efficient methods that greatly minimize delays,
reduce costs, and improve quality. Lean manufacturing is a whole-systems approach that
creates a culture in which everyone in the organization continuously improves processes
and production. It is a system focused on and driven by customers, both internal and
external.
The main objective of this paper is to provide a background on lean manufacturing,
present an overview of manufacturing wastes and introduce the tools and techniques that
are used to transform a company into a high performing lean enterprise. One of the
important tools of Lean Manufacturing Value stream mapping is used to identify the
wastes in the assembly processes. Time study of all the processes and non-value added
activities in the rack and pinion housing assembly line of a leading automotive component
manufacturing Industry in a South India is taken as case. The data of cycle time of all
processes were taken; the bottleneck operations have been identified. A current state value
stream map has been developed. From this map, the wastes present in the system were
identified and the necessary kaizens were implemented in the process. Finally the future
state map was developed for the system with lean tools for improvement in the existing
process.
1.0 INTRODUCTION
Lean manufacturing is one of the initiatives that many major businesses are trying to
adopt in order to remain competitive in an increasingly global market. The focus of the
approach is on cost reduction by eliminating non-value added activities. Many of the tools and
techniques of lean manufacturing have been widely used in discrete manufacturing. The main
objective of this paper is to provide background on lean manufacturing, present an overview of
seven manufacturing wastes and introduce tools and techniques used to transform a company
into a high performing lean enterprise. The key to lean manufacturing is to compress time by
eliminating waste. In this paper, lean principles were applied for the process sector for
application in rack and housing assembly in an automotive industry to ensure shorter lead time,
increased productivity, reduced production cost, improved quality and increased customer
satisfaction.
Fawaz A. Abdulmalek and Jayant Rajagopal (2007) describe a case where lean
principles were adapted for the process sector for application at a large integrated steel mill.
Value stream mapping was the main tool used to identify the opportunities for various lean
techniques. They also describe a simulation model that was developed to contrast the “before”
and “after” scenarios in detail, in order to illustrate to managers potential benefits such as
reduced production lead-time and lower work-in-process inventory.
Sanchez and Nagi, 2001 Agile manufacturing systems are born as a solution to a
society with an unpredictable and dynamic demand, and with a high degree of mass
customization in its products. It is the strategy that many enterprises are adopting as a solution to
the new market opportunities. ()
Ram Narasimhan et al (2006) have sought clarification and empirical validation of
lean manufacturing and agile manufacturing paradigms in manufacturing plants. Through
analysis they have identified plant groups whose characteristics accord well with the
descriptions found in the lean and agile manufacturing, literatures. The results of this study
provide a foundation on which the strategic roles and impacts of lean and agile plant types can
be assessed.
Par Ahlstrom (1998) examines whether any sequence of manufacturing
improvement initiatives exists and what these sequences are. He groups the principles of lean
production into four different categories, depending on when management devoted effort and
resources to the principles. Based on the experiences of the Office Machines, the answer to
this question is that there is a need to implement principles both in parallel and sequentially.
Many manufacturers are now critically evaluating their processes to determine their
effectiveness in bringing maximum value to customers. Factory management techniques of
yesterday are being replaced by more efficient methods that greatly minimize delays, reduce
costs, and improve quality.
Lean manufacturing is a whole-systems approach that creates a culture in which
everyone in the organization continuously improves processes and production. It is a system
focused on and driven by customers, both internal and external.
Lean manufacturing isn't just the latest industry buzzword or quick-fix alternative.
Increasing competition demands a continuous focus on minimal costs, maximum customer
options, fast delivery, and high-quality products and services. Today's manufacturers must be
innovative while focusing on waste reduction, improved lead-time, maximized flexibility, and
upgraded quality. Lean manufacturing concepts are proven strategies to help manufacturers
obtain these attributes. Converting to a lean production system is a process that requires every
level of an organization to develop a complete understanding to the basic tents of the concept and
its execution. Companies that have fully implemented lean systems are rare, but the list of
manufacturers trying to become lean is growing fast.
5.6 Defects
In addition to physical defects which directly add to the cost of goods sold, this may
include error in paperwork, provision of incorrect information about the product, late delivery,
production to incorrect specifications, use of too much raw materials or generation of
unnecessary scrap.
5.7 Over-processing
Over-processing is unintentionally doing more processing work than the customer
requires in terms of product quality or features- such as polishing or applying finishing on some
areas of a product that won’t be seen by the customer
6.0 DATA COLLECTION
6.1 CURRENT CYCLE TIME OF ALL THE PROCESSES
6.2 Cycle Time for LINE II
CYCLE TIME (SECONDS)
PROCESS
MAN MACHINE
MOVEMENT TIME TIME TIME TOTAL
First Stage 0 4 56 60
6.3 TAKT
TIME FOR
Rack insertion 8 40 8 56 LINE II
Valve Flushing 0 2 12 14
Valve Insertion 10 25 70 105
Pre-conditioning 8 32 30 70 “Takt time”
Yoke Setting 10 35 0 45 refers to the
Feed pipe assembly 6 110 0 116 rate at which
Air leak test 10 15 135 160 customers
Functional test 4 35 130 169 are buying
Etching 0 78 0 78 products
IBJ assembly 10 50 0 60 from the
Mounting bush pressing 8 20 0 28 production
OBJ &Bellow assembly 10 70 0 80 line; that is
Exit Inspection 4 40 0 44 the unit
production
rate required to match customer requirements.
From the above figures it is evident that bottleneck occurs in each line at various operations. It is
necessary that this bottleneck should be reduced to balance the line. Some of the modifications in the
layout have been proposed and the layout changes for LINE II.
Current Layout
L
36.5 26.5 27.4
INE II
the layout, implementing total preventive maintenance and giving training to the workers wastes due to
Transportation, motion, WIP Inventory, defects and waiting were reduced. Set up time was also
reduced. The reduction in cycle time, reduction in floor space and reduction in operator movement is
shown below.
Proposed Layout
9.0 CONCLUSION
1. Brett W. Braiden and Kenneth G.
In this paper, lean principles were applied for the Morrison (2003)’ Lean
process sector for application in rack and housing Manufacturing Optimization of
assembly in an automotive industry to ensure Automotive Motor Compartment
shorter lead time, increased productivity, reduced System’ Journal of Operations
production cost, improved quality and increased Management, vol 21, pp 129–
customer satisfaction. Work was carried out to 149.
find out the takt time of the processes, and non- 2. Colin Herrona and Christian
value added activities in the rack and housing Hicksb (2008) ‘The transfer of
assembly line. Secondly, the data of cycle time selected lean manufacturing
of all processes were taken; the bottleneck techniques from Japanese
operations were identified. A current state vale automotive manufacturing into
stream map was developed. From the current general manufacturing (UK)
state map it was identified that wastes due to through change agents’ Robotics
waiting, inventory, transportation, motion and and Computer-Integrated
defects were present in the system. Further, Manufacturing, vol 24 pp 524–
various suggestions for improvement were 531.
identified from the current state value stream map 3. David Jacobs and Semyon M.
and the necessary kaizens were implemented in Meerkov (1993) ‘Due-Time
the process. Also, a future state value stream Performance in Lean and Mass
map, which is essentially a snapshot of how the Manufacturing Environments’
system should look with lean tools applied to it, Proceedings of the 32nd
was developed. Conference on Decision and
Control, San Antonio, Texas.
4. Eric S. Grajo (1995) ‘Strategic
Layout Planning and Simulation
for Lean Manufacturing: A
REFERENCES
LAYOPT Tutorial’ Proceedings of the Journal of Operations
Winter Simulation Conference. Management.
5. Rachna Shah and Peter T. Ward (2007) 14. Ulises Martinez and William S.
‘Defining and developing measures of Duff (2004) ‘Heuristic
lean production’ Journal of Operations Approaches to Solve the U-
Management vol 25, pp 785–805. Shaped Line Balancing Problem
6. Luis M. Sanchez and Rakesh Nagi Augmented By Genetic
(2001) ‘A review of agile Algorithm’ Proceedings of the
manufacturing systems’ Int. J. prod. Systems and Information
res., vol. 39, no. 16, pp 3561-3600. Engineering Design Symposium,
7. Thomas I. Seidman and Lawarance E. pp 287-294.
Holloway (2002) ‘Stability of Pull
Production Control Methods for
systems With Significant Setups’ IEEE
Transaction on Automatic Control,
Vol.47, No.10, pp 1637-1646.
