Solidification Phenomena and Reduction of Skull in the Ladle Using Finite Deference Method and Matlab

Vol. 2 No. 4

Year: 2012

Issue: August-October

Title: Solidification Phenomena and Reduction of Skull in the Ladle Using Finite Deference Method and Matlab 

Author Name: Srinivasa rao Putti, G. Ananda Rao, P. Sudhakar Chowdary 

Synopsis: 

In this era of nano and precise accuracies we have great concern of productivity and finish in all levels of manufacturing which also includes casting process. In casting process we prepare casts, for this we require to carry the molten metal for which we require a device to carry i.e. ladle.  A ladle is a component used for carrying the molten metal in the casting process and it undergoes a considerable heat loss. The molten metal gets solidified in the interior surface of the ladle and it is called as skull. To increase the productivity and yield rate we surely require an alternative solution, to reduce the skull formation in the ladle. In this paper it is focused to give theoretical and analytical information about the heat loss; problem of skull in the ladle. The Mathematical formulation used for solving of the problem is presented. It also presents the results graphically and comparisons will be laid out using MAT LAB software.

Modeling of bead Penetration behavior for varying constituents of agglomerated fluxes during submerged arc welding

Vol. 2 No. 4

Year: 2012

Issue: August-October

Title: Modeling of bead Penetration behavior for varying constituents of agglomerated fluxes during submerged arc welding 

Author Name: Ajay Kumar, Hari Singh, Sachin Maheshwaric 

Synopsis: 

In the present work, the response surface methodology (RSM) was used for the modeling of weld bead penetration during submerged arc welding. For this, the fluxes of varying constituents have been studied and with the help of proposed model, departure from the predicted value is studied. A validation exercise was performed with the help of developed agglomerated fluxes. The MnO, CaF2, MgO, NiO and Fe-Cr constituents of developed agglomerated fluxes added into the main constituents CaO, Sio2 and Al2o3, were chosen as variables to study the performance in terms of penetration. It was concluded that the model for prediction of penetration value for the specified range was in close proximity with the actual results obtained.

Application of Electromagnetic Energy for Joining Inconel 718 Plates

Vol. 2 No. 4

Year: 2012

Issue: August-October

Title: Application of Electromagnetic Energy for Joining Inconel 718 Plates 

Author Name: Amit Bansal, A.K. Sharma , Pradeep Kumar , Shantanu Das 

Synopsis: 

In the present work microwave energy has been explored as a new processing method of joining bulk metallic materials. Microwave joining of Inconel 718 plates has been successfully carried out using a multimode applicator at a frequency of 2.45 GHz and a power of 900 W. Principles of microwave hybrid heating (MHH) were effectively employed for joining of Inconel 718 plates by placing an interlayer of Ni powder of average thickness of about 0.2 mm between the interfacing surfaces. The susceptor material, charcoal was used for initial coupling of microwave with powder interlayer. Resulting joints were characterized using X ray diffraction (XRD), (SEM) scanning electron microscope and (EPMA) electron probe micro analysis. The back scattered electron (BSE) microgaph confirm that the faying surfaces were well fused and metallurgical bonding takes place on either side of the base material. Tests were conducted to examine the joint tensile strength. The analysis shows that the joints have an average strength of 400 MPa with an percentage elongation of 6 percent.

An experimental Investigation and optimization of turning fabricated Al/SiC/B4C Hybrid Metal Matrix Composites using Desirability Analysis

Vol. 2 No. 4

Year: 2012

Issue: August-October

Title: An experimental Investigation and optimization of turning fabricated Al/SiC/B4C Hybrid Metal Matrix Composites using Desirability Analysis 

Author Name: Mahesh Babu T S, N. Muthukrishnan 

Synopsis: 

This paper presents the detailed discussions on fabrication of Aluminium - silicon carbide (10% by weight of particles) and boron carbide (5% by weight of particles) Hybrid Metal Matrix Composites (Al/SiC/B4C — MMC) using stir casting method. SiC and a B4C particle range from 30µm to 50 µm. The cylindrical rods of diameter 60 mm and length 250 mm are fabricated and subsequently machined using medium duty lathe of 2 kW spindle power to study the   machinability issues of Hybrid MMC using Poly Crystalline Diamond (PCD) insert of 1600 grade. The optimum machining parameters have been identified by a composite desirability value obtained from desirability function analysis as the performance index, and significant contribution of parameters can then be determined by analysis of variance. Confirmation test is also conducted to validate the test result. Experimental results have shown that machining performance can be improved effectively through this approach.  Results show at higher cutting speeds, good surface finish is obtained with faster tool wear. It is concluded that, tool wear and cutting force are directly proportional to the cutting speed, where as surface roughness is inversely proportional to the cutting speed. Percentage of error obtained between experimental value and predicted value is within the limit.

