Showing posts with label Mechanical. Show all posts
Showing posts with label Mechanical. Show all posts
Abstract:
Abrasive water jet machine tools are suddenly being a hit in the market since they are quick to program and could make money on short runs. They are quick to set up, and offer quick turn-around on the machine. They complement existing tools used for either primary or secondary operations and could make parts quickly out of virtually out of any material. One of the major advantage is that they donot heat the material. All sorts of intricate shapes are easy to make. They turns to be a money making machine.
So ultimately a machine shop without a water jet , is like a carpenter with out a hammer. Sure the carpenter can use the back of his crow bar to hammer in nails, but there is a better way. It is important to understand that abrasive jets are not the same thing as the water jet although they are nearly the same. Water Jet technology has been around since the early 1970s or so, and abrasive jets extended the concept about ten years later. Both technology use the principle of pressuring water to extremely high pressure, and allowing the water to escape through opening typically called the orifice or jewel. Water jets use the beam of water exiting the orifice to cut soft stuffs like candy bars, but are not effective for cutting harder materials. The inlet water is typically pressurized between 20000 and 60000 Pounds Per Square Inch (PSI). This is forced through a tiny wall in the jewel which is typically .007” to .015” diameter (0.18 to0.4 mm) . This creates a vary high velocity beam of water. Abrasive jets use the same beam of water to accelerate abrasive particles to speeds fast enough to cut through much faster material.
Source: www.newtechpapers.com
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Abstract:
Magnetic levitation is the latest in transportation technology and has been the interest of many countries around the world. The idea has been around since 1904 when Robert Goddard, an American Rocket scientist, created a theory that trains could be lifted off the tracks by the use of electromagnetic rails. Many assumptions and ideas were brought about throughout the following years, but it was not until the 1970’s that Japan and Germany showed interest in it and began researching and designing.
Magnetic levitation is the latest in transportation technology and has been the interest of many countries around the world. The idea has been around since 1904 when Robert Goddard, an American Rocket scientist, created a theory that trains could be lifted off the tracks by the use of electromagnetic rails. Many assumptions and ideas were brought about throughout the following years, but it was not until the 1970’s that Japan and Germany showed interest in it and began researching and designing.
The motion of the Maglev train is based purely on magnetism and magnetic fields. This magnetic field is produced by using high-powered electromagnets. By using magnetic fields, the Maglev train can be levitated above its track, or guideway, and propelled forward. Wheels, contact with the track, and moving parts are eliminated on the Maglev train, allowing the Maglev train to essentially move on air without friction.
Source: www.newtechpapers.com
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Synthetic polymers are often referred to as "plastics", such as the well-known polyethylene and nylon. However, most of them can be classified in at least three main categories: thermoplastics, thermosets and elastomers.
Man-made polymers are used in a bewildering array of applications: food packaging, films, fibers, tubing, pipes, etc. The personal care industry also uses polymers to aid in texture of products, binding, and moisture retention (e.g. in hair gel and conditioners).
Source: www.newtechpapers.com
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Abstract:
Flywheel energy storage systems store kinetic energy (i.e. energy produced by motion) by constantly spinning a compact rotor in a low-friction environment. When short term back-up power is required (i.e. when utility power fluctuates or is lost), the rotor's inertia allows it to continue spinning and the resulting kinetic energy is converted to electricity.
Active Power's CleanSource Flywheel Technology, as shown Below, integrates the function of a motor, flywheel rotor and generator into a single intergrated system, The motor, which uses electric current from the utility grid to provide energy to rotate the flywheel, spins constantlyto maintain a ready source kinetic energy.
Flywheel energy storage systems store kinetic energy (i.e. energy produced by motion) by constantly spinning a compact rotor in a low-friction environment. When short term back-up power is required (i.e. when utility power fluctuates or is lost), the rotor's inertia allows it to continue spinning and the resulting kinetic energy is converted to electricity.
Active Power's CleanSource Flywheel Technology, as shown Below, integrates the function of a motor, flywheel rotor and generator into a single intergrated system, The motor, which uses electric current from the utility grid to provide energy to rotate the flywheel, spins constantlyto maintain a ready source kinetic energy.
