Search results for: Hole machining

Authors: Suraka Bhattacharjee, Ranjan Chaudhury

Abstract:

The interaction between the charge degrees of freedom for itinerant antiferromagnets is investigated in terms of generalized charge stiffness constant corresponding to nearest neighbour t-J model and t1-t2-t3-J model. The low dimensional hole doped antiferromagnets are the well known systems that can be described by the t-J-like models. Accordingly, we have used these models to investigate the fermionic pairing possibilities and the coupling between the itinerant charge degrees of freedom. A detailed comparison between spin and charge couplings highlights that the charge and spin couplings show very similar behaviour in the over-doped region, whereas, they show completely different trends in the lower doping regimes. Moreover, a qualitative equivalence between generalized charge stiffness and effective Coulomb interaction is also established based on the comparisons with other theoretical and experimental results. Thus it is obvious that the enhanced possibility of fermionic pairing is inherent in the reduction of Coulomb repulsion with increase in doping concentration. However, the increased possibility can not give rise to pairing without the presence of any other pair producing mechanism outside the t-J model. Therefore, one can conclude that the t-J-like models themselves solely are not capable of producing conventional momentum-based superconducting pairing on their own.

Keywords: Generalized charge stiffness constant, charge coupling, effective Coulomb interaction, t-J-like models, momentum-space pairing.

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Authors: Mohammed Kamil, M. M. Rahman, Rosli A. Bakar

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Modeling of hydrogen fueled engine (H₂ICE) injection system is a very important tool that can be used for explaining or predicting the effect of advanced injection strategies on combustion and emissions. In this paper, a common rail injection system (CRIS) is proposed for 4-strokes 4-cylinders hydrogen fueled engine with port injection feeding system (PIH₂ICE). For this system, a numerical one-dimensional gas dynamic model is developed considering single injection event for each injector per a cycle. One-dimensional flow equations in conservation form are used to simulate wave propagation phenomenon throughout the CR (accumulator). Using this model, the effect of common rail on the injection system characteristics is clarified. These characteristics include: rail pressure, sound velocity, rail mass flow rate, injected mass flow rate and pressure drop across injectors. The interaction effects of operational conditions (engine speed and rail pressure) and geometrical features (injector hole diameter) are illustrated; and the required compromised solutions are highlighted. The CRIS is shown to be a promising enhancement for PIH₂ICE.

Keywords: Common rail, hydrogen engine, port injection, wave propagation.

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Authors: G.H. Montazeri, Z. Dastkhan, H. Aliabadi

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Gas condensate Reservoirs show complicated thermodynamic behavior when their pressure reduces to under dew point pressure. Condensate blockage around the producing well cause significant reduction of production rate as well bottom-hole pressure drops below saturation pressure. The main objective of this work was to examine the well test analysis of naturally fractured lean gas condensate reservoir and investigate the effect of condensate formed around the well-bore on behavior of single phase pseudo pressure and its derivative curves. In this work a naturally fractured lean gas condensate reservoir is simulated with compositional simulator. Different sensitivity analysis done on Corry parameters and result of simulator is feed to analytical well testing software. For consideration of these phenomena eighteen compositional models with Capillary number effect are constructed. Matrix relative permeability obeys Corry relative permeability and relative permeability in fracture is linear. Well testing behavior of these models are studied and interpreted. Results show different sensitivity analysis on relative permeability of matrix does not have strong effect on well testing behavior even most part of the matrix around the well is occupied with condensate.

Keywords: Lean gas, fractured condensate reservoir, capillary number, well testing analysis, relative permeability.

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Authors: Ahmed A. D. Sarhan, Hong Wan Ping, M. Sayuti

Abstract:

In this current era of competitive machinery productions, the industries are designed to place more emphasis on the product quality and reduction of cost whilst abiding by the pollution-preventing policy. In attempting to delve into the concerns, the industries are aware that the effectiveness of existing lubrication systems must be improved to achieve power-efficient and pollution-preventing machining processes. As such, this research is targeted to study on a plausible solution to the issue in grinding titanium alloy (Ti-6Al-4V) by using nanolubrication, as an alternative to flood grinding. The aim of this research is to evaluate the optimum condition of grinding force and surface roughness using MQL lubricating system to deliver nano-oil at different level of weight concentration of Silicon Dioxide (SiO₂) mixed normal mineral oil. Taguchi Design of Experiment (DoE) method is carried out using a standard Taguchi orthogonal array of L16(43) to find the optimized combination of weight concentration mixture of SiO₂, nozzle orientation and pressure of MQL. Surface roughness and grinding force are also analyzed using signal-to-noise(S/N) ratio to determine the best level of each factor that are tested. Consequently, the best combination of parameters is tested for a period of time and the results are compared with conventional grinding method of dry and flood condition. The results show a positive performance of MQL nanolubrication.  

Keywords: Grinding, MQL, precision grinding, Taguchi optimization, titanium alloy.

