Improvement of Process Performance and Calculation of 5S Activity in Organized Sector: A Case Study

Vol. 4 No. 3

Year: 2014

Issue: May-Jul

Title : Improvement of Process Performance and Calculation of 5S Activity in Organized Sector: A Case Study

Author Name : ROHIT KUMAR KANDPAL, Ajay

Synopsis :

The 5S method is a key component of the lean. The lean manufacturing process is a proven approach to more efficient workspaces adopted by leading manufacturers worldwide. The concept of lean is more value for less work. The objective of this work was to use 5S methodology to manage, and improve the working conditions of fastener production area in a fastener company. This directly results in improvement of process performance. To accomplish the goal, the authors focused on the implementation of 5S method as one of the lean tool. In order to develop a better organization of the workspace, and its utilization, the authors have focused on finding the weakest point of the system through which the overall efficiency of the system will be affected. A study was carried out in the case company to calculate its efficiency using 5S methodology, and to find out the weakest point on production area. Thus, the results after applying the proposed methodology estimates the production system efficiency as 75.64%.

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Design and Analysis of Connecting Rod of Die Pillar Station of Vacuum Thermoforming Machine

Vol. 4 No. 3

Year: 2014

Issue: May-Jul

Title : Design and Analysis of Connecting Rod of Die Pillar Station of Vacuum Thermoforming Machine

Author Name : Chetan Gaikwad, Dr. S.D. Kalpande

Synopsis :

The objective of this work is to design and analyze the performance of connecting rod, through a simple experimental model of Forming and Trimming Die Pillar Station of Vacuum Thermoforming Machine. A connecting rod is a machine member subjected to alternating direct compressive and tensile forces, where compressive forces are generally more in connecting rods so that it is considered for its prime safety. A parametric mathematical model of connecting rod is modeled using Pro-E Wildfire 4.0 Software and its Static Structural Analysis is carried on Ansys v-11.0 Workbench. FEA of connecting rod is done using C50 as its base material to determine its von-Misses stress, Max shear Stress, Total Deformation, and Alternating stress to cycles graph. Also, the Stiffness of connecting rod is calculated. Basically, the analysis is carried with four different element sizes such as 1 mm, 2 mm, 3 mm, and 4 mm and best element is selected indicating correct results.

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A Simulation Approach to Analysis of Mixing Performance for Different Geometry of Microchannels

Vol. 4 No. 3

Year: 2014

Issue: May-Jul

Title : A Simulation Approach to Analysis of Mixing Performance for Different Geometry of Microchannels

Author Name : SOURAV ACHARYA, Apurbba Kumar Sharma

Synopsis :

Mixing in microfluidics has become a pivotal issue in the field of Microelectromechanical systems. Mixing can be enhanced in microchannels by complicating the geometry of the channel. Different microchannel structures have been studied to analyse the mixing performance. In this paper, a numerical simulation has been done to compare the mixing performance of straight, serpentine, and three-dimensional serpentine microchannels with the help of ANSYS Fluent. The study shows that due to chaotic advection caused by the formation of secondary flows, the 3D serpentine microchannel shows better mixing performance.

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Fabrication and Characterization Of MMCs Using Stir Casting Method

Vol. 4 No. 3

Year: 2014

Issue: May-Jul

Title : Fabrication and Characterization Of MMCs Using Stir Casting Method

Author Name : jeevan bisht, Akshay Dvivedi , Apurbba Kumar Sharma

Synopsis :

Metal Matrix Composites have a great demand in the area of automotive, aerospace, and marine industries. It has exceptional properties like high strength, high hardness, lightweight, high corrosion resistance etc. Stir casting is one of the simplest and promising routes for manufacturing of metal matrix composites. In the present study, the Al6063-T5 alloy was reinforced with SiC abrasive particles in a weight ratio of 5%, 10%, and 15%. The mechanical properties such as tensile strength, macro-hardness, and impact strength of fabricated Al6063-T5-SiC MMCs were investigated for different weight fractions of reinforced SiC. The experimental investigation shows that the mechanical properties improve with increase in SiC weight percentage from 5% to 15%.

