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.
Abrasive water jet review and parameter selection by AHP method.IOSR Journals
An Abrasive Water Jet is one of the most recently developed non-traditional manufacturing
processes. Abrasive water jet offers the potential for the development in cutting which is less sensitive to
material properties, has virtually no thermal effects, and imposes minimal stresses. As it is a cold process has
also important applications where heat-affected zones are to be avoided. In this work, a deep study of this newer
non-conventional technique of machining i.e., abrasive water jet machining is done. In this paper more focus is
on selection of various process parameters like-angle of impact, Pressure inside the pumping system, abrasive
material type, Stand-off distance, focusing tube diameter, nozzle speed, abrasive mass flow rate and target
material properties for getting the required output like- depth of cut and cut quality. For cutting Stainless steel
(Grade 304), important task is to find out a few parameters which influence more. With the help of Analytical
Hierarchy Process technique the selection of a few parameters are done which are comparatively more
influencing. Weighteges are given to parameters on the basis of previous study and experience of owner of the
company who is dealing with abrasive water jet technology since many years.
Prediction of output Responses in Milling of Casted Aluminum by using ANNijiert bestjournal
The important goal in the modern industries is to m anufacture the products with lower cost and with hi gh quality in short span of time. There are two main p ractical problems that engineers face in a manufacturing process. The first is to determine th e values of process parameters that will yield the desired product quality (meet technical specificati ons) and the second is to maximize manufacturing system performance using the available resources. T he increase of customer needs for quality products (more precise tolerances and better product surface roughness) have driven the metal cutting process. The main objective of this project work is to study the effect of surface roughness and Material Removal R ate in a machining of cast aluminum on CNC milling mach ine with High Speed Steel cutting tool. The feasibility of implementation of design of experime nts (DOE),and Artificial Neural network in milling process is analyzed.
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.
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.
Abrasive water jet review and parameter selection by AHP method.IOSR Journals
An Abrasive Water Jet is one of the most recently developed non-traditional manufacturing
processes. Abrasive water jet offers the potential for the development in cutting which is less sensitive to
material properties, has virtually no thermal effects, and imposes minimal stresses. As it is a cold process has
also important applications where heat-affected zones are to be avoided. In this work, a deep study of this newer
non-conventional technique of machining i.e., abrasive water jet machining is done. In this paper more focus is
on selection of various process parameters like-angle of impact, Pressure inside the pumping system, abrasive
material type, Stand-off distance, focusing tube diameter, nozzle speed, abrasive mass flow rate and target
material properties for getting the required output like- depth of cut and cut quality. For cutting Stainless steel
(Grade 304), important task is to find out a few parameters which influence more. With the help of Analytical
Hierarchy Process technique the selection of a few parameters are done which are comparatively more
influencing. Weighteges are given to parameters on the basis of previous study and experience of owner of the
company who is dealing with abrasive water jet technology since many years.
Prediction of output Responses in Milling of Casted Aluminum by using ANNijiert bestjournal
The important goal in the modern industries is to m anufacture the products with lower cost and with hi gh quality in short span of time. There are two main p ractical problems that engineers face in a manufacturing process. The first is to determine th e values of process parameters that will yield the desired product quality (meet technical specificati ons) and the second is to maximize manufacturing system performance using the available resources. T he increase of customer needs for quality products (more precise tolerances and better product surface roughness) have driven the metal cutting process. The main objective of this project work is to study the effect of surface roughness and Material Removal R ate in a machining of cast aluminum on CNC milling mach ine with High Speed Steel cutting tool. The feasibility of implementation of design of experime nts (DOE),and Artificial Neural network in milling process is analyzed.
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.
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.
A study of professional advantages to manufacturing organizations by the way ...IJERA Editor
This paper presents the study and analysis of long term advantages gained by electromechanical product
manufacturing Industries when the A class components like brass electrical contacts are manufactured by
newly devised advance manufacturing technique of hot brass extrusion .After completion of the research and
practical application this new advance manufacturing technique this has replaced previous traditional
manufacturing technique of green sand molding and casting used for commercial production of brass
contacts. The prime impact of research covers a newly devised innovative product life cycle which increases
product life.
Analyze Gear Failures and Identify Defects in Gear System for Vehicles Using ...IOSR Journals
Abstract: Gear defects are a major reason for poor quality and of embarrassment for manufacturers. 0 Inspection processes done on these industries are mostly manual and time consuming. To reduce error on identifying gear defects requires more automotive and accurate inspection process. Considering this lacking, this research implements a Gear Defect Recognizer which uses computer vision methodology with the combination of local thresholding to identify possible defects. The recognizer identifies the gear defects within economical cost and produces less error prone inspection system in real time. In order to generate data set, primarily the recognizer captures digital gear images by image acquisition device and converts the RGB images into binary images by restoration process and local threshold techniques. Later, the outputs of the processed image are the area of the faulty portion and compute the possible defective and non -defective gear as an output. Detection of bad quality plastic gears is critical for any manufacturing unit trying to make a mark in the market in terms of quality standard and cost. Here we explore the possibility of using image segmentation and algorithms like non-smooth surface detection algorithms to automate the process of defect detection. In these plastics we have picked industrial strength plastic gears used typically in applications like robotic arms where quality in paramount for the functioning of the device. In this paper review of various gear defects and the possible automated solutions using image processing techniques for defect detection is given. Keywords: Defect detection, image processing, computer vision, thresholding, counting number of teeth's.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
Effect of process factors on surface roughness in dip cryogenic machining of ...eSAT Journals
Abstract A large number of structures that are being constructed at present tend to be wind-sensitive because of their slenderness, shapes, size, lightness and flexibility. With the ever increase in the vertical growth of urban cities, high rise buildings are being constructed in large numbers. In this study, analytical investigation of different shapes of buildings are taken as an example and various analytical approaches are performed on the building. These plans are modeled and wind loads are found out according to I.S 875(part 3)-1987 by taking gust factor and without taking gust factor. These models are compared in different aspects such as storey drift, storey displacement, storey shear, etc. for different shapes of buildings by using finite element software package ETAB’s 13.1.1v. Among these results, which shape of building provide sound wind loading to the structure as well as the structural efficiency would be selected. Key Words: Storey displacement, Storey drift, Storey shear, Gust, Wind load
Prediction of Surface Roughness and Optimization of Machining Parameters in D...ijtsrd
In this paper, an experimental research was conducted to investigate the influence of the tool diameter, spindle speed, and feed rate on the surface roughness in hole drilling process. The Box Behken experimental matrix that was used with 15 experiments. The Minitab 16 software was used to evaluate the experimental results. The analyzed results showed that the spindle speed was a parameter that has the most important influence on the surface roughness. The second factors that affect on the surface roughness was tool diameter. And, the feed rate was the factor that has smallest effect on the surface roughness. The interaction factor between the tool diameter and the feed rate has the largest degree of the influence on the surface roughness, the second interaction factor that influenced on the surface roughness was the interaction between the diamter and the spindle speed. The interaction between the spindle speed and the feed rate has the smallest effect on the surface roughness. The suitable regression model of surface roughness is quadractic function. The predicted results of surface roughness are very close to the experimental values of that one. The genetic algorithm was used to find the optimal value of surface roughness. In this study, the optimum value of surface roughness was obtained for each case of drill tool diameter. The optimized cutting parameters was applied to improve the surface roughness with very satisfactory results. The optimum value of surface was quite small. Nguyen Hong Son | Nhu-Tung Nguyen "Prediction of Surface Roughness and Optimization of Machining Parameters in Drilling Process of Aluminum Alloy Al6061" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-3 , April 2020, URL: https://www.ijtsrd.com/papers/ijtsrd30193.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/30193/prediction-of-surface-roughness-and-optimization-of-machining-parameters-in-drilling-process-of-aluminum-alloy-al6061/nguyen-hong-son
Infrared Monitoring of Aluminium Milling Processes for Reduction of Environme...IRJESJOURNAL
Abstract:-In modern manufacturing contexts, process monitoring is an important tool aimed at ensuring quality standard fulfilment whilst maximising throughput. In this work, a monitoring system comprised of an infrared (IR) camera was employed for tool state identification and surface roughness assessment with the objective of reducing environmental impacts of a milling process. Two data processing techniques, based on statistical parameters and polynomial fitting, were applied to the temperature signal acquired from the IR camera during milling operations in order to extract significant features. These features were inputted to two different neural network based procedures: pattern recognition and fitting, for decision making support on tool condition and surface roughness evaluation respectively. These capabilities are discussed in terms of reducing waste products and energy consumption whilst further improvingproductivity.
