Search results for: milling operation.

Authors: Naresh Yadav, I.A. Khan, Sandeep Grover

Abstract:

This paper presents a methodology for operational and economic characteristics based evaluation and selection of a power plant using Graph theoretic approach. A universal evaluation index on the basis of Operational and economics characteristics of a plant is proposed which evaluates and ranks the various types of power plants. The index thus obtained from the pool of operational characteristics of the power plant attributes Digraph. The Digraph is developed considering Operational and economics attributes of the power plants and their relative importance for their smooth operation, installation and commissioning and prioritizing their selection. The sensitivity analysis of the attributes towards the objective has also been carried out in order to study the impact of attributes over the desired outcome i.e. the universal operational-economics index of the power plant.

Keywords: Power plant evaluation, Digraph methods, Matrixmethod, operational characteristics of Power plant, Gas turbines

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Authors: Helia Moayedi, Mahdi Moaidi

Abstract:

Nowadays, the managing and planning of hospitals is facing many problems. Failure to recognize the main criteria for strategic management to ensure long-term hospital performance can lead to many health problems. To achieve this goal, a qualitative-quantitate method titled Delphi-Fuzzy has been applied. This strategy makes it possible for experts to screen among the most important criteria in strategic management. To conduct this operation, a statistical society consisting of 20 experts in Ahwaz hospitals has been questioned. The final model confirms the key criterions after three stages of Delphi. This model provides the possibility to focus on the basic criteria and can determine the organization’s main orientation.

Keywords: Delphi-Fuzzy Method, hospital management, long-term planning, qualitative-quantitate method, screening of strategic criteria, strategic planning.

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Authors: Tânia Manso, Luís Teixeira, Paula M. Reis Correia

Abstract:

Glazing is a process used to reduce undesirable drying or dehydration of fish during frozen or cold storage. To evaluate the effect of the time/ temperature binomial of the cryogenic frozen tunnel in the amount of glazing watera Central Composite Rotatable Design was used, with application of the Response Surface Methodology. The results reveal that the time/ temperature obtained for pink cusk-eel in experimental conditions for glazing water are similar to the industrial process, but for red fish and merluza the industrial process needs some adjustments. Control charts were established and implementedto control the amount of glazing water on sardine and merluza. They show that the freezing process was statistically controlled but there were some tendencies that must be analyzed, since the trend of sample mean values approached either of the limits, mainly in merluza. Thus, appropriate actions must be taken, in order to improve the process.

Keywords: Control charts, frozen fish, glazing, RSM.

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Authors: Yousra Zakaria Ahmed, Ahmed El Gendy, Salah El Haggar

Abstract:

In this paper, our methodology to assess sustainability of wastewater treatment technologies in Egypt is presented. The preliminary list of factors to be considered, as well as their ranking listed. The factors include, but are not limited to pollutants removal efficiency and energy consumption under the environmental dimension, construction cost, operation and maintenance costs and required land area cost under the economic dimension and public acceptance, noise and generating job opportunities for local residents. This methodology is intended to be a user-friendly screening tool to support the decision making process when investigating different wastewater treatment technologies in Egypt. Based on the research work results presented in this paper, it can be generally concluded that the categorization of some of the social and environmental aspects of sustainability is subjective and highly dependent on the local conditions and researchers’ background.

Keywords: Sustainability, wastewater treatment, sustainability assessment, Egypt.

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Authors: Bahar Razavi, Mansour Parehkar, Ali Gholami

Abstract:

Pore water pressure is normally because of consolidation, compaction and water level fluctuation on reservoir. Measuring, controlling and analyzing of pore water pressure have significant importance in both of construction and operation period. Since end of 2002, (dam start up) nature of KARKHEH dam has been analyzed by using the gathered information from instrumentation system of dam. In this lecture dam condition after start up have been analyzed by using the gathered data from located piezometers in core of dam. According to TERZAGHI equation and records of piezometers, consolidation lasted around five years during early years of construction stage, and current pore water pressure in core of dam is caused by water level fluctuation in reservoir. Although there is time lag between water level fluctuation and results of piezometers. These time lags have been checked and the results clearly show that one of the most important causes of it is distance between piezometer and reservoir.