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Prediction of Ultimate Strength of Glass/Epoxy Tensile Specimen Using Acoustic Emission RMS Data

Vol. 4 No. 3

Year: 2014

Issue: May-Jul

Title : Prediction of Ultimate Strength of Glass/Epoxy Tensile Specimen Using Acoustic Emission RMS Data

Author Name : Kalidasan Krishnamoorthy, Sasikumar.T Thangaswamy

Synopsis :

The objective of this research paper is to predict the ultimate strength of the glass/epoxy composite laminates using the online Acoustic Emission (AE) monitoring and Artificial Neural Networks (ANN). The laminates were made by six layered glass fiber (in woven mat form) with epoxy as the binding medium by hand lay-up technique, cured at room temperature 2 at the pressure of 30 kg/cm . Tensile specimens with ASTM D3039 standard dimensions were cut from the laminates. These specimens were subjected to uni-axial tension under the acoustic emission monitoring using 10 ton capacity universal tensile machine. The dominant AE parameters such as counts, energy, duration, RMS, ASL ,and amplitude are recorded during monitoring. The RMS value corresponding to the amplitude ranges obtained during tensile testing were used to predict the failure load of a similar specimen subjected to uni-axial tension well before its failure load.

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Mathematical Modeling of Tube-Support Fouling in Nuclear Steam Generators

Vol. 4 No. 3

Year: 2014

Issue: May-Jul

Title : Mathematical Modeling of Tube-Support Fouling in Nuclear Steam Generators

Author Name : Yasser Rihan

Synopsis :

Particle deposition on steam generator tubes and supports is a complex phenomenon involving many mechanisms that interact. The approach taken in this paper was to characterize the two-phase flow patterns existing designs, correlate these with fouling patterns observed in the field, and develop a support fouling mathematical model to better understand the dynamics of the fouling mechanisms. A computer program was coded to predict the deposit is thickness in and near a support. This model has the same classic particle deposition models as in the larger codes, but considers additional factors such as stagnation zones and surface normal to the flow.

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Fabrication And Dielectric, Structural Analysis On PMN-PT

Vol. 4 No. 2

Year: 2014

Issue: Feb-Apr

Title : Fabrication And Dielectric, Structural Analysis On PMN-PT

Author Name : NAGAKALYAN SOMESULA, Dr. B. Raghu kumar

Synopsis :

The analysis of commercially available piezoelectric coefficient of mono-crystalline materials such as PMN-PT (Lead Magnesium Niobate - Lead Titanate) helps to broaden the gate for silicon-integrated applications (Piezo-MEMS) becoming more compatible with micro technology batch processes. Further, advances are expected in terms of miniaturization, optimization, functionality or integration with electronics. Subsequently, operating voltage will be lower and devices response time will improve dramatically. Fabrications of the piezoelectric materials have been performed and analysis on the structure and dielectric has been carried out. This work shows how to improve the dielectric properties for synthesis material.

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Modeling and analysis of process parameters in machining AISI 304 stainless steel using fuzzy logic

Vol. 4 No. 2

Year: 2014

Issue: Feb-Apr

Title : Modeling and analysis of process parameters in machining AISI 304 stainless steel using fuzzy logic

Author Name : K. Rajasekhar, Naresh Neeli

Synopsis :

Analysis of surface roughness and Material Removal Rate play vital roles in machining Austenitic steels. Austenitic stainless steels have high ductility, low yield stress and relatively high ultimate tensile strength, when compared to typical carbon steel. In the present work, prediction of surface roughness and material removal rate in milling of AISI 304 stainless steel is carried out using fuzzy logic. 27 experiments based on Taguchi's L orthogonal array were carried out 27 involving three machining parameters namely, cutting speed, feed rate and depth of cut, each defined at three levels. Subsequently, the prediction model was developed using triangular fuzzy logic membership function. It is found that the predicted values of proposed responses such as surface roughness and Material Removal Rate are very close to the experimental values within the chosen ranges of the process parameters. The statistical analysis using ANOVA on machining parameters are also presented and discussed.

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Effect of operating variables on modified compression-absorption refrigeration system

Vol. 4 No. 2

Year: 2014

Issue: Feb-Apr

Title : Effect of operating variables on modified compression-absorption refrigeration system

Author Name : Navneet Kumar Pandey, V. K. Bajpai

Synopsis :

The vapour-absorption refrigeration cycle is a traditional and well-established technique, particularly with ammonia/water and water/LiBr (Lithium Bromide). Energy management has further enhanced its possibilities in day-today applications. Modifications have been suggested in compression–absorption refrigeration system which offers numerous advantages compared to conventional absorption systems. A detailed thermodynamic analysis and parametric study of NH -H O based compression absorption system has been carried out with an objective to get an 3 2 insight into the performance and feasibility of this system under varying operating conditions. The operating parameters studied are the effects of concentration of weak solution leaving the desorber on COP and variation of saturation pressure with respect to concentration keeping in view certain assumptions.