Full factorial method for optimization of process parameters for surface roug...Editor IJMTER
Quality and productivity play significant role in today’s manufacturing market.In
machining operations, achieving desired surface quality features of the machined product, is really a
challenging job on cnc machine. Because, these quality features are highly correlated and are
expected to be influenced directly or indirectly by the direct effect of process parameters. There are a
number of parameters like cutting speed, feed and depth of cut etc. which must be given
consideration during the machining of SS 316L. The prediction of optimal machining conditions for
good surface roughness and material removal rate plays a very important role in process planning.
A study of professional advantages to manufacturing organizations by the way ...IJERA Editor
This paper presents the study and analysis of long term advantages gained by electromechanical product
manufacturing Industries when the A class components like brass electrical contacts are manufactured by
newly devised advance manufacturing technique of hot brass extrusion .After completion of the research and
practical application this new advance manufacturing technique this has replaced previous traditional
manufacturing technique of green sand molding and casting used for commercial production of brass
contacts. The prime impact of research covers a newly devised innovative product life cycle which increases
product life.
Analyze Gear Failures and Identify Defects in Gear System for Vehicles Using ...IOSR Journals
Abstract: Gear defects are a major reason for poor quality and of embarrassment for manufacturers. 0 Inspection processes done on these industries are mostly manual and time consuming. To reduce error on identifying gear defects requires more automotive and accurate inspection process. Considering this lacking, this research implements a Gear Defect Recognizer which uses computer vision methodology with the combination of local thresholding to identify possible defects. The recognizer identifies the gear defects within economical cost and produces less error prone inspection system in real time. In order to generate data set, primarily the recognizer captures digital gear images by image acquisition device and converts the RGB images into binary images by restoration process and local threshold techniques. Later, the outputs of the processed image are the area of the faulty portion and compute the possible defective and non -defective gear as an output. Detection of bad quality plastic gears is critical for any manufacturing unit trying to make a mark in the market in terms of quality standard and cost. Here we explore the possibility of using image segmentation and algorithms like non-smooth surface detection algorithms to automate the process of defect detection. In these plastics we have picked industrial strength plastic gears used typically in applications like robotic arms where quality in paramount for the functioning of the device. In this paper review of various gear defects and the possible automated solutions using image processing techniques for defect detection is given. Keywords: Defect detection, image processing, computer vision, thresholding, counting number of teeth's.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
Effect of process factors on surface roughness in dip cryogenic machining of ...eSAT Journals
Abstract A large number of structures that are being constructed at present tend to be wind-sensitive because of their slenderness, shapes, size, lightness and flexibility. With the ever increase in the vertical growth of urban cities, high rise buildings are being constructed in large numbers. In this study, analytical investigation of different shapes of buildings are taken as an example and various analytical approaches are performed on the building. These plans are modeled and wind loads are found out according to I.S 875(part 3)-1987 by taking gust factor and without taking gust factor. These models are compared in different aspects such as storey drift, storey displacement, storey shear, etc. for different shapes of buildings by using finite element software package ETAB’s 13.1.1v. Among these results, which shape of building provide sound wind loading to the structure as well as the structural efficiency would be selected. Key Words: Storey displacement, Storey drift, Storey shear, Gust, Wind load
Prediction of Surface Roughness and Optimization of Machining Parameters in D...ijtsrd
In this paper, an experimental research was conducted to investigate the influence of the tool diameter, spindle speed, and feed rate on the surface roughness in hole drilling process. The Box Behken experimental matrix that was used with 15 experiments. The Minitab 16 software was used to evaluate the experimental results. The analyzed results showed that the spindle speed was a parameter that has the most important influence on the surface roughness. The second factors that affect on the surface roughness was tool diameter. And, the feed rate was the factor that has smallest effect on the surface roughness. The interaction factor between the tool diameter and the feed rate has the largest degree of the influence on the surface roughness, the second interaction factor that influenced on the surface roughness was the interaction between the diamter and the spindle speed. The interaction between the spindle speed and the feed rate has the smallest effect on the surface roughness. The suitable regression model of surface roughness is quadractic function. The predicted results of surface roughness are very close to the experimental values of that one. The genetic algorithm was used to find the optimal value of surface roughness. In this study, the optimum value of surface roughness was obtained for each case of drill tool diameter. The optimized cutting parameters was applied to improve the surface roughness with very satisfactory results. The optimum value of surface was quite small. Nguyen Hong Son | Nhu-Tung Nguyen "Prediction of Surface Roughness and Optimization of Machining Parameters in Drilling Process of Aluminum Alloy Al6061" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-4 | Issue-3 , April 2020, URL: https://www.ijtsrd.com/papers/ijtsrd30193.pdf Paper Url :https://www.ijtsrd.com/engineering/mechanical-engineering/30193/prediction-of-surface-roughness-and-optimization-of-machining-parameters-in-drilling-process-of-aluminum-alloy-al6061/nguyen-hong-son
Infrared Monitoring of Aluminium Milling Processes for Reduction of Environme...IRJESJOURNAL
Abstract:-In modern manufacturing contexts, process monitoring is an important tool aimed at ensuring quality standard fulfilment whilst maximising throughput. In this work, a monitoring system comprised of an infrared (IR) camera was employed for tool state identification and surface roughness assessment with the objective of reducing environmental impacts of a milling process. Two data processing techniques, based on statistical parameters and polynomial fitting, were applied to the temperature signal acquired from the IR camera during milling operations in order to extract significant features. These features were inputted to two different neural network based procedures: pattern recognition and fitting, for decision making support on tool condition and surface roughness evaluation respectively. These capabilities are discussed in terms of reducing waste products and energy consumption whilst further improvingproductivity.