Residual stress in resistance spot welded aluminum alloy sheets

Vol. 2  No. 4

Year: 2012

Issue: August-October

Title       : Residual stress in resistance spot welded aluminum alloy sheets

Author Name     : Davood Afshari, M. Sedighi , Z. Barsoum

Synopsis              :

In this study, residual stress measurement in resistance spot welded aluminum joint is investigated. A pair of 2 mm thickness aluminum 6061-T6 sheets are prepared and welded according to the American Welding Society (AWS)  standard. Due to the small dimensions of nugget and heat affected zone in this process, the X-ray diffraction method utilized for residual stress measurement. The results show that the outside areas of the nugget are influenced by the preliminary sandpaper grinding process. Also, residual stress measurement on the edge of the nugget shows a wide deviation which is due to the changes in surface height. The results imply that, the residual stress measurements in resistance spot welded joints are limited within nugget area for which the grinding stresses were relaxed by the high temperature during welding. The observed residual stresses at this zone show tensile stresses at surface which increase from center toward the edge of the nugget.

Computer-Aided Analysis of Gas Turbine with Hot Spinning

Vol. 2 No. 4

Year: 2012

Issue: August-October

Title       : Computer-Aided Analysis of Gas Turbine with Hot Spinning

Author Name     : Jeremy (Zheng) Li

Synopsis              :

Gas turbine disc wheels usually operate at high temperatures. The hot gases contact the turbine rotor rim and blades causing these parts operating under extremely high temperature. Even the different cooling methods were used to lower the disc temperatures, it still remains at the high temperature due to continuous contact between rim and hot gases. Plus, even the cooling methods can reduce the temperature in central rotor area, it in turns increases the temperature gradients which produces the thermal stresses in gas turbine disks. To help understanding the mechanism of centrifugal and thermal stresses generated in gas turbine, a computer-aided modeling and simulation methodology is developed in this research paper to determine the effect of critical turbine functioning parameters and improve the turbine performance. So far, there are few related technical papers published in this research field. This paper introduces the computer-aided modeling and simulation methodology to determine the mechanical and thermal stresses produced in gas turbine. One prototype has been built and tested to validate the results from computational simulation. All gained results can potentially help future gas turbine design.

Development of Electroplating Setup for Plating Abs Plastics

Vol. 2 No. 3

Year: 2012

Issue: May-July

Title: Development of Electroplating Setup for Plating Abs Plastics 

Author Name: Mithun Kulkarni, K. Elangovan, K. Hemachandra Reddy 

Synopsis: 

Over the recent years there has been an ever-increasing trend to replace metals with plastics in the manufacture of computers, business and industrial machines, automotive and telecommunication components and other electronic equipments. Usually a plastic component will be lighter in weight which in aerospace Industry especially always has been an important consideration. Weight savings have assumed greater importance in other market for example, motor vehicles, where a key factor in achieving greater fuel economy has been reduction in weight overall brought about by changes from metals to plastics, ABS chrome plated parts are one such example for weight reduction in automobile components. Plating on plastics therefore has been developed and widely concerned in manufacturing printed circuit boards, automobile parts, in the electromagnetic interference (EMI) shielding application, regulator knobs for fan cooler, push buttons, etc. After plating there is no apparent difference visually between metal and plastic parts. For electroplating, the plastic model needs to be made electrically conductive in order for the electroplating process to work, and in this paper an attempt has been made to show and understand the development of electroplating setup for plating ABS plastics.

An experimental flow analysis of R 410A through adiabatic and non-adiabatic helical capillary tubes

Vol. 2 No. 3

Year: 2012

Issue: May-July

Title: An experimental flow analysis of R 410A through adiabatic and non-adiabatic helical capillary tubes 

Author Name: V. Krishna Reddy 

Synopsis: 

The performance of vapor compression refrigeration system depends on the individual performance of its type, components and quantity of the refrigerant. In this regard the design of capillary tube used as an expansion device requires proper attention for better design, control and operation of the system. Many researchers have done works on straight capillary tube under homogeneous flow conditions for limited refrigerants without considering coiled effects, separated and non adiabatic conditions. The objective of this work is to estimate the performance of a coiled capillary tube under adiabatic and non-adiabatic, separated flow including metastable conditions. The effect of various design parameters such as tube diameter, coil diameter, subcooling on the flow rate of capillary tube was studied. The experimental results are validated with previous results from developed models & experimental observations and a good agreement was observed. 6 to 15% decrease in mass flow rate of R 410A is noticed in coiled capillary tubes over a range of coil diameters 40-120mm as compared to that of straight capillary tubes under similar operating conditions. The effects of the length of capillary tube on the mass flow rates were studied and it is noticed that there is only a marginal drop in mass flow rates about 1.5% and even smaller beyond 1000 mm length.

Characterization of AA2219 Weldments in T6 Condition

Vol. 2 No. 3

Year: 2012

Issue: May-July

Title: Characterization of AA2219 Weldments in T6 Condition 

Author Name: Paul M Souza, S. Mohanraj, S. Santhi 

Synopsis: 

Characterization of AA 2219 weldments in T6 condition has been presented in this paper. Automatic TIG welding process has been employed to weld 6.5mm thick 2219-T87 plates. 2319 filler wire has been considered for welding.  Tensile and microhardness values have been studied and results confirmed by metallography. 2219 wrought aluminium alloy derives its high strength from the precipitation of CuAl2. T6 has been given as the post weld heat treatment condition to regain the strength lost during the welding.

