Abstract Plastic injection mold made of tool steel is generally utilized for large lots production. Running for small lots of product is a new trend of demand, so that the mold would be relatively expensive and not competitive. The aim of the present work is to find an alternative material and process for low cost injection mold that suitable for small lots. For these reasons, aluminum-glass-acrylic particulate composite would be proposed as a material for manufacturing of low cost plastic injection mold. In this work, an insert mold as part of the injection molding was selected for the case study. Composite was examined to know its characteristics. The part with size of (80mm x 10mm x 10mm) and (30mm x30mm x30mm) made of particulate composite material was selected as specimen. Material of the specimen was aluminum powders (<297><74><74 μm); the volume ratio is 1:1:1. Acrylic was used for binder when composite made by layer manufacturing method, using Selective Heater Melting (SHM) machine. The specimen was prepared into three steps: manufacturing of composite (green specimen) by SHM machine, heating green specimen to burn up the acrylic, and resin impregnation. There were 3 types of specimens: green specimen before heating at 700°C, green specimen after heating at 700°C, and green specimen after heating at 700°C that continued by resin impregnation. Tests was performed to investigate its bending strength, surface hardness, surface roughness, and dimensional error. The other composite (specimen) was insert mold, made by layer manufacturing method, using SHM machine. Case study was carried out by testing an insert mold to know the reliability of insert mold. Bending strengths of green specimen, before and after heating at 700°C, were 2.07 and 8.23 MPa, respectively; and after resin impregnation was 17.15 MPa. Dimensional errors in the direction of X, Y, and Z-axis for green specimen of (30mm x 30mm x30mm) before heating at 700°C were 8.65, 2.7, and 3.8 mm, respectively; and after heating at 700°C were 7.90, 1.10 and 0.90 mm, respectively. Surface roughness of green specimen before and after heating at 700°C were 46.12 and 33.48 μm, respectively; and after resin impregnation was 12.17 μm. Surface hardness of specimen after resin impregnation was 14.199 BHN. The amount of plastic parts that could be produced by insert mold was 120 and 126 pieces. Although mechanical strength of this composite was lower than that of tool steel that used for common plastic injection mold, but this composite material was less expensive and suitable for small lots production. Keywords: Layer manufacturing, Selective Heater Melting (SHM) machine, green specimen, insert mold.
Forwa Mould Specialzing in:
Super high precision moulds and special moulds like insert mould,double injection moulds(2K injection mould), overmould, Unscrew injection mould for OA, House electronic application, Automobile and Communication etc industry.
Main market:
Automotive accessories
Electronic and medical
Office automation
Gear and clock movement
Connector
Precise parts
Powder metallurgy (PM) is a term covering a wide range of ways in which materials or components are made from metal powders. PM processes can avoid, or greatly reduce, the need to use metal removal processes, thereby drastically reducing yield losses in manufacture and often resulting in lower costs.
Conventional Powder-Metallurgy Process
The powder-metallurgy (PM) process, depicted in the diagram below, involves mixing elemental or alloy powders, compacting the mixture in a die and then sintering, or heating, the resultant shapes in an atmosphere-controlled furnace to metallurgically bond the particles.
The present research work demonstrates the
preparation of Copper Oxide Nanoparticles (CuO NPs) and
investigates the thermo mechanical properties of the CuO NPs
embedded in the polymer composites experimentally. In this study,
CuO NPs were produced by aqueous precipitation method and
morphology of the NPs was studied using Field Emission
Transmission Electron Microscope (FESEM). Epoxy resin and glass microsphere were considered the base material for the preparation of
the Nano based polymer composites. In order to fabricate the Nano
based polymer composites, CuO NPs with 1.0wtpercentage were
embedded in the base material by means of compression moulding
press. Nano composites proved higher thermal conductivity
enhancement rather than the base material. While comparing to the
base material, the maximum four-point bending strength of 415 MPa
was obtained from the Nano based polymer composites. The test
results obtained from the TG study revealed that an addition of CuO
NPs had acted as the thermal retardant and CuO NPs had delayed
thermal degradation of the Nano based polymer composites. Based
on the test results, it can be suggested that the newly fabricated
nanocomposites have achieved the improved thermal and mechanical
properties.
Powder Metallurgy enables the processing of materials with very high melting points, including refractory metals such as tungsten, molybdenum, and tantalum. Such metals are very difficult to produce by melting and casting and are often very brittle in the cast state.
Advantages of Powder Metallurgy
It can be very economical for mass production (100,000 parts). Long term reliability through close control of dimensions and physical properties. Very good material utilization - loss of material very less. Minimization or elimination of Machining.
Forwa Mould Specialzing in:
Super high precision moulds and special moulds like insert mould,double injection moulds(2K injection mould), overmould, Unscrew injection mould for OA, House electronic application, Automobile and Communication etc industry.
Main market:
Automotive accessories
Electronic and medical
Office automation
Gear and clock movement
Connector
Precise parts
Powder metallurgy (PM) is a term covering a wide range of ways in which materials or components are made from metal powders. PM processes can avoid, or greatly reduce, the need to use metal removal processes, thereby drastically reducing yield losses in manufacture and often resulting in lower costs.
Conventional Powder-Metallurgy Process
The powder-metallurgy (PM) process, depicted in the diagram below, involves mixing elemental or alloy powders, compacting the mixture in a die and then sintering, or heating, the resultant shapes in an atmosphere-controlled furnace to metallurgically bond the particles.
The present research work demonstrates the
preparation of Copper Oxide Nanoparticles (CuO NPs) and
investigates the thermo mechanical properties of the CuO NPs
embedded in the polymer composites experimentally. In this study,
CuO NPs were produced by aqueous precipitation method and
morphology of the NPs was studied using Field Emission
Transmission Electron Microscope (FESEM). Epoxy resin and glass microsphere were considered the base material for the preparation of
the Nano based polymer composites. In order to fabricate the Nano
based polymer composites, CuO NPs with 1.0wtpercentage were
embedded in the base material by means of compression moulding
press. Nano composites proved higher thermal conductivity
enhancement rather than the base material. While comparing to the
base material, the maximum four-point bending strength of 415 MPa
was obtained from the Nano based polymer composites. The test
results obtained from the TG study revealed that an addition of CuO
NPs had acted as the thermal retardant and CuO NPs had delayed
thermal degradation of the Nano based polymer composites. Based
on the test results, it can be suggested that the newly fabricated
nanocomposites have achieved the improved thermal and mechanical
properties.
Powder Metallurgy enables the processing of materials with very high melting points, including refractory metals such as tungsten, molybdenum, and tantalum. Such metals are very difficult to produce by melting and casting and are often very brittle in the cast state.
Advantages of Powder Metallurgy
It can be very economical for mass production (100,000 parts). Long term reliability through close control of dimensions and physical properties. Very good material utilization - loss of material very less. Minimization or elimination of Machining.
This give complete idea of Powder Metallurgy with following contents:
A.Steps in Powder Metallurgy:
B. Advantages and Disadvantages of Powder Metallurgy
C. Applications of Powder Metallurgy
I hope you appreciate my efforts in same
Do like share and comment.
Thanks
Aditya Deshpande
You can reach me - deshadi805@gmail.com
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
Powder Metallurgy or PM is a process of producing components or materials from powders made of metal. Different geometries can be obtained by this process. This may also include non metal powders. PM or Powder Metallurgy reduces the metal removal process to obtain a desired structure, reduces yield loss while manufacturing and cut down cost.
www.catalystrecoveryfilter.com
Productivity improvement of castings, switching to shell mould process from g...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
This give complete idea of Powder Metallurgy with following contents:
A.Steps in Powder Metallurgy:
B. Advantages and Disadvantages of Powder Metallurgy
C. Applications of Powder Metallurgy
I hope you appreciate my efforts in same
Do like share and comment.