8. Wagner C. and Abduelmula A. (2001)
‘Design and Evaluation of Lean
Manufacturing Cells: A Simulation
Model’ IIE Annual Conference.
9. Yang-Hua Lian and Hendrik Van
Landeghem (2002) ‘An Application of
Simulation and Value Stream Mapping
In Lean Manufacturing’. Proceedings
14th European Simulation Symposium
(c) SCS Europe BVBA.
10. Wagner C. and Abduelmula A. (2001)
‘Design and Evaluation of Lean
Manufacturing Cells: A Simulation
Model’ IIE Annual Conference.
11. William G. Sullivan et al. (2002)
‘Equipment replacement decisions and
lean manufacturing’ Robotics and
Computer Integrated Manufacturing
Vol 18 pp 255-265.
12. Thomas I. Seidman and Lawarance E.
Holloway (2002) ‘Stability of Pull
Production Control Methods for
systems With Significant Setups’ IEEE
Transaction on Automatic Control,
Vol.47, No.10, pp 1637-1646.
2. EXPERIMENTAL WORK
2.1Materials
2.3Steps in planning of the experiment
The Material used for this
investigation is a composite plate of size 300 1. Identify the input parameters
mm x 300 mm x 3mm developed from PAN (independent variables)
based carbon fabric (65% by volume) 2. Identify the output parameters to be
laminated using thermosetting epoxy resin and measured (dependent variables).
cured under application of pressure and 3. Determine the various levels of the
temperature. The resistivity of the specimen is input parameters
0.05 Ωcm. The electrode used was Nickel- 4. Select the appropriate orthogonal array
Brass alloy coated with Zinc wire having a and assign the process parameters to
nominal diameter of 0.25mm. the orthogonal array and conduct the
experiment.
2.2WEDM Machine 5. Construct the regression equations
connecting the dependent and
The WEDM machine used is Electronica – independent variables.
Ultracut F1 series (Fig 2.1) with high precision 6. Find the optimal cutting conditions
5 axes CNC control and incorporated with using GA.
Antielectrolysis Equienergy pulse technology. 7. Verify the optimal process parameter
The dielectric medium used is de-ionised through a confirmation experiment.
water. Polarity of the electrode is negative and
that of the composite is positive. 2.4Parameter Design
A total of six input parameters
(independent variables) with three levels for
each input parameter. Input parameters are X1
(Input Current), X2 (Pulse on Time), X3
(Pulse off Time), X4 (Wire speed), X5 (Wire
tension), X6 (Flushing rate) considered while
the output parameters (dependent variables)
are Metal Removal Rate (Y1) (MRR,
mm3/min) and Surface Roughness (Y2) (Ra).
According to the capability of commercial
WEDM machine available and general
recommendation of machining conditions for
carbon composites, the range and the number
of levels of the input parameters are selected
Fig 2.1 WEDM Machine as given in the Table 2.1.
Sl. Level
Parameter
No. I II III
Input
1 Power 10 11 12
(amp)
2 Ton (sec) 102 105 108
3 Toff (sec) 58 60 63
Wire
Speed
4 5 7 9
(Ws)
(m/min)
5 Wire 1000 1100 1200
Tension
(Wt)
(gms)
6 Flushing
Rate (Wp) 4 5 6
(lpm)
Table2.1 Machining parameters and their levels
2.5Experimental layout
gmsWire Tension(Wt)
(μs)Ton
(μs)Toff
Ex. No
m/minWire Speed(Ws)
(Amps)Input Power
lpmFlushing Rate(Wp)
F
act X1 X2 X3 X4 X5 X6
ors
1 1 1 1 1 1 1
2 1 1 2 2 2 2
3 1 1 3 3 3 3
4 1 2 1 2 2 2
5 1 2 2 3 3 3
6 1 2 3 1 1 1
7 1 3 1 3 3 3
8 1 3 2 1 1 1
9 1 3 3 2 2 2
10 2 1 1 1 2 3
11 2 1 2 2 3 1
12 2 1 3 3 1 2
13 2 2 1 2 3 1
14 2 2 2 3 1 2
15 2 2 3 1 2 3
16 2 3 1 3 1 2
17 2 3 2 1 2 3
18 2 3 3 2 3 1
19 3 1 1 1 3 2
20 3 1 2 2 1 3
21 3 1 3 3 2 1
22 3 2 1 2 1 3
23 3 2 2 3 2 1
24 3 2 3 1 3 2
25 3 3 1 3 2 1
26 3 3 2 1 3 2
27 3 3 3 2 1 3
3. EXPERIMENTAL PROCEDURE
Experiments were performed according to the experimental layout as shown in table 2.6,
on a carbon fabric reinforced / epoxy composite plate of size 300mm x 300mm x 3 mm. A straight
cut of 7 mm length was made for all the experiments. The time taken for the 7 mm cut was noted
down for each experiment using a stopwatch and the mean cutting speed was calculated as below.
ExNo MRR
1 0.585
2 0.520
3 0.481
4 0.701
5 0.685
6 0.632
7 0.864
8 0.750
9 0.849
10 1.050
11 0.513
12 0.875
13 1.406
14 1.500
15 0.868
16 2.126
17 1.969
18 1.348
19 0.760
20 0.680
21 0.728
22 1.200
23 1.059
24 1.440
25 2.572
26 2.022
27 1.757
4.1Regression Equation:
Regression equations were formed using MTab software. The Equation relating
the Material removal rate (MRR) and the input variables and the normal plot (fig4.1) is given
below.
C12 =-18.6 - 9.41 X1 + 0.148 X2 + 1.64 X3 + 0.75 X4 +
0.00708 X5 - 0.08 X6+ 0.0918X1.X2 - 0.01668X2.X3 +
0.0076X3.X4 - 0.00111 X4.x5 + 0.00007 X5.X6
95
90
80
70
Percent
60
50
40
30
20
10
1
-0.5 -0.4 -0.3 -0.2 -0.1 0.0 0.1 0.2 0.3 0.4
Residual
Fig 4.1
The equation relating the Surface roughness to the input variables and the normal plot(fig4.2) is
given below.
C7 = -197 + 15.5X1 + 1.70 X2 + 0.15 X3 + 0.38 X4 + 0.00664 X5
+ 1.40 X6-0.130 X1.X2 - 0.0017 X2.X3 + 0.0029 X3.X4 -
0.000512 X4.x5 - 0.00125 X5.X6
95
90
80
70
Percent
60
50
40
30
20
10
1
-0.50 -0.25 0.00 0.25 0.50
Residual
Fig 4.2
The regression analysis predicts that the input power (amps), T on and Toff are the major
influential factors on MRR and Ra. The equations shows that, R2 = 89.1% and Ra2 = 81.2%
etc. for MRR equation and for the surface roughness equation R2 = 98.3% and Ra2 = 97.1% etc.
2.2
1.8
Fitness
1.6
1.4
1.2
0.8
0 50 100 150 200 250 300
Generations
Fig 4.3
Fig 4.3 shows the fitness graph obtained for the maximum MRR by GA.
V. ANALYSIS OF VARIANCE
1 k =18
m= ∑ηk
18 k =1
The statistical procedure used most often to
analyze data is known as the analysis of
(6) variance (ANOVA). This technique determines
the effects of the treatments, as reflected by A factor j with largest SS value will
their means, through an analysis of their have significant role in controlling the
variability. The ANOVA establishes the relative response.
significance of factors in terms of their 3. The sum of the squares due to error
percentage contribution to the response and (SSe) is given by
also needed for estimating the variance of error 3
for the effects and confidence interval of the
prediction error.