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Authors: Joseph C. Chen, Joshua Cox

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This research focuses on the use of the Taguchi method to reduce the surface roughness and improve dimensional accuracy of parts machined by Wire Electrical Discharge Machining (EDM) with S7 heat treated steel material. Due to its high impact toughness, the material is a candidate for a wide variety of tooling applications which require high precision in dimension and desired surface roughness. This paper demonstrates that Taguchi Parameter Design methodology is able to optimize both dimensioning and surface roughness successfully by investigating seven wire-EDM controllable parameters: pulse on time (ON), pulse off time (OFF), servo voltage (SV), voltage (V), servo feed (SF), wire tension (WT), and wire speed (WS). The temperature of the water in the Wire EDM process is investigated as the noise factor in this research. Experimental design and analysis based on L₁₈ Taguchi orthogonal arrays are conducted. This paper demonstrates that the Taguchi-based system enables the wire EDM process to produce (1) high precision parts with an average of 0.6601 inches dimension, while the desired dimension is 0.6600 inches; and (2) surface roughness of 1.7322 microns which is significantly improved from 2.8160 microns.

Keywords: Taguchi parameter design, surface roughness, dimensional accuracy, Wire EDM.

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Authors: G. H. Li, M. Liu, H. J. Qi, Q. Zhu, W. Z. He

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The drilling and riveting processes are widely used in the assembly of carrier rocket, which makes the efficiency and quality of drilling become the important factor affecting the assembly process. According to the problem existing in the drilling of thick stacked plate (thickness larger than 10mm) of carrier rocket, such as drill break, large noise and burr etc., experimental study of the influence of tool material on the drilling was carried out. The cutting force was measured by a piezoelectric dynamometer, the aperture was measured with an outline projector, and the burr is observed and measured by a digital stereo microscope. Through the measurement, the effects of tool material on the drilling were analyzed from the aspects of drilling force, diameter, and burr. The results show that, compared with carbide drill and coated carbide one, the drilling force of high speed steel is larger. But, the application of high speed steel also has some advantages, e.g. a higher number of hole can be obtained, the height of burr is small, the exit is smooth and the slim burr is less, and the tool experiences wear but not fracture. Therefore, the high speed steel tool is suitable for the drilling of thick stacked plate of 2219 Aluminum alloy.

Keywords: 2219 aluminum alloy, thick stacked plate, drilling, tool material.

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Authors: Sky Chou, Joseph C. Chen

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This paper focuses on using Six Sigma methodologies to improve the surface roughness of a manufactured part produced by the CNC milling machine. It presents a case study where the surface roughness of milled aluminum is required to reduce or eliminate defects and to improve the process capability index C_p and C_pk for a CNC milling process. The six sigma methodology, DMAIC (design, measure, analyze, improve, and control) approach, was applied in this study to improve the process, reduce defects, and ultimately reduce costs. The Taguchi-based six sigma approach was applied to identify the optimized processing parameters that led to the targeted surface roughness specified by our customer. A L₉ orthogonal array was applied in the Taguchi experimental design, with four controllable factors and one non-controllable/noise factor. The four controllable factors identified consist of feed rate, depth of cut, spindle speed, and surface roughness. The noise factor is the difference between the old cutting tool and the new cutting tool. The confirmation run with the optimal parameters confirmed that the new parameter settings are correct. The new settings also improved the process capability index. The purpose of this study is that the Taguchi–based six sigma approach can be efficiently used to phase out defects and improve the process capability index of the CNC milling process.

Keywords: CNC machining, Six Sigma, Surface roughness, Taguchi methodology.

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Authors: Jui-Pui Hung, Yu-Sheng Lai, Tzuo-Liang Luo, Kung-Da Wu, Yun-Ji Zhan

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This study presented the investigation of the influence of the tool holder interface stiffness on the dynamic characteristics of a spindle tool system. The interface stiffness was produced by drawbar force on the tool holder, which tends to affect the spindle dynamics. In order to assess the influence of interface stiffness on the vibration characteristic of spindle unit, we first created a three dimensional finite element model of a high speed spindle system integrated with tool holder. The key point for the creation of FEM model is the modeling of the rolling interface within the angular contact bearings and the tool holder interface. The former can be simulated by a introducing a series of spring elements between inner and outer rings. The contact stiffness was calculated according to Hertz contact theory and the preload applied on the bearings. The interface stiffness of the tool holder was identified through the experimental measurement and finite element modal analysis. Current results show that the dynamic stiffness was greatly influenced by the tool holder system. In addition, variations of modal damping, static stiffness and dynamic stiffness of the spindle tool system were greatly determined by the interface stiffness of the tool holder which was in turn dependent on the draw bar force applied on the tool holder. Overall, this study demonstrates that identification of the interface characteristics of spindle tool holder is of very importance for the refinement of the spindle tooling system to achieve the optimum machining performance.