Full factorial method for optimization of process parameters for surface roug...Editor IJMTER
Quality and productivity play significant role in today’s manufacturing market.In
machining operations, achieving desired surface quality features of the machined product, is really a
challenging job on cnc machine. Because, these quality features are highly correlated and are
expected to be influenced directly or indirectly by the direct effect of process parameters. There are a
number of parameters like cutting speed, feed and depth of cut etc. which must be given
consideration during the machining of SS 316L. The prediction of optimal machining conditions for
good surface roughness and material removal rate plays a very important role in process planning.
Control Chart Analysis of Ek/M/1 Queueing Model IJMER
Queueing problems are most common features not only in our daily-life situations such as bank
counters, post offices, ticket booking centres, public transportation systems, but also in more technical
environments such as in manufacturing, computer networking and telecommunications. For any queueing
system average queue length, average system length, average waiting time in the queue and average
waiting time in the system are the main observable performance characteristics. Control chart is a graph
used to study how a process changes over time and it is also used to control ongoing processes. In this
paper control limits are established to study the behavior of Ek
/M /1 queueing model using the
performance characteristics. Numerical results are given to highlight its applications.
Enhanced Methodology for supporting approximate string search in Geospatial ...IJMER
In recent years many websites have started providing keyword search services on maps. In
these systems, users may experience difficulties finding the entities they are looking for if they do not
know their exact spelling, such as a name of a restaurant. In this paper, we present a novel index
structure and corresponding search algorithm for answering map based approximate-keyword in an
Euclidean space so that the users get their desired results even though they have typos in the keyword.
This work mainly focuses on investigating range queries in Euclidean space
Many entrepreneurs don't get to startup in major tech hubs. Being the center of your own startup oasis is a way to keep sane, especially during the prototyping / MVP dev / bootstrapping phase.
Virtualization Technology using Virtual Machines for Cloud ComputingIJMER
Cloud computing is the delivery of computing and storage capacity as a service to a community of end users. The name “cloud computing” comes from the use of a cloud-shaped symbol as an abstraction for the complex infrastructure it contains in system diagrams. Cloud computing entrusts services with a user's software, data and computation over a network. End users access cloud-based applications through a web browser or mobile application or a light-weight desktop while the business software and user's data are stored on servers at a remote location. Proponents claim that cloud computing environment allows enterprises to get their applications up and running faster, with improved manageability and less maintenance, and enables IT industry to more rapidly adjust resources to meet fluctuating and unpredictable business demand. In this paper, we present a system that uses virtualization technology to allocate the data center resources dynamically based on the application demands and support green computing by optimizing the number of servers in use. This method multiplexes virtual to physical resources adaptively based on the changing demand. We use the concept of skewness metric to combine virtual machines with different resource characteristics appropriately so that the capacities of servers are well utilized.
MK-Prototypes: A Novel Algorithm for Clustering Mixed Type Data IJMER
Clustering mixed type data is one of the major research topics in the area of data mining. In
this paper, a new algorithm for clustering mixed type data is proposed where the concept of distribution
centroid is used to represent the prototype of categorical variables in a cluster which is then combined
with the mean to represent the prototype of clusters with mixed type variables. In the method, data is
observed from different views and the variables are grouped into different views. Those instances that
can be viewed differently from different viewpoints can be defined as multiview data. During clustering
process the differences among views are ignored in usual cases. Here, both views and variables weights
are computed simultaneously. The view weight is used to determine the closeness or density of view and
variable weight is used to identify the significance of each variable. With the intention of determining
the cluster of objects both these weights are used in the distance function. In the proposed method,
enhancement to the k-prototypes is done so that it automatically computes both view and variable
weights. The proposed algorithm MK-Prototypes algorithm is compared with two other clustering
algorithms.
The Queue M/M/1 with Additional Servers for a Longer QueueIJMER
This paper deals with the queuing system M/M/1 with additional servers for a longer queue.
Clearly the traffic intensity for this system will depend on the number of additional servers. The expected
number of customers in the system, the probability of the additional of one server and the probability of
the additional of two servers are obtained under the assumption that the number of additional servers
depends on the number of customers in the system. The condition under which the M/M/1 queuing system
with additional servers is profitable is discussed. A MATLAB program is used to illustrate this condition
numerically. Finally, the maximum likelihood estimators of the parameters for this queuing system are
obtained.
Accelerometer and EOG Based Wireless Gesture Controlled Robotic ArmIJMER
- This paper deals with the Robotic arm controlled by arm and eye movements, where data
is acquired through the use of accelerometer and EOG amplifier. The hand movements are captured by
the Accelerometer and the eye movements are captured by EOG amplifier. The Robotic arm will pick
and place the object according to the movement of the hand and Robotic arm will move left and right
according to our eye movements. Signals are wirelessly transmitted through RF Encoder and Decoder.
Robotic arm is based on Arduino Duemilanove controller for signal processing, and interfaced with the
Controller serially. This Embedded system will help disabled persons to do work by their own. The
Robotic arm can be used to pick and place hazardous objects.
Impact and Dynamics of Centralization in Transportation Cost of Cement Bag’s ...IJMER
The goal of many research efforts cognate to supply chain management is to propose
mechanisms to reduce operational costs. Inventory holding and conveyance costs are regarded as the
most paramount operational costs in inventory management. Many researches in supply chain
management only consider the inventory cost as a criterion to decide replenishment policy. In the
replenishment process, in juxtaposition of the inventory cost, the conveyance cost is a major cost factor
which affects the shipment size. Thus in this research work the conveyance cost is additionally considered
to minimize the inventory cost.
Two models are studied: when the retailers make decisions independently i.e. Decentralized decision
model and when the retailers are branches of the same firm i.e. Centralized decision model to determine
the best solution to minimize costs.
Modeling Of a Bucket Air Cooler by Using Solar EnergyIJMER
In a conventional energy sources day to day decreasing in their energy levels. Going green
and conservation as much energy as possible has become the focal point in their eyes of the world.
There are many sources of energy available to us that will conserve our natural resources and decrease
on harmful emissions that are destroying our environment. Many energy sources available in world like
hydro electrical, thermal, mechanical, solar, tidal, bio gas, wave, wind, geothermal, ocean thermal
energy. Many incentives are now available to individuals and industries who implement the use of this
ecofriendly environment through in this direction we are selected solar energy is main sources.
Our design and construction of a bucket air cooler by using solar energy is new alternative to
conventional energy sources. We set out to create an air cooler that does not create any harmful
emissions in environment and provide no pollution in the surrounding. The solar power as the main
energy sources to help in the project work. It is providing to cooling the enclosed space and also
measured the temperature levels of before and after in absorbed enclosed space
Optimization of Factors Affecting Glucuronic Acid Production in Yogurt Ferme...IJMER
Drinking yogurt fermentation with two bacteria strains Lactobacillus acidophilus and
Gluconacetobacter nataicola was optimized to get maximal glucuronic acid concentration. A Blackett –
Burman matrix was designed to screen the effect of seven factors to glucuronic acid concentration in
yogurt. The design in Response surface methodology (RSM) with Central composite design (CCD) was
applied to get maximum value of glucuronic acid concentration was 59.81mg/L in fermentation at 4.43
log CFU/mL of G. nataicola density, 5.1 log CFU/mL of L. acidophilus density, 9.96% sucrose, initial
pH 5 and incubation time 32°C.