Thanks
Aditya Deshpande
You can reach me - deshadi805@gmail.com
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
Powder Metallurgy or PM is a process of producing components or materials from powders made of metal. Different geometries can be obtained by this process. This may also include non metal powders. PM or Powder Metallurgy reduces the metal removal process to obtain a desired structure, reduces yield loss while manufacturing and cut down cost.
www.catalystrecoveryfilter.com
Productivity improvement of castings, switching to shell mould process from g...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 main objective of this paper is to
determine casting defects generally happening in an
aluminium die casting process and efforts have been
taken to identify the tools which eliminate the casting
defects. In global prospective this study briefs the
application of the various tools that are used in the
industries for improvement of quality in foundry
industry. In our national prospective these tools are not
so popular, hence this study will help us to utilise the
available technology through which the productivity is
enhanced with safe and economical means. The QC
tools were used to analyse the casting condition of the
given pattern with three dimensional simulations for the
result preparation. This work has been carried out to
improve the quality of the pattern which is made with
gravity die casting process and this was achieved
through continuous quality control operation with QC
tools, then it was taken to test in some simulation
software. The latest trend available in casting and
foundry shops are the scientific approach in
optimization of all kind of fields including optimization
of defects in castings. These trends are incorporated in
the analysis of aluminium die casting.
Optimization of ceramic shell mold materials in investment castingeSAT Journals
Abstract Ceramic shell investment casting process is used to produce high quality casting products with relatively close dimensional tolerance. The refractory material use as primary coat on shell mold of investment casting play a very important role to form surface finish. Zircon flour though costly, is being used as a primary slurry material in the ceramic shell investment casting process. To reduce the cost of primary slurry material, some alternate refractory material like, alumina, silica, used with zircon to enhance properties. The hardness test of the casted samples and micro-examination under binocular metallurgical microscope has been done to study the micro-characteristic evaluation. The result reveals that the ceramic shell contains 100% zircon primary refractory gives the best results. Keywords: shell mold, refractory, slurry, investment casting
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.
Similar to Mechanical properties and reliability of glass aluminium composite as insert mold (20)
Mechanical properties of hybrid fiber reinforced concrete for pavementseSAT Journals
Abstract
The effect of addition of mono fibers and hybrid fibers on the mechanical properties of concrete mixture is studied in the present
investigation. Steel fibers of 1% and polypropylene fibers 0.036% were added individually to the concrete mixture as mono fibers and
then they were added together to form a hybrid fiber reinforced concrete. Mechanical properties such as compressive, split tensile and
flexural strength were determined. The results show that hybrid fibers improve the compressive strength marginally as compared to
mono fibers. Whereas, hybridization improves split tensile strength and flexural strength noticeably.
Keywords:-Hybridization, mono fibers, steel fiber, polypropylene fiber, Improvement in mechanical properties.
Material management in construction – a case studyeSAT Journals
Abstract
The objective of the present study is to understand about all the problems occurring in the company because of improper application
of material management. In construction project operation, often there is a project cost variance in terms of the material, equipments,
manpower, subcontractor, overhead cost, and general condition. Material is the main component in construction projects. Therefore,
if the material management is not properly managed it will create a project cost variance. Project cost can be controlled by taking
corrective actions towards the cost variance. Therefore a methodology is used to diagnose and evaluate the procurement process
involved in material management and launch a continuous improvement was developed and applied. A thorough study was carried
out along with study of cases, surveys and interviews to professionals involved in this area. As a result, a methodology for diagnosis
and improvement was proposed and tested in selected projects. The results obtained show that the main problem of procurement is
related to schedule delays and lack of specified quality for the project. To prevent this situation it is often necessary to dedicate
important resources like money, personnel, time, etc. To monitor and control the process. A great potential for improvement was
detected if state of the art technologies such as, electronic mail, electronic data interchange (EDI), and analysis were applied to the
procurement process. These helped to eliminate the root causes for many types of problems that were detected.
Managing drought short term strategies in semi arid regions a case studyeSAT Journals
Abstract
Drought management needs multidisciplinary action. Interdisciplinary efforts among the experts in various fields of the droughts
prone areas are helpful to achieve tangible and permanent solution for this recurring problem. The Gulbarga district having the total
area around 16, 240 sq.km, and accounts 8.45 per cent of the Karnataka state area. The district has been situated with latitude 17º 19'
60" North and longitude of 76 º 49' 60" east. The district is situated entirely on the Deccan plateau positioned at a height of 300 to
750 m above MSL. Sub-tropical, semi-arid type is one among the drought prone districts of Karnataka State. The drought
management is very important for a district like Gulbarga. In this paper various short term strategies are discussed to mitigate the
drought condition in the district.
Keywords: Drought, South-West monsoon, Semi-Arid, Rainfall, Strategies etc.
Life cycle cost analysis of overlay for an urban road in bangaloreeSAT Journals
Abstract
Pavements are subjected to severe condition of stresses and weathering effects from the day they are constructed and opened to traffic
mainly due to its fatigue behavior and environmental effects. Therefore, pavement rehabilitation is one of the most important
components of entire road systems. This paper highlights the design of concrete pavement with added mono fibers like polypropylene,
steel and hybrid fibres for a widened portion of existing concrete pavement and various overlay alternatives for an existing
bituminous pavement in an urban road in Bangalore. Along with this, Life cycle cost analyses at these sections are done by Net
Present Value (NPV) method to identify the most feasible option. The results show that though the initial cost of construction of
concrete overlay is high, over a period of time it prove to be better than the bituminous overlay considering the whole life cycle cost.
The economic analysis also indicates that, out of the three fibre options, hybrid reinforced concrete would be economical without
compromising the performance of the pavement.
Keywords: - Fatigue, Life cycle cost analysis, Net Present Value method, Overlay, Rehabilitation
Laboratory studies of dense bituminous mixes ii with reclaimed asphalt materialseSAT Journals
Abstract
The issue of growing demand on our nation’s roadways over that past couple of decades, decreasing budgetary funds, and the need to
provide a safe, efficient, and cost effective roadway system has led to a dramatic increase in the need to rehabilitate our existing
pavements and the issue of building sustainable road infrastructure in India. With these emergency of the mentioned needs and this
are today’s burning issue and has become the purpose of the study.
In the present study, the samples of existing bituminous layer materials were collected from NH-48(Devahalli to Hassan) site.The
mixtures were designed by Marshall Method as per Asphalt institute (MS-II) at 20% and 30% Reclaimed Asphalt Pavement (RAP).
RAP material was blended with virgin aggregate such that all specimens tested for the, Dense Bituminous Macadam-II (DBM-II)
gradation as per Ministry of Roads, Transport, and Highways (MoRT&H) and cost analysis were carried out to know the economics.
Laboratory results and analysis showed the use of recycled materials showed significant variability in Marshall Stability, and the
variability increased with the increase in RAP content. The saving can be realized from utilization of recycled materials as per the
methodology, the reduction in the total cost is 19%, 30%, comparing with the virgin mixes.
Keywords: Reclaimed Asphalt Pavement, Marshall Stability, MS-II, Dense Bituminous Macadam-II
Laboratory investigation of expansive soil stabilized with natural inorganic ...eSAT Journals
Abstract
Soil stabilization has proven to be one of the oldest techniques to improve the soil properties. Literature review conducted revealed
that uses of natural inorganic stabilizers are found to be one of the best options for soil stabilization. In this regard an attempt has
been made to evaluate the influence of RBI-81 stabilizer on properties of black cotton soil through laboratory investigations. Black
cotton soil with varying percentages of RBI-81 viz., 0, 0.5, 1, 1.5, 2, and 2.5 percent were studied for moisture density relationships
and strength behaviour of soils. Also the effect of curing period was evaluated as literature review clearly emphasized the strength
gain of soils stabilized with RBI-81 over a period of time. The results obtained shows that the unconfined compressive strength of
specimens treated with RBI-81 increased approximately by 250% for a curing period of 28 days as compared to virgin soil. Further
the CBR value improved approximately by 400%. The studies indicated an increasing trend for soil strength behaviour with
increasing percentage of RBI-81 suggesting its potential applications in soil stabilization.