Keywords: Dynamic stiffness, Drawbar force, Interface stiffness, Spindle-tool holder.

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Authors: Mahdad M’hamed, Belaidi Idir

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This paper develops a meshless approach, called Element Free Galerkin (EFG) method, which is based on the weak form Moving Least Squares (MLS) of the partial differential governing equations and employs the interpolation to construct the meshless shape functions. The variation weak form is used in the EFG where the trial and test functions are approximated bye the MLS approximation. Since the shape functions constructed by this discretization have the weight function property based on the randomly distributed points, the essential boundary conditions can be implemented easily. The local weak form of the partial differential governing equations is obtained by the weighted residual method within the simple local quadrature domain. The spline function with high continuity is used as the weight function. The presently developed EFG method is a truly meshless method, as it does not require the mesh, either for the construction of the shape functions, or for the integration of the local weak form. Several numerical examples of two-dimensional static structural analysis are presented to illustrate the performance of the present EFG method. They show that the EFG method is highly efficient for the implementation and highly accurate for the computation. The present method is used to analyze the static deflection of beams and plate hole

Keywords: Numerical computation, element-free Galerkin, moving least squares, meshless methods.

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Authors: Valentina Di Maria, Anton Ianakiev

Abstract:

The use OF adhesive anchors for wooden constructions is an efficient technology to connect and design timber members in new timber structures and to rehabilitate the damaged structural members of historical buildings. Due to the lack of standard regulation in this specific area of structural design, designers’ choices are still supported by test analysis that enables knowledge, and the prediction, of the structural behaviour of glued in rod joints. The paper outlines an experimental research activity aimed at identifying the tensile resistance capacity of several new adhesive joint prototypes made of epoxy resin, steel bar and timber, Oak and Douglas Fir species. The development of new adhesive connectors has been carried out by using epoxy to glue stainless steel bars into pre-drilled holes, characterised by smooth and rough internal surfaces, in timber samples. The realization of a threaded contact surface using a specific drill bit has led to an improved bond between wood and epoxy. The applied changes have also reduced the cost of the joints’ production. The paper presents the results of this parametric analysis and a Finite Element analysis that enables identification and study of the internal stress distribution in the proposed adhesive anchors.

Keywords: Glued in rod joints, adhesive anchors, timber, epoxy, rough contact surface, threaded hole shape.

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Authors: Arun Kumar Datta, M. A. Ansari, N. R. Mondal, B. V. Raghavaiah, Manisha Dubey, Shailendra Jain

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This study is carried out to understand the effects of Static frequency converter (SFC) on large machine. SFC has a feature of four quadrant operations. By virtue of this it can be implemented to run a synchronous machine either as a motor or alternator. This dual mode operation helps a single machine to start & run as a motor and then it can be converted as an alternator whenever required. One such dual purpose machine is taken here for study. This machine is installed at a laboratory carrying out short circuit test on high power electrical equipment. SFC connected with this machine is broadly described in this paper. The same SFC has been modeled with the MATLAB/Simulink software. The data applied on this virtual model are the actual parameters from SFC and synchronous machine. After running the model, simulated machine voltage and current waveforms are validated with the real measurements. Processing of these waveforms is done through Fast Fourier Transformation (FFT) which reveals that the waveforms are not sinusoidal rather they contain number of harmonics. These harmonics are the major cause of generating shaft voltage. It is known that bearings of electrical machine are vulnerable to current flow through it due to shaft voltage. A general discussion on causes of shaft voltage in perspective with this machine is presented in this paper.

Keywords: Alternators, AC-DC power conversion, capacitive coupling, electric discharge machining, frequency converter, Fourier transforms, inductive coupling, simulation, Shaft voltage, synchronous machines, static excitation, thyristor.

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Authors: M.H.Ghaffari

Abstract:

A theoretical study is conducted to design and explore the effect of different parameters such as heat loads, the tube size of piping system, wick thickness, porosity and hole size on the performance and capability of a Loop Heat Pipe(LHP). This paper presents a steady state model that describes the different phenomena inside a LHP. Loop Heat Pipes(LHPs) are two-phase heat transfer devices with capillary pumping of a working fluid. By their original design comparing with heat pipes and special properties of the capillary structure, they-re capable of transferring heat efficiency for distances up to several meters at any orientation in the gravity field, or to several meters in a horizontal position. This theoretical model is described by different relations to satisfy important limits such as capillary and nucleate boiling. An algorithm is developed to predict the size of the LHP satisfying the limitations mentioned above for a wide range of applied loads. Finally, to assess and evaluate the algorithm and all the relations considered, we have used to design a new kind of LHP to recover the heat from the exhaust of an actual Gas Turbine. By finding the results, it showed that we can use the LHP as a very high efficient device to recover the heat even in high amount of loads(exhaust of a gas turbine). The sizes of all parts of the LHP were obtained using the developed algorithm.

