International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
EXPERIMENTAL ANALYSIS AND MODELLING OF GRINDING AISI D3 STEELijmech
Grinding of hardened steels for the realisation of better surface quality of the workpiece is an essentiality
of high productivity environments. The surface grinding of high carbon high chromium steels like AISI D3
with a production level grinding wheel used in the industry is the driver of the present research article. The
experimentation is done in dry as well as pool cooling conditions to ascertain the better of the two
conditions in providing a better set of cutting forces and surface finish. A mathematical model for
evaluating the forces generated during grinding is evolved and on comparison of the results obtained from
the model with the ones from experimentation is found to be correlating. The usage of production level
vitrified grinding wheel has shown good results in terms of lower forces generated and good surface finish
during surface grinding. The results are optimised and the set of inputs which yield good surface finish and
low forces are given. Dry grinding of AISI D13 yields good surface finish than wet grinding. Surface finish
of 0.14 microns is achievable using dry grinding.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
EXPERIMENTAL ANALYSIS AND MODELLING OF GRINDING AISI D3 STEELijmech
Grinding of hardened steels for the realisation of better surface quality of the workpiece is an essentiality
of high productivity environments. The surface grinding of high carbon high chromium steels like AISI D3
with a production level grinding wheel used in the industry is the driver of the present research article. The
experimentation is done in dry as well as pool cooling conditions to ascertain the better of the two
conditions in providing a better set of cutting forces and surface finish. A mathematical model for
evaluating the forces generated during grinding is evolved and on comparison of the results obtained from
the model with the ones from experimentation is found to be correlating. The usage of production level
vitrified grinding wheel has shown good results in terms of lower forces generated and good surface finish
during surface grinding. The results are optimised and the set of inputs which yield good surface finish and
low forces are given. Dry grinding of AISI D13 yields good surface finish than wet grinding. Surface finish
of 0.14 microns is achievable using dry grinding.
Effect of machining parameters on surface roughness for 6063 al tic (5 & 10 %...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
APPLICATION OF GREY RELATIONAL ANALYSIS FOR MULTI VARIABLE OPTIMIZATION OF PR...IAEME Publication
The present work deals with a simple approach which predicts the optimum setting
of process parameters of drilling operation on Polymer Based Glass Fiber (PBGF)
composite. The process parameters selected are drill angle (DA), Drill diameter (DD),
Material Thickness (MT), Speed (N) and Feed (f). The output parameters are Thrust,
Torque, Surface Roughness and Delamination. Three levels of each input parameters
are considered. Taguchi’s L27 array is used to set the process parameters. Gray
relational analysis (GRA) is used to find the optimum value of process parameters.
Conduction of ANOVA on GRA shown the significance of each factor on the process
output. A conformation test conducted revealed that the setting of parameters ensures
optimum output
Thinning and springback prediction of Mg alloy AZ31 in deep drawing process –...IJCMESJOURNAL
Magnesium is nowadays the lighter metal used in structural applications with expressive advantages over steel and aluminum. Due to its low density and high specific strength, magnesium alloys represent a promising alternative, especially for applications in automobile industry, being used in structural components in order to reduce weight and, consequently, improve fuel efficiency. In the recent decades, several researches have been performed in order to improve the use of Mg alloys in forming process since its formability is strongly affected by some conditions as temperature. In this study, a Finite Element Analysis (FEA) is performed to simulate the sheet metal deep drawing process of the magnesium alloy AZ31. The main objective is to evaluate the effect of the blank holder force and friction conditions in the formability by predicting results of springback, thickness distribution and thinning of the sheet metal blank. In total, 54 simulations were performed.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
Finite element analysis of center pin and bracket of jig fixture assembly ijm...Dr.Vikas Deulgaonkar
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Parametric Optimization on MIG Welded EN8 Material Joints by using Taguchi Me...ijsrd.com
Welding is a manufacturing process, which is carried out for joining of metals. By MIG Welding it is possible to weld in all positions. Optimization of the parameter will be carried out by Taguchi method. We will use EN-8 material which is more use in Automobile parts. EN8 plate with dimensions 250mm x 125mm x 6mm with V- Groove 650.Where the input parameters are welding current, Wire feed and gas flow rate and output parameters are tensile strength and Hardness.
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
Numerical Simulation of Knuckle Joint Using Finite Element Method: A New Appr...dbpublications
For the past few decades, there has
been a rapidprogress in the field ofmaterial science
which has resulted in the reduction of cost and
weight of materials. This modified systems
developed by incorporating various advanced and
smarter materialshas led to areduction in number of
accidents andtherefore, the safety has increased,
which again has been an utmost concern for any
industry in modern times.