Influence of reinforcement on the behavior of hollow concrete block masonry p...eSAT Journals
Abstract
Reinforced masonry was developed to exploit the strength potential of masonry and to solve its lack of tensile strength. Experimental
and analytical studies have been carried out to investigate the effect of reinforcement on the behavior of hollow concrete block
masonry prisms under compression and to predict ultimate failure compressive strength. In the numerical program, three dimensional
non-linear finite elements (FE) model based on the micro-modeling approach is developed for both unreinforced and reinforced
masonry prisms using ANSYS (14.5). The proposed FE model uses multi-linear stress-strain relationships to model the non-linear
behavior of hollow concrete block, mortar, and grout. Willam-Warnke’s five parameter failure theory has been adopted to model the
failure of masonry materials. The comparison of the numerical and experimental results indicates that the FE models can successfully
capture the highly nonlinear behavior of the physical specimens and accurately predict their strength and failure mechanisms.
Keywords: Structural masonry, Hollow concrete block prism, grout, Compression failure, Finite element method,
Numerical modeling.
Influence of compaction energy on soil stabilized with chemical stabilizereSAT Journals
Abstract
Increase in traffic along with heavier magnitude of wheel loads cause rapid deterioration in pavements. There is a need to improve
density, strength of soil subgrade and other pavement layers. In this study an attempt is made to improve the properties of locally
available loamy soil using twin approaches viz., i) increasing the compaction of soil and ii) treating the soil with chemical stabilizer.
Laboratory studies are carried out on both untreated and treated soil samples compacted by different compaction efforts. Studies
show that increase in compaction effort results in increase in density of soil. However in soil treated with chemical stabilizer, rate of
increase in density is not significant. The soil treated with chemical stabilizer exhibits improvement in both strength and performance
properties.
Keywords: compaction, density, subgradestabilization, resilient modulus
Geographical information system (gis) for water resources managementeSAT Journals
Abstract
Water resources projects are inherited with overlapping and at times conflicting objectives. These projects are often of varied sizes
ranging from major projects with command areas of millions of hectares to very small projects implemented at the local level. Thus,
in all these projects there is seldom proper coordination which is essential for ensuring collective sustainability.
Integrated watershed development and management is the accepted answer but in turn requires a comprehensive framework that can
enable planning process involving all the stakeholders at different levels and scales is compulsory. Such a unified hydrological
framework is essential to evaluate the cause and effect of all the proposed actions within the drainage basins.
The present paper describes a hydrological framework developed in the form of a Hydrologic Information System (HIS) which is
intended to meet the specific information needs of the various line departments of a typical State connected with water related aspects.
The HIS consist of a hydrologic information database coupled with tools for collating primary and secondary data and tools for
analyzing and visualizing the data and information. The HIS also incorporates hydrological model base for indirect assessment of
various entities of water balance in space and time. The framework would be maintained and updated to reflect fully the most
accurate ground truth data and the infrastructure requirements for planning and management.
Keywords: Hydrological Information System (HIS); WebGIS; Data Model; Web Mapping Services
Forest type mapping of bidar forest division, karnataka using geoinformatics ...eSAT Journals
Abstract
The study demonstrate the potentiality of satellite remote sensing technique for the generation of baseline information on forest types
including tree plantation details in Bidar forest division, Karnataka covering an area of 5814.60Sq.Kms. The Total Area of Bidar
forest division is 5814Sq.Kms analysis of the satellite data in the study area reveals that about 84% of the total area is Covered by
crop land, 1.778% of the area is covered by dry deciduous forest, 1.38 % of mixed plantation, which is very threatening to the
environmental stability of the forest, future plantation site has been mapped. With the use of latest Geo-informatics technology proper
and exact condition of the trees can be observed and necessary precautions can be taken for future plantation works in an appropriate
manner
Keywords:-RS, GIS, GPS, Forest Type, Tree Plantation
Factors influencing compressive strength of geopolymer concreteeSAT Journals
Abstract
To study effects of several factors on the properties of fly ash based geopolymer concrete on the compressive strength and also the
cost comparison with the normal concrete. The test variables were molarities of sodium hydroxide(NaOH) 8M,14M and 16M, ratio of
NaOH to sodium silicate (Na2SiO3) 1, 1.5, 2 and 2.5, alkaline liquid to fly ash ratio 0.35 and 0.40 and replacement of water in
Na2SiO3 solution by 10%, 20% and 30% were used in the present study. The test results indicated that the highest compressive
strength 54 MPa was observed for 16M of NaOH, ratio of NaOH to Na2SiO3 2.5 and alkaline liquid to fly ash ratio of 0.35. Lowest
compressive strength of 27 MPa was observed for 8M of NaOH, ratio of NaOH to Na2SiO3 is 1 and alkaline liquid to fly ash ratio of
0.40. Alkaline liquid to fly ash ratio of 0.35, water replacement of 10% and 30% for 8 and 16 molarity of NaOH and has resulted in
compressive strength of 36 MPa and 20 MPa respectively. Superplasticiser dosage of 2 % by weight of fly ash has given higher
strength in all cases.
Keywords: compressive strength, alkaline liquid, fly ash
Experimental investigation on circular hollow steel columns in filled with li...eSAT Journals
Abstract
Composite Circular hollow Steel tubes with and without GFRP infill for three different grades of Light weight concrete are tested for
ultimate load capacity and axial shortening , under Cyclic loading. Steel tubes are compared for different lengths, cross sections and
thickness. Specimens were tested separately after adopting Taguchi’s L9 (Latin Squares) Orthogonal array in order to save the initial
experimental cost on number of specimens and experimental duration. Analysis was carried out using ANN (Artificial Neural
Network) technique with the assistance of Mini Tab- a statistical soft tool. Comparison for predicted, experimental & ANN output is
obtained from linear regression plots. From this research study, it can be concluded that *Cross sectional area of steel tube has most
significant effect on ultimate load carrying capacity, *as length of steel tube increased- load carrying capacity decreased & *ANN
modeling predicted acceptable results. Thus ANN tool can be utilized for predicting ultimate load carrying capacity for composite
columns.
Keywords: Light weight concrete, GFRP, Artificial Neural Network, Linear Regression, Back propagation, orthogonal
Array, Latin Squares
Experimental behavior of circular hsscfrc filled steel tubular columns under ...eSAT Journals
Abstract
This paper presents an outlook on experimental behavior and a comparison with predicted formula on the behaviour of circular
concentrically loaded self-consolidating fibre reinforced concrete filled steel tube columns (HSSCFRC). Forty-five specimens were
tested. The main parameters varied in the tests are: (1) percentage of fiber (2) tube diameter or width to wall thickness ratio (D/t
from 15 to 25) (3) L/d ratio from 2.97 to 7.04 the results from these predictions were compared with the experimental data. The
experimental results) were also validated in this study.
Keywords: Self-compacting concrete; Concrete-filled steel tube; axial load behavior; Ultimate capacity.
Evaluation of punching shear in flat slabseSAT Journals
Abstract
Flat-slab construction has been widely used in construction today because of many advantages that it offers. The basic philosophy in
the design of flat slab is to consider only gravity forces; this method ignores the effect of punching shear due to unbalanced moments
at the slab column junction which is critical. An attempt has been made to generate generalized design sheets which accounts both
punching shear due to gravity loads and unbalanced moments for cases (a) interior column; (b) edge column (bending perpendicular
to shorter edge); (c) edge column (bending parallel to shorter edge); (d) corner column. These design sheets are prepared as per
codal provisions of IS 456-2000. These design sheets will be helpful in calculating the shear reinforcement to be provided at the
critical section which is ignored in many design offices. Apart from its usefulness in evaluating punching shear and the necessary
shear reinforcement, the design sheets developed will enable the designer to fix the depth of flat slab during the initial phase of the
design.
