Search results for: rough surface contact
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 2503

Search results for: rough surface contact

2203 Prediction of Optimum Cutting Parameters to obtain Desired Surface in Finish Pass end Milling of Aluminium Alloy with Carbide Tool using Artificial Neural Network

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

Abstract:

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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2202 A Study on Removal Characteristics of (Mn2+) from Aqueous Solution by CNT

Authors: Nassereldeen A. Kabashi, Suleyman A. Muyibi. Mohammed E. Saeed., Farhana I. Yahya

Abstract:

It is important to remove manganese from water because of its effects on human and the environment. Human activities are one of the biggest contributors for excessive manganese concentration in the environment. The proposed method to remove manganese in aqueous solution by using adsorption as in carbon nanotubes (CNT) at different parameters: The parameters are CNT dosage, pH, agitation speed and contact time. Different pHs are pH 6.0, pH 6.5, pH 7.0, pH 7.5 and pH 8.0, CNT dosages are 5mg, 6.25mg, 7.5mg, 8.75mg or 10mg, contact time are 10 min, 32.5 min, 55 min, 87.5 min and 120 min while the agitation speeds are 100rpm, 150rpm, 200rpm, 250rpm and 300rpm. The parameters chosen for experiments are based on experimental design done by using Central Composite Design, Design Expert 6.0 with 4 parameters, 5 levels and 2 replications. Based on the results, condition set at pH 7.0, agitation speed of 300 rpm, 7.5mg and contact time 55 minutes gives the highest removal with 75.5%. From ANOVA analysis in Design Expert 6.0, the residual concentration will be very much affected by pH and CNT dosage. Initial manganese concentration is 1.2mg/L while the lowest residual concentration achieved is 0.294mg/L, which almost satisfy DOE Malaysia Standard B requirement. Therefore, further experiments must be done to remove manganese from model water to the required standard (0.2 mg/L) with the initial concentration set to 0.294 mg/L.

Keywords: Adsorption, CNT, DOE, Manganese, Parameters.

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2201 An Infrared Investigation on Surface Species over Iron-Based Catalysts: Implications for Oxygenates Formation

Authors: Wanyu Mao, Hongfang Ma, Haitao Zhang, WeixinQian, Weiyong Ying

Abstract:

The nature of adsorbed species on catalytic surface over an industrial precipitated iron-based high temperature catalyst during FTS was investigated by in-situ DRIFTS and chemical trapping. The formulation of the mechanism of oxygenates formation and key intermediates were also discussed. Numerous oxygenated precursors and crucial intermediates were found by in-situ DRIFTS, such as surface acetate, acetyl and methoxide. The results showed that adsorbed molecules on surface such as methanol or acetaldehyde could react with basic sites such as lattice oxygen or free surface hydroxyls. Adsorbed molecules also had reactivity of oxidizing. Moreover, acetyl as a key intermediate for oxygenates was observed by investigation of CH3OH + CO and CH3I + CO + H2. Based on the nature of surface properties, the mechanism of oxygenates formation on precipitated iron-based high temperature catalyst was discussed.

Keywords: Iron-based catalysts, intermediates, oxygenates, in-situ DRIFTS, chemical trapping.

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2200 Finite Element Modeling of two-dimensional Nanoscale Structures with Surface Effects

Authors: Weifeng Wang, Xianwei Zeng, Jianping Ding

Abstract:

Nanomaterials have attracted considerable attention during the last two decades, due to their unusual electrical, mechanical and other physical properties as compared with their bulky counterparts. The mechanical properties of nanostructured materials show strong size dependency, which has been explained within the framework of continuum mechanics by including the effects of surface stress. The size-dependent deformations of two-dimensional nanosized structures with surface effects are investigated in the paper by the finite element method. Truss element is used to evaluate the contribution of surface stress to the total potential energy and the Gurtin and Murdoch surface stress model is implemented with ANSYS through its user programmable features. The proposed approach is used to investigate size-dependent stress concentration around a nanosized circular hole and the size-dependent effective moduli of nanoporous materials. Numerical results are compared with available analytical results to validate the proposed modeling approach.

