Search results for: railway wheel/rail wear

Authors: Majid Mokhtari, Masoud Bahrami Alamdarlo, Babak Nazari, Hossein Zakerinya, Mehdi Salehi

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In this study, microstructure, macro, and microhardness of phases for three grades of cast iron rolls with modified chemical composition using a light microscope (OM) and electron microscopy (SEM) were investigated. The grades were chosen from Chodan Sazan Manufacturing Co. (CSROLL) productions for finishing stands of hot strip mills. The percentage of residual austenite was determined with a ferrite scope magnetic device. Thermal susceptibility testing was also measured. The results show the best oxidation resistance at high temperatures is graphitic high chromium white cast iron alloy. In order to evaluate the final properties of these grades in rolling lines, the results of the Pin on Disk abrasion test showed the superiority of the abrasive behavior of the white chromium graphite cast iron alloy grade sample at the same hardness compared to conventional alloy grades and the enhanced grades.

Keywords: hot roller, wear, behavior, microstructure

Procedia PDF Downloads 216

Authors: Rafał Kamiński, Joel Rech, Philippe Bertrand, Christophe Desrayaud

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Additive manufacturing is a hot topic for industry. Among the additive techniques, Selective Laser Melting (SLM) becomes even more popular, especially for making parts for aerospace applications, thanks to its design freedom (customized and light structures) and its reduced time to market. However, some functional surfaces have to be machined to achieve small tolerances and low surface roughness to fulfill industry specifications. The complex shapes designed for SLM (ex: titanium turbine blades) necessitate the use of ball end milling operations like in the conventional process after forging. However, the metallurgical state of TA6V is very different from the one obtained usually from forging, because of the laser sintering layer by layer. So this paper aims to investigate the influence of new TA6V metallurgies produced by SLM on the machinability in ball end milling. Machinability is considered as the property of a material to obtain easily and by a cheap way a functional surface. This means, for instance, the property to limit cutting tool wear rate and to get smooth surfaces. So as to reach this objective, SLM parts have been produced and heat treated with various conditions leading to various metallurgies that are compared with a standard equiaxed α+β wrought microstructure. The machinability is analyzed by measuring surface roughness, tool wear and cutting forces for a range of cutting conditions (depth of cut 'ap', feed per tooth 'fz', spindle speed 'N') in accordance with industrial practices. This work has revealed that TA6V produced by SLM can lead to a better machinability that standard wrought alloys.

Keywords: ball milling, selective laser melting, surface roughness, titanium, wear

Procedia PDF Downloads 263

Authors: Masoud Safarishaal

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Detecting the location of pole-to-earth faults is essential for the safe operation of the electrical system of the railroad. This paper aims to use a combination of evolutionary algorithms and neural networks to increase the accuracy of single pole-to-earth fault detection and location on the Tehran railroad power supply system. As a result, the Imperialist Competitive Algorithm (ICA) and Particle Swarm Optimization (PSO) are used to train the neural network to improve the accuracy and convergence of the learning process. Due to the system's nonlinearity, fault detection is an ideal application for the proposed method, where the 600 Hz harmonic ripple method is used in this paper for fault detection. The substations were simulated by considering various situations in feeding the circuit, the transformer, and typical Tehran metro parameters that have developed the silicon rectifier. Required data for the network learning process has been gathered from simulation results. The 600Hz component value will change with the change of the location of a single pole to the earth's fault. Therefore, 600Hz components are used as inputs of the neural network when fault location is the output of the network system. The simulation results show that the proposed methods can accurately predict the fault location.

Keywords: single pole-to-pole fault, Tehran railway, ICA, PSO, artificial neural network

Procedia PDF Downloads 100

Authors: Chao He, Shunhua Zhou, Peijun Guo

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The vast majority of existing underground railway lines consist of twin tunnels. In this paper, the dynamic interaction between two neighboring tunnels in a layered half-space is investigated by an analytical model. The two tunnels are modelled as cylindrical thin shells, while the soil in the form of a layered half-space with two cylindrical cavities is simulated by the elastic continuum theory. The transfer matrix method is first used to derive the relationship between the plane wave vectors in arbitrary layers and the source layer. Thereafter, the wave translation and transformation are introduced to determine the plane and cylindrical wave vectors in the source layer. The solution for the dynamic interaction between twin tunnels in a layered half-space is obtained by means of the compatibility of displacements and equilibrium of stresses on the two tunnel–soil interfaces. By coupling the proposed model with a fully track model, the train-induced vibrations from twin tunnels in a multi-layered half-space are investigated. The numerical results demonstrate that the existence of a neighboring tunnel has a significant effect on ground vibrations.

Keywords: underground railway, twin tunnels, wave translation and transformation, transfer matrix method

Procedia PDF Downloads 95

Authors: Monish Sengupta, Benjamin Heydecker, Daniel Woodland

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New train control systems rely mainly on Automatic Train Protection (ATP) and Automatic Train Operation (ATO) dynamically to control the speed and hence performance. The ATP and the ATO form the vital element within the CBTC (Communication Based Train Control) and within the ERTMS (European Rail Traffic Management System) system architectures. Reliable and accurate measurement of train location, speed and acceleration are vital to the operation of train control systems. In the past, all CBTC and ERTMS system have deployed a balise or equivalent to correct the uncertainty element of the train location. Typically a CBTC train is allowed to miss only one balise on the track, after which the Automatic Train Protection (ATP) system applies emergency brake to halt the service. This is because the location uncertainty, which grows within the train control system, cannot tolerate missing more than one balise. Balises contribute a significant amount towards wayside maintenance and studies have shown that balises on the track also forms a constraint for future track layout change and change in speed profile.This paper investigates the causes of the location uncertainty that is currently experienced and considers whether it is possible to identify an effective filter to ascertain, in conjunction with appropriate sensors, more accurate speed, distance and location for a CBTC driven train without the need of any external balises. An appropriate sensor fusion algorithm and intelligent sensor selection methodology will be deployed to ascertain the railway location and speed measurement at its highest precision. Similar techniques are already in use in aviation, satellite, submarine and other navigation systems. Developing a model for the speed control and the use of Kalman filter is a key element in this research. This paper will summarize the research undertaken and its significant findings, highlighting the potential for introducing alternative approaches to train positioning that would enable removal of all trackside location correction balises, leading to huge reduction in maintenances and more flexibility in future track design.