The present work is an attempt to provide
the readers with a comparative overview in the
context of conventional and advanced materials
focusing on a mechanical joint, i.e. the Knuckle
joint. A Knuckle joint finds its extensive
application for connecting two rods subjected to
normal tensile load and requiring flexibility in its
angular movements. Here, we are suggesting a
modification over theconventionally used material,
such as Aluminium alloythat is widely used for
manufacturing the Knuckle joints.The results
obtained from our study approves that the use of
composite material not only decreases the weight
of the material but it also improves the life of the
component as the composite material shows less
deformation in comparison to the conventional one.
In the present work, CATIA V5R18 has been used
for modellingthe 3D geometry of Knuckle Joint
and ANSYS (Workbench 16.2) is been used for
finite element analysis of the same with
the conventional and composites materials
respectively. Composite analysis is based on Rule
of mixtures.
Scope of Improving Energy Utilization in Coal Based Co-Generation on Thermal ...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
A Novel Clustering Method for Similarity Measuring in Text DocumentsIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Effect of machining parameters on surface roughness for 6063 al tic (5 & 10 %...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
APPLICATION OF GREY RELATIONAL ANALYSIS FOR MULTI VARIABLE OPTIMIZATION OF PR...IAEME Publication
The present work deals with a simple approach which predicts the optimum setting
of process parameters of drilling operation on Polymer Based Glass Fiber (PBGF)
composite. The process parameters selected are drill angle (DA), Drill diameter (DD),
Material Thickness (MT), Speed (N) and Feed (f). The output parameters are Thrust,
Torque, Surface Roughness and Delamination. Three levels of each input parameters
are considered. Taguchi’s L27 array is used to set the process parameters. Gray
relational analysis (GRA) is used to find the optimum value of process parameters.
Conduction of ANOVA on GRA shown the significance of each factor on the process
output. A conformation test conducted revealed that the setting of parameters ensures
optimum output
Thinning and springback prediction of Mg alloy AZ31 in deep drawing process –...IJCMESJOURNAL
Magnesium is nowadays the lighter metal used in structural applications with expressive advantages over steel and aluminum. Due to its low density and high specific strength, magnesium alloys represent a promising alternative, especially for applications in automobile industry, being used in structural components in order to reduce weight and, consequently, improve fuel efficiency. In the recent decades, several researches have been performed in order to improve the use of Mg alloys in forming process since its formability is strongly affected by some conditions as temperature. In this study, a Finite Element Analysis (FEA) is performed to simulate the sheet metal deep drawing process of the magnesium alloy AZ31. The main objective is to evaluate the effect of the blank holder force and friction conditions in the formability by predicting results of springback, thickness distribution and thinning of the sheet metal blank. In total, 54 simulations were performed.
Finite Element Simulation and Experiment of Chip Formation Process during Hig...IDES Editor
As an advanced manufacturing technology which
has been developed rapidly in recent years, high speed
machining is widely applied in many industries. The chip
formation during high speed machining is a complicated
material deformation and removing process. In research area
of high speed machining, the prediction of chip morphology is
a hot and difficult topic. A finite element method based on the
software ABAOUS which involves Johnson-Cook material
model and fracture criterion was used to simulate the serrated
chip morphology and cutting force during high speed
machining of AISI 1045 hardened steel. The serrated chip
morphology and cutting force were observed and measured by
high speed machining experiment of AISI 1045 hardened steel.
The effects of rake angle on cutting force, sawtooth degree
and space between sawteeth were discussed. The investigation
indicates that the simulation results are consistent with the
experiments and this finite element simulation method
presented can be used to predict the chip morphology and
cutting force accurately during high speed machining of
hardened steel.
Finite element analysis of center pin and bracket of jig fixture assembly ijm...Dr.Vikas Deulgaonkar
The manufacturing industry caters the range of products to satisfy the ever changing market needs.
To overcome the increasing production demands, the industry implies various techniques. We need a technique for
increasing the production of drilling two holes on a Railway Pinion, improve the quality of product and reduce the
operation time. This project aims to design the Jig and Fixture for the same. The 3-dimensional Computer Aided Model
of the components is made using CATIA V5-R21 software. To study the behavior of component, simulation is carried out.
Preprocessing of the CAD model is carried in Hypermesh software. Boundary conditions are applied using physical
situations of the components. Finite element analysis of the components is done, and the results obtained are compared
with the theoretical analysis and also with the available literature. The stresses and deformations are found within desired limits. Using FE analysis, the parts are manufactured and assembled.
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Parametric Optimization on MIG Welded EN8 Material Joints by using Taguchi Me...ijsrd.com
Welding is a manufacturing process, which is carried out for joining of metals. By MIG Welding it is possible to weld in all positions. Optimization of the parameter will be carried out by Taguchi method. We will use EN-8 material which is more use in Automobile parts. EN8 plate with dimensions 250mm x 125mm x 6mm with V- Groove 650.Where the input parameters are welding current, Wire feed and gas flow rate and output parameters are tensile strength and Hardness.