Source: www.newtechpapers.com
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Abstract:
Phase Change Materials (PCM) are used in latent heat storage system. The use of PCM is the best method of thermal energy storage, because the process of storage is isothermal and the specific heat capacity of the PCM is infinite and hence the storage density is very high. But the thermal conductivity of PCM is manifestly low. In order to counterbalance that Nanoparticles are utilized. The selection of PCM plays vital role in the thermal energy storage system. In this paper an attempt is made to provide information on Phase Change Materials for thermal energy storage for various applications and the use of proper nanoparticle for it. This paper also assists to enhance the rate of heat transfer while charging and discharging of stored thermal energy.
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Abstract:
Shape change and dimension change in association with the plastic flow of residual stresses are the perennial problems as far as welding is concerned. Apart from shape and dimensional changes the distortion poses problem of difficulties on further assembly and maintaining the aesthetics. Correcting distortion involves heavy cost and time and in many cases the correction becomes impossible. These difficulties prompt to develop methods to control distortion during various stages of fabrication. They involve theoretical prediction and proper sequencing to balance the heat input to control distortion rather than correcting it after occurring. It is to be noted that the prediction of distortion is not an easy task since it involves analysis of transient thermal stresses and computation of incompatible plastic strains.Hence in many, the practical application of proper sequence of weld would relieve us from the worry of distortion..
The objective was to control distortion during fabrication of a vessel which has many internals. Each internal has a number of stiffeners which were to be welded on the internal. Considering the amount of welding and high heat input, it is found out that the distortion would likely to be more. Further, to add to this problem, the stiffeners were to be welded only on one side of the all the internals and also the maximum thickness of internals were 8 mm. After a detailed analysis on heat input, size of the internal and one side welding, it was decided to devise proper weld sequence of each internal and also proper sequences for the internal to the main vessel welding. Accordingly weld sequences were devised for more than 20 internals. Due to heavy welding on one side, one of the internals got deformed slightly above the required levels. Since heating on the component was restricted, this deformation was corrected mechanically. After fabricating all the internal assemblies they were welded to the main shell with suitable sequences so the mismatching problem was avoided.
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LOW COST AUTOMATION USING ELECTRO PNEUMATIC SYSTEM – AN ON LINE CASE STUDY IN MULTISTATION PART TRANSFER, DRILLING AND TAPPING MACHINE
Abstract:
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This paper discusses the case study and, comparison of productivity of a component using a real time multi stationed AUTOMATED ROTARY TRANSFER LINE used for Drilling, tapping and inspecting a standard block of size 50 X 50 X 75 mm with drill size diameter 5 x 20 mm long and tapping the drill by M6 machine Tap.
The clamping of the component, part transfer and feed of the drilling machine spindle is done using electro-pneumatics. The total logic of the system is based on Low cost automation with the micro controllers. The following studies are carried out 1. Time saved by component handling (loading and unloading), using pneumatic clamping, 2. Increase in productivity both qualitative and quantitative, 3. Improved repeatability and accuracy, 4. Less human intervention, indirectly reduction in operator fatigue, 5.Less rejection due to automatic controls 6.Minimization of production costs.
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Abstract:
This paper is based on the project “Design and Fabrication of Vacuum Groundnut Dryer”. This is a design innovative project. The project provides solution for drying groundnuts in efficiently and economically.
Groundnut is one of the major oil seeds of India. In our Country the drying of unshelled groundnut is carried out mostly in natural lights which take longer times. Moreover the harvesting of groundnut takes place during rainy season, which affects the drying time and quality. Groundnut accounts for around 28% of the total oilseed production of the country. Annual production of seed and oil are around 5-8 and 1.5 million tons respectively. Due to industrialization of Indian economy, labour cost is becoming high for agricultural and related activities. Labour availability is also less. So there is need for alternative method in agricultural processes. Like most other agriculture crops, groundnuts are semi perishable and their quality during storage can be deteriorated through microbial proliferation, insect and rodent infestation, loss of flavor, viability and rancidity due to biochemical changes as well as absorption of certain odours and chemicals. After going through the advantages and principles of the vacuum drying technique, and keeping the problems faced by the Indian farmers in mind, an attempt has been made for drying groundnut with the help of vacuum energy. That’s this project called VACUUM GROUNDNUT DRYER. The operating characteristics of the vacuum drying process result in significant advantages in terms of productivity, quality and energy consumption.
