Welding is invariably used in the automotive industries for joining variety of structural
components and engine parts. The constant demand for new improved material requirement for
automotive applications necessitates the development of innovative joining techniques. In this paper, the
welding techniques commonly adapted in the automotive industries are discussed. Illustrative diagrams
and specific automotive applications are included in the paper. The novel technique of joining dissimilar
metals viz., magnetic pulse welding is also discussed. The latest update on medium frequency welding
method used by auto manufacturers is also presented with its technical and operational merits
Electron Beam Welding is a fusion welding process in which a beam of high-velocity electrons is applied to the material to be joined. The work-piece melt as the kinetic energy of the electrons is transformed into heat upon impact. The EBW process is well-positioned to provide industries with highest quality welds and machine designs that have proven to be adaptable to specific welding tasks and production environments.
Here I have explained theoretical view of ultrasonic welding and its applications in real world.
In addition to that, advantages and disadvantages of this process also discussed.
Welding process
Arc Welding
Resistance Welding
Oxy fuel Gas Welding
Other Fusion Welding Processes
Solid State Welding
Weld Quality
Weld ability
Design Considerations in Welding
Selective Laser Sintering is one of the most used processes of Rapid Prototyping. It is a powder based process where powder of different metals/materials get sintered by LASER.
One of the welding processes that used in Engineering field is the metal inert gas welding. There are several types of welding processes similar to this, but MIG welding has its unique features.
Thanks for the colleagues who give this slides to publish.
Electron Beam Welding is a fusion welding process in which a beam of high-velocity electrons is applied to the material to be joined. The work-piece melt as the kinetic energy of the electrons is transformed into heat upon impact. The EBW process is well-positioned to provide industries with highest quality welds and machine designs that have proven to be adaptable to specific welding tasks and production environments.
Here I have explained theoretical view of ultrasonic welding and its applications in real world.
In addition to that, advantages and disadvantages of this process also discussed.
Welding process
Arc Welding
Resistance Welding
Oxy fuel Gas Welding
Other Fusion Welding Processes
Solid State Welding
Weld Quality
Weld ability
Design Considerations in Welding
Selective Laser Sintering is one of the most used processes of Rapid Prototyping. It is a powder based process where powder of different metals/materials get sintered by LASER.
One of the welding processes that used in Engineering field is the metal inert gas welding. There are several types of welding processes similar to this, but MIG welding has its unique features.
Thanks for the colleagues who give this slides to publish.
the slide shows the advance welding technic like as Tig And Mig Welding Process.
it help people to understand the advance manufacturing process for welding.
it made by Sk Samsuddin.
One of the welding processes that used in Engineering field is the electron beam welding. There are several types of welding processes similar to this, but electron beam welding has its unique features.
Thanks for the colleagues who give this slides to publish.
One of the welding processes that used in Engineering field is the electrogas welding. There are several types of welding processes similar to this, but electrogas welding has its unique features.
Thanks for the colleagues who give this slides to publish.
This Presentation covers the basic concepts of Hot cracks and cold cracks in welding. For more information, please refer the books mentioned in the references slide.... Thank you
The objective of this subject is to develop a practical understanding of welding with regard to welding processes, and auxiliary welding equipment for the welder. Also, to develop a technical understanding of the information contained on engineering drawings and the use of the information to communicate setup and welding instructions from the designer to the welder and fitter.This subject is very important for engineering as well as diploma in Mechanical Engineering department students.I hope you will get some ideas about welding technology.
The industrial development program of any country, by and large, is based on its natural resources.
Currently the majority of the world’s steel is produced through either one of the two main routes: i) the integrated Blast Furnace – Basic Oxygen Furnace (BF – BOF) route or ii) the Direct Reduced Iron - Electric Arc Furnace (DRI - EAF) route.
Depleting resources of coking coal, the world over, is posing a threat to the conventional (Blast Furnace [Bf]–Basic Oxygen Furnace [BOF]) route of iron and steelmaking.