In this paper the finite element analysis of aHeat Exchanger is done. The geometry was
modelled in CATI A V5 R21 and finite element analysis had been performed in ANSYS12 WB. FE analysis
is was used to determine stress analysis at.
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
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.
SPRING BACK PREDICTION OF SHEET METAL IN DEEP DRAWING PROCESSIAEME Publication
Spring back is one of the most significant phenomenon that affect the accurateness of the sheet metal parts. In order to obtain fixed tolerances for the formed parts it is highly recommended to use such process parameters/tool geometry that allow a considerably diminishing of the spring back amount. A Finite Element (FE) model is developed for the 2- D numerical simulation of sheet metal deep drawing process (Parametric Analysis) by using HYPERFORM with the appropriate material properties (anisotropic material) and simplifies boundary conditions
FE Analysis for Investment Casting and Computer Simulation: A Reviewijsrd.com
In the present paper a review for the experimental and finite element analysis techniques is adopted for Investment casting. Experimental Data taken for Solidification of investment Casting is modeled and meshed initially then validation is followed by comparing the experimental and modeled results. This helps to optimize the design criteria for investment casting. To overcome the problem of current gating /riser system and by comparing simulation results of optimized casting model with that of original model we can reduce the shrinkage porosity.
A Review on Factors Affecting the Sheet Metal Blanking ProcessIJMER
Metal blanking is a widely used process in high volume production of sheet metal
components. The main objective of this paper is to present the study model to predict the shape of the cut
side. The study investigates the effect of potential parameters influencing the blanking process and their
interactions. Different methodology like use of simulation software’s (e.g. abacus,ansys),FEM,DOE tech
are applied. Finally, the factors affecting blanking process observed are Clearance ,tool wear, Sheet
Thickness, Material properties .
DESIGN AND FABRICATION OF WELDING FIXTURES AND POSITIONERSvivatechijri
In recent times, manufacturing industries have shown more interest towards Automation. In other
words, the industries today emerge with evolving technology. It is obvious that Industrial Automation streamlines
the operations in terms of speed, reliability and product output. In this thesis, welding fixture for two wheeler
steering handle is modeled using CATIA software, forces are calculated, and an analysis has been carried out in
the precisions placing of one circular component over another circular component during the welding process.
Welding circular rod over another circular rod, the possibility of maintaining the accuracy in placing of curved
surfaces is very less in the mass production. Here the difficulty is overcome by the new design of the fixture, and
the angle as well as the linear movements is maintained in the accuracy of 0.1 mm without any robots. In the field
of welding engineering where a consistently good quality, low cost with a maximum productivity is a must, this
accuracy canbe done by without automation. Welding fixtures are available in different size, shapes, materials
and mechanisms based on their need of operations. The precision of the fixture play a major role in the
manufacturing component. Batch production is the commonly used method in various small and large industries.
Welding a curved surface over an another curved surface is very challenging so is positioning the components.
In mass production, positioning a job takes significant amount of time due to manual process. To overcome this
challenge, theoretical approach has been carried out on the fixture like design fabrication and analysis.
Role of Simulation in Deep Drawn Cylindrical PartIJSRD
Simulation is widely used in forming industry due to its speed and lower cost and it has been proven to be effective in prediction of formability and spring back behavior. The purpose of finite element simulation in the sheet metal forming process is to minimize the time and cost in the design phase by predicting key outcomes such as the final shape of the part, the possibility of various defects and the flow of material. Such simulation is most useful and efficient when it is performed in the early stage of design by designers, rather than by analysis specialists after the detailed design is complete. The accuracy of such simulation depends on knowledge of material properties, boundary conditions and processing parameters. In the industry today, numerical sheet metal forming simulation is very important tool for reducing load time and improving part quality. In this paper finite element model for the deep-drawing of cylindrical cups is constructed and the simulation results are obtained by using different simulation parameters, i.e. punch velocity, coefficient of friction and blank holder force of the FE mesh-elements and these results are compared with experimental work.
A Design and Analysis of Two Plate Injection Mould Tool For Wi-Fi RouterTherm...EditorJST
This A Wi-Fi router is a device that performs the function of a wireless access point, it is used to provide
access to the internet or a private computer. It is the hardware device that provide basic infrastructure for a home
or small office network.Proposed to make a single impression semi-automatic family mould to design top and
bottom cover for Wi-Fi router to make it more aesthetic, to reduce material cost, better heat dissipation, and to
reduce the tooling cost, to make the product more competitive in the market.It is proposed select the suitable plastic
material, to modify the existing plastic product design and to develop a suitable two plate family mould of one
impression each using SIEMENS NX software. It is also proposed to make detailing of mould parts and its assembly
for manufacturing using SIEMENS NX software. The analysis was done in AUTODESK MOLDFLOW. The mould
cost, raw material cost and processing cost per component are to be estimated to find the cost per component and to
compare it with the existing component part.
Manufacturing Process Simulation Based Geometrical Design for Complicated PartsLiu PeiLing
More than ever, it is critical that products are designed and manufactured right the first time. Design for Manufacturing (DFM) methodology has been recognized as one of the most effective ways to short product lifecycle time and reduce manufacturing cost. The main function of DFM in the detailed design stage is analyzing the manufacturability of the part. Various existing manufacturability evaluation methods have their limitations. In this paper, a new approach to DFM for the complicated parts is proposed. Instead of checking the manufacturability following the design, the in-process model resulting from the manufacturing process simulation is used to generate process dependent geometry surfaces at the design stage. The definition of the manufacturing process dependent geometry is given, and the methodology for creation of in-process model is presented in details.
Application and development of numerical simulation technology in CastingIJRES Journal
The basic theory of the numerical simulation of casting and casting process, also the development and application of numerical calculations in the foundry engineering. Outlined the main feature of the softwares of numerical simulation of casting both here and abroad , analyzes the softwares played a significant role in actual casting and research, meanwhile pointed out the problems and development direction of the casting simulation softwares. Description reasonable use of simulation software can improve the quality of castings, Optimize the casting process, shorten the duration of the casting design and reduce costs.
A Study on Translucent Concrete Product and Its Properties by Using Optical F...IJMER
- Translucent concrete is a concrete based material with light-transferring properties,
obtained due to embedded light optical elements like Optical fibers used in concrete. Light is conducted
through the concrete from one end to the other. This results into a certain light pattern on the other
surface, depending on the fiber structure. Optical fibers transmit light so effectively that there is
virtually no loss of light conducted through the fibers. This paper deals with the modeling of such
translucent or transparent concrete blocks and panel and their usage and also the advantages it brings
in the field. The main purpose is to use sunlight as a light source to reduce the power consumption of
illumination and to use the optical fiber to sense the stress of structures and also use this concrete as an
architectural purpose of the building
Developing Cost Effective Automation for Cotton Seed DelintingIJMER
A low cost automation system for removal of lint from cottonseed is to be designed and
developed. The setup consists of stainless steel drum with stirrer in which cottonseeds having lint is mixed
with concentrated sulphuric acid. So lint will get burn. This lint free cottonseed treated with lime water to
neutralize acidic nature. After water washing this cottonseeds are used for agriculter purpose
Study & Testing Of Bio-Composite Material Based On Munja FibreIJMER
The incorporation of natural fibres such as munja fiber composites has gained
increasing applications both in many areas of Engineering and Technology. The aim of this study is to
evaluate mechanical properties such as flexural and tensile properties of reinforced epoxy composites.