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Drawing - The Engineer’s Language

Vol. 4 No. 2

Year: 2014

Issue: Feb-Apr

Title : Drawing - The Engineer’s Language

Author Name : Bheemanjaneyulu S, Dr.K.L.Narayana

Synopsis :

When the subjects for Engineering curriculum were thought of and designed, importance to the “power of imagination” was given preference. This requirement gave birth to the subject “Engineering Drawing”. Over a period of time though the content underwent modifications, the basic ideas/requirements were retained. With the introduction of super specialties in engineering specializations, new subjects were introduced in the place of existing ones, as latest inventions were to find place in the curriculum. However, the subject Engineering Drawing could not be touched/replaced because of its importance to the engineer.

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A study on the effect of ultrasonic vibrations on electrical discharge machining processes

Vol. 4 No. 2

Year: 2014

Issue: Feb-Apr

Title : A study on the effect of ultrasonic vibrations on electrical discharge machining processes

Author Name : Govindan P

Synopsis :

Ultrasonic vibrations have various kinds of applications in machining operations. A large number of researchers have been involved in the investigation of ultrasonic effects in conventional machining operations. In most of the cases, they have obtained favorable effects. In this regard, this paper discusses the effects of ultrasonic vibrations, especially in EDM processes. The mechanisms which are helpful in improving the material removal include, cavitation, micro-streaming and impact forces by ultrasonic waves. One of the major challenges in EDM is to improve the sparking and flushing efficiency, which is critical in processes such as micro-EDM. Generally, it is understood that ultrasonic vibrations reduce thermal damage of the surfaces generated in EDM. Two ultrasonic parameters influencing the processes are ultrasonic amplitude and frequency of ultrasonic vibration. Several researchers have done mathematical modeling of the effects of ultrasonic vibrations in EDM. It helps in the prediction of key factors influencing the process, such as ultrasonic force required for debris evacuation and debris concentration at the inter-electrode gap.

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Effect of Natural Convection Heat Transfer from Horizontal Square Channel

Vol. 4 No. 2

Year: 2014

Issue: Feb-Apr

Title : Effect of Natural Convection Heat Transfer from Horizontal Square Channel

Author Name : RajaBhushan T.V.S.M., Dr. K. Vijaya Kumar Reddy

Synopsis :

Experiments have been conducted on square duct to investigate natural convection heat transfer from the outer surface of axially horizontal square ducts. Steady State Heat Transfer characteristics are studied under laminar and transition regions. Constant heat flux heating element is used to heat the duct from the center and 10 equidistant points are located on each side of the duct to measure temperature from all the four sides using IR-Thermometer. Correlations were developed in the form of circumferential averaged Nusselt number, modified Rayleigh number.

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Effect of Independent Variables on the Maximization of Gasoline Yield and Closed Loop Studies in Catalytic Cracking Unit

Vol. 4 No. 1

Year: 2014

Issue: Nov-Jan

Title : Effect of Independent Variables on the Maximization of Gasoline Yield and Closed Loop Studies in Catalytic Cracking Unit

Author Name : R. Raja Nandhini, M. Mythily , Dr. D. Manamalli

Synopsis :

Fluid Catalytic Cracking Unit (FCCU) is an important processing unit in an oil refinery. Fluid catalytic cracking is a process used to convert heavy petroleum products to light products such as gasoline, light fuel oil, and petroleum gas. In the fluid catalytic cracking reactor, heavy gas oil is cracked into more valuable lighter hydrocarbon products. The reactor input (the gas oil feed to the reactor) is a mixture of hydrocarbons that makes the reaction kinetics very complicated due to the involved reactions. The process is highly nonlinear and multi variable with severe interactions. For the simulated dynamic model of FCCU plugged with yield model, sensitivity studies has been carried out to study the effects of independent variables such as feed preheat temperature, feed flow rate and air flow rate in maximizing gasoline yield. With the optimized model, the closed loop studies have been carried out for reactor and regenerator temperature control of FCCU with minimum overshoot as the performance criteria.