During the last four decades, a new route of ironmaking has rapidly developed for Direct Reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas.
This product is known as Direct Reduced Iron (DRI) or Sponge Iron.
Processes that produce iron by reduction of iron ore (in solid state) below the melting point are generally classified as DR processes.
Based on the types of reductant used, DR processes can be broadly classified into two groups: (1) coal-based DR process and (2) gas-based DR process.
Details of DR processes, reoxidation, storage, transportation, and application of DRI are discussed in this presentation.
This presentation reviews the different DR processes used to produce Direct Reduced Iron (DRI), providing an analysis on the quality requirements of iron-bearing ores for use in these processes. The presentation also discusses the environmental sustainability of such processes. DR processes reduce iron ore in its solid state by the use of either natural gas or coal as reducing agents, and they have a comparative advantage of low capital costs, low emissions and production flexibility over the BF process.
the slide shows the advance welding technic like as Tig And Mig Welding Process.
it help people to understand the advance manufacturing process for welding.
it made by Sk Samsuddin.
One of the welding processes that used in Engineering field is the electron beam welding. There are several types of welding processes similar to this, but electron beam welding has its unique features.
Thanks for the colleagues who give this slides to publish.
One of the welding processes that used in Engineering field is the electrogas welding. There are several types of welding processes similar to this, but electrogas welding has its unique features.
Thanks for the colleagues who give this slides to publish.
This Presentation covers the basic concepts of Hot cracks and cold cracks in welding. For more information, please refer the books mentioned in the references slide.... Thank you
The objective of this subject is to develop a practical understanding of welding with regard to welding processes, and auxiliary welding equipment for the welder. Also, to develop a technical understanding of the information contained on engineering drawings and the use of the information to communicate setup and welding instructions from the designer to the welder and fitter.This subject is very important for engineering as well as diploma in Mechanical Engineering department students.I hope you will get some ideas about welding technology.
The industrial development program of any country, by and large, is based on its natural resources.
Currently the majority of the world’s steel is produced through either one of the two main routes: i) the integrated Blast Furnace – Basic Oxygen Furnace (BF – BOF) route or ii) the Direct Reduced Iron - Electric Arc Furnace (DRI - EAF) route.
Depleting resources of coking coal, the world over, is posing a threat to the conventional (Blast Furnace [Bf]–Basic Oxygen Furnace [BOF]) route of iron and steelmaking.
During the last four decades, a new route of ironmaking has rapidly developed for Direct Reduction (DR) of iron ore to metallic iron by using noncoking coal/natural gas.
This product is known as Direct Reduced Iron (DRI) or Sponge Iron.
Processes that produce iron by reduction of iron ore (in solid state) below the melting point are generally classified as DR processes.
Based on the types of reductant used, DR processes can be broadly classified into two groups: (1) coal-based DR process and (2) gas-based DR process.
Details of DR processes, reoxidation, storage, transportation, and application of DRI are discussed in this presentation.
This presentation reviews the different DR processes used to produce Direct Reduced Iron (DRI), providing an analysis on the quality requirements of iron-bearing ores for use in these processes. The presentation also discusses the environmental sustainability of such processes. DR processes reduce iron ore in its solid state by the use of either natural gas or coal as reducing agents, and they have a comparative advantage of low capital costs, low emissions and production flexibility over the BF process.
Spot welding /certified fixed orthodontic courses by Indian dental academy Indian dental academy
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Industrial robots play an increasing role in modern production and assembly facilities. The different types of robot available and their configuration are discussed. Examples of typical uses in sectors of the engineering industry are also identified.
Now days robots are used every where. Most of the robots are used in manufacturing industry. With automation of automobile industry robots are used to work that are hard, dangerous for humans.
Resistance Spot Welding - Development of Simulation Tool for EngineersRashidi Asari
The development of graphical tool for welding engineers & technicians to select the optimized welding parameters that suit with sheet metal and equipment to be used at production line side.