SS e = SST − ∑SS j
j =1
(12)
VI. CONCLUSION
The factor that affecting the performance has obtained using modified Taguchi method using
been determined using this analysis. In this utility concept. It is clearly shown that the
process peak current and Pulse off time are the multiple performance characteristics in EDM of
more significant EDM parameter in terms of Titanium are greatly improved. The optimal
affecting the multiple performance EDM parameters for multiple performance
characteristics. In the confirmation test characteristics are: Peak current 4A. Pulse on
improvements are calculated based on the time 7μs, and Pulse off time 1μs.
optimal machining parameter, which was
TABLE I
MACHINING PARAMETERS AND THEIR LEVELS
TABLE II
Symbo Machining
symbol
l parameter
Parameters Level -1 unitLevel – 2LevelLevel
I - 3 Level II – Min.
Max. Level III
AA Peak current
Peak current -29.87 amps -31.61 4 -32.08 6 2.21 8
BB Pulse ON timeon time
Pulse -34.05 µs -31.58 500 --27.68 700 6.40 900
CC Pulse
Pulse OFF off time
time -30.39 µs -31.32 10 -31.69 20 1.57 30
TABLE III
MEAN EFFECT RESPONSE TABLE FOR MULTI-RESPONSE S/N RATIO
Source of
variance
Sum of
squares
df
Variance
Test f
F,5%
P(%)
Peak current
7.91
2
3.95
0.260
3.98
4.33
Pulse on
time
140.96
2
70.36
4.63
3.98
77.26
Pulse off
time
3.15
2
1.57
0.103
3.98
1.72
Error
30.4
11
2.76
16.67
TABLE IV
RESULTS OF ANOVA FOR MULTIPLE PERFORMANCE CHARACTERISTICS
TABLE V
of fiber in a common matrix forms the 2.1 MATERIALS: Untreated jute mats of
hybrid composites. The concept of density 0.315 g/m3 and dimensions 304 x
hybridization gives flexibility to the design 254 x 1.6 mm is used. Woven roving glass
engineer to tailor the material properties fibers of E-type having dimensions 304 x
according to the requirements. 254 x 0.5 mm and density 610g/m3 along
Hybridization of natural fiber with with jute forms the fiber part of the
stronger and more corrosion-resistance composite laminate. The resin system
synthetic fiber, for example, glass fiber or consists of polyester of density 1.4g/cm3,
carbon fiber can improve the stiffness, MEKP catalyst and Cobalt naphthenate
strength, as well as moisture resistant accelerator.
behavior of the composites and hence a
balance between environmental impact 2.2 LAMINATE FABRICATION
and performance could be achieved.
Among all the natural fiber reinforcing Hybrid laminates of woven jute
materials jute appears to be a promising and glass mat has been prepared by simple
material because it is relatively hand lay-up technique at room
inexpensive and commercially available in temperature. PVA release agent is applied
the required form. The fiber has a high to the table surface. First a layer of
aspect ratio, high strength to weight ratio, polyester mixed with 1.5% each of
is low in energy conversion, and has good accelerator and catalyst is applied
insulation properties. The long jute fiber uniformly on the table. Alternate layers of
bundles can be used to make fiber mats jute and glass has been stacked with the
which can be used for geo-textiles and can matrix layer between them. Thus 6 layers
be formed into complex structural and each of jute and glass fibers, 1000gm of
non-structural products. The use of jute polyester, 15g each of accelerator and
fiber alone in polymer matrix is inadequate catalyst forms the hybrid panel of
in satisfactorily tackling all thechnical dimension 304 x 254 x 170 mm. The fiber
needs of a fiber reinforced composite. In volume fraction is has been found to be
an effort to develop a superior, but 58.05% which qualifies the laminate in the
economical composite, a jute fiber can be category of thin laminates (high fiber
combined with a synthetic fiber, glass content and low matrix content).
fiber, in the same matrix material so as to
take the best advantage of the properties of 2.3 MECHANICAL TESTING
both the fibers. Glass fibers have high 2.3.1 Tensile Testing
tensile strength, dimensional stability, low
weight, excellent insulation properties and Specimens for tensile test were
have high corrosion and chemical carefully cut from the laminate to a width
resistant. of 25mm and length 30mm. were gripped
Polyester is used as resin because of its on the Universal Testing Machine with the
adequate resistance to water and variety of pyrometer attached to the specimen. The
chemicals, weathering, and aging and is machine being attached to a software
very cheap and easily available. This system gives the respective graphs
results in a jute-glass hybrid composite. In between various parameters and also the
this paper the effect of hybridization on the stress strain curve. The test was conducted
tensile strength, impact strength and for two specimens. . Fig 2.3.1: Tensile Test
flexural strength is studied on the hybrid setup 2.3.2 Hardness Testing This is an
laminate. important mechanical test used for
evaluating the hardness of the laminates.
2. EXPERIMENTAL PROCE DURES Here hardness being calculated with
equipment called Bar coal impresser. In
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
this process the indentor of the equipment 0.384 kN/mm2 and 5.67 kN/mm2
is pressed against the glass laminate respectively. Jute laminates show a
surface and the respective value got from modulus of elasticity of 3.75 kN/mm2.
the dial gauge present on it. The hardness Observation of failed specimens revealed
is measuring unit is BAIU. Important thing that failure in hybrid laminates is governed
to be kept in mind is that the indentor by extensive fiber pull out and breakage.
should be pressed against the surface One reason for this may be due to greater
where resin is present. extensibility of glass fibers than jute fibers.
Fig 2.3.2:- Hardness testing machine 3.2 Hardness testing The glass fiber
forms one extreme layer of the laminate
2.3.3 Impact Testing while the jute fiber is the other extreme.
The Izod test is conducted for The hardness value of the laminate with
getting the impact value in Joules. Here glass top is 40.124 BAIU while for the jute
the specimens are cut to a width 12.3 mm top it is 5.875 BAIU. Thus the glass top
length 65mm and being fixed on the shows more hardness than the jute top 3.3
apparatus. Fig 2.3.3: - Impact test set up Impact Testing The energy absorbed
during impact was 10.6J thereby showing
2.3.4 Flexural Testing impact strength of 47.30N/mm.
The flexural test is initiated by 0
applying the load perpendicular to the 3.4 Flexural Testing
fiber direction. For composite specimens a For a span of 60mm the specimen
three-point bend test and for resin was able to withstand a peak load of
specimens a four-point bend test are 833.35N thereby showing an elongation of
adopted. The relations for flexural 8.747%. The flexural stress for the
strengths is; =3FL/2bd2 MPa, where F= maximum force was calculated as 42
load, N; L= span length, mm; the distance N/mm2.
between inner and outer loading point is 0
L/3 and the load span is also equal to L/3 3.5 Erosion Wear Test
as per ASTM-D 790 standard After conducting the slurry erosion
test, the eroded pieces were weighted
2.3.3 Erosion wear Studies again to determine mass loss. The ratio of
The pot erosion tester, H.M. Clark the distance traversed (km) gives erosion
and W. Tsai et al, has been used for rate (mg/km). The procedure was repeated
carrying out the Erosion Test. Specimens for various samples using 30/80 sand. The
were rotated in a slurry pot tester test was carried out for different
containing solid-liquid mixture and concentrations and different time period at
average mass or thickness loss of the a constant speed of 500rpm. The results
specimen have been measured to evaluate are depicted in the tabular form.
wear. Hence, a pot erosion tester consists
of a slurry container, in which the Concentratio Test Surface Erosion
proportionate amount of sand and water is n parameters impact wear
fed. The samples of dimension 76.2 x 25.4 velocity rate
x 12.7 mm were cut. % hrs m/s mg/km
1 20 4 2.59 15.36
3 RESULTS AND DISCUSSION 20 7 2.59 12.44
3.1 Tensile Testing 20 12 2.59 8.62
The Hybrid samples under a 30 4 2.59 41.2
maximum tensile force of 20kN showed 30 7 2.59 26.94
elongation of 16.7%. The tensile strength 30 12 2.59 18.87
and young’s modulus have been found as
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
Thus we see that as the time and single extruder and injection molding
concentration of slurry increases the method
erosion wear rate increases.
1 [2] T. Munikenche Gowdaa, A.C.B.