Keywords: Flat slabs, punching shear, unbalanced moment.
Evaluation of performance of intake tower dam for recent earthquake in indiaeSAT Journals
Abstract
Intake towers are typically tall, hollow, reinforced concrete structures and form entrance to reservoir outlet works. A parametric
study on dynamic behavior of circular cylindrical towers can be carried out to study the effect of depth of submergence, wall thickness
and slenderness ratio, and also effect on tower considering dynamic analysis for time history function of different soil condition and
by Goyal and Chopra accounting interaction effects of added hydrodynamic mass of surrounding and inside water in intake tower of
dam
Key words: Hydrodynamic mass, Depth of submergence, Reservoir, Time history analysis,
Evaluation of operational efficiency of urban road network using travel time ...eSAT Journals
Abstract
Efficiency of the road network system is analyzed by travel time reliability measures. The study overlooks on an important measure of
travel time reliability and prioritizing Tiruchirappalli road network. Traffic volume and travel time were collected using license plate
matching method. Travel time measures were estimated from average travel time and 95th travel time. Effect of non-motorized vehicle
on efficiency of road system was evaluated. Relation between buffer time index and traffic volume was created. Travel time model has
been developed and travel time measure was validated. Then service quality of road sections in network were graded based on
travel time reliability measures.
Keywords: Buffer Time Index (BTI); Average Travel Time (ATT); Travel Time Reliability (TTR); Buffer Time (BT).
Estimation of surface runoff in nallur amanikere watershed using scs cn methodeSAT Journals
Abstract
The development of watershed aims at productive utilization of all the available natural resources in the entire area extending from
ridge line to stream outlet. The per capita availability of land for cultivation has been decreasing over the years. Therefore, water and
the related land resources must be developed, utilized and managed in an integrated and comprehensive manner. Remote sensing and
GIS techniques are being increasingly used for planning, management and development of natural resources. The study area, Nallur
Amanikere watershed geographically lies between 110 38’ and 110 52’ N latitude and 760 30’ and 760 50’ E longitude with an area of
415.68 Sq. km. The thematic layers such as land use/land cover and soil maps were derived from remotely sensed data and overlayed
through ArcGIS software to assign the curve number on polygon wise. The daily rainfall data of six rain gauge stations in and around
the watershed (2001-2011) was used to estimate the daily runoff from the watershed using Soil Conservation Service - Curve Number
(SCS-CN) method. The runoff estimated from the SCS-CN model was then used to know the variation of runoff potential with different
land use/land cover and with different soil conditions.
Keywords: Watershed, Nallur watershed, Surface runoff, Rainfall-Runoff, SCS-CN, Remote Sensing, GIS.
Estimation of morphometric parameters and runoff using rs & gis techniqueseSAT Journals
Abstract
Land and water are the two vital natural resources, the optimal management of these resources with minimum adverse environmental
impact are essential not only for sustainable development but also for human survival. Satellite remote sensing with geographic
information system has a pragmatic approach to map and generate spatial input layers of predicting response behavior and yield of
watershed. Hence, in the present study an attempt has been made to understand the hydrological process of the catchment at the
watershed level by drawing the inferences from moprhometric analysis and runoff. The study area chosen for the present study is
Yagachi catchment situated in Chickamaglur and Hassan district lies geographically at a longitude 75⁰52’08.77”E and
13⁰10’50.77”N latitude. It covers an area of 559.493 Sq.km. Morphometric analysis is carried out to estimate morphometric
parameters at Micro-watershed to understand the hydrological response of the catchment at the Micro-watershed level. Daily runoff
is estimated using USDA SCS curve number model for a period of 10 years from 2001 to 2010. The rainfall runoff relationship of the
study shows there is a positive correlation.
Keywords: morphometric analysis, runoff, remote sensing and GIS, SCS - method
-
Effect of variation of plastic hinge length on the results of non linear anal...eSAT Journals
Abstract The nonlinear Static procedure also well known as pushover analysis is method where in monotonically increasing loads are applied to the structure till the structure is unable to resist any further load. It is a popular tool for seismic performance evaluation of existing and new structures. In literature lot of research has been carried out on conventional pushover analysis and after knowing deficiency efforts have been made to improve it. But actual test results to verify the analytically obtained pushover results are rarely available. It has been found that some amount of variation is always expected to exist in seismic demand prediction of pushover analysis. Initial study is carried out by considering user defined hinge properties and default hinge length. Attempt is being made to assess the variation of pushover analysis results by considering user defined hinge properties and various hinge length formulations available in literature and results compared with experimentally obtained results based on test carried out on a G+2 storied RCC framed structure. For the present study two geometric models viz bare frame and rigid frame model is considered and it is found that the results of pushover analysis are very sensitive to geometric model and hinge length adopted. Keywords: Pushover analysis, Base shear, Displacement, hinge length, moment curvature analysis
Effect of use of recycled materials on indirect tensile strength of asphalt c...eSAT Journals
Abstract
Depletion of natural resources and aggregate quarries for the road construction is a serious problem to procure materials. Hence
recycling or reuse of material is beneficial. On emphasizing development in sustainable construction in the present era, recycling of
asphalt pavements is one of the effective and proven rehabilitation processes. For the laboratory investigations reclaimed asphalt
pavement (RAP) from NH-4 and crumb rubber modified binder (CRMB-55) was used. Foundry waste was used as a replacement to
conventional filler. Laboratory tests were conducted on asphalt concrete mixes with 30, 40, 50, and 60 percent replacement with RAP.
These test results were compared with conventional mixes and asphalt concrete mixes with complete binder extracted RAP
aggregates. Mix design was carried out by Marshall Method. The Marshall Tests indicated highest stability values for asphalt
concrete (AC) mixes with 60% RAP. The optimum binder content (OBC) decreased with increased in RAP in AC mixes. The Indirect
Tensile Strength (ITS) for AC mixes with RAP also was found to be higher when compared to conventional AC mixes at 300C.
Keywords: Reclaimed asphalt pavement, Foundry waste, Recycling, Marshall Stability, Indirect tensile strength.
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
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Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
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Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
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Technical Specifications
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
Key Features
Indigenized remote control interface card suitable for MAFI system CCR equipment. Compatible for IDM8000 CCR. Backplane mounted serial and TCP/Ethernet communication module for CCR remote access. IDM 8000 CCR remote control on serial and TCP protocol.
• Remote control: Parallel or serial interface
• Compatible with MAFI CCR system
• Copatiable with IDM8000 CCR
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
Application
• Remote control: Parallel or serial interface.
• Compatible with MAFI CCR system.
• Compatible with IDM8000 CCR.
• Compatible with Backplane mount serial communication.
• Compatible with commercial and Defence aviation CCR system.
• Remote control system for accessing CCR and allied system over serial or TCP.
• Indigenized local Support/presence in India.