Resistance Spot Welding - Process Optimization using Lobe Curve GeneratorRashidi Asari
In spot welding process, process parameters optimization means improve spot welding quality while reduce operational cost especially power consumption and welding consumables. Lobe curve generators may assist welding engineers and technicians to select the best welding parameters according to their requirements.
A REVIEW ON OPTIMIZATION OF RESISTANCE SPOT WELDING OF ALUMINUM COMPONENTS US...AM Publications
Resistance Spot welding (RSW) is one of the common welding processes used for sheet joining especially in the automobile and aerospace industry. It is used in a wide range of industries but notably for the assembly of sheet steel vehicle bodies. This is a type of resistance welding where the spot welds are made at regular intervals on overlapping sheets of metal. Spot welding is primarily used for joining parts that are normally up to 3 mm in thickness. The joint quality can be defined in terms of properties such as weld-bead geometry, mechanical properties and distortion.The objective of the research is to determine the optimum combination of parameters responsible for better quality of joints. The complicated behavior of the process must be analyzed to set the optimum parameters to get the optimum weld quality. The paper also presents the FEA simulation of the RSW process.
A Review: Welding Of Dissimilar Metal Alloys by Laser Beam Welding & Friction...IJERA Editor
Welding of dissimilar metals has attracted attention of the researchers worldwide, owing to its many advantages and challenges. There is no denial in the fact that dissimilar welded joints offer more flexibility in the design and production of the commercial and industrial components. Many welding techniques have been analyzed to join dissimilar metal combinations. The objective of this paper is to review two such techniques – Laser welding and Friction stir welding. Laser beam welding, a high power density and low energy-input process, employs a laser beam to produce welds of dissimilar materials. Friction stir welding, a solid-state joining process, is also successfully used in dissimilar welding applications like aerospace and ship building industries. This paper summarizes the trends and advances of these two welding processes in the field of dissimilar welding. Future aspects of the study are also discussed.
Numerical Simulation of Resistance Spot Welding of Steel Sheets HCT600X ZFijtsrd
Nowadays, there are so many reasons behind utilizing high strength steel sheets, more precisely DP dual phase steels in car body production. Car producers tend to choose steel with optimal parameters such as great formability and the capacity to absorb the energy of the collision. HCT600X ZF steel is among the best known and most used high strength materials in car body production. The most used and well known technology for joining high strength steel sheets is precisely the technology of resistance spot welding. RSW Resistance spot welding , is the well known method to join mentioned materials. Simulation programs are utilized to optimize the processes of joining before the joining system is carried out. One of the most popular software for simulating the process of RSW is Simufact Welding. The article deals with parameter optimization of RSW resistance spot welding for hot dip zinc iron coated dual phase steel sheets. The mechanical properties and metallographic observation of joints created by RSW technology on galvanized steel sheets were performed. The result of the simulation of the RSW process was compared with metallographic images after the joining process. Denis Cmorej | Luboš Kašcák | Julius Hajduk "Numerical Simulation of Resistance Spot Welding of Steel Sheets HCT600X+ZF" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-6 | Issue-7 , December 2022, URL: https://www.ijtsrd.com/papers/ijtsrd52472.pdf Paper URL: https://www.ijtsrd.com/engineering/mechanical-engineering/52472/numerical-simulation-of-resistance-spot-welding-of-steel-sheets-hct600xzf/denis-cmorej
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