4 . CONCLUSION Naidua, Rajput Chhaya on some
It is concluded that although the mechanical properties of untreated jute
mechanical properties of jute/polyester fabric-reinforced polyester composites.
composites do not possess strengths and
moduli as high as those of conventional [3] N. Sgriccia, M.C. Hawley and M.
composites, they do have better strengths Misra on the development of natural fiber
than wood composites [19] and some reinforced composites as a replacement for
plastics. However their performance can glass fiber composites from Department of
be enhanced by the concept of Chemical Engineering and Materials
hybridization. Therefore, these composites Science, Michigan State University in
could be considered for future materials 2008.
use. Since the reinforcing material is eco-
friendly, non-toxic, non-health hazardous, [4] K. Sabeel Ahmed and S.
low in cost and easily available as Vijayarangan “on effect of stacking
compared to conventional fibers like glass, sequence on tensile, flexural and
Kevlar, asbestos etc., the composites are a interlaminar shear properties of untreated
good substitute for wood in indoor woven jute and glass fabric reinforced
applications such as shelves, partitions, polyester hybrid composites,” from
wash basins and table tops, and may also Department of Production Engineering,
be suitable for outdoor uses such as PSG College of Technology,
roofing, drainage pipes, automobile Coimbatoreepartment of Production
components, electrical fittings as well as Engineering, PSG College of Technology,
larger items such as lightweight fishing Coimbatore, 2008
boats. However based on the various
mechanical and erosion tests and results [5] Ha Na Yua, Seong Su Kima, In Uk
obtained it can be concluded that: Hwanga and Dai Gil Lee from
1a. The value of tensile strength of jute Department of Mechanical Engineering,
composite can be enhanced by Korea Advanced Institute of Science and
incorporating glass fibers in it by 51.2%. Technology, ME3221, Guseong-dong,
Thus the area of application of these Yuseong-gu, Daejeon “On the permeability
hybrids widens. and structural strength of the composite
2b. The glass top shows better hardness reinforcements composed of inner jute mat
than the jute top. Hence the hardness can and outer glass fabric for the trenchless
be increased by having two extreme layers rehabilitation of underground pipes were
of the hybrid as glass. measured and compared to those of
3c. At higher slurry concentration, the conventional glass fabric reinforcements”
amount of wear and wear rate are high. in 2008.
Traditional (functional)
Work Groups Cross-functional teams
departments
By traditional FASB*
Accounting “Through-put” Accounting
guidelines
Current Level : Drill change takes place once in 40 nos. which takes 4 min to complete.
Total Machining time : (2200 X 45 ) / 3600 = 27.5 hrs. (Value adding time)
With 2 m/cs. = 13.75 hrs.
No. of parts to be produced = 2200 parts. / day
Total tool change time : 55 X 240 = 13200 / 3600 = 3.7 hrs. (Non Value adding time)
10%
21%
90%
79%
Result :
Total tool change time : 30 X 240 = 7200 / 3600 = 2 hrs. (Non Value adding time)
change = 240 sec
ABSTRACT
The project deals with analysis Drawbead. It is observed that the
of effect of Drawbead geometry in Sheet Drawbead influences in distribution of
metal drawing process. Finite element stress, strain and thickness distribution.
analysis of drawing circular blanks into The reduction in thickness of wall
hemi-spherical cup is carried out. The indicates that the presence of Drawbead
effect of Drawbeads are analysed by offer high restraining force to the flow
considering the single circular, double of blank.
circular and rectangular Drawbeads. An experimental study is
The Drawbeads with tooling are described in which active drawbead
modeled by using DYNAFORM technology is used to attempt to
package and the analysis is carried out optimize the sheet metal forming
in LS- DYNA package. From the process. Oval AA 6111-T4 panels were
analysis, influence of Drawbead on drawn in a series of tests using various
binder surface is studied. The wrinkled drawbead trajectories to establish the
perimeter of cup has been reduced by feasibility of the approach. The selection
providing the Drawbead. By placing the of drawbead trajectory was shown to
bead at different position on the binder have a dramatic effect on maximum
surface with respect to center of die attainable draw depth at fracture.
cavity optimises the location of Increasing drawbead penetration from
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
zero to 5 mm in the early stages of the The Sheet metal forming process is
drawing process and retracting midway a long established practice for mass
through the draw resulted in a 40% production of Sheet metal parts. In the
increase in draw depth compared to forming operation, the Sheet metal is first
using a fixed 5 mm penetration. In the clamped by the binders around the
second part of the investigation, active periphery of the die cavity. It is
drawbead technology was used to study subsequently drawn into the die cavity by
its effect on highly nonsymmetric panel a moving punch. During the draw, the
forming. Drawing limit curves in terms binder exerts a restraining force by friction
of drawbead depth versus blankholder generated between binder and the sheet
forces (BHF) were plotted, and different metal. The sheet metal forming technology
drawbead trajectories were tested to is then mainly focused on the design of die
determine an optimal drawbead surfaces including the Draw bead which
trajectory scheme. A corresponding depends mostly on the experience and
finite element model was also created. know how of engineers.
The results of strain path analysis
successfully support the experiments. FLOW STRESS
Keywords: Sheet Formability, The flow curve describes the Stress-
Drawbeads, Deep Drawing, Drawing Strain relationship in the region in
Forces which metal forming takes place. It
INTRODUCTION indicates the flow stress of metal, i.e
SHEET METAL FORMING the strength property that determines
forces and power required to
Sheet metal forming process involves accomplish a particular forming
work pieces with high ratio of surfaces to operation.
thickness. Typical examples of application
that use sheets include metal desks, Flow stress
appliance bodies, hubcaps, Aircraft For most of the metal at room
fuselages, beverage cans, car bodies and temperature, the Stress- Strain plot
kitchen utensils. Thus sheet forming also indicates that as the metal is deformed, its
called press working or stamping. strength increases due to strain hardening.
Metal forming includes a large The stress required to continue
group of manufacturing process in which deformation must be increased to match
plastic deformation is used to change the this increase in strength. Flow stress is
shape of metal work pieces. Deformation defined as the instantaneous value of stress
results from the use of tool usually called a required to continue deformation of metal.
die in metal forming, which applies i.e. To keep the strength of metal as
stresses that exceed the yield strength of function of strain, which can be expressed
the metal. The metal therefore deforms to by
take a shape determined by the geometry n
of the die. Yf = K
Sheet metal parts offer the advantages of
light weight and versatile shape. Because FORMING LIMIT DIAGRAM (FLD)
of low cost, Yield strength and formability
characteristics, low carbon steel is the
most commonly used sheet metal. For
aircraft and aerospace applications, the
common sheet materials are aluminium
and titanium
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
bead ends. The results of these additional trajectories with early penetration are
tests are shown in Figure 6. A higher explored in this phase. The formability of
constant drawbead penetration results in a material is primarily affected by two
higher punch load curve as well as earlier parameters in active drawbead die, namely
fracture. The curve for trajectory T5 peaks BHF and drawbead trajectory. The first
at 68.8 kN, which is 19.2% less than the family of tests is conducted to study the
baseline curve for a constant 5 mm formability improvement using active
penetration. Although neither part drawbeads versus flat tooling forming and
fractured (both were drawn to the fixed drawbead forming. Trajectories for
maximum available depth of 54.5 mm), this study are shown in Figure 11. A
trajectory TS results in a 6.5% drop in trajectory without drawbead penetration is
peak punch force compared to trajectory selected to mimic flat tooling forming. The
T1. 5 mm constant drawbead penetration is
chosen as the benchmark to be compared
Plotting depth at fracture as a with the active drawbead case at the same
function of maximum punch force for all maximum penetration. For each of these
of the above cases results in the inverse cases, curves are plotted in terms of draw
relationship shown in Figure 7. This depth versus BHF to determine an optimal
relationship indicates the need to minimize BHF for maximum drawability. For a
punch force to maximize part depth for a given BHF setup, different drawbead
given set of operating conditions (for trajectories can cause changes in drawing
example, blank size, binder force, performance. Therefore, the set of active
lubrication). The experimental data drawbead trajectories shown in Figure 12
indicate that the product of the draw depth, was investigated at a chosen BHF to
d, and the fracture force, F, is a constant, eventually determine the optimal
as follows: drawbead trajectory. For these trajectories,
only the maximum penetration is varied.
limit curves are experimentally established trajectory depends on the selection of the
and studied in this work, using the BHE
drawbead trajectories of Figure 11.