• Easy in configuration using DIP switches.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Cosmetic shop management system project report.pdf
Mechanical properties and reliability of glass aluminium composite as insert mold
1. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 06 | June-2015, Available @ http://www.ijret.org 485
MECHANICAL PROPERTIES AND RELIABILITY OF GLASS-
ALUMINIUM COMPOSITE AS INSERT MOLD
Alva Edy Tontowi1
, Suryo Darmo2
, Suyitno3
, Muslim Mahardika4
1
Departement of Mechanical & Industrial Engineering, Faculty of Engineering, Universitas Gadjah Mada, Jl. Grafika
No.2 Yogyakarta 55281 Indonesia
2
Departement of Mechanical Engineering, School of Vocation, Universitas Gadjah Mada, Jl. Grafika No.2A
Yogyakarta 55281 Indonesia
3
Departement of Mechanical & Industrial Engineering, Faculty of Engineering, Universitas Gadjah Mada, Jl. Grafika
No.2 Yogyakarta 55281 Indonesia
4
Departement of Mechanical & Industrial Engineering, Faculty of Engineering, Universitas Gadjah Mada, Jl. Grafika
No.2 Yogyakarta 55281 Indonesia
Abstract
Plastic injection mold made of tool steel is generally utilized for large lots production. Running for small lots of product is a new
trend of demand, so that the mold would be relatively expensive and not competitive. The aim of the present work is to find an
alternative material and process for low cost injection mold that suitable for small lots. For these reasons, aluminum-glass-
acrylic particulate composite would be proposed as a material for manufacturing of low cost plastic injection mold. In this work,
an insert mold as part of the injection molding was selected for the case study. Composite was examined to know its
characteristics. The part with size of (80mm x 10mm x 10mm) and (30mm x30mm x30mm) made of particulate composite material
was selected as specimen. Material of the specimen was aluminum powders (<297 µm), glass powders (<74 µm) and acrylic
powders (<74 µm); the volume ratio is 1:1:1. Acrylic was used for binder when composite made by layer manufacturing method,
using Selective Heater Melting (SHM) machine. The specimen was prepared into three steps: manufacturing of composite (green
specimen) by SHM machine, heating green specimen to burn up the acrylic, and resin impregnation. There were 3 types of
specimens: green specimen before heating at 700°C, green specimen after heating at 700°C, and green specimen after heating at
700°C that continued by resin impregnation. Tests was performed to investigate its bending strength, surface hardness, surface
roughness, and dimensional error. The other composite (specimen) was insert mold, made by layer manufacturing method, using
SHM machine. Case study was carried out by testing an insert mold to know the reliability of insert mold.
Bending strengths of green specimen, before and after heating at 700°C, were 2.07 and 8.23 MPa, respectively; and after resin
impregnation was 17.15 MPa. Dimensional errors in the direction of X, Y, and Z-axis for green specimen of (30mm x 30mm
x30mm) before heating at 700°C were 8.65, 2.7, and 3.8 mm, respectively; and after heating at 700°C were 7.90, 1.10 and 0.90
mm, respectively. Surface roughness of green specimen before and after heating at 700°C were 46.12 and 33.48 µm, respectively;
and after resin impregnation was 12.17 µm. Surface hardness of specimen after resin impregnation was 14.199 BHN. The amount
of plastic parts that could be produced by insert mold was 120 and 126 pieces. Although mechanical strength of this composite
was lower than that of tool steel that used for common plastic injection mold, but this composite material was less expensive and
suitable for small lots production.
Keywords: Layer manufacturing, Selective Heater Melting (SHM) machine, green specimen, insert mold.
------------------------------------------------------------------***--------------------------------------------------------------------
1. INTRODUCTION
Injection molds that are presently applied in industrial
plastic, generally made by machining process, using
materials such as carbon steel, alloy steel, shock-resisting
steel, cold-work steel, mold steel, martensitic stainless steel,
high-grade zinc alloys, tin-bismuth alloys [1], carburizing
steel, maraging steel, maraging SS, high-speed steel, and
beryllium-copper [1]. Bulk steel for injection mold generally
has a tensile strength of 520 to 2070 MPa, yield strength of
360 to 1900 MPa, and hardness of 122 to 300 BHN [1]. The
surface roughness of mold for general use or general purpose
was 0.2 µm [2]. Another material for injection mold such as
tin-bismuth alloys has a melting point of 138-170°C, tensile
strength of 56 MPa and hardness of 20 BHN.
In term of fabrication method, mold could be made by
several methods such as machining of bulk material, casting
and layer manufacturing methods; and the mold could be
tested its reliability by running the mold in the plastic
injection machines for producing the products and counted
the number of product till the mold wear. Machining of bulk
steel for making mold was very common till present day.
However, the shape and geometry of its cavity was limited to
the symetric shape. Since it was only drilling or boring tool
that available in this machining technology, therefore it was
only straight cooling channel could be made. For another
geometry like cylindric or irregular shape, conformal cooling
channel could not be made. In casting method, Jetley and
Low [3] fabricated a mold using tin-bismuth alloys. The
2. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 06 | June-2015, Available @ http://www.ijret.org 486
products that were produced and met the criteria could reach
500 pieces. In layer manufacturing technology, mold can be
made by arranging plate or sheet or sintering of powder,
depending on the form of materials they will be used.
Doehler [4] fabricated mold by arranging thin plates of
carbon steel. In this method, the plates was stacked and
machined to shape into mold. Fabrication method of part by
arranging material in the form of plate or sheet later on it was
known as Layered Object Manufacturing (LOM) method. In
making mold by selective laser sintering metal powder, there
were two methods depending on the material powder which
called direct sintering and indirect sintering. In the direct
sintering, sintering process was carried out directly to the
metal powder. In this, sintering temperature was set up at a
few degree below the melting temperature of the metal
powders. Whilst in the indirect sintering, sintering
temperature was set up at the melting temperature of the
binder material. Thus, green part/green specimen would be
produced and it needs further post processing such as
infiltration to obtain better strength and density. The post
processing can be performed by heating up the green part to
burn the binder. Since the binder was out from the part, voids
was then exist and in order to have a dense part, the part is
infiltrated with another melted material. Several materials
have been widely used for making this mold, namely
polymer coated low-carbon steel powder with copper
infiltrant that could produced 50,000 part pieces [5]; polymer
coated steel powder with bronze infiltrant which could
produced 200,000 pieces per year for 5 years life time [6];
and tool steel powder with cast iron infiltrant [7]. All those
mold material based steel were dedicated for mass production
or large lots product, it was high wear resistant and of course
expensive. Thus, in the situation where small lots is needed,
this mold would not be suitable and probably high
operational cost. For these reasons, finding an alternative low
cost material and fabrication method would be challenging.
Material such as metal reinforced glass matrix composites
with binder probably could be used, although it was not
widely explored as a plastic injection mold material.
Attention was paid to find composite composition and
mechanical strength. It was few existing research could be
found. Bernardo [8] found that the advantage of using thus
composite was low sintering temperature of about 50°C
above the dilatometric softening temperature and save
energy. In addition to this, the sintering process does not
require the rigorous atmosphere, because the sintering
process can also occur in the normal air atmosphere. In the
study, they used glass matrix composite including aluminium
reinforced lead-silicate glass matrix composite. The lead-
silicate glass waste was obtained from the waste of cathode
ray tubes (CRTs) of PC’s and TV’s monitors. The size of the
glass powder < 37 m and the aluminum powder < 75 m. A
mixture of 80 vol% of glass powders and 20 vol% of
aluminum powders was pressed at a uniaxial pressure of 350
bar (35 MPa) in a steel mold (rectangular cross-section, 50
mm x 34 mm) using a hydraulic press at room temperature
(cold-pressing) to form a compact part. Subsequently, the
compact was pressureless sintered at a temperature of 600°C
for 5 hours. In the mechanical testing, they found that its
bending strength of the specimen was 65.40 9.32 MPa.
