Abstract Casting defects is one and the only limitation in any casting process. Sand casting process too suffers from the same problem. Finding out the optimum condition towards acquiring minimum casting defects is very critical. The normal method that most of the companies use is the trial and error method. But due to limitations like error prone results, expensive and time consuming, this method causes too much cost to company. In this paper, an attempt has been made to minimize the casting defects by optimizing the process parameters of sand casting defect using Artificial Neural Network (ANN). The Toolbox of the MATLAB software is used to run the different values of the parameters. Parameters are selected on the basis of survey from different industry and a rigorous research of the previous paper on this topic. Before that a program was prepared in MATLAB to generate the values of different parameter by using their highest and smallest values which has been collected from a local casting industry. In our first attempt to optimize the sand casting process parameters, it is found that if we consider randomly both input and output just by considering their limits the results are satisfactory just up to a limit. And it changes if the parameters are being changed. For specific conditions the result is found to be 3.175 as casting defect. Later on a new type of program is generated based on the relation of sand casting parameters and sand casting defects. Three specific casting defects are considered called, Expansion Defect, Gas Defect, Weak sand Defect. At last, their results are found to be Expansion defect: 6.23%, Gas Defect: 7.28%, Weak Sand Defect: 5.74%. Keywords: Sand casting, Artificial Neural Network (ANN), MATLAB, Casting Defect
The purpose of this paper is to perform a structural optimization of a flat thermoplastic plate (tile). This task is developed computationally through the interface between an optimization algorithm and the finite element method with the goal of minimizing the equivalent stress with specified target stress of 2 MPa when applied with a load intensity of 1000N. A 300 x 300 x 20 mm thermoplastic plate was selected for the optimization, which was performed with a tool in MATLAB R2012b known as genetic algorithm accompanied with static analysis in ANSYS 15. The results produced the optimum equivalent stress (δopt) of 2.136 MPa with the optimum dimensions of 305 x 302 x 20 mm. Also, the dimensions of the plate with the optimum value of the equivalent stress were discovered to be within the lower and upper bound dimensions of the plate. The thermoplastic plate object of the optimization was a square plate of 300 x 300mm, and 20 mm thick with isotropic properties and a particular load and boundary conditions were applied on the entire plate.
ARTIFICIAL NEURAL NETWORK MODELING AND OPTIMIZATION IN HONING PROCESSIAEME Publication
Determination of process parameters and maximum utility of the resources are the two main concerns while designing the manufacturing process for the products. The process parameters affect the final product shape and aesthetic look; whereas the utility refers to the output. The present study is devoted to the development of ANN models for the analysis of the honing process applied to an actual industrial component, namely the connecting rod of a motor bike. The surface quality of the honed components is measured with the help of a Talysurf Intra machine.
This document reviews the direct metal deposition (DMD) process and the effects of various process parameters on the geometrical characteristics of parts produced. It discusses how the laser power, beam diameter, scanning speed, powder flow rate, and other parameters influence characteristics like clad height, width, roughness, and dilution. Several studies that developed models and experiments to relate parameters to outcomes are summarized. In general, increasing laser power or powder flow rate tends to increase clad height while increasing scanning speed decreases height. Process maps and models have been created but further research is still needed to better understand and control the complex interactions in the DMD process.
CFD SIMULATION OF SOLDER PASTE FLOW AND DEFORMATION BEHAVIOURS DURING STENCIL...ijmech
In 20th century, Electronics elements have become most significant part of the regular life. The main heart
of electronic element is PCB which supports and manages mostly machines and equipments these days.
Therefore manufacturing of board and assembly of electronic elements is one of the crucial and significant
objectives for most of the companies. Better life of PCB’s depends on electronic elements and its assembly
with board. Solder paste is used as adhesive material for assembly purpose. It is deposited on board using
stencil and electronic elements are mounted on it and heated for strong bond.
This study investigates on factors affecting stencil printing process due to variation in squeegee speed and
density of solder paste. This study is based on computational fluid dynamics virtual simulation. Prototype is
developed for modelling purpose and simulation software is used to simulate the flow behaviour of solder
paste during stencil printing process.
Analysis of Serial Pinned Joints in Composite Materialsijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
A Comparison of Optimization Methods in Cutting Parameters Using Non-dominate...Waqas Tariq
Since cutting conditions have an influence on reducing the production cost and time and deciding the quality of a final product the determination of optimal cutting parameters such as cutting speed, feed rate, depth of cut and tool geometry is one of vital modules in process planning of metal parts. With use of experimental results and subsequently, with exploitation of main effects plot, importance of each parameter is studied. In this investigation these parameters was considered as input in order to optimized the surface finish and tool life criteria, two conflicting objectives, as the process performance simultaneously. In this study, micro genetic algorithm (MGA) and Non-dominated Sorting Genetic Algorithm (NSGA-II) were compared with each other proving the superiority of Non-dominated Sorting Genetic Algorithm over micro genetic since Non-dominated Sorting Genetic Algorithm results were more satisfactory than micro genetic algorithm in terms of optimizing machining parameters.
Application of knowledge engineering and computational intelligence for struc...IAEME Publication
This document describes the development of a knowledge-based expert system for structural topology optimization of forging dies for connecting rods. It establishes an analytical algorithm and methodology based on mechanics, physics, and metallurgy. Computational intelligence techniques including 3D modeling, geometry recognition, and finite element analysis are used within an inference engine to predict optimal forging process parameters and die design. Validation is provided through a case study comparing analytical and finite element analysis results for a connecting rod die, showing good agreement between the two methods.
Analyze Gear Failures and Identify Defects in Gear System for Vehicles Using ...IOSR Journals
This document summarizes a research paper that analyzes gear failures and identifies defects in gear systems for vehicles using digital image processing. The paper proposes a gear defect recognition system that uses computer vision and local thresholding techniques to identify possible defects in gears. The recognizer processes digital images of gears, applies restoration and thresholding techniques to generate binary images, counts the number of teeth to determine if it matches expected specifications, and can identify defective areas. Experimental results on plastic gear images demonstrate the system's ability to detect defects like differences in tooth counts and surface blemishes. The paper concludes that future work could apply machine learning to make defect detection more robust and accurate over time.
The purpose of this paper is to perform a structural optimization of a flat thermoplastic plate (tile). This task is developed computationally through the interface between an optimization algorithm and the finite element method with the goal of minimizing the equivalent stress with specified target stress of 2 MPa when applied with a load intensity of 1000N. A 300 x 300 x 20 mm thermoplastic plate was selected for the optimization, which was performed with a tool in MATLAB R2012b known as genetic algorithm accompanied with static analysis in ANSYS 15. The results produced the optimum equivalent stress (δopt) of 2.136 MPa with the optimum dimensions of 305 x 302 x 20 mm. Also, the dimensions of the plate with the optimum value of the equivalent stress were discovered to be within the lower and upper bound dimensions of the plate. The thermoplastic plate object of the optimization was a square plate of 300 x 300mm, and 20 mm thick with isotropic properties and a particular load and boundary conditions were applied on the entire plate.
ARTIFICIAL NEURAL NETWORK MODELING AND OPTIMIZATION IN HONING PROCESSIAEME Publication
Determination of process parameters and maximum utility of the resources are the two main concerns while designing the manufacturing process for the products. The process parameters affect the final product shape and aesthetic look; whereas the utility refers to the output. The present study is devoted to the development of ANN models for the analysis of the honing process applied to an actual industrial component, namely the connecting rod of a motor bike. The surface quality of the honed components is measured with the help of a Talysurf Intra machine.
This document reviews the direct metal deposition (DMD) process and the effects of various process parameters on the geometrical characteristics of parts produced. It discusses how the laser power, beam diameter, scanning speed, powder flow rate, and other parameters influence characteristics like clad height, width, roughness, and dilution. Several studies that developed models and experiments to relate parameters to outcomes are summarized. In general, increasing laser power or powder flow rate tends to increase clad height while increasing scanning speed decreases height. Process maps and models have been created but further research is still needed to better understand and control the complex interactions in the DMD process.
CFD SIMULATION OF SOLDER PASTE FLOW AND DEFORMATION BEHAVIOURS DURING STENCIL...ijmech
In 20th century, Electronics elements have become most significant part of the regular life. The main heart
of electronic element is PCB which supports and manages mostly machines and equipments these days.
Therefore manufacturing of board and assembly of electronic elements is one of the crucial and significant
objectives for most of the companies. Better life of PCB’s depends on electronic elements and its assembly
with board. Solder paste is used as adhesive material for assembly purpose. It is deposited on board using
stencil and electronic elements are mounted on it and heated for strong bond.
This study investigates on factors affecting stencil printing process due to variation in squeegee speed and
density of solder paste. This study is based on computational fluid dynamics virtual simulation. Prototype is
developed for modelling purpose and simulation software is used to simulate the flow behaviour of solder
paste during stencil printing process.
Analysis of Serial Pinned Joints in Composite Materialsijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
A Comparison of Optimization Methods in Cutting Parameters Using Non-dominate...Waqas Tariq
Since cutting conditions have an influence on reducing the production cost and time and deciding the quality of a final product the determination of optimal cutting parameters such as cutting speed, feed rate, depth of cut and tool geometry is one of vital modules in process planning of metal parts. With use of experimental results and subsequently, with exploitation of main effects plot, importance of each parameter is studied. In this investigation these parameters was considered as input in order to optimized the surface finish and tool life criteria, two conflicting objectives, as the process performance simultaneously. In this study, micro genetic algorithm (MGA) and Non-dominated Sorting Genetic Algorithm (NSGA-II) were compared with each other proving the superiority of Non-dominated Sorting Genetic Algorithm over micro genetic since Non-dominated Sorting Genetic Algorithm results were more satisfactory than micro genetic algorithm in terms of optimizing machining parameters.
Application of knowledge engineering and computational intelligence for struc...IAEME Publication
This document describes the development of a knowledge-based expert system for structural topology optimization of forging dies for connecting rods. It establishes an analytical algorithm and methodology based on mechanics, physics, and metallurgy. Computational intelligence techniques including 3D modeling, geometry recognition, and finite element analysis are used within an inference engine to predict optimal forging process parameters and die design. Validation is provided through a case study comparing analytical and finite element analysis results for a connecting rod die, showing good agreement between the two methods.
Analyze Gear Failures and Identify Defects in Gear System for Vehicles Using ...IOSR Journals
This document summarizes a research paper that analyzes gear failures and identifies defects in gear systems for vehicles using digital image processing. The paper proposes a gear defect recognition system that uses computer vision and local thresholding techniques to identify possible defects in gears. The recognizer processes digital images of gears, applies restoration and thresholding techniques to generate binary images, counts the number of teeth to determine if it matches expected specifications, and can identify defective areas. Experimental results on plastic gear images demonstrate the system's ability to detect defects like differences in tooth counts and surface blemishes. The paper concludes that future work could apply machine learning to make defect detection more robust and accurate over time.
Experimental & Numerical Analysis of Composites with DelaminationsIRJET Journal
This document summarizes research on analyzing the effect of delaminations on the vibration characteristics of composite materials. It presents both experimental and numerical (ANSYS) analysis of a composite beam with varying percentages of delamination (0-40%). The results show that natural frequency decreases with increasing delamination size, as delamination reduces structural stiffness. Experimentally measured natural frequencies closely matched those from numerical analysis. The research demonstrates that vibration testing can successfully detect internal delaminations and monitor damage in composite structures.
A Review on Finite Element Analysis of Automobile roof header Manufactured By...ijiert bestjournal
In stamping operations,sheet metal is formed into a desired s hape by pressing it in a hydraulic or mechanical press between suitably shaped dies. As a predominant manufacturing pr ocess,sheet metal forming has been widely used for the production of automobiles,aircraft,home appliance s,beverage cans and many other industrial and commercial products. Given that the press force itsel f is an integral of the contact pressure distribution over the die and binder contact interfaces,it is concei vable that defects may be better identified by analyzing the contact pressure distribution directly at the tooling-work piece interface.
