IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
A new technique near minimum material zone, to reduce the weight of the com...eSAT Journals
Abstract Customers buy a product when the quality of the product is high. So manufacturers produce their components to high quality. The product such as aircraft, automobile, motorcycle, etc. not only need to be produced at high quality but also at reduced weight. This is because these products performance is depend on weight of the product. A component could consist of several components. So all relevant component weights are reduced, then the overall weight of the component could be reduced. This paper introduces as new technique called "near minimum material zone" where not only the weight of the component could be reduced but also helps to increase the quality. To demonstrate this technique, two sets of experiments with 20 samples were conducted using Deckel Maho CTX310 ECO VI CNC machine. The first experiment was conducted under normal machining condition. The second experiment was conducted under this new technique. Several tools such as process capability analysis (Cp, Cpk), cause and effect diagram, X Hi/Lo and R-charts were used to analyze the case study data. The paper outcome suggests that this new technique not only helped to control the weight of the components but also improved the desired quality by minimizing the dispersion of the component dimensions to obtain higher sigma level. Keywords: Near Minimum Material Zone, Process Capability, Cpk, Cause and Effect diagram, X Hi/Lo chart, R chart, Quality.
Application of non traditional optimization for quality improvement in tool ...iaemedu
This document discusses applying non-traditional optimization techniques to improve quality in tool holders. It begins with an abstract that describes using Taguchi's design of experiments, response surface methodology, and genetic algorithms to optimize grinding process parameters and minimize defects. The document then reviews literature on using techniques like genetic algorithms and particle swarm optimization to optimize machining processes. It presents the methodology used, which includes conducting experiments using an L9 orthogonal array to evaluate control parameters, developing a mathematical model relating parameters to quality, and using genetic algorithm and particle swarm optimization to minimize deviations from quality targets.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
A comparative study of PSO, GSA and SCA in parameters optimization of surface...journalBEEI
The selection of parameters in grinding process remains as a crucial role to guarantee that the machined product quality is at the minimum production cost and maximum production rate. Therefore, it is required to utilize more advance and effective optimization methods to obtain the optimum parameters and resulting an improvement on the grinding performance. In this paper, three optimization algorithms which are particle swarm optimization (PSO), gravitational search, and Sine Cosine algorithms are employed to optimize the grinding process parameters that may either reduce the cost, increase the productivity or obtain the finest surface finish and resulting a higher grinding process performance. The efficiency of the three algorithms are evaluated and comparedwith previous results obtained by other optimization methods on similar studies.The experimental results showed that PSO algorithm achieves better optimization performance in the aspect of convergence rate and accuracy of best solution.Whereas in the comparison of results of previous researchers, the obtained result of PSO proves that it is efficient in solving the complicated mathematical model of surface grinding process with different conditions.
Parametric optimization of centrifugal magnetic force assisted abrasive flow ...eSAT Journals
Abstract: The traditional Taguchi method is widely used for optimizing the process parameters of a single response problem. Optimization of a single response results the non-optimum values for remaining. But, the performance of a machining process is often evaluated by several quality responses. Under such circumstances, multi-characteristics response optimization may be the solution to optimize multi-responses simultaneously. In the present work, a multi-characteristics response optimization model based on Taguchi and Utility concept is used to optimize process parameters, such as magnetic flux, rotational speed of CFG rod, shape of CFG rod, number of cycles, abrasive-to-iron ratio and abrasive particle size on multiple performance characteristics, namely, surface roughness (Ra) and material removal (MR) during polishing of hollow cylindrical brass work-pieces with Centrifugal-Magnetic Force Assisted Abrasive Flow Machining (CMA2FM) Process. Taguchi’s L27 orthogonal array (OA) is selected for experimental planning. The ANOVA and F-tests are used to analyze the results. It is found that all the input parameters significantly improve the Utility function comprising of two quality characteristics (MR and %ΔRa). Further, the confirmation tests are conducted and the results are found to be within the confidence interval.
Keywords: Abrasive Flow Machining (AFM), Centrifugal Force, Magnetic Force, CFG Rod, CMA2FM, Utility Concept,TaguchiMethod,MultiResponseOptimization
This document discusses improving the process capability of a connecting rod manufacturing process. It begins with defining the critical-to-quality characteristic as the bolt-holes center distance. Next, it measures the process capability indices including Cp, Cpk, and standard deviation. It then analyzes the data using ANOVA to identify sources of variation. Finally, it details improving the process by reducing standard deviation from 0.017 to 0.009 and increasing Cp from 0.97 to 1.77 and Cpk from 0.57 to 1.49 through applying statistical process control methods like process monitoring charts. The goal is to center the process within specifications to produce connecting rods meeting tight dimensional tolerances.
This document presents a geometric programming model to optimize the production rate of a turning process. It develops a mathematical model to express the production time as a function of cutting parameters like cutting speed and feed rate. The objective is to minimize production time by determining the optimal cutting conditions. Experimental validation of the model shows it provides an efficient way to maximize production rate within operating constraints like maximum speed, feed rate, power requirements and surface roughness. The geometric programming technique offers advantages over other optimization methods for this application.
A new technique near minimum material zone, to reduce the weight of the com...eSAT Journals
Abstract Customers buy a product when the quality of the product is high. So manufacturers produce their components to high quality. The product such as aircraft, automobile, motorcycle, etc. not only need to be produced at high quality but also at reduced weight. This is because these products performance is depend on weight of the product. A component could consist of several components. So all relevant component weights are reduced, then the overall weight of the component could be reduced. This paper introduces as new technique called "near minimum material zone" where not only the weight of the component could be reduced but also helps to increase the quality. To demonstrate this technique, two sets of experiments with 20 samples were conducted using Deckel Maho CTX310 ECO VI CNC machine. The first experiment was conducted under normal machining condition. The second experiment was conducted under this new technique. Several tools such as process capability analysis (Cp, Cpk), cause and effect diagram, X Hi/Lo and R-charts were used to analyze the case study data. The paper outcome suggests that this new technique not only helped to control the weight of the components but also improved the desired quality by minimizing the dispersion of the component dimensions to obtain higher sigma level. Keywords: Near Minimum Material Zone, Process Capability, Cpk, Cause and Effect diagram, X Hi/Lo chart, R chart, Quality.
Application of non traditional optimization for quality improvement in tool ...iaemedu
This document discusses applying non-traditional optimization techniques to improve quality in tool holders. It begins with an abstract that describes using Taguchi's design of experiments, response surface methodology, and genetic algorithms to optimize grinding process parameters and minimize defects. The document then reviews literature on using techniques like genetic algorithms and particle swarm optimization to optimize machining processes. It presents the methodology used, which includes conducting experiments using an L9 orthogonal array to evaluate control parameters, developing a mathematical model relating parameters to quality, and using genetic algorithm and particle swarm optimization to minimize deviations from quality targets.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
A comparative study of PSO, GSA and SCA in parameters optimization of surface...journalBEEI
The selection of parameters in grinding process remains as a crucial role to guarantee that the machined product quality is at the minimum production cost and maximum production rate. Therefore, it is required to utilize more advance and effective optimization methods to obtain the optimum parameters and resulting an improvement on the grinding performance. In this paper, three optimization algorithms which are particle swarm optimization (PSO), gravitational search, and Sine Cosine algorithms are employed to optimize the grinding process parameters that may either reduce the cost, increase the productivity or obtain the finest surface finish and resulting a higher grinding process performance. The efficiency of the three algorithms are evaluated and comparedwith previous results obtained by other optimization methods on similar studies.The experimental results showed that PSO algorithm achieves better optimization performance in the aspect of convergence rate and accuracy of best solution.Whereas in the comparison of results of previous researchers, the obtained result of PSO proves that it is efficient in solving the complicated mathematical model of surface grinding process with different conditions.
Parametric optimization of centrifugal magnetic force assisted abrasive flow ...eSAT Journals
Abstract: The traditional Taguchi method is widely used for optimizing the process parameters of a single response problem. Optimization of a single response results the non-optimum values for remaining. But, the performance of a machining process is often evaluated by several quality responses. Under such circumstances, multi-characteristics response optimization may be the solution to optimize multi-responses simultaneously. In the present work, a multi-characteristics response optimization model based on Taguchi and Utility concept is used to optimize process parameters, such as magnetic flux, rotational speed of CFG rod, shape of CFG rod, number of cycles, abrasive-to-iron ratio and abrasive particle size on multiple performance characteristics, namely, surface roughness (Ra) and material removal (MR) during polishing of hollow cylindrical brass work-pieces with Centrifugal-Magnetic Force Assisted Abrasive Flow Machining (CMA2FM) Process. Taguchi’s L27 orthogonal array (OA) is selected for experimental planning. The ANOVA and F-tests are used to analyze the results. It is found that all the input parameters significantly improve the Utility function comprising of two quality characteristics (MR and %ΔRa). Further, the confirmation tests are conducted and the results are found to be within the confidence interval.