An Experimental Study on Changes of Mechanical Properties of Medium Carbon Steel Due to Hardening

Vol. 2 No. 3

Year: 2012

Issue: May-July

Title: An Experimental Study on Changes of Mechanical Properties of Medium Carbon Steel Due to Hardening 

Author Name: P. Pradhana, P. R. Dasha, C. Mishra, S. K. Roy, A. B. Harichandan 

Synopsis: 

Hardening is one of the heat treatment process, which is done for improving some desirable mechanical properties of carbon steel. Medium carbon steel is used as various structural parts in industries. Among those, chain conveyor pin, etc are required hardening to increase the surface hardness and to resist wear. But due to hardening some other mechanical properties are being changed. In this present experimental work, changes of mechanical properties like UTS, impact strength, and fatigue strength of medium carbon steel due to hardening have been studied. Hardness of specimen has been changed by water quenching and oil quenching. Subsequently micro structural study under SEM has been carried out for fatigue failed surface. Significant changes have been observed in both mechanical strength level and micro structural level.

Numerical Simulations of Ferrofluids for Magnetic Drug Targeting Applications

Vol. 2 No. 3

Year: 2012

Issue: May-July

Title: Numerical Simulations of Ferrofluids for Magnetic Drug Targeting Applications 

Author Name: Jon Mackey, Douglas J Perkins, Allan Hill, Abhilash Chandy 

Synopsis: 

Numerical simulations of ferrofluids are carried out in two-dimensional and three-dimensional space in order to analyze the magnetic effects on flow behavior for magnetic drug targeting (MDT) applications. MDT is a novel technique that allows the concentration of drugs to be guided to a defined target region (TR) with the help of a magnetic field, made possible by the magnetic property of the fluid itself. Ferrofluids, are two-phase solutions composed of magnetic nanoparticles suspended in a carrier fluid Ferrofluids are modeled in a pipe geometry with a sphere-shaped target site and magnetic effects are modeled as fields resulting from current carrying wires. Parameters that are studied include different strengths and locations of magnetic field.  Pressure distributions and velocity contours particularly in the TR show the added flow recirculation and increase in the fluid’s retention time at the TR, due to the magnetic field.Furthermore, the studies presented here provide a fundamental understanding of the behavior of a magnetic fluid, modeled here as a single-phase fluid thereby affirming the feasibility of such fluids in MDT applications with regard to enhanced drug transfer.

Theoretical Relationship between Modulus of Elasticity and Temperature for Engineering Materials

Vol. 2 No. 3

Year: 2012

Issue: May-July

Title: Theoretical Relationship between Modulus of Elasticity and Temperature for Engineering Materials 

Author Name: Yaomin Dong, Iosif E. Shkolnik , Timothy M. Cameron 

Synopsis: 

The modulus of elasticity is one of the most important mechanical properties of a material. It needs to be determined accurately in order to facilitate mechanical design, ensure reliability and promote compliance with legislative restrictions. The modulus-temperature relationship is traditionally determined experimentally, and the procedure is time consuming, expensive, and often impossible. The main goal of this work is to obtain a comprehensive analytical relationship between modulus of elasticity and temperature, based on the kinetic nature of the strength of solids and a nonlinear equation of state for materials. The analytical modulus-temperature relationship is compared with existing experimental data. Results demonstrate the potential of the nonlinear approach to predict the static and dynamic elastic modulus of different engineering materials (metals, plastics, and concrete) as a function of temperature.

Integration of Vision System, Intelligent ROBO Actuator, HMI and PLC to Design a Universal Quality Inspection or Control Machine

Vol. 2 No. 3

Year: 2012

Issue: May-July

Title: Integration of Vision System, Intelligent ROBO Actuator, HMI and PLC to Design a Universal Quality Inspection or Control Machine 

Author Name: Madhav Patil, Jack Toporovsky 

Synopsis: 

In this paper, a universal quality inspection and quality control machine is presented. This machine is a fusion of different technologies such as vision system, programmable logic controller (PLC), Human machine interface (HMI) and Intelligent ROBO Actuators with other types of sensors. The electrical and mechanical design of the machine and plc program is illustrated in detail. Generally, inspection of raw materials or products at any stage in production or manufacturing or assembly industries may be done manually using measuring instruments, or by machines based on laser sensor technology, using probes, weighing scales, etc. Manual process is too slow and meant to test only few batches out of the entire lot which is less effective. Dedicated machines are usually confined to a single type of raw material considering specific property of the component. This option can be expensive when several different raw materials and product at any stage are to be tested at in-feed line. The proposed universal quality inspection machine is designed and implemented in the PLC lab at University of Bridgeport.