Surface Topology Evaluation of P20 Steel by Multipass Cutting Strategy in Wir...IJERA Editor
Wire EDM process eliminates the work materials by a series of electrical sparks between the workpiece and wire electrode. These sparks creates craters and burs on the machined surface. Machined surface with poor integrity is a major disadvantage of WEDM. This work presents the investigation on multi-pass cutting operation (single rough cut followed by multi trim cuts) in wire electrical discharge machining (WEDM) of p20 steel. Trim cuts were performed using Taguchi’s design of experiment method to investigate the influence of discharge current (Ip), pulse-on time (Ton), pulse-off time, servo voltage and number of trim cuts on two performance characteristics namely cutting rate and surface roughness (SR).Experiments were performed using 0.25mm brass wire. Result shows that the surface finish improves significantly in trim cutting operation.
“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
Finite Element Simulation of Serrated Chip Formation in High Speed CuttingIJRES Journal
The description of high speed cutting process with simulation based on finite element method provides huge superiorities compared to analytical and experimental models. This work focused on the study of high speed cutting process with finite element method, using commercial software ABAQUS/Explicit. The chip morphology is predicted, and the stress, strain and temperature in the chip are all simulated vividly when cutting stably. The serrated chip formation is explained by the adiabatic shear theory. The results showed that it is better to use the adiabatic shear theory to explain the formation of serrated chip.
Numerical Simulation of Knuckle Joint Using Finite Element Method: A New Appr...dbpublications
For the past few decades, there has
been a rapidprogress in the field ofmaterial science
which has resulted in the reduction of cost and
weight of materials. This modified systems
developed by incorporating various advanced and
smarter materialshas led to areduction in number of
accidents andtherefore, the safety has increased,
which again has been an utmost concern for any
industry in modern times.
The present work is an attempt to provide
the readers with a comparative overview in the
context of conventional and advanced materials
focusing on a mechanical joint, i.e. the Knuckle
joint. A Knuckle joint finds its extensive
application for connecting two rods subjected to
normal tensile load and requiring flexibility in its
angular movements. Here, we are suggesting a
modification over theconventionally used material,
such as Aluminium alloythat is widely used for
manufacturing the Knuckle joints.The results
obtained from our study approves that the use of
composite material not only decreases the weight
of the material but it also improves the life of the
component as the composite material shows less
deformation in comparison to the conventional one.
In the present work, CATIA V5R18 has been used
for modellingthe 3D geometry of Knuckle Joint
and ANSYS (Workbench 16.2) is been used for
finite element analysis of the same with
the conventional and composites materials
respectively. Composite analysis is based on Rule
of mixtures.
Scope of Improving Energy Utilization in Coal Based Co-Generation on Thermal ...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
A Novel Clustering Method for Similarity Measuring in Text DocumentsIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Effect Estimation Method of Parallel Computing Based on Dynamic Generation of...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
Strehl Ratio with Higher-Order Parabolic FilterIJMER
In all the branches of science, engineering and technology, it is known that the output due to
an input impulse function, spatial or temporal, is never an impulse. There is a spread of the input impulse
function in the output due to the noise introduced by the physical device. It was Strehl who first
introduced the important image-quality assessment parameter “Definitionshelligkeit” or simply known
as the Strehl Ratio (SR) after his name. In this paper, we have studied this parameter for an optical
system apodised with the higher-order super-resolving parabolic filters. The results obtained have been
discussed graphically
Analysis of MOS Capacitor Loaded Annular Ring MICROSTRIP AntennaIJMER
In this paper a new technique is proposed for achieving increased frequency agility by loading
the patch antenna with a MOS capacitor. Theoretical investigations have been carried out for the MOS
capacitor loaded Annular Ring microstrip antenna, for oxide thicknesses from 100 A to 500 A, to predict
the achievable range of operational bandwidth. In spite of numerous advantages, the simple patch antenna
has a low operational bandwidth, which limits its applicability. Hence this technique of MOS capacitor
loaded Annular Ring microstrip patch antenna is to improve the operating frequency range.
A Technology Review of Electricity Generation from Nuclear Fusion Reaction in...IJMER
In this review paper, we have tried to revisit the basic concept of nuclear fusion and the recent
thrust that has been witnessed in the recent times towards power generation from it . In fusion we get the
energy when two atoms fused together to form one atoms. With current technology the reaction most
readily feasible is between the nuclei of the deuterium (D) and tritium (T). Each D-T releases 17.6 MeV of
energy. The use of nuclear fusion plant will substantially will reduce the environmental impacts of
increasing world electricity demands. Fusion power offers the prospect of an almost inexhaustible source of
energy for future generation but it also presents so far insurmountable scientific and engineering
challenges.