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Abstract:
Our paper aims at controlling the flow rate of coolant by regulating the valve by implementing FUZZY LOGIC. In conventional process the flow rate is constant over the entire engine jacket. These effects in over heating and excessive cooling, which induces thermal stresses & reduction in efficiency.. The flow rate of coolant will be controlled by control unit & intelligent sensors. In this system the sensor will sense the cylinder temperature as similar as thermostat and will control the opening and closing of water passage in the piston cylinder arrangement. The mass flow rate of water will be controlled by a valve arrangement. If the temperature of the engine cylinders increases, the sensor will sense the temperature and the signal is given to the control unit and it controls the valve opening resulting in increase in the flow rate. Similarly when the engine retards the temperature of the cylinder decreases which will be sensed by the sensor and will operate the valve. It helps in improving thermal efficiency and mechanical efficiency.
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Abstract:
The market for air cooled steels has matured in the last 10 years. The advantages of these steels, in terms of elimination of heat treatment, reduced distortion, improved machinability and more consistent properties have led to their use in a wide range of automotive components. In Europe, most forgers, working in partnership with steel producers, now have the necessary equipment and expertise to enable cooling after forging to be controlled accurately and reliably. The use of controlled rolling and cooling has also enabled the required mechanical properties to be achieved in bar stock without the need for heat treatment. The paper reviews the grades of microalloyed and carbon manganese steels in current use and the properties of these steels. It considers how these properties can be influenced by the steelmaker through composition adjustment and controlled rolling, and by the forger by control of the forging and cooling conditions. A number of case studies are used to demonstrate these points. Possible future developments of both microalloyed and carbon steels are also reviewed. These include the use of accelerated cooling and the use of higher carbon and nitrogen steels.
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The market for air cooled steels has matured in the last 10 years. The advantages of these steels, in terms of elimination of heat treatment, reduced distortion, improved machinability and more consistent properties have led to their use in a wide range of automotive components. In Europe, most forgers, working in partnership with steel producers, now have the necessary equipment and expertise to enable cooling after forging to be controlled accurately and reliably. The use of controlled rolling and cooling has also enabled the required mechanical properties to be achieved in bar stock without the need for heat treatment. The paper reviews the grades of microalloyed and carbon manganese steels in current use and the properties of these steels. It considers how these properties can be influenced by the steelmaker through composition adjustment and controlled rolling, and by the forger by control of the forging and cooling conditions. A number of case studies are used to demonstrate these points. Possible future developments of both microalloyed and carbon steels are also reviewed. These include the use of accelerated cooling and the use of higher carbon and nitrogen steels.
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Abstract:
Distortion resulting from heat treatment has a significant effect upon final component costs. Most of the factors which influence distortion behaviour arise during the machining and heat treatment processes and are therefore outside the control of the steelmaker. One important factor which is under the jurisdiction of the steelmaker is hardenability. Consistent hardenability performance can have a significant effect in reducing the variability in distortion. In a number of instances, it has been shown that the macrostructure and as-cast shape of the steel can also influence distortion. Other downstream processing effects, such as forging, may also be influential in these circumstances. This paper gives examples of some of the experiences of British Steel Engineering Steels, with customers and endusers, and refers to relevant published work.
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Distortion resulting from heat treatment has a significant effect upon final component costs. Most of the factors which influence distortion behaviour arise during the machining and heat treatment processes and are therefore outside the control of the steelmaker. One important factor which is under the jurisdiction of the steelmaker is hardenability. Consistent hardenability performance can have a significant effect in reducing the variability in distortion. In a number of instances, it has been shown that the macrostructure and as-cast shape of the steel can also influence distortion. Other downstream processing effects, such as forging, may also be influential in these circumstances. This paper gives examples of some of the experiences of British Steel Engineering Steels, with customers and endusers, and refers to relevant published work.
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Abstract:
Automotive steel forgings are under threat from alternative materials offering either reduced weight (e.g. aluminium) or reduced cost (e g. cast iron). The competition is particularly acute in the chassis, and it is not unusual to find a range of different materials and manufacturing technologies employed within modern suspension systems. British Steel Engineering Steels (BSES) has recognised that Early Vendor Involvement with vehicle manufacturers can be exploited in order to reverse the trend and promote the use of steel forgings. BSES has carried out two demonstration projects with a major vehicle manufacturer, involving two forging companies. One of the projects optimised an existing steel forging and the other successfully demonstrated the replacement of a cast iron component with a steel forging. The projects sought to optimise components in terms of design, manufacturing and materials, using the expertise of all elements of the supply chain and were coordinated by British Steel's Automotive Engineering Group (BS AEG). The results of the projects have shown that there is a significant opportunity to improve the weight and cost competitiveness of steel forgings and thus ensure their continued or extended use in future automotive applications. It has also demonstrated that the steel industry can present a highly credible automotive engineering input to vehicle programmes and become valued partners in those programmes at the earliest opportunity.
