This document discusses optimizing design parameters for effective molding of a gas sensor through mold flow simulation. It analyzes two trials of injection molding simulations to determine the optimal gate location, moldability, defects, and processing parameters. Trial 2 with parameters of 2 second fill time, 50°C mold temperature, 245°C melt temperature, and 55MPa injection pressure produced fewer sink marks, air traps, and weld lines than Trial 1. Trial 2 also had a faster cooling time of 8 seconds, making it the ideal design for molding the gas sensor part.
Estimation Of Optimum Dilution In The GMAW Process Using Integrated ANN-SAIJRES Journal
To improve the corrosion resistant properties of carbon steel usually cladding process is used. It is a process of depositing a thick layer of corrosion resistant material over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long term reliability and performance. By cladding these properties can be achieved with minimum cost. The main problem faced on cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, contact tip to work distance and pinch) to get optimum dilution in stainless steel cladding of low carbon structural steel plates using Gas Metal Arc Welding (GMAW). Experiments were conducted based on central composite rotatable design with full replication technique and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. In this study, Artificial Neural Network (ANN) and Simulated Annealing Algorithm (SA) techniques were integrated labels as integrated ANN-SA to estimate optimal process parameters in GMAW to get optimum dilution.
Optimization of Weld Bead Parameters of Nickel Based Overlay Deposited by Pla...IJERA Editor
Plasma Transferred Arc surfacing is a kind of Plasma Transferred Arc Welding process. Plasma Transferred Arc surfacing (PTA) is increasingly used in applications where enhancement of wear, corrosion and heat resistance of materials surface is required. The shape of weld bead geometry affected by the PTA Welding process parameters is an indication of the quality of the weld. In this paper the analysis and optimization of weld bead parameters, during deposition of a Nickel based alloy Colmonoy on stainless steel plate by plasma transferred arc surfacing, are made and values of process parameters to produce optimal weld bead geometry are estimated. The experiments are conducted based on a five input process parameters and mathematical models are developed using multiple regression technique. The direct effects of input process parameters on weld bead geometry are discussed using graphs. Finally, optimization of the weld bead parameters, that is minimization of penetration and maximization of reinforcement and weld bead width, are made with a view to economize the input process parameters to achieve the desirable welding joint.
Estimation Of Optimum Dilution In The GMAW Process Using Integrated ANN-SAIJRES Journal
To improve the corrosion resistant properties of carbon steel usually cladding process is used. It is a process of depositing a thick layer of corrosion resistant material over carbon steel plate. Most of the engineering applications require high strength and corrosion resistant materials for long term reliability and performance. By cladding these properties can be achieved with minimum cost. The main problem faced on cladding is the selection of optimum combinations of process parameters for achieving quality clad and hence good clad bead geometry. This paper highlights an experimental study to optimize various input process parameters (welding current, welding speed, gun angle, contact tip to work distance and pinch) to get optimum dilution in stainless steel cladding of low carbon structural steel plates using Gas Metal Arc Welding (GMAW). Experiments were conducted based on central composite rotatable design with full replication technique and mathematical models were developed using multiple regression method. The developed models have been checked for adequacy and significance. In this study, Artificial Neural Network (ANN) and Simulated Annealing Algorithm (SA) techniques were integrated labels as integrated ANN-SA to estimate optimal process parameters in GMAW to get optimum dilution.
Optimization of Weld Bead Parameters of Nickel Based Overlay Deposited by Pla...IJERA Editor
Plasma Transferred Arc surfacing is a kind of Plasma Transferred Arc Welding process. Plasma Transferred Arc surfacing (PTA) is increasingly used in applications where enhancement of wear, corrosion and heat resistance of materials surface is required. The shape of weld bead geometry affected by the PTA Welding process parameters is an indication of the quality of the weld. In this paper the analysis and optimization of weld bead parameters, during deposition of a Nickel based alloy Colmonoy on stainless steel plate by plasma transferred arc surfacing, are made and values of process parameters to produce optimal weld bead geometry are estimated. The experiments are conducted based on a five input process parameters and mathematical models are developed using multiple regression technique. The direct effects of input process parameters on weld bead geometry are discussed using graphs. Finally, optimization of the weld bead parameters, that is minimization of penetration and maximization of reinforcement and weld bead width, are made with a view to economize the input process parameters to achieve the desirable welding joint.
In manufacturing, many products need to undergo increasing customisation, and a shortening of the manufacturing cycle time. This makes the time needed to produce prototypes one of the most important contributors to product development cycles. Rapid Prototyping (RP) offers the user the ability to optimise part design in order to meet customer requirements with few manufacturing restrictions. One of the most common RP processes is Laser Sintering (LS). A problem with LS is that sometimes the surface of the parts produced displays a texture similar to that of the skin of an orange (the so-called orange peel texture). This problem must be addressed before the technology can gain wider acceptance. The main aim of this research is to develop a methodology of controlling the input material properties that will ensure consistent and good quality of the fabricated parts. From the experiment, it was found that PA12 powder with high melt flow rate, low melting temperature, low glass transition temperature and low degree of crystallization temperature could improve the sintering process to produce a good Laser Sintering (LS) parts with lower shrinkage rate. The powder which has higher melt viscosity and lower melting heat becomes liquid more easily and therefore flows better during the sintering process due to a shorter chain molecular structure. The results of experimental work indicate that the melt viscosity, and part surface finish are correlated.