Keywords: Nanomaterials, finite element method, sizedependency, surface stress

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2199 The Influence of Surface Roughness of Drawbead on Non-Symmetry Deep Drawing Cold Rolled Steel Sheet

Authors: A. Watanapa, S. Torsakul

Abstract:

This study was aimed to explain the influence of surface roughness of the drawbead on non-symmetry deep drawing cold rolled steel sheet to improve the drawability of cold rolled steel sheet. The variables used in this study included semi-circle drawbead with 3 levels of surface roughness which are 6.127 mm Ra, 0.963 mm Ra and 0.152 mm Ra and cold rolled steel sheet according to 3 grades of the JIS standards which are SPCC, SPCE and SPCD with the thickness of 1.0 mm and the blankholder force which is 50% of the drawing force and the depth of 50 mm. According to the test results, when there was the increase in the surface roughness of drawbead, there would be the increase in deep drawing force, especially the SPCC cold rolled steel sheet. This is similar to the increase in the equivalent strain and the wall thickness distribution when the surface roughness of the drawbead increased. It could be concluded that the surface roughness of drawbead has an influence on deep drawing cold rolled steel sheet, especially the drawing force, the equivalent strain and the wall thickness distribution.

Keywords: Drawbead, Deep Drawing, Drawing Force, Equivalent Strain, Surface roughness

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2198 Effect of Coolant on Cutting Forces and Surface Roughness in Grinding of CSM GFRP

Authors: P Chockalingam, K Kok, R Vijayaram

Abstract:

This paper presents a comparative study on dry and wet grinding through experimental investigation in the grinding of CSM glass fibre reinforced polymer laminates using a pink aluminium oxide wheel. Different sets of experiments were performed to study the effects of the independent grinding parameters such as grinding wheel speed, feed and depth of cut on dependent performance criteria such as cutting forces and surface finish. Experimental conditions were laid out using design of experiment central composite design. An effective coolant was sought in this study to minimise cutting forces and surface roughness for GFRP laminates grinding. Test results showed that the use of coolants reduces surface roughness, although not necessarily the cutting forces. These research findings provide useful economic machining solution in terms of optimized grinding conditions for grinding CSM GFRP.

Keywords: Chopped Strand Mat GFRP laminates, Dry and Wet Grinding, Cutting Forces, Surface Finish.

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2197 Using Ultrasonic and Infrared Sensors for Distance Measurement

Authors: Tarek Mohammad

Abstract:

The amplitude response of infrared (IR) sensors depends on the reflectance properties of the target. Therefore, in order to use IR sensor for measuring distances accurately, prior knowledge of the surface must be known. This paper describes the Phong Illumination Model for determining the properties of a surface and subsequently calculating the distance to the surface. The angular position of the IR sensor is computed as normal to the surface for simplifying the calculation. Ultrasonic (US) sensor can provide the initial information on distance to obtain the parameters for this method. In addition, the experimental results obtained by using LabView are discussed. More care should be taken when placing the objects from the sensors during acquiring data since the small change in angle could show very different distance than the actual one. Since stereo camera vision systems do not perform well under some environmental conditions such as plain wall, glass surfaces, or poor lighting conditions, the IR and US sensors can be used additionally to improve the overall vision systems of mobile robots.

Keywords: Distance Measurement, Infrared sensor, Surface properties, Ultrasonic sensor.

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2196 Study on Robot Trajectory Planning by Robot End-Effector Using Dual Curvature Theory of the Ruled Surface

Authors: Y. S. Oh, P. Abhishesh, B. S. Ryuh

Abstract:

This paper presents the method of trajectory planning by the robot end-effector which accounts for more accurate and smooth differential geometry of the ruled surface generated by tool line fixed with end-effector based on the methods of curvature theory of ruled surface and the dual curvature theory, and focuses on the underlying relation to unite them for enhancing the efficiency for trajectory planning. Robot motion can be represented as motion properties of the ruled surface generated by trajectory of the Tool Center Point (TCP). The linear and angular properties of the six degree-of-freedom motion of end-effector are computed using the explicit formulas and functions from curvature theory and dual curvature theory. This paper explains the complete dualization of ruled surface and shows that the linear and angular motion applied using the method of dual curvature theory is more accurate and less complex.