Keywords: Earth dam, Reservoir, Piezometer, Terzaghi, Consolidation

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Authors: Hidemi Ogasawara, Kiyoshi Akama, Hiroshi Mabuchi

Abstract:

The purpose of this paper is to propose a framework for constructing correct parallel processing programs based on Equivalent Transformation Framework (ETF). ETF regards computation as In the framework, a problem-s domain knowledge and a query are described in definite clauses, and computation is regarded as transformation of the definite clauses. Its meaning is defined by a model of the set of definite clauses, and the transformation rules generated must preserve meaning. We have proposed a parallel processing method based on “specialization", a part of operation in the transformations, which resembles substitution in logic programming. The method requires “Memo-tree", a history of specialization to maintain correctness. In this paper we proposes the new method for the specialization-base parallel processing without Memo-tree.

Keywords: Parallel processing, Program correctness, Equivalent transformation, Specializer generation rule

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Authors: Hazem M. El-Bakry, Qiangfu Zhao

Abstract:

In this paper, an approach to reduce the computation steps required by fast neural networksfor the searching process is presented. The principle ofdivide and conquer strategy is applied through imagedecomposition. Each image is divided into small in sizesub-images and then each one is tested separately usinga fast neural network. The operation of fast neuralnetworks based on applying cross correlation in thefrequency domain between the input image and theweights of the hidden neurons. Compared toconventional and fast neural networks, experimentalresults show that a speed up ratio is achieved whenapplying this technique to locate human facesautomatically in cluttered scenes. Furthermore, fasterface detection is obtained by using parallel processingtechniques to test the resulting sub-images at the sametime using the same number of fast neural networks. Incontrast to using only fast neural networks, the speed upratio is increased with the size of the input image whenusing fast neural networks and image decomposition.

Keywords: Fast Neural Networks, 2D-FFT, CrossCorrelation, Image decomposition, Parallel Processing.

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Authors: Suwardo, Madzlan B. Napiah, Ibrahim B. Kamaruddin

Abstract:

Stage bus operated in the mixed traffic might always meet many problems about low quality and reliability of services. The low quality and reliability of bus service can make the system not attractive and directly reduce the interest of using bus service. This paper presents the result of field investigation and analysis of on-time performance and service regularity of stage bus in mixed traffic. Data for analysis was collected from the field by on-board observation along the Ipoh-Lumut corridor in Perak, Malaysia. From analysis and discussion, it can be concluded that on-time performance and service regularity varies depend on station, typical day, time period, operation characteristics of bus and characteristics of traffic. The on-time performance and service regularity of stage bus in mixed traffic can be derived by using data collected by onboard survey. It is clear that on-time performance and service regularity of the existing stage bus system was low.

Keywords: mixed traffic, on-time performance, service regularity, stage bus

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Authors: P. Georgieva, S. Feyo de Azevedo

Abstract:

This paper is focused on issues of process modeling and two model based control strategies of a fed-batch sugar crystallization process applying the concept of artificial neural networks (ANNs). The control objective is to force the operation into following optimal supersaturation trajectory. It is achieved by manipulating the feed flow rate of sugar liquor/syrup, considered as the control input. The control task is rather challenging due to the strong nonlinearity of the process dynamics and variations in the crystallization kinetics. Two control alternatives are considered – model predictive control (MPC) and feedback linearizing control (FLC). Adequate ANN process models are first built as part of the controller structures. MPC algorithm outperforms the FLC approach with respect to satisfactory reference tracking and smooth control action. However, the MPC is computationally much more involved since it requires an online numerical optimization, while for the FLC an analytical control solution was determined.