Keywords: Abrasive Flow Machining (AFM), Centrifugal Force, Magnetic Force, CFG Rod, CMA2FM, Utility Concept,TaguchiMethod,MultiResponseOptimization
This document discusses improving the process capability of a connecting rod manufacturing process. It begins with defining the critical-to-quality characteristic as the bolt-holes center distance. Next, it measures the process capability indices including Cp, Cpk, and standard deviation. It then analyzes the data using ANOVA to identify sources of variation. Finally, it details improving the process by reducing standard deviation from 0.017 to 0.009 and increasing Cp from 0.97 to 1.77 and Cpk from 0.57 to 1.49 through applying statistical process control methods like process monitoring charts. The goal is to center the process within specifications to produce connecting rods meeting tight dimensional tolerances.
This document presents a geometric programming model to optimize the production rate of a turning process. It develops a mathematical model to express the production time as a function of cutting parameters like cutting speed and feed rate. The objective is to minimize production time by determining the optimal cutting conditions. Experimental validation of the model shows it provides an efficient way to maximize production rate within operating constraints like maximum speed, feed rate, power requirements and surface roughness. The geometric programming technique offers advantages over other optimization methods for this application.
Study of Surface Roughness measurement in turning of EN 18 steelIRJET Journal
This document presents a study that uses response surface methodology to optimize surface roughness in the turning of EN 18 steel. Experimental work was conducted using a CNC lathe machine with spindle speed, feed rate, and depth of cut as input variables. A central composite design and Design Expert software were used to develop a test plan and analyze results. Regression equations were developed relating surface roughness to the input parameters. Confirmation experiments found less than 2.32% error between predicted and experimental surface roughness values, validating the developed model. Optimal parameters were identified as 1740.68 rpm spindle speed, 0.82 mm/min feed rate, and 1.27 mm depth of cut to achieve minimum surface roughness.
Enhancing the Submersible Pump Rotor Performance by Taguchi Optimization Tech...IRJET Journal
The document describes an experimental study that used Taguchi optimization techniques to improve the surface roughness of rotor components made from silicon steel for submersible pumps. Three turning cutting parameters - cutting speed, feed rate, and depth of cut - were investigated at three levels each using an orthogonal array experiment. Analysis of variance was conducted on the surface roughness measurements to determine the most significant parameters. The results showed that cutting speed had the greatest influence on surface roughness, followed by depth of cut, while feed rate was less significant. This provides information on optimal cutting conditions for machining silicon steel rotors to reduce surface roughness.
Optimization by heuristic procedure of scheduling constraints in manufacturin...Alexander Decker
This document discusses optimization of scheduling constraints in manufacturing systems using heuristic procedures. It proposes a simple heuristic rule for staggering replenishments of products under an equal order interval method. This provides a formula to calculate the upper limit of maximum investment in inventory. The heuristic rule is shown to perform better than traditional Lagrange multiplier techniques by providing lower costs. An example is provided to illustrate determining optimal order quantities and sequences for machines and jobs using heuristic scheduling with layout constraints. The heuristic approach is concluded to provide better results than traditional methods while being easier to implement in real manufacturing situations.
11.optimization by heuristic procedure of scheduling constraints in manufactu...Alexander Decker
This document summarizes an article that proposes using a heuristic procedure to optimize scheduling constraints in a manufacturing system with multiple products. The heuristic procedure arranges machines in an optimal sequence to minimize manufacturing lead time and maximize profit.
The document first discusses traditional optimization approaches using economic order quantities and Lagrange multipliers that are difficult to implement in practice. It then presents a simple heuristic rule for staggering product replenishments under an equal order interval method.
Finally, the document provides an example application of the heuristic procedure to determine optimal job sequences, machine sequences, waiting times, and layout costs for different manufacturing layouts like linear, loop and ladder layouts. Computational results demonstrate that the heuristic approach performs better than traditional optimization methods
This document describes a biased linear feedback machining process for asymmetric cost functions. It presents a feedback control rule that allows the process quality characteristic to converge to the target value from the lower cost side when the cost function is asymmetric. The control rule adds a bias term to enable one-sided convergence. The paper derives optimal biased control rules for constant and quadratic cost asymmetric cost functions. It also applies the biased linear adjustment procedure to a real hole-finishing machining process and compares the performance to Grubbs' rule and an EWMA controller in terms of expected costs. The biased rule is shown to generate cost savings, especially for small production lots.
Job Shop Layout Design Using Group TechnologyIJMER
This document summarizes a study that uses simulation to improve the performance of a job shop layout by reconfiguring the machines. 34 job elements that are processed on 6 machines were analyzed. The jobs were clustered into 4 part families using direct clustering. Similar machines were then grouped together. Computerized Relative Allocation of Facilities Technique (CRAFT) with computer graphics was used to design a new layout. The initial layout had a total material handling cost of 1738.75 units per period. The optimized layout designed using CRAFT reduced this cost to 1071.25 units, a significant improvement without additional investment.
AN EXPERIMENTAL STUDY ON THE AUTOMOTIVE PRODUCTION LINE USING ASSEMBLY LINE B...IAEME Publication
The main aim of an assembly line is to group the different facilities and workers inan efficient manner in order to obtain effective utilization of man power and machine.This calls for uniform rate of production as well as decrease in the work in process
inventory. Hence, this paper attempts to achieve these in an assembly line of anautomotive manufacturing unit using three different techniques such as Largestcandidate rule (LCR), Kilbridge and wester column method (KWC) and Rank
positional weighted method (RPW). All the three methods show better efficiency and acomparison is also drawn amongst the three to determine the best suited techniquepertaining to the current research work
IRJET-Design Optimization of Free Standing Communication Tower using Genetic ...IRJET Journal
This document describes research optimizing the design of free standing communication towers using a genetic algorithm approach. It summarizes the objectives of minimizing tower weight while satisfying structural constraints. The study develops a genetic algorithm using MATLAB to optimize 7 configurations of communication towers. Results show the genetic algorithm yields a 1-2% reduction in optimal tower weight compared to other optimization methods like particle swarm optimization. The genetic algorithm is validated on benchmark problems and applied to optimize the member sizing of communication towers with different bracing configurations. Overall, the research demonstrates genetic algorithms can effectively optimize structural designs like tower configurations for reduced weight.
IRJET- Optimum Design of Fan, Queen and Pratt TrussesIRJET Journal
The document discusses the optimum design of various truss configurations including fan, queen, and Pratt trusses. The author formulates the design of these trusses as an optimization problem to minimize weight. The problem considers stress, buckling, and deflection constraints with cross-sectional area as the design variable. A sequential linear programming technique is used to solve the optimization problem. Parametric studies are performed to understand the effect of truss geometry including span, purlin spacing, truss spacing, and height on selecting the best design. The results of optimizing double fan, triple fan, modified queen, double Pratt, and triple Pratt trusses are presented and discussed.
This document summarizes a research paper that used computer simulation to optimize the design of three feeders for a sand casting process. It begins with background on sand casting and finite element analysis. The document then describes how Ansys software was used to perform transient thermal analysis and optimize the height of three feeders on a dumbbell-shaped casting. First, a traditional modulus approach was used to initially size the feeders. Then, Ansys optimization was performed to maximize feeder yield by minimizing temperature differences between feeders and casting zones. The optimized design from Ansys improved feeder yield to 50.76% compared to 13.36% from the modulus approach. Temperature plots from Ansys verified the feeders contained the hot
Multi-Response Optimization of Aluminum alloy using GRA & PCA by employing Ta...IRJET Journal
This document summarizes a study that used multi-response optimization techniques including Grey Relational Analysis (GRA) and Principal Component Analysis (PCA) to optimize the machining parameters for end milling of an aluminum alloy. The goal was to provide better surface quality with optimal Material Removal Rate (MRR). Taguchi's design of experiments was used to design and conduct 27 experiments varying speed, depth of cut, and feed rate. GRA and PCA were then used to analyze the experimental data and determine the optimal machining parameter settings to achieve the desired surface roughness and MRR. The techniques effectively identified the optimal parameter combinations for end milling the aluminum alloy.
Design evaluation and optimization of steering yoke of an automobileeSAT Publishing House
This document describes research conducted to optimize the design of an automobile steering yoke through finite element analysis and experimental testing. The researchers created 3D models of the steering yoke in CATIA software and applied topology, shape, and size optimization techniques. They then conducted finite element analysis in HyperWorks to analyze von Mises stresses, displacement, and mass. Experimental testing was also performed on the steering yoke using a universal testing machine and strain gauges. The optimized design was found to have lower stresses, displacement, and mass than the original design, validating the finite element analysis model.