This is mainly due to their applicable benefits as they are light weight and offer low cost compared to
synthetic fibre composites. Munja fibres recently have been a substitute material in many weight-critical
applications in areas such as aerospace, automotive and other high demanding industrial sectors. In
this study, natural munja fibre composites and munja/fibreglass hybrid composites were fabricated by a
combination of hand lay-up and cold-press methods. A new variety in munja fibre is the present work
the main aim of the work is to extract the neat fibre and is characterized for its flexural characteristics.
The composites are fabricated by reinforcing untreated and treated fibre and are tested for their
mechanical, properties strictly as per ASTM procedures.
Hybrid Engine (Stirling Engine + IC Engine + Electric Motor)IJMER
Hybrid engine is a combination of Stirling engine, IC engine and Electric motor. All these 3 are
connected together to a single shaft. The power source of the Stirling engine will be a Solar Panel. The aim of
this is to run the automobile using a Hybrid engine
Fabrication & Characterization of Bio Composite Materials Based On Sunnhemp F...IJMER
The present day technology demands eco-friendly developments. In this era the
composite material are playing a vital roal in different field of Engineering .The composite materials
are using as a principle materials. Nowaday the composite materials are utilizing as a important
component of engineering field .Where as the importance of the applications of composites is well
known, but thrust on the use of natural fibres in it for reinforcement has been given priority for some
times. But changing from synthetic fibres to natural fibres provides only half green-composites. A
partial green composite will be achieved if the matrix component is also eco-friendly. Keeping this in
view, a detailed literature surveyed has been carried out through various issues of the Journals
related to this field. The material systems used are sunnhemp fibres. Some epoxy and hardener has
been also added for stability and drying of the bio-composites. Various graphs and bar-charts are
super-imposed on each other for comparison among themselves and Graphs is plotted on MAT LAB
and ORIGIN 6.0 software. To determining tensile strengths, Various properties for different biocomposites
have been compared among themselves. Comparison of the behaviour of bio-composites of
this work has been also compare with other works. The bio-composites developed in this work are
likely to get applications in fall ceilings, partitions, bio-degradable packagings, automotive interiors,
sports things (e.g. rackets, nets, etc.), toys etc.
Geochemistry and Genesis of Kammatturu Iron Ores of Devagiri Formation, Sandu...IJMER
The Greenstone belts of Karnataka are enriched in BIFs in Dharwar craton, where Iron
formations are confined to the basin shelf, clearly separated from the deeper-water iron formation that
accumulated at the basin margin and flanking the marine basin. Geochemical data procured in terms of
major, trace and REE are plotted in various diagrams to interpret the genesis of BIFs. Al2O3, Fe2O3 (T),
TiO2, CaO, and SiO2 abundances and ratios show a wide variation. Ni, Co, Zr, Sc, V, Rb, Sr, U, Th,
ΣREE, La, Ce and Eu anomalies and their binary relationships indicate that wherever the terrigenous
component has increased, the concentration of elements of felsic such as Zr and Hf has gone up. Elevated
concentrations of Ni, Co and Sc are contributed by chlorite and other components characteristic of basic
volcanic debris. The data suggest that these formations were generated by chemical and clastic
sedimentary processes on a shallow shelf. During transgression, chemical precipitation took place at the
sediment-water interface, whereas at the time of regression. Iron ore formed with sedimentary structures
and textures in Kammatturu area, in a setting where the water column was oxygenated.
Experimental Investigation on Characteristic Study of the Carbon Steel C45 in...IJMER
In this paper, the mechanical characteristics of C45 medium carbon steel are investigated
under various working conditions. The main characteristic to be studied on this paper is impact toughness
of the material with different configurations and the experiment were carried out on charpy impact testing
equipment. This study reveals the ability of the material to absorb energy up to failure for various
specimen configurations under different heat treated conditions and the corresponding results were
compared with the analysis outcome
Non linear analysis of Robot Gun Support Structure using Equivalent Dynamic A...IJMER
Robot guns are being increasingly employed in automotive manufacturing to replace
risky jobs and also to increase productivity. Using a single robot for a single operation proves to be
expensive. Hence for cost optimization, multiple guns are mounted on a single robot and multiple
operations are performed. Robot Gun structure is an efficient way in which multiple welds can be done
simultaneously. However mounting several weld guns on a single structure induces a variety of
dynamic loads, especially during movement of the robot arm as it maneuvers to reach the weld
locations. The primary idea employed in this paper, is to model those dynamic loads as equivalent G
force loads in FEA. This approach will be on the conservative side, and will be saving time and
subsequently cost efficient. The approach of the paper is towards creating a standard operating
procedure when it comes to analysis of such structures, with emphasis on deploying various technical
aspects of FEA such as Non Linear Geometry, Multipoint Constraint Contact Algorithm, Multizone
meshing .
Static Analysis of Go-Kart Chassis by Analytical and Solid Works SimulationIJMER
This paper aims to do modelling, simulation and performing the static analysis of a go
kart chassis consisting of Circular beams. Modelling, simulations and analysis are performed using 3-D
modelling software i.e. Solid Works and ANSYS according to the rulebook provided by Indian Society of
New Era Engineers (ISNEE) for National Go Kart Championship (NGKC-14).The maximum deflection is
determined by performing static analysis. Computed results are then compared to analytical calculation,
where it is found that the location of maximum deflection agrees well with theoretical approximation but
varies on magnitude aspect.
In récent year various vehicle introduced in market but due to limitation in
carbon émission and BS Séries limitd speed availability vehicle in the market and causing of
environnent pollution over few year There is need to decrease dependancy on fuel vehicle.
bicycle is to be modified for optional in the future To implement new technique using change in
pedal assembly and variable speed gearbox such as planetary gear optimise speed of vehicle
with variable speed ratio.To increase the efficiency of bicycle for confortable drive and to
reduce torque appli éd on bicycle. we introduced epicyclic gear box in which transmission done
throgh Chain Drive (i.e. Sprocket )to rear wheel with help of Epicyclical gear Box to give
number of différent Speed during driving.To reduce torque requirent in the cycle with change in
the pedal mechanism
Integration of Struts & Spring & Hibernate for Enterprise ApplicationsIJMER
The proposal of this paper is to present Spring Framework which is widely used in
developing enterprise applications. Considering the current state where applications are developed using
the EJB model, Spring Framework assert that ordinary java beans(POJO) can be utilize with minimal
modifications. This modular framework can be used to develop the application faster and can reduce
complexity. This paper will highlight the design overview of Spring Framework along with its features that
have made the framework useful. The integration of multiple frameworks for an E-commerce system has
also been addressed in this paper. This paper also proposes structure for a website based on integration of
Spring, Hibernate and Struts Framework.