Keywords: artificial neural networks, nonlinear model control, process identification, crystallization process

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Authors: Amin Sahraeian

Abstract:

One of the criteria in production scheduling is Make Span, minimizing this criteria causes more efficiently use of the resources specially machinery and manpower. By assigning some budget to some of the operations the operation time of these activities reduces and affects the total completion time of all the operations (Make Span). In this paper this issue is practiced in parallel flow shops. At first we convert parallel flow shop to a network model and by using a linear programming approach it is identified in order to minimize make span (the completion time of the network) which activities (operations) are better to absorb the predetermined and limited budget. Minimizing the total completion time of all the activities in the network is equivalent to minimizing make span in production scheduling.

Keywords: parallel flow shop, make span, linear programming, budget

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Authors: Eiko Takaoka, Ryohei Takahashi, Takashi Toyoda

Abstract:

We installed solar panels and digital meteorological equipments whose electrical power is supplied using PV on July 13, 2011. Then, the relationship between the electric power generation and the irradiation, air temperature, and wind velocity was investigated on a roof at a university. The electrical power generation, irradiation, air temperature, and wind velocity were monitored over two years. By analyzing the measured meteorological data and electric power generation data using PTC, we calculated the size of the solar panel that is most suitable for this system. We also calculated the wasted power generation using PTC with the measured meteorological data obtained in this study. In conclusion, to reduce the "wasted power generation", a smaller-size solar panel is required for stable operation.

Keywords: Digital meteorological equipments, PV, photovoltaic, irradiation, PTC.

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Authors: Mohammed S. ALSaidi, John P. Mo

Abstract:

Modern engineering assets are complex and very high in value. They are expected to function for years to come, with ability to handle the change in technology and ageing modification. The aging of an engineering asset and continues increase of vendors and contractors numbers forces the asset operation management (or Owner) to design an asset system which can capture these changes. Furthermore, an accurate performance measurement and risk evaluation processes are highly needed. Therefore, this paper explores the nature of the asset management system performance evaluation for an engineering asset based on the System Support Engineering (SSE) principles. The research work explores the asset support system from a range of perspectives, interviewing managers from across a refinery organization. The factors contributing to complexity of an asset management system are described in context which clusters them into several key areas. It is proposed that SSE framework may then be used as a tool for analysis and management of asset. The paper will conclude with discussion of potential application of the framework and opportunities for future research.

Keywords: Asset management, performance, evaluation.

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Authors: Bin Cai, Shilong Wang, Haibo Hu

Abstract:

The job shop scheduling problem (JSSP) is a notoriously difficult problem in combinatorial optimization. This paper presents a hybrid artificial immune system for the JSSP with the objective of minimizing makespan. The proposed approach combines the artificial immune system, which has a powerful global exploration capability, with the local search method, which can exploit the optimal antibody. The antibody coding scheme is based on the operation based representation. The decoding procedure limits the search space to the set of full active schedules. In each generation, a local search heuristic based on the neighborhood structure proposed by Nowicki and Smutnicki is applied to improve the solutions. The approach is tested on 43 benchmark problems taken from the literature and compared with other approaches. The computation results validate the effectiveness of the proposed algorithm.

Keywords: Artificial immune system, Job shop scheduling problem, Local search, Metaheuristic algorithm

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Authors: Federica Cornali

Abstract:

Does education matter to the quality of our life? The results of extensive studies offer an affirmative answer to this question: high education levels are positively associated with higher income, with more highly qualified professions, with lower risk of unemployment, with better physical health and also, it is said, with more happiness. However, exploring these relationships is far from straightforward. Aside from educational credentials, what properties distinguish functionally literate individuals? How can their personal level of satisfaction be measured? What are the social mechanisms whereby education affects well-being?Using a literacy index and several measures for well-being developed by secondary analysis of the Adult Literacy and Life Skills Survey database, this investigation examined the relationship between literacy skills and subjective wellbeing in several OECD (Organisation for Economic Co-operation and Development) countries. Special attention was been addressed to Italy, and in particular to two regions representing territorial differences in this country: Piedmont and Campania.