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Student information management system project report ii.pdfKamal Acharya
Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
AKS UNIVERSITY Satna Final Year Project By OM Hardaha.pdf
Automotive Applications of Welding Technology – A Study
1. International
OPEN ACCESS Journal
Of Modern Engineering Research (IJMER)
| IJMER | ISSN: 2249–6645 | www.ijmer.com | Vol. 4 | Iss.9| Sept. 2014 | 13|
Automotive Applications of Welding Technology – A Study Devarasiddappa. D Department of Automobile Engineering, Rajiv Gandhi Govt. Polytechnic, Itanagar, Arunachal Pradesh, India
I. INTRODUCTION
Basically, welding is used to obtain permanent joint of two metals through localized application of suitable combination of temperature, pressure and metallurgical conditions. A wide variety of welding processes have been developed by different combinations of temperature and pressure. Welding is the principal means of fabricating and repairing of metal products and is used in every industry [1]. Amongst the major areas of applications, welding is extensively used in automotive industries. The most commonly used welding methods for automotive applications include resistance spot welding (RSW), resistance seam welding (RSEW), metal inert gas (MIG) welding, tungsten inert gas (TIG) welding, laser beam welding (LBW), friction welding (FW) and plasma arc welding (PAW). The advanced welding processes for automotive applications have been developed envisaging reduction in vehicle weight and increase in fuel efficiency [2]. In conventional welding methods, an additional material is always added to the weld joint that flows into the materials to be joined to produce an extremely strong bond. The added metal at each weld increases the vehicle weight which in turn decreases fuel economy. In this paper, welding techniques used in automotive applications viz., RSW, RSEM, FW, LBW are discussed. The advanced technique viz., magnetic pulse welding (MPW) process used to produce lighter weld components is also presented. The latest welding technology i.e. medium frequency welding (MFW) used in the automotive industries is also discussed in this paper.
II. AUTOMOTIVE APPLICATIONS OF WELDING
A wide variety of automobile body components are joined together using welding techniques. The necessity for development of new welding techniques for automotive applications is ever growing to meet the new material combinations for auto body parts. The requirement for innovative welding processes is felt strongly in the recent days with automotive manufactures focusing on lighter yet strong and fuel efficient vehicles employing light weight alternative materials. The most commonly used welding techniques in automotives applications are explained in the following sections. 2.1 Resistance spot welding The conventional steel body of a car, on an average, contains 4500 spot weld joints. Resistance spot welding is the principle joining method used in automotive industries and has been for many years. In this method the joint is produced by the heat generated due to the resistance of work pieces to the flow of current and application of pressure [3]. The weld is limited to the spots on overlapped work pieces and hence not continuous. The pointed copper electrodes conduct the welding current to the work spot and also serve to apply pressure to form the strong joint as shown in the Fig. 1.
Abstract: Welding is invariably used in the automotive industries for joining variety of structural components and engine parts. The constant demand for new improved material requirement for automotive applications necessitates the development of innovative joining techniques. In this paper, the welding techniques commonly adapted in the automotive industries are discussed. Illustrative diagrams and specific automotive applications are included in the paper. The novel technique of joining dissimilar metals viz., magnetic pulse welding is also discussed. The latest update on medium frequency welding method used by auto manufacturers is also presented with its technical and operational merits.