Keywords: Loop Heat Pipe, Head Load, Liquid-Vapor Interface, Heat Transfer, Design Algorithm

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Authors: Luc Conti, Dimitry Dumont-Fillon, Harald van Lintel, Eric Chappel

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Flow control valves comprise a silicon flexible membrane that deflects against a substrate, usually made of glass, containing pillars, an outlet hole, and anti-stiction features. However, there is a strong interest in using silicon instead of glass as substrate material, as it would simplify the process flow by allowing the use of well controlled anisotropic etching. Moreover, specific devices demanding a bending of the substrate would also benefit from the inherent outstanding mechanical strength of monocrystalline silicon. Unfortunately, direct Si-Si bonding is not easily achieved with highly structured wafers since residual stress may prevent the good adhesion between wafers. Using a thermoplastic polymer, such as parylene, as intermediate layer is not well adapted to this design as the wafer-to-wafer alignment is critical. An alternative anodic bonding method using an intermediate borosilicate layer has been successfully tested. This layer has been deposited onto the silicon substrate. The bonding recipe has been adapted to account for the presence of the SOI buried oxide and intermediate glass layer in order not to exceed the breakdown voltage. Flow control valves dedicated to infusion of viscous fluids at very high pressure have been made and characterized. The results are compared to previous data obtained using the standard anodic bonding method.

Keywords: Anodic bonding, evaporated glass, microfluidic valve, drug delivery.

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Authors: Cristiano R. Cervi, Renata Galante, José Palazzo M. de Oliveira

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In this paper, we address the problem of identifying academic reputation of researchers using scientific metrics in different research areas. Due to the characteristics of each area, researchers can present different behaviors. In previous work, we define Rep-Index that makes use of a profile template to individually identify the reputation of researchers. The Rep-Index is comprehensive and adaptive because involves hole trajectory of the researcher built throughout his career and can be used in different areas and in different contexts. Now, we compare our metric (Rep-Index) with the h-index and the g-index through experiments with researchers in the fields of Economics, Dentistry and Computer Science. We analyze the trajectory of 830 Brazilian researchers from the National Council of Technological and Scientific Development (CNPq), which receive grants research productivity. The grants are aimed at productivity researchers that stand out among their peers, enhancing their scientific normative criteria established by CNPq. Of the 830 researchers, 210 are in the area of Economics, 216 of Dentistry e 404 of Computer Science. The experiments show that our metric is strongly correlated with h-index, g-index and CNPq ranking. We also show good results for our hypothesis that our metric can be used to evaluate research in several areas. We apply our metric (Rep-Index) to compare the behavior of researchers in relation to their h-index and g-index through extensive experiments. The experiments showed that our metric is strongly correlated with h-index, g-index and CNPq ranking.

Keywords: Researcher reputation, profile model, scientific metrics.

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Authors: Deng Zengming, Wang Mingjiang

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As 3D video is explored as a hot research topic in the last few decades, free-viewpoint TV (FTV) is no doubt a promising field for its better visual experience and incomparable interactivity. View synthesis is obviously a crucial technology for FTV; it enables to render images in unlimited numbers of virtual viewpoints with the information from limited numbers of reference view. In this paper, a novel hybrid synthesis framework is proposed and blending priority is explored. In contrast to the commonly used View Synthesis Reference Software (VSRS), the presented synthesis process is driven in consideration of the temporal correlation of image sequences. The temporal correlations will be exploited to produce fine synthesis results even near the foreground boundaries. As for the blending priority, this scheme proposed that one of the two reference views is selected to be the main reference view based on the distance between the reference views and virtual view, another view is chosen as the auxiliary viewpoint, just assist to fill the hole pixel with the help of background information. Significant improvement of the proposed approach over the state-of –the-art pixel-based virtual view synthesis method is presented, the results of the experiments show that subjective gains can be observed, and objective PSNR average gains range from 0.5 to 1.3 dB, while SSIM average gains range from 0.01 to 0.05.

Keywords: View synthesis, Gaussian mixture model, hybrid framework, fusion method.

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Authors: Yusri Yusof, Stephen Newman, Aydin Nassehi, Keith Case

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The changing economic climate has made global manufacturing a growing reality over the last decade, forcing companies from east and west and all over the world to collaborate beyond geographic boundaries in the design, manufacture and assemble of products. The ISO10303 and ISO14649 Standards (STEP and STEP-NC) have been developed to introduce interoperability into manufacturing enterprises so as to meet the challenge of responding to production on demand. This paper describes and illustrates a STEP compliant CAD/CAPP/CAM System for the manufacture of rotational parts on CNC turning centers. The information models to support the proposed system together with the data models defined in the ISO14649 standard used to create the NC programs are also described. A structured view of a STEP compliant CAD/CAPP/CAM system framework supporting the next generation of intelligent CNC controllers for turn/mill component manufacture is provided. Finally a proposed computational environment for a STEP-NC compliant system for turning operations (SCSTO) is described. SCSTO is the experimental part of the research supported by the specification of information models and constructed using a structured methodology and object-oriented methods. SCSTO was developed to generate a Part 21 file based on machining features to support the interactive generation of process plans utilizing feature extraction. A case study component has been developed to prove the concept for using the milling and turning parts of ISO14649 to provide a turn-mill CAD/CAPP/CAM environment.