Keywords: Cultural Divide, Literacy Index, Life Satisfaction, Subjective Well-being Index

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Authors: Yizhi Gai, Yukinori Kobayashi, Yohei Hoshino, Takanori Emaru

Abstract:

Motion control of flexible arms is more difficult than that of rigid arms, however utilizing its dynamics enables improved performance such as a fast motion in short operation time. This paper investigates a ball throwing robot with one rigid link and one flexible link. This robot throws a ball at a set speed with a proper control torque. A mathematical model of this ball throwing robot is derived through Hamilton’s principle. Several patterns of torque input are designed and tested through the proposed simulation models. The parameters of each torque input pattern is optimized and determined by chaos embedded vector evaluated particle swarm optimization (CEVEPSO). Then, the residual vibration of the manipulator after throwing is suppressed with input shaping technique. Finally, a real experiment is set up for the model checking.

Keywords: Motion control, flexible robotic arm, CEVEPSO, ball throwing robot.

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Authors: Hyeyoung Cho, Sungho Kim, SangDong Lee

Abstract:

I/O workload is a critical and important factor to analyze I/O pattern and file system performance. However tracing I/O operations on the fly distributed parallel file system is non-trivial due to collection overhead and a large volume of data. In this paper, we design and implement a parallel file system logging method for high performance computing using shared memory-based multi-layer scheme. It minimizes the overhead with reduced logging operation response time and provides efficient post-processing scheme through shared memory. Separated logging server can collect sequential logs from multiple clients in a cluster through packet communication. Implementation and evaluation result shows low overhead and high scalability of this architecture for high performance parallel logging analysis.

Keywords: I/O workload, PVFS, I/O Trace.

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Authors: Tomáš Ludík, Josef Navrátil

Abstract:

Managing the emergency situations at the Emergency Staff requires a high co-operation between its members and their fast decision making. For these purpose it is necessary to prepare Emergency Staff members adequately. The aim of this paper is to describe the development of information support that focuses to emergency staff processes and effective decisions. The information support is based on the principles of process management, and Process Framework for Emergency Management was used during the development. The output is the information system that allows users to simulate an emergency situation, including effective decision making. The system also evaluates the progress of the emergency processes solving by quantitative and qualitative indicators. By using the simulator, a higher quality education of specialists can be achieved. Therefore, negative impacts resulting from arising emergency situations can be directly reduced.

Keywords: Information Support for Emergency Staff, Effective Decisions, Process Framework, Simulation of Emergency Processes, System Development.

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Authors: S. Sabzchi Asl, N. Tahouni, M. H. Panjeshahi

Abstract:

Benchmarking of a process with respect to energy consumption, without accomplishing a full retrofit study, can save both engineering time and money. In order to achieve this goal, the first step is to develop a conceptual-mathematical model that can easily be applied to a group of similar processes. In this research, we have aimed to identify a set of key parameters for the model which is supposed to be used for benchmarking of combined cycle power plants. For this purpose, three similar combined cycle power plants were studied. The results showed that ambient temperature, pressure and relative humidity, number of HRSG evaporator pressure levels and relative power in part load operation are the main key parameters. Also, the relationships between these parameters and produced power (by gas/ steam turbine), gas turbine and plant efficiency, temperature and mass flow rate of the stack flue gas were investigated.

Keywords: Combined cycle power plant, energy benchmarking, modelling, Retrofit.

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Authors: Rudy Agustriyanto, Akbarningrum Fatmawati

Abstract:

The utilization of cheese whey as a fermentation substrate to produce bio-ethanol is an effort to supply bio-ethanol demand as a renewable energy. Like other process systems, modeling is also required for fermentation process design, optimization and plant operation. This research aims to study the fermentation process of cheese whey by applying mathematics and fundamental concept in chemical engineering, and to investigate the characteristic of the cheese whey fermentation process. Steady state simulation results for inlet substrate concentration of 50, 100 and 150 g/l, and various values of hydraulic retention time, showed that the ethanol productivity maximum values were 0.1091, 0.3163 and 0.5639 g/l.h respectively. Those values were achieved at hydraulic retention time of 20 hours, which was the minimum value used in this modeling. This showed that operating reactor at low hydraulic retention time was favorable. Model of bio-ethanol production from cheese whey will enhance the understanding of what really happen in the fermentation process.