Similar to this reseach was Montazerian et al. [9] They
examined the partially stabilized zirconia (Y-PSZ) reinforced
mica glass-ceramic composites with 5%, 10% and 15%
weight ZrO2. They used glass powders and Y-PSZ powders
with particle size of 12.5 m and 0.89 m, respectively. The
mixtured powders was pressed using uniaxial hydraulic press
of 65 MPa into discs of 10 mm diameter and 4 mm thick. The
process was conducted at room temperature and sintered
without pressure at temperatures ranging from 1060 to
1170°C with holding time of 240 minutes. They found that
the maximum bending strength of 132.47 ± 13.80 MPa
occurred for the specimen with 15 wt. % ZrO2. Another
research was Rajesh, et al. [10]. They investigated the
composite was made of alumina filler with average particle
size of 5m and matrix of G018-250 (lead-free
aluminoborosilicate) and bismuth glass with particle size of 4
m. A mixture of 50 wt.% Al2O3 and 50 wt. % glass was
uniaxially pressed into pellets with diameter of 11 mm and
height of 2 mm. Pellets were sintered at temperatures ranging
from 600°C to 750°C with heating rate of 5°C/min in air
atmosphere. While, Kim et al. [11] examined the composite
made of 50% Al2O3 - 50% PBS glass (lead borosilicate
glass). Samples in the form of disk with diameter of 15 mm
were prepared by compacting the powder mixture at a
pressure of 50 MPa and sinter at temperature of 600-950°C
for 2 hours. The last similar research was done by Darmo
et.al [12]. They developed composite of glass, aluminum, and
acrylic powders with volume ratio of 3:2:1. Particle size of
each powder was about <425 µm. Green specimens were
made by filling a mixture of these materials into the mold
with a size of 10mm x 10mm x90mm, heated in a furnace at
a temperature of 250 °C for 1 hour. The green specimens
then was further heated in a furnace at a temperature of
600°C, 650°C, and 700°C for 1 hour. Maximum bending
strength their achieved was 40 kg/cm2
. At the same year,
Darmo [13] carried out a similar study, but using a finer
powder with different volume ratio. The particle size of
aluminum powders was < 297 µm; glass and acrylic powders
was < 74 µm, respectively; and the volume ratio of the
composite was 1:1:1. Green specimen was made by heating
the mixture at a temperature of 250°C, subsequently, heated
at a temperature of 650°C, 700°C, 750°C, 800°C, and 850°C,
and followed by a bending test. Maximum bending strength
was 323.20 kg/cm2
achieved by sample with heating at a
temperature of 750°C. This bending strength, more over, was
almost 8 times higher than that of using coarse powder.
Continuing study of thus composite material using selective
heater melting (SHM) for fabrication specimen, Darmo et.al
[14] found that quality of bonding between the particles in
the composite was strongly influenced by the volume ratio of
the powder mixture and scanning speed of the heater with
assuming that tip heater temperature was remain constant.
Quality of the bonding observed included the strength of the
bond and the shape of the specimens. The shape of the
specimens must be maintained (not collapse), when green
specimens are reheated at a temperature of 700°C. The
results showed that a good bond between the particles was
occurred if the heater scanning speed was 100 mm/min, and
the volume ratio of the mixture of the aluminum, glass, and
acrylic powders was 1:1:1. Naturally, aluminum is an active
3. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
_______________________________________________________________________________________
Volume: 04 Issue: 06 | June-2015, Available @ http://www.ijret.org 487
metal and reacts with oxygen from the air to form a thin hard
layer of aluminum oxide (Al2O3) on the surface. Layer
thickness of the oxide (alumina) at room temperature
condition was 2-3 nm and approximately 1μm when heated
up at 600°C [15]. Melting point of Al2O3 was approximately
1926°C, while pure aluminum was only 660°C
[16][17][18][19]. Heating aluminum of which the size of
particles was in micro-scale (µm), causing the formation of
γ-Al2O3 scale, before reaching the melting point of the
aluminum; whereas the liquid of the aluminum was remained
inside the γ-Al2O3 shell. Further heating caused the formation
of θ-Al2O3 scale, grew simultaneously with γ-Al2O3. The γ-
Al2O3/θ-Al2O3 scales remained stable and protective at
isothermal conditions, up to a temperature reach 800°C [20].
The oxide layer decreased the properties of sinterability of
aluminum powders. Therefore, pressure should be performed
on the aluminium powders up to 490 MPa which was carried
out before carrying sintering process at a temperature of
640°C to gain better sinterability [21]. This pressure caused
the plastic particles deformation and breakup the oxide layer.
As a result, cold-weld occured at the areas of the oxide-free
as a location of diffusion processes of atoms during sintering
process [22]. Glass and aluminium are good combination
material. Glass powder was able to bind aluminum powder
due to chemical reaction at the interface between aluminum
and glass particles [8]. The ability of glass to bond to
aluminum at 700°C was also proven by Liu, et al. [23]. Their
research was performed by mixing Pyrex 7740 glass (80.9
wt% SiO2, 12.7 wt% B2O3, 2.3 wt% Al2O3, and 4.0 wt%
Na2O) and aluminum (purity: 99.997%) at temperatures of
350-450 °C that generated by DC electric field at a voltage of
400-700 V. Bonding between the glass and the aluminum
occurred due to the diffusion bonding. Na+
ions move away
from the interface of glass-aluminum, whereas oxygen ions
diffuse into that region, and react with the silicon (Si) to form
Si-O bonding [23]. Alumina in the glass serves as
intermediate oxides, enter into the silica network as
tetrahedra AlO4
4-
, replacing some groups of SiO4
4-
[24].
In order to sinter at relatively low temperature, binder is
required for manufacturing of composite green part. Yan, et
al. [25] conducted a study on green parts made by using
Indirect Selective Laser Sintering (SLS) process. In their
study, the specimen was made of carbon steel powder as the
main material and nylon-12 resin as a binder. Nylon-12 has a
glass transition temperature of 181.1°C [26]. For the green
specimen, bending strength was influenced by the nature of
bonding of binder. The increase in bending strength was due
to the increase of the laser energy density and vise versa. The
decrease in bending strength was happened when the
viscosity of the polymer as a binder was decreased, so that
the binder was decomposed. Another binder like acrylic was
introduced by Darmo, et al. [12] to fabricate composite of
aluminum and glass powders. Acrylic serves as a binder of
the mixed of glass and aluminum powders. Acrylic
(polymethyl methacrylate, PMMA) has a melting
temperature of 149°C [16]; aluminum was about 660°C [16];
glass was about 1400°C, and the glass transition temperature
was about 530°C [27]. In the study, when aluminium
particles were heated at a temperature of 700°C, the shape of
aluminium particles was not change, and the surface of
aluminum particles undergos strong oxidation to form
alumina [28], but the particle of aluminum and the glass was
bonded very well. Sure that many beneficial of employing
layer manufacturing technique in fabricating a 3-dimensional
object can have it. Not only its ability in building a complex
geometry that machining process could not able to perform,
but also a wide range of material types can be processed.
Beyond those advantages, there is dimensional error still
exist in x, y and z directions. But, mostly in z-direction which
is biggest error and known as bonus-Z. So far, this
dimensional error have been solved by giving size
compensation and positioning the part orientation before
running the process. However, pay attention of the research
still in it. Yan, et.al [25] found that dimensional error of the
selective laser sintered part (carbon steel and nylon-12
powders) was influenced by heat energy density and travel
speed of the heater. The heat received by the composite
material became higher if traveling speed was low, and vice
versa [29]. Dimensional errors occurred to the green
specimen in the direction of x, y, and z axis were 0.207,
0.199, and 0.587%, respectively. The dimensional errors
occurred due to the loose powders that directly in contact
with the sintered parts reached temperature above a caking
sintering tempera-ture, causing the part grew larger.
Following success of developing the composite of aluminum-
glass with binder of acrylic and trial in making specimen
using SHM in the previous research, then the present work
would like to focus on manufacturing of an insert of plastic
injection molding and testing of running production. SHM
machine is a machine used for making 3D objects, by means
of layer by layer method, using radiation heater of pencil
type (use glow plug) as a heat source. The maximum
temperature of the heater is about 500°C.