A review on Parametric Optimization of Submerged arc welding processIJSRD
Submerged arc welding is preferable more its inherent qualities such as Higher deposition rate, deeper penetration, control of variables, high quality, smooth finish. The bead geometry shows the quality of weld which is depends on input process parameters. The present work gives review of the effect of these Input parameters on weld bead geometry. Selection of process parameters has great influence on the quality of a welded connection. To automate a welding process, which is the present trend in any fabrication industry. It is also important that mathematical models have to be developed to relate the process variables to the weld bead parameters. All the welding processes are used with the aim of getting a welded joint with the desires weld bead geometry and excellent mechanical properties with a efficient quality welded joint at a relatively low cost with high productivity. Optimization designs concentrate on only one or two parameters, but in very more depth to gain a precise understanding of relationships between parameters.
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.
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
A practical approach to eliminate defects in gravity die cast al alloy castin...eSAT Journals
Abstract
This paper deals with elimination of defects in aluminium alloy castings produced by gravity die casting process. The main intention of work is to investigate the defects and improve quality of a gravity die cast component using Computer Aided Casting Simulation Software. In this study an industrial gravity casting die is used which was producing defective components. The die and components produced by the die are studied to eliminate the defects using virtual simulations. The defects in the components are identified to be solidification shrinkage, cracks, unfilled riser and incomplete mould cavity. The reasons for the defects are analyzed as either improper selection of process parameters, or improper design of gating and risering system. SOLIDCast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. The work is carried out in two stages. In first stage, few test castings are produced by modifying the process parameters (pouring temperature, pouring time, pre heat and alloy type) and results are compared with simulation results produced using same parameters. The pouring and simulation results are observed to be in good accordance with each other. In second stage, number of virtual iterations of casting is performed by changing riser dimensions. It was found from the simulation results that riser with 35mm diameter is required to produce casting with zero defects. The die is modified accordingly with the simulation results and metal is poured. The castings produced are observed to be sound and contain no defects; and also it is verified that solidification simulation helps in locating the defects, eliminating them and ultimately improving the quality of castings without any shop-floor trails.
Keywords: Aluminum-Alloys, Casting Defects, Gravity Die Casting, Material Density and SOLIDCast Simulation
Integrating flow simulation for injection moulding component basetta tu baseeSAT 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
Design of ‘plastic injection mold’ for an ‘air vent bezel’ through flow analy...eSAT Journals
Abstract Designer's of plastic injection Molds need to study from this point of view, the type of Mold to be designed, the physical Mold orientation, the dimensions for each of the element in the Mold, the location of the gate, runner, requirement of insert, draft angle requirement, shrinkage factor, location of cooling channels. Design can also be simplified by using standardized parts of the mold such as ejector pins. By eliminating the obstruction to smooth flow of plastic a good of quality component can be achieved. The effort of this thesis work is to find out the nuances in the Plastic Injection Mold Design while borrowing the inputs from the Flow Analysis (CAE) conducted for the 'Air vent bezel' to study the behavior of the Melt during flow. The Mold Design would incorporate suitable checking to ensure the best quality product in terms of `defect-free’ output. This thesis work consist methodology of plastic injection molding process, material requirement, how to overcome weld mark, shrinkage etc to satisfactorily assemble the component. Keywords: Draft angle, Shrinkage, CAE, weld mark
In manufacturing, many products need to undergo increasing customisation, and a shortening of the manufacturing cycle time. This makes the time needed to produce prototypes one of the most important contributors to product development cycles. Rapid Prototyping (RP) offers the user the ability to optimise part design in order to meet customer requirements with few manufacturing restrictions. One of the most common RP processes is Laser Sintering (LS). A problem with LS is that sometimes the surface of the parts produced displays a texture similar to that of the skin of an orange (the so-called orange peel texture). This problem must be addressed before the technology can gain wider acceptance. The main aim of this research is to develop a methodology of controlling the input material properties that will ensure consistent and good quality of the fabricated parts. From the experiment, it was found that PA12 powder with high melt flow rate, low melting temperature, low glass transition temperature and low degree of crystallization temperature could improve the sintering process to produce a good Laser Sintering (LS) parts with lower shrinkage rate. The powder which has higher melt viscosity and lower melting heat becomes liquid more easily and therefore flows better during the sintering process due to a shorter chain molecular structure. The results of experimental work indicate that the melt viscosity, and part surface finish are correlated.