Keywords: Dual curvature theory, robot end effector, ruled surface, TCP, tool center point.

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2195 Determination of the Quality of the Machined Surface Using Fuzzy Logic

Authors: Dejan Tanikić, Jelena Đoković, Saša Kalinović, Miodrag Manić, Saša Ranđelović

Abstract:

This paper deals with measuring and modelling of the quality of the machined surface of the metal machining process. The average surface roughness (Ra) which represents the quality of the machined part was measured during the dry turning of the AISI 4140 steel. A large number of factors with the unknown relations among them influences this parameter, and that is why mathematical modelling is extremely complicated. Different values of cutting speed, feed rate, depth of cut (cutting regime) and workpiece hardness causes different surface roughness values. Modelling with soft computing techniques may be very useful in such cases. This paper presents the usage of the fuzzy logic-based system for determining metal machining process parameter in order to find the proper values of cutting regimes.

Keywords: Metal machining, surface roughness, fuzzy logic, process modelling.

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2194 Surface Flattening Assisted with 3D Mannequin Based On Minimum Energy

Authors: Shih-Wen Hsiao, Rong-Qi Chen, Chien-Yu Lin

Abstract:

The topic of surface flattening plays a vital role in the field of computer aided design and manufacture. Surface flattening enables the production of 2D patterns and it can be used in design and manufacturing for developing a 3D surface to a 2D platform, especially in fashion design. This study describes surface flattening based on minimum energy methods according to the property of different fabrics. Firstly, through the geometric feature of a 3D surface, the less transformed area can be flattened on a 2D platform by geodesic. Then, strain energy that has accumulated in mesh can be stably released by an approximate implicit method and revised error function. In some cases, cutting mesh to further release the energy is a common way to fix the situation and enhance the accuracy of the surface flattening, and this makes the obtained 2D pattern naturally generate significant cracks. When this methodology is applied to a 3D mannequin constructed with feature lines, it enhances the level of computer-aided fashion design. Besides, when different fabrics are applied to fashion design, it is necessary to revise the shape of a 2D pattern according to the properties of the fabric. With this model, the outline of 2D patterns can be revised by distributing the strain energy with different results according to different fabric properties. Finally, this research uses some common design cases to illustrate and verify the feasibility of this methodology.

Keywords: Surface flattening, Strain energy, Minimum energy, approximate implicit method, Fashion design.

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2193 Adsorption Studies on the Removal of Pesticides(Carbofuran) using Activated Carbon from Rice Straw Agricultural Waste

Authors: Ken-Lin Chang, Jun-Hong Lin, Shui-Tein Chen

Abstract:

In this study, we used a two-stage process and potassium hydroxide (KOH) to transform waste biomass (rice straw) into activated carbon and then evaluated the adsorption capacity of the waste for removing carbofuran from an aqueous solution. Activated carbon was fast and effective for the removal of carbofuran because of its high surface area. The native and carbofuran-loaded adsorbents were characterized by elemental analysis. Different adsorption parameters, such as the initial carbofuran concentration, contact time, temperature and pH for carbofuran adsorption, were studied using a batch system. This study demonstrates that rice straw can be very effective in the adsorption of carbofuran from bodies of water.