Microcontroller Based Automatic Sprinkler Irrigation SystemIJMER
Microcontroller based Automatic Sprinkler System is a new concept of using
intelligence power of embedded technology in the sprinkler irrigation work. Designed system replaces
the conventional manual work involved in sprinkler irrigation to automatic process. Using this system a
farmer is protected against adverse inhuman weather conditions, tedious work of changing over of
sprinkler water pipe lines & risk of accident due to high pressure in the water pipe line. Overall
sprinkler irrigation work is transformed in to a comfortableautomatic work. This system provides
flexibility & accuracy in respect of time set for the operation of a sprinkler water pipe lines. In present
work the author has designed and developed an automatic sprinkler irrigation system which is
controlled and monitored by a microcontroller interfaced with solenoid valves.
On some locally closed sets and spaces in Ideal Topological SpacesIJMER
In this paper we introduce and characterize some new generalized locally closed sets
known as
δ
ˆ
s-locally closed sets and spaces are known as
δ
ˆ
s-normal space and
δ
ˆ
s-connected space and
discussed some of their properties
Intrusion Detection and Forensics based on decision tree and Association rule...IJMER
This paper present an approach based on the combination of, two techniques using
decision tree and Association rule mining for Probe attack detection. This approach proves to be
better than the traditional approach of generating rules for fuzzy expert system by clustering methods.
Association rule mining for selecting the best attributes together and decision tree for identifying the
best parameters together to create the rules for fuzzy expert system. After that rules for fuzzy expert
system are generated using association rule mining and decision trees. Decision trees is generated for
dataset and to find the basic parameters for creating the membership functions of fuzzy inference
system. Membership functions are generated for the probe attack. Based on these rules we have
created the fuzzy inference system that is used as an input to neuro-fuzzy system. Fuzzy inference
system is loaded to neuro-fuzzy toolbox as an input and the final ANFIS structure is generated for
outcome of neuro-fuzzy approach. The experiments and evaluations of the proposed method were
done with NSL-KDD intrusion detection dataset. As the experimental results, the proposed approach
based on the combination of, two techniques using decision tree and Association rule mining
efficiently detected probe attacks. Experimental results shows better results for detecting intrusions as
compared to others existing methods
Natural Language Ambiguity and its Effect on Machine LearningIJMER
"Natural language processing" here refers to the use and ability of systems to process
sentences in a natural language such as English, rather than in a specialized artificial computer
language such as C++. The systems of real interest here are digital computers of the type we think of as
personal computers and mainframes. Of course humans can process natural languages, but for us the
question is whether digital computers can or ever will process natural languages. We have tried to
explore in depth and break down the types of ambiguities persistent throughout the natural languages
and provide an answer to the question “How it affects the machine translation process and thereby
machine learning as whole?” .
Today in era of software industry there is no perfect software framework available for
analysis and software development. Currently there are enormous number of software development
process exists which can be implemented to stabilize the process of developing a software system. But no
perfect system is recognized till yet which can help software developers for opting of best software
development process. This paper present the framework of skillful system combined with Likert scale. With
the help of Likert scale we define a rule based model and delegate some mass score to every process and
develop one tool name as MuxSet which will help the software developers to select an appropriate
development process that may enhance the probability of system success.
Material Parameter and Effect of Thermal Load on Functionally Graded CylindersIJMER
The present study investigates the creep in a thick-walled composite cylinders made
up of aluminum/aluminum alloy matrix and reinforced with silicon carbide particles. The distribution
of SiCp is assumed to be either uniform or decreasing linearly from the inner to the outer radius of
the cylinder. The creep behavior of the cylinder has been described by threshold stress based creep
law with a stress exponent of 5. The composite cylinders are subjected to internal pressure which is
applied gradually and steady state condition of stress is assumed. The creep parameters required to
be used in creep law, are extracted by conducting regression analysis on the available experimental
results. The mathematical models have been developed to describe steady state creep in the composite
cylinder by using von-Mises criterion. Regression analysis is used to obtain the creep parameters
required in the study. The basic equilibrium equation of the cylinder and other constitutive equations
have been solved to obtain creep stresses in the cylinder. The effect of varying particle size, particle
content and temperature on the stresses in the composite cylinder has been analyzed. The study
revealed that the stress distributions in the cylinder do not vary significantly for various combinations
of particle size, particle content and operating temperature except for slight variation observed for
varying particle content. Functionally Graded Materials (FGMs) emerged and led to the development
of superior heat resistant materials.
Energy Audit is the systematic process for finding out the energy conservation
opportunities in industrial processes. The project carried out studies on various energy conservation
measures application in areas like lighting, motors, compressors, transformer, ventilation system etc.
In this investigation, studied the technical aspects of the various measures along with its cost benefit
analysis.
Investigation found that major areas of energy conservation are-
1. Energy efficient lighting schemes.
2. Use of electronic ballast instead of copper ballast.
3. Use of wind ventilators for ventilation.
4. Use of VFD for compressor.
5. Transparent roofing sheets to reduce energy consumption.
So Energy Audit is the only perfect & analyzed way of meeting the Industrial Energy Conservation.
An Implementation of I2C Slave Interface using Verilog HDLIJMER
The focus of this paper is on implementation of Inter Integrated Circuit (I2C) protocol
following slave module for no data loss. In this paper, the principle and the operation of I2C bus protocol
will be introduced. It follows the I2C specification to provide device addressing, read/write operation and
an acknowledgement. The programmable nature of device provide users with the flexibility of configuring
the I2C slave device to any legal slave address to avoid the slave address collision on an I2C bus with
multiple slave devices. This paper demonstrates how I2C Master controller transmits and receives data to
and from the Slave with proper synchronization.
The module is designed in Verilog and simulated in ModelSim. The design is also synthesized in Xilinx
XST 14.1. This module acts as a slave for the microprocessor which can be customized for no data loss.
Discrete Model of Two Predators competing for One PreyIJMER
This paper investigates the dynamical behavior of a discrete model of one prey two
predator systems. The equilibrium points and their stability are analyzed. Time series plots are obtained
for different sets of parameter values. Also bifurcation diagrams are plotted to show dynamical behavior
of the system in selected range of growth parameter
Discrete Model of Two Predators competing for One Prey
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1. International Journal of Modern Engineering Research (IJMER)
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A Review on Finite Element Simulations in Metal Forming
Dr. P. V. R. Ravindra Reddy1, G. Chandra Mohan Reddy2,
P. Radhakrishna Prasad3
1, 3
Associate Professors, Dept. of Mech. Engg., CBIT, Gandipet, Hyderabad-75;
2
Principal, MGIT, Gandipet, Hyderabad-75
Abstract: Finite element simulations are often required to reduce the experimental cost and time by reducing number of
trials in the product development cycle. Metal forming is one of such area where a lot of trials are required to arrive at the
die design to produce defect free parts. Hence in this paper the authors review the literature on finite element analysis in the
area of metal forming
Key Words: Metal Forming, Finite Element Analysis, Simulations
The term simulation is derived from the Latin word “simulare” what means “to pretend”. However, the technical meaning of
simulation is the description and reproduction of physical and technical processes by use of mathematical and physical
models. In comparison with practical tests, the simulation often is cheaper and not so dangerous. Combined with modern
methods of computation, the simulation is a powerful tool which gains more and more importance for describing and
developing new processing methods. Because of higher requirements on the quality of products and narrow tolerances of
measures, optimizing, planning and simulating of forming processes becomes more and more important. As the
computational power has increased during the last years, numerical methods play an outstanding roll. The most important
numerical method is the method of finite elements (FEM). Numerous finite element programmes have been developed which
are able to solve linear, non linear, static, dynamic, elastic, plastic, elastic – plastic, steady state, transient, isothermal as well
as non isothermal problems [1].