A review on Parametric Optimization of Submerged arc welding processIJSRD
Submerged arc welding is preferable more its inherent qualities such as Higher deposition rate, deeper penetration, control of variables, high quality, smooth finish. The bead geometry shows the quality of weld which is depends on input process parameters. The present work gives review of the effect of these Input parameters on weld bead geometry. Selection of process parameters has great influence on the quality of a welded connection. To automate a welding process, which is the present trend in any fabrication industry. It is also important that mathematical models have to be developed to relate the process variables to the weld bead parameters. All the welding processes are used with the aim of getting a welded joint with the desires weld bead geometry and excellent mechanical properties with a efficient quality welded joint at a relatively low cost with high productivity. Optimization designs concentrate on only one or two parameters, but in very more depth to gain a precise understanding of relationships between parameters.
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.
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
A practical approach to eliminate defects in gravity die cast al alloy castin...eSAT Journals
Abstract
This paper deals with elimination of defects in aluminium alloy castings produced by gravity die casting process. The main intention of work is to investigate the defects and improve quality of a gravity die cast component using Computer Aided Casting Simulation Software. In this study an industrial gravity casting die is used which was producing defective components. The die and components produced by the die are studied to eliminate the defects using virtual simulations. The defects in the components are identified to be solidification shrinkage, cracks, unfilled riser and incomplete mould cavity. The reasons for the defects are analyzed as either improper selection of process parameters, or improper design of gating and risering system. SOLIDCast simulation software is used for simulating the solidification process of casting and visualizing outputs showing possible problematic areas or defects which may occur in the cast product. The work is carried out in two stages. In first stage, few test castings are produced by modifying the process parameters (pouring temperature, pouring time, pre heat and alloy type) and results are compared with simulation results produced using same parameters. The pouring and simulation results are observed to be in good accordance with each other. In second stage, number of virtual iterations of casting is performed by changing riser dimensions. It was found from the simulation results that riser with 35mm diameter is required to produce casting with zero defects. The die is modified accordingly with the simulation results and metal is poured. The castings produced are observed to be sound and contain no defects; and also it is verified that solidification simulation helps in locating the defects, eliminating them and ultimately improving the quality of castings without any shop-floor trails.
Keywords: Aluminum-Alloys, Casting Defects, Gravity Die Casting, Material Density and SOLIDCast Simulation
Integrating flow simulation for injection moulding component basetta tu baseeSAT 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
Design of ‘plastic injection mold’ for an ‘air vent bezel’ through flow analy...eSAT Journals
Abstract Designer's of plastic injection Molds need to study from this point of view, the type of Mold to be designed, the physical Mold orientation, the dimensions for each of the element in the Mold, the location of the gate, runner, requirement of insert, draft angle requirement, shrinkage factor, location of cooling channels. Design can also be simplified by using standardized parts of the mold such as ejector pins. By eliminating the obstruction to smooth flow of plastic a good of quality component can be achieved. The effort of this thesis work is to find out the nuances in the Plastic Injection Mold Design while borrowing the inputs from the Flow Analysis (CAE) conducted for the 'Air vent bezel' to study the behavior of the Melt during flow. The Mold Design would incorporate suitable checking to ensure the best quality product in terms of `defect-free’ output. This thesis work consist methodology of plastic injection molding process, material requirement, how to overcome weld mark, shrinkage etc to satisfactorily assemble the component. Keywords: Draft angle, Shrinkage, CAE, weld mark
Analysis and design of mold for plastic side release buckle using moldflow so...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
The injection molding process itself is a complex mix of time, temperature and pressure
variables with a multitude of manufacturing defects that can occur without the right combination of
processing parameters and design components. Determining optimal initial process parameter
settings critically influences productivity, quality, and costs of production in the plastic injection
molding (PIM) industry. Up to now, most production engineers have used trial-and-error method to
determine initial settings for a number of parameters, including melt temperature, injection pressure,
injection velocity, injection time, packing pressure, packing time, cooling temperature, and cooling
time which depend on the engineers’ experience and intuition to determine initial process parameter
settings. However, the trial-and-error process is costly and time consuming.
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.
Influence of feeding system in injection moulding for lower washer of a bearingeSAT Journals
Abstract
Optimisation of cycle time, avoid scrap and manual interface plays a vital role in manufacturing of plastic parts to improve the
productivity of the process and at the time it should not affect the quality of the final product. This paper describes the influence of
gate location and size through a repeated number of analyses which is carried out by plastic flow advisor software to reduce fill time,
scrap and automatic degating. The process parameters like fill time, shrinkage, weld lines, pressure drop, and air traps are analysed
by simulation in successive trials. Experimental verification has been done with new optimised gate location with designed mould in
injection moulding machine. The results showed an improvement in fill time from 1.64 sec to 1.2 sec with increase in injection
pressure by 15 MPa. Shrinkage and air traps were reduced minimising trouble shooting defeats.
Index Terms: Plastic Injection mould, Mould Flow Plastic Advisor, Feeding system, Submarine gate, Nylon 6/6 30% GF
International Journal of Engineering Research and Development (IJERD)IJERD Editor
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