2. METHODS
2.1 Materials
Composite materials have been used in this work consists of
aluminum powder (< 297 µm), glass powder (< 74 µm), and
acrylic powder (< 74 µm). The powders have been
characterized following the previous work by Scanning
Electron Microscope (SEM), Energy Dispersive X-Ray
Analysis (EDAX) and X-Ray Fluorescence (XRF). Glass
powders have angular shape particles with composition of
70% SiO2, 1.5% K2O, 24.7% CaO, 0.43% TiO2,
0.075%Cr2O3, 0.01% V2O5, 0.074% MnO, 1.8% Fe2O3,
0.959% NiO, CuO 0.12%, 0.014% ZnO, BaO 0.1%, and
0.1% Re2O7. Aluminum powders have flake shape particles
with composition of 96.14% Al, 2.67% Mg, and 1.19% Si.
While the acrylic powders have irregular shape particles with
composition of 8.10% C, 34.78% O, 16.67% Na, Mg 0.79%,
0.96% Al, Si 15.73%, and 22.96% Ca.
2.2 Bending Test
Fig-1 shows the flowchart of manufacture of specimen and
bending test.
4. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 06 | June-2015, Available @ http://www.ijret.org 488
Fig-1 Flowchart of manufacture of specimen and bending
test
The aluminum, glass and acrylic powders, mixed with a
volume ratio of 1:1:1, using a rotary mixer for 3 hours, at 70
rpm. Selective Heater Melting (SHM) machine, was prepared
and programmed, for the manufacture of green specimens
with the size of (80mm x10mm x 10mm). The heater
velocity, was designed at 100 mm/min; path length of actual
movement of the heater of the Selective Heater Melting
(SHM) machine was measured in the direction of X-axis and
Y-axis. Actual length in Z-axis direction, i.e the distance of
movement of build piston, measured in the vertical direction.
Measurement was performed when the Heater Selective
Melting (SHM) machine was being operated. Preparation of
the specimens was done by making green specimens, made
of the powder mixture, by means of layer by layer method,
using Selective Heater Melting (SHM) machine. Fig-2 shows
the SHM machine that used in this research.
Fig-2 Selective Heater Melting (SHM) machine
Steps of manufacturing method of green specimen
(composite) made by using SHM machine is as shown in Fig-
3 to Fig-6. Step 1: powders are fed into the build chamber,
from hopper (Fig-3). Step 2: powder sweeper plate
sweeps/flatten the pile of the powders (Fig-4). Step 3: the
heater move down, approached the surface of the powder,
then heating the powders; one layer of composite (green
specimen) is formed (Fig-5). Step 4: the heater moves up and
build piston moves down to the distance of 1 mm (Fig-6).
Step 5: powders were fed into the build chamber, from
hopper (Fig-7). The next step is the same as step 1 and so on.
The process is repeating until the amount of the layers is
appropriate with the design.
Fig-3 Step 1 of manufacturing process of green specimen;
powders are fed into the build chamber, from hopper
5. IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 04 Issue: 06 | June-2015, Available @ http://www.ijret.org 489
Fig-4 Step 2 of manufacturing process of green specimen,
powder sweeper plate sweeps the pile of the powders
Fig-5 Step 3 of manufacturing process of green specimen, the
heater move down approached the surface of the powder,
then heating the powders
The amount of green specimens for the design size of (80mm
x10mm x 10mm) was 15 pieces. Green specimens were
divided into three groups. Group 1: green specimens were not
reheated, tests performed for bending strength. Group 2:
green specimens were heated at a temperature of 700°C; tests
performed for bending strength. Group 3: green specimens
were heated at a temperature of 700°C and then impregnated
by resin; tests performed for bending strength. Bending test
that was performed, based on the ASTM D 790-07 standard,
by three-point loading method. Fig-8b is the green specimen
for bending test, that made by using SHM machine.
Fig-6 Step 4 of manufacturing process of green specimen, the
heater moves up, and simultaneously build piston moves
down to the distance of 1 mm
Fig-7 Step 5 of manufacturing process of green specimen,
powders were fed into the build chamber from hopper
Fig-8 Green specimen made by SHM machine.
(a)Design size of (30mm x 30mm x 30mm);
(b) design size of (80mm x 10mm x 10mm)
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2.3 Dimensional Error, Surface Roughness, and
Surface Hardness Test.
Fig-9 shows the flowchart of manufacture of specimen, and
tests of dimensional error, surface roughness, and surface
hardness.
Fig-9 Flowchart of manufacture of specimen and tests of
dimensional error, surface roughness, and surface hardness
The amount of green specimens for the design size of (30mm
x 30mm x 30mm) was 3 pieces. Green specimens were
divided into six groups. Group 1, green specimens were not
reheated, the dimensions measured in the direction of X, Y
and Z-axis; this data used for dimensional error calculation.
Group 2, green specimens were not reheated, without
polished (not smoothed); tests performed for surface
roughness. Group 3, green specimens were reheated at a
temperature of 700°C, the dimensions measured in the
direction of the X, Y and Z-axis; this data used for
dimensional error calculation. Group 4, green specimens
were heated at a temperature of 700°C, without polished (not
smoothed); tests performed for the surface roughness. Group
5, green specimens were heated at a temperature of 700°C,
impregnated by resin, without polished (not smoothed); tests
performed for the surface roughness. Group 6, green
specimens heated at a temperature of 700°C, impregnated by
resin, polished (smoothed) by the sandpaper of a grit number
of 100 to 1000; tests performed for the surface roughness and
for the surface hardness. Fig-10 shows the schematic of
manufacturing of green specimen using Selective Heater
Melting (SHM) machine. The heater move in the X-axis
direction and Y-axis direction, while the build piston move in
the Z-axis direction.
Fig-10 Schematic of manufacturing of green specimen using
Selective Heater Melting (SHM) machine. The heater move
in the X-axis direction and Y-axis direction, while the build
piston move in the Z-axis direction
2.4 Reability Test of Insert Mold
Fig-11 shows the flowchart of manufacture of insert mold
and reliability test. The mixture of aluminiumium, glass, and
acylic powders was used for material of insert mold. Green
insert molds, made by layer manufacturing method using
Selective Heater Melting (SHM) machine. The amount of
green insert mould was 2 pieces. Green insert molds (Fig-
12), were heated at a temperature of 700°C, and then im-
pregnated with the resin. The entire of the surface of the
insert mold was polished by sand paper, and at the same
time, the dimension of insert mold were adapted to the
dimensions of steel mold. Finished insert mold (insert mold
that has been polished, Fig-13), was mounted on the steel
mold, as shown in the Fig-14. The reliability test was done
by using the mold in the operation of plastic injection
machine in industry. Product made by plastic injection
machine was sliding plastics (Fig-15), made of HDPE (High
Density Polyethylene). The function of finished insert mold
was to make a hole of slider plastics as shown in Fig-15.
Reliability test was done by counting the number of slider
plastics that produced by mold till the finished insert molds
were fractured.
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Fig-11 Flowchart of manufacture of insert mold and
reliability test
Fig-12: Green insert mold and of the dimension
Fig-13 (a) Finished insert mold; (b) dimension of finished
insert mold
Fig-14 Finished insert mold (made of composite) mounted on
the steel mold
Fig-15 Slider plastic
3. RESULTS AND DISCUSSION
Table-1 and Fig-16 are the bending strengths of the green
specimens before and after heating at a temperature of
700°C, and the bending strengths of the green specimens
after heating at a temperature of 700°C and resin
impregnation. In these, among those measurement results,
specimen with heating at 700°C and then impregnated with
the resin shows the highest bending strength. The bending
strength of green specimen before heating at 700°C was 1.86
± 0.20 MPa. This bending strength was higher than that of
Yan’s results i.e 1.4 MPa [25]. This composite was formed
due to the melted acrylic bind the particle of glass and
aluminum as depicted in Fig-17a. In term of bending
strength, this green specimen was feasible as a material of
green part. After heating at temperature 700°C, the bending
strength increased to 7.85 ± 0.49 MPa. At this temperature,
acrylic was burn out and at the same time, glass particle start
to be softening and to bond the alumnum particle. There was
in agreement with Liu, et al. [23], that bonding between the
glass and the aluminum occurred due to the diffusion
bonding.