Query Answering Approach Based on Document SummarizationIJMER
The growing of online information obliged the availability of a thorough research in the
domain of automatic text summarization within the Natural Language Processing (NLP)
community.The aim of this paper is to propose a novel approach for a language independent automatic
summarization approach that combines three main approaches. The Rhetorical Structure Theory
(RST), the query processing approach, and the Network Representationapproach (NRA). RST, as a
theory of major aspect for the structure of natural text, is used to extract the semantic relation behind
the text.Query processing approachclassifies the question type and finds the answer in a way that suits
the user’s needs. The NRA is used to create a graph representing the extracted semantic relation. The
output is an answer, which not only responses to the question, but also gives the user an opportunity to
find additional information that is related to the question.We implemented the proposed approach. As a
case study, the implemented approachis applied on Arabic text in the agriculture field. The
implemented approach succeeded in summarizing extension documents according to user's query. The
approach results have been evaluated using Recall, Precision and F-score measures.
Optical and Impedance Spectroscopy Study of ZnS NanoparticlesIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
ANALYSIS AND OPTIMIZATION OF EXTRUSION PROCESS USING HYPERWORKSijsrd.com
Minimizing the amount of scrap generated in an aluminum extrusion process. An optimizing method is constructed based on Simulation Analysis approach. In present thesis the Simulation approach is presented to optimize the amount of Scrap generated during Aluminum extrusion process. The model applied to real data obtained from an existing extrusion factory. Results from using the suggested model provided substantial reductions in the amount of scrap generated. Using sound simulation analysis approaches contribute significantly in reducing waste and savings when compared to the existing nonscientific techniques.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
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
Finite Element simulation of Rotary Sheet Bending.pdfmeet kalola
introduction, literature review, material selection and dimensions, steps to perform simulation in ls-dyna ,implementation issues, results, conclusion and further implementation.
Simulation of Deep-Drawing Process of Large Panelstheijes
The article deals with the analysis of formability of deep-drawing DC06 steel sheets. The aim of the investigations is to verify possibilities of formability of sheet metal with thickness of 0.85 mm. The mechanical parameters of the sheets have been determined in uniaxial tensile and bulge tests. The numerical simulations using AUTOFORM has been carried out for two drawpiece models. Obtained results can be used during the simulation of real forming process.
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology.
A 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
Dx2645324539
1. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.6, July-Aug. 2012 pp-4532-4539 ISSN: 2249-6645
Preform Shape Optimization of Connecting Rod Using Finite Element
Method and Taguchi Method
Md. Israr Equbal1, Rajkumar Ohdar2, Md. Nadeem Bhat3, Suhail Ahmad lone4
1,2
Department of Forge technology, NIFFT, Ranchi 834003, India
3
Department of Foundry and Forge technology, NIFFT, Ranchi 834003, India,
4
Department of Material science and Engineering, NIFFT, Ranchi, 834003, India
ABSTRACT : Preform design in forging processes is an important aspect for improving the forging quality and decreasing
the production cost. The objective of this paper is to obtain an optimal perform shape in the consideration of the influence of
the metal flow deformation in closed die forging process. Finite element method based DEFORMTM 3D software in
conjunction with Taguchi method has been used to simulate the closed die forging process and then performing a series of
optimization iterations in order to obtain the optimal shape of the billet based on forging load minimization. The goal of the
simulation and optimization process is to minimize the forging load and produce defect-free forgings. The optimal shape of
the billet that gives minimum forging load with complete die filling was obtained after several optimization iterations. The
approach used in this study could be extended to the optimization of more complicated forging products.
Keywords: Preform, Hot forging, Optimization, Finite element analysis, Taguchi method.
I. INTRODUCTION
In the forging process of complicated parts, the selection of appropriate preform shapes is crucial. The preform
design in metal forging plays a key role in improving product quality, such as ensuring defect-free property and proper metal
flow. In addition, it may produce more uniform strain distribution through the final forging product. Thus, the metallurgical
and mechanical properties reduce the material waste and less die wear may be achieved [1]. In designing this process,
preform shape, final shape and material behaviour should be contemplated in a way to fill the die cavity completely.
Furthermore, the designer should regard the process not causing any defect or undesirable properties. Main purpose of the
preform design process is achieving the following:
· Assuring the metal flow without any defect and appropriately filling of the die.
· Minimizing the material wastes in the flash.
· Minimizing the die wear.
·Obtaining the desirable grain flow and suitable mechanical properties.
Traditionally, forging process design and forging process plan has employed trial & error methods which are a time
consuming process and expensive. However, in the recent years a significant increase of computer and numerical simulations
are reported based on finite element (FE) analysis of forging process. Moreover, traditional techniques have been substituted
into numerically based analysis. Therefore, more robust and efficient computer based approaches has been introduced
recently. As a result, a large number of investigations have been reported by different scientists in the preform design field.