Keywords: Cheese whey, ethanol, fermentation, modeling.

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Authors: Harpreet Singh Dhillon, Abhijit Mitra

Abstract:

A reduced-bit multiplication algorithm based on the ancient Vedic multiplication formulae is proposed in this paper. Both the Vedic multiplication formulae, Urdhva tiryakbhyam and Nikhilam, are first discussed in detail. Urdhva tiryakbhyam, being a general multiplication formula, is equally applicable to all cases of multiplication. It is applied to the digital arithmetic and is shown to yield a multiplier architecture which is very similar to the popular array multiplier. Due to its structure, it leads to a high carry propagation delay in case of multiplication of large numbers. Nikhilam Sutra, on the other hand, is more efficient in the multiplication of large numbers as it reduces the multiplication of two large numbers to that of two smaller numbers. The framework of the proposed algorithm is taken from this Sutra and is further optimized by use of some general arithmetic operations such as expansion and bit-shifting to take advantage of bit-reduction in multiplication. We illustrate the proposed algorithm by reducing a general 4x4-bit multiplication to a single 2 x 2-bit multiplication operation.

Keywords: Multiplication, algorithm, Vedic mathematics, digital arithmetic, reduced-bit.

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Authors: Kelaiaia Mounia Samira, Labar Hocine, Bounaya Kamel, Kelaiaia Samia

Abstract:

With the rapid advanced of technology, the industrial processes become increasingly demanding, from the point of view, power quality and controllability. The advent of multi levels inverters responds partially to these requirements. But actually, the new generation of multi-cells inverters permits to reach more performances, since, it offers more voltage levels. The disadvantage in the increase of voltage levels by the number of cells in cascades is on account of series igbts synchronisation loss, from where, a limitation of cells in cascade to 4. Regarding to these constraints, a new topology is proposed in this paper, which increases the voltage levels of the three-cell inverter from 4 to 8; with the same number of igbts, and using less stored energy in the flaying capacitors. The details of operation and modelling of this new inverter structure are also presented, then tested thanks to a three phase induction motor. KeywordsFlaying capacitors, Multi-cells inverter, pwm, switchers, modelling.

Keywords: Flaying capacitors, Multi-cells inverter, pwm, switchers, modelling.

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Authors: The Nan Chang, Ping-Tang Yu, Jyun-Ming Lin

Abstract:

A triple band circularly polarized antenna covering 1.17, 1.22, and 1.57 GHz is presented. To extend to the triple-band operation, we need to add one more ring while maintaining the mechanism to independently control each ring. The inset-part in the feeding scheme is used to excite the band at 1.22 GHz, while the proximate-part of the feeding scheme is used to excite not only the band at 1.57 GHz but also the band at 1.17 GHz. This is achieved by up-vertically coupled with one ring to radiate at 1.57 GHz and down-vertically coupled another ring to radiate at 1.17 GHz. It is also noted that the inset-part in our feeding scheme is by horizontal coupling. Furthermore, to increase the gain at all three bands, three air-layers are added to make the total height of the antenna be 7.8 mm. The total thickness of the three air-layers is 3 mm. The gains of the three bands are all greater than 5 dBiC after adding the air-layers.

Keywords: Circular polarization, global position system, triband antenna, high gain.

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Authors: Wenhua Hou, Xing Liu, Deqiang Chen

Abstract:

The ubiquitous payment problems within construction industry of China are notoriously hard to be resolved, thus lead to a series of impacts to the industry chain. Among of them, the most direct result is affecting the normal operation of contractors negatively. A wealth of research has already discussed reasons of the payment problems by introducing a number of possible improvement strategies. But the causalities of these problems are still far from harsh reality. In this paper, the authors propose a model for cash flow system of construction projects by introducing System Dynamics techniques to explore causal facets of the payment problem. The effects of payment arrears on both cash flow and profitability of project are simulated into four scenarios by using data from real projects. Simulating results show visible clues to help contractors quantitatively determining the consequences for the construction project that arise from payment delay.