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Table-1 Bending strength of specimens
Fig-16 Effect of the treatment of the specimens to the
bending strength
Fig-17 (a) Surface fracture of green specimen before heating
at 700°C, most of the surface is covered by acrylic; (b)
Surface fracture of green specimen after heating at 700°C.
Na+
ions move away from the interface of glass-aluminum,
whereas oxygen ions diffuse into that region, and react with
the silicon (Si) to form Si-O bonding. After heating, the
specimen still performed better bending strength as
contribution of glass bonding as shown in Fig-17b. There
were pores in the specimen as a replacement of the acrylic
position that has been burn out (Fig-18). For the specimens
that has been im-
Fig-18 Green specimen after heating at a temperature of
700°C. Pores accurred because the acrylics were burned.
pregnated by resin show much higher bending strength
compared to that of the specimen that only treated by
heating. The bending strength of this specimen was 16.73 ±
0.47 MPa. This was about twice of the heated specimen and
almost 10 times to the green specimen that before being
heated at 700°C. Impregnation of resin in the specimens
could improve the bending strength. However, the bending
strength of present work was still far below comparing to
bending strength of Bernardo et.al work of 65.40 ± 9.32 MPa
[8], and Montazerian et al. work of 132.47 ± 13.80 MPa [9].
Dimensional errors, that expressed by the difference of the
dimension of design (computer) and the dimension of
specimens in 3-axes direction (x, y and z axes), show that
there was over size in x-direction, higher than that of y and z-
directions before and after heating as depicted in Table 2 and
Fig-19. The over size in x, y and z-direction of the green
specimen before heating were 8.58 ± 0.07 mm, 2.50 ± 0.17
mm and 3.71 ± 0.07 mm, respectively; and after heating there
were 7.51 ± 0.40 mm, 0.75 ± 0.52 mm and 0.76 ± 0.15 mm,
respectively. In these, over size that happen to the green
specimen before heating was higher than that after heating. It
was about 10 % differences. There was any shrinkage after
the acrylic burn out and re-arrangement of glass and
aluminum particles resulting the pore size decreased. These
over size in general might be due to the loose powder located
outer ring of the desire size reach the caking temperature and
solidified after cooling down. The dimensional error in the
direction of the X-axis (ΔX) was differ with that of in the
direction of the Y-axis (ΔY). It was caused by the pat-tern of
movement of the heater, as shown in Fig-10. The path length
of movement of the heater on the direction of the Y-axis, was
greater than that in the direction of the X- axis; and also,
backward and foreward movement of the heater in the
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direction of the Y-axis causing the heat flowed to the lateral
direc-tion (X-axis direction) was greater than that of the Y-
axis direction (Fig-20). So that the dimensional error in the
direction of X-axis was greater than dimensional error in the
direction of Y-axis. The dimensional error of the green
specimen at the direction of Z-axis (ΔZ) was due to the effect
of the heat that flowed on the direction of Z-axis. Fig-21
shows a schematic of part of the powder mixture of which
undergo hardening (bonding) after the heater passed over the
first time. Fig-21 shows, maximum thickness was 1.1 mm,
exceeded the thickness that was designed for each layer (i.e 1
mm), thus the bonding between the layers was always
occurred. The actual length of each step of the movement of
the heater, in the X-axis direction was 0.95 mm. Fig-19
shows the layer building along hatch vectors. A hatch vector
refers to the path that the heater has to follow within a
contour to build a portion of the layer [30]. When the
manufacture of the layer was in progress, the additional of
the heat takes place on the layer that was formed previously;
heat flows from the layer being formed, toward the layer
below it (at the Z- axis direction). The addition of the heat
from the top caused the loose powders, that were directly in
contact with the upper layer, reached the temperature above a
caking temperature, resulting in secondary heating [25]. In
the surface roughness test of the specimens shown in Table 3
and Fig-22, showed that the surface roughness of the green
specimens were the highest comparing to
Table-2 Dimensional error of green specimen
that of the specimen after heating and impregnation. It may
be due to the nature of selective heater melting process i.e.
there aren’t compaction process. Improve-ment of the surface
roughness could be carried out by impregnation and
polishing. In the current work, impregnation was done by
resin and polishing by sand paper with grit number of 100
and 1000. Applying these, the finished specimens have an
average value of the surface roughness Ram = 2.454 µm as
illustarted in Table 4. This roughness was still larger than
that of the mold which generally used in plastic injection
molding industry, i.e 0.2 µm [2]. Beyond the surface
polishing, improvement of the surface finish probably could
be done by using finer particle size of particle.
Fig-19 Dimensional error of the green specimens before and
after heating at a temperature of 700°C
Fig-20 The pattern of the movement of heater. Movement of
the heater back and forth in the direction of Y-axis, causing
the amount of the heat flows to the direction of the X-axis
(lateral direction) was greater than the direction of Y-axis
Fig- 21 Schematic of shape and dimension of the powder
mixture, that was hardened (i.e: bonding was occurred
between the powder particles), after being heated by the
heater, at the first path.
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Table-3 Surface Roughness of Specimens
Fig-22 Surface roughness of green specimen before and after
heating at 700°C, and after impregnating by resin
Table-4 Surface roughness of finished specimen
In this present work, surface hardness was only carried out
for the specimen that treated with heating at 700o
C,
impregnation and surface polishing. The hardness of surface
finished specimens was shown in Table 5. The average of the
surface hardness of finished specimen was 13.02 BHN.
Comparing to that of existing mold which manufactured by
machining of tin-bismuth alloy bulk (20 BHN) and steel bulk
(122 BHN) [1], this hardness was smaller.
Table-5 Surface hardness of finished specimen (BHN)
In the reliability test, in the first running test, the amount of
products (slider plastics) was 120 pieces, and in the second
running test there was 126 pieces. The number of part that
could be produced much lower than that has been conducted
by Pham, et al. [5]. However, the composite of the mixture of
the aluminum, glass, and acrylic powders would be still
useful and applicable for small lots for plastic part product.
The number of part will be much improved probably for
injecting functional part with another material that has lower
melting point such as wax based composite. Another
application is for prototyping part.
4. CONCLUSION
Particulate composite of Aluminum-Glass-Acrylic powders
has been developed successfuly and tested for mechanical
strength. The insert mold made of this composite material
using Selective Heater Melting machine have also been
tested for running production. Tests have been carried out for
green specimen, after heating and impregnation without and
with polishing, and tests also have been carried out for insert
mold. These tests included bending, dimensional error,
surface roughness and hardness as well as reliability. Based
on these, it can be concluded that resin impregnated
specimen with polishing show the highest bending strength
(16.73 ± 0.47 MPa) and surface hardness (13.02 ± 1.16
BHN) and the most fine surface finish (2.454 µm). While for
dimension error, heating at 700o
C for the green specimen
could reduce dimensional error. In reliability test, however,
the injection mold with insert mold made of this particulate
composite could produce 120 and 126 pieces of slider
plastics. Although, it was smaller than that of common
injection mold, this material was less expensive and would
have prospect to be used for small lots production that
currently small number and custome product demand become
a new trend in consumer industry.
ACKNOWLEDGEMENTS
The authors would like to thanks to the Department of
Mechanical Engineering School of Vocation Universitas
Gadjah Mada for their financial support.
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