Each material has its own effect and behavior on external impacts like heat, force, tension, compression, torsion etc. It is important to study and analyze these behaviors before selecting a material for an engineering application in the design aspects itself. If predicted values analyzed by both mathematical and software are available it is easy to get the reliable details in the pre design itself. By this one can ensure the safety of the component and the system also. In this investigation, the effects of torsional loads on mild steel
round shafts with various diameters and lengths have been analyzed. The additional effects like angle of rotation, rpm and duration also considered to find the optimum predicted value. The data observed by various experiments are analyzed by design of experiments especially by response surface methodology. Minitab software is used for canalization. The data are tabulated and kept for future reference. Noise effect
due to the gradual torsional load performed in the gear box and other rotating components is also studied for healthy working environment. The nature and characteristics of material also be explained by this noise analysis.
Finite element modeling and bending stress analysis of non standard spur geareSAT Journals
Abstract Gears are toothed wheels, transmitting power and motion from one shaft to another by means of successive engagement of teeth. Having a higher degree of reliability, compactness, high velocity ratio and finally able to transmit motion at a very low velocity, gears are gaining importance as the most efficient means for transmitting power. A gearing system is susceptible to problems such as interference, backlash and undercut. The contact portions of tooth profiles that are not conjugate is called interference. Furthermore due to interference and in the absence of undercut, the involute tip or face of the driven gear tends to dig out the non-involute flank of the driver. The response of a spur gear and its wear is an engineering problem that has not been completely overcome yet. With the perspective of overcoming such defects and for increase the efficiency of gearing system, the use of a non-standard spur gear i.e., an asymmetric spur gear having different pressure angles for drive and coast side of the tooth comes into picture. This paper emphasis on the generation of an asymmetric spur gear tooth using modeling software and bending stress at the root of Asymmetric spur gear tooth is estimated by finite element analysis using ANSYS software and results were compared with the standard spur gear tooth. Keywords: Asymmetric spur gear, Bending stress, Finite element method, Pressure angle
Finite element modeling and bending stress analysis of non standard spur geareSAT Journals
Abstract Gears are toothed wheels, transmitting power and motion from one shaft to another by means of successive engagement of teeth. Having a higher degree of reliability, compactness, high velocity ratio and finally able to transmit motion at a very low velocity, gears are gaining importance as the most efficient means for transmitting power. A gearing system is susceptible to problems such as interference, backlash and undercut. The contact portions of tooth profiles that are not conjugate is called interference. Furthermore due to interference and in the absence of undercut, the involute tip or face of the driven gear tends to dig out the non-involute flank of the driver. The response of a spur gear and its wear is an engineering problem that has not been completely overcome yet. With the perspective of overcoming such defects and for increase the efficiency of gearing system, the use of a non-standard spur gear i.e., an asymmetric spur gear having different pressure angles for drive and coast side of the tooth comes into picture. This paper emphasis on the generation of an asymmetric spur gear tooth using modeling software and bending stress at the root of Asymmetric spur gear tooth is estimated by finite element analysis using ANSYS software and results were compared with the standard spur gear tooth. Keywords: Asymmetric spur gear, Bending stress, Finite element method, Pressure angle
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.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
TENSILE BEHAVIOUR OF ALUMINIUM PLATES (5083) WELDED BY FRICTION STIR WELDING IAEME Publication
Using arc welding, gas welding and other welding process, it is very difficult to weld the aluminum alloys. Friction stir welding, on the other hand, can be used to join most Al alloys and
better surface finishing is achieved. Although the work piece does heat up during friction stir weld, the temperature does not reach the melting point.
Experimental Investigation of Tensile Strength and Deflection Characteristics...IOSR Journals
Aluminum alloys are used in many applications in which the combination of high strength and low
weight is attractive; ship building, air frame, transportation industry etc. are some areas in which the low
weight can be significant value. Friction stir welding (FSW) is a new welding technique particularly well suited
to aluminum alloys though this technique is also used for other materials. Friction stir welding promises joints
with low porosity, fine microstructures, minimum phase transformation and low oxidation compared to
conventional welding techniques. It is capable of joining combinations of alloys not amenable to conventional
welding.Experiments for tensile and deflection tests were carried out and reported in this research paper. The
base material used for friction stir welding was AA 6351–T4 Aluminum alloy. Tensile strength and breaking
loads were increased with increase of rotational speed of the tool but it drops after attaining marginal speed.