Keywords: ERTMS, CBTC, ATP, ATO

Procedia PDF Downloads 399

Authors: R. A. Ribeiro, P. D. Angelo Assunção, E. M. Braga

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The microhardness in weld beads is a function of the microstructure obtained in the welding process, and this by its time is dependent of the input variables established at the outset of the process. In this study the influence of angle between the plate and the cold wire, the position in which the cold wire is introduced and the rate in which this introduction is made are assessed as input parameters in CW-GMAW process. This paper looks to show that ordinary changes in the frame of CW-GMAW can improve microhardness, which is expected to vary as the input parameters change. To properly correlate the changes in the input parameters to consequent changes in microhardness of the weld bead, a full factorial design was employed. In fact, changes in the operational parameters improved the overall microhardness of the weld bead, which in turns can be an indication of improvement in the resistance to abrasive wear, constituting a cheap way to augment the abrasion wear resistance of welds used for cladding.

Keywords: abrasion, CW-GMAW, full factorial design, microhardness

Procedia PDF Downloads 534

Authors: Mauricio E. Cruz, Ilse Cervantes, Manuel J. Fabela

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The evaluation of the maneuverability of road vehicles is generally carried out through the use of specialized computer programs due to the advantages they offer compared to the experimental method. These programs are based on purely geometric considerations of the characteristics of the vehicles, such as main dimensions, the location of the axles, and points of articulation, without considering parameters such as weight distribution and magnitude, tire properties, etc. In this paper, we address the problem of maneuverability in a semi-trailer truck to navigate urban streets, maneuvering yards, and parking lots, using the Ackerman principle to propose a kinematic model that, through geometric considerations, it is possible to determine the space necessary to maneuver safely. The model was experimentally validated by conducting maneuverability tests with an articulated vehicle. The measurements were made through a GPS that allows us to know the position, trajectory, and speed of the vehicle, an inertial motion unit (IMU) that allows measuring the accelerations and angular speeds in the semi-trailer, and an instrumented steering wheel that allows measuring the angle of rotation of the flywheel, the angular velocity and the torque applied to the flywheel. To obtain the steering angle of the tires, a parameterization of the complete travel of the steering wheel and its equivalent in the tires was carried out. For the tests, 3 different angles were selected, and 3 turns were made for each angle in both directions of rotation (left and right turn). The results showed that the proposed kinematic model achieved 95% accuracy for speeds below 5 km / h. The experiments revealed that that tighter maneuvers increased significantly the space required and that the vehicle maneuverability was limited by the size of the semi-trailer. The maneuverability was also tested as a function of the vehicle load and 3 different load levels we used: light, medium, and heavy. It was found that the internal turning radii also increased with the load, probably due to the changes in the tires' adhesion to the pavement since heavier loads had larger contact wheel-road surfaces. The load was found as an important factor affecting the precision of the model (up to 30%), and therefore I should be considered. The model obtained is expected to be used to improve maneuverability through a robust control system.

Keywords: articuled vehicle, experimental validation, kinematic model, maneuverability, semi-trailer truck

Procedia PDF Downloads 104

Authors: Cheuk Wing Lee, Kit Lun Yick, Sun Pui Ng, Joanne Yip

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Daily activities and exercise may result in large displacements of the breasts, which lead to breast pain and discomfort. Therefore, a proper bra design and fit can help to control excessive breast motion to prevent the over-stretching of the connective tissues. Nevertheless, bra fit problems, such as excessively high tension of the shoulder straps and a tight underband could have substantially negative effects on the wear comfort and health of the wearer. The purpose of this study is to, therefore, examine the effects of bra band tension on breast displacement. Usually, human wear trials are carried out, but there are inconsistencies during testing. Therefore, a soft manikin torso is used to examine breast displacement at walking speeds of 2.30 km/h and 4.08 km/h. The breast displacement itself is determined by using a VICON motion capture system. The 3D geometric changes of the underwire bra band tension and the corresponding control of breast movement are also analyzed by using a 3D handheld scanner along with Rapidform software. The results indicate that an appropriate bra band tension can help to reduce breast displacement and provide a comfortable angle for the underwire. The findings can be used by designers and bra engineers as a reference source to advance bra design and development.

Keywords: bra band, bra features, breast displacement, underwire angle

Procedia PDF Downloads 239

Authors: Amirreza Heidari, Akram Avami, Ehsan Heidari

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Evaporative cooling systems are known as energy efficient cooling systems, with much lower electricity consumption than conventional vapor compression systems. A serious limitation of these systems, however, is that they are not applicable in humid regions. Combining a desiccant wheel with these systems, known as desiccant-based evaporative cooling systems, makes it possible to use evaporative cooling in humid climates. This paper evaluates the performane of a cooling system combining desiccant wheel, direct and indirect evaporative coolers (called desiccant-based indirect-direct evaporative cooling (DIDE) system) and then evaluates the energy saving potential of this system over the conventional vapor compression cooling and drying system. To illustrate the system ability of providing comfort conditions, a dynamic hourly simulation of this system is performed for a typical 60 m² building in Sydney, Australia. To evaluate the energy saving potential of this system, a conventional cooling and drying system is also simulated for the same cooling capacity. It has been found that the DIE system is able to provide comfort temperature and relative humidity in a subtropical humid climate like Sydney. The electricity and natural gas consumption of this system are respectively 39.2% and 2.6% lower than that of conventional system over a week. As the research has demonstrated, the innovative DIDE system is an energy efficient cooling system for subtropical humid regions.