Design evaluation and optimization of steering yoke of an automobileeSAT Journals
Abstract The purpose of a steering system is to control the direction of the vehicle by operating the steering wheel of the steering system. The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and steady movement of the vehicle. The steering yoke consists of two forged-steel yokes or forks joined to the two shafts being coupled and situated at right angles to each other. A spider hinges these two yokes together. Since the arms of the spider are at right angles the spider arm rocks backwards and forward between four extreme positions. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some common reasons for the failures may be manufacturing, design faults, maintenance faults, raw material faults, material processing faults as well as the user originated faults. In this paper structural optimization of the steering yoke is carried out. For modeling of the component, CATIA V5 R17 software is used. It has been found that there are essentially in two stages of the design process that structural optimization can be applied. In the early stage of concept generation, topology optimization should be used to develop an efficient structure from the beginning. At this level an automatized variation of optimization parameters was proven useful to and the best feasible design possible. In the later stage, shape and size optimization should be used to fine-tune the structure realized from the topology optimization and carried out physical experimentation to validate the model. Keywords: Steering Yoke, Structural optimization, CATIA V5, Hyperworks
This document outlines a research project that aims to improve the performance of structural components using topological optimization and additive manufacturing. The author conducted topological optimization on a right-angled joint to reduce its volume by 75%, resulting in a lighter part with 3.8 times less maximum stress than a comparable conventionally-manufactured part. Nine copies of the optimized part were 3D printed with different layer orientations and physically tested. It was found that parts with layer planes perpendicular to applied forces exhibited superior mechanical performance due to the directional anisotropy of the additive manufacturing process.
Parametric optimisation by using response surfaceprj_publication
This document describes a study that used response surface methodology (RSM) to develop mathematical models relating submerged arc welding process parameters to weld bead geometry characteristics. Researchers conducted experiments with varying levels of welding current, voltage, speed, and nozzle-to-plate distance. Regression analysis was used to develop models and optimize the parameters to achieve desired bead reinforcement and width. The optimal parameters found were a current of 337 amps, voltage of 32 volts, speed of 20 inches/minute, and distance of 25mm for maximum reinforcement of 2.30mm.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
PRODUCTIVITY IMPROVEMENT IN STITCHING SECTION OF A GARMENT MANUFACTURING COMPANYAM Publications
In this study one heuristic assembly line balancing technique known as the “Ranked Positional weight Technique”, developed by Helgeson and Birnie was applied to solve the problem of assembly line balancing in a garment manufacturing company for one model. Information about solution methods related to assembly line balancing problems is given. Operator reduction is achieved by line balancing. Layout was modified using the template method. The aim of this article is the usage of these techniques to improve the productivity in a clothing company.
Structural optimization of a powered industrial lift truck frameIAEME Publication
This document summarizes the structural optimization of a powered industrial lift truck frame. Topology and size optimization techniques were used to redesign the frame in Altair Engineering's OptiStruct software. Up to 15% weight reduction was achieved in the frame without compromising functional requirements or assembly fitments. Considerable cost savings of Rs. 10,000 per vehicle were realized through this optimization process. The optimized design was verified using an alternate solver and showed only marginal increases in stress and deflection compared to the original design.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Impact assessment of factors affecting information technology projects in riv...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Behaviour of bituminous concrete modified with polyethylene glycol for blade ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Study of Surface Roughness measurement in turning of EN 18 steelIRJET Journal
This document presents a study that uses response surface methodology to optimize surface roughness in the turning of EN 18 steel. Experimental work was conducted using a CNC lathe machine with spindle speed, feed rate, and depth of cut as input variables. A central composite design and Design Expert software were used to develop a test plan and analyze results. Regression equations were developed relating surface roughness to the input parameters. Confirmation experiments found less than 2.32% error between predicted and experimental surface roughness values, validating the developed model. Optimal parameters were identified as 1740.68 rpm spindle speed, 0.82 mm/min feed rate, and 1.27 mm depth of cut to achieve minimum surface roughness.
Enhancing the Submersible Pump Rotor Performance by Taguchi Optimization Tech...IRJET Journal
The document describes an experimental study that used Taguchi optimization techniques to improve the surface roughness of rotor components made from silicon steel for submersible pumps. Three turning cutting parameters - cutting speed, feed rate, and depth of cut - were investigated at three levels each using an orthogonal array experiment. Analysis of variance was conducted on the surface roughness measurements to determine the most significant parameters. The results showed that cutting speed had the greatest influence on surface roughness, followed by depth of cut, while feed rate was less significant. This provides information on optimal cutting conditions for machining silicon steel rotors to reduce surface roughness.
Optimization by heuristic procedure of scheduling constraints in manufacturin...Alexander Decker
This document discusses optimization of scheduling constraints in manufacturing systems using heuristic procedures. It proposes a simple heuristic rule for staggering replenishments of products under an equal order interval method. This provides a formula to calculate the upper limit of maximum investment in inventory. The heuristic rule is shown to perform better than traditional Lagrange multiplier techniques by providing lower costs. An example is provided to illustrate determining optimal order quantities and sequences for machines and jobs using heuristic scheduling with layout constraints. The heuristic approach is concluded to provide better results than traditional methods while being easier to implement in real manufacturing situations.
11.optimization by heuristic procedure of scheduling constraints in manufactu...Alexander Decker
This document summarizes an article that proposes using a heuristic procedure to optimize scheduling constraints in a manufacturing system with multiple products. The heuristic procedure arranges machines in an optimal sequence to minimize manufacturing lead time and maximize profit.
The document first discusses traditional optimization approaches using economic order quantities and Lagrange multipliers that are difficult to implement in practice. It then presents a simple heuristic rule for staggering product replenishments under an equal order interval method.
Finally, the document provides an example application of the heuristic procedure to determine optimal job sequences, machine sequences, waiting times, and layout costs for different manufacturing layouts like linear, loop and ladder layouts. Computational results demonstrate that the heuristic approach performs better than traditional optimization methods
This document describes a biased linear feedback machining process for asymmetric cost functions. It presents a feedback control rule that allows the process quality characteristic to converge to the target value from the lower cost side when the cost function is asymmetric. The control rule adds a bias term to enable one-sided convergence. The paper derives optimal biased control rules for constant and quadratic cost asymmetric cost functions. It also applies the biased linear adjustment procedure to a real hole-finishing machining process and compares the performance to Grubbs' rule and an EWMA controller in terms of expected costs. The biased rule is shown to generate cost savings, especially for small production lots.
Job Shop Layout Design Using Group TechnologyIJMER
This document summarizes a study that uses simulation to improve the performance of a job shop layout by reconfiguring the machines. 34 job elements that are processed on 6 machines were analyzed. The jobs were clustered into 4 part families using direct clustering. Similar machines were then grouped together. Computerized Relative Allocation of Facilities Technique (CRAFT) with computer graphics was used to design a new layout. The initial layout had a total material handling cost of 1738.75 units per period. The optimized layout designed using CRAFT reduced this cost to 1071.25 units, a significant improvement without additional investment.
AN EXPERIMENTAL STUDY ON THE AUTOMOTIVE PRODUCTION LINE USING ASSEMBLY LINE B...IAEME Publication
The main aim of an assembly line is to group the different facilities and workers inan efficient manner in order to obtain effective utilization of man power and machine.This calls for uniform rate of production as well as decrease in the work in process
inventory. Hence, this paper attempts to achieve these in an assembly line of anautomotive manufacturing unit using three different techniques such as Largestcandidate rule (LCR), Kilbridge and wester column method (KWC) and Rank
positional weighted method (RPW). All the three methods show better efficiency and acomparison is also drawn amongst the three to determine the best suited techniquepertaining to the current research work
IRJET-Design Optimization of Free Standing Communication Tower using Genetic ...IRJET Journal
This document describes research optimizing the design of free standing communication towers using a genetic algorithm approach. It summarizes the objectives of minimizing tower weight while satisfying structural constraints. The study develops a genetic algorithm using MATLAB to optimize 7 configurations of communication towers. Results show the genetic algorithm yields a 1-2% reduction in optimal tower weight compared to other optimization methods like particle swarm optimization. The genetic algorithm is validated on benchmark problems and applied to optimize the member sizing of communication towers with different bracing configurations. Overall, the research demonstrates genetic algorithms can effectively optimize structural designs like tower configurations for reduced weight.
IRJET- Optimum Design of Fan, Queen and Pratt TrussesIRJET Journal
The document discusses the optimum design of various truss configurations including fan, queen, and Pratt trusses. The author formulates the design of these trusses as an optimization problem to minimize weight. The problem considers stress, buckling, and deflection constraints with cross-sectional area as the design variable. A sequential linear programming technique is used to solve the optimization problem. Parametric studies are performed to understand the effect of truss geometry including span, purlin spacing, truss spacing, and height on selecting the best design. The results of optimizing double fan, triple fan, modified queen, double Pratt, and triple Pratt trusses are presented and discussed.