STRAIN ON PUNCH FACE
The results are shown in Figure 13. It
is obvious that use of active drawbeads Strain on the punch face is one of
with early penetration indeed results in the critical factors that determine how
better formability than either flat tooling severely the final geometry will be
forming or fixed drawbead forming. affected by springback. According to the
Quantitatively, the active drawbead case information about industrial practice at
produces a successful part 7.69% deeper General Motors, for example, the amount
than that obtained with flat tooling and of strains in this region is generally
16.7% deeper than with the fixed expected to be at least 2% to hold an ideal
drawbeads. Furthermore, a relative punch face dimension and minimize
maximal draw depth is achieved by active springback.14
drawbeads employing a BHF in the range
of 20 to 40 kN. Because customary grid pattern
measurement systems with their small
"OPTIMAL" DRAWBEAD elements (circles) would tend to produce a
TRAJECTORY measurement error of about 2%, which is
in the realm of the expected strains, three
The above results clearly prove that big circles were precisely scribed onto the
using active drawbeads can be an effective punch face area of blanks, as shown in
method to improve the formability of Al Figure 15. Blanks were drawn with the
6111-T4. However, the optimal penetration four drawbead trajectories of Figure 12 to
for the drawbead trajectory had yet to be a depth of 30 mm, which was chosen
determined. Five different maximum because it produced safe draws and made
drawbead penetrations, 3, 4, 5, 6, and 7 possible comparisons between the
mm, were selected for this purpose, as different trajectories.
shown in Figure 12. All panels were
formed with a BHF of 36.65 kN. The The circles were measured along the
results are presented in Figure 14. Every W (width) and L (length) directions, as
single trajectory produced a part with a indicated in Figure 15. Each circle was
maximum draw depth as marked by each measured 5 or 6 times, and the average
column in the figure. It turns out that the 5 reading in each direction was obtained to
mm trajectory provides the best calculate the corresponding true strain.
formability among the five trajectories at Figures 16 through 18 display the
the prescribed BHR measurement results for all circles. It is
seen that all strains are very small in
This experimental investigation magnitude, and the values in the two
clearly demonstrates that first, the active perpendicular directions are both positive
drawbead is an effective way to improve in each case, which indicates a biaxial
formability of Al 6111-T4 in the deep tension state in the punch face area. In all
drawing process and may, in fact, be better cases, the strains in the length direction
than either flat tooling or a fixed exceed those in the width direction.
drawbead. Second, an optimal choice of
the drawbead trajectory has to be based on Comparing the data without
a comprehensive consideration of BHF In drawbeads to the other three with active
other words, the choice of drawbead drawbeads, shows that active drawbead
trajectories always generate higher strains
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
in this region. The drawbead trajectory Effective plastic strain. The simulation is
with 5 mm maximum penetration results in carried out to optimise the Draw bead
the highest strains of all three circles. The position with respect to center of die
larger deformation over the punch face cavity. Drawing of hemispherical cup with
indicates that a small amount of extra circular, double circular, rectangular Draw
material in this area has been stretched bead are considered for the purpose.
outward toward the punch corner area so
that the lack of metal along the punch METHODOLOGY
corner is somehow compensated to some
degree, and thinning or necking in this Modeling of tool, blank and
region is slightly delayed. Active preprocessing is carried out by
drawbeads are thus proving advantageous DYNAFORM package which is
not only to improving the formability of specifically used to model for Sheet metal
A1 6111-T4 from yet another standpoint, forming process. The input information is
but also to benefit shape control in the material type, blank thickness, friction
punch bottom coefficient, and travel speed of punch.
PROBLEM FORMULATION Shell elements are selected, because the
PROBLEM SPECIFICATION bending deformation is dominant during
most of the sheet forming process.
In Sheet metal drawing process,
the unsupported flange surface and wall The FEA solver, LS-DYNA is used
surface subjected to defects like wrinkling, as processor. It is being an explicit solver
tearing and galling. In most of the cases employs the direct integration technique,
wrinkling defect is dominant. To avoid which is capable of providing accurate
such defect rate of blank flow must be solution for the dynamic equation of
controlled and thereby increasing the equilibrium that describes the behavior of
restraining forces. The resistant force to the Sheet in sheet metal forming problem.
the flow of blank depends upon the
location of Draw bead on the binder Post –Processing of the result is
surface. Hence this project is concentrated carried out using LS-POST processor. The
on the analysis of effect of Draw bead on main features of the result that are interest
wrinkling tendency, investigation of include distribution of strain and thickness
thickness distribution, stress distribution, of deformed sheet.
MATHEMATICAL CALCULATION
PUNCH FORCE
The force required to draw the blank into the die cavity is termed as punch force. It is
denoted as Fp. It is expressed in Newton (N). It is calculated as follows
The punch force depends on the thickness of blank, Yield strength of blank, Diameter of
Shell, Diameter of blank
For circular blank, punch force = F= π*d*t*S*((D/d)-c)
F= π* 0.1*0.00102*260*106*((0.174/0.1)- 0.65)
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
F= 90.849*103 N.
BINDER FORCE
The force required to hold the blank along with the die surface and allow the blank to
restricted flow into die cavity. Normally, binder force will be 1/3 of the punch force. It is
expressed as Fb
fig
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
MATERIAL PROPERTIES
1. Tool
Material : Rigid material
Density : 7850 Kg/m3
Young’s modulus : 2.1E11 N/m2
Poisson’s ratio : 0.3
2. Sheet metal
Material : FLD Hardening model
Density : 7580 Kg/m3
Young’s modulus : 2.06E11 N/m2
Poisson’s ratio : 0.29
Yield stress : 260E6 N/m2
Tangent modulus : 34.34E6 N/m2
Hardening Exponent : 0.2
MESHING
Element Selection
Shell elements were selected because of bending deformation is dominant during most of the
sheet forming process.
Element Description
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
Shell element is a 4 node element with both bending and membrane capabilities. Both in
plane and normal loads are permitted. The element has 12 DOF at each node. i.e. Translation,
Acceleration, Velocity in x,y,z and Rotation in x,y,z
Shell Element input Data
Number of integration points (NIP) ranges from 1 to 100. The node thickness is given
by indicating the NIP value. If NIP is 0 or blank, the default value as 2. If the thickness is
uniform at all nodes, the NIP value at only one node is enough.
Complete Model
Figure.7.4.4.Complete Model
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
Section of
Centre
die
of die
cavity
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
The draw bead is positioned at various varied the resistance offered to the blank
locations over the binder surface from the flow is increased. This increase in
center of the die cavity. The Draw bead resistance causes crack on the cup. The
location is varied in the die surface with location where minimum Von-mises stress
respect to center of the die cavity. From noted is considered as optimal position.
the Table 1, it is clear that as the location is
Figure 8.2(a )& (b) Effect of Draw bead on reduction of wrinkling tendency
The fig. 8.2.a and 8.2.b indicates that the draw bead offers resistance to the material
flow. Thus the wrinkled perimeter of cup is reduced when compared to the cup drawn without
draw bead. The image gives the clarity of where cup tends to crack. The different changes are
indicated in the fringe levels.
Fig.8.3.a Fig.8.3.b
Figure. 8.3 .(a) & (b) Effect of draw bead on thickness distribution
The fig.8.3. Shows the distribution of thickness region where stretching takes place. Gradually
along the cup profile when the blank is passed thickness increases towards the bottom portion.
through the single circular draw bead. It is Due to compressive strain the flange portion has
observed that the thickness at the center of the the maximum thickness, which is even thicker
blank is very minimum. At the location 1 the than original sheet thickness.
predicted value is 0.771mm. The maximum value Graphical comparison of thickness along
of thickness is 1.025mm at location 16. i.e. at the component with and without Draw
flange portion. Thinning is more in the middle bead condition is given in the Table.8.3.
Table 8.3.
Table 8.4.