Keywords: Rice straw, Carbofuran, Activated carbon

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2192 Influence of Selected Finishing Technologies on the Roughness Parameters of Stainless Steel Manufactured by Selective Laser Melting Method

Authors: J. Hajnys, M. Pagac, J. Petru, P. Stefek, J. Mesicek, J. Kratochvil

Abstract:

The new progressive method of 3D metal printing SLM (Selective Laser Melting) is increasingly expanded into the normal operation. As a result, greater demands are placed on the surface quality of the parts produced in this way. The article deals with research of selected finishing methods (tumbling, face milling, sandblasting, shot peening and brushing) and their impact on the final surface roughness. The 20 x 20 x 7 mm produced specimens using SLM additive technology on the Renishaw AM400 were subjected to testing of these finishing methods by adjusting various parameters. Surface parameters of roughness Sa, Sz were chosen as the evaluation criteria and profile parameters Ra, Rz were used as additional measurements. Optical measurement of surface roughness was performed on Alicona Infinite Focus 5. An experiment conducted to optimize the surface roughness revealed, as expected, that the best roughness parameters were achieved through a face milling operation. Tumbling is particularly suitable for 3D printing components, as tumbling media are able to reach even complex shapes and, after changing to polishing bodies, achieve a high surface gloss. Surface quality after tumbling depends on the process time. Other methods with satisfactory results are shot peening and tumbling, which should be the focus of further research.

Keywords: Additive manufacturing, selective laser melting, surface roughness, stainless steel.

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2191 The Optimum Aeration Time of Wastewater Treatment by Surface Aerators in Suan Sunandha Rajabhat University

Authors: Anat Thapinta

Abstract:

This research aimed to study on the efficiency of wastewater treatment by comparing the different aeration times of surface aerators in Suan Sunandha Rajabhat University. In doing so, the operation of surface aerators was divided into 2 groups which included the groups of 8 hours (8-0/opened-closed) and 4 hours (2-2/opened-closed) of aeration time per day. As a result of the study, it was found that the efficiency of wastewater treatment in the forms of DO, BOD, turbidity and NO2- by 8 hours (8-0/opened-closed) and 4 hours (2-2/opened-closed) of aeration time per day of surface aerators was not statistically different [Sig. = .644, .488, .716 and .054 > α (.05)] while the efficiency in the forms of NO3- and P was significantly different at the statistical level of .01 [Sig. = .001 and .000 < α (.01)].

Keywords: Aeration time, Surface aerator, Wastewater treatment.

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2190 An Alternative Approach for Assessing the Impact of Cutting Conditions on Surface Roughness Using Single Decision Tree

Authors: S. Ghorbani, N. I. Polushin

Abstract:

In this study, an approach to identify factors affecting on surface roughness in a machining process is presented. This study is based on 81 data about surface roughness over a wide range of cutting tools (conventional, cutting tool with holes, cutting tool with composite material), workpiece materials (AISI 1045 Steel, AA2024 aluminum alloy, A48-class30 gray cast iron), spindle speed (630-1000 rpm), feed rate (0.05-0.075 mm/rev), depth of cut (0.05-0.15 mm) and tool overhang (41-65 mm). A single decision tree (SDT) analysis was done to identify factors for predicting a model of surface roughness, and the CART algorithm was employed for building and evaluating regression tree. Results show that a single decision tree is better than traditional regression models with higher rate and forecast accuracy and strong value.

Keywords: Cutting condition, surface roughness, decision tree, CART algorithm.

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2189 Conformation Prediction of Human Plasmin and Docking on Gold Nanoparticle

Authors: Wen-Shyong Tzou, Chih-Ching Huang, Chin-Hwa Hu, Ying-Tsang Lo, Tun-Wen Pai, Chia-Yin Chiang, Chung-Hao Li, Hong-Jyuan Jian

Abstract:

Plasmin plays an important role in the human circulatory system owing to its catalytic ability of fibrinolysis. The immediate injection of plasmin in patients of strokes has intrigued many scientists to design vectors that can transport plasmin to the desired location in human body. Here we predict the structure of human plasmin and investigate the interaction of plasmin with the gold-nanoparticle. Because the crystal structure of plasminogen has been solved, we deleted N-terminal domain (Pan-apple domain) of plasminogen and generate a mimic of the active form of this enzyme (plasmin). We conducted a simulated annealing process on plasmin and discovered a very large conformation occurs. Kringle domains 1, 4 and 5 had been observed to leave its original location relative to the main body of the enzyme and the original doughnut shape of this enzyme has been transformed to a V-shaped by opening its two arms. This observation of conformational change is consistent with the experimental results of neutron scattering and centrifugation. We subsequently docked the plasmin on the simulated gold surface to predict their interaction. The V-shaped plasmin could utilize its Kringle domain and catalytic domain to contact the gold surface. Our findings not only reveal the flexibility of plasmin structure but also provide a guide for the design of a plasmin-gold nanoparticle.