This document summarizes a research paper that used computer simulation to optimize the design of three feeders for a sand casting process. It begins with background on sand casting and finite element analysis. The document then describes how Ansys software was used to perform transient thermal analysis and optimize the height of three feeders on a dumbbell-shaped casting. First, a traditional modulus approach was used to initially size the feeders. Then, Ansys optimization was performed to maximize feeder yield by minimizing temperature differences between feeders and casting zones. The optimized design from Ansys improved feeder yield to 50.76% compared to 13.36% from the modulus approach. Temperature plots from Ansys verified the feeders contained the hot
Multi-Response Optimization of Aluminum alloy using GRA & PCA by employing Ta...IRJET Journal
This document summarizes a study that used multi-response optimization techniques including Grey Relational Analysis (GRA) and Principal Component Analysis (PCA) to optimize the machining parameters for end milling of an aluminum alloy. The goal was to provide better surface quality with optimal Material Removal Rate (MRR). Taguchi's design of experiments was used to design and conduct 27 experiments varying speed, depth of cut, and feed rate. GRA and PCA were then used to analyze the experimental data and determine the optimal machining parameter settings to achieve the desired surface roughness and MRR. The techniques effectively identified the optimal parameter combinations for end milling the aluminum alloy.
Design evaluation and optimization of steering yoke of an automobileeSAT Publishing House
This document describes research conducted to optimize the design of an automobile steering yoke through finite element analysis and experimental testing. The researchers created 3D models of the steering yoke in CATIA software and applied topology, shape, and size optimization techniques. They then conducted finite element analysis in HyperWorks to analyze von Mises stresses, displacement, and mass. Experimental testing was also performed on the steering yoke using a universal testing machine and strain gauges. The optimized design was found to have lower stresses, displacement, and mass than the original design, validating the finite element analysis model.
Design evaluation and optimization of steering yoke of an automobileeSAT Journals
Abstract The purpose of a steering system is to control the direction of the vehicle by operating the steering wheel of the steering system. The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and steady movement of the vehicle. The steering yoke consists of two forged-steel yokes or forks joined to the two shafts being coupled and situated at right angles to each other. A spider hinges these two yokes together. Since the arms of the spider are at right angles the spider arm rocks backwards and forward between four extreme positions. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some common reasons for the failures may be manufacturing, design faults, maintenance faults, raw material faults, material processing faults as well as the user originated faults. In this paper structural optimization of the steering yoke is carried out. For modeling of the component, CATIA V5 R17 software is used. It has been found that there are essentially in two stages of the design process that structural optimization can be applied. In the early stage of concept generation, topology optimization should be used to develop an efficient structure from the beginning. At this level an automatized variation of optimization parameters was proven useful to and the best feasible design possible. In the later stage, shape and size optimization should be used to fine-tune the structure realized from the topology optimization and carried out physical experimentation to validate the model. Keywords: Steering Yoke, Structural optimization, CATIA V5, Hyperworks
This document outlines a research project that aims to improve the performance of structural components using topological optimization and additive manufacturing. The author conducted topological optimization on a right-angled joint to reduce its volume by 75%, resulting in a lighter part with 3.8 times less maximum stress than a comparable conventionally-manufactured part. Nine copies of the optimized part were 3D printed with different layer orientations and physically tested. It was found that parts with layer planes perpendicular to applied forces exhibited superior mechanical performance due to the directional anisotropy of the additive manufacturing process.
Parametric optimisation by using response surfaceprj_publication
This document describes a study that used response surface methodology (RSM) to develop mathematical models relating submerged arc welding process parameters to weld bead geometry characteristics. Researchers conducted experiments with varying levels of welding current, voltage, speed, and nozzle-to-plate distance. Regression analysis was used to develop models and optimize the parameters to achieve desired bead reinforcement and width. The optimal parameters found were a current of 337 amps, voltage of 32 volts, speed of 20 inches/minute, and distance of 25mm for maximum reinforcement of 2.30mm.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
PRODUCTIVITY IMPROVEMENT IN STITCHING SECTION OF A GARMENT MANUFACTURING COMPANYAM Publications
In this study one heuristic assembly line balancing technique known as the “Ranked Positional weight Technique”, developed by Helgeson and Birnie was applied to solve the problem of assembly line balancing in a garment manufacturing company for one model. Information about solution methods related to assembly line balancing problems is given. Operator reduction is achieved by line balancing. Layout was modified using the template method. The aim of this article is the usage of these techniques to improve the productivity in a clothing company.
Structural optimization of a powered industrial lift truck frameIAEME Publication
This document summarizes the structural optimization of a powered industrial lift truck frame. Topology and size optimization techniques were used to redesign the frame in Altair Engineering's OptiStruct software. Up to 15% weight reduction was achieved in the frame without compromising functional requirements or assembly fitments. Considerable cost savings of Rs. 10,000 per vehicle were realized through this optimization process. The optimized design was verified using an alternate solver and showed only marginal increases in stress and deflection compared to the original design.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Impact assessment of factors affecting information technology projects in riv...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Behaviour of bituminous concrete modified with polyethylene glycol for blade ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Log into android mobile to fetch the device oriented information using remote...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
A novel method for detecting and characterizing low velocity impact (lvi) in ...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Software testing effort estimation with cobb douglas function a practical app...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
This document discusses several dynamic thresholding approaches for segmenting continuous Bangla speech sentences into words or subwords. It proposes using k-means clustering, fuzzy c-means clustering (FCM), and Otsu's thresholding method to determine optimal thresholds for segmentation. K-means and FCM clustering produce better segmentation results than Otsu's method. The algorithms are implemented in MATLAB and achieve an average segmentation accuracy of 94%. Blocking black areas and boundary detection techniques are used to properly detect word boundaries in continuous speech and label the segmented units.
Synthesis, characterisation and antibacterial activity of copolymer (n vinylp...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Energy efficient task scheduling algorithms for cloud data centerseSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
An enhanced adaptive scoring job scheduling algorithm with replication strate...eSAT Publishing House
This document describes an enhanced adaptive scoring job scheduling algorithm with replication strategy for grid environments. The algorithm aims to improve upon an existing adaptive scoring job scheduling algorithm by identifying whether jobs are data-intensive or computation-intensive. It then divides large jobs into subtasks, replicates the subtasks, and allocates the replicas to clusters based on a computed cluster score in order to improve resource utilization and job completion times. The algorithm is evaluated through simulation using the GridSim toolkit.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Weight optimization of fix jaw of rear vice of horizontal band saw machine us...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
WEIGHT OPTIMIZATION OF FIX JAW OF REAR VICE OF HORIZONTAL BAND SAW MACHINE US...prashant patil
1. The document summarizes topology optimization performed to reduce the weight of the fixed jaw of a rear vice on a horizontal band saw machine.
2. Finite element analysis was conducted on the existing fixed jaw model to determine stresses and displacements. Topology optimization was then performed to identify material that could be removed without compromising strength.
3. The optimized model was 12% lighter than the original at 10.7kg compared to 12.1kg. Analysis showed reduced displacement and stress compared to the original design. The optimized design was manufactured and successfully tested.
Design of ‘plastic injection mold’ for an ‘air vent bezel’ through flow analy...eSAT Journals
Abstract Designer's of plastic injection Molds need to study from this point of view, the type of Mold to be designed, the physical Mold orientation, the dimensions for each of the element in the Mold, the location of the gate, runner, requirement of insert, draft angle requirement, shrinkage factor, location of cooling channels. Design can also be simplified by using standardized parts of the mold such as ejector pins. By eliminating the obstruction to smooth flow of plastic a good of quality component can be achieved. The effort of this thesis work is to find out the nuances in the Plastic Injection Mold Design while borrowing the inputs from the Flow Analysis (CAE) conducted for the 'Air vent bezel' to study the behavior of the Melt during flow. The Mold Design would incorporate suitable checking to ensure the best quality product in terms of `defect-free’ output. This thesis work consist methodology of plastic injection molding process, material requirement, how to overcome weld mark, shrinkage etc to satisfactorily assemble the component. Keywords: Draft angle, Shrinkage, CAE, weld mark
Modal analysis of Support bracket for air compressor systemIRJET Journal
This document summarizes a modal analysis of a supporting bracket for an air compressor system. The analysis was performed using finite element analysis in ABAQUS. The modal analysis determined the natural frequencies and mode shapes of the bracket. The first natural frequency was found to be 24.45 cycles/sec by FEA, which had 13.12% error compared to the analytical calculation of 21.24 cycles/sec. Additional modes were identified with frequencies up to 204.85 cycles/sec. A static analysis found stresses of 25.90 MPa by FEA and 26.64 MPa by analysis, demonstrating the design is safe under static loads. The modal analysis provides data to improve performance and avoid damage from vibration.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
Balancing the line by using heuristic method based on cpm in salbp –a case studyeSAT Journals
Abstract
In mass production systems, line balancing plays a great role, but this is not easy even if it is a simple straight line. So, in order to
solve these problems Heuristic methods are very much desirable. It is also found that Heuristic methods play a great role in the
formation of metaheuristic methods.Therefore it is very much important to use more efficient heuristic methods. In this research
paper we presents a heuristic method that is based on critical path method for simple assembly line balancing. This research is
mainly concerned with objectives of minimizing the number of workstations, improvement of smoothness index, mean absolute
deviation (MAD) and increasing line efficiency.