Smart Prediction Of Surface Finishing Quality Of En-8 Work Piece By Ann ModelIJERA Editor
Turning is a material removal process a subtractive form of machining which is used to create parts of circular
or rotational form of desired geometry/shape by removing unwanted material. Accuracy of any process depends
on involvement of operational variables. The operating parameters that contribute to turning process are Cutting
speed, Depth of cut, Feed rate. Vibrations, tool life, tool wear, surface finish and cutting forces etc are also in
direct relation with values selected for process parameters. So to improve the efficiency of process and quality
of the product it is necessary to control the process parameters. We have considered surface roughness the
parameters with main focus as it dictates the aesthetics and sometimes ergonomical characteristics of the
product. In this work a neural network is created using feed forward back propagation technique for simulation
of the process using the Matlab Neural network toolbox. So with assurance of accuracy of the predictive
capabilities of the neural network it was then used for optimization.
A review paper on Optimization of process parameter of EDM for air hardening ...IJERA Editor
EDM is now more economical non convectional machining process. It is used widely used on small scale as well major industries. EDM process is affect by so many process parameter which are electrical and non electrical. In this project work the rotating tool is used to improve the Metal removal rate (MRR) and to observe its effect on surface finish. I am using Taguchi’s method as a design of experiments and response surface methodology for analysis and optimization. The machining parameters selected as a variables are pulse off time, pulse on time, servo voltage. The output measurement include MRR and surface roughness.
This document discusses the analysis of different process parameters on the properties of components manufactured using Fused Deposition Modeling (FDM). It aims to study the effect of road width, air gap, and build orientation (0°, 45°, 90°) on properties like accuracy, surface finish, and build time. Samples will be manufactured at different combinations of these parameters and tested to determine their properties, with results analyzed and presented graphically. Prior research has found orientation affects properties like surface quality, accuracy, build time and cost, so optimization of orientation is important for FDM.
Optimization of Force and Surface Roughness for Carbonized Steel in Turning P...IJERA Editor
This paper discusses the optimization of cutting parameters in turning processes using neural networks. The paper aims to determine optimal cutting speed, depth of cut, and feed rate to achieve maximum cutting force and minimum surface roughness. A neural network model is developed and trained using input cutting parameters and output responses of cutting force and surface roughness. The results found that neural networks can quickly converge on an optimal combination of cutting parameters. It was concluded that machining efficiency and process can be improved through optimization of cutting parameters using neural networks.
Investigation of mrr in wedm for wc co sintered compositeIAEME Publication
The document investigates the influence of wire electrical discharge machining (WEDM) parameters on material removal rate when machining tungsten carbide-cobalt (WC-Co) sintered composite. Experiments were conducted using a response surface methodology with five control factors (pulse on-time, pulse off-time, peak current, servo voltage, and wire tension). The results were used to derive a mathematical model to predict material removal rate and optimize the WEDM process for machining WC-Co composite.
Modeling of wedm process for complex shape using multilayer perceptron and re...eSAT Journals
Abstract
Wire cut electric discharge machining is the present days requirement in manufacturing the intricate and complex shape parts as required in the modern industrial products. The process being complex in nature for control over the machining process parameters. In the present study Multilayer perceptron (MLP) model is developed to predict the Material removal rate. The mathematical regression model is also developed by using Response Surface Methodology (RSM) to establish the relationshIp between the MRR and input process parameters like pulse on time (Ton), Pulse off time (Toff), Peak current (IP) and Servo voltage (SV). The predicted value by using MLP and RSM were compared with the experimental values. The average percentage errors are found to be 1.29 and -0.36527 for MLP and RSM respectively. It is observed that the predicted values with RSM are closer to experimental values as compared to MLP model. Key Words: WEDM, Response Surface Methodology, Neural Network, Multi Layer Perception, Material Removal Rate, Surface Roughness
REVIEW PAPER ON EFFECT OF PROCESS PARAMETERS OF ECDM ON RESPONSE VARIABLES ijiert bestjournal
Electrochemical discharge machining is a versatile machining process for micro drilling,micro texturi ng,and micro grooving of variety of glasses,ceramics and compos ites. Electrochemical discharge machining (ECDM),a lso known as spark assisted chemical engraving (SACE),is an effective micro-machining process for non-con ducting materials. It has high demand in Micro Electro Mech anical System (MEMS) applications. In this present review Paper,a study of the effective Parameters of ECDM has been carried out with their specific role in Ma terial removal;Surface Finish and Tool wear Rate. The eff ects of the electrolyte,the pulse on/off-time rati o,the voltage,the feed rate,the rotational speed,and the electr olyte concentration in the drilling and milling pro cesses were studied.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
Damage Detection based on the Natural Frequency shifting of a clamped rectang...Irfan Hilmy
Damage detection of any structure becomes the main concern in a failure analysis. Early failure detection is very important as it can prevent any catastrophic failure by replacing or repairing the damage part at early stage. One of the non-destructive methods of damage detection is using frequency based vibration analysis. Identification and comparison of a set of natural frequencies before and after damage is the main concern of this research. A rectangular plate clamped at all edges represented an initial undamaged structure. Based on Kachanov's definition, damage existence in a structure is introduced in the presence of some circular voids. The voids are generated randomly at different level of damage value. To obtain the Natural Frequencies, a Finite Element Model (FEM) of a clamped plate with the updated value of Young's Modulus is analyzed. From the FEM analysis result, it is found that the Natural Frequencies are shifted as the void existence increase. Using curve fitting, the model of Natural Frequency shifting as a function of damage evolution has been generated. It is found that the shifting of the Natural Frequency is greater at higher frequency value as indicated by the higher absolute gradient.
Predicting Resilient Modulus of Clayey Subgrade Soils by Means of Cone Penetr...Pouyan Fakharian
Resilient modulus (Mr) of subgrade soils is considered as one of the most important factors for designing flexible pavements using empirical methods as well as mechanistic-empirical methods. The resilient modulus is commonly measured by a dynamic triaxial loading test, which is complex and expensive. In this research, back-propagation artificial neural network method has been employed to model the resilient modulus of clayey subgrade soils based on the results of the cone penetration test. The prediction of the resilient modulus of clayey subgrade soil can be possible through the developed neural network based on the parameters of the cone tip resistance (qc), sleeve friction (fs), moisture content (w), and dry density (γd). The results of the present study show that the coefficients of determination (R2) for training and testing sets are 0.9837 and 0.9757, respectively. According to the sensitivity analysis results, the moisture content is the least important parameter to predict the resilient modulus of clayey subgrade soils, while the importance of other parameters is almost the same. In this study, the effect of different parameters on the resilient modulus of clayey subgrade soil was evaluated using parametric analysis and it was found that with increasing the cone tip resistance (qc), the sleeve friction (fs) and the dry density (γd) and also with decreasing the moisture content (w) of soils, the resilient modulus of clayey subgrade soils increases.
Waste concrete is one of the most usable and economic kind of concrete which is used in many civil projects all around the world, and its importance is undeniable. Also, the explanation of constructional process and destruction of them cause the extensive growth of irreversible waste to the industry cycle, which can be as one of the main damaging factors to the economy. In this investigation, with using of constructional waste included concrete waste, brick, ceramic and tile and stone new aggregate was made. Also it was used with different weight ratios of cement in the mix design. The results of laboratory studies showed that the using of the ratio of sand to cement 1 and waste aggregate with 20% weight ratio (W20), replacing of normal aggregate, increased the 28 days compressive strength to the maximum stage 45.23 MPa. In the next stage, in order to develop the experimental results backpropagation neural network was used. This network with about 91% regression, 0.24 error, and 1.41 seconds, is a proper method for estimating results.
This document summarizes a research paper on using finite element analysis software to predict the limiting draw ratio (LDR) for deep drawing processes. The paper describes using RADIOSS software to simulate deep drawing with varying blank diameters and analyze displacement, strain, and thinning. Simulations were run for SAE_J2340_CR_210A_Dent_Resist steel. The results showed safe, marginal, and failure conditions for different diameters. The simulated LDR value matched the analytical value within 16% deviation. Therefore, finite element analysis can accurately predict LDR and identify failure diameters, providing an alternative to experimental testing.
This document describes a study investigating the optimal processing parameters for injection molding two microfluidic chip models through simulations and experimental data. Model 1 is made of COC and Model 2 is made of ABS and PP. The study examines the influence of processing parameters like mold temperature, melt temperature, injection speed, packing pressure and time on the flatness error of the molded parts. Autodesk Moldflow Insight is used to simulate the injection molding process and calculate temperature distribution, shrinkage, warpage and pressure. GOM Inspect measures the flatness error from the simulated warpage. Minitab performs statistical analysis to compare the simulation and experimental results and determine the influence of different materials and parameters on flatness error.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
IRJET- Simulation and Analysis of Step Light Mid Part using Mold Flow AnalysisIRJET Journal
This document summarizes a study that used mold flow analysis and the Taguchi method to optimize the injection molding process parameters for a step light mid part. The researchers 3D modeled the part, performed meshing, and selected polycarbonate as the material. They identified four critical parameters (mold surface temperature, melt temperature, injection time, and V/P switch over) and used an L9 orthogonal array to design experiments varying the parameters at three levels. Nine experiments were conducted and analyzed for signal-to-noise ratios to determine the optimum parameters. Simulation results showed fill time, pressure distribution, velocity, and identified the optimum gate location. Comparing the simulation and experimental trial results validated the optimized parameters.
A study on influence of polarity on the machining characteristics of sinker edmIAEME Publication
1. The study examines the effect of polarity on material removal rate, electrode wear, and surface roughness in electrical discharge machining of stainless steel.
2. Experiments were conducted using straight and reverse polarity at various currents. Reverse polarity and higher currents produced higher material removal rates but lower surface quality.
3. Straight polarity produced lower material removal rates but better surface finish. The results indicate that polarity and current setting have significant effects and can be optimized based on priorities for material removal rate versus surface roughness.
This document discusses various types of blowholes that can occur in castings, including wet sand blowholes, surface blowholes, subsurface slag reaction blowholes, subsurface blowholes, mould or core gas blowholes, entrapped air blowholes, and chaplet blowholes. For each type of blowhole, the document describes possible causes and suggested remedies to prevent or reduce the occurrence of that specific blowhole type in castings. The document is intended to share information on casting defects in order to help those working in the casting industry address and remedy quality issues.
Process optimization of pressure die casting to eliminate defect using cae so...eSAT Journals
Abstract
Die Casting is the manufacturing process by which a liquid material is pressurized in to the mould, which contains a hallow
cavity of the desired shape, and then molten metal is allowed to solidify. The solidified part is known as casting which is ejected
or broken out to complete the process. Objective in this project is to develop tools, dies and gating system. Identify defects such as
gas defects, shrinkage cavities, and mould material defects, pouring material defects, metallurgical defects etc. and take measures
to reduce flaws by using CAE software. To reduce the amount airs entrapped in the mould by changing the gating system, runner
and overflow location and optimize the gating system and process parameters for best quality product and improved productivity.
Defects can be formed easily at critical location during pressure die casting of aluminium alloy part. It has defective effect on the
casting. Mould filling and solidification process of a part was simulated using Z-cast software.
Key Words: Casting, HPDC, Z-cast, CAE Software, Simulation.
This document discusses casting defects in aluminium bronze and enhancing its mechanical properties through heat treatment. It provides background on aluminium bronze, including its composition, properties, applications in foundry and wrought products, and casting techniques. It then outlines the objectives and plan of work, which are to study the effects of composition changes and heat treatment on reducing oxide formation from casting and improving mechanical properties. The document contains an index that lists the various topics that will be covered in the project report.
This document discusses sand casting and provides details on:
- The types of casting sand including green sand, water glass sand, and resin sand.
- The key properties of casting sand such as strength, permeability, grain size, thermal stability, and reusability.