Keywords: Docking, gold nanoparticle, molecular simulation, plasmin.

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2188 The Water Quantity and Quality for Conjunctive Use in Saline Soil Problem Area

Authors: P. Mekpruksawong, S. Chuenchooklin, T. Ichikawa

Abstract:

The aim of research project is to evaluate quantity and quality for conjunctive use of groundwater and surface water in lower in the Lower Nam Kam area, Thailand, even though there have been hints of saline soil and water. The mathematical model named WUSMO and MIKE Basin were applied for the calculation of crop water utilization. Results of the study showed that, in irrigation command area, water consumption rely on various sources; rain water 21.56%, irrigation water 78.29%, groundwater and some small surface storage 0.15%. Meanwhile, for non-irrigation command area, water consumption depends on the Nam Kam and Nambang stream 42%, rain water 36.75% and groundwater and some small surface storage 19.18%. Samples of surface water and groundwater were collected for 2 seasons. The criterion was determined for the assessment of suitable water for irrigation. It was found that this area has very limited sources of suitable water for irrigation.

Keywords: Conjunctive use, Groundwater, Surface water, Saline soil.

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2187 Modeling and Analysis of Process Parameters on Surface Roughness in EDM of AISI D2 Tool Steel by RSM Approach

Authors: M. K. Pradhan, C. K. Biswas

Abstract:

In this research, Response Surface Methodology (RSM) is used to investigate the effect of four controllable input variables namely: discharge current, pulse duration, pulse off time and applied voltage Surface Roughness (SR) of on Electrical Discharge Machined surface. To study the proposed second-order polynomial model for SR, a Central Composite Design (CCD) is used to estimation the model coefficients of the four input factors, which are alleged to influence the SR in Electrical Discharge Machining (EDM) process. Experiments were conducted on AISI D2 tool steel with copper electrode. The response is modeled using RSM on experimental data. The significant coefficients are obtained by performing Analysis of Variance (ANOVA) at 5% level of significance. It is found that discharge current, pulse duration, and pulse off time and few of their interactions have significant effect on the SR. The model sufficiency is very satisfactory as the Coefficient of Determination (R2) is found to be 91.7% and adjusted R2-statistic (R2 adj ) 89.6%.

Keywords: Electrical discharge machining, surface roughness, response surface methodology, ANOVA, central composite design.

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2186 The Estimation of Semi Elliptical Surface Cracks Advancement via Fuzzy Logic

Authors: Gürol Önal, Ahmet Avcı

Abstract:

This paper presented the results of an experimental investigation into the axial fatigue behavior of a 5086 aluminum alloy which have several notch-aspect ratios a0/c0 and notch thickness ratio a/t with semi-elliptical surface cracks. Tests were conducted in la b air for stress levels of 50 % of their yield strength. Experiments were carried out for various notch to thickness ratios. Crack growth rates of test specimens both in surface and depth directions were determined by using die penetration method. Fuzzy Logic method was used to predict the deep direction crack growth because the dept of the crack is considerably difficult to measure.

Keywords: Axial fatigue, Crack growth rate, surface crack, Al-Mg alloy.

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2185 Numerical Investigation of the Jacketing Method of Reinforced Concrete Column

Authors: S. Boukais, A. Nekmouche, N. Khelil, A. Kezmane

Abstract:

The first intent of this study is to develop a finite element model that can predict correctly the behavior of the reinforced concrete column. Second aim is to use the finite element model to investigate and evaluate the effect of the strengthening method by jacketing of the reinforced concrete column, by considering different interface contact between the old and the new concrete. Four models were evaluated, one by considering perfect contact, the other three models by using friction coefficient of 0.1, 0.3 and 0.5. The simulation was carried out by using Abaqus software. The obtained results show that the jacketing reinforcement led to significant increase of the global performance of the behavior of the simulated reinforced concrete column.