The fig. 8.5.(a) &(b) shows the Von-mises distribution in the drawn cup. It is seen that
the Draw bead offers more resistance with low blank holder pressure. The stress estimated
without Draw bead at location 1 is 550Mpa. and with Draw bead at the same location is
estimated as 750Mpa. There is no considerable difference from location 1 to 10. The
maximum change occurs at the flange area only. (i.e. 550- 800Mpa.)
The Fig.8.6, 8.7 and 8.8 shows the comparison of effectiveness of the draw beads by
considering Von-mises stresses, Plastic strain and Percentage of thickness reduction. It is
clearly observed that the thickness reduction is more incase of double Draw bead.
EFFECT OF DOUBLE (COMBINED) DRAW BEAD
Fig. 8.9. (a) Effective stress Fig. 8.9(b) Effective plastic strain
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
The fig.8.9(c) Shows the changes in the shell thickness along the cup profile. It is
clear that the minimum value observed is 0.76mm and the maximum value at the flange area
is 1.067mm.Fig.8.9(d) shows the variation of percentage thickness reduction along the cup
profile. The maximum percentage thickness reduction is 17% at location 7 and minimum
value 1% at location 16. At the center of the cup, percentage reduction is 15%.
EFFECT OF RECTANGULAR DRAW BEAD
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
1.2
Thickness in mm
1
0.8
With bead
0.6
0.4 without bead
0.2
0
1 3 5 7 9 11 13 15
Location along cup profile
Table
8.10(a)
Figure. 8.10(a) Thickness distribution
0.3
strain
Without bead
0.2
Wth bead
0.1
0
1 3 5 7 9 11 13 15
Location along the cup profile
From the Fig.8.10. The thickness of cup at location 1 is estimated as 0.88 mm without Draw
bead and with Draw bead 0.761 mm. At the flange portion estimated thickness is 1.017 mm
(without Draw bead) and 1.01 mm (withdraw bead). The thickness reduction caused by
rectangular draw bead is more compared to circular draw bead due to the reason that blank is
bent and unbent four times over rectangular bead instead of three times over circular bead.
CONCLUSION
A numerical model has been
introduced to simulate the hemispherical
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
cup forming process. The model is sheet metal stamping can be influenced
formulated to fit the Finite Element considerably by the introduction of active
package DYNAFORM and LS- DYNA. drawbeads. Fixed drawbeads, which are
The Draw bead is introduced to offer the immovable components of the binder, are
restraining forces to the blank flow. The shown to perform poorly when compared
simulation is carried out to investigate the with active drawbeads. An up to 57%
effect of Draw bead geometries. It is found increase in draw depth can be realized
that Sheet thinning taken place while when fixed drawbeads are replaced by
introducing Draw bead. The optimisation is active drawbeads. The draw depth that can
carried out by varying the Draw bead be achieved with active drawbeads
position on the die surface. Effective depends on the duration of drawbead
stresses, Effective Plastic strain and penetration and the stage of the draw at
distribution of thickness along the cup which the drawbeads become active. It
profile have been found. The following appears that a brief extension of the
conclusion has been drawn. drawbeads during the earliest stage of the
draw results in the deepest panels. Early
1. Due to the influence of draw bead drawbead penetration trajectories produced
geometry, the wrinkling tendency is 22% deeper panels when compared with
reduced in the perimeter of hemi-spherical the latest drawbead trajectories tested in
cup. It is seen from the fig.8.2 (a) and8.2 this investigation. An added benefit to
(b). Wrinkled area has been reduced. early drawbead action is a reduction in
2. The Draw bead locations are crucial to maximum drawing forces.
their effectiveness. The simulation allows
to tryout different locations for In the second part of the study, a
optimisation. As the location of bead complex nonsymmetric panel was formed
moves away or towards the center of die of A1 6111-T4 sheet using active
cavity on the die surface, the Effective drawbeads. Flat binder forming, fixed
stress is increased that causes crack on the drawbead forming, and active drawbead
cup. forming were carried out, and different
3. The reduction in thickness of wall active drawbead trajectories were tested
indicates that the presence of Draw bead and analyzed by modifying the maximum
offer high restraining force or resistance to drawbead penetration. Both results indicate
the flow of blank. that active drawbeads, when compared
4. Influence of rectangular and double (or) with traditional flat binder forming and
combined Draw bead offering resistance to fixed drawbead forming, provide improved
the material flow is more than that of formability of A1 6111 T4. The analysis of
single circular Draw bead. In the center the strain on the punch face represents
portion of the cup, the thickness reduction another approach to prove that active
is almost 15% .The maximum thickness drawbeads produce parts with greater draw
reduction is 17.5% at location 7. depth. Furthermore, comparatively higher
5. There is no considerable change in the strains in this region indicate the beneficial
effective plastic strain and stress with the usage of active drawbeads on shape
use of single circular and double circular control. Strain paths near the punch nose
draw bead. Only at the flange portion, the usually show a near plane strain
stresses are varied from 750Mpa. to deformation mode, which indicates that
850Mpa. this region is the area most susceptible to
fracture defect initiation in a deep drawing
The initial phase of the study operation
revealed that draw depth in aluminum
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
REFERENCES
3. RESULTS AND DISCUSSIONS processes are carried out till the crack
To study and analyze the deformation appears on the lateral deformed surface.
and densification behavior of Fe-0.5%C- Fe-0.5%C-1%Cu steel deforming much
1%Cu, Fe-0.5%C-1%Cu-1%Mo-1%Ti, better than other alloys, it attains the
Fe-0.5%C-2%Cu-2%Mo-2%Ti and Fe- maximum deformation 0.853 for the stress
0.5C%-2%Cu-2%Mo-4%Ti. The cold and value of 628.6 MPa. Addition of other
hot upsetting were carried out on sintered alloying elements such as copper,
P/M preforms with aspect ratio (A.R) 0.5. molybdenum and titanium reduces the
The specimens were prepared after deformation behavior of P/M steels.
sintering, by removing the oxide film over Addition of 1%Mo, 1%Cu and 1%Ti to the
the preforms. The correct dimensions of base material gives better yielding
preforms were taken by using a digital property nearly 0.7 next to the plain
vernier caliper. The initial density of carbon steel. Addition of any more
preforms was also measured by quantity of 2%Cu, 2%Mo, 2%Ti and 4%Ti
Archimede’s principle. The deformation to the base material still reduces the plastic
and densification behavior of preforms deformation characteristics. The axial
were studied under step by step increment stress required to any value of axial
axial stress applied by 100 T hydraulic deformation is maximum for Fe-0.5%C-
press (Universal Testing Machine). 2%Cu-2%Mo-4%Ti and minimum for Fe-
0.5%C-1%Cu
3.1 Stress Versus True Height Strain
Figure.1 shows the plots of
deformation of plain carbon steel and
alloys after axial increment of stress
during cold upsetting. From the plots, it is
clearly evident that the plain carbon steel,
copper, molybdenum and titanium based
alloys are deforming in two distinct stages.
During the first stage, the rate of
increasing the axial stress is more with
lower rate of true height strain, this is due
to the geometrical hardening of sintered
preforms during cold upsetting. In the
second stage the deformation of preforms
is gradual with corresponding values of steel.
the axial stress. The cold upsetting
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
Figure.1
Figure.2
Stress vs. True height Strain Stress vs. Percentage Theoretical Density
3.2 Stress Versus Percentage Theoretical of sintered P/M preforms. The axial stress
Density required for any particular densification of
P/M steels is more for Fe-0.5%C-2%Cu-
The densification behavior of all P/M 2%Mo-4%Ti (785 MPa) and minimum for
steels under varying axial stress is shown in Plain carbon steel (628 MPa).