Keywords: Automotive applications, Magnetic pulse welding, Medium frequency welding, Welding
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Fig. 1 Resistance spot welding RSW is automated and used in the form of robotic spot welding in automotive industries to weld the sheet metals to form car body. Industrial robots spot welding the car body in production line is shown in the photograph given in Fig. 2. Fig. 2 Industrial robots welding car body (Source: Rexroth- Bosh group) [4] 2.2 Resistance seam welding In this type of resistance welding, the joint is produced progressively along the length of the weld. This gives a continuous and leak tight joint in sheet metals. The weld may be made with overlapping or continuous work pieces. In automobile industries, this welding process is used to produce leak proof fuel tanks. The principle of RSEW is depicted in the Fig. 3. This process provides high welding speeds, but its applicability is limited by component shape and wheel access. A seam welding process in operation is shown in Fig. 4. Fig. 3 Principle of resistance seam welding
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Fig. 4 RSEW producing continuous joint 2.3 Friction welding In solid state welding the joint is produced by the application of pressure without significant melting any of the work parts. Friction welding is a form of solid state welding where the heat is obtained from the mechanically induced sliding motion between the parts to be welded [5]. The weld parts are held together under pressure. Generally, the frictional heat is generated by rotating one part against the other. When certain temperature is reached, the rotational motion is seized and the pressure applied welds the parts together. The two shafts joined by FW process is depicted in Fig. 5. This welding process can be controlled by regulating the time, rotational speed and pressure. Fig. 5 Shafts joined by friction welding process The metallic materials possessing certain degrees of plasticity at high temperature and thermal stability can easily be friction welded. Although all common engineering alloys can be friction welded, cast iron is an exception. In automotive industries, the FW is used to fabricate a wide range of components including half shafts, axle cases, steering columns, hydraulic cylinders, pistons rods and engine valves etc. The Fig. 6 shows few friction welded automotive components. Fig. 6 Friction welded automotive components (Engine valves and tie rod)
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2.4 Laser beam welding
The application of laser technology for welding the high volume automotive components has gained
popularity because of its distinct advantages. The main benefits include good flexibility, improved productivity
with substantial saving on maintenance and energy cost while producing a strong weld. The LBW process uses
the heat generated when a focused laser beam impinges on the joint. Metal sheets having thickness in the
range 0.2 to 6mm can easily be laser welded. Majority of the automotive industries employ cross flow CO2
laser system in the power range of 3 to 5 kW [6]. The schematic arrangement of components of a typical laser
welding system is depicted in the Fig. 7.
Fig. 7 Diagram of laser beam welding (Source: Oguzhan Yılmaz )
The laser beam directed on the workstation is focused on the parts to be welded using the copper
mirrors. It is a non contact process and well suited for automated applications. The process parameters such as
laser power, speed and focused spot size determine the weld depth and width. A beam from one laser source
can easily be switched to several workstations allowing optimum utilization of laser for different welding
functions. This inherent flexibility of LBW satisfies high volume automotive production requirement for
different part geometries without extensive set up. The Fig. 8 shows welding of low carbon steel sheet using
CO2 laser system.
Fig. 8 Laser beam welding of low carbon steel sheet
Joining automatic transmission components found particularly suited for LBW. The components
produced from powder metallurgy (PM) process are increasingly used in the automotives. The performance of
PM components is characterized by combination of finished density, composition of alloying elements and part
microstructure. These factors provide greater flexibility to determine weldability of PM components. The
density is reported to have pronounced influence on performance and weldability [7]. The other automotive
applications LBW include welding of roof to the side panels of car body structure. A continuous water tight
joint with better accuracy can be obtained as less material is displaced. Also, post treatment of the weld is not
necessary [8]. The evaluation of laser beam process for joining hinges to the reinforcement structure of car
door is presented by Quintino et al., [9, 10]. The CO2 laser equipment giving output power of 6 kW was used
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in the evaluation. The surface finish of the parts affected porosity formation with LBW, hence improved surface finish can overcome this problem. 2.5 Medium frequency welding The medium frequency welding is a type of resistance welding and latest offering from Bosch-Rexroth Ltd, Great Britain. The Fig. 9 depicts the basic working principle of MFW. In this welding process, the three- phase 50 Hz alternating current (AC) is rectified and supplied to an inverter. The inverter converts the current to a frequency of 1000 Hz (medium frequency) and is fed to a transformer, usually integrated into the welding gun [4]. Hence the welding current available is always direct current (DC). The technical and operational merits of MFW are listed in the Table 1. Fig. 9 Working principle of MFW Table 2 Technical and operational advantages of MFW
Sl. No.
Merit
Description
1
Reduced bill
It is less demanding on electrical distribution network since it draws current from all the three phases. This in turn results reduced electricity charges.
2
More tolerant
The welding current is supplied thorough an inverter and hence the process is more tolerant of mains disturbances.
3
Higher operating efficiency
As much as 25 % power savings can be achieved against single phase AC system. The transformers used are more compact and lighter. Most suitable for robotic applications. Hence robots can be made smaller and less power is expended in moving welding gun.