Keywords: payment problems, cash flow, profitability, system dynamics.

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Authors: M. Umabharathi, S. Vijayabaskar

Abstract:

Evolutionary Fuzzy PID Speed Controller for Permanent Magnet Synchronous Motor (PMSM) is developed to achieve the Speed control of PMSM in Closed Loop operation and to deal with the existence of transients. Consider a Fuzzy PID control design problem, based on common control Engineering Knowledge. If the transient error is big, that Good transient performance can be obtained by increasing the P and I gains and decreasing the D gains. To autotune the control parameters of the Fuzzy PID controller, the Evolutionary Algorithms (EA) are developed. EA based Fuzzy PID controller provides better speed control and guarantees the closed loop stability. The Evolutionary Fuzzy PID controller can be implemented in real time Applications without any concern about instabilities that leads to system failure or damage.

Keywords: Evolutionary Algorithm (EA), Fuzzy system, Genetic Algorithm (GA), Membership, Permanent Magnet Synchronous Motor (PMSM).

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Authors: Viet-Hung Nguyen, Luh-Maan Chang

Abstract:

Design should be viewed concurrently by three ways as transformation, flow and value generation. An innovative approach to solve design – related problems is described as the integrated product - process design. As a foundation for a formal framework consisting of organizing principles and techniques, Work Structuring has been developed to guide efforts in the integration that enhances the development of operation and process design in alignment with product design. Vietnam construction projects are facing many delays, and cost overruns caused mostly by design related problems. A better design management that integrates product and process design could resolve these problems. A questionnaire survey and in – depth interviews were used to investigate the feasibility of applying Work Structuring to construction projects in Vietnam. The purpose of this paper is to present the research results and to illustrate the possible problems and potential solutions when Work Structuring is implemented to construction projects in Vietnam.

Keywords: integrated product – process design, Work Structuring, construction projects, Vietnam

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Authors: Emanuela Paranhos Lima, Vitaly Félix Rodríguez Esquerre

Abstract:

In this work, efficient directional coupler composed of dielectric waveguides and metallic film has been analyzed in details by simulations using finite element method (FEM). The structure consists of a step-index fiber with dielectric core, silica cladding, and a metal nanowire parallel to the core. The results show that an efficient conversion of optical dielectric modes to long range plasmonic is possible. Low insertion losses in conjunction with short coupling length and a broadband operation can be achieved under certain conditions. This kind of couplers has potential applications for the design of photonic integrated circuits for signal routing between dielectric/plasmonic waveguides, sensing, lithography, and optical storage systems. A high efficient focusing of light in a very small region can be obtained.

Keywords: Directional coupler, finite element method, metallic nanowire, plasmonic, surface plasmon polariton.

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Authors: Houshang Taghizadeh, Gholamreza Soltani Fesghandis

Abstract:

Nowadays, without the awareness of consumer behavior and correct understanding of it, it is not possible for organizations to take appropriate measures to meet the consumer needs and demands. The aim of this paper is the identification and prioritization of the factors affecting the consumer behavior based on the product value. The population of the study includes all the consumers of furniture producing firms in East Azarbaijan province, Iran. The research sample includes 93 people selected by the sampling formula in unlimited population. The data collection instrument was a questionnaire, the validity of which was confirmed through face validity and the reliability of which was determined, using Cronbach's alpha coefficient. The Kolmogorov-Smironov test was used to test data normality, the t-test for identification of factors affecting the product value, and Friedman test for prioritizing the factors. The results show that quality, satisfaction, styling, price, finishing operation, performance, safety, worth, shape, use, and excellence are placed from 1 to 11 priorities, respectively.