Deflections of friction stir welded specimens and base materials were compared and they exhibited almost
similar trends at different load conditions and deflections of all the specimens were increased with increment of
load
Damage tolerance study of honeycomb sandwich structureeSAT Journals
Abstract
Composite materials are essential component in today’s modern world. Structural sandwich construction is one of the first form of composite structures. In this study honeycomb sandwich structure which is a peculiar type of composite structure was investigated for crashworthiness. They are manmade structures with a honeycomb geometry. It consists of three elements ; Top face sheet, Core, Bottom face sheet. They are widely used in aerospace industry, marine, rail, automotive industry, in construction field as prefabricated partition walls, mezzanine floor, doors etc. The main objective of this study was to assess the damage tolerance of honeycomb sandwich structure based on serviceability and safety of the structure ie. to understand ability of structure to sustain defects safely until repair/replacement is performed. Damage tolerance study was performed to know with how much load this structure would safely withstand and also to know till how much load this structure would be made serviceable, if a damage is caused to it. Investigations were performed on both damaged and undamaged specimens by conducting. Four point bending flexure test and Edgewise compression test based on ASTM standards. Also finite element modeling of honeycomb sandwich structure was developed and analysis of the two experiments were performed in Ansys. Ultimate load, tensile and compressive stress values etc. obtained from the two experiments were compared for both damaged and undamaged specimen. Based on the results obtained it could be inferred that the load carrying capacity of honeycomb sandwich structure reduces, if a damage is caused to it but can perform its duty with reduced efficiency.
Keywords: Honeycomb Sandwich, Crashworthiness, Four point bending and Edgewise compression.
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
DESIGN AND ANALYSIS OF AXIAL CROSSING OF WORK ROLLS IN ROLLING MILL WORK ROLL...IAEME Publication
Rolling Mill is one of the machine for rolling steel or other metal into sheets. For reliable and efficient working of rolling mill it is necessary that all the components used in rolling mill should work properly without fail. Work roll assembly is very important part of the rolling mill. It has been observed that In hot rolling mill during the metal rolling at finishing mill (4-Hi mill Reversible) , work roll pair come out due to the axial crossing of work rolls and due to which uneven thickness of metal, strip breakage, bending of locking plate, metal shifting and equipment breakdown occurs. After the Study it has been observed that wear of the work roll liner is one of the reasons for the axial crossing of the work rolls.
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.
Investigation on Mechanical Properties of AL6061 Alloy Processed by FSWijtsrd
The aim of this experiment was to improve the mechanical properties of 6061 aluminium alloys by friction stir processing FSP , a solid-state technique for micro structural modification using the heat from a friction and stirring. The Aluminium alloy 6061 is widely used in the fabrication of lightweight structures with high strength-to-weight ratio and good corrosion resistance. Welding is main fabrication method of 6061 alloy for manufacturing various engineering components. Friction stir welding FSW is a recently developed solid state welding process to overcome the problems encountered in fusion welding. This process uses a non-consumable tool to generate frictional heat on the abutting surfaces. The welding parameters, such as tool pin profile, rotational speed, welding speed and axial force, play major role in determining the micro structure and corrosion resistance of welded joint. In this work a central composite design with two different speeds, traverse speeds and Four tools has been used to minimize the experimental conditions. B. S. Bharadwaj | N. Phani Raja Rao "Investigation on Mechanical Properties of AL6061 Alloy Processed by FSW" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-6 , October 2018, URL: http://www.ijtsrd.com/papers/ijtsrd18802.pdf
Modeling and Simulation of Base Plate of Friction Stir Welding-Advanced Weldi...ijsrd.com
Friction stir processing is an emerging technique based on the principles of friction stir welding (FSW). It is a solid-state joining method that is energy efficient, environmentally friendly, and versatile. It is considered by many to be the most significant development in metal joining in a decade. The basic concept of friction stir processing is remarkably simple. A rotating tool with pin and shoulder is inserted in the material to be joined, and traversed along the line of interest. The heating is localized, and is generated by friction between the tool and the work piece, with additional adiabatic heating from metal deformation. A processed zone is produced by movement of material from the front of the pin to the back of the pin.