Keywords: desiccant, evaporative cooling, dehumidification, indirect evaporative cooler

Procedia PDF Downloads 136

Authors: Elżbieta Cygan, Bączek, Piotr Wyżga

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This paper presents the results of research on the physical, mechanical, and tribological properties of materials constituting the matrix in sintered metallic-diamond tools. The ground powders based on the Fe-Mn-Cu-Sn-C system were modified with micro-sized particles of the ceramic phase: SiC, Al₂O₃ and consolidated using the SPS (spark plasma sintering) method to a relative density of over 98% at 850-950°C, at a pressure of 35 MPa and time 10 min. After sintering, an analysis of the microstructure was conducted using scanning electron microscopy. The resulting materials were tested for the apparent density determined by Archimedes’ method, Rockwell hardness (scale B), Young’s modulus, as well as for technological properties. The performance results of obtained diamond composites were compared with the base material (Fe–Mn–Cu–Sn–C) and the commercial alloy Co-20% WC. The hardness of composites has achieved the maximum at a temperature of 900°C; therefore, it should be considered that at this temperature it was obtained optimal physical and mechanical properties of the subjects' composites were. Research on tribological properties showed that the composites modified with micro-sized particles of the ceramic phase are characterized by more than twice higher wear resistance in comparison with base materials and the commercial alloy Co-20% WC. Composites containing Al₂O₃ phase particles in the matrix material were composites containing Al₂O₃ phase particles in the matrix material were characterized by the lowest abrasion wear resistance. The manufacturing technology presented in the paper is economically justified and can be successfully used in the production process of the matrix in sintered diamond-impregnated tools used for the machining of an industrial floor system. Acknowledgment: The study was performed under LIDER IX Research Project No. LIDER/22/0085/L-9/17/NCBR/2018 entitled “Innovative metal-diamond tools without the addition of critical raw materials for applications in the process of grinding industrial floor systems” funded by the National Centre for Research and Development of Poland, Warsaw.

Keywords: abrasive wear resistance, metal matrix composites, sintered diamond tools, Spark Plasma Sintering

Procedia PDF Downloads 60

Authors: Mohammad Syed Ali Molla, Mohammed Azim, Mohammad Esharuzzaman

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Centrifugal-casting machine is used in manufacturing special machine components like multi-layer journal bearing used in all internal combustion engine, steam, gas turbine and air craft turboengine where isotropic properties and high precisions are desired. Moreover, this machine can be used in manufacturing thin wall hightech machine components like cylinder liners and piston rings of IC engine and other machine parts like sleeves, and bushes. Heavy-duty machine component like railway wheel can also be prepared by centrifugal casting. A lot of technological developments are required in casting process for production of good casted machine body and machine parts. Usually defects like blowholes, surface roughness, chilled surface etc. are found in sand casted machine parts. But these can be removed by centrifugal casting machine using rotating metallic die. Moreover, die rotation, its temperature control, and good pouring practice can contribute to the quality of casting because of the fact that the soundness of a casting in large part depends upon how the metal enters into the mold or dies and solidifies. Poor pouring practice leads to variety of casting defects such as temperature loss, low quality casting, excessive turbulence, over pouring etc. Besides these, handling of molten metal is very unsecured and dangerous for the workers. In order to get rid of all these problems, the need of an automatic pouring device arises. In this research work, a robot assisted pouring device and a centrifugal casting machine are designed, developed constructed and tested experimentally which are found to work satisfactorily. The robot assisted pouring device is further modified and developed for using it in actual metal casting process. Lot of settings and tests are required to control the system and ultimately it can be used in automation of centrifugal casting machine to produce high-tech machine parts with desired precision.

Keywords: bearing, centrifugal casting, cylinder liners, robot

Procedia PDF Downloads 394

Authors: H. Yanar, G. Purcek, H. H. Ayar

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The ingredients of composite materials used for the production of composite brake pads play an important role in terms of safety braking performance of automobiles and trains. Therefore, the ingredients must be selected carefully and used in appropriate ratios in the matrix structure of the brake pad materials. In the present study, a non-asbestos organic composite brake pad materials containing binder resin, space fillers, solid lubricants, and friction modifier was developed, and its fillers content was optimized by adding natural rubber with different rate into the specified matrix structure in order to achieve the best combination of tribo-performance and mechanical properties. For this purpose, four compositions with different rubber content (2.5wt.%, 5.0wt.%, 7.5wt.% and 10wt.%) were prepared and then test samples with the diameter of 20 mm and length of 15 mm were produced to evaluate the friction and mechanical behaviors of the mixture. The friction and wear tests were performed using a pin-on-disc type test rig which was designed according to NF-F-11-292 French standard. All test samples were subjected to two different types of friction tests defined as periodic braking and continuous braking (also known as fade test). In this way, the coefficient of friction (CoF) of composite sample with different rubber content were determined as a function of number of braking cycle and temperature of the disc surface. The results demonstrated that addition of rubber into the matrix structure of the composite caused a significant change in the CoF. Average CoF of the composite samples increased linearly with increasing rubber content into the matrix. While the average CoF was 0.19 for the rubber-free composite, the composite sample containing 20wt.% rubber had the maximum CoF of about 0.24. Although the CoF of composite sample increased, the amount of specific wear rate decreased with increasing rubber content into the matrix. On the other hand, it was observed that the CoF decreased with increasing temperature generated in-between sample and disk depending on the increasing rubber content. While the CoF decreased to the minimum value of 0.15 at 400 °C for the rubber-free composite sample, the sample having the maximum rubber content of 10wt.% exhibited the lowest one of 0.09 at the same temperature. Addition of rubber into the matrix structure decreased the hardness and strength of the samples. It was concluded from the results that the composite matrix with 5 wt.% rubber had the best composition regarding the performance parameters such as required frictional and mechanical behavior. This composition has the average CoF of 0.21, specific wear rate of 0.024 cm³/MJ and hardness value of 63 HRX.