The deep drawing process is applied with the intention of manufacturing a product with a desired shape and no
failures. The final product shape after deep drawing is defined by the tools, the blank and the process parameters. An
incorrect design of the tools and blank shape or an incorrect choice of material and process parameters can yield a product
with a deviating shape or with failures. A deviating shape is caused by elastic springback after forming and retracting the
tools. The most frequent types of failure are wrinkling, necking (and subsequently tearing), scratching and orange peel.
Wrinkling may occur in areas with high compressive strains, necking may occur in areas with high tensile strains, scratching
is caused by defects of the tool surface and orange peel may occur after excessive deformations, depending on the grain size
of the material. The deformation patterns of the sheet material are influenced by the material properties and the processing
and tooling variables. Generally, sheet material behaves anisotropically which means that the material shows a different
deformation behavior in different directions because of the rolling process. An example of anisotropy is the development of
„ears‟ in cylindrical cup drawing. The friction conditions during forming depend on the lubricant, the presence of coatings on
the blank, surface roughness of the tools and the blank, blank holder pressure and process velocity. Without extensive
knowledge of the influences of all these variables on the deep drawing process, it is hardly possible to design the tools
adequately and make a proper choice of blank material and lubricant to manufacture a product with the desired shape and
performance. As a result, after the first design of the tools and choice of blank material and lubricant, an extensive and time
consuming trial and error process is started to determine the proper tool design and all other variables, leading to the desired
product. This trial and error process can yield an unnecessary number of deep drawing strokes, or may even require
redesigning the expensive tools. To reduce this waste of time and cost, process modeling for computer simulation can be
used to replace the experimental trial and error process by a virtual trial and error process. The prime objective of an analysis
is to assist in the design of a product. To design or select the tools and the equipment, such design essentially consists of
predicting the material flow, determining whether it is possible to form the part without surface or internal defects, predicting
the forces necessary to execute the forming operation and stresses induced during the operation.
Analytical study of Metal forming processes was started in the mid of 20 th century [2,3]. Later a number of
analyzing methods have been developed and applied to various forming processes. Some of these methods are the slab
method, the slip-line field method, the viscoplasticity method, upper and lower bound techniques and Hill‟s general method.
These methods have been useful in qualitatively predicting forming loads, overall geometry changes of the deformed blank
and material flow and approximate optimum process conditions. Numerical procedures (finite difference method) were
applied to analyze axisymetric deep drawing process in 1960s[4] Althouh the work contributed to greatly to the development
of theory of sheet metal forming analysis, that could not be applicable to the industrial components. However, a more
accurate determination of the effects of various process parameters on the deep drawing process has become possible only,
when the non linear finite element method was developed for these analyses [5-7]. Later, three dimensional auto body panel
forming process was simulated using elasto-plastic finite element method by Arlinghaus [8] and Tang [9]. They simulated
the drawing process of and left window outer and binder wrapping process of deck lid. But they were in the state of testing
and evaluation. Because finite element analysis by that time is was still extremely time consuming and unreliable tool to the
engineers in the press shop.
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2. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.4, July-Aug. 2012 pp-2326-2330 ISSN: 2249-6645
Rapid developments in computer hardware make the finite element analysis of complex deformation responses increasingly
applicable. The finite element method is used worldwide to simulate the deep drawing process and has become a reliable
numerical simulation technology. For an accurate simulation of a real-life deep drawing process an accurate numerical
description of the tools is necessary, as well as an accurate description of material behavior, contact behavior and other
process variables. The numerical description of the tools is provided by CAD packages which are generally used by tool
designers. The description of material behavior, contact behavior and other process variables evolved from rather simple
models in the earlier days to more and more sophisticated models nowadays. Developments have been made in the field of
finite element types, mesh adaptivity, material laws, failure criteria, wrinkling and surface defects, springback, contact
algorithms, friction, and simulation of new processes (optimization and process design). The conventional finite element
codes are based on implicit time integration. This involves repeated solutions of large systems of equations. Furthermore,
equilibrium must be fulfilled after each incremental step. As a result, implicit codes are computational time and memory
consuming. Hence, a new class of finite element codes based on explicit time integration was developed, resulting in a
drastic decrease of computational time. Honecker et.al [10] first demonstrated the deep drawing of an oil pan and a radiator
part by explicit method, obtaining deeply drawn shapes including wrinkle on the flange. After this several dynamic explicit
codes specialized to the sheet metal forming were developed and many automotive industries started to develop these codes.
In an explicit code no system of equations needs to be solved and static equilibrium is not checked after each incremental
step, as the algorithm assumes an inertia dominated process. The explicit procedure is conditionally stable with a critical
time step, which is proportional to the smallest element in the mesh [11]. However, in most sheet metal forming processes
inertia effects can be neglected. In order to apply the explicit algorithms in these processes, it is necessary to assume
artificially high velocities and accelerations or artificially high mass density, which seems rather unrealistic [12].
On the other hand one step method proposed by Batoz et.al [13] was developed based on the idea of Chung and Lee [14] in
which single time step was used, deforming the sheet inversely from final part configuration to initial blank configuration. A
major advantage of this method is very short computation time. Mean while there were several activities to develop codes
based on static implicit incremental approach [15-19] . But convergence is the basic problem of this approach. To avoid the
convergence problem static explicit codes were developed [20,21].
In a nutshell all these codes may be classified into five categories based on the formulation and solution strategy
used. These are dynamic explicit codes, static explicit codes, Static implicit incremental codes, Static implicit large step code
and Static implicit one step code.
The dynamic explicit approach was originally developed for the problems in which dynamic effects are important,
such as impact problems and crash simulation, and includes inertia in the equilibrium equations. The reasons for using a
method like this in metal forming are two fold. The method is extremely robust and it is very efficient for large scale
problems. In this approach the central difference explicit scheme is used to integrate the equations of motion. Lumped mass
matrices are used, which implies that the mass matrix is diagonal, and no system equations has to be solved. A typical time
step is of the order of a micro seconds and the number of time steps in typical sheet forming simulation are normally several
tens of thousands. In spite of its success for industrial applications, it has also some intrinsic drawbacks i.e. in order to
achieve significant computational advantage several numerical artifacts have to be introduced into the explicit solution
procedure. In particular the parameters like mass density, punch velocity, loading history etc are to be modified. Since the
maximum permissible time step, as defined by the current stability limit is directly proportional to the square root of the
material density, this parameter is increased, usually by at least one order of magnitude. In order to reduce the total number
of time steps necessary to model the sheet metal forming process, the punch velocity is increased, again by at least one order
of magnitude. Since increase in both the material density and punch velocity results in increased inertia forces, the punch
travel must be suitably controlled so as to minimize the inertia effects. Thus, the very nature of the dynamic explicit method,
the simulation of forming defects requires a considerable experience on the user side for adequately designing the finite
element mesh and choosing the scaling parameters of mass, velocity and damping. Other issues that must be given attention
in the dynamic explicit analysis is the simulation of the spring back. One way of improving reliability of spring back is to
combine the dynamic explicit analysis with quasi -static implicit simulation.