Keywords-Heuristic methods,Assembly line balancing problem, Critical path method, Simple assembly line balancing.
Structural analysis of steering yoke of an automobile for withstanding torsio...eSAT Journals
Abstract
The steering columns in a steering system are one of the main devices of an automobile. It is a very important part to attain stability and
steady movement of the vehicle. It consists of two yokes, one on each shaft, connected by a cross-shaped intermediate member i.e.
spider. Motion transmission system of vehicles consist several components which sometimes encounter unfortunate failures. Some
common reasons for the failures may be manufacturing and design faults, maintenance faults, raw material faults, material processing
faults as well as the user originated faults. In this paper finite element analysis of the component is carried out to find the stress and
displacement of the final product. For modeling of the component, CATIA V5 R17 software is used. Preprocessing work like meshing
and analysis work is carried out in HYPERWORKS software. Using FEA analysis, we can identify the nature and characteristics of
stresses acting on the yoke and also evaluate the influence of the loads/ mass/ geometry/ boundary conditions over the yoke.
Keywords: Steering Yoke, Structural analysis, FEA, CATIA V5, Hyper works
The document discusses the structural analysis and optimization of a steering yoke component in an automobile. Finite element analysis was conducted on the original design using Hyperworks software to determine stresses and displacement under an applied torque load. The analysis found high stresses in some areas. Topology optimization was then used to modify the design by removing unnecessary material. Analysis of the modified design showed lower stresses within the yield strength of the material, indicating an improved and safe design.
This document summarizes research on designing the column structure of a Horizontal Machining Center (HMC) to withstand vibration during operation. Three column structure concepts were modeled and analyzed in CREO and ANSYS to determine their natural frequencies and deformation under load. Modal analysis found Concept 1 had the highest natural frequency, lowest weight, and least deformation, indicating it would provide the most stability. Cutting force calculations for milling and drilling operations were also presented to estimate the loads the column would experience from dynamic machine components like the spindle motor. A pre-stressed analysis was proposed to validate the column's performance under the cutting forces generated during heavy machining processes.
Design and Fatigue Analysis of a Typical Aircraft Wing fuselage Lug attachmen...SonuKumar1049
- The structure of a fighter jet is quite complicated. The aeroplane is required to do challenging
manoeuvres while fighting off enemies. During that, high magnitude stresses will be placed on the wings as a result
of the combination of high level acceleration and challenging maneuvers. The fighter aircraft often has multiple wing-fuselage attachment points. An aircraft
rarely has a static overload-related failure during its service life. Fatigue and damage tolerance design, analysis, testing, and service experience correlation are
crucial for maintaining an aircraft's airworthiness during
its entire economic service life. The fatigue loading that
occurs during service on lug-type joints completes load
transmission through the pin. This is why the wing-fuselage lug joints are regarded as the aircraft structure's most fracture-critical parts.In the current project, an attempt is made to
predict the fatigue life of a wing-fuselage attachment
bracket of a fighter aircraft to meet the stress and fatigue
design considerations. Subsequently, linear static analysis
is carried out. The stress results of finite element analysis
show that stress levels of lug structure meet the strength
requirement. Furthermore, utilizing constant amplitude SN data for various stress ratios and local stress history at
stress concentration, fatigue life computation is carried for a typical service loading. The lug structure's computed damage factor for the given load spectrum comes out to be less than one. This demonstrates that the wing lug structure is safe to use and that the crack has not initiated
Design and Fatigue Analysis of a Typical Aircraft Wing fuselage Lug attachmen...IRJET Journal
This document describes a study on the fatigue analysis of a wing-fuselage lug attachment structure for a fighter aircraft. It involves modeling the lug geometry in a CAD software, applying loads and boundary conditions representing flight maneuvers, performing finite element analysis to determine stresses, and using those results to calculate fatigue life. The analysis shows the maximum stresses meet strength requirements and the fatigue life calculation indicates the lug structure is safe to withstand the expected service loads without crack initiation. This fatigue analysis approach can help ensure the reliability of critical aircraft components.
A Method for Finding Document Containning Reactionary ViewpointsIRJET Journal
The document describes using topology optimization to optimize the design of a front suspension shackle support. It discusses setting up the topology optimization parameters including design variables, constraints, and objective functions. It then performs finite element analysis on the optimized design under different load cases and compares the stresses to the permissible limits and the original baseline design. The optimized design showed a 30% mass reduction while keeping all stresses below limits, making it a manufacturable and improved design for the suspension shackle support.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
The inspiration driving CNC machining undertakings is to make explicit shapes or surface
characteristics for a thing. In view of math and surface completion determinations, conditions for machining
assignments have for the most part been chosen. Assembling ventures endeavor to make high phenomenal things
at decay cost to stay serious inside the market. This exploration zeroed in on growing the advantage of benefit
on PC mathematical control (CNC) by enhancing machining boundaries by processing activities. In this
exploration, the profundity of cut, cutting velocity and feed rate on the aluminum amalgam work piece by the
utilization of carbide unit, embed shaper, HSS were utilized to enhance the advantage of CNC processing
measures by advancing machining boundaries picked to be assessed in this investigation by utilizing Taguchi's
System approach including symmetrical exhibit. The Taguchi strategy is utilized to notice the impact of cycle
boundaries and to look at a portion of the decrease speed, feed and profundity with acknowledgment of the
essential machinability part, surface end. The surface completion has been portrayed as quality attributes and is
accepted to be straightforwardly identified with efficiency.
Design Optimization of Display Unit Supporting Structure Under Static and Spe...IRJET Journal
This document describes the design optimization of a display unit support structure using finite element analysis. A 3D model of the display unit was created and imported into Hypermesh for meshing. An initial analysis found failure in some components under the design loads. Design optimization was then performed through Ansys' design optimizer module to vary the thickness of 7 components. 21 optimized design iterations were obtained with stresses below allowable limits and increased structural safety for the given loads. The final optimized design had higher thickness values for critical components and improved stress distribution compared to the initial design.
IRJET- Design and Development of a Bandsaw Machine Roller Bracket for Wei...IRJET Journal
This document summarizes a study on optimizing the weight of roller brackets used in a horizontal bandsaw machine. The researchers used topology optimization tools in Altair Hyperworks to reduce the weight of the roller bracket by 27%, saving approximately Rs. 336 per machine. They validated the optimized design through stress analysis in Hyperworks and experimental testing using a photoelastic model and polariscope instrument. The optimized bracket design was then 3D printed to verify functionality. Overall, the study achieved the goals of reducing material usage, costs, and improving the environmental sustainability of the machine tool.
This document provides guidance on calculating and interpreting the process capability index Cpk. It defines Cpk as a ratio that compares the specification tolerance to the process variation expressed in terms of standard deviations. It explains how to calculate Cpk and discusses factors that influence Cpk values such as sample size, process centering, and measurement uncertainty. The document also provides examples of the expected defective parts per million that correspond to different Cpk values and factors to consider when improving Cpk, such as machine, tooling, workholding, and workpiece variables.
IRJET- Optimization of Fink and Howe TrussesIRJET Journal
This document describes research on optimizing the weight of different truss configurations, including double fink, triple fink, modified fink, double Howe, and triple Howe trusses. The optimization problem aims to minimize weight by treating cross-sectional areas as design variables, while satisfying stress, buckling, and deflection constraints. An improved sequential linear programming technique is used to solve the optimization problem. The process involves developing a C program for load calculation, using MATLAB for truss analysis, and applying an optimizer based on improved SLP to determine optimized cross-sectional areas. A parametric study is then carried out by varying span, height, and spacing to identify the most economical truss configuration under the given conditions.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
Performance analysis of production line with bernoulli’s machineseSAT Journals
Abstract In flexible manufacturing environments, the performance of a production system is often affected by the sequence of operation. While performance evaluation, improvement and lean design of production system have been studied extensively, the joint effect of productivity and quality parameters on operation sequencing remains practically unexplored. Indeed, determining the optimal operation sequence has significant implication from both theoretical and practical perspectives. In this work the frame work of Bernoulli reliability and quality models, we develop effective indicator that area simple and easy to implement in practice to determine the optimal operation sequence that maximize the system production rate.
Similar to A new technique near minimum material zone, to (20)
Hudhud cyclone caused extensive damage in Visakhapatnam, India in October 2014, especially to tree cover. This will likely impact the local environment in several ways: increased air pollution as trees absorb less; higher temperatures without tree canopy; increased erosion and landslides. It also created large amounts of waste from destroyed trees. Proper management of solid waste is needed to prevent disease spread. Suggested measures include restoring damaged plants, building fountains to reduce heat, mandating light-colored buildings, improving waste management, and educating public on health risks. Overall, changes are needed to water, land, and waste practices to rebuild the environment after the cyclone removed green cover.