Figure 2. It is clearly shown in the graph
that the densification of sintered P/M
preforms of all materials are taking place in 3.3 Percentage Theoretical Density
three distinct stages during cold upsetting. Versus True Height Strain
During the densification initially the
sintered P/M steels are densified at lower The densification and deformation
rate with corresponding rapid rate of axial behavior of sintered P/M preforms are
stress. This is due to the geometrical shown in figure.3. During cold upsetting
hardening of the preforms. Next stage, the Fe-0.5%C-1%Cu steels are subjected to
there is a gradual increase in both axial more deformation and densification
stress and corresponding values of relative behavior. Fe-0.5%C-2%Cu-2%Mo-4%Ti
density. Once again in the third stage the alloys are subjected to less deformation and
rate of densification is lowered, as the densification behavior. From the above it is
preforms already densified to the maximum concluded that adding more quantity of
level. Sintered preforms of P/M Fe-0.5%C- Cu, Mo and Ti to the Fe-0.5%C-1%Cu steel
1%Cu steel are densifying to the maximum reduces the densification and deformation
level nearly 98% of theoretical density properties.
during densification. Addition of alloying
elements reduces the densification behavior
Recent Advances in Design, Application & Manufacturing Systems RADAMS ‘09
Figure.3 Figure.4
Percentage theoretical density Vs. True height strain Stress Vs. Lateral Strain
Figure.6 Figure.7
% Theoretical density Vs. True height strain % Theoretical density Vs. Lateral strain
4. CONCLUSION and hot upsetting adding of 1%Mo and
The Fe-0.5%C-1%Cu exhibits 1%Ti to Fe-0.5%C-1%Cu steel exhibits
better densification and deformation better densification and deformation
behavior during cold and hot upsetting. behavior. Adding any more quantity of
Addition of alloying elements like Cu, Mo Mo, and Ti (above 1%) to the Fe-0.5%C-
and Ti to the Fe-0.5%C-1%Cu steel reduces 1%Cu steel deteriorates the densification
the densification and deformation and deformation properties during cold and
characteristics of alloy steels. During cold hot upsetting.
5. REFERENCES
ABSTRACT- job shop scheduling is used eminent approach to select the optimum
minimize the makes span of the jobs in the schedule for the operation.
corresponding machines. Its major Certain neighbour hood selection
application is in aircraft, automobile, methods are also discussed. We had solved
semiconductor manufacturing Industry. In an n×m job shop scheduling problem and
this paper we have solved the job shop executed it using the C language program
scheduling problem using simulated and presented the results in an tabulation.
annealing optimization technique. It is an We had selected the best optimum schedule
for the selected problem.
1. INTRODUCTION
Job shop scheduling (JSS) belongs to the the machines. The problem is to find the
class of NP hard optimization problem. Even in schedule of minimum time. Solving the JSS
the N P hard class of problems,JSS appears to problem requires a high computational effort
belong to the more difficult ones .The JSS and considerable sophistication much simpler
problem can be described as follows. A set of task is to find an optimum schedule. JSSP
jobs whose operations are to be processed on consists of a set m of machines and a set n of
set of machines is given. Each job consists of a jobs, where each machine carries out an
sequence of operations have to be processed operation of each job. This problem attempts to
uninterrupted on a given machine for a find the optimum sequence of operations in
specified length of time. There is an additional each machine that allows for the minimization
constraint that each machine can process at of the maximum completion time of the jobs
most one operation at a time. A schedule is an (make span). The models that have been applied
allocation of the operations to time intervals on to JSSP are the disjunctive graph model , the
disjunctive formulation model and the current scheduling solution, the energy function
satisfiability model . The disjunctive graph for the thermodynamic system is analogous to
model is used most frequently due to the fact the objective function and the ground state is
that it is possible to easily manipulate the meta- similar to the global optimum
heuristics applied to JSSP in which minimizing
the make span is desired. 2. LITERATURE REVIEW
Simulated annealing (SA) is a generic Most papers in the literature dealt with
probabilistic metaheuristic for the global the minimization of makespan. In view of the
optimization problem of applied mathematics, NP hardness of problem O||Cmax, branch and
namely good approximation to the global bound as well as heuristic algorithms have been
minimum of a given function in a large search developed for this problem. Among the exact
space. It is often used when the search space is algorithms, we only mention those given by
discrete (e.g., all tours that visit a given set of Laborie and Tamura et al. which were able to
cities). For certain problems, simulated solve open benchmark instances from the recent
annealing may be more effective than literature. A complete search for cumulative
exhaustive enumeration — provided that the scheduling based on the detection and
goal is merely to find an acceptably good resolution of minimal critical sets was
solution in a fixed amount of time, rather than performed.
the best possible solution. The heuristic for selecting such sets
The name and inspiration come from annealing relied on an estimation of the related reduction
in metallurgy, a technique involving heating of the search space, where additionally an
and controlled cooling of a material to increase extension of the search procedure using a self
the size of its crystals and reduce their defects. adapted shaving was proposed. This approach
Simulated annealing (SA) is a random-search was implemented on the top of classical
technique and one of the optimization constraint propagation algorithms. The
technique which exploits an analogy between algorithm was able to solve the remaining 34
the way in which a metal cools and freezes into open instances out of the 80 instances with up
a minimum energy crystalline structure (the to 10 jobs and 10 machines given by Gueret and
annealing process) and the search for a Prins. A method to encode constraint
minimum in a more general system; it forms the satisfaction problems with integer linear
basis of an optimization technique for constraints into
combinatorial and other problems.
The effectiveness of this approach
Local search based scheduling of job was tested on several benchmark instances for
shop plays an important role to solve our the open shop problem. In particular, this
problem and become very popular in recent algorithm was able to solve all the 192
years. The applicable approximation procedures benchmark instances of three sets from the
in the local search process include tabu search, literature. Among metaheuristic algorithms, we
simulated annealing and genetic algorithm. only discuss two papers presenting simulated
These methods can be viewed as tools for annealing algorithms. The first algorithm by
searching a space of legal alternatives in order Liaw used particular neighborhoods based on
to find a best solution within reasonable time up to three pairwise interchanges of two
limitation. adjacent operations belonging to the same job
or being processed on the same machine such
Simulated annealing is based on the that the resulting neighbor satisfies a necessary
analogy to the physical process of cooling and condition for an improvement of the objective
recrystalization of metals. According to Jones function value. The cooling scheme was of the
and Rabelo , the current state of the geometric type and used an initial temperature
thermodynamic system is equivalent to the of 15. The recommended variant had a low
temperature reduction scheme (it used a
reduction factor of 0.995 for the temperature). (i) Select a large starting value for the
The number of iterations with a constant temperature T = T0.
temperature was set to be equal to 30 · n · m. (ii) Select a suitable value for the reducing
Taking into account that at least 100 epochs parameter α, 0 < α < 1.
with constant temperatures have been (iii) Set the initial net ordering at random.
considered per run in [15] (usually even (iv) Evaluate the initial energy (make span),
substantially more epochs), this means that e.g. E(i).
for problems with 20 jobs and 20 machines, at (v) While T is in the cooling range,
least 30 · 20 · 20 · 100 = 1, 200, 000 iterations (a) Select a net at random and change its
had to be performed. Moreover, since five runs position.
were made for each instance and in one (b) Evaluate the new energy, E (j) from this
iteration of the algorithm, up to four neighbors configuration and the resulting change
were checked (see neighborhood NH1 in ) in the energy ∆E.
and the best neighbor among them was then (vi) If ∆E < 0, accept the new state.
taken, much more than 6, 000, 000 feasible If ∆E > 0, accept the new state if Pr(accepted) =
solutions EXP(−∆E/T) > ε.
had to be evaluated per instance to get the (vii) Update T according to T `= αT.
results presented in [15]. Thus, extremely long (viii) Repeat steps from (v) to (vii) until ∆E is
runs of simulated annealing were considered in not significant for small changes in T.
that paper (up to 3.5 hours per single run of an
instance with n = m = 30). On the other side, 3. PROBLEM DESCRIPTION
the quality of the solutions obtained was
comparable to the results obtained by the A five jobs and four machine problem is
insertion algorithm combined with beam search taken .the following problem is taken for
given in [6]. finding the best optimum sequence.
E(n)= total make span in the ‘nth ` stage The first schedule we have used is geometric
cooling, where the new temperature (T’) of the
∆E= current solution-best solution SA algorithm is computed using
T’=α T
ε = probability of acceptance= EXP (−∆E/T) where α (0 < α < 1) denotes the cooling factor.