Zhao G. et al. [2] apply a method, which employs an alternative boundary node release criterion in the FEM
simulation of a backward deformation of forging processes. The method makes use of the shape complexity factor, which
provides an effective measure of forging difficulty. Bramley [3] initiated a reversed method by Upper Bound Elemental
Technique (UBET) and has attained the preform shape by reversing the velocity field direction to a minimum amount for
whole of the energy distribution rate which optimized by contact conditions. Biglari et al. [4] succeed to design optimum
axisymmetric forging preforms by combining the backward tracing and fuzzy logic concepts. A new approach is introduced
by Yiguo, L., et al. [5] for pre-form design called Simulation Block Technique (SBT) in which, the two half-parts of the
forging die is imaginarily separated from their closed position, they move backward from each other in opposite direction of
the forward (normal) forging process, so that the initial billet or a pre-form can be obtained, the model incorporates the use
of UBET. Kang, B., S., et al. [6] presented pre-form shapes design in forging of rib-web shaped plane-strain parts were
designed using rigid-plastic finite element method in order to obtain flash-less part. The preform was obtained by changing
the aspect ratio- the height to width ratios of the rib geometry used in the analysis. An optimization approach for the design
of intermediate forging die shapes using backward deformation simulation and design optimization was developed by Han,
C., S., et al. [7]. This approach could determine the pre-form die shapes from the final part shape by imposing constrains on
the plastic deformation of the material. In this paper computer simulation of the connecting rod using DEFORM (Design
Environment for Forming) is adopted for the purpose of optimizing the perform shape. Deform is a Finite Element Method
(FEM) based process simulation system designed to analyze various forming and heat treatment processes used by metal
forming and related industries. By simulating manufacturing processes on a computer, this advanced tool allows designer
and engineers to
Reduce the need for costly shop floor trails and redesign of tooling and process.
Improve tool and die design to reduce production and material costs.
Shorten lead-time in bringing a new product to market.
www.ijmer.com 4532 | Page
2. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.6, July-Aug. 2012 pp-4532-4539 ISSN: 2249-6645
II. METHODOLOGY
The main objective of closed die forging are complete die filling without defects viz. cracks, fold-over, wrinkles
with minimum forging load. The goal of the simulation is to find out the shape of the billet that leads to a minimum forging
load and complete die filling without any defects. Taguchi‟s experimental method is utilized to design the process parameter
combinations to identify the relative influence of each parameter considered in the study. Study of the influence of design
related variables on output performance characteristics are time consuming and costly during the real-time forging process.
Whereas finite element method (FEM) based simulation software permits simulation of the system in solving linear
and non-linear problems in a cost effective and timely manner. In this paper the effect of design parameters viz. flash
thickness, flash width, corner radii and fillet radii on perform has been studied in order to obtain minimum forging load with
complete die filling along with minimum material loss by using FEM based DEFORMTM 3D V6.1 to simulate and validate
the optimum result. For simulation purpose 3-D modeling software CATIA V5 is used to model part and dies. Final part and
its die are as shown in Fig. 1 and Fig. 2. Dies and billets are drawn in such a manner that they are Z-axis aligned. As
DEFORMTM accepts only ‘.STL’ files, upper die, lower die and billets are saved with ‘STL’ extension.
Figure 1: 3D CAD model of connecting rod
Figure 2: Die of Connecting rod
The material of connecting rod is AISI 1045 alloy steel, whereas AISI-H-13 die steel is used as die material and their
properties are given in Table I.
Table I: Material Properties
Property Component Die Units
Density 7870 7800 Kg/m3
s
Poisson‟ Ratio 0.29 0.3 ---
Elastic modulus 200 210 GPa
Tensile strength 585 1990 MPa
Yield strength 505 1650 MPa
Hardness 84 45 HRC
Thermal conductivity 51.9 24.6 W/m-K
III. DESIGN CONSIDERATIONS
3.1 Determination of Stock Size
The factors in estimating the stock size include the size and shape of the forging, method of heating and method of forging.
The terms used in weight calculation are
Net weight – it is the weight of forging as per the given dimension of the component.
Net weight = volume of forging × density of material
Volume of forging = 45700 mm3
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3. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.6, July-Aug. 2012 pp-4532-4539 ISSN: 2249-6645
Density of material = 7.86×10-6 kg/mm3
Net weight = 0.36 kg
Flash loss – it is the loss of extra material comes out when the top and bottom die block has filled. It is determined by flash
thickness and flash width.
Flash loss = 15 to 20 % of the net weight
= 0.20× 0.36
= 0.072
Gross weight- the amount of material required to fabricate a forging.