Impact of flood disaster in a drought prone area – case study of alampur vill...eSAT Publishing House
1) In September-October 2009, unprecedented heavy rainfall and dam releases caused widespread flooding in Alampur village in Mahabub Nagar district, a historically drought-prone area.
2) The flood damaged or destroyed homes, buildings, infrastructure, crops, and documents. It displaced many residents and cut off the village.
3) The socioeconomic conditions and mud-based construction of homes in the village exacerbated the flood's impacts, making damage more severe and recovery more difficult.
The document summarizes the Hudhud cyclone that struck Visakhapatnam, India in October 2014. It describes the cyclone's formation, rapid intensification to winds of 175 km/h, and landfall near Visakhapatnam. The cyclone caused extensive damage estimated at over $1 billion and at least 109 deaths in India and Nepal. Infrastructure like buildings, bridges, and power lines were destroyed. Crops and fishing boats were also damaged. The document then discusses coping strategies and improvements needed to disaster management plans to better prepare for future cyclones.
Groundwater investigation using geophysical methods a case study of pydibhim...eSAT Publishing House
This document summarizes the results of a geophysical investigation using vertical electrical sounding (VES) methods at 13 locations around an industrial area in India. The VES data was interpreted to generate geo-electric sections and pseudo-sections showing subsurface resistivity variations. Three main layers were typically identified - a high resistivity topsoil, a weathered middle layer, and a basement rock. Pseudo-sections revealed relatively more weathered areas in the northwest and southwest. Resistivity sections helped identify zones of possible high groundwater potential based on low resistivity anomalies sandwiched between more resistive layers. The study concluded the electrical resistivity method was useful for understanding subsurface geology and identifying areas prospective for groundwater exploration.
Flood related disasters concerned to urban flooding in bangalore, indiaeSAT Publishing House
1. The document discusses urban flooding in Bangalore, India. It describes how factors like heavy rainfall, population growth, and improper land use have contributed to increased flooding in the city.
2. Flooding events in 2013 are analyzed in detail. A November rainfall caused runoff six times higher than the drainage capacity, inundating low-lying residential areas.
3. Impacts of urban flooding include disrupted daily life, damaged infrastructure, and decreased economic activity in affected areas. The document calls for improved flood management strategies to better mitigate urban flooding risks in Bangalore.
Enhancing post disaster recovery by optimal infrastructure capacity buildingeSAT Publishing House
This document discusses enhancing post-disaster recovery through optimal infrastructure capacity building. It presents a model to minimize the cost of meeting demand using auxiliary capacities when disaster damages infrastructure. The model uses genetic algorithms to select optimal capacity combinations. The document reviews how infrastructure provides vital services supporting recovery activities and discusses classifying infrastructure into six types. When disaster reduces infrastructure services, a gap forms between community demands and available support, hindering recovery. The proposed research aims to identify this gap and optimize capacity selection to fill it cost-effectively.
Effect of lintel and lintel band on the global performance of reinforced conc...eSAT Publishing House
This document analyzes the effect of lintels and lintel bands on the seismic performance of reinforced concrete masonry infilled frames through non-linear static pushover analysis. Four frame models are considered: a frame with a full masonry infill wall; a frame with a central opening but no lintel/band; a frame with a lintel above the opening; and a frame with a lintel band above the opening. The results show that the full infill wall model has 27% higher stiffness and 32% higher strength than the model with just an opening. Models with lintels or lintel bands have slightly higher strength and stiffness than the model with just an opening. The document concludes lintels and lintel
Wind damage to trees in the gitam university campus at visakhapatnam by cyclo...eSAT Publishing House
1) A cyclone with wind speeds of 175-200 kph caused massive damage to the green cover of Gitam University campus in Visakhapatnam, India. Thousands of trees were uprooted or damaged.
2) A study assessed different types of damage to trees from the cyclone, including defoliation, salt spray damage, damage to stems/branches, and uprooting. Certain tree species were more vulnerable than others.
3) The results of the study can help in selecting more wind-resistant tree species for future planting and reducing damage from future storms.
Wind damage to buildings, infrastrucuture and landscape elements along the be...eSAT Publishing House
1) A visual study was conducted to assess wind damage from Cyclone Hudhud along the 27km Visakha-Bheemli Beach road in Visakhapatnam, India.
2) Residential and commercial buildings suffered extensive roof damage, while glass facades on hotels and restaurants were shattered. Infrastructure like electricity poles and bus shelters were destroyed.
3) Landscape elements faced damage, including collapsed trees that damaged pavements, and debris in parks. The cyclone wiped out over half the city's green cover and caused beach erosion around protected areas.
1) The document reviews factors that influence the shear strength of reinforced concrete deep beams, including compressive strength of concrete, percentage of tension reinforcement, vertical and horizontal web reinforcement, aggregate interlock, shear span-to-depth ratio, loading distribution, side cover, and beam depth.
2) It finds that compressive strength of concrete, tension reinforcement percentage, and web reinforcement all increase shear strength, while shear strength decreases as shear span-to-depth ratio increases.
3) The distribution and amount of vertical and horizontal web reinforcement also affects shear strength, but closely spaced stirrups do not necessarily enhance capacity or performance.
Role of voluntary teams of professional engineers in dissater management – ex...eSAT Publishing House
1) A team of 17 professional engineers from various disciplines called the "Griha Seva" team volunteered after the 2001 Gujarat earthquake to provide technical assistance.
2) The team conducted site visits, assessments, testing and recommended retrofitting strategies for damaged structures in Bhuj and Ahmedabad. They were able to fully assess and retrofit 20 buildings in Ahmedabad.
3) Factors observed that exacerbated the earthquake's impacts included unplanned construction, non-engineered buildings, improper prior retrofitting, and defective materials and workmanship. The professional engineers' technical expertise was crucial for effective post-disaster management.
This document discusses risk analysis and environmental hazard management. It begins by defining risk, hazard, and toxicity. It then outlines the steps involved in hazard identification, including HAZID, HAZOP, and HAZAN. The document presents a case study of a hypothetical gas collecting station, identifying potential accidents and hazards. It discusses quantitative and qualitative approaches to risk analysis, including calculating a fire and explosion index. The document concludes by discussing hazard management strategies like preventative measures, control measures, fire protection, relief operations, and the importance of training personnel on safety.
Review study on performance of seismically tested repaired shear wallseSAT Publishing House
This document summarizes research on the performance of reinforced concrete shear walls that have been repaired after damage. It begins with an introduction to shear walls and their failure modes. The literature review then discusses the behavior of original shear walls as well as different repair techniques tested by other researchers, including conventional repair with new concrete, jacketing with steel plates or concrete, and use of fiber reinforced polymers. The document focuses on evaluating the strength retention of shear walls after being repaired with various methods.
Monitoring and assessment of air quality with reference to dust particles (pm...eSAT Publishing House
This document summarizes a study on monitoring and assessing air quality with respect to dust particles (PM10 and PM2.5) in the urban environment of Visakhapatnam, India. Sampling was conducted in residential, commercial, and industrial areas from October 2013 to August 2014. The average PM2.5 and PM10 concentrations were within limits in residential areas but moderate to high in commercial and industrial areas. Exceedance factor levels indicated moderate pollution for residential areas and moderate to high pollution for commercial and industrial areas. There is a need for management measures like improved public transport and green spaces to combat particulate air pollution in the study areas.
Low cost wireless sensor networks and smartphone applications for disaster ma...eSAT Publishing House
This document describes a low-cost wireless sensor network and smartphone application system for disaster management. The system uses an Arduino-based wireless sensor network comprising nodes with various sensors to monitor the environment. The sensor data is transmitted to a central gateway and then to the cloud for analysis. A smartphone app connected to the cloud can detect disasters from the sensor data and send real-time alerts to users to help with early evacuation. The system aims to provide low-cost localized disaster detection and warnings to improve safety.
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A NEW TECHNIQUE - NEAR MINIMUM MATERIAL ZONE, TO
REDUCE THE WEIGHT OF THE COMPONENTS IN MACHINING
Ganesh Kumar N1
, Selvaraj P2
, Radhakrishnan P3
1
Assistant Professor (SG), Department of Mechanical Engg., PSG College of Technology, India, gkncbe@yahoo.com
2
Group Director, CAD & PLM-PM, ADA, selvaraj.pon@gmail.com
3
Director, PSGIAS, rkp_n@yahoo.com
Abstract
Customers buy a product when the quality of the product is high. So manufacturers produce their components to high quality. The
product such as aircraft, automobile, motorcycle, etc. not only need to be produced at high quality but also at reduced weight. This is
because these products performance is depend on weight of the product. A component could consist of several components. So all
relevant component weights are reduced, then the overall weight of the component could be reduced. This paper introduces as new
technique called "near minimum material zone" where not only the weight of the component could be reduced but also helps to increase
the quality. To demonstrate this technique, two sets of experiments with 20 samples were conducted using Deckel Maho CTX310 ECO
VI CNC machine. The first experiment was conducted under normal machining condition. The second experiment was conducted under
this new technique. Several tools such as process capability analysis (Cp, Cpk), cause and effect diagram, X Hi/Lo and R-charts were
used to analyze the case study data. The paper outcome suggests that this new technique not only helped to control the weight of the
components but also improved the desired quality by minimizing the dispersion of the component dimensions to obtain higher sigma
level.