Keywords:

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Authors: J. K. Khare, Abhay Kumar Sharma, Ajay Tiwari, Amol A. Talankar

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Powder metallurgy (P/M) is the only economic way to produce porous parts/products. P/M can produce near net shape parts hence reduces wastage of raw material and energy, avoids various machining operations. The most vital use of P/M is in production of metallic filters and self lubricating bush bearings and siding surfaces. The porosity of the part can be controlled by varying compaction pressure, sintering temperature and composition of metal powder mix. The present work is aimed for experimental analysis of friction and wear properties of self lubricating copper and tin bush bearing. Experimental results confirm that wear rate of sintered component is lesser for components having 10% tin by weight percentage. Wear rate increases for high tin percentage (experimented for 20% tin and 30% tin) at same sintering temperature. Experimental results also confirms that wear rate of sintered component is also dependent on sintering temperature, soaking period, composition of the preform, compacting pressure, powder particle shape and size. Interfacial friction between die and punch, between inter powder particles, between die face and powder particle depends on compaction pressure, powder particle size and shape, size and shape of component which decides size & shape of die & punch, material of die & punch and material of powder particles.

Keywords: Interfacial friction, porous bronze bearing, sintering temperature, wear rate.

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Authors: Sundara Subramanian Karuppasamy, Che Hua Yang

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In this work, the laser ultrasound technique has been used for analyzing and imaging the inner defects in metal blocks. To detect the defects in blocks, traditionally the researchers used piezoelectric transducers for the generation and reception of ultrasonic signals. These transducers can be configured into the sparse and phased array. But these two configurations have their drawbacks including the requirement of many transducers, time-consuming calculations, limited bandwidth, and provide confined image resolution. Here, we focus on the non-contact method for generating and receiving the ultrasound to examine the inner defects in aluminum blocks. A Q-switched pulsed laser has been used for the generation and the reception is done by using Laser Doppler Vibrometer (LDV). Based on the Doppler effect, LDV provides a rapid and high spatial resolution way for sensing ultrasonic waves. From the LDV, a series of scanning points are selected which serves as the phased array elements. The side-drilled hole of 10 mm diameter with a depth of 25 mm has been introduced and the defect is interrogated by the linear array of scanning points obtained from the LDV. With the aid of the Synthetic Aperture Focusing Technique (SAFT) algorithm, based on the time-shifting principle the inspected images are generated from the A-scan data acquired from the 1-D linear phased array elements. Thus the defect can be precisely detected with good resolution.

Keywords: Laser ultrasonics, linear phased array, nondestructive testing, synthetic aperture focusing technique, ultrasonic imaging.

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Authors: Khairul Jauhari, Achmad Widodo, Ismoyo Haryanto

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The spindle system is one of the most important components of machine tool. The dynamic properties of the spindle affect the machining productivity and quality of the work pieces. Thus, it is important and necessary to determine its dynamic characteristics of spindles in the design and development in order to avoid forced resonance. The finite element method (FEM) has been adopted in order to obtain the dynamic behavior of spindle system. For this reason, obtaining the Campbell diagrams and determining the critical speeds are very useful to evaluate the spindle system dynamics. The unbalance response of the system to the center of mass unbalance at the cutting tool is also calculated to investigate the dynamic behavior. In this paper, we used an ANSYS Parametric Design Language (APDL) program which based on finite element method has been implemented to make the full dynamic analysis and evaluation of the results. Results show that the calculated critical speeds are far from the operating speed range of the spindle, thus, the spindle would not experience resonance, and the maximum unbalance response at operating speed is still with acceptable limit. ANSYS Parametric Design Language (APDL) can be used by spindle designer as tools in order to increase the product quality, reducing cost, and time consuming in the design and development stages.

Keywords: ANSYS parametric design language (APDL), Campbell diagram, Critical speeds, Unbalance response, The Spindle system.