Keywords: brake pad composite, friction and wear, rubber, friction materials

Procedia PDF Downloads 123

Authors: James Freeman, Andry Rakotonirainy

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Train pedestrian collisions are common and are the most likely to result in severe injuries and fatalities when compared to other types of rail crossing accidents. However, there is limited research that has focused on understanding the reasons why some pedestrians’ break level crossings rules, which limits the development of effective countermeasures. As a result, this study undertook a deeper exploration into the origins of risky pedestrian behaviour through structured interviews. A total of 40 pedestrians who admitted to either intentionally breaking crossing rules or making crossing errors participated in an in-depth telephone interview. Qualitative analysis was undertaken via thematic analysis that revealed participants were more likely to report deliberately breaking rules (rather than make errors), particular after the train had passed the crossing as compared to before it arrives. Predominant reasons for such behaviours were identified to be: calculated risk taking, impatience, poor knowledge of rules and low likelihood of detection. The findings have direct implications for the development of effective countermeasures to improve crossing safety (and managing risk) such as increasing surveillance and transit officer presence, as well as installing appropriate barriers that either deter or incapacitate pedestrians from violating crossing rules. This paper will further outline the study findings in regards to the development of countermeasures as well as provide direction for future research efforts in this area.

Keywords: crossings, mistakes, risk, violations

Procedia PDF Downloads 397

Authors: Nelson Andres, Meeko C. Masangcap, John Denver D. Catapang

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Balanga City as, the heart of Bataan, is a growing City and is now at its fast pace of development. The growth of commerce in the city results to an increase in commuters who travel back and forth through the city, leading to congestions. Consequently, queuing of vehicles along national roads and even in the highways of the city have become a regular occurrence. This common scenario of commuters flocking the city, private and public vehicles going bumper to bumper, especially during the rush hours, greatly affect the flow of traffic vehicles and is now a burden not only to the commuters but also to the government who is trying to address this dilemma. Seeing these terrible events, the implementation of an elevated Automated Guide-way transit is seen as a possible solution to help in the decongestion of the affected parts of Balanga City.In response to the problem, the researchers identify if it is feasible to have an elevated guide-way transit in the vicinity of Sapphire Street in Balanga City, Bataan. Specifically, the study aims to determine who will be the riders based on the demographic profile, where the trip can be generated and distributed, the time when volume of people usually peaks and the estimated volume of passengers. Statistical analysis is applied to the data gathered to find out if there is an important relationship between the demographic profile of the respondents and their preference of having an elevated railway transit in the City of Balanga.

Keywords: ridership, AGT, railway, elevated track

Procedia PDF Downloads 58

Authors: Lydia Chan, Islam Shyha, Dale Dreyer, John Hamilton, Phil Hackney

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Nickel-based superalloys are generally known to be difficult to cut due to their strength, low thermal conductivity, and high work hardening tendency. Superalloy such as alloy 625 is often used in the oil and gas industry as a surfacing material to provide wear and corrosion resistance to components. The material is typically applied onto a metallic substrate through weld overlay cladding, an arc welding technique. Cladded surfaces are always rugged and carry a tough skin; this creates further difficulties to the machining process. The present work utilised design of experiment to optimise the internal cylindrical rough turning for weld overlay surfaces. An L27 orthogonal array was used to assess effects of the four selected key process variables: cutting insert, depth of cut, feed rate, and cutting speed. The optimal cutting conditions were determined based on productivity and the level of tool wear.

Keywords: cylindrical turning, nickel superalloy, turning of overlay, weld overlay

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Authors: Mohamed Seghouani, Ahmed Tafraoui, Soltane Lebaili

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The purpose of this study widened knowledge on the use of the cutting tools out of metal carbide and to define it the influence of the elements of the mode of cut on the behavior of these tools during the machining of treated steel XC38 and untreated. This work aims at evolution determined in experiments of the wear of a cutting tool out of metal carbide with plate reported of P30 nuance for an operation of slide-lathing in turning on soaked and not hardened steel XC38 test-tubes. This research is based on the model of Taylor to determine the life span of the cutting tool according to the various parameters of cut, like the cutting speed Vc, the advance of cut a, the depth of cutting P. In order to express the operational limits of the tool for slide-lathing in a preventive way. The model makes it possible to determine the time of change of the tool and to regard it as a constraint for the respect of the roughness of the workpiece during a work of series in conventional machining.

Keywords: machining, wear, lifespan, model of Taylor, cutting tool, carburize metal

Procedia PDF Downloads 377

Authors: Amita Singha

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The project describes the scope of magnetic braking. The potential applications of the braking system can be a de-accelerating system to increase the safety of an elevator or any guided rail transportation system.