4
Faster welding
Due to reduced or no current fluctuations weld times are approximately 15 % shorter and can be controlled to millisecond. This gives 20 times more accuracy than 50 Hz AC supply. Since there is no resistance in the welding arm, the arm lengths and tip characteristics do not affect weld times. The enhanced tip life results in considerable savings on tip dressing and consumables.
5
Cleaner weld
It gives high quality weld with peak voltage is almost same as RMS voltage. No splash or sparks are present in the weld.
6
More material choices
The process is controllable to high accuracy. Difficult to weld materials such as high strength steel, aluminium, laminated steels, polymer composites, coated steels etc can be welded easily.
2.6 Magnetic pulse welding The demand for lighter and fuel efficient vehicles has increased in the recent days. The automotive manufactures strive to produce lighter components. This helps to make existing cars more fuel efficient and meet the requirement of alternative fuel powered vehicles viz. fuel-cell powered cars and hybrid gas/electric vehicles. The use of lighter material like aluminum and development of new manufacturing processes using less steel in weld can help to achieve the above goal. The additional material deposited on weld joint as in conventional welding process increases the weight of the welded component. The MPW is a novel technology developed by Dana Corporation, USA for bonding aluminium and steel (dissimilar metals) without using additional metal at the weld joint [2]. In this method, the pre-shaped aluminum and steel tubular stock are subjected to high pressure using precision machined die cavities. This process is called hydro-forming and results in more precise fitting of structural components requiring very little fill material in the subsequent welding steps.
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The hydro-formed components are then fitted together loosely. A rapidly switching magnetic field produced by an inductor (either internally or externally) causes one of the metallic components to form quickly and impact the other stationary metal part with sufficient velocity and force to create a weld. This requires high end machines to produce proper welds in complex geometric designs. The MPW process enhances manufacturing productivity due to reduction in production steps, materials, equipments and personnel expenses. The vehicle frame welded with MPW process is reported to be two–thirds lighter resulting in 8-10% improvement in fuel efficiency. This further reduces air pollution. The reduced energy consumption and shielded gases further aid to decrease air pollution. The MPW process is more efficiently used to produce automobile parts such as frames, side rails, cradles, stampings, space frames, and bumper reinforcements (Fig. 10). Fig. 10 Automobile components (frames) produced by MPW process (Source: Dana Corporation, USA) With the commercialization of MPW process, it is possible to weld dissimilar metals (bimetallic welding) most effectively. This helps to design new geometries for automobile transmissions and undercarriage systems using different combinations of lighter materials to enhance fuel economy and cost savings.
III. Conclusions
The automotive application of permanent joining methods is discussed with illustrative diagrams. The resistance welding techniques namely spot and seam welding are presented with specific applications. The solid state welding method viz. the friction welding is also discussed. The need for innovative and cost effective welding methodologies to meet the growing requirement of lighter and fuel efficient vehicles is highlighted. The technological advancement in the metal joining in the context of auto industry is presented. The working aspect of medium frequency welding is briefed with its distinct merits. The magnetic pulse welding-a breakthrough in metal joining technique is also explained. The following points concluded from this above study.
The automotive manufacturers focused on producing lighter yet strong and fuel efficient vehicles using new improved alternative materials. This necessitated most efficient welding techniques that produce lighter weld joints without adding additional material.
The commercial implementation of magnetic pulse welding can prove advantageous for automotive industries to manufacture lighter and fuel efficient cars.
The advancement in laser beam welding and medium frequency welding allows evolving new geometries for automobile transmissions and undercarriage systems using new combinations of materials, particularly made from powder metallurgy process.
Acknowledgements The author acknowledges the financial support extended by his parent institute under the NE-QIP scheme of AICTE in the publication of this paper. The author also acknowledges the valuable feedback/suggestion of the anonymous reviewers.
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