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Authors: Jooho Hwang, Chang-Kyu Song, Chun-Hong Park

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This paper describes a method to measure and compensate a 4 axes ultra-precision machine tool that generates micro patterns on the large surfaces. The grooving machine is usually used for making a micro mold for many electrical parts such as a light guide plate for LCD and fuel cells. The ultra precision machine tool has three linear axes and one rotational table. Shaping is usually used to generate micro patterns. In the case of 50 μm pitch and 25 μm height pyramid pattern machining with a 90° wedge angle bite, one of linear axis is used for long stroke motion for high cutting speed and other linear axis are used for feeding. The triangular patterns can be generated with many times of long stroke of one axis. Then 90° rotation of work piece is needed to make pyramid patterns with superposition of machined two triangular patterns. To make a two dimensional positioning error, straightness of two axes in out of plane, squareness between the each axis are important. Positioning errors, straightness and squarness were measured by laser interferometer system. Those were compensated and confirmed by ISO230-6. One of difficult problem to measure the error motions is squareness or parallelism of axis between the rotational table and linear axis. It was investigated by simultaneous moving of rotary table and XY axes. This compensation method is introduced in this paper.

Keywords: Ultra-precision machine tool, muti-axis errors, squraness, positioning errors.

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Authors: R. Ibrahim, M. Azmirruddin, M. Jabir, N. Johari, M. Muhamad, A. R. A. Talib

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Inconel718 has been widely used as a super alloy in aerospace application due to the high strength at elevated temperatures, satisfactory oxidation resistance and heat corrosion resistance. In this study, the Inconel718 has been fabricated using high technology of Metal Injection Molding (MIM) process due to the cost effective technique for producing small, complex and precision parts in high volume compared with conventional method through machining. Through MIM, the binder system is one of the most important criteria in order to successfully fabricate the Inconel718. Even though, the binder system is a temporary, but failure in the selection and removal of the binder system will affect on the final properties of the sintered parts. Therefore, the binder system based on palm oil derivative which is palm stearin has been formulated and developed to replace the conventional binder system. The rheological studies of the mixture between the powder and binders system have been determined properly in order to be successful during injection into injection molding machine. After molding, the binder holds the particles in place. The binder system has to be removed completely through debinding step. During debinding step, solvent debinding and thermal pyrolysis has been used to remove completely of the binder system. The debound part is then sintered to give the required physical and mechanical properties. The results show that the properties of the final sintered parts fulfill the Standard Metal Powder Industries Federation (MPIF) 35 for MIM parts.

Keywords: Binder system, rheological study, metal injection molding, debinding and sintered parts.

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Authors: Azadeh Yazdi, Mohammadreza Nezamirad, Sepideh Amirahmadian, Nasim Sabetpour, Amirmasoud Hamedi

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Cavitation inside diesel injector nozzle is investigated using Reynolds-Stress-Navier stokes equations. Schnerr-Sauer cavitation model is used for modeling cavitation inside diesel injector nozzle. The carrying fluid utilized in the current study is diesel fuel. The flow is verified at the beginning by comparing with the previous experimental data and it was found that K-Epsilon turbulent model could lead to a better accuracy comparing to K-Omega turbulent model. Moreover, mass flow rate obtained numerically is compared with the experimental value and discrepancy was found to be less than 5% - which shows the accuracy of the current results. Finally, a real-size four-hole nozzle is investigated and the flow inside it is visualized based on velocity profile, discharge coefficient and cavitation number. It was found that the mesh density could be reduced significantly by utilizing periodic boundary condition. Velocity contour at the mid nozzle showed that maximum value of velocity occurs at the end of the needle before entering the orifice area. Last but not least, at the same boundary conditions, when different needle heights were utilized, it was found that as needle height increases with an increase in cavitation number, discharge coefficient increases, while the mentioned increases is more tangible at smaller values of needle heights.

Keywords: cavitation, diesel fuel, CFD, real size nozzle, mass flow rate

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Authors: N. H. Othman, N. Udin, M. Ishak, L. H. Shah

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This study focuses on the effect of pin taper tool ratio on friction stir welding of magnesium alloy AZ31. Two pieces of AZ31 alloy with thickness of 6 mm were friction stir welded by using the conventional milling machine. The shoulder diameter used in this experiment is fixed at 18 mm. The taper pin ratio used are varied at 6:6, 6:5, 6:4, 6:3, 6:2 and 6:1. The rotational speeds that were used in this study were 500 rpm, 1000 rpm and 1500 rpm, respectively. The welding speeds used are 150 mm/min, 200 mm/min and 250 mm/min. Microstructure observation of welded area was studied by using optical microscope. Equiaxed grains were observed at the TMAZ and stir zone indicating fully plastic deformation. Tool pin diameter ratio 6/1 causes low heat input to the material because of small contact surface between tool surface and stirred materials compared to other tool pin diameter ratio. The grain size of stir zone increased with increasing of ratio of rotational speed to transverse speed due to higher heat input. It is observed that worm hole is produced when excessive heat input is applied. To evaluate the mechanical properties of this specimen, tensile test was used in this study. Welded specimens using taper pin ratio 6:1 shows higher tensile strength compared to other taper pin ratio up to 204 MPa. Moreover, specimens using taper pin ratio 6:1 showed better tensile strength with 500 rpm of rotational speed and 150mm/min welding speed.

Keywords: Friction stir welding, magnesium AZ31, cylindrical taper tool, taper pin ratio.