Keywords: Near Minimum Material Zone, Process Capability, Cpk, Cause and Effect diagram, X Hi/Lo chart, R chart,
Quality.
-----------------------------------------------------------------------***-----------------------------------------------------------------------
1. INTRODUCTION
In recent years, global competition has changed the
fundamental requirements in defining a quality in
manufacturing industry. The customers dedicates the product
sales, which is directly related to product quality. Therefore, to
sustain the product sales, manufacturers are forced to produce
a high quality products. Traditionally, when a component is
machined and the dimensions falls within the tolerance band
(upper control limit and lower control limit), then that part is
said to be good quality product (black dots in Figure 1).
However, due to high competitions, manufacturers are force to
produce their products closer to the targeted mean (blue
triangle in Figure 1). Taguchi [1] point out that keeping the
part process variability close to the target values requires
continuous monitoring and adjustments to the manufacturing
processes during the production cycle.
In this paper, a new technique called "near minimum material
zone" was introduced to demonstrate how the component
targeted dimension could be moved closer to target mean by
shifting the means. The outcome of this technique is it helps to
reduce the weight of the component and able to machine the
components at higher quality levels. This technique could be
applied to any industry, where the weight of the component
should be reduce and at the same time, the quality of the
product should be improved.
Fig.1. Process variations under normal and "near minimum
material zone" conditions
Aircraft is made of several components such as ribs, spars,
brackets, etc. The rib is the chord-wise member of the wing
structure of an aircraft, which used to give the wing section its
form and to transmit the load from the fabric to the spars. By,
analogy with the anatomical definition of a “rib” is that the
ribs attach to the main spars, and by being repeated at frequent
intervals, from a skeletal shape for the wing. Usually, the ribs
incorporate the airfoil shape of the wing, and the skin
(composite materials) adopts over the ribs. Figure 2 shows the
jack rib component of a aircraft wing.
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Fig 2 Aerospace rib component
Similarly, this technique could be applied to automobile and
motorcycle industry, where the weight of the components
needs to be reduced. Figure 3 and 4 illustrates some of the
automobile and motorcycle components.
Fig 3. Automobile components.
Fig 4. Motorcycle components.
Aluminum alloys are widely used metal in many aircraft,
automobile and motorcycle structural components. The
reasons for this selection are its low cost, light-weight, and
modern appearance. Most of these structural components have
complex geometry and they need to be machined with high
precision and dimensional accuracy. Currently, CNC machine
tools are used to machine these components. Despite this, with
the current technology, achieving this geometric dimensional
accuracy on consistent basis is a difficult task. In addition,
achieving this dimensional accuracy on machining the same
component (assume that the component is lengthier)
throughout the complete machining cycle is also difficult.
The component process variability could be occurring due to
two main factors: deterministic and randomization. The
deterministic factors such as spindle speed, feed, depth of cut,
etc. are the ones which could be predicted easily and it can be
controlled. However, the randomization factors such as
thermal gradients, vibrations, etc. are unpredictable and it is
very difficult to control. The randomization factors cannot be
eliminated completely, but could be minimized. Automation is
one method, which could aid to minimize this gap. Siemens
[2] suggest that automation helps to increase the quality of
manufacturing process and reduce investment costs by 20%.
2. BACKGROUND
The final product (for example, aircraft, automobile,
motorcycle) is composed of one or more sub-components. The
weight of each sub-component contributes the overall weight
of the final product. Therefore, it is very importance to control
the weight of the each component. The weight of the aircraft
impact the flying ability such as longer take-off distance,
shorter range, higher stalling, higher landing speed, reduced
rate and angle of climb, reduced cruising speed, longer landing
distance and higher take-off speed [3][4]. Similarly, reducing
the weight of the components save fuel costs [3][5][6][8].
Reducing the weight of each component even by small
percentage shall contribute the overall performance of a
system. Kaw [5] reported that reducing 0.453 kg of mass in a
commercial aircraft saves up to 1360 liters of fuel each year.
This paper reveals the new technique called "near minimum
material zone" to control the weight of the components and
able to machine the components within the tolerance band
with desired quality level.
For the past twenty two years, process capability analysis was
and being used as one of the tools in statistics process control
(SPC) for continuous improvement in quality and productivity.
It helps to determine whether the parts are within the tolerance
limits and engineering specifications [10]. The process
capability index (PCI) is used to measure the capability of a
process are Cp, Cpk, [15]. Cp is widely used by the industry to
check the capability of production process [11]. It does not
deal with cases where process mean is not centered [13]. This
drawback is overcome by Cpk. The Equations (1) to (7)
depicts the Cp and Cpk formulas.
Cp =
σ
----------- (1)
2-sided Specification Limits:
Cpk = Minimum [Cpku , Cpkl ] ----------- (2)
Cpku =
μ
σ
----------- (3)
Cpkl =
μ
σ
----------- (4)
1-sided Specification Limits:
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Cpk = Cpk(max) or Cpk(min) ----------- (5)
Cpk (max) =
μ )
σ
----------- (6)
Cpk (min) =
( μ )
σ
----------- (7)
A process is said to be a centred distribution or process when
Cp = Cpk, otherwise it is said to be a not-centred distribution
or process. Winton [16] clearly illustrated that the process
capability (Cpk) gradually reduces (even goes to a negative
value) when the mean is shifted while the variation (Cp and σ)
remains the same.
3. A NEW TECHNIQUE - NEAR MINIMUM
MATERIAL ZONE
A new technique called "near minimum material zone" was
introduced to control the material zone and at the same time,
the desired quality output would be achieved. To explain this
concept, an aerospace component was taken as an example
and it was machined using "near minimum materials zone"
technique, where the weight of the component was reduced
and at the same time, the quality of the component was
improved. For a given machining condition, there could be
two machining scenarios: (a) what strategy to use when
machining the inner dimension of the component; (b) what
strategy to use when machining the outer dimension of the
component.
3.1 Scenario 1
Machining the inner dimensions of a component (ex. hole of a
component) For this, machine the component to the upper
limit of the control chart. This is illustrated in Figure 5.
Fig.5. “Near minimum material zone” condition for inner
dimension.
3.2 Scenario 2
Machining the outer dimensions of a component (ex. shaft)
For this, machine the component to the lower limit of the
control limit, which is illustrated in Figure 6.
Fig.6. Near minimum material zone requirement for outside
dimension.
In both the scenarios, the desired outcome was to minimize the
dispersion of component dimension (reduced sigma spread).
From Figures 2 and 3, it was clear that the target mean was
shifted closer to the desired UCL or LCL. In other words,
when machining an outer dimension of the component, shift
the target mean closer to LCL. Similarly, when machining an
inner dimension of the component, shift the targeted mean
closer to UCL. When the process capability study was
conducted under both scenarios, the Cp and Cpk values may
be very low or even negative. This is because the Cp and Cpk
equations (Equations 1 to 7) were calculated under normal
condition, where targeted mean (μ) was not shifted.
When near minimum material zone condition was applied,
then targeted mean (μ) was shifted based on the above
scenarios. Therefore, the Cp and Cpk formulas were modified,
which were depicted in Equations 8 to 10.
Cp(m) =
( ( ) ( ) )
( σ (σ) )
--- (8)
Cpku (m) =
–( ) ( μ (μ) )
( σ (σ) )
--- (9)
Cpkl (m) =
μ –(μ) ( ( ) )
( σ (σ) )
--- (10)
The process flow chart of a machining process is depicted in
Figure 7.
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Fig 7. Process flow chart of a machining process.
4. EXPERIMENTS
A simple experiment was conducted to machine a raw work
piece diameter of 24 mm in Deckel Maho CTX310 ECO VI
CNC Lathe. The work piece was machined to 20 mm diameter
with h6 (+0.037 and +0.059) tolerance specifications. The
brand new carbide tool tip - ZCC 120408 and ZCC 120404
were used for rough and finish machining respectively.
According to vendor specifications and PSG data book [24],
the spindle speed was set at 1300 rpm and 3000 rpm for rough
and finish cut respectively. Similarly, the feed rate was set at
0.2 mm/rev and 0.11 mm/rev for rough and finish cut
respectively. The depth of cut was set to 0.4 for finish cut. The
same operator was engaged throughout the study. The NC
codes were programmed with targeted mean (20.048) and 20
work piece (samples) were machined. For each sample, five
data points were measured. Thus, 100 data points were
collected. Table 1 illustrates the sample data collection.
The collected sample data was verified against the normally
distributed population (within tolerance spread) using
normality test. Minitab was used to analyze the data. Figure 8
illustrates the normality test result for the collected sample.