- Common casting defects related to issues with the sand mold like sand blow, pinholes, and sand wash.
- How to test sand properties including measuring moisture content, clay content, and grain size distribution.
Experimental & Numerical Analysis of Composites with DelaminationsIRJET Journal
This document summarizes research on analyzing the effect of delaminations on the vibration characteristics of composite materials. It presents both experimental and numerical (ANSYS) analysis of a composite beam with varying percentages of delamination (0-40%). The results show that natural frequency decreases with increasing delamination size, as delamination reduces structural stiffness. Experimentally measured natural frequencies closely matched those from numerical analysis. The research demonstrates that vibration testing can successfully detect internal delaminations and monitor damage in composite structures.
A Review on Finite Element Analysis of Automobile roof header Manufactured By...ijiert bestjournal
In stamping operations,sheet metal is formed into a desired s hape by pressing it in a hydraulic or mechanical press between suitably shaped dies. As a predominant manufacturing pr ocess,sheet metal forming has been widely used for the production of automobiles,aircraft,home appliance s,beverage cans and many other industrial and commercial products. Given that the press force itsel f is an integral of the contact pressure distribution over the die and binder contact interfaces,it is concei vable that defects may be better identified by analyzing the contact pressure distribution directly at the tooling-work piece interface.
Smart Prediction Of Surface Finishing Quality Of En-8 Work Piece By Ann ModelIJERA Editor
Turning is a material removal process a subtractive form of machining which is used to create parts of circular
or rotational form of desired geometry/shape by removing unwanted material. Accuracy of any process depends
on involvement of operational variables. The operating parameters that contribute to turning process are Cutting
speed, Depth of cut, Feed rate. Vibrations, tool life, tool wear, surface finish and cutting forces etc are also in
direct relation with values selected for process parameters. So to improve the efficiency of process and quality
of the product it is necessary to control the process parameters. We have considered surface roughness the
parameters with main focus as it dictates the aesthetics and sometimes ergonomical characteristics of the
product. In this work a neural network is created using feed forward back propagation technique for simulation
of the process using the Matlab Neural network toolbox. So with assurance of accuracy of the predictive
capabilities of the neural network it was then used for optimization.
A review paper on Optimization of process parameter of EDM for air hardening ...IJERA Editor
EDM is now more economical non convectional machining process. It is used widely used on small scale as well major industries. EDM process is affect by so many process parameter which are electrical and non electrical. In this project work the rotating tool is used to improve the Metal removal rate (MRR) and to observe its effect on surface finish. I am using Taguchi’s method as a design of experiments and response surface methodology for analysis and optimization. The machining parameters selected as a variables are pulse off time, pulse on time, servo voltage. The output measurement include MRR and surface roughness.
This document discusses the analysis of different process parameters on the properties of components manufactured using Fused Deposition Modeling (FDM). It aims to study the effect of road width, air gap, and build orientation (0°, 45°, 90°) on properties like accuracy, surface finish, and build time. Samples will be manufactured at different combinations of these parameters and tested to determine their properties, with results analyzed and presented graphically. Prior research has found orientation affects properties like surface quality, accuracy, build time and cost, so optimization of orientation is important for FDM.
Optimization of Force and Surface Roughness for Carbonized Steel in Turning P...IJERA Editor
This paper discusses the optimization of cutting parameters in turning processes using neural networks. The paper aims to determine optimal cutting speed, depth of cut, and feed rate to achieve maximum cutting force and minimum surface roughness. A neural network model is developed and trained using input cutting parameters and output responses of cutting force and surface roughness. The results found that neural networks can quickly converge on an optimal combination of cutting parameters. It was concluded that machining efficiency and process can be improved through optimization of cutting parameters using neural networks.
Investigation of mrr in wedm for wc co sintered compositeIAEME Publication
The document investigates the influence of wire electrical discharge machining (WEDM) parameters on material removal rate when machining tungsten carbide-cobalt (WC-Co) sintered composite. Experiments were conducted using a response surface methodology with five control factors (pulse on-time, pulse off-time, peak current, servo voltage, and wire tension). The results were used to derive a mathematical model to predict material removal rate and optimize the WEDM process for machining WC-Co composite.
Modeling of wedm process for complex shape using multilayer perceptron and re...eSAT Journals
Abstract
Wire cut electric discharge machining is the present days requirement in manufacturing the intricate and complex shape parts as required in the modern industrial products. The process being complex in nature for control over the machining process parameters. In the present study Multilayer perceptron (MLP) model is developed to predict the Material removal rate. The mathematical regression model is also developed by using Response Surface Methodology (RSM) to establish the relationshIp between the MRR and input process parameters like pulse on time (Ton), Pulse off time (Toff), Peak current (IP) and Servo voltage (SV). The predicted value by using MLP and RSM were compared with the experimental values. The average percentage errors are found to be 1.29 and -0.36527 for MLP and RSM respectively. It is observed that the predicted values with RSM are closer to experimental values as compared to MLP model. Key Words: WEDM, Response Surface Methodology, Neural Network, Multi Layer Perception, Material Removal Rate, Surface Roughness
REVIEW PAPER ON EFFECT OF PROCESS PARAMETERS OF ECDM ON RESPONSE VARIABLES ijiert bestjournal
Electrochemical discharge machining is a versatile machining process for micro drilling,micro texturi ng,and micro grooving of variety of glasses,ceramics and compos ites. Electrochemical discharge machining (ECDM),a lso known as spark assisted chemical engraving (SACE),is an effective micro-machining process for non-con ducting materials. It has high demand in Micro Electro Mech anical System (MEMS) applications. In this present review Paper,a study of the effective Parameters of ECDM has been carried out with their specific role in Ma terial removal;Surface Finish and Tool wear Rate. The eff ects of the electrolyte,the pulse on/off-time rati o,the voltage,the feed rate,the rotational speed,and the electr olyte concentration in the drilling and milling pro cesses were studied.
Wire electrical discharge machining (WEDM) is a specialized thermal machining process
capable of accurately machining parts of hard materials with complex shapes. Response surface
methodology (RSM) with central composite design is selected for experimentation. In the present
work, four factors are taken as input parameters, and the effect of these parameters on MRR are
studied. The influence of the input parameters on response in WEDM process has been examined.
The input parameters are Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak
current (IP). The experiments have been performed on high chromium high carbon steel with a wire
of diameter 0.2 mm and the obtained data has been analyzed with the help of RSM using design
expert software. The work piece material was a high carbon high chromium (HCHCr) die steel with
excellent wear resistance, hot toughness and good thermal shock resistance. The experiments shows
that Pulse on time (Ton), Pulse off time (Toff), Servo voltage (SV) and peak current (IP) influence
MRR. Results show that machining speed increases with increase in the pulse on-time and the pulse
off-time increases as the number of discharges within given period of time decreases. Moreover,
there is not much influence of servo voltage on MRR and it increases very slightly with increase in
peak current. Also, as the Ton increases the MRR increases and as Toff increases MRR decreases.
This is because as Ton increases number of sparks per unit time increases and as Toff increases the
sparks per unit time decreases.
Damage Detection based on the Natural Frequency shifting of a clamped rectang...Irfan Hilmy
Damage detection of any structure becomes the main concern in a failure analysis. Early failure detection is very important as it can prevent any catastrophic failure by replacing or repairing the damage part at early stage. One of the non-destructive methods of damage detection is using frequency based vibration analysis. Identification and comparison of a set of natural frequencies before and after damage is the main concern of this research. A rectangular plate clamped at all edges represented an initial undamaged structure. Based on Kachanov's definition, damage existence in a structure is introduced in the presence of some circular voids. The voids are generated randomly at different level of damage value. To obtain the Natural Frequencies, a Finite Element Model (FEM) of a clamped plate with the updated value of Young's Modulus is analyzed. From the FEM analysis result, it is found that the Natural Frequencies are shifted as the void existence increase. Using curve fitting, the model of Natural Frequency shifting as a function of damage evolution has been generated. It is found that the shifting of the Natural Frequency is greater at higher frequency value as indicated by the higher absolute gradient.
Predicting Resilient Modulus of Clayey Subgrade Soils by Means of Cone Penetr...Pouyan Fakharian
Resilient modulus (Mr) of subgrade soils is considered as one of the most important factors for designing flexible pavements using empirical methods as well as mechanistic-empirical methods. The resilient modulus is commonly measured by a dynamic triaxial loading test, which is complex and expensive. In this research, back-propagation artificial neural network method has been employed to model the resilient modulus of clayey subgrade soils based on the results of the cone penetration test. The prediction of the resilient modulus of clayey subgrade soil can be possible through the developed neural network based on the parameters of the cone tip resistance (qc), sleeve friction (fs), moisture content (w), and dry density (γd). The results of the present study show that the coefficients of determination (R2) for training and testing sets are 0.9837 and 0.9757, respectively. According to the sensitivity analysis results, the moisture content is the least important parameter to predict the resilient modulus of clayey subgrade soils, while the importance of other parameters is almost the same. In this study, the effect of different parameters on the resilient modulus of clayey subgrade soil was evaluated using parametric analysis and it was found that with increasing the cone tip resistance (qc), the sleeve friction (fs) and the dry density (γd) and also with decreasing the moisture content (w) of soils, the resilient modulus of clayey subgrade soils increases.
Waste concrete is one of the most usable and economic kind of concrete which is used in many civil projects all around the world, and its importance is undeniable. Also, the explanation of constructional process and destruction of them cause the extensive growth of irreversible waste to the industry cycle, which can be as one of the main damaging factors to the economy. In this investigation, with using of constructional waste included concrete waste, brick, ceramic and tile and stone new aggregate was made. Also it was used with different weight ratios of cement in the mix design. The results of laboratory studies showed that the using of the ratio of sand to cement 1 and waste aggregate with 20% weight ratio (W20), replacing of normal aggregate, increased the 28 days compressive strength to the maximum stage 45.23 MPa. In the next stage, in order to develop the experimental results backpropagation neural network was used. This network with about 91% regression, 0.24 error, and 1.41 seconds, is a proper method for estimating results.
This document summarizes a research paper on using finite element analysis software to predict the limiting draw ratio (LDR) for deep drawing processes. The paper describes using RADIOSS software to simulate deep drawing with varying blank diameters and analyze displacement, strain, and thinning. Simulations were run for SAE_J2340_CR_210A_Dent_Resist steel. The results showed safe, marginal, and failure conditions for different diameters. The simulated LDR value matched the analytical value within 16% deviation. Therefore, finite element analysis can accurately predict LDR and identify failure diameters, providing an alternative to experimental testing.
This document describes a study investigating the optimal processing parameters for injection molding two microfluidic chip models through simulations and experimental data. Model 1 is made of COC and Model 2 is made of ABS and PP. The study examines the influence of processing parameters like mold temperature, melt temperature, injection speed, packing pressure and time on the flatness error of the molded parts. Autodesk Moldflow Insight is used to simulate the injection molding process and calculate temperature distribution, shrinkage, warpage and pressure. GOM Inspect measures the flatness error from the simulated warpage. Minitab performs statistical analysis to compare the simulation and experimental results and determine the influence of different materials and parameters on flatness error.
International Journal of Computational Engineering Research(IJCER)ijceronline
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity
IRJET- Simulation and Analysis of Step Light Mid Part using Mold Flow AnalysisIRJET Journal
This document summarizes a study that used mold flow analysis and the Taguchi method to optimize the injection molding process parameters for a step light mid part. The researchers 3D modeled the part, performed meshing, and selected polycarbonate as the material. They identified four critical parameters (mold surface temperature, melt temperature, injection time, and V/P switch over) and used an L9 orthogonal array to design experiments varying the parameters at three levels. Nine experiments were conducted and analyzed for signal-to-noise ratios to determine the optimum parameters. Simulation results showed fill time, pressure distribution, velocity, and identified the optimum gate location. Comparing the simulation and experimental trial results validated the optimized parameters.