Through this paper an attempt is made to study and review a special welding technology of friction stir welding (FSW) which is a solid-state joining process. Friction Stir Welding (FSW) is a recent advanced technique, invented by The Welding Institute (TWI) in 1991, that utilizes a nonconsumable rotating welding tool to generate frictional heat and plastic deformation at the welding location; thereby, affecting the formation of a joint while the material is in the solid state. In particular, FSW can be used to join high-strength aerospace aluminum alloys and other high temperature metallic alloys that are difficult to weld by conventional fusion welding method. FSW is considered to be the most significant development in metal joining process in a decade The comprehensive body of knowledge that has built up with respect to the friction stir welding (FSW) of aluminum alloys. This study addresses the current state of understanding and development of the FSW process. The principles of weld formation, welding parameters, design principles, including metal flow and thermal history, before discussing how process parameters affect the weld properties Danail Abdullah"A Review of Friction Stirs Welding" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-1 | Issue-4 , June 2017, URL: http://www.ijtsrd.com/papers/ijtsrd124.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/124/a-review-of-friction-stirs-welding/danail-abdullah
Project presentation on fixture design for eliminating key hole defectSubed Satyal
This project presentation includes the introduction of Friction stir welding along the pipe's circumference and the pipe is made of Aluminum alloy because it is suitable for friction stir welding. It also includes literature review regarding the key hole defect & its elimination. A brief methodology which is adopted for eliminating this defect is also mentioned. The final parts includes introduction, consequences & proposed method to eliminate key hole defect by using sacrificial material. A especially designed fixture is used to clamp the sacrificial material which is manually slides in a cross slide to connect pipe along the weld line with the sacrificial material's curved surface.
This presentation contains basics of Fire, Technical terminologies related to fire, Causes of fire and Effects of fire, General Requirements of Fire Resisting building as per IS and NBC 2005,Characteristics of Fire resisting materials, Fire Fighting Installations for Horizontal Exit, Roof Exit / Fire Lifts, External Stairs ect...This presentation is useful to Civil Engineers, Fire Fighting Engineering Students and Faculty members to convey Lecture on Fire Protection.
Combustion can be described as the burning of fuel as well as oxidant so as to produce heat.
Fire is a special type of the oxidant that is popularly known as combustion.
Fire has a triangular characteristics involving high temperature, oxygen and fuel as indicated in the diagram.
Lack of oxygen is what causes fire to be extinguished.
The presentation will highlight the type of hazards as well as the protection systems needed in fighting fire outbreak.
Hazards in steel plant and their control, By B C dasBimal Chandra Das
Hazards and Accidents In the iron and Integrated steel industry- Recommendations to prevent and control exposure to ….. Safety Awareness, It is sharing of knowledge. By Bimal Chandra Das, Rtd. AGM (Safety), Bokaro Steel Plant,/ Bokaro. Kolkata
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.
The International Journal of Engineering & Science is aimed at providing a platform for researchers, engineers, scientists, or educators to publish their original research results, to exchange new ideas, to disseminate information in innovative designs, engineering experiences and technological skills. It is also the Journal's objective to promote engineering and technology education. All papers submitted to the Journal will be blind peer-reviewed. Only original articles will be published.
The papers for publication in The International Journal of Engineering& Science are selected through rigorous peer reviews to ensure originality, timeliness, relevance, and readability.
TENSILE BEHAVIOUR OF ALUMINIUM PLATES (5083) WELDED BY FRICTION STIR WELDING IAEME Publication
Using arc welding, gas welding and other welding process, it is very difficult to weld the aluminum alloys. Friction stir welding, on the other hand, can be used to join most Al alloys and
better surface finishing is achieved. Although the work piece does heat up during friction stir weld, the temperature does not reach the melting point.