In the static explicit method, the system of equations representing the rate of equilibrium is integrated with a simple
forward Euler scheme, involving no iterations. This implies that equilibrium equations are satisfied only in rate form and the
obtained solution can gradually drift away from the true one. Inorder to reduce the error involved vary small incremental
steps have to be taken. An ordinary simulations normally involves several thousand steps. The main advantage of this
approach is the robustness, since there are no iterative processes.
The Static implicit incremental approach may seem ideally suited for metal forming problems, since the static
equilibrium equations are solved iteratively, ensuring that the equilibrium conditions are full filled in every step. However, in
practice complex nonlinear problems involving many contacts may results in slow or even lack of convergence. The method
is also inefficient for solving large scale problems, since time taken for solving the system of equations increases
approximately quadratically with the number of degrees of freedom.
Static implicit large step codes employ large incremental time step under special contact treatment, uncoupled
bending and stretching solution algorithm, and adoptive mesh refinement of refinement levels. These features, specialized
for the simulations of thin sheet metal forming renders code extremely efficient ,but unfortunately also make the results
approximate in respects. For instance, the contact and discontact process are not accurately simulated and there fore
wrinkling and buckling are poorly predicted.
In static implicit one step codes use a single time step, usually taking the deformation process from the final part
configuration to the initial flat blank configuration, assuming a linear strain path and neglecting the history of contact.
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3. International Journal of Modern Engineering Research (IJMER)
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Although, this method incorporates significantly drastic simplifications, its major advantage is a very short computation time
and less input data. These features enable the use of these codes at the product design stage, in the absence of information of
the stamping tools.
Currently, the accuracy and reliability of numerical simulations of sheet metal forming processes do not yet satisfy
the industrial requirements. One of the limitations of numerical simulations is still the high computational time for complex
deep drawing parts, despite the development of iterative solvers, fast contact algorithms and the ever ongoing progress in
computer hardware. Another limitation is the lack of detailed knowledge of material physics such as material behavior at
high deformations and contact behavior. Therefore extensive research in the field of sheet metal forming is and will be
necessary to decrease the existing gap between the real-life deep drawing process and the predictions obtained from deep
drawing simulations.
Deep drawing, even though is one of the most basic processes in sheet metal working, it involves very complicated
deformation mechanics. The numerical difficulty in the finite element analysis of the deep drawing processes arises due to
the existence of compressive stress in the sheet plane and the occurrence of unloading. The drawing load increases with the
punch displacement. As the punch moves, the flange part of the sheet is drawn into the die cavity. The punch load decreases
after a critical point because less resisting force to drawing is developed in the flange. In the range of decreasing punch load,
unloading occurs at the wall of a drawn cup. Therefore, in analyzing the bending-dominant processes like deep drawing, the
effect of unloading should be also considered. The state of stress at the wall and at the flange is basically tensile stress in
axial or radial direction and compressive stress in the circumferential direction. As the sheet metal has relatively a small
dimension in the thickness direction, the compressive stress may cause wrinkling in the actual process or numerical buckling
in simulation [22]. The numerical buckling is the mesh buckling phenomenon occurring in the finite element analysis at the
region of high compressive stress like actual buckling.
The modeling of the blank elements can be done by two alternative approaches [23] namely a structural based
elasto-plastic / elasto-viscoplastic approach or rigid-plastic/ rigid-visco- plastic approach. Elastic-plastic analysis of sheet
metal forming can be broadly classified into three categories according to the element types; membrane analysis, continuum
analysis and shell analysis. Membrane analysis done by Wang [24] Arlinghaus [25], Mattiason [26], Massoni (27), Saran
(28) and Batoz (29), has been widely applied to various sheet metal forming problems because of small computation time
and small memory size. However, it provides insufficient information when treating the bending-dominant processes.
Continuum analysis by Wifi (30), Anderson (31), Stalman (32), Makinouchi (33,34), Keck (35) has several merits; e.g. the
bending effect can be considered and the formulation is much simpler than other methods of analysis using different element
types. The continuum analysis, however, involves extremely large computation time and enormous memory size when three-
dimensional problems are to be treated for any practical purposes. The shell analysis by Tatenami (36), Wang (37, 38), Gelin
(39), Honnor (40), Batoz (29) and Honecker (41) may be regarded as a compromise between the continuum analysis and the
membrane analysis. It is possible to consider the effect of bending with much less computation time and less memory size
than the continuum analysis. However, most of the applications using shell elements are limited to the axisymmetric and
plane strain problems because of the difficulty in treating kinematics of three-dimensional shells, computation time and
memory size etc. Recently, the effect of bending has been studied through the comparison between the membrane analysis,
the continuum analysis and the shell analysis. Wang and Tang (38) analyzed stretching and deep drawing with axisymmetric
membrane elements and axisymmetric shell elements. In the analysis of stretching, both theories do not show any
appreciable discrepancy, while the discrepancy between two theories becomes apparent in the analysis of deep drawing.
Hambrecht et al. (42) studied the effect of bending in the plane strain punch stretching and axisymmetric stretching by the
comparison of above-mentioned three kinds of approaches. Through the study, the continuum or shell theory is necessary in
analyzing deep drawing and above three kinds of approaches do not give any difference in analyzing stretching. Yang et al.
(22) analyzed stretching of a square plate as well as deep drawing of a cylindrical cup with the rigid-plastic finite element
analyses using membrane and then they have investigated the effect of bending in the stretch dominant process and draw-
dominant processes. Now, the effect of bending has become significant in the modelling of sheet metal forming process in
order to obtain more accurate information for the die design of deep drawing. Shim and Yang [43] analysed deep drawing of
cylindrical and square cups using membrane and shell elements. They found that both theories are in good agreement with
each other in case of load-displacement curve. How ever in the neighborhood of punch round, the thinning appearing in the
experiment can not be predicted by membrane analysis. In the shell analysis the thickness strain distribution is better
predicted over whole range of sheet. It is due to the fact that bending of sheet effects considerably the thickness strain
distribution and bending has no significant affect in load-displacement curve. So shell element is considered to be most
suitable for the analysis in deep drawing process.
Finite Element models for rigid visco-plastic thin sheet problems was presented by Bellet et.al.[44]. A viscous shell
formulation was introduced by Onate et.al [28] , who considered visco-plastic deformation of the work material as well as
frictional affects of punch and die. Onate et.al [45]discussed viscous shell approach based on bending and membrane shell
elements.
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