Keywords: boost and buck converter, electromagnet, elevator, ferromagnetic material, sensor, solenoid, timer

Procedia PDF Downloads 422

Authors: Robert S. Giachetti, Emanuele Grossi

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Loosening of bolted joints in rotating machines can adversely affect their performance, cause mechanical damage, and lead to injuries. In this paper, two potential loosening phenomena in rotating applications are discussed. First, ‘precession,’ is governed by thread/nut contact forces, while the second is based on inertial effects of the fastened assembly. These mechanisms are reviewed within the context of historical usage of left-handed fasteners in rotating machines which appears absent in the literature and common machine design texts. Historically, to prevent loosening of wheel nuts, vehicle manufacturers have used right-handed and left-handed threads on different sides of the vehicle, but most modern vehicles have abandoned this custom and only use right-handed, tapered lug nuts on all sides of the vehicle. Other classical machines such as the bicycle continue to use different handed threads on each side while other machines such as, bench grinders, circular saws and brush cutters still use left-handed threads to fasten rotating components. Despite the continued use of left-handed fasteners, the rationale and analysis of left-handed threads to mitigate self-loosening of fasteners in rotating applications is not commonly, if at all, discussed in the literature or design textbooks. Without scientific literature to support these design selections, these implementations may be the result of experimental findings or aged institutional knowledge. Based on a review of rotating applications, historical documents and mechanical design references, a formal study of the paradoxical nature of left-handed threads in various applications is merited.

Keywords: rotating machinery, self-loosening fasteners, wheel fastening, vibration loosening

Procedia PDF Downloads 124

Authors: Gor Muradyan

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The paper is about friction and wear, including mechanisms, modeling, characterization, measurement and testing case in Bangladesh. Bangladesh is a country under development, A lot of people live here, approximately 145 million. The territory of this country is very small. Therefore buildings are very close to each other. As the pipe lines are very old, and people get almost dirty water, there are a lot of ongoing projects under ADB. In those projects the contractors using HDD machines (Horizontal Directional Drilling ) and grundoburst. These machines are working underground. As ground in Bangladesh is very sludge, machine can't work relevant because of big friction in the soil. When drilling works are finished machine is pulling the pipe underground. Very often the pulling of the pipes becomes very complicated because of the friction. Therefore long section of the pipe laying can’t be done because of a big friction. In that case, additional problems rise, as well as additional work must be done. As we mentioned above it is not possible to do big section of the pipe laying because of big friction in the soil, Because of this it is coming out that contractors must do more joints, more pressure test. It is always connected with additional expenditure and losing time. This machine can pull in 75 mm to 500 mm pipes connected with the soil condition. Length is possible till 500m related how much friction it will had on the puller. As less as much it can pull. Another machine grundoburst is not working at this soil condition at all. The machine is working with air compressor. This machine are using for the smaller diameter pipes, 20 mm to 63 mm. Most of the cases these machines are being used for the installing of the house connection pipes, for making service connection. To make a friction less contractors using bigger pulling had then the pipe. It is taking down the friction, But the problem of this machine is that it can't work at sludge. Because of mentioned reasons the friction has a big mining during this kind of works. There are a lot of ways to reduce the friction. In this paper we'll introduce the ways that we have researched during our practice in Bangladesh.

Keywords: Bangladesh, friction and wear, HDD machines, reducing friction

Procedia PDF Downloads 291

Authors: M. A. Hafiz, P. T. Matevenga

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Micro-level machining of metals is a developing field which has shown to be a prospective approach to produce features on the parts in the range of a few to a few hundred microns with acceptable machining quality. It is known that the mechanics (i.e. the material removal mechanism) of micro-machining and conventional machining have significant differences due to the scaling effects associated with tool-geometry, tool material and work piece material characteristics. Shape memory alloys (SMAs) are those metal alloys which display two exceptional properties, pseudoelasticity and the shape memory effect (SME). Nickel-titanium (NiTi) alloys are one of those unique metal alloys. NiTi alloys are known to be difficult-to-cut materials specifically by using conventional machining techniques due to their explicit properties. Their high ductility, high amount of strain hardening, and unusual stress–strain behaviour are the main properties accountable for their poor machinability in terms of tool wear and work piece quality. The motivation of this research work was to address the challenges and issues of micro-machining combining with those of machining of NiTi alloy which can affect the desired performance level of machining outputs. To explore the significance of range of cutting conditions on surface roughness and tool wear, machining tests were conducted on NiTi. Influence of different cutting conditions and cutting tools on surface and sub-surface deformation in work piece was investigated. Design of experiments strategy (L9 Array) was applied to determine the key process variables. The dominant cutting parameters were determined by analysis of variance. These findings showed that feed rate was the dominant factor on surface roughness whereas depth of cut found to be dominant factor as far as tool wear was concerned. The lowest surface roughness was achieved at the feed rate of equal to the cutting edge radius where as the lowest flank wear was observed at lowest depth of cut. Repeated machining trials have yet to be carried out in order to observe the tool life, sub-surface deformation and strain induced hardening which are also expecting to be amongst the critical issues in micro machining of NiTi. The machining performance using different cutting fluids and strategies have yet to be studied.

Keywords: nickel titanium, micro-machining, surface roughness, machinability

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Authors: Sudhanshu Kumar

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Electrical discharge machining, also known as EDM, process is one of the most applicable machining process for removal of material in hard to machine materials like superalloy metals. EDM process utilizes electrical energy into sparks to erode the metals in presence of dielectric medium. In the present investigation, superalloy, Inconel 718 has been selected as workpiece and electrolytic copper as tool electrode. Attempt has been made to understand the effect of size of tool with varying cavity depth during drilling of hole through EDM process. In order to systematic investigate, tool size in terms of tool diameter and cavity depth along with other important electrical parameters namely, peak current, pulse-on time and servo voltage have been varied at three different values and the experiments has been designed using fractional factorial (Taguchi) method. Each experiment has been repeated twice under the same condition in order to understand the variability within the experiments. The effect of variations in parameters has been evaluated in terms of material removal rate, tool wear rate and surface roughness. Results revel that change in tool diameter during machining affects the response characteristics significantly. Larger tool diameter yielded 13% more material removal rate than smaller tool diameter. Analysis of the effect of variation in cavity depth is notable. There is no significant effect of cavity depth on material removal rate, tool wear rate and surface quality. This indicates that number of experiments can be performed to analyze other parameters effect even at smaller depth of cavity which can reduce the cost and time of experiments. Further, statistical analysis has been carried out to identify the interaction effect between parameters.