Keywords: Consumer Behavior, Consumer Satisfaction, Product, Value

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Authors: T. Tanitteerapan, E.Thanpo

Abstract:

This paper, a simple continuous conduction mode (CCM) pulse-width-modulated (PWM) controller for high power factor boost converters is introduced. The duty ratios were obtained by the comparison of a sensed signal from inductor current or switch current and a negative slope ramp carrier waveform in each switching period. Due to the proposed control requires only the inductor current or switch current sensor and the output voltage sensor, its circuit implementation was very simple. To verify the proposed control, the circuit experimentation of a 350 W boost converter with the proposed control was applied. From the results, the input current waveform was shaped to be closely sinusoidal, implying high power factor and low harmonics.

Keywords: High power factor converters, boost converters, low harmonic rectifiers, power factor correction, and current control.

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Authors: Madina Hamiane, Amina Khunji

Abstract:

Detecting changes in multiple images of the same scene has recently seen increased interest due to the many contemporary applications including smart security systems, smart homes, remote sensing, surveillance, medical diagnosis, weather forecasting, speed and distance measurement, post-disaster forensics and much more. These applications differ in the scale, nature, and speed of change. This paper presents an application of image processing techniques to implement a real-time change detection system. Change is identified by comparing the RGB representation of two consecutive frames captured in real-time. The detection threshold can be controlled to account for various luminance levels. The comparison result is passed through a filter before decision making to reduce false positives, especially at lower luminance conditions. The system is implemented with a MATLAB Graphical User interface with several controls to manage its operation and performance.

Keywords: Image change detection, Image processing, image filtering, thresholding, B/W quantization.

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Authors: Pavana Manvikar, G K Purohit

Abstract:

The functional performance of machined components, often, depends on surface topography, hardness, nature of stress and strain induced on the surface, etc. Invariably, surfaces of metallic components obtained by turning, milling, etc., consist of irregularities such as machining marks are responsible for the above. Surface finishing/coating processes used to produce improved surface quality/textures are classified as chip-removal and chip-less processes. Burnishing is chip-less cold working process carried out to improve surface finish, hardness and resistance to fatigue and corrosion; not obtainable by other surface coating and surface treatment processes. It is a very simple, but effective method which improves surface characteristics and is reported to introduce compressive stresses.

Of late, considerable attention is paid to post-machining, finishing operations, such as burnishing. During burnishing the micro-irregularities start to deform plastically, initially the crests are gradually flattened and zones of reduced deformation are formed. When all the crests are deformed, the valleys between the micro-irregularities start moving in the direction of the newly formed surface. The grain structure is then condensed, producing a smoother and harder surface with superior load-carrying and wear-resistant capabilities.

Burnishing can be performed on a lathe with a highly polished ball or roller type tool which is traversed under force over a rotating/stationary work piece. Often, several passes are used to obtain the work piece surface with the desired finish and hardness.

This paper presents the findings of an experimental investigation on the effect of ball burnishing parameters such as, burnishing speed, feed, force and number of passes; on surface roughness (Ra) and micro-hardness (Hv) of a 60/40 copper/zinc alloy, using a 2-level fractional factorial design of experiments (DoE). Mathematical models were developed to predict surface roughness and hardness generated by burnishing in terms of the above process parameters. A ball-type tool, designed and constructed from a high chrome steel material (HR_C=63 and Ra=0.012 µm), was used for burnishing of fine-turned cylindrical bars (0.68-0.78µm and 145Hv). They are given by,

 

Ra= 0.305-0.005X₁ - 0.0175X₂ + 0.0525X₄ + 0.0125X₁X₄ -0.02X₂X₄ - 0.0375X₃X₄

 

Hv=160.625 -2.37 5X₁ + 5.125X₂ + 1.875X₃ + 4.375X₄ - 1.625X₁X₄ + 4.375X₂X₄ - 2.375X₃X₄

 

High surface microhardness (175H_V) was obtained at 400rpm, 2passes, 0.05mm/rev and 15kgf., and high surface finish (0.20µm) was achieved at 30kgf, 0.1mm/rev, 112rpm and single pass. In other words, surface finish improved by 350% and microhardness improved by 21% compared to as machined conditions.

Keywords: Ball burnishing, surface roughness, micro-hardness.

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