Keywords: Strengthening, jacketing, reinforced concrete column, 3D simulation, Abaqus.

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2184 Numerical Analysis of Electrical Interaction between two Axisymmetric Spheroids

Authors: Kuan-Liang Liu, Eric Lee, Jung-Jyh Lee, Jyh-Ping Hsu

Abstract:

The electrical interaction between two axisymmetric spheroidal particles in an electrolyte solution is examined numerically. A Galerkin finite element method combined with a Newton-Raphson iteration scheme is proposed to evaluate the spatial variation in the electrical potential, and the result obtained used to estimate the interaction energy between two particles. We show that if the surface charge density is fixed, the potential gradient is larger at a point, which has a larger curvature, and if surface potential is fixed, surface charge density is proportional to the curvature. Also, if the total interaction energy against closest surface-to-surface curve exhibits a primary maximum, the maximum follows the order (oblate-oblate) > (sphere-sphere)>(oblate-prolate)>(prolate-prolate), and if the curve has a secondary minimum, the absolute value of the minimum follows the same order.

Keywords: interaction energy, interaction force, Poisson-Boltzmann equation, spheroid.

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2183 Selection of Plants as Possible Rhizoremediators for Restoration of Oil Contaminated Soil

Authors: Togzhan D. Mukasheva, Anel A. Omirbekova, Raikhan S. Sydykbekova, Ramza Zh. Berzhanova, Lyudmila V. Ignatova

Abstract:

In studying the possibility of using plants as rhizoremediators, barley and grass mixture which showed resistance to various concentrations of oil were selected. The minimum inhibitory effect of oil on these plants by morphological parameters such as survival of plants, length and biomass of shoot and root compared with the control was showed. In determining physiological parameters, a slight decrease in the number of chlorophyll a and b in the leaves of plants was noted. The differences in the ratio of the total surface of the roots to the work surface with the growth of plants in soil with oil in the study of adsorption of the root surface were showed.

Keywords: Length of shoot and root, biomass, chlorophyll a and b, adsorption surface, barley, grass mixture.

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2182 A Review of the Characteristics and Optimization of Optical Properties of Zirconia Ceramics for Aesthetic Dental Restorations

Authors: R. A. Shahmiri, O. C. Standard, J. N. Hart, C. C. Sorrell

Abstract:

The ceramic yttria-stabilized tetragonal zirconia polycrystal (Y-TZP) has been used as a dental biomaterial for several decades. The strength and toughness of this material can be accounted for by its toughening mechanisms, which include transformation toughening, crack deflection, zone shielding, contact shielding, and crack bridging. Prevention of crack propagation is of critical importance in high-fatigue situations, such as those encountered in mastication and para-function. However, the poor translucence of Y-TZP in polycrystalline form is such that it may not meet the aesthetic requirements due to its white/grey appearance. To improve the optical properties of Y-TZP, more detailed study of the optical properties is required; in particular, precise evaluation of the refractive index, absorption coefficient, and scattering coefficient are necessary. The measurement of the optical parameters has been based on the assumption that light scattered from biological media is isotropically distributed over all angles. In fact, the optical behavior of real biological materials depends on the angular scattering of light due to the anisotropic nature of the materials. The purpose of the present work is to evaluate the optical properties (including color, opacity/translucence, scattering, and fluorescence) of zirconia dental ceramics and their control through modification of the chemical composition, phase composition, and surface microstructure.

Keywords: Optical properties, opacity/translucence, scattering, fluorescence, chemical composition, phase composition, surface microstructure.