Table 1 Sample data collection of the experiment #1
Sa
mpl
e
Measured data points
P1 P2 P3 P4 P5
1 20.047 20.046 20.046 20.046 20.046
2 20.042 20.044 20.042 20.046 20.046
3 20.044 20.041 20.042 20.043 20.042
4 20.045 20.043 20.045 20.041 20.044
5 20.046 20.045 20.046 20.047 20.046
6 20.049 20.043 20.042 20.044 20.043
7 20.047 20.048 20.048 20.046 20.046
8 20.046 20.050 20.047 20.048 20.047
9 20.045 20.044 20.044 20.046 20.045
10 20.043 20.044 20.049 20.046 20.044
Fig 8. Normality test of the sample data.
The mean of the sample data was 20.05 and the standard
deviation was 0.002344. Using a significance level of 0.05, the
Anderson-Darling normality test (P-value = 0.01) indicates
that the dimensions measured do not follow a normal
distribution. In other words, the null hypothesis test is rejected.
Figure 9 illustrates the distribution and variation of process
dataset, in histogram graph. This helps to identify which
dataset was closer to UCL and LCL. Thus, appropriate actions
could be taken in improve phase of the lean six sigma
roadmap.
Fig.9 Histogram of the sample data.
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4.1 Process Capability Study
The process capability study was an excellent method for
determining the rate of failure and stability on measurable
processes. The higher the Cpk, the more stable the process.
Figure 10 illustrates the process capability study of the
collected sample data.
Fig 10. Process capability study of the sample data.
The Cp and Cpk for the given study was 1.57 and 1.23
respectively. It was important to note that the Cpk value was
more than one. This tells that the variation in the process is
good. In addition, Cp value was close to Cpk value; therefore,
the quality of the process was also good.
4.2 X-Bar Hi/Lo and R-Charts Analysis
Doering [25] describe true distribution for precision
machining shall be continuous uniform or rectangular
distribution. He suggested X-bar Hi/Lo and R chart would be
appropriate for precision machining applications. The X-bar
Hi/Lo chart shows the relationship between high and low
values, whereas the R-chart study shows the closeness of the
readings. In other words, it represents the roundness of the
data collection. Doering suggested that when the roundness
value falls within 10%, then the machining is considered as
precision machining. The capability of the process could be
calculated as below:
Capability =
)
( )
--- (11)
Figure 11 illustrates the X-bar Hi/Lo and R- charts for the
normal condition. The upper specification limit and lower
specification limit (tolerance band) was set at 20.059 and
20.037 respectively (representing the green dotted line in
Figure 11). The upper control limit and lower control limit was
set at 75% of the tolerance (20.056 and 20.040), representing
the blue dashed line in Figure 11. The roundness (range limit)
was calculated as 0.022 mm.
From the Figure 11, it was noted that all the data collected
were within 75% of the control limit. The above values are
plugged into equation 11, which leads to 1.375.
Capability =
( . . )
( . . )
= 1.375
It was interesting to note that R-chart tolerance falls within
15%, which means some variations exists during machining.
This led to cause and effect analysis, which is covered in next
section.
The second set of experiment was conducted to demonstrate
the “near minimum material zone” technique. In this, the
factors such as operator negligence, tools were gauged, use of
old tool, etc. (listed in Figure 12) were controlled. It was
assumed that factors such as temperature, humidity, etc. do not
impact the study.
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Fig 11. X-bar Hi/Lo and R-charts for Normal condition
Fig 12. Cause and effect diagram to determine the factors affecting the weight control of the compoent.
The case study which was considered was to machine on the
outside of the component. Therefore, scenario 2 was
considered. In this scenario, the targeted mean (μ) was shifted
closer to the lower control limit.
Similar experiments were carried out but with a shifted
targeted mean (20.041). The speed, feed and depth of cut were
used as similar to the previous experiments. The same operator
machined was engaged in this experiments as well. The NC
program was created based on the above specifications and
new 20 work piece samples were machined. For each sample,
again five data points were measured. Thus, 100 more data
points were collected, which was similar to Table 1.
The capability formula (equation 11) may not work for this
“near minimum material zone” condition because of shifted
20.025
20.030
20.035
20.040
20.045
20.050
20.055
20.060
20.065
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
0.000
0.050
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
quality (Y)
with desired
component
aircraft
controlled
Weight
Cutting Tools
Environment
Measurements
Methods
Material
Machines
Personnel
Inexperience (X26)
Fatigue (X25)
Lack of training (X24)
Improper cleaning (X20)
Improper jaws (X19)
Vibration (X18)
Chuck alignment (X17)
Thickness (X16)
Width (X15)
Length (X14)
Hardness (X13)
Composition (X12)
measuring equip. (X33)
Improper use of
equipment (X32)
Damage measuring
Improper gauge (X31)
(X30)
No standard procedure
Improper planning (X29)
Lack of preparation (X28)
Shared gauge (X27)
Cutting force (X7)
Coolant age (X6)
(X5)
Coolant pressure
Coolant type (X4)
Depth of cut (X3)
Feed rate (X2)
Spindle speed (X1)
Ambient (X23)
Temperature (X22)
Humudity (X21)
Tool offset (X11)
Tool wear (X10)
(X9)
Tool geometry
Tool material (X8)
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targeted mean. Therefore, the process capability formula was
modified to this condition:
(Capability)m=
–
–
-- (12)
For this new condition, the upper specification limit and
lower specification limit (tolerance band) was set at 20.045
and 20.037 respectively (representing the light green dashed
line in Figure 13). The upper control limit and lower control
limit was set at 75% of the tolerance (20.044 and 20.038),
representing the red dotted line in Figure 13. The roundness
(range limit) was calculated as 0.008 mm.
Fig 13. X-bar Hi/Lo and R-charts with “near minimum material zone” condition.
From the Figure 13, it was noted that still all the data collected
were within 75% of the control limit. The above values are
plugged into equation 12, which leads to 1.411.
(Capability)m =
. . – . .
. . – . .
= 1.411
It was interesting to note that R-chart tolerance falls within
10%, which means the machining was performed well.
Table 2 illustrates the comparison of parameters between
normal and “near minimum material zone” conditions.
Table 2. X-bar Hi/Lo and R-chart specifications for Normal
and "near minimum material zone" conditions.
Specification Limits Normal Shifted
Upper Spec Limit 20.059 20.045
Lower SpecLimit 20.037 20.037
Control Limits
Upper Control Limit 20.056 20.044
Lower Control Limit 20.040 20.038
Range limit 0.022 0.008
Capability
Relative Index 1.375 1.411
CONCLUSIONS
The new technique called “near minimum material zone” was
introduced in this paper. To prove this concept, an application
was chosen. With this technique, it was demonstrated that the
weight of the component (in this case study - aerospace
component) in machining could be reduced and this technique
also aided to improve the quality of the component. For, this
two sets of experiments were carried out The first experiment
was to machine the components using normal methodology.
Process capability study, cause and effect diagram, X-bar
Hi/Lo R-charts etc. were used for data analysis. The Cpk value
for normal condition was determined. The second experiment
was conducted using “near minimum material zone”
technique. Identical setups were arranged and the data were
analyzed. The Cpk value for "near minimum material zone"
technique was also determined. The findings of this paper was
that the weight of the components were reduced and the
quality of the machining was improved significantly (see
Table 2).
REFERENCES
[1]. G. Taguchi, E. A. Elsayed and T. H. Siang, 1989, Quality
Engineering in Production Systems, McGraw-Hill
International Editions, Engineering Series Siemens. 2011.
Non-stop Manufacturing Excellence—Automotive: Answers
20.025
20.030
20.035
20.040
20.045
20.050
20.055
20.060
20.065
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
0.000
0.020
0.040
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
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for industry, Siemens website:
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BIOGRAPHIES:
Ganesh Kumar N – Currently, the author is working as
Assistant Professor (SG) in Mechanical Engineering
department, PSG College of Technology, Coimbatore, India.
He is pursuing his PhD in Automation and Robotics in Anna
University (India) under the guidance of Dr P Radhakrishnan.
The author has completed three Master's degree from United
States and has fifteen years of manufacturing plant floor
experiences in Automobile industry in United States.
Selvaraj P – Currently, the author is working as Group
Director of CAD & PLM-PM, Aeronautical Development
Agency (ADA), Bangalore, India. He worked in various
department of ADA since 1987. He received his Doctoral from
VIT University, India in 2009. He has more than 10
publications in various Journals and Conferences.
Radhakrishnan P – Currently, the author is working as
Director of PSG Institute of Advanced Studies, Coimbatore,
India. He is also working as visiting Professor in Mechanical
Engineering department, PSG College of Technology,
Coimbatore, India. Prior to this, he worked as Vice Chancellor
of VIT, Principal of PSG College of Technology, India and
Professor of PSG College of Technology, India. He is working
in teaching field for more than 30 years and has more than 50
publications in International Journals and International
Conferences.