Gross weight = net weight +losses
= 0.36+0.072kg
= 0.43 kg
3.2 Design of Flash
The purpose of the flash is to control the metal flow within the die cavity. The flash normally cools faster than the
main body of the forging and hence results resistance in metal flow outwards. The consequence of this flow restriction, metal
is forced to take an alternative route, the path of least resistance, which normally results in filling dipper die cavities. The
flash thickness and width is directly related to the amount of waste material, acts as a pressure release valve for the almost
incompressible work metal and restrict the outward flow of the metal so that remote corners and deeper cavities can be filled
up. The finisher impression generally includes as provision for flash. The flash depression can be in either die or in both dies.
Thus design of flash dimensions plays a vital role in metal filling. While designing for flash, care must be taken in
selecting flash thickness, as thickness being small will necessitate greater energy or extra blows to bring forging to size, on
the other hand thickness being more may cause inadequate die filling. Thus a balanced condition is needed with just enough
volume of metal to ensure that the flash thickness provided would force the work-metal to fill the impression properly
without causing excess wear and pressure. Flash thickness is calculated by using the various formulas as given in Table II.
Table II: Design of Flash
Author Flash thickness Result
Bruchanov & Rebelskii [8] 1 mm
Thomas [9] 1.25mm
Vieregge [10] 1.5 mm
Neuberger & Mockel [11] 1.67mm
Teterin & Tarnovski [12] 1.4 mm
Here,
A= plan projected area including flash land = 3950 mm 2
D= equivalent diameter = 72 mm
W= forging weight = 0.36 kg
3.3 Fillet and Corner radii
Fillets and corners are curved surface connecting ribs, bosses and webs, and are defined by their transverse section.
A corner is a convex arc, which joins two intersecting sides at an external angle of more than 180°, whereas fillet is a
concave arc, which joins two intersecting sides at an external angle of less than 180°. Design of fillet and corner affect grain
flow, forging pressure requirement, die wear, grain flow, amount of metal to be removed during machining, amount of cut
grain at junction and cost of dies and forgings. Proper selection of fillet and corner radii is vital in designing dies for
forgings. Sharp corners must be avoided in forging design as they weaken both the dies and finished forgings. A sharp
internal corner or very small fillet in forging introduces a danger of cracking in heat treatments while the corresponding
sharp external corner on the die prevents a satisfactory flow of metal in impression and may result in a defective forging.
3.4 Press selection
The main requirement selecting the press to produce a given forging is an estimate of the forging load. This will
depend on the material, forging temperature, forging complexity and flash and land dimension.
For non circular forging
(1)
(2)
Where, Dreduced = Reduced diameter of Non- Circular forging including flash land = 1.13(S1)1/2=72mm
S1= Plan projected area of Non-Circular forging including flash land = 6130 mm2
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4. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.6, July-Aug. 2012 pp-4532-4539 ISSN: 2249-6645
σ= Tensile strength at forging temperature=6.5 kg/mm2
b= Average width of forging including flash land = S1/Lmax =39.3 mm
Lmax = maximum length of forging at parting plane including flash land= 156mm
P=8x(1-.001x72)x1.898x6130x6.5=561526 kg
= 574 ton
For simulation work press capacity is taken 574 ton
IV. TAGUCHI EXPERIMENTAL DESIGN
Taguchi design of experiment is a powerful analysis tool for modeling and analyzing the influence of control factors
on performance characteristics. The most important stage in this method lies in the selection of control factors. An
exhaustive literature review reveals that the optimized preform shape largely influenced by flash thickness (FT), flash width
(FW), corner radius (RC), fillet radius (RF). These parameters each at three levels are considered for the present study. The
operating conditions under which test are carried are shown in Table III.
Table III: Factors and their levels
Factors Symbol Level Unit
1 2 3
Flash thickness FT 1 1.5 2 mm
Flash width FW 6 8 10 mm
Corner radius RC 1.5 2 3 mm
Fillet radius RF 2 3 5 mm
The total degree of freedom (DOF) for four factors each at three levels is 8. Therefore L9 orthogonal array [13] is selected for
experimental design and is shown in Table IV.
Table IV: Taguchi Design for Preform (All dim. are in mm)
Flash thickness Flash width Corner radii Fillet radii
1 6 1.5 2
1 8 2 3
1 10 3 5
1.5 6 2 5
1.5 8 3 2
1.5 10 1.5 3
2 6 3 3
2 8 1.5 5
2 10 2 2
V. PREFORM DESIGN
Preform design is one of the most important aspects in metal forming process design. Pre-form impression allows
adequate metal distribution in the final impression. Thus, defect-free, complete die fill and small metal loses into flash can be
achieved by a properly designed perform. If the component has varied cross-section as in case of spanner, connecting rod,
break, pedal lever etc. it is necessary to reduce or increase cross sectional area of the bar at desired points with a view to
improve die life. This will necessitate the preforming operation before finishing. For better quality forging productions, care
must be taken that in the finishing impression to minimize deformation to achieve final shape. Traditionally, the preform
design is based on empirical or approximate analysis, requiring time consuming and expensive trial-and–error. Hence it is
necessary to optimize the perform design in order to minimize the above drawbacks.