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2181 Optimization of Surface Finish in Milling Operation Using Live Tooling via Taguchi Method

Authors: Harish Kumar Ponnappan, Joseph C. Chen

Abstract:

The main objective of this research is to optimize the surface roughness of a milling operation on AISI 1018 steel using live tooling on a HAAS ST-20 lathe. In this study, Taguchi analysis is used to optimize the milling process by investigating the effect of different machining parameters on surface roughness. The L9 orthogonal array is designed with four controllable factors with three different levels each and an uncontrollable factor, resulting in 18 experimental runs. The optimal parameters determined from Taguchi analysis were feed rate – 76.2 mm/min, spindle speed 1150 rpm, depth of cut – 0.762 mm and 2-flute TiN coated high-speed steel as tool material. The process capability Cp and process capability index Cpk values were improved from 0.62 and -0.44 to 1.39 and 1.24 respectively. The average surface roughness values from the confirmation runs were 1.30 µ, decreasing the defect rate from 87.72% to 0.01%. The purpose of this study is to efficiently utilize the Taguchi design to optimize the surface roughness in a milling operation using live tooling.

Keywords: Live tooling, surface roughness, Taguchi analysis, Computer Numerical Control (CNC) milling operation, CNC turning operation.

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2180 The Implementation of Good Manufacturing Practice in Polycarbonate Film Industry

Authors: Nisachon Mawai, Jeerapat Ngaoprasertwong

Abstract:

This study reports the implementation of Good Manufacturing Practice (GMP) in a polycarbonate film processing plant. The implementation of GMP took place with the creation of a multidisciplinary team. It was carried out in four steps: conduct gap assessment, create gap closure plan, close gaps, and follow up the GMP implementation. The basis for the gap assessment is the guideline for GMP for plastic materials and articles intended for Food Contact Material (FCM), which was edited by Plastic Europe. The effective results of the GMP implementation in this study showed 100% completion of gap assessment. The key success factors for implementing GMP in production process are the commitment, intention and support of top management.

Keywords: Implementation, Good Manufacturing Practice, Polycarbonate Film, Food Contact Materials.

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2179 A Fuzzy Logic Based Model to Predict Surface Roughness of A Machined Surface in Glass Milling Operation Using CBN Grinding Tool

Authors: Ahmed A. D. Sarhan, M. Sayuti, M. Hamdi

Abstract:

Nowadays, the demand for high product quality focuses extensive attention to the quality of machined surface. The (CNC) milling machine facilities provides a wide variety of parameters set-up, making the machining process on the glass excellent in manufacturing complicated special products compared to other machining processes. However, the application of grinding process on the CNC milling machine could be an ideal solution to improve the product quality, but adopting the right machining parameters is required. In glass milling operation, several machining parameters are considered to be significant in affecting surface roughness. These parameters include the lubrication pressure, spindle speed, feed rate and depth of cut. In this research work, a fuzzy logic model is offered to predict the surface roughness of a machined surface in glass milling operation using CBN grinding tool. Four membership functions are allocated to be connected with each input of the model. The predicted results achieved via fuzzy logic model are compared to the experimental result. The result demonstrated settlement between the fuzzy model and experimental results with the 93.103% accuracy.

Keywords: CNC-machine, Glass milling, Grinding, Surface roughness, Cutting force, Fuzzy logic model.

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2178 Study on Specific Energy in Grinding of DRACs: A Response Surface Methodology Approach

Authors: Dayananda Pai, Shrikantha S. Rao, Savitha G.Kini

Abstract:

In this study, the effects of machining parameters on specific energy during surface grinding of 6061Al-SiC35P composites are investigated. Vol% of SiC, feed and depth of cut were chosen as process variables. The power needed for the calculation of the specific energy is measured from the two watt meter method. Experiments are conducted using standard RSM design called Central composite design (CCD). A second order response surface model was developed for specific energy. The results identify the significant influence factors to minimize the specific energy. The confirmation results demonstrate the practicability and effectiveness of the proposed approach.

Keywords: ANOVA, Metal matrix composites, Response surface methodology, Specific energy, Two watt meter method.