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Automotive steel forgings are under threat from alternative materials offering either reduced weight (e.g. aluminium) or reduced cost (e g. cast iron). The competition is particularly acute in the chassis, and it is not unusual to find a range of different materials and manufacturing technologies employed within modern suspension systems. British Steel Engineering Steels (BSES) has recognised that Early Vendor Involvement with vehicle manufacturers can be exploited in order to reverse the trend and promote the use of steel forgings. BSES has carried out two demonstration projects with a major vehicle manufacturer, involving two forging companies. One of the projects optimised an existing steel forging and the other successfully demonstrated the replacement of a cast iron component with a steel forging. The projects sought to optimise components in terms of design, manufacturing and materials, using the expertise of all elements of the supply chain and were coordinated by British Steel's Automotive Engineering Group (BS AEG). The results of the projects have shown that there is a significant opportunity to improve the weight and cost competitiveness of steel forgings and thus ensure their continued or extended use in future automotive applications. It has also demonstrated that the steel industry can present a highly credible automotive engineering input to vehicle programmes and become valued partners in those programmes at the earliest opportunity.
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Abstract:
Corus Engineering Steels (CES) produces approximately 1.5MTpa of engineering steel, over half of which is consumed by the automotive industry, through its associated supply chains. Two of the most significant drivers in the automotive component sector are weight and through-cost reduction. Forged engineering steels face increasing challenges to their dominant role in the automotive engine, transmission and suspension sectors. Not only are alternative materials and competitive processing routes significant elements of that challenge, but so are the globalisation of the automotive industry and progressive rationalisation of component supply chains. Steel suppliers, forgers and other supply chain players must therefore co-operate effectively if engineering steel components are to meet the automotive industry's through-cost, weight, durability, recyclability and other performance expectations. This paper illustrates how, through working closely with its supply chain, involving forgers, machinists and end users, CES has exploited its materials expertise and the component design expertise of Corus colleagues, to develop innovative and effective solutions to the automotive industry's evolving needs.
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Corus Engineering Steels (CES) produces approximately 1.5MTpa of engineering steel, over half of which is consumed by the automotive industry, through its associated supply chains. Two of the most significant drivers in the automotive component sector are weight and through-cost reduction. Forged engineering steels face increasing challenges to their dominant role in the automotive engine, transmission and suspension sectors. Not only are alternative materials and competitive processing routes significant elements of that challenge, but so are the globalisation of the automotive industry and progressive rationalisation of component supply chains. Steel suppliers, forgers and other supply chain players must therefore co-operate effectively if engineering steel components are to meet the automotive industry's through-cost, weight, durability, recyclability and other performance expectations. This paper illustrates how, through working closely with its supply chain, involving forgers, machinists and end users, CES has exploited its materials expertise and the component design expertise of Corus colleagues, to develop innovative and effective solutions to the automotive industry's evolving needs.
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Abstract:
When a metal is formed, its material properties change compared to the virgin 'as delivered' material. These changes can have an important effect on the performance of the resulting part in service. Corus has developed advanced techniques to incorporate the new material properties resulting from forming operations into CAE models that predict e.g. Crash or Fatigue behaviour. Presented at the LS-DYNA conference.
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When a metal is formed, its material properties change compared to the virgin 'as delivered' material. These changes can have an important effect on the performance of the resulting part in service. Corus has developed advanced techniques to incorporate the new material properties resulting from forming operations into CAE models that predict e.g. Crash or Fatigue behaviour. Presented at the LS-DYNA conference.
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Characterisation and modelling of the plastic material behaviour and its application in sheet metal forming simulation
Abstract:
The application of simulation models in sheet metal forming in the automotive industry has proven to be beneficial to reduce tool costs at the designing stage and for optimising current processes. Moreover, it is a promising tool for a material supplier to optimise material choice and development for both its final application and its forming capability. The present practice requires a high predictive value of these simulations. A first stage is to implement the improved material models which describe this single strain path behaviour in a better way. Results are compared with predictions using Marciniak-Kuczinsky-analysis with both the new material model and the conventional material model. Finally, the validation on real pressed products is shown by comparing simulation results using different material models with the experimental data. The test required to measure the required material data are described in this conference paper.