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Authors: Anjan Kumar Kakati, M. Chandrasekaran, Amitava Mandal, Amit Kumar Singh

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End milling process is one of the common metal cutting operations used for machining parts in manufacturing industry. It is usually performed at the final stage in manufacturing a product and surface roughness of the produced job plays an important role. In general, the surface roughness affects wear resistance, ductility, tensile, fatigue strength, etc., for machined parts and cannot be neglected in design. In the present work an experimental investigation of end milling of aluminium alloy with carbide tool is carried out and the effect of different cutting parameters on the response are studied with three-dimensional surface plots. An artificial neural network (ANN) is used to establish the relationship between the surface roughness and the input cutting parameters (i.e., spindle speed, feed, and depth of cut). The Matlab ANN toolbox works on feed forward back propagation algorithm is used for modeling purpose. 3-12-1 network structure having minimum average prediction error found as best network architecture for predicting surface roughness value. The network predicts surface roughness for unseen data and found that the result/prediction is better. For desired surface finish of the component to be produced there are many different combination of cutting parameters are available. The optimum cutting parameter for obtaining desired surface finish, to maximize tool life is predicted. The methodology is demonstrated, number of problems are solved and algorithm is coded in Matlab®.

Keywords: End milling, Surface roughness, Neural networks.

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Authors: M. Jayekumar, V. Nagarajan

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Wireless sensor network finds role in environmental monitoring, industrial applications, surveillance applications, health monitoring and other supervisory applications. Sensing devices form the basic operational unit of the network that is self-battery powered with limited life time. Sensor node spends its limited energy for transmission, reception, routing and sensing information. Frequent energy utilization for the above mentioned process leads to network lifetime degradation. To enhance energy efficiency and network lifetime, we propose a modified energy optimization and node recovery post failure method, Energy-Link Failure Recovery Routing (E-LFRR) algorithm. In our E-LFRR algorithm, two phases namely, Monitored Transmission phase and Replaced Transmission phase are devised to combat worst case link failure conditions. In Monitored Transmission phase, the Actuator Node monitors and identifies suitable nodes for shortest path transmission. The Replaced Transmission phase dispatches the energy draining node at early stage from the active link and replaces it with the new node that has sufficient energy. Simulation results illustrate that this combined methodology reduces overhead, energy consumption, delay and maintains considerable amount of alive nodes thereby enhancing the network performance.

Keywords: Actuator node, energy efficient routing, energy hole, link failure recovery, link utilization, wireless sensor network.

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Authors: S. D. El Wakil

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The research work reported here was aimed at investigating the feasibility of joining high-porosity stainless steel discs and wrought iron bars by friction welding. The sound friction-welded joints were then subjected to a metallurgical investigation and an analysis of failure resulting from tensile loading. Discs having 50 mm diameter and 10 mm thickness were produced by loose sintering of stainless steel powder at a temperature of 1350 ^oC in an argon atmosphere for one hour. Minor machining was then carried out to control the dimensions of the discs, and the density of each disc could then be determined. The level of porosity was calculated and was found to be about 40% in all of those discs. Solid wrought iron bars were also machined to facilitate tensile testing of the joints produced by friction welding. Using our previously gained experience, the porous stainless steel disc and the wrought iron tube were successfully friction welded. SEM was employed to examine the fracture surface after a tensile test of the joint in order to determine the type of failure. It revealed that the failure did not occur in the joint, but rather in the in the porous metal in the area adjacent to the joint. The load carrying capacity was actually determined by the strength of the porous metal and not by that of the welded joint. Macroscopic and microscopic metallographic examinations were also performed and showed that the welded joint involved a dense heat-affected zone where the porous metal underwent densification at elevated temperature, explaining and supporting the findings of the SEM study.

Keywords: Fracture of friction-welded joints, metallurgy of friction welding, solid-porous structures, strength of joint.

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Authors: Taposh Roy, Anna Paradowska, Ralph Abrahams, Quan Lai, Michael Law, Peter Mutton, Mehdi Soodi, Wenyi Yan

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In this investigation, a laser cladding process with a powder feeding was used to deposit stainless steel 410L (high strength, excellent resistance to abrasion and corrosion, and great laser compatibility) onto railhead (higher strength, heat treated hypereutectoid rail grade manufactured in accordance with the requirements of European standard EN 13674 Part 1 for R400HT grade), to investigate the development and controllability of process-induced residual stress in the cladding, heat-affected zone (HAZ) and substrate and to analyse their correlation with hardness profile during two different laser cladding directions (across and along the track). Residual stresses were analysed by neutron diffraction at OPAL reactor, ANSTO. Neutron diffraction was carried out on the samples in longitudinal (parallel to the rail), transverse (perpendicular to the rail) and normal (through thickness) directions with high spatial resolution through the thickness. Due to the thick rail and thin cladding, 4 mm thick reference samples were prepared from every specimen by Electric Discharge Machining (EDM). Metallography across the laser claded sample revealed four distinct zones: The clad zone, the dilution zone, HAZ and the substrate. Compressive residual stresses were found in the clad zone and tensile residual stress in the dilution zone and HAZ. Laser cladding in longitudinally cladding induced higher tensile stress in the HAZ, whereas transversely cladding rail showed lower tensile behavior.

