Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 4

weight reduction Related Abstracts

4 Development of Methods for Plastic Injection Mold Weight Reduction

Authors: Bita Mohajernia, R. J. Urbanic

Abstract:

Mold making techniques have focused on meeting the customers’ functional and process requirements; however, today, molds are increasing in size and sophistication, and are difficult to manufacture, transport, and set up due to their size and mass. Presently, mold weight saving techniques focus on pockets to reduce the mass of the mold, but the overall size is still large, which introduces costs related to the stock material purchase, processing time for process planning, machining and validation, and excess waste materials. Reducing the overall size of the mold is desirable for many reasons, but the functional requirements, tool life, and durability cannot be compromised in the process. It is proposed to use Finite Element Analysis simulation tools to model the forces, and pressures to determine where the material can be removed. The potential results of this project will reduce manufacturing costs. In this study, a light weight structure is defined by an optimal distribution of material to carry external loads. The optimization objective of this research is to determine methods to provide the optimum layout for the mold structure. The topology optimization method is utilized to improve structural stiffness while decreasing the weight using the OptiStruct software. The optimized CAD model is compared with the primary geometry of the mold from the NX software. Results of optimization show an 8% weight reduction while the actual performance of the optimized structure, validated by physical testing, is similar to the original structure.

Keywords: Finite Element Analysis, topology optimization, plastic injection molding, weight reduction

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3 Design Modification in CNC Milling Machine to Reduce the Weight of Structure

Authors: Harshkumar K. Desai, Anuj K. Desai, Jay P. Patel, Snehal V. Trivedi, Yogendrasinh Parmar

Abstract:

The need of continuous improvement in a product or process in this era of global competition leads to apply value engineering for functional and aesthetic improvement in consideration with economic aspect too. Solar industries located at G.I.D.C., Makarpura, Vadodara, Gujarat, India; a manufacturer of variety of CNC Machines had a challenge to analyze the structural design of column, base, carriage and table of CNC Milling Machine in the account of reduction of overall weight of a machine without affecting the rigidity and accuracy at the time of operation. The identified task is the first attempt to validate and optimize the proposed design of ribbed structure statically using advanced modeling and analysis tools in a systematic way. Results of stress and deformation obtained using analysis software are validated with theoretical analysis and found quite satisfactory. Such optimized results offer a weight reduction of the final assembly which is desired by manufacturers in favor of reduction of material cost, processing cost and handling cost finally.

Keywords: Optimization, Finite Element Analysis (FEA), weight reduction, CNC milling machine

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2 Reducing Weight and Fuel Consumption of Civil Aircraft by EML

Authors: Herve Morvan, Luca Bertola, Tom Cox, Pat Wheeler, Seamus Garvey

Abstract:

Electromagnetic launch systems have been proposed for military applications to accelerate jet planes on aircraft carriers. This paper proposes the implementation of similar technology to aid civil aircraft take-off, which can provide significant economic, environmental and technical benefits. Assisted launch has the potential of reducing ground noise and emissions near airports and improving overall aircraft efficiency through reducing engine thrust requirements. This paper presents a take-off performance analysis for an Airbus A320-200 taking off with and without the assistance of the electromagnetic catapult. Assisted take-off allows for a significant reduction in take-off field length, giving more capacity with existing airport footprints and reducing the necessary footprint of new airports, which will both reduce costs and increase the number of suitable sites. The electromagnetic catapult may allow the installation of smaller engines with lower rated thrust. The consequent fuel consumption and operational cost reduction are estimated. The potential of reducing the aircraft operational costs and the runway length required making electromagnetic launch system an attractive solution to the air traffic growth in busy airports.

Keywords: Fuel Consumption, weight reduction, electromagnetic launch, take-off analysis

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1 Performance Enhancement of Hybrid Racing Car by Design Optimization

Authors: Tarang Varmora, Krupa Shah, Karan Patel

Abstract:

Environmental pollution and shortage of conventional fuel are the main concerns in the transportation sector. Most of the vehicles use an internal combustion engine (ICE), powered by gasoline fuels. This results into emission of toxic gases. Hybrid electric vehicle (HEV) powered by electric machine and ICE is capable of reducing emission of toxic gases and fuel consumption. However to build HEV, it is required to accommodate motor and batteries in the vehicle along with engine and fuel tank. Thus, overall weight of the vehicle increases. To improve the fuel economy and acceleration, the weight of the HEV can be minimized. In this paper, the design methodology to reduce the weight of the hybrid racing car is proposed. To this end, the chassis design is optimized. Further, attempt is made to obtain the maximum strength with minimum material weight. The best configuration out of the three main configurations such as series, parallel and the dual-mode (series-parallel) is chosen. Moreover, the most suitable type of motor, battery, braking system, steering system and suspension system are identified. The racing car is designed and analyzed in the simulating software. The safety of the vehicle is assured by performing static and dynamic analysis on the chassis frame. From the results, it is observed that, the weight of the racing car is reduced by 11 % without compromising on safety and cost. It is believed that the proposed design and specifications can be implemented practically for manufacturing hybrid racing car.

Keywords: Simulation, Vehicle, Design optimization, weight reduction, hybrid racing car

Procedia PDF Downloads 168