Keywords: EDM, Inconel 718, material removal rate, roughness, tool wear, tool size

Procedia PDF Downloads 193

Authors: Fangyuan Shao, Wei Liu, Deli Gao

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Polycrystalline diamond compact (PDC) bits have occupied a large market of unconventional oil and gas drilling. The application of PDC bits benefits from the efficient rock breaking of PDC cutters. In response to increasingly complex formations, many shaped cutters have been invited, but many of them have not been solved by the mechanism of rock breaking. In this paper, two kinds of PDC cutters: a new axe-shaped (NAS) cutter and cylindrical cutter (benchmark) were studied by laboratory experiments. NAS cutter is obtained by optimizing two sides of axe-shaped cutter with curved surfaces. All the cutters were put on a vertical turret lathe (VTL) in the laboratory for cutting tests. According to the cutting distance, the VTL tests can be divided into two modes: single-turn rotary cutting and continuous cutting. The cutting depth of cutting (DOC) was set at 1.0 mm and 2.0 mm in the former mode. The later mode includes a dry VTL test for thermal stability and a wet VTL test for wear resistance. Load cell and 3D optical profiler were used to obtain the value of cutting forces and wear area, respectively. Based on the findings of the single-turn rotary cutting VTL tests, the performance of A NAS cutter was better than the benchmark cutter on elastoplastic material cutting. The cutting forces (normal forces, tangential force, and radial force) and special mechanical energy (MSE) of a NAS cutter were lower than that of the benchmark cutter under the same condition. It meant that a NAS cutter was more efficient on elastoplastic material breaking. However, the wear resistance of a new axe-shaped cutter was higher than that of a benchmark cutter. The results of the dry VTL test showed that the thermal stability of a NAS cutter was higher than that of a benchmark cutter. The cutting efficiency can be improved by optimizing the geometric structure of the PDC cutter. The change of thermal stability may be caused by the decrease of the contact area between cutter and rock at given DOC. The conclusions of this paper can be used as an important reference for PDC cutters designers.

Keywords: axe-shaped cutter, PDC cutter, rotary cutting test, vertical turret lathe

Procedia PDF Downloads 187

Authors: Michael C. Barbecho, Romeo B. Morcilla

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This study focused on the development of a solar powered front wheel drive electric trike for personal use and short distance travel, utilizing solar power and a variable speed transmission to adapt in places where varying road grades and unavailability of plug-in charging stations are of great problems. The actual performance of the vehicle was measured in terms of duration of charging using solar power, distance travel and battery power duration, top speed developed at full power, and load capacity. This project followed the research and development process which involved planning, designing, construction, and testing. Solar charging tests revealed that the vehicle requires 6 to 8 hours sunlight exposure to fully charge the batteries. At full charge, the vehicle can travel 35 km utilizing battery power down to 42%. Vehicle showed top speed of 25 kph at 0 to 3% road grade carrying a maximum load of 122 kg. The maximum climbing grade was 23% with the vehicle carrying a maximum load of 122 kg. Technically the project was feasible and can be a potential model for possible conversion of traditional Philippine made “pedicabs” and gasoline engine powered tricycle into modern electric vehicles. Moreover, it has several technical features and advantages over a commercialized electric vehicle such as the use solar charging system and variable speed power transmission and front drive power train for adaptability in any road gradient.

Keywords: electric vehicle, solar vehicles, front drive, solar, solar power

Procedia PDF Downloads 551

Authors: Abdul Basit, Shahid Latif, Shah Mehmood

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Lawn fabric was usually prepared from originally of linen but at present chiefly cotton. Lawn fabric is worn in summer. Cotton Lawn is a lightweight pure cloth which is heavier than voile. It is so fine that it is somewhat transparent. It is soft and superb to wear thus it is perfect for summer clothes or for regular wear in hotter climates. Tencel (Lyocell) fiber is considered as the fiber of the future as Tencel fibers are absorbent, soft, and extremely strong when wet or dry, and resistant to wrinkles. Fibers are more absorbent than cotton, softer than silk and cooler than linen. High water absorption and water vapor absorption give more heat capacity and heat balancing effect for thermo-regulation. This thermo-regulation is analogous with the action of phase-change-materials. The thermal wear properties result in cool and dry touch that gives cooling effect in sportswear, and the warmth properties (when used as an insulation layer). These cooling and warming effects are adaptive to the environment giving comfort in a broad range of climatic conditions. In this work, single yarns of Ne 80s were made. Yarns were made from conventional ring spinning. Different yarns of 100% cotton, 100% micro-Tencel and Cotton:micro-Tencel blends (67:33, 50:50:33:67) were made. The mechanical and comfort properties of the woven fabrics were compared. The mechanical properties include the tensile and tear strength, bending length, pilling and abrasion resistance whereas comfort properties include the air permeability, moisture management and thermal resistance. It is found that as the content of the micro-Tencel is increased, the mechanical and comfort properties of the woven fabric are also increased.