Typically the value of α is chosen in the range
0:90 to 0:99. This cooling schedule has the
6. NEIGHBOURHOODSELECTION advantage of being well understood, having a
solid theoretical foundation, and being the most
For a JSSP, a neighborhood N(S) of a widely used annealing schedule. Our results
schedule S can be defined as the set of feasible obtained from using this standard cooling
schedules that can be reached from S by exactly schedule will be used as a baseline for
one transition (a single perturbation of S). For comparison with those using the other two
example, a transition operator that exchanges a schedules, which allow the rate of cooling to be
pair of consecutive operations in a critical block varied.
and forms a neighborhood has been used in
Laarhoven, Aarts and Lenstra (1992) and in The physical analogy that is used to
Taillard (1994). The transition operator was justify SA assumes that the cooling rate is low
originally defined by Balas (1969) in his branch enough for the probability distribution of the
and bound approach. Another very powerful current state to be near thermodynamic
transition operator was used in Brucker, Jurisch equilibrium at all times. Unfortunately, the
and Sievers (1994) and in Dell’Amico and relaxation time—the time one must wait for the
Trubian (1993). The transition operator equilibrium to be restored after a change in
permutes the order of operations in a critical temperature—strongly depends on the
block by moving an operation to the beginning "topography" of the energy function and on the
or end of the critical block, thus forming a CB current temperature. In the SA algorithm, the
neighborhood. A schedule obtained from S by relaxation time also depends on the candidate
moving an operation within a block to the front generator, in a very complicated way. Note that
of the block is called a before candidate, and a all these parameters are usually provided as
schedule moving an operation to the rear of the black box functions to the SA algorithm.
block is called an after candidate. A set of all
before and after candidates N’C(S) may contain Therefore, in practice the ideal cooling
infeasible schedules. The CB neighborhood is rate cannot be determined beforehand, and
given as: should be empirically adjusted for each
problem. The variant of SA known as
Nc(S) = {S′ ∈ N’c(S) | S′ is a feasible thermodynamic simulated annealing tries to
schedule}. avoid this problem by dispensing with the
cooling schedule, and instead automatically
It has been experimentally shown byYamada, adjusting the temperature at each step based on
Rosen andNakano (1994) that the CB the energy difference between the two states,
neighborhood is more powerful than the former according to the laws of thermodynamics.
one.
8. STEPS TO BE FOLLOWED FOR
7. ANNEALING SCHEDULES SOLVING THE PROBLEM
Three annealing schedules have been used in I. Initially select an random sequence
our experiments to update the temperature of of jobs
the SA algorithm geometric cooling, adaptive
II. Then we have to calculate the total T=100ºc
completion time for all the five jobs Best solution = 39
in the four machines. Next for the second random sequence
III. From the above calculated In the second stage
completion time select the
maximum completion time as the J1 J5 J3 J4 J2
total makes span E(1)=39
IV. Total makes span= ∆E=0
max(tM1,tM2,tM3,tM4).where Corresponding temperature T’=0.9(100)=90ºc
tMn= total completion time of jobs
in the corresponding machine. keep Same value therefore no change in the best
this makes span as the best solution. solution
V. Initialize the temperature
VI. Initialize the ending temperature to In the 12th stage
stop searching. ∆E=-1<0 E(11)=38
VII. Initialize the cooling rate and
probability of acceptance. Change best solution = 38 and corresponding
VIII. Select the next neighborhood by temperature is 31.38ºc. for full schedules see
following the above discussed and table 1.
conditions and form next random
sequence of job order. 9. ABOUT PROGRAM IN C LANGUAGE
IX. For the selected random sequence of A C program had been written to
jobs find the total makes span. This calculate the best schedule from the given
is the current solution. Calculate the problem. That coding will require the following
∆E= current solution-best solution inputs
and temperature T `= αT. Assume
cooling rate=0.90 1) The number of jobs and number of
X. If ∆E> 0. Calculate probability of machines. The input of the processing
acceptance. time of jobs in the corresponding
XI. If ∆E<0. Change the best solution. machines.
Best solution= current solution. 2) The cooling rate value , probability of
Accept the corresponding schedule. acceptance value
3) The starting and ending temperature
XII. If probability of acceptance lies value
with in the given range accept them Then it will calculate the make span ,
as probably accepted schedules. temperature, probability of acceptance.
XIII. Repeat all these steps until the
decreasing temperature reaches the From this it will generate an output in
given ending temperature. the notepad format containing all the details.
Finally it will show the best and probably
8. EXAMPLE CALCULATION FOR accepted the schedules from the given data.
SELECTED RANDOM SCHEDULE
10. BARRIER AVOIDANCE
For example select this random sequence
J1J2 J3 J4 J5 When choosing the candidate generator
neighbor one must also try to reduce the
For this calculate the total makes span when it number of "deep" local minima — states (or
comes out of the fourth machine finally. sets of connected states) that have much lower
Total makes span E(0)= 39 energy than all its neighboring states. Such
"closed catchment basins" of the energy
function may trap the SA algorithm with high simple changes to the generator. In the traveling
probability (roughly proportional to the number salesman problem, for instance, it is not hard to
of states in the basin) and for a very long time exhibit two tours A, B, with nearly equal
(roughly exponential on the energy difference lengths, such that (0) A is optimal, (1) every
between the surrounding state and the bottom of sequence of city-pair swaps that converts A to B
the basin). goes through tours that are much longer than
both, and (2) A can be transformed into B by
As a rule, it is impossible to design a flipping (reversing the order of) a set of
candidate generator that will satisfy this goal consecutive cities. In this example, A and B lie
and also prioritize candidates with similar in different "deep basins" if the generator
energy. On the other hand, one can often vastly performs only random pair-swaps; but they will
improve the efficiency of SA by relatively be in the same basin if the generator performs
random segment-flips.
Best Schedule is J3 J4 J1 J2 J5
and the corresponding temperature is 6.46
11. RESULTS AND CONCLUSION cooling of the temperature. SA can find the
global optimum. However, this requires infinite
Thus the given problem is solved using the time. Fast annealing and very fast simulated
simulated annealing approach and the optimum reannealing
schedule is selected from the set of solutions (VFSR) or adaptive simulated annealing (ASA)
which takes the minimum makes span. It has are each in turn exponentially faster and
been solved by carefully controlling the rate of overcome this problem.
12. REFERENCES
[1] K. R. Barker, Introduction to Sequencing and Scheduling, John Wiley & Sons, New
York, 1974.
[2] J. Blazewicz, W. Domschke, E. Pesch, The Job Shop Scheduling Problem: Conventional
And New Solution Techniques, European Journal of Operational Research 93
(1996), 1–33.
[3] J. Blazewicz, K. H. Ecker, E. Pesch, G. Schmidt, J. Weglarz, Scheduling Computer
and Manufacturing Processes, Springer-Verlag, Berlin Heidelberg New York, 2001.
[5] A Branch and Bound and Simulated Annealing Approach for Job Shop Scheduling Tan Hui
Woon & Sutinah Salim Department of Mathematics, Universiti Teknologi Malaysia, 81310 UTM,
Skudai, Johor, Malaysia
[6] S. Kirkpatrick, C.D. Gelatt, and M.P. Vecchi, Optimization by Simulated Annealing,
Science, Vol. 220. No. 4598.(1983), 671–680.
[7] K. Krishna, K. Ganeshan, and D. Janaki Ram, Distributed Simulated Annealing Algorithms
for Job Shop Scheduling, IEEE Transactions on Systems, Man. And Cybernetics.
Vol. 25. No. 7.(1995), 1102–1109.
An Estimate of Parallelism in
In-parallel Robotic Structures
Prof. A.B.SRINIVASA RAO1 & Mr. V.V.KAMESH2
1DEAN(ACADEMICS),ADITYA ENGINEERING COLLE
GE,SURAMPALEM, E.G.DIST.,AP
Email: absrao71@gmail.com 2PG STUDENT, JNT UNIVERSITY, KAKINADA
Email: kameshvv@gmail.com
Fig 4(c)
Fig 5(a)
Fig 4(d)
CONCLUSIONS