Experimental Investigation of Tensile Strength and Deflection Characteristics...IOSR Journals
Aluminum alloys are used in many applications in which the combination of high strength and low
weight is attractive; ship building, air frame, transportation industry etc. are some areas in which the low
weight can be significant value. Friction stir welding (FSW) is a new welding technique particularly well suited
to aluminum alloys though this technique is also used for other materials. Friction stir welding promises joints
with low porosity, fine microstructures, minimum phase transformation and low oxidation compared to
conventional welding techniques. It is capable of joining combinations of alloys not amenable to conventional
welding.Experiments for tensile and deflection tests were carried out and reported in this research paper. The
base material used for friction stir welding was AA 6351–T4 Aluminum alloy. Tensile strength and breaking
loads were increased with increase of rotational speed of the tool but it drops after attaining marginal speed.
Deflections of friction stir welded specimens and base materials were compared and they exhibited almost
similar trends at different load conditions and deflections of all the specimens were increased with increment of
load
Damage tolerance study of honeycomb sandwich structureeSAT Journals
Abstract
Composite materials are essential component in today’s modern world. Structural sandwich construction is one of the first form of composite structures. In this study honeycomb sandwich structure which is a peculiar type of composite structure was investigated for crashworthiness. They are manmade structures with a honeycomb geometry. It consists of three elements ; Top face sheet, Core, Bottom face sheet. They are widely used in aerospace industry, marine, rail, automotive industry, in construction field as prefabricated partition walls, mezzanine floor, doors etc. The main objective of this study was to assess the damage tolerance of honeycomb sandwich structure based on serviceability and safety of the structure ie. to understand ability of structure to sustain defects safely until repair/replacement is performed. Damage tolerance study was performed to know with how much load this structure would safely withstand and also to know till how much load this structure would be made serviceable, if a damage is caused to it. Investigations were performed on both damaged and undamaged specimens by conducting. Four point bending flexure test and Edgewise compression test based on ASTM standards. Also finite element modeling of honeycomb sandwich structure was developed and analysis of the two experiments were performed in Ansys. Ultimate load, tensile and compressive stress values etc. obtained from the two experiments were compared for both damaged and undamaged specimen. Based on the results obtained it could be inferred that the load carrying capacity of honeycomb sandwich structure reduces, if a damage is caused to it but can perform its duty with reduced efficiency.
Keywords: Honeycomb Sandwich, Crashworthiness, Four point bending and Edgewise compression.
Friction Stir Welding of Magnesium Alloys - A Reviewmsejjournal
The selection of proper material for each application is a critical part in every manufacturing industry.
In the field of aerospace and automobile the major requirement is light weight yet strong material which
can possess every aspect of design parameters. Magnesium alloy one of the major raw material used in
these industries due to its light weight, good thermal conductivity etc. Also Friction stir welding is the
joining process that is being used in these industries as it is a solid state joining process. This paper
gives a detailed review about Friction Stir welding of Mg alloys. The review period is considered from
2009 to 2015.A detailed review about Friction stir welding of Mg alloys has not been done before in this
manner. This review work may be a ready reference for subsequent researchers.
DESIGN AND ANALYSIS OF AXIAL CROSSING OF WORK ROLLS IN ROLLING MILL WORK ROLL...IAEME Publication
Rolling Mill is one of the machine for rolling steel or other metal into sheets. For reliable and efficient working of rolling mill it is necessary that all the components used in rolling mill should work properly without fail. Work roll assembly is very important part of the rolling mill. It has been observed that In hot rolling mill during the metal rolling at finishing mill (4-Hi mill Reversible) , work roll pair come out due to the axial crossing of work rolls and due to which uneven thickness of metal, strip breakage, bending of locking plate, metal shifting and equipment breakdown occurs. After the Study it has been observed that wear of the work roll liner is one of the reasons for the axial crossing of the work rolls.
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.