Keywords: combed cotton, comfort properties , mechanical properties, micro-Tencel

Procedia PDF Downloads 299

Authors: Khaled Mohamed Ibrahim

Abstract:

A comprehensive study on two biomaterials of NiTi and Ti-6Al-4V (Ti64) was done. Those materials were cast using vacuum arc remelting technique. As-cast structure of Ni-Ti alloy consists of NiTi matrix and some fine precipitates of Ni4Ti3. Ti-6Al-4V alloy showed a structure composed of equiaxed β grains and varied α-phase morphologies. Maximum ultimate compressive strength and reduction in height of 2042 MPa of 18%, respectively, were reported for the cast Ti64 alloy. However, minimum ultimate compressive strength of 1804 MPa and low reduction in height of 3% were obtained for the cast NiTi alloy. Wear rate of both Ni-Ti and Ti-6Al-4V alloys significantly increased at saline solution (0.9% NaCl) condition as compared to dry testing condition. Saline solution harmed the wear resistance of about 2 to 4 times compared to the dry condition. Corrosion rate of NiTi alloy at saline solution (0.9% NaCl) was (0.00038 mm/yr) is almost three times the value of Ti64 alloy (0.000171 mm/yr). The corrosion rate of Ti64 in SBF (0.00024 mm/yr) was lower than Ni-Ti (0.0003 mm/yr).

Keywords: NiTi, Ti64, vacuum casting, biomaterials

Procedia PDF Downloads 65

Authors: Bernd Sauer, Michel Werner, Stefan Emrich, Michael Kopnarski, Oliver Koch

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Friction reduction is an important aspect in the context of sustainability and energy transition. Rolling bearings are therefore used in many applications in which components move relative to each other. Conventionally lubricated rolling bearings are used in a wide range of applications, but are not suitable under certain conditions. Conventional lubricants such as grease or oil cannot be used at very high or very low temperatures. In addition, these lubricants evaporate at very low ambient pressure, e.g. in a high vacuum environment, making the use of solid lubricated bearings unavoidable. With the use of solid-lubricated bearings, predicting the service life becomes more complex. While the end of the service life of bearings with conventional lubrication is mainly caused by the failure of the bearing components due to material fatigue, solid-lubricated bearings fail at the moment when the lubrication layer is worn and the rolling elements come into direct contact with the raceway during operation. In order to extend the service life of these bearings beyond the service life of the initial coating, the use of transfer lubrication is recommended, in which pockets or sacrificial cages are used in which the balls run and can thus absorb the lubricant, which is then available for lubrication in tribological contact. This contribution presents the results of wear and service life tests on solid-lubricated rolling bearings with sacrificial cage pockets. The cage of the bearing consists of a polyimide (PI) matrix with 15% molybdenum disulfide (MoS2) and serves as a lubrication depot alongside the silver-coated balls. The bearings are tested under high vacuum (pE < 10-2 Pa) at a temperature of 300 °C on a four-bearing test rig. First, investigations of the bearing system within the bearing service life are presented and the torque curve, the wear mass and surface analyses are discussed. With regard to wear, it can be seen that the bearing rings tend to increase in mass over the service life of the bearing, while the balls and the cage tend to lose mass. With regard to the elementary surface properties, the surfaces of the bearing rings and balls are examined in terms of the mass of the elements on them. Furthermore, service life investigations with different material pairings are presented, whereby the focus here is on the service life achieved in addition to the torque curve, wear development and surface analysis. It was shown that MoS2 in the cage leads to a longer service life, while a silver (Ag) coating on the balls has no positive influence on the service life and even appears to reduce it in combination with MoS2.

Keywords: ball bearings, molybdenum disulfide, solid lubricated bearings, solid lubrication mechanisms

Procedia PDF Downloads 28

Authors: Ajay Mandal, Jitendar Kumar Tiwari, N. Sathish, A. K. Srivastava

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A fundamental investigation is performed on the development of graphene (Gr) reinforced stainless steel 316L (SS 316L) metal matrix composite via selective laser melting (SLM) in order to improve specific strength and wear resistance property of SS 316L. Firstly, SS 316L powder and graphene were mixed in a fixed ratio using low energy planetary ball milling. The milled powder is then subjected to the SLM process to fabricate composite samples at a laser power of 320 W and exposure time of 100 µs. The prepared composite was mechanically tested (hardness and tensile test) at ambient temperature, and obtained results indicate that the properties of the composite increased significantly with the addition of 0.2 wt. % Gr. Increment of about 25% (from 194 to 242 HV) and 70% (from 502 to 850 MPa) is obtained in hardness and yield strength of composite, respectively. Raman mapping and XRD were performed to see the distribution of Gr in the matrix and its effect on the formation of carbide, respectively. Results of Raman mapping show the uniform distribution of graphene inside the matrix. Electron back scatter diffraction (EBSD) map of the prepared composite was analyzed under FESEM in order to understand the microstructure and grain orientation. Due to thermal gradient, elongated grains were observed along the building direction, and grains get finer with the addition of Gr. Most of the mechanical components are subjected to several types of wear conditions. Therefore, it is very necessary to improve the wear property of the component, and hence apart from strength and hardness, a tribological property of composite was also measured under dry sliding condition. Solid lubrication property of Gr plays an important role during the sliding process due to which the wear rate of composite reduces up to 58%. Also, the surface roughness of worn surface reduces up to 70% as measured by 3D surface profilometry. Finally, it can be concluded that SLM is an efficient method of fabricating cutting edge metal matrix nano-composite having Gr like reinforcement, which was very difficult to fabricate through conventional manufacturing techniques. Prepared composite has superior mechanical and tribological properties and can be used for a wide variety of engineering applications. However, due to the unavailability of a considerable amount of literature in a similar domain, more experimental works need to perform, such as thermal property analysis, and is a part of ongoing study.