The following procedure is used to design preform impression from forging drawing.
The plan and the elevation of forging are laid out to full scale.
An estimated outline of the flash of the forging preside is than laid out.
The forging is then divided into various element based on geometric shape.
Vertical lines are drawn through largest and smallest cross sectional area of each element found as above.
The area of the above cross section is calculated and to each such area, cross sectional area of flash is added (flash
width× flash thickness).
From the base line of above measurement are plotted and connected with smooth line, then the cross sectional area of
perform at each line is determined.
The diameter “D” of the perform is evaluated at each element using the equation 3.
D= (4xA/π) (1/2) (3)
Where D – equivalent diameter
A - Total area (flash area + job section area)
Thereafter, the dimension D is symmetrically plotted about the reference line. These points are finally connected
with a smooth curve as shown in Fig.3. A perform impression having this as an approximate contour can provide smooth
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5. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.6, July-Aug. 2012 pp-4532-4539 ISSN: 2249-6645
flow of metal from blank into perform and finally finisher impression. For the present work 9 such performs and their dies
were designed for different values of flash thickness, flash width corner and fillet radii [14].
Front view
Plan view
Figure 3: Preform shape of Connecting rod
VI. COMPUTER SIMULATION AND ANALYSIS OF THE FORGING PROCESS
Main objective of this study is to investigate the effect of design parameters on preform shape. The computer
simulation of hot forging process has been done to obtain the optimum perform shape. The DEFORM™-3D V6.1 software
package was employed in the present research for the simulation and analysis of results. So far most FE based software that
simulate billet forming processes that consider only plane-strain or axis symmetric deformations. Since many industrial parts
such as connecting rods have very complex geometries, the metal flow is three dimensional and cannot be properly modelled
with a two dimensional approximation. Therefore, a three dimensional simulation of the manufacturing process must be
performed to get adequate results. The commercial package DEFORM™-3D V6.1 offers the possibility of simulating three
dimensional material flows of complex geometries.
Main objective of this paper is to investigate the effect of process and design parameter to die performance and
quality of the forged part. In this study, computer simulation of hot forging process has been done to obtain the optimum
design and process parameters. The DEFORM™-3D V6.1 software package was employed in the present research for the
simulation and analysis. DEFORM essentially consists of three parts, described below.
6.1 Pre-processor
The pre-processor includes (i) an input module for iterative data input verification, (ii) an automatic mesh
generation program which creates a mesh by considering various process related parameters such as temperature, strain,
strain-rate as well as die and work piece geometry; and (iii) an interpolation module that can interpolate various simulation
results of an old mesh onto a newly generated mesh. The combined and the automated use of the modules for automatic
mesh generation and interpolation, called automatic remeshing, allow a continuous simulation of a forming process without
any intervention by the user, even if several remeshings are required. This automatic remeshing capability drastically reduces
the total processing time of finite element analysis. All the input data generated in the pre-processor can be saved (i) in a text
form which enables the user to access the input data through any text editor; and /or (ii) in a binary form which is used by the
simulation engine explained below.
6.2 The simulation engine
The actual FEM-based analysis is carried out in this portion of DEFORM. This simulation engine is based on a
rigid – plastic FE formulation and can handle a multiple number of billets (either dense material or porous material, or
combination of these materials) and dies (either rigid or linear elastic) with non-isothermal simulation capability. The
simulation results are stored in binary form and accessed by the user through the post – processor.
6.3 Post processor
The post processor is used to display the results of the simulation in graphical or alphanumeric form. Thus,
available graphic representations include (i) FE mesh; (ii) contour plots of distributions of strain, stress, temperature etc, (iii)
velocity vectors, and (iv) load – stroke curves. Two other useful capabilities in the post –processor are (i) „ point tracking‟,
which provides deformation histories of selected points in the workpiece throughout the deformation; and (ii) „flownet‟,
which allows the user to observe the deformation of circles or rectangles „inscribed‟ on the undeformed workpiece for any
desired step through the simulation [15].
There are some assumed models in this paper, including that the plastic material model and the rigid die model are
assumed. The velocity of the moving ram is kept constant. The strain rate at the first of deformation is equal to 2 S -1. All the
simulations started with 45000 elements. Table V shows the assumed models.
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6. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.6, July-Aug. 2012 pp-4532-4539 ISSN: 2249-6645
Table V: Operation parameters assigned to complete the simulation
Problem Type Closed die hot forging
Forging Equipment Mechanical press
No. of elements 45000
Mesh type Tetrahedral
Simulation mode Isothermal
Primary die Top die
Const. Envir. Temp. 200c
Billet Temp. 10500c
Die Temp. 3000c
Friction Coeff. 0.3 with lubrication
Die velocity 1.5 mm/s
VII. RESULTS
Simulations are run as per Taguchi experiment plan based on the experimental layout depicted in Table 4, and
respective value of forging load for each simulation run are converted into their respective S/N ratios as per equation 1 and
are given in Table VI.