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The application of simulation models in sheet metal forming in the automotive industry has proven to be beneficial to reduce tool costs at the designing stage and for optimising current processes. Moreover, it is a promising tool for a material supplier to optimise material choice and development for both its final application and its forming capability. The present practice requires a high predictive value of these simulations. A first stage is to implement the improved material models which describe this single strain path behaviour in a better way. Results are compared with predictions using Marciniak-Kuczinsky-analysis with both the new material model and the conventional material model. Finally, the validation on real pressed products is shown by comparing simulation results using different material models with the experimental data. The test required to measure the required material data are described in this conference paper.
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Abstract:
The main thesis of this paper is to analyze the effect of inlet center body (spike) extending forwardly of the cowl inlet capture area of adjustable air inlet of variable geometry, for a supersonic aircraft, to continuously and effectively regulate the incoming air throughout the aircraft operating range of idle, subsonic, sonic and supersonic speeds. This is done by axially translating the inlet center body, for positioning of an external or initial shock wave front such that it extends conically between the apex of the spike and leading edge of the cowl for external
supersonic spillage of the air thereby regulating the engine air mass requirements. The main object is to provide inlet which is adjustable to match engine air flow characteristics while achieving high performance through high pressure recovery and low drag. In this a movable spike is utilized at supersonic speed for regulating both external supersonic low drag spillage and internal throat supersonic diffusion and the results are analyzed using CFX solver computationally.
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Abstract:
Due to increasing environmental concerns the need for inexpensive selective gas sensors is increasing. This work deals with transferring a novel zeolite-based impedimetric hydrocarbon gas sensor principle, which has been originally manufactured in a costly combination of photo lithography, thin-film processes, and thick-film processes to a lowcost technology comprising only thick-film processes and one electroplating step. Thesensing effect is based on a thin chromium oxide layer between the interdigital electrodes and a Pt-loaded ZSM-5 zeolite film. When hydrocarbons are present in the sensor ambient, the electrical sensor impedance increases strongly and selectively. In the present work, the chromium oxide film is electroplated on Au screen-printed interdigital electrodes and then oxidized to Cr2O3. The electrode area is covered with the screen-printed zeolite. The sensor device is self-heated utilizing a planar platinum heater on the backside. The best sensor performance is obtained at a frequency of 3 Hz at around 350 °C. The good selectivity of the original sensor setup could be confirmed, but a strong cross-sensitivity to ammonia occurs, which might prohibit its original intention for use in automotive exhausts.
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Abstract:
Positional control is fundamental to most manufacturing processes as well as a wide range of other applications. Many types of positional devices have been proposed and used, ranging from robotic arms to Stewart platforms this paper discusses about the usage of nanotechnology in military field and implementing the concept of nanorobotics in the battle fields. Nanotechnology is an enabling technique that could have an impact on the world that dwarfs the internet’s impact on our daily life. Nanotechnology as a rapidly growing era in this decade, including how it could enhance national security, making the soldier more effective in the battle field. Small computers would be embedded in nano equipments and linked into pervasive networks on all levels to contribute to our future security.
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Abstract:
Welding has become an indispensable metal joining process in fabrication industries. Welding fumes evolved during welding process not only pollute environment, but also cause occupational health problem to the welders.
The National Institute for Occupational Safety and Health (NIOSH) defines welding fumes as potential occupational carcinogens. Welding fumes require more filtrations practically than any other application in industry, so strategy was developed to save environment as well as workers. Fumes with sub micron particle size can be cleaned by filters, fabric collectors, electrostatic precipitator, cyclone separators, and spray towers for purification. A fume extraction system employing ESP (Electro Static Precipitator) is high compare with other air cleaning devices.
This paper focuses on the effectiveness of the fume extractor with an Electrostatic Precipitator used in a welding environment.
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Abstract:
Rotary motion of the drill is achieved through motor and linear motion through hydro pneumatic cylinder. Clamping of the component is achieved by pneumatic cylinder. This project provides a better accuracy, repeatability and high productivity against the existing machines, where the drill is done one at a time and tolerance in centre distance is obtained through a jig. As far as the electrical part is concerned, the actuation of the hydro pneumatic cylinder is obtained through a double solenoid 5/2 direction control valve. The motor used is a 3 phase flange mounted type motor with a speed of 1440 rpm which is reduced through a step cone pulley coupled through v-belt. The motor is switched on via an overload contactor for safety. Manual and automatic control options are provided for safe operation. In case of any accidents, for immediate shut off of the system an emergency stop switch is provided. Indicators are provided for motor, cylinder and system on/off condition.
This project is a perfect illustration of what is Mechatronics, how automation can be done and through which how increased productivity can be obtained.