Keywords: selective laser melting, graphene, composite, mechanical property, tribological property

Procedia PDF Downloads 116

Authors: Anjula Negi, Sanjay Gupta

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Paradigms studied inform inadequacies of financial resources, be it to finance metro rails for construction or to meet operational revenues or to derive profits in the long term. Funding sustainability is far and wide for much-needed public transport modes, like urban rail or metro rails, to be successfully operated. India embarks upon a sustainable transport journey and has proposed metro rail systems countrywide. As an emerging economic leader, its fiscal constraints are paramount, and the land value capture (LVC) mechanism provides necessary support and innovation toward development. India’s metro rail policy promotes multiple methods of financing, including private-sector investments and public-private-partnership. The critical question that remains to be addressed is what factors can make such mechanisms work. Globally, urban rail is a revolution noted by many researchers as future mobility. Researchers in this study deep dive by way of literature review and empirical assessments into factors that can lead to the adoption of LVC mechanisms. It is understood that the adoption of LVC methods is in the nascent stages in India. Research posits numerous challenges being faced by metro rail agencies in raising funding and for incremental value capture. A few issues pertaining to land-based financing, inter alia: are long-term financing, inter-institutional coordination, economic/ market suitability, dedicated metro funds, land ownership issues, piecemeal approach to real estate development, property development legal frameworks, etc. The question under probe is what are the parameters that can lead to success in the adoption of land value capture (LVC) as a financing mechanism. This research provides insights into key parameters crucial to the adoption of LVC in the context of Indian metro rails. Researchers have studied current forms of LVC mechanisms at various metro rails of the country. This study is significant as little research is available on the adoption of LVC, which is applicable to the Indian context. Transit agencies, State Government, Urban Local Bodies, Policy makers and think tanks, Academia, Developers, Funders, Researchers and Multi-lateral agencies may benefit from this research to take ahead LVC mechanisms in practice. The study deems it imperative to explore and understand key parameters that impact the adoption of LVC. Extensive literature review and ratification by experts working in the metro rails arena were undertaken to arrive at parameters for the study. Stakeholder consultations in the exploratory factor analysis (EFA) process were undertaken for principal component extraction. 43 seasoned and specialized experts participated in a semi-structured questionnaire to scale the maximum likelihood on each parameter, represented by various types of stakeholders. Empirical data was collected on chosen eighteen parameters, and significant correlation was extracted for output descriptives and inferential statistics. Study findings reveal these principal components as institutional governance framework, spatial planning features, legal frameworks, funding sustainability features and fiscal policy measures. In particular, funding sustainability features highlight sub-variables of beneficiaries to pay and use of multiple revenue options towards success in LVC adoption. Researchers recommend incorporation of these variables during early stage in design and project structuring for success in adoption of LVC. In turn leading to improvements in revenue sustainability of a public transport asset and help in undertaking informed transport policy decisions.

Keywords: Exploratory factor analysis, land value capture mechanism, financing metro rails, revenue sustainability, transport policy

Procedia PDF Downloads 66

Authors: H. S. Sathish, H. S. Jagadeesh, Skanda Kumar

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Journey time and delay study is used to evaluate the quality of service, the travel time and study can also be used to evaluate the quality of traffic movement along the route and to determine the location types and extent of traffic delays. Components of delay are boarding and alighting, issue of tickets, other causes and distance between each stops. This study investigates the total journey time required to travel along the stretch and the influence the delays. The route starts from Kempegowda Bus Station to Yelahanka Satellite Station of Bangalore City. The length of the stretch is 16.5 km. Modal split analysis has been done for this stretch. This stretch has elevated highway connecting to Bangalore International Airport and the extension of metro transit stretch. From the regression analysis of total journey time it is affected by delay due to boarding and alighting moderately, Delay due to issue of tickets affects the journey time to a higher extent. Some of the delay factors affecting significantly the journey time are evident from F-test at 10 percent level of confidence. Along this stretch work trips are more prevalent as indicated by O-D study. Modal shift analysis indicates about 70 percent of commuters are ready to shift from current system to Metro Rail System. Metro Rail System carries maximum number of trips compared to private mode. Hence Metro is a highly viable choice of mode for Bangalore Metropolitan City.

Keywords: delay, journey time, modal choice, regression analysis

Procedia PDF Downloads 479

Authors: Abhishek Agarwal, Manoj Sarda, Juhi Kaushik, Vatsal Sanjay, Arup Kumar Das

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Propagation of fire through a non-air conditioned railway compartment is studied by virtue of numerical simulations. Simultaneous computational fire dynamics equations, such as Navier-Stokes, lumped species continuity, overall mass and energy conservation, and heat transfer are solved using finite volume based (for radiation) and finite difference based (for all other equations) solver, Fire Dynamics Simulator (FDS). A single coupe with an eight berth occupancy is used to establish the numerical model, followed by the selection of a three coupe system as the fundamental unit of the locomotive compartment. Heat Release Rate Per Unit Area (HRRPUA) of the initial fire is varied to consider a wide range of compartmental fires. Parameters, such as air inlet velocity relative to the locomotive at the windows, the level of interaction with the ambiance and closure of middle berth are studied through a wide range of numerical simulations. Almost all the loss of lives and properties due to fire breakout can be attributed to the direct or indirect exposure to flames or to the inhalation of toxic gases and resultant suffocation due to smoke and soot. Therefore, the temporal stature of fire and smoke are reported for each of the considered cases which can be used in the present or extended form to develop guidelines to be followed in case of a fire breakout.

Keywords: fire dynamics, flame propagation, locomotive fire, soot flow pattern, non-air-conditioned coaches

Procedia PDF Downloads 279