Keywords: Laser cladding, residual stress, neutron diffraction, HAZ.

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Authors: Omid A. Zargar

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In this project three type of tools, straight cylindrical, taper cylindrical and triangular tool all made of High speed steel (Wc-Co) used for the friction stir welding (FSW) aluminum alloy H20–H20 and the mechanical properties of the welded joint tested by tensile test and vicker hardness test. Besides, mentioned mechanical properties compared with each other to make conclusion. The result helped design of welding parameter optimization for different types of friction stir process like rotational speed, depth of welding, travel speed, type of material, type of joint, work piece dimension, joint dimension, tool material and tool geometry. Previous investigations in different types of materials work pieces; joint type, machining parameter and preheating temperature take placed. In this investigation 3 mentioned tool types that are popular in FSW tested and the results completed other aspects of the process. Hope this paper can open a new horizon in experimental investigation of mechanical properties for friction stir welded joint with other different type of tools like oval shape probe, paddle shape probe, three flat sided probe, and three sided re-entrant probe and other materials and alloys like titanium or steel in near future.

Keywords: Friction stir welding (FSW), tool, CNC milling machine, aluminum alloy H20, Vickers hardness test, tensile test, straight cylindrical tool, taper cylindrical tool, triangular tool.

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Authors: Raphael de Oliveira Garcia, Samuel Rocha de Oliveira

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We have developed a new computer program in Fortran 90, in order to obtain numerical solutions of a system of Relativistic Magnetohydrodynamics partial differential equations with predetermined gravitation (GRMHD), capable of simulating the formation of relativistic jets from the accretion disk of matter up to his ejection. Initially we carried out a study on numerical methods of unidimensional Finite Volume, namely Lax-Friedrichs, Lax-Wendroff, Nessyahu-Tadmor method and Godunov methods dependent on Riemann problems, applied to equations Euler in order to verify their main features and make comparisons among those methods. It was then implemented the method of Finite Volume Centered of Nessyahu-Tadmor, a numerical schemes that has a formulation free and without dimensional separation of Riemann problem solvers, even in two or more spatial dimensions, at this point, already applied in equations GRMHD. Finally, the Nessyahu-Tadmor method was possible to obtain stable numerical solutions - without spurious oscillations or excessive dissipation - from the magnetized accretion disk process in rotation with respect to a central black hole (BH) Schwarzschild and immersed in a magnetosphere, for the ejection of matter in the form of jet over a distance of fourteen times the radius of the BH, a record in terms of astrophysical simulation of this kind. Also in our simulations, we managed to get substructures jets. A great advantage obtained was that, with the our code, we got simulate GRMHD equations in a simple personal computer.

Keywords: Finite Volume Methods, Central Schemes, Fortran 90, Relativistic Astrophysics, Jet.

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Authors: A. Arockia Selvakumar, R. Sivaramakrishnan, Srinivasa Karthik.T.V, Valluri Siva Ramakrishna, B.Vinodh.

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Industrial robots play a vital role in automation however only little effort are taken for the application of robots in machining work such as Grinding, Cutting, Milling, Drilling, Polishing etc. Robot parallel manipulators have high stiffness, rigidity and accuracy, which cannot be provided by conventional serial robot manipulators. The aim of this paper is to perform the modeling and the workspace analysis of a 3 DOF Parallel Manipulator (3 DOF PM). The 3 DOF PM was modeled and simulated using 'ADAMS'. The concept involved is based on the transformation of motion from a screw joint to a spherical joint through a connecting link. This paper work has been planned to model the Parallel Manipulator (PM) using screw joints for very accurate positioning. A workspace analysis has been done for the determination of work volume of the 3 DOF PM. The position of the spherical joints connected to the moving platform and the circumferential points of the moving platform were considered for finding the workspace. After the simulation, the position of the joints of the moving platform was noted with respect to simulation time and these points were given as input to the 'MATLAB' for getting the work envelope. Then 'AUTOCAD' is used for determining the work volume. The obtained values were compared with analytical approach by using Pappus-Guldinus Theorem. The analysis had been dealt by considering the parameters, link length and radius of the moving platform. From the results it is found that the radius of moving platform is directly proportional to the work volume for a constant link length and the link length is also directly proportional to the work volume, at a constant radius of the moving platform.

Keywords: Three Degrees of freedom Parallel Manipulator (3DOF PM), ADAMS, Work volume, MATLAB, AUTOCAD, Pappus- Guldinus Theorem.

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