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Experimental Investigations of the Process Parameters for SKD11 on Wire-cut Electric Discharge Machine

Vol. 4 No. 1

Year: 2014

Issue: Nov-Jan

Title : Experimental Investigations of the Process Parameters for SKD11 on Wire-cut Electric Discharge Machine

Author Name : Navneet Kumar, Neeraj Sharma, Neeraj Ahuja, Deepak Matta

Synopsis :

Wire Electric Discharge Machining (WEDM) is a thermal-erosion process to machine the hard to cut conductive material. This process is used for complex shapes, which have sharp edges that are difficult to machine using conventional machining processes. SKD11 is used as a work piece and performance analysis is done to find out the significant control factors for SKD11 by using one factor approach at a time. In this research paper, effect of various control factors like pulse on time, pulse off time, servo voltage, peak current, water pressure, wire tension, wire feed, peak voltage and, servo feed on cutting rate has been investigated while machining on SKD11 using one variable at a time approach. Experiments show the response for different parameters on WEDM. Cutting rate increases as the pulse on time and peak current increases. Cutting rate decreases with the pulse off time and servo voltage increases. Wire feed and wire tension has no effect on cutting rate.

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Machining parameters optimisation for milling AISI 304 stainless steel using Taguchi method

Vol. 4 No. 1

Year: 2014

Issue: Nov-Jan

Title : Machining parameters optimisation for milling AISI 304 stainless steel using Taguchi method

Author Name : Naresh Neeli, K. Rajasekhar

Synopsis :

AISI 304 stainless steel has wide applications in fabrication, architectural panelling, paper industry, food and pharmaceutical production equipment, nuclear vessels and cryogenic vessels. Austenitic steels are hard materials to machine, due to their high strength, high ductility, low thermal conductivity and excellent corrosion resistance in a wide variety of environments. This paper presents optimisation of machining parameters for milling AISI 304 stainless steel. In this work, a plan of experiments based on Taguchi's L orthogonal array was established and milling experiments were 27 conducted with prefixed process parameters using tungsten carbide end mill. The machining parameters such as, cutting speed, feed rate and depth of cut were optimised with the objective of minimizing the surface roughness (Ra) and maximizing the Material Removal Rate (MRR). Finally an analysis of variance (ANOVA) was performed for finding the effects of each parameter on the surface roughness and the Material Removal Rate. It is being inferred that cutting speed has the main influence on the surface roughness and as it increases, the surface roughness also increases. The depth of cut has the most important influence on material removal rate and as it increases, the material removal rate also increases.

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Numerical Approach for Solving Time- and Robust Time-Optimal Control Problems

Vol. 4 No. 1

Year: 2014

Issue: Nov-Jan

Title : Numerical Approach for Solving Time- and Robust Time-Optimal Control Problems

Author Name : Mohammad Amin Rashidifar, Ali Amin Rashidifar

Synopsis :

A numerical technique for solving time and robust time-optimal control problems has been presented. The method relies on the special feature that the optimal control structure contains as many free parameters as there are interior or boundary conditions. Two Boundary Value Problems (BVPs) are formulated for the state variables and co-states independently, thus, reducing the dimension of the original problem into half. Then, a numerical algorithm is developed, that is based on the shooting method, to solve the resulting BVPs. The computed optimal solution is verified by comparing the control input resulting from the first BVP with the switching function obtained by solving the second BVP. Next, the numerical technique is modified to solve robust time-optimal control problems. The capability of the proposed method is demonstrated through numerical examples, whose output optimal solution is shown to be identical to those presented in the literature. These examples include linear as well as non-linear systems. Finally, the numerical technique is utilized to design a time-optimal control for a rest-to-rest maneuver of flexible structure while eliminating the residual vibrations at the end of the maneuver.

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Computational Simulation and Experimental Study of A Biogas Reactor

Vol. 4 No. 1

Year: 2014

Issue: Nov-Jan

Title : Computational Simulation and Experimental Study of A Biogas Reactor

Author Name : Jeremy (Zheng) Li

Synopsis :

The available fuel sources in the market are less than demand, therefore the alternative fuels are substitutes for different commercial and residential applications, such as diesel and petrol for automobiles. Currently, many countries need to import significant amount of crude oil and other petroleum products. Also the air pollution is another environmental problem caused by the pollutant emissions from the automobiles running on petroleum products. The biogas is a renewable clean fuel that can potentially replace the traditional petroleum fuels in the future. Biogas contains 55% CH , 4 40.5% Co , and 4.5% pollutants including H , N , H S, and O to minimize the pollutant amount. Biogas can be processed 2 2 2 2 2 by going through the enrichment system of scrubbing and bottling mechanisms to produce Bio-CNG gas for automobiles. Biogas can be widely utilized after performing purification process to remove pollutants. The pure Bio- Methane in this analysis is pressurized to 19.5 MPa to fill in CNG cylinder by compressor. The capacity of producing Biogas 3 is about 148 m daily and Biogas production efficiency will rely on environment and other conditions. The design analysis of bio-reactor in this biomass system is accomplished by performing the mathematical modeling, computer aided simulation, and prototype experiment.

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