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2177 Comparison of Response Surface Designs in a Spherical Region

Authors: Boonorm Chomtee, John J. Borkowski

Abstract:

The objective of the research is to study and compare response surface designs: Central composite designs (CCD), Box- Behnken designs (BBD), Small composite designs (SCD), Hybrid designs, and Uniform shell designs (USD) over sets of reduced models when the design is in a spherical region for 3 and 4 design variables. The two optimality criteria ( D and G ) are considered which larger values imply a better design. The comparison of design optimality criteria of the response surface designs across the full second order model and sets of reduced models for 3 and 4 factors based on the two criteria are presented.

Keywords: design optimality criteria, reduced models, response surface design, spherical design region

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2176 Analysis of Electric Field and Potential Distributions along Surface of Silicone Rubber Insulators under Various Contamination Conditions Using Finite Element Method

Authors: B. Marungsri, W. Onchantuek, A. Oonsivilai, T. Kulworawanichpong

Abstract:

This paper presents the simulation results of electric field and potential distributions along surface of silicone rubber polymer insulators under clean and various contamination conditions with/without water droplets. Straight sheds insulator having leakage distance 290 mm was used in this study. Two type of contaminants, playwood dust and cement dust, have been studied the effect of contamination on the insulator surface. The objective of this work is to comparison the effect of contamination on potential and electric field distributions along the insulator surface when water droplets exist on the insulator surface. Finite element method (FEM) is adopted for this work. The simulation results show that contaminations have no effect on potential distribution along the insulator surface while electric field distributions are obviously depended on contamination conditions.

Keywords: electric field distribution, potential distribution, silicone rubber polymer insulator, finite element method

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2175 Modeling of Surface Roughness for Flow over a Complex Vegetated Surface

Authors: Wichai Pattanapol, Sarah J. Wakes, Michael J. Hilton, Katharine J.M. Dickinson

Abstract:

Turbulence modeling of large-scale flow over a vegetated surface is complex. Such problems involve large scale computational domains, while the characteristics of flow near the surface are also involved. In modeling large scale flow, surface roughness including vegetation is generally taken into account by mean of roughness parameters in the modified law of the wall. However, the turbulence structure within the canopy region cannot be captured with this method, another method which applies source/sink terms to model plant drag can be used. These models have been developed and tested intensively but with a simple surface geometry. This paper aims to compare the use of roughness parameter, and additional source/sink terms in modeling the effect of plant drag on wind flow over a complex vegetated surface. The RNG k-ε turbulence model with the non-equilibrium wall function was tested with both cases. In addition, the k-ω turbulence model, which is claimed to be computationally stable, was also investigated with the source/sink terms. All numerical results were compared to the experimental results obtained at the study site Mason Bay, Stewart Island, New Zealand. In the near-surface region, it is found that the results obtained by using the source/sink term are more accurate than those using roughness parameters. The k-ω turbulence model with source/sink term is more appropriate as it is more accurate and more computationally stable than the RNG k-ε turbulence model. At higher region, there is no significant difference amongst the results obtained from all simulations.

Keywords: CFD, canopy flow, surface roughness, turbulence models.

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2174 Development of a GPS Buoy for Ocean Surface Monitoring: Initial Results

Authors: Anuar Mohd Salleh, Mohd Effendi Daud

Abstract:

This study presents a kinematic positioning approach that uses a global positioning system (GPS) buoy for precise ocean surface monitoring. The GPS buoy data from the two experiments are processed using an accurate, medium-range differential kinematic technique. In each case, the data from a nearby coastal site are collected at a high rate (1 Hz) for more than 24 hours, and measurements are conducted in neighboring tidal stations to verify the estimated sea surface heights. The GPS buoy kinematic coordinates are estimated using epoch-wise pre-elimination and a backward substitution algorithm. Test results show that centimeterlevel accuracy can be successfully achieved in determining sea surface height using the proposed technique. The centimeter-level agreement between the two methods also suggests the possibility of using this inexpensive and more flexible GPS buoy equipment to enhance (or even replace) current tidal gauge stations.

Keywords: Global positioning system, kinematic GPS, sea surface height, GPS buoy, tide gauge.

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