Investigation on Mechanical Properties of AL6061 Alloy Processed by FSWijtsrd
The aim of this experiment was to improve the mechanical properties of 6061 aluminium alloys by friction stir processing FSP , a solid-state technique for micro structural modification using the heat from a friction and stirring. The Aluminium alloy 6061 is widely used in the fabrication of lightweight structures with high strength-to-weight ratio and good corrosion resistance. Welding is main fabrication method of 6061 alloy for manufacturing various engineering components. Friction stir welding FSW is a recently developed solid state welding process to overcome the problems encountered in fusion welding. This process uses a non-consumable tool to generate frictional heat on the abutting surfaces. The welding parameters, such as tool pin profile, rotational speed, welding speed and axial force, play major role in determining the micro structure and corrosion resistance of welded joint. In this work a central composite design with two different speeds, traverse speeds and Four tools has been used to minimize the experimental conditions. B. S. Bharadwaj | N. Phani Raja Rao "Investigation on Mechanical Properties of AL6061 Alloy Processed by FSW" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-6 , October 2018, URL: http://www.ijtsrd.com/papers/ijtsrd18802.pdf
Modeling and Simulation of Base Plate of Friction Stir Welding-Advanced Weldi...ijsrd.com
Friction stir processing is an emerging technique based on the principles of friction stir welding (FSW). It is a solid-state joining method that is energy efficient, environmentally friendly, and versatile. It is considered by many to be the most significant development in metal joining in a decade. The basic concept of friction stir processing is remarkably simple. A rotating tool with pin and shoulder is inserted in the material to be joined, and traversed along the line of interest. The heating is localized, and is generated by friction between the tool and the work piece, with additional adiabatic heating from metal deformation. A processed zone is produced by movement of material from the front of the pin to the back of the pin.
Through this paper an attempt is made to study and review a special welding technology of friction stir welding (FSW) which is a solid-state joining process. Friction Stir Welding (FSW) is a recent advanced technique, invented by The Welding Institute (TWI) in 1991, that utilizes a nonconsumable rotating welding tool to generate frictional heat and plastic deformation at the welding location; thereby, affecting the formation of a joint while the material is in the solid state. In particular, FSW can be used to join high-strength aerospace aluminum alloys and other high temperature metallic alloys that are difficult to weld by conventional fusion welding method. FSW is considered to be the most significant development in metal joining process in a decade The comprehensive body of knowledge that has built up with respect to the friction stir welding (FSW) of aluminum alloys. This study addresses the current state of understanding and development of the FSW process. The principles of weld formation, welding parameters, design principles, including metal flow and thermal history, before discussing how process parameters affect the weld properties Danail Abdullah"A Review of Friction Stirs Welding" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-1 | Issue-4 , June 2017, URL: http://www.ijtsrd.com/papers/ijtsrd124.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/124/a-review-of-friction-stirs-welding/danail-abdullah
Project presentation on fixture design for eliminating key hole defectSubed Satyal
This project presentation includes the introduction of Friction stir welding along the pipe's circumference and the pipe is made of Aluminum alloy because it is suitable for friction stir welding. It also includes literature review regarding the key hole defect & its elimination. A brief methodology which is adopted for eliminating this defect is also mentioned. The final parts includes introduction, consequences & proposed method to eliminate key hole defect by using sacrificial material. A especially designed fixture is used to clamp the sacrificial material which is manually slides in a cross slide to connect pipe along the weld line with the sacrificial material's curved surface.
This presentation contains basics of Fire, Technical terminologies related to fire, Causes of fire and Effects of fire, General Requirements of Fire Resisting building as per IS and NBC 2005,Characteristics of Fire resisting materials, Fire Fighting Installations for Horizontal Exit, Roof Exit / Fire Lifts, External Stairs ect...This presentation is useful to Civil Engineers, Fire Fighting Engineering Students and Faculty members to convey Lecture on Fire Protection.
Combustion can be described as the burning of fuel as well as oxidant so as to produce heat.
Fire is a special type of the oxidant that is popularly known as combustion.
Fire has a triangular characteristics involving high temperature, oxygen and fuel as indicated in the diagram.
Lack of oxygen is what causes fire to be extinguished.
The presentation will highlight the type of hazards as well as the protection systems needed in fighting fire outbreak.
Hazards in steel plant and their control, By B C dasBimal Chandra Das
Hazards and Accidents In the iron and Integrated steel industry- Recommendations to prevent and control exposure to ….. Safety Awareness, It is sharing of knowledge. By Bimal Chandra Das, Rtd. AGM (Safety), Bokaro Steel Plant,/ Bokaro. Kolkata
Regression analysis of shot peening process for performance characteristics o...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Computational Engineering Research (IJCER) is dedicated to protecting personal information and will make every reasonable effort to handle collected information appropriately. All information collected, as well as related requests, will be handled as carefully and efficiently as possible in accordance with IJCER standards for integrity