Table VI: L9 orthogonal array with their response
Exp. No. Parameters Response
FT FW RC RF Forging load(N) (10^6) S/N Ratio Complete filling
1 1 6 1.5 2 7.86 -17.9085 No
2 1 8 2 3 7.29 -17.2546 No
3 1 10 3 5 9.73 -19.7623 No
4 1.5 6 2 5 3.82 -11.6413 Yes
5 1.5 8 3 2 7.53 -17.5359 No
6 1.5 10 1.5 3 6.25 -15.9176 Yes
7 2 6 3 3 3.17 -10.0212 Yes
8 2 8 1.5 5 3.47 -10.8066 Yes
9 2 10 2 2 4.01 -12.0629 No
After conducting the experiments according to Taguchi‟s experimental design we observed that in experiment no. 1,
2, 3 and 5 the problem of underfilling occurred and the forging load was also very high. This is due to small flash thickness
and improper value of corner and fillet radii. While during experiment no. 9 problem of underfilling occur because it has
been observed that material is going out in the form of flash without filling die cavity completely.
Under filling
Figure 4. Critical areas of underfilling during Simulation
Figure 5. Comple die filling achieved during simulation
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7. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.6, July-Aug. 2012 pp-4532-4539 ISSN: 2249-6645
VIII. DISCUSSION
Data analysis is made using MINITAB R14 software at 95% of confidence. Main effect plot (Fig. 6) is used to
determine the optimum factor levels for minimum forging load, which FT3, FW1, RC1 and RF2 are corresponding to the
largest values of S/N ratio for all control parameters. Relative influence of each factor is determined by analysis of variance
method (ANOVA) presented in Table VII.
Table VII: ANOVA Table for forging load
Parameters Degree of freedom Sum of square Variance % Contribution F- value
Flash thickness 2 81.234 40.617 77.1526 6.72
Flash width 2 11.966 5.983 11.3648 0.99
Corner radii - 6.797* - - -
Fillet radii - 5.293* - - -
Error 4 12.09 6.045
Total 8 105.29
*pooled
ANOVA depicts that the process parameter namely Flash thickness and Flash width are the most significant
parameters affecting the Forging load. Fillet radius and corner radius shows the least contribution. It is necessary to mention
that confidence level of 95% is used for analysis purpose, so p-value less than 0.05 will establish the significance of factor.
Adequacy of analysis is carried out using Anderson–Darling (AD) test and results are illustrated in Fig. 7, which
shows that data follows normal distribution and develop procedure is suitable enough to explore the design space.
Flash thickness Flash width
-10
-12
-14
-16
Mean of SN ratios
-18
1 2 3 1 2 3
Corner radius Fillet radius
-10
-12
-14
-16
-18
1 2 3 1 2 3
Figure 6: S/N ratio response graph for forging load
99
Mean 5.903
StDev 2.358
95
N 9
90
AD 0.433
80 P-Value 0.233
70
Percent
60
50
40
30
20
10
5
1
-5 0 5 10 15
Re s idue
Figure 7: Normal probability plot of residue at 95% of confidence
IX. CONFIRMATION EXPERIMENT
For confirmation purpose process is simulated at optimum factor level setting keeping all the simulation parameter
fixed as given in Table 5. Fig. 8 shows the optimal forging load value of 2.13x106 N. At this load the complete die filling is
achieved with maximum yield (Fig. 9). On comparing the simulation results with Taguchi predictive model which is 2.17 x10 6
small error of 1.84 % indicate the Taguchi experimental plan has proceeded in a smooth manner.
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8. International Journal of Modern Engineering Research (IJMER)
www.ijmer.com Vol.2, Issue.6, July-Aug. 2012 pp-4532-4539 ISSN: 2249-6645
Figure 8: Load vs. stroke curve showing minimum forging load
Figure 9: Complete die filling with maximum forging yield and without any defect
X. CONCLUSION
FEM-based computer simulation has been used to optimize the design parameters viz. flash thickness, flash width,
corner radius and fillet radius on perform shape of connecting rod.Using Taguchi method, design parameters were optimized
individually for forging load. In order to study the significance of the parameters in effecting the quality characteristics of
interest i.e. forging load ANOVA has been performed. The conformation experiment was conducted by taking the optimized
value (output of Taguchi,s experiment) and was simulated once again. The results shows that at optimum factor level setting
complete die filling is achieved with minimum forging load. It is found that optimization can be achieved quickly and
efficiently through the use of simulation software. Modeling provides more information about the process i.e. load
requirement and metal flow at different stages of the process. These techniques are also cheaper than performing tryouts with
actual dies and equipments.
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