A study on influence of polarity on the machining characteristics of sinker edmIAEME Publication
1. The study examines the effect of polarity on material removal rate, electrode wear, and surface roughness in electrical discharge machining of stainless steel.
2. Experiments were conducted using straight and reverse polarity at various currents. Reverse polarity and higher currents produced higher material removal rates but lower surface quality.
3. Straight polarity produced lower material removal rates but better surface finish. The results indicate that polarity and current setting have significant effects and can be optimized based on priorities for material removal rate versus surface roughness.
This document discusses various types of blowholes that can occur in castings, including wet sand blowholes, surface blowholes, subsurface slag reaction blowholes, subsurface blowholes, mould or core gas blowholes, entrapped air blowholes, and chaplet blowholes. For each type of blowhole, the document describes possible causes and suggested remedies to prevent or reduce the occurrence of that specific blowhole type in castings. The document is intended to share information on casting defects in order to help those working in the casting industry address and remedy quality issues.
Process optimization of pressure die casting to eliminate defect using cae so...eSAT Journals
Abstract
Die Casting is the manufacturing process by which a liquid material is pressurized in to the mould, which contains a hallow
cavity of the desired shape, and then molten metal is allowed to solidify. The solidified part is known as casting which is ejected
or broken out to complete the process. Objective in this project is to develop tools, dies and gating system. Identify defects such as
gas defects, shrinkage cavities, and mould material defects, pouring material defects, metallurgical defects etc. and take measures
to reduce flaws by using CAE software. To reduce the amount airs entrapped in the mould by changing the gating system, runner
and overflow location and optimize the gating system and process parameters for best quality product and improved productivity.
Defects can be formed easily at critical location during pressure die casting of aluminium alloy part. It has defective effect on the
casting. Mould filling and solidification process of a part was simulated using Z-cast software.
Key Words: Casting, HPDC, Z-cast, CAE Software, Simulation.
This document discusses casting defects in aluminium bronze and enhancing its mechanical properties through heat treatment. It provides background on aluminium bronze, including its composition, properties, applications in foundry and wrought products, and casting techniques. It then outlines the objectives and plan of work, which are to study the effects of composition changes and heat treatment on reducing oxide formation from casting and improving mechanical properties. The document contains an index that lists the various topics that will be covered in the project report.
This document discusses sand casting and provides details on:
- The types of casting sand including green sand, water glass sand, and resin sand.
- The key properties of casting sand such as strength, permeability, grain size, thermal stability, and reusability.
- Common casting defects related to issues with the sand mold like sand blow, pinholes, and sand wash.
- How to test sand properties including measuring moisture content, clay content, and grain size distribution.
PPT on fully study about DIE CASTING by M.M.RAFIK.M.M. RAFIK
In this presentation following parameters like Introduction,
History of casting,
Types of Die casting,
Types of Dies are used in Die casting.
Possible Defects in Die casting.
Minimum recommended wall thickness.
Design Rules in Die casting.
Advantages & Disadvantages of die casting.
covered by M.M.RAFIK.
The document discusses various types of casting defects including their forms, causes, and prevention methods. It covers shaping faults from pouring like misruns and cold shuts caused by low metal temperature or moisture in sand. Shrinkage defects from inadequate gating and risering are described. Contraction defects like hot tears occur when thin and thick sections cool at different rates. Gas defects result from entrapped gases or gases evolving during solidification. Inclusions and sand defects enter the melt during pouring. Dimensional errors occur from mold distortions. Compositional errors and segregation vary the alloy composition.
Casting process and moulding process file for trainning report complet trainn...chourasiya12345
The document provides information about sand casting and sand testing methods used in casting industries. It discusses the basic sand casting process which involves creating a mold from sand, pouring molten metal, and allowing it to solidify. It then describes various tests conducted on molds sands to evaluate properties like moisture content, clay content, grain size, permeability, and strength. These sand tests help control mold sand composition and ensure required properties are achieved.
The document discusses the history of sand casting, including early uses by the Assyrians in the 8th century BC and developments in the early 20th century with the invention of the sand slinger and sand mixer. It then provides details about the group's project to produce an exhaust manifold using sand casting, including explaining the process, materials, defects, and alternative manufacturing methods. Within the group, members will explain the different types of casting processes, the function of an exhaust manifold, suitable materials for an exhaust manifold, and details about the sand casting process.
This document discusses casting quality control and inspection. It begins with an introduction to casting quality control and outlines the agenda to be covered, including casting defects, factors responsible, remedies, cleaning methods, and inspection testing. It then defines different types of casting defects based on location, cause, type, size, and other factors. Common defects like shrinkage cavities, hot tears, and cold shuts are described along with their causes and remedies. The document also covers cleaning methods for castings like removing gates and risers. Various inspection methods for evaluating castings like mechanical impact cleaning and hydroblasting are then outlined.
This document discusses common casting defects such as surface defects, internal defects, incorrect chemical composition, and unsatisfactory mechanical properties. It defines casting defects and explains how they reduce output and increase production costs. Specific defects covered include swell, fins, gas holes, shrinkage cavities, hot tears, and cold shuts. For each defect, the causes and remedies are described. Even in modern foundries, the rejection rate can be as high as 20% of total castings produced due to these defects.
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The document discusses various types of casting defects including gas defects, shrinkage cavities, molding material defects, pouring metal defects, and metallurgical defects. It provides detailed descriptions and characteristics of different specific defects such as blowholes, pinhole porosity, cuts and washes, penetration, fusion, rattails, swell, washout, misruns, and cold shuts. The document emphasizes the importance of properly identifying and classifying defects in order to determine their causes and implement appropriate corrective actions to control quality.
This document discusses the casting procedure and defects in dentistry. It begins with a brief history of casting techniques from the 11th century to present. The basic steps of casting include attaching a sprue former to the wax pattern, investing the pattern in a ring, burnout of the wax, and casting of the alloy. Key aspects covered are types of sprue formers and their attachment, crucible formers, casting rings and liners, and the investing procedure. The goals of investing are to produce an accurate mold with adequate expansion to compensate for casting shrinkage.
The instructor's manual provides concise solutions to problems to allow instructors to check their work. It requests that the solutions not be used for classroom teaching. Additionally, it contains approximately 40 solved transparency problems that instructors can reproduce for classroom use to illustrate applications of the textbook concepts.
A practical approach to eliminate defects in gravity die cast al alloy castin...eSAT Journals
Abstract
This paper deals with elimination of defects in aluminium alloy castings produced by gravity die casting process. The main intention of work is to investigate the defects and improve quality of a gravity die cast component using Computer Aided Casting Simulation Software. In this study an industrial gravity casting die is used which was producing defective components. The die and components produced by the die are studied to eliminate the defects using virtual simulations. The defects in the components are identified to be solidification shrinkage, cracks, unfilled riser and incomplete mould cavity. The reasons for the defects are analyzed as either improper selection of process parameters, or improper design of gating and risering system. SOLIDCast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. The work is carried out in two stages. In first stage, few test castings are produced by modifying the process parameters (pouring temperature, pouring time, pre heat and alloy type) and results are compared with simulation results produced using same parameters. The pouring and simulation results are observed to be in good accordance with each other. In second stage, number of virtual iterations of casting is performed by changing riser dimensions. It was found from the simulation results that riser with 35mm diameter is required to produce casting with zero defects. The die is modified accordingly with the simulation results and metal is poured. The castings produced are observed to be sound and contain no defects; and also it is verified that solidification simulation helps in locating the defects, eliminating them and ultimately improving the quality of castings without any shop-floor trails.
Keywords: Aluminum-Alloys, Casting Defects, Gravity Die Casting, Material Density and SOLIDCast Simulation
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
Theoretical work submitted to the Journal should be original in its motivation or modeling structure. Empirical analysis should be based on a theoretical framework and should be capable of replication. It is expected that all materials required for replication (including computer programs and data sets) should be available upon request to the authors.
The document reviews finite element simulations in metal forming. It discusses different finite element modeling approaches for metal forming processes like deep drawing, including dynamic explicit, static explicit, static implicit incremental, static implicit large step, and static implicit one step methods. It also examines factors like bending effects, material models, element types (membrane, continuum, shell), and contact algorithms that influence the accuracy and efficiency of finite element simulations in metal forming. Current limitations of simulations are also noted, along with ongoing research needs to improve simulations and close the gap with real-life metal forming processes.
This document reviews rapid prototyping (RP) techniques. It discusses fused deposition modeling (FDM), stereolithography, selective laser sintering, and laminated object manufacturing as common RP methods. The authors analyze spur gear design and stress using different 3D printing materials and finite element analysis software. They 3D print spur gears using FDM with ABS, PLY, and nylon filaments to test load capacity. The document concludes FDM is a lower-cost option suitable for home use, though it has limited material options and less accuracy than other RP methods.
IRJET- Experimental Study of Taguchi Vs GRA Parameters During CNC Boring in S...IRJET Journal
This document describes an experimental study comparing the Taguchi method and Grey Relational Analysis (GRA) parameters for CNC boring of steel plate SS-304. Nine experiments were designed using Taguchi's L9 orthogonal array to evaluate the effects of cutting speed, feed rate, and depth of cut on material removal rate (MRR) and surface roughness (Ra). The experiments were conducted on a CNC lathe and the responses measured. Taguchi analysis and GRA were used to analyze the data and determine the optimal cutting conditions for maximizing MRR and minimizing Ra. The Taguchi method predicted an optimal MRR of 29.233 mm3/min at 110 rpm, 0.08 mm/min feed, and 1.
This document summarizes research on optimizing cutting parameters to achieve desired surface roughness in turning operations. The research uses design of experiments to collect data on surface roughness under varying cutting speed, feed, and depth of cut. Regression equations are developed to relate the parameters to surface roughness. Genetic algorithms and particle swarm optimization are then applied to optimize the parameters to minimize surface roughness. The results from genetic algorithms and particle swarm optimization are compared to determine which technique finds a better optimal parameter combination for achieving the desired surface roughness.
Optimization of Cutting Parameters Using Genetic Algorithm and Particle Swar...IJMER
In machining operations, achieving desired surface quality features of the machined product,
is really a challenging job. Because, these quality features are highly correlated and are expected to be
influenced directly or indirectly by the direct effect of process parameters or their interactive effects
(i.e. on process environment). However, the extents of significant influence of the process parameters
are different for different responses. Therefore, optimization of surface roughness is a multi-factor,
multi-objective optimization problem. Therefore, to solve such a multi-objective optimization problem, it
is felt necessary to identify the optimal parametric combination, following which all objectives could be
optimized simultaneously. In this context, it is essential to convert all the objective functions into an
equivalent single objective function or overall representative function to meet desired multi-quality
features of the machined surface. The required multi-quality features may or may not be conflicting in
nature. The representative single objective function, thus calculated, would be optimized finally. In the
present work, Design of Experiment (DOE) with Design of Expect software, Mini Tab & optimized
using genetic algorithm by MAT Lab and Particle Swarm Optimization (PSO) by “C” program in
straight turning operation. Collected data related to surface roughness have been utilized for
optimization. Due to complexity of this machining optimization problem, a genetic algorithm (GA) and
Particle Swarm Optimization (PSO) are applied to resolve the problem and the results obtained from
GA and PSO are compared
Optimization of sealing casting by identifying solidification defect and impr...IRJET Journal
1. The document discusses optimization of sealing castings through casting simulation. It aims to identify solidification defects in sealing castings and minimize them by optimizing the casting design using simulation software.
2. The current sealing casting design is analyzed using casting simulation software to identify solidification defects like shrinkage and misruns. Modifications are then made to the design using simulation to improve strength.
3. The methodology involves 3D modeling the casting, meshing it, applying material properties and boundary conditions in simulation software, and analyzing the results to identify defects and optimize the design.
Optimization of sealing casting by identifying solidification defect and impr...IRJET Journal
1. The document discusses optimization of sealing castings through casting simulation. It aims to identify solidification defects in sealing castings and minimize them by optimizing the casting design using simulation software.
2. The current sealing casting design is analyzed using casting simulation software to identify solidification defects like shrinkage and misruns. Modifications are then made to the design using simulation to improve strength.
3. The methodology involves 3D modeling the casting, meshing it, applying material properties and boundary conditions in simulation software, and analyzing the results to identify defects and optimize the design.
DEVELOPMENT OF GEAR PROFILE INSPECTION USING MACHINE LEARNING.pptxshrikantsargad2
The document presents the development of a machine vision system using deep learning to inspect gear profiles for defects. It aims to develop an automated inspection method that is more accurate and efficient than human inspection. The proposed system uses a novel image acquisition system and image processing methods to detect various gear defects. Experimental results show the vision system achieves high accuracy that is comparable to skilled human inspectors. References are provided on related work using computer vision and machine learning for defect detection.
Sand casting conventional and rapid prototyping manufacturing approacheseSAT 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
IRJET- Multi-Response Parametric Optimization During Turning of En-31 Bar usi...IRJET Journal
The document discusses using the Grey Relational Analysis (GRA) method to optimize multiple responses during turning of EN-31 steel bar. GRA was used to determine the best process parameters to simultaneously maximize material removal rate and minimize surface roughness. An experiment was conducted using a CNC lathe with varying cutting speed, feed rate, and depth of cut. Response values for material removal rate and surface roughness were measured and a GRA coefficient was calculated for each experimental condition. The condition with the highest GRA coefficient ranking would provide the optimal settings to meet the goals of high productivity and quality.
This document discusses experimental and numerical analysis of composites with delaminations. It summarizes that composites are widely used due to properties like strength and stiffness but are prone to delamination defects. The presence of delaminations reduces stiffness and changes vibration characteristics. The study investigates the effect of different percentages of delamination on the natural frequency of composite beams, through both experimental modal testing and numerical simulation using ANSYS. The results show that natural frequency decreases with increasing delamination size, with good agreement between experimental and numerical analysis. Frequency response functions also demonstrate changes with delamination.
An Overview of Clearance Optimization in Sheet Metal Blanking ProcessIJMER
Abstract: This document prescribes a model investigation the effect of potential parameters influencing the blanking
process and their interaction. The blanking process optimization carried out by using Design of Experiment (DOE), Finite
Element Method (FEM) with ANSYS Package, Simulation with ABAQUS-Explicit software, Blank soft Software and Neural
Network Simulation in order to achieve the intended model objectives.
Keywords: Blanking Process, DOE, FEM, Optimum Clearance and Simulation.
This document discusses optimization of clearance in sheet metal blanking processes. It investigates how parameters like clearance, tool wear, and sheet thickness affect blanking results. The blanking process is modeled using finite element analysis and design of experiments to understand interactions. An optimum clearance is defined as the point where the crack propagation direction coincides with the diagonal line between punch and die contact points, resulting in clean separation. The document outlines algorithms to predict blanking forces, crack initiation and geometry based on clearance and other factors.
Process parameter optimization of SLM process and application of Taguchi appr...ijsrd.com
Selective Laser Melting (SLM) is an emerging powder based additive layer manufacturing technology that used to fabricate three-dimensional fully functional parts from metal powders by fusing the material in a layer by layer manner as per a CAD model. The quality of SLM produced parts is significantly affected by various manufacturing parameters of SLM machine. Hence optimization of SLM process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of SLM process and application of Taguchi approach. This review of work can be helpful to the other researchers to carry out further work in the same era.
Use of Rapid Prototyping Technology in Mechanical IndustryIRJET Journal
This document discusses the use of rapid prototyping technology in the mechanical industry. It begins by defining rapid prototyping as a process that produces 3D objects directly from a CAD model in a layer-by-layer method. This allows prototypes to be produced in just hours and cuts down product development time and costs. The document then examines different rapid prototyping methods like fused deposition modeling, stereolithography, and selective laser sintering. It also discusses factors to consider in developing rapid prototyping techniques such as initial costs, availability of training, and selection of modeling software. Rapid prototyping is concluded to be essential for reducing design time in fields like manufacturing.
This document summarizes research on 3D printing hollow compounds of different shapes. It discusses how 3D printing allows for more optimized geometries compared to traditional manufacturing and can produce hollow turbine blades, gears, and disc brakes with properties similar to solid compounds. Finite element analysis was performed on hollow and solid shapes of different cross-sections, finding equivalent stresses were approximately the same. 3D printing reduces material costs and makes manufacturing hollow compounds easier compared to traditional methods. The document concludes 3D printing technologies provide design flexibility while creating parts with layer-by-layer printing instead of traditional manufacturing approaches.
Development of models using genetic programming for turningIAEME Publication
The document summarizes a study that used genetic programming to develop models for predicting surface roughness and cutting forces during the turning of Inconel 718 alloy with coated carbide tools. Experiments were conducted according to a Taguchi orthogonal array with cutting speed, feed rate, and depth of cut as input variables and surface roughness, cutting force, feed force, and thrust force as output responses. Genetic programming was used to generate mathematical models relating the input and output variables. The models were validated using experimental data and able to reasonably predict the output values. The models can be used to optimize the turning process and identify parameters that achieve better surface finish and higher material removal rates.
Similar to Analysis and optimization of sand casting defects with the help of artificial neural network (20)
Mechanical properties of hybrid fiber reinforced concrete for pavementseSAT Journals
Abstract
The effect of addition of mono fibers and hybrid fibers on the mechanical properties of concrete mixture is studied in the present
investigation. Steel fibers of 1% and polypropylene fibers 0.036% were added individually to the concrete mixture as mono fibers and
then they were added together to form a hybrid fiber reinforced concrete. Mechanical properties such as compressive, split tensile and
flexural strength were determined. The results show that hybrid fibers improve the compressive strength marginally as compared to
mono fibers. Whereas, hybridization improves split tensile strength and flexural strength noticeably.
Keywords:-Hybridization, mono fibers, steel fiber, polypropylene fiber, Improvement in mechanical properties.
Material management in construction – a case studyeSAT Journals
Abstract
The objective of the present study is to understand about all the problems occurring in the company because of improper application
of material management. In construction project operation, often there is a project cost variance in terms of the material, equipments,
manpower, subcontractor, overhead cost, and general condition. Material is the main component in construction projects. Therefore,
if the material management is not properly managed it will create a project cost variance. Project cost can be controlled by taking
corrective actions towards the cost variance. Therefore a methodology is used to diagnose and evaluate the procurement process
involved in material management and launch a continuous improvement was developed and applied. A thorough study was carried
out along with study of cases, surveys and interviews to professionals involved in this area. As a result, a methodology for diagnosis
and improvement was proposed and tested in selected projects. The results obtained show that the main problem of procurement is
related to schedule delays and lack of specified quality for the project. To prevent this situation it is often necessary to dedicate
important resources like money, personnel, time, etc. To monitor and control the process. A great potential for improvement was
detected if state of the art technologies such as, electronic mail, electronic data interchange (EDI), and analysis were applied to the
procurement process. These helped to eliminate the root causes for many types of problems that were detected.
Managing drought short term strategies in semi arid regions a case studyeSAT Journals
Abstract
Drought management needs multidisciplinary action. Interdisciplinary efforts among the experts in various fields of the droughts
prone areas are helpful to achieve tangible and permanent solution for this recurring problem. The Gulbarga district having the total
area around 16, 240 sq.km, and accounts 8.45 per cent of the Karnataka state area. The district has been situated with latitude 17º 19'
60" North and longitude of 76 º 49' 60" east. The district is situated entirely on the Deccan plateau positioned at a height of 300 to
750 m above MSL. Sub-tropical, semi-arid type is one among the drought prone districts of Karnataka State. The drought
management is very important for a district like Gulbarga. In this paper various short term strategies are discussed to mitigate the
drought condition in the district.
Keywords: Drought, South-West monsoon, Semi-Arid, Rainfall, Strategies etc.
Life cycle cost analysis of overlay for an urban road in bangaloreeSAT Journals
Abstract
Pavements are subjected to severe condition of stresses and weathering effects from the day they are constructed and opened to traffic
mainly due to its fatigue behavior and environmental effects. Therefore, pavement rehabilitation is one of the most important
components of entire road systems. This paper highlights the design of concrete pavement with added mono fibers like polypropylene,
steel and hybrid fibres for a widened portion of existing concrete pavement and various overlay alternatives for an existing
bituminous pavement in an urban road in Bangalore. Along with this, Life cycle cost analyses at these sections are done by Net
Present Value (NPV) method to identify the most feasible option. The results show that though the initial cost of construction of
concrete overlay is high, over a period of time it prove to be better than the bituminous overlay considering the whole life cycle cost.
The economic analysis also indicates that, out of the three fibre options, hybrid reinforced concrete would be economical without
compromising the performance of the pavement.
Keywords: - Fatigue, Life cycle cost analysis, Net Present Value method, Overlay, Rehabilitation
Laboratory studies of dense bituminous mixes ii with reclaimed asphalt materialseSAT Journals
Abstract
The issue of growing demand on our nation’s roadways over that past couple of decades, decreasing budgetary funds, and the need to
provide a safe, efficient, and cost effective roadway system has led to a dramatic increase in the need to rehabilitate our existing
pavements and the issue of building sustainable road infrastructure in India. With these emergency of the mentioned needs and this
are today’s burning issue and has become the purpose of the study.
In the present study, the samples of existing bituminous layer materials were collected from NH-48(Devahalli to Hassan) site.The
mixtures were designed by Marshall Method as per Asphalt institute (MS-II) at 20% and 30% Reclaimed Asphalt Pavement (RAP).
RAP material was blended with virgin aggregate such that all specimens tested for the, Dense Bituminous Macadam-II (DBM-II)
gradation as per Ministry of Roads, Transport, and Highways (MoRT&H) and cost analysis were carried out to know the economics.
Laboratory results and analysis showed the use of recycled materials showed significant variability in Marshall Stability, and the
variability increased with the increase in RAP content. The saving can be realized from utilization of recycled materials as per the
methodology, the reduction in the total cost is 19%, 30%, comparing with the virgin mixes.
Keywords: Reclaimed Asphalt Pavement, Marshall Stability, MS-II, Dense Bituminous Macadam-II
Laboratory investigation of expansive soil stabilized with natural inorganic ...eSAT Journals
This document summarizes a study on stabilizing expansive black cotton soil with the natural inorganic stabilizer RBI-81. Laboratory tests were conducted to evaluate the effect of RBI-81 on the soil's engineering properties. The tests showed that with 2% RBI-81 and 28 days of curing, the unconfined compressive strength increased by around 250% and the CBR value improved by approximately 400% compared to the untreated soil. Overall, the study found that RBI-81 effectively improved the strength properties of the black cotton soil and its suitability as a soil stabilizer was supported.
Influence of reinforcement on the behavior of hollow concrete block masonry p...eSAT Journals
Abstract
Reinforced masonry was developed to exploit the strength potential of masonry and to solve its lack of tensile strength. Experimental
and analytical studies have been carried out to investigate the effect of reinforcement on the behavior of hollow concrete block
masonry prisms under compression and to predict ultimate failure compressive strength. In the numerical program, three dimensional
non-linear finite elements (FE) model based on the micro-modeling approach is developed for both unreinforced and reinforced
masonry prisms using ANSYS (14.5). The proposed FE model uses multi-linear stress-strain relationships to model the non-linear
behavior of hollow concrete block, mortar, and grout. Willam-Warnke’s five parameter failure theory has been adopted to model the
failure of masonry materials. The comparison of the numerical and experimental results indicates that the FE models can successfully
capture the highly nonlinear behavior of the physical specimens and accurately predict their strength and failure mechanisms.
Keywords: Structural masonry, Hollow concrete block prism, grout, Compression failure, Finite element method,
Numerical modeling.
Influence of compaction energy on soil stabilized with chemical stabilizereSAT Journals
This document summarizes a study on the influence of compaction energy on soil stabilized with a chemical stabilizer. Laboratory tests were conducted on locally available loamy soil treated with a patented polymer liquid stabilizer and compacted at four different energy levels. The study found that increasing the compaction effort increased the density of both untreated and treated soil, but the rate of increase was lower for stabilized soil. Treating the soil with the stabilizer improved its unconfined compressive strength and resilient modulus, and reduced accumulated plastic strain, with these properties further improved by higher compaction efforts. The stabilized soil exhibited strength and performance benefits compared to the untreated soil.
Geographical information system (gis) for water resources managementeSAT Journals
This document describes a hydrological framework developed in the form of a Hydrologic Information System (HIS) to meet the information needs of various government departments related to water management in a state. The HIS consists of a hydrological database coupled with tools for collecting and analyzing spatial and non-spatial water resources data. It also incorporates a hydrological model to indirectly assess water balance components over space and time. A web-based GIS portal was created to allow users to access and visualize the hydrological data, as well as outputs from the SWAT hydrological model. The framework is intended to facilitate integrated water resources planning and management across different administrative levels.
Forest type mapping of bidar forest division, karnataka using geoinformatics ...eSAT Journals
Abstract
The study demonstrate the potentiality of satellite remote sensing technique for the generation of baseline information on forest types
including tree plantation details in Bidar forest division, Karnataka covering an area of 5814.60Sq.Kms. The Total Area of Bidar
forest division is 5814Sq.Kms analysis of the satellite data in the study area reveals that about 84% of the total area is Covered by
crop land, 1.778% of the area is covered by dry deciduous forest, 1.38 % of mixed plantation, which is very threatening to the
environmental stability of the forest, future plantation site has been mapped. With the use of latest Geo-informatics technology proper
and exact condition of the trees can be observed and necessary precautions can be taken for future plantation works in an appropriate
manner
Keywords:-RS, GIS, GPS, Forest Type, Tree Plantation
Factors influencing compressive strength of geopolymer concreteeSAT Journals
Abstract
To study effects of several factors on the properties of fly ash based geopolymer concrete on the compressive strength and also the
cost comparison with the normal concrete. The test variables were molarities of sodium hydroxide(NaOH) 8M,14M and 16M, ratio of
NaOH to sodium silicate (Na2SiO3) 1, 1.5, 2 and 2.5, alkaline liquid to fly ash ratio 0.35 and 0.40 and replacement of water in
Na2SiO3 solution by 10%, 20% and 30% were used in the present study. The test results indicated that the highest compressive
strength 54 MPa was observed for 16M of NaOH, ratio of NaOH to Na2SiO3 2.5 and alkaline liquid to fly ash ratio of 0.35. Lowest
compressive strength of 27 MPa was observed for 8M of NaOH, ratio of NaOH to Na2SiO3 is 1 and alkaline liquid to fly ash ratio of
0.40. Alkaline liquid to fly ash ratio of 0.35, water replacement of 10% and 30% for 8 and 16 molarity of NaOH and has resulted in
compressive strength of 36 MPa and 20 MPa respectively. Superplasticiser dosage of 2 % by weight of fly ash has given higher
strength in all cases.
Keywords: compressive strength, alkaline liquid, fly ash
Experimental investigation on circular hollow steel columns in filled with li...eSAT Journals
Abstract
Composite Circular hollow Steel tubes with and without GFRP infill for three different grades of Light weight concrete are tested for
ultimate load capacity and axial shortening , under Cyclic loading. Steel tubes are compared for different lengths, cross sections and
thickness. Specimens were tested separately after adopting Taguchi’s L9 (Latin Squares) Orthogonal array in order to save the initial
experimental cost on number of specimens and experimental duration. Analysis was carried out using ANN (Artificial Neural
Network) technique with the assistance of Mini Tab- a statistical soft tool. Comparison for predicted, experimental & ANN output is
obtained from linear regression plots. From this research study, it can be concluded that *Cross sectional area of steel tube has most
significant effect on ultimate load carrying capacity, *as length of steel tube increased- load carrying capacity decreased & *ANN
modeling predicted acceptable results. Thus ANN tool can be utilized for predicting ultimate load carrying capacity for composite
columns.
Keywords: Light weight concrete, GFRP, Artificial Neural Network, Linear Regression, Back propagation, orthogonal
Array, Latin Squares
Experimental behavior of circular hsscfrc filled steel tubular columns under ...eSAT Journals
This document summarizes an experimental study that tested circular concrete-filled steel tube columns with varying parameters. 45 specimens were tested with different fiber percentages (0-2%), tube diameter-to-wall-thickness ratios (D/t from 15-25), and length-to-diameter (L/d) ratios (from 2.97-7.04). The results found that columns filled with fiber-reinforced concrete exhibited higher stiffness, equal ductility, and enhanced energy absorption compared to those filled with plain concrete. The load carrying capacity increased with fiber content up to 1.5% but not at 2.0%. The analytical predictions of failure load closely matched the experimental values.
Evaluation of punching shear in flat slabseSAT Journals
Abstract
Flat-slab construction has been widely used in construction today because of many advantages that it offers. The basic philosophy in
the design of flat slab is to consider only gravity forces; this method ignores the effect of punching shear due to unbalanced moments
at the slab column junction which is critical. An attempt has been made to generate generalized design sheets which accounts both
punching shear due to gravity loads and unbalanced moments for cases (a) interior column; (b) edge column (bending perpendicular
to shorter edge); (c) edge column (bending parallel to shorter edge); (d) corner column. These design sheets are prepared as per
codal provisions of IS 456-2000. These design sheets will be helpful in calculating the shear reinforcement to be provided at the
critical section which is ignored in many design offices. Apart from its usefulness in evaluating punching shear and the necessary
shear reinforcement, the design sheets developed will enable the designer to fix the depth of flat slab during the initial phase of the
design.
Keywords: Flat slabs, punching shear, unbalanced moment.
Evaluation of performance of intake tower dam for recent earthquake in indiaeSAT Journals
Abstract
Intake towers are typically tall, hollow, reinforced concrete structures and form entrance to reservoir outlet works. A parametric
study on dynamic behavior of circular cylindrical towers can be carried out to study the effect of depth of submergence, wall thickness
and slenderness ratio, and also effect on tower considering dynamic analysis for time history function of different soil condition and
by Goyal and Chopra accounting interaction effects of added hydrodynamic mass of surrounding and inside water in intake tower of
dam
Key words: Hydrodynamic mass, Depth of submergence, Reservoir, Time history analysis,
Evaluation of operational efficiency of urban road network using travel time ...eSAT Journals
This document evaluates the operational efficiency of an urban road network in Tiruchirappalli, India using travel time reliability measures. Traffic volume and travel times were collected using video data from 8-10 AM on various roads. Average travel times, 95th percentile travel times, and buffer time indexes were calculated to assess reliability. Non-motorized vehicles were found to most impact reliability on one road. A relationship between buffer time index and traffic volume was developed. Finally, a travel time model was created and validated based on length, speed, and volume.
Estimation of surface runoff in nallur amanikere watershed using scs cn methodeSAT Journals
Abstract
The development of watershed aims at productive utilization of all the available natural resources in the entire area extending from
ridge line to stream outlet. The per capita availability of land for cultivation has been decreasing over the years. Therefore, water and
the related land resources must be developed, utilized and managed in an integrated and comprehensive manner. Remote sensing and
GIS techniques are being increasingly used for planning, management and development of natural resources. The study area, Nallur
Amanikere watershed geographically lies between 110 38’ and 110 52’ N latitude and 760 30’ and 760 50’ E longitude with an area of
415.68 Sq. km. The thematic layers such as land use/land cover and soil maps were derived from remotely sensed data and overlayed
through ArcGIS software to assign the curve number on polygon wise. The daily rainfall data of six rain gauge stations in and around
the watershed (2001-2011) was used to estimate the daily runoff from the watershed using Soil Conservation Service - Curve Number
(SCS-CN) method. The runoff estimated from the SCS-CN model was then used to know the variation of runoff potential with different
land use/land cover and with different soil conditions.
Keywords: Watershed, Nallur watershed, Surface runoff, Rainfall-Runoff, SCS-CN, Remote Sensing, GIS.
Estimation of morphometric parameters and runoff using rs & gis techniqueseSAT Journals
This document summarizes a study that used remote sensing and GIS techniques to estimate morphometric parameters and runoff for the Yagachi catchment area in India over a 10-year period. Morphometric analysis was conducted to understand the hydrological response at the micro-watershed level. Daily runoff was estimated using the SCS curve number model. The results showed a positive correlation between rainfall and runoff. Land use/land cover changes between 2001-2010 were found to impact estimated runoff amounts. Remote sensing approaches provided an effective means to model runoff for this large, ungauged area.
Effect of variation of plastic hinge length on the results of non linear anal...eSAT Journals
Abstract The nonlinear Static procedure also well known as pushover analysis is method where in monotonically increasing loads are applied to the structure till the structure is unable to resist any further load. It is a popular tool for seismic performance evaluation of existing and new structures. In literature lot of research has been carried out on conventional pushover analysis and after knowing deficiency efforts have been made to improve it. But actual test results to verify the analytically obtained pushover results are rarely available. It has been found that some amount of variation is always expected to exist in seismic demand prediction of pushover analysis. Initial study is carried out by considering user defined hinge properties and default hinge length. Attempt is being made to assess the variation of pushover analysis results by considering user defined hinge properties and various hinge length formulations available in literature and results compared with experimentally obtained results based on test carried out on a G+2 storied RCC framed structure. For the present study two geometric models viz bare frame and rigid frame model is considered and it is found that the results of pushover analysis are very sensitive to geometric model and hinge length adopted. Keywords: Pushover analysis, Base shear, Displacement, hinge length, moment curvature analysis
Effect of use of recycled materials on indirect tensile strength of asphalt c...eSAT Journals
Abstract
Depletion of natural resources and aggregate quarries for the road construction is a serious problem to procure materials. Hence
recycling or reuse of material is beneficial. On emphasizing development in sustainable construction in the present era, recycling of
asphalt pavements is one of the effective and proven rehabilitation processes. For the laboratory investigations reclaimed asphalt
pavement (RAP) from NH-4 and crumb rubber modified binder (CRMB-55) was used. Foundry waste was used as a replacement to
conventional filler. Laboratory tests were conducted on asphalt concrete mixes with 30, 40, 50, and 60 percent replacement with RAP.
These test results were compared with conventional mixes and asphalt concrete mixes with complete binder extracted RAP
aggregates. Mix design was carried out by Marshall Method. The Marshall Tests indicated highest stability values for asphalt
concrete (AC) mixes with 60% RAP. The optimum binder content (OBC) decreased with increased in RAP in AC mixes. The Indirect
Tensile Strength (ITS) for AC mixes with RAP also was found to be higher when compared to conventional AC mixes at 300C.
Keywords: Reclaimed asphalt pavement, Foundry waste, Recycling, Marshall Stability, Indirect tensile strength.
Understanding Inductive Bias in Machine LearningSUTEJAS
This presentation explores the concept of inductive bias in machine learning. It explains how algorithms come with built-in assumptions and preferences that guide the learning process. You'll learn about the different types of inductive bias and how they can impact the performance and generalizability of machine learning models.
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By understanding inductive bias, you can gain valuable insights into how machine learning models work and make informed decisions when building and deploying them.
A review on techniques and modelling methodologies used for checking electrom...nooriasukmaningtyas
The proper function of the integrated circuit (IC) in an inhibiting electromagnetic environment has always been a serious concern throughout the decades of revolution in the world of electronics, from disjunct devices to today’s integrated circuit technology, where billions of transistors are combined on a single chip. The automotive industry and smart vehicles in particular, are confronting design issues such as being prone to electromagnetic interference (EMI). Electronic control devices calculate incorrect outputs because of EMI and sensors give misleading values which can prove fatal in case of automotives. In this paper, the authors have non exhaustively tried to review research work concerned with the investigation of EMI in ICs and prediction of this EMI using various modelling methodologies and measurement setups.
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As digital technology becomes more deeply embedded in power systems, protecting the communication
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represents a multi-tiered application layer protocol extensively utilized in Supervisory Control and Data
Acquisition (SCADA)-based smart grids to facilitate real-time data gathering and control functionalities.
Robust Intrusion Detection Systems (IDS) are necessary for early threat detection and mitigation because
of the interconnection of these networks, which makes them vulnerable to a variety of cyberattacks. To
solve this issue, this paper develops a hybrid Deep Learning (DL) model specifically designed for intrusion
detection in smart grids. The proposed approach is a combination of the Convolutional Neural Network
(CNN) and the Long-Short-Term Memory algorithms (LSTM). We employed a recent intrusion detection
dataset (DNP3), which focuses on unauthorized commands and Denial of Service (DoS) cyberattacks, to
train and test our model. The results of our experiments show that our CNN-LSTM method is much better
at finding smart grid intrusions than other deep learning algorithms used for classification. In addition,
our proposed approach improves accuracy, precision, recall, and F1 score, achieving a high detection
accuracy rate of 99.50%.
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Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
KuberTENes Birthday Bash Guadalajara - K8sGPT first impressionsVictor Morales
K8sGPT is a tool that analyzes and diagnoses Kubernetes clusters. This presentation was used to share the requirements and dependencies to deploy K8sGPT in a local environment.
Embedded machine learning-based road conditions and driving behavior monitoringIJECEIAES
Car accident rates have increased in recent years, resulting in losses in human lives, properties, and other financial costs. An embedded machine learning-based system is developed to address this critical issue. The system can monitor road conditions, detect driving patterns, and identify aggressive driving behaviors. The system is based on neural networks trained on a comprehensive dataset of driving events, driving styles, and road conditions. The system effectively detects potential risks and helps mitigate the frequency and impact of accidents. The primary goal is to ensure the safety of drivers and vehicles. Collecting data involved gathering information on three key road events: normal street and normal drive, speed bumps, circular yellow speed bumps, and three aggressive driving actions: sudden start, sudden stop, and sudden entry. The gathered data is processed and analyzed using a machine learning system designed for limited power and memory devices. The developed system resulted in 91.9% accuracy, 93.6% precision, and 92% recall. The achieved inference time on an Arduino Nano 33 BLE Sense with a 32-bit CPU running at 64 MHz is 34 ms and requires 2.6 kB peak RAM and 139.9 kB program flash memory, making it suitable for resource-constrained embedded systems.
Electric vehicle and photovoltaic advanced roles in enhancing the financial p...IJECEIAES
Climate change's impact on the planet forced the United Nations and governments to promote green energies and electric transportation. The deployments of photovoltaic (PV) and electric vehicle (EV) systems gained stronger momentum due to their numerous advantages over fossil fuel types. The advantages go beyond sustainability to reach financial support and stability. The work in this paper introduces the hybrid system between PV and EV to support industrial and commercial plants. This paper covers the theoretical framework of the proposed hybrid system including the required equation to complete the cost analysis when PV and EV are present. In addition, the proposed design diagram which sets the priorities and requirements of the system is presented. The proposed approach allows setup to advance their power stability, especially during power outages. The presented information supports researchers and plant owners to complete the necessary analysis while promoting the deployment of clean energy. The result of a case study that represents a dairy milk farmer supports the theoretical works and highlights its advanced benefits to existing plants. The short return on investment of the proposed approach supports the paper's novelty approach for the sustainable electrical system. In addition, the proposed system allows for an isolated power setup without the need for a transmission line which enhances the safety of the electrical network
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Analysis and optimization of sand casting defects with the help of artificial neural network
1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 05 | May-2015, Available @ http://www.ijret.org 24
ANALYSIS AND OPTIMIZATION OF SAND CASTING DEFECTS
WITH THE HELP OF ARTIFICIAL NEURAL NETWORK
Shraban Kumar Singha1
, Simran Jeet Singh2
1
Master’s Student, Mechanical Engineering Department, Lovely Professional University, Punjab, INDIA -144411
2
Assistant Professor, Mechanical Engineering Department, Lovely Professional University, Punjab, INDIA -144411
Abstract
Casting defects is one and the only limitation in any casting process. Sand casting process too suffers from the same problem.
Finding out the optimum condition towards acquiring minimum casting defects is very critical. The normal method that most of
the companies use is the trial and error method. But due to limitations like error prone results, expensive and time consuming, this
method causes too much cost to company. In this paper, an attempt has been made to minimize the casting defects by optimizing
the process parameters of sand casting defect using Artificial Neural Network (ANN). The Toolbox of the MATLAB software is
used to run the different values of the parameters. Parameters are selected on the basis of survey from different industry and a
rigorous research of the previous paper on this topic. Before that a program was prepared in MATLAB to generate the values of
different parameter by using their highest and smallest values which has been collected from a local casting industry. In our first
attempt to optimize the sand casting process parameters, it is found that if we consider randomly both input and output just by
considering their limits the results are satisfactory just up to a limit. And it changes if the parameters are being changed. For
specific conditions the result is found to be 3.175 as casting defect. Later on a new type of program is generated based on the
relation of sand casting parameters and sand casting defects. Three specific casting defects are considered called, Expansion
Defect, Gas Defect, Weak sand Defect. At last, their results are found to be Expansion defect: 6.23%, Gas Defect: 7.28%, Weak
Sand Defect: 5.74%.
Keywords: Sand casting, Artificial Neural Network (ANN), MATLAB, Casting Defect
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1. INTRODUCTION
Metal casting process is one of the oldest manufacturing
method dates back to 3600 B C. In the earlier centuries this
method was mainly used to make weapons like arrow heads,
swords etc. Even though metal casting comprises of many
steps but they are very easy to execute. Over the centuries
human being has progressed in the field of manufacturing
and invented many kinds of metal casting processes
according to their requirements. Sand casting, Centrifugal
casting, Injection casting, Shell mould casting and
Investment casting are some of the prominent examples of
metal casting processes.
Sand casting is one of the oldest and mostly used casting
process of all. It is also the easiest process. In sand casting
the procedure starts with the same concept like any other
casting method. At first the pattern which is the replica of
the end product is created with the help of machining. Then
the sand mixture is created with different materials like clay,
moisture, lime etc. The quality of sand casted product
mostly depends on this mould mixture. Then the pattern is
dipped in the mould. The dipping process differs from
pattern to pattern. There are many kinds of pattern are there,
viz cope and drag pattern, skeleton pattern, split pattern etc.
When the cavity made by the pattern inside the mould is
ready molten metal is poured and wait until the metal
solidifies. As soon as the molten metal solidifies the product
is taken out by breaking the sand mould. Finally the product
is machined for cleaning of any kind of extra material or any
kind of foreign object. Sand casting is like any other casting
and has its limitation. This limitation is specifically termed
as casting defect. Sand casting has many forms of casting
defect and they are classified by many authors into many
categories. Getting rid of these defects is impossible due to
the reason that it depends on many factors of sand casting
process. The only option is to minimize these casting defects
as low as possible. At present casting defects are first
analyzed with the help of different tools like historical data
analysis, cause effect diagram, design of experiment (DOE),
if-then rules etc. When the casting data are analyzed then
they are used in some optimization tools like Taguchi
method, or ANOVA method etc. So far these techniques are
providing satisfactory results. But in the recent past the
concept of simulation is growing in every sector including
manufacturing industry. The concept of simulation is the
trying the real process in simulated version so that we can
save money and time. The Artificial Neural Network (ANN)
is one of the most promising simulation techniques at
present.
An Artificial Neural Network is nothing but a computational
model of the human brain. Here the information‟s are
processed with the help of some processing elements called
nodes or neuron. These neurons are structured normally in
three layers known as input layer, output layer and hidden
layer as shown in the figure 1. The thorough details are
given in the later chapters. ANN is a scientific tool which
can be used in many ways. Some of them are face
2. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 05 | May-2015, Available @ http://www.ijret.org 25
recognition, pattern recognition, optimization etc. The
optimization technique is used in this thesis to optimize the
conditions of the casting process parameters for optimized
casting defects.
Fig -1: Graphical representation of an ANN
2. LITERATURE REVIEW
Metal casting process is one of the easiest manufacturing
methods among all. People have been using casting process
from many centuries now. In the earlier days the
manufacturers or the customers didn‟t have to think about
high accuracy or precision. In the earlier times they were
only few numbers of manufacturing companies, so they
didn‟t have to compete so much. Now a day thousands of
manufacturing companies exists and so the competition is
cut throat. The customers are demanding more and more
accurate products at their convenient time so the companies
are trying every possible means.
Rajagopalan et al. (1996) [1] studied about the mechanism
of Artificial Neural Network (ANN) and its use in the world
of manufacturing.. The methods, structures and applications
of neural networks were presented in this paper. Yarlagadda
et al. (1999) [2] studied in the area of neural network system
for the prediction of process parameters in pressure die
casting. In their work an artificial intelligent neural network
system was developed to generate the process parameters
for the pressure die casting process. They used Levenberg–
Mrquardt approximation algorithm for this method. The
accuracy of the network developed is tested by comparing
the data generated from the network with that from an
expert from a local die casting industry. Basheera &
Hajmeer (2000) [3] studied about the fundamentals,
computing, design, and application of ANN. Sadeghi et al.
(2000) [4] developed a BP-neural network predictor model
for plastic injection molding process. A neural network
model for predicting the quality or soundness of the injected
plastic parts based on key process variables and material
grade variations has been developed. Upon training of the
network, its performance was tested on several sets of data
taken from the simulation works on Eltex A3300 etc.
Yarlagadda et al. (2001) [5] has developed a hybrid neural
network system for prediction of process parameters in
injection molding. The training data were generated by
simulation using C-MOLD flow simulation software. A total
of 114 data were collected out of which 94 were to train the
network using MATLAB and the remaining 20 for testing
the network. Khan et al. (2003) [6] studied the modeling of
porosity defects in high pressure die casting with a neural
network. The aim of the paper was to improve current
modeling and understanding of defects formation in HPDC
machines. They have conducted conventional die casting
tests with a neural network model of HPDC machine and
compared the obtained results with the current
understanding of formation of porosity. They found some
conflict with the previous studies of die casting. Due to the
conflicts with previous results they decided that as a result it
needs more investigation. S. Guharaja et al. (2004) [7]
analyzed the various process parameters of the green sand
casting process. They made an attempt to reach optimal
settings of green sand casting process in order to acquire the
optimum quality characteristics of the spheroidal graphite
(SG) cast iron rigid coupling castings. Ultimately they
considered the four most prominent parameters and they
were green strength, mould hardness, moisture content and
permeability. The effect of the selected process parameters
and its effect on different level on casting defects were
optimized using Taguchi‟s optimization approach. Chandran
et al. (2009) [8] researched in the area of optimization of
process parameters to minimize the casting defects and
found out how to minimize the casting defects such as, sand
drop, sand blow holes, scabs, pinholes. He used Taguchi
method to optimize and the parameters considered are
moisture content (%), green strength (g/cm2), mould
hardness, sand practical size (AFS). In his research he
realized the optimum conditions of taken parameters as
follows Moisture (%) – level 2 – 3.8 Green Strength (g/cm2)
– level 2 – 1400 Sand Particle Size (AFS) – level 1 – 50
Mould Hardness (Nu) – level 3 – 75. Vosniakos et al. (2009)
[9] studied in the field of the scope of artificial neural
network metamodels for precision casting process planning.
In this paper the researchers tried to optimize the precision
casting process by using computer simulating software‟s
using „what if‟ scenarios. Simulation results cannot help the
engineers for work pieces other than the one simulated
product. In this paper a series of feed forward artificial
neural network (ANN) models is presented aiming at such
generalization. Zheng et al. (2009) [10] studied optimization
of high-pressure die-casting process parameters using
artificial neural network. They found that high pressure die
casting process has many attributes involved which
contribute to the complexity of the process. It is essential for
the engineers to optimize the process parameters and
improve the surface quality. They considered mold
temperature, pouring temperature, and injection Velocity are
as the parameters for the network. It was found that the
trained network has great forecast ability. Mane et al. (2010)
[11] researched about a new approach to casting defects
classification and analysis supported by simulation. They
discussed about the different problems that the
manufacturing industry mainly casting industry is facing till
now even though the technology now a days is beyond
imagination. They mentioned that global buyer demands
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Volume: 04 Issue: 05 | May-2015, Available @ http://www.ijret.org 26
defect free castings and strict delivery schedule, which
foundries are finding it very difficult to meet. At last they
summarized showing all the measures the researchers taking
all over the world to overcome the existing casting defects.
Wisam M. Abu Jadayil (2011) [12] researched in studying
the effects of varying the pouring rate on the casting defects
using nondestructive testing techniques Then Al casting
samples have been prepared with different pouring rate for
each. Then they have been tested using the penetrant test
(PT) and the ultrasonic test (UT) to describe the surface and
subsurface defects respectively. It was found that when the
pouring rate increases surface defects are significantly
increases as the penetrant testing results showed Igor
Gresovnik (2012) et al. [13] had applied the Artificial
Neural Network (ANN) to improve steel production process.
They tried to optimize the steel production by optimizing the
process parameters of different processes of steel production
such as continuous casting. First it was intended only to use
in the production of carbon nano materials in arc discharge
reactors. Then it was generalized for other purposes too.
Ganesh G. Patil et al. (2014) [14] reviewed about the
improvement of casting process with the help of Artificial
Neural network (ANN). They realized that industry
generally tries to eliminate the defects by trial and error
method, which is an expensive and error-prone process. This
paper presents review on a use of Artificial neural network
(ANN) for the casting processes better than the other
techniques such as design of experiment (DOE), inspection
method, casting simulation, cause-effect diagram, genetic
algorithm, fuzzy logic. They discussed about the challenges
faced by ANN method in the area of prediction,
optimization, control, monitor, identification, classification,
modeling and so on particularly in the field of
manufacturing. The also discussed about the number of key
issues which should be addressed while applying neural
network to practical problems.
3. IMPLEMENTATION OF ANN
Neural Networks are the artificial representation of
biological neurons of human brain. This neuron system is
circulated in parallel around processing system. These
neurons are highly interconnected among them and have the
ability learn from real life experiences and adapt
information‟s and make it available for future use. Several
learning methods are available to enable the NN to acquire
knowledge. NN architectures are classified into many types.
Some NN refers their learning process as training. Neural
Networks are simply imitations of human brains central
nervous system and they are designed to act more and more
like a human brain. A human brain has billions of nodes
termed as neurons which are capable of performing
computations like cognition, logical inference or pattern
recognition. For example a human brain can distinguish
between two persons though the two people have the same
features physically. So a NN is nothing but imitation of
human brain and that is why these NNs are called Artificial
Neural Network (ANN).
Fig 2 Curve between output and target value
Implementation of ANN to optimize the sand casting defects
is one of the modern techniques used in industries now a
day. Prediction of the most optimized conditions for defect
free casting is nearly impossible. But all it can be done is
minimizing the casting defects as low as possible. Artificial
Neural Network has many forms of algorithms but the most
common and famous for optimization is the back
propagation algorithm. In back propagation process first the
input weights are given randomly and a target is been set.
When the program runs it gives outputs and accordingly the
network shows the error between the output and the set
target values and the Network corrects itself continuously
until the network exceeds the minimum error goal possible.
A several amount of data which is been used in optimizing
the casting defect problem were collected from a local
industry call Ajay casting and forging. In total eight number
of process input parameter were selected on the basis of
thorough literature survey on this specific area and also on
the expertise of the engineers working on the industries form
a very long time. The output parameter was termed as
casting defect. The higher and the lower limits of all the
process parameter and the output parameter were collected
from the casting company and different research papers. All
the input parameters are given as per the table 1.
Table -1: Different sand parameters and their values
Sl.
No.
Name Unit Lower
value
Higher
Value
1. Moisture content (%) 3 5
2. Permeability AFS
120 190
3. Loss on Ignition (%) 3 5
4. Compressive
strength
(Kg/cm2
) 1 1.45
5. Volatile Content (%) 2 3.5
6. Vent Holes (No.) 7 10
7. Pouring Time (Sec) 44 48
8. Mould Pressure (Kg/Cm2
) 4.5 7
4. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 05 | May-2015, Available @ http://www.ijret.org 27
After the input process parameters has been chosen and the
higher and lower limits of their value in specific unit has
been registered then the final work starts for ANN. At first a
program was developed depending on the higher and lower
limit values of the process parameters using the following
formula
𝑿𝒊 = 𝑿𝒊
𝑳
=
𝑿𝒊
𝑼
− 𝑿𝒊
𝑳
𝟐 𝒏 − 𝟏
∗ (Decoded value of string)
Where, Xi = Value of the parameter,
Xi
U
= Upper limit value of the parameter
Xi
L
= Lower limit value of the parameter
n= Number of bits.
The data is first generated in the MATLAB with the help of
the aforementioned program. Then the data is stored in the
workspace of the ANN tool of the MATLAB. At first
minimum of 100 sets of input and target values are
generated on a trial basis. A network is created as shown in
the figure 2 in the NN function of the ANN tool in
MATLAB software. The input and target values are
provided to the network from the data stored in workspace.
Network starts calculating by comparing the input values
with the target values and by passing the weighted inputs to
the nodes of the first layer. The outputs produced are passed
on to the set of target values and it goes on and on until the
nodes of the output layer compute the final outputs.
Fig -3: Physical view of the created neural network
The training and testing of a newly prepared network as
shown in figure 3 is heavy duty work and it takes time. The
aforementioned 8 parameters are fed as input parameters
and output parameter was given as casting defect in
percentage as collected from the company. In this paper
when data generation was complete they were stored in the
workspace for easy access. As shown in the following a
network is created by putting the data stored in the
workspace. Then the network was trained using the
parameter values. At first a network is created with two
hidden layer and sigmoidal function as their activation
function. At first the learning rate is given at minimum 0.1
and in one go 1000 iterations are considered.
4. RESULTS AND DISCUSSION
To optimize the sand casting process parameters for
minimum casting defect the data were generated randomly
by providing a higher limit and lower limit of the process
parameters and applying a normalization formula which was
shown earlier. After few thousand iterations in ANN toolbox
in MATLAB, results are found. The results are applicable to
some extent for a specific number of data. But, when we
change the numbers of process parameter values the
optimum casting defect in percentage fluctuates by a great
deal, which is not acceptable.
Table 2: Optimum sand casting defect
Optimum input process parameters casting
defect
1 Moisture
content
% 4.73
3.17%
2 Permeability AFS 166.
7
3 Loss on
Ignition
% 4.2
4 Green strength Kg/cm
2
1.42
5 Volatile
Content
% 3.4
6 Vent Holes No. 11
7 Pouring Time Sec 47.2
8 Mould
Pressure
Kg/cm
2
5.83
It is concluded after the first trial that the results are suitable
only for specific type of material and conditions. As per the
data provided by the local casting manufacturing company
namely, Ajay casting and forging company following is the
first set of results as shown in the table 2.
Later on a new idea of finding out a temporary relationship
among the considered process parameter and a specific kind
of defect is generated by keeping few parameters as
constant. In this equations process parameters are related to
this specific casting defect casting process are considered.
There are the few casting defects which were considered and
they are shown below:
1. Expansion defects.
2. Gas defect.
3. Weak sand defect.
After many considerations out of that eight, five sand
casting process parameters are selected for the development
of the temporary equations which relates the casting process
parameters and different casting defects.
1. Moisture content (MC).
2. Permeability (P).
3. Pouring temperature (PT).
4. Green compression strength (GS).
5. Number of vent holes (NV).
Out of the five parameters three terms are considered as
constants since these parameters has very low impact on the
specific casting defect. These values of parameter are
crucially consulted with company experts and verified with
all previous research. They are as follows
5. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 05 | May-2015, Available @ http://www.ijret.org 28
1. Pouring temperature (PT) = 14000
C.
2. Permeability (P) = 180(AFS/unit)
3. Green Compression strength (GS) = 2.2418 Kg/cm2
The defects and the process parameters are equated in the
following way
Min (f) = (MC, P, PT, GS, NV)
Where f= Function denoting casting defect.
MC = Moisture content
P = Permeability.
PT = Pouring temperature.
GS = Green compression strength.
NV = Number of vent holes.
Table -3: Final Results
Sl.
N
o.
Output
Optimu
m
Casting
Defect
Value
Input
Optimum
Parameter
Unit Value
1.
Expansi
on
Defect
6.23%
Moisture
content
% 3.67
Permeability AFS 180
Pouring
temperature
K 1400
Green
compression
strength
Kg/cm2
2.242
Number of
vent holes
Numbe
rs
9
2.
Gas
Defects
7.28%
Moisture
content
% 4.12
Permeability AFS 180
Pouring
temperature
K 1400
Green
compression
strength
Kg/cm2
2.242
Number of
vent holes
Numbe
rs
11
3.
Weak
Sand
Defects
5.74%
Moisture
content
% 3.9
Permeability AFS 180
Pouring
temperature
K 1400
Green
compression
strength
Kg/cm2
2.242
Number of
vent holes
Numbe
rs
8
All the parameters have their specific values at specific
conditions. While configuring the equations of defects and
the parameters few parameters are again selected which has
less effect on the specific casting defect and therefore they
are considered as constraints. Remaining terms are put to the
equations as per their relation with that casting defect. When
the equations are prepared for all 3 kinds of defects there is
always 2 or 3 parameters are used as variables and when the
equations are applied in the previous program these variable
vary from their lower value to higher value. At the same
time the targeted values also generated according to the
relationship.
When the data are generated and they are applied in the
network created in the ANN toolbox of MATLAB the
network starts training to achieve the optimum condition for
the output result. In this case it is to minimize the output
value as low as possible since the result is sand casting
defect. The output result and the related optimizing
conditions are given below in the tabulated form as shown
in the Table 3.
5. CONCLUSION
It is been established that Artificial Neural Network has
many applications. Among them, face recognition; pattern
recognition and optimization are the most important ones.
To use ANN in optimization of sand casting defect first we
need to consider the parameters. At first the aforementioned
eight parameters are selected and the program is run and the
data was generated. Then the generated data are applied in
the ANN toolbox in MATLAB. The results are coming one
by one but still not satisfactory since ANN takes time. At
first trial the results were not so satisfactory but as the
training continued it was better. The ultimate goal behind
the trainings is to minimize the Mean square Error (MSE).
The program is generated using MATLAB. Along the way it
is been modified many times to improve the outcomes.
Theoretically speaking the outcome of the last training is
much more reliable than the previous one. In the final
program few parameters like pouring temperature, Green
compressive strength etc. are considered as constant and
some fixed values are used. Then a relation is established
between casting defects and parameters. Three specific
kinds of sand casting defect are selected for this approach.
Ultimate results of the defects are found as, Expansion
defect (DExp) = 6.23%, Gas defect (DGas) =7.28 %, Weak
sand defect (DWS) =5.74% validating the methodology
adopted for this work as the results are similar to the
previous results available from experiments conducted by
Taguchi. From these validation it is concluded that
minimization of the casting defect percentages is possible
with the help of ANN.
ACKNOWLEDGEMENTS
I am profoundly grateful to my respected supervisor Mr.
Simran Jeet Singh, Assistant Professor, Department of
Mechanical Engineering, LPU, Punjab for his constant
involvement, energetic efforts and proficient guidance.
6. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 05 | May-2015, Available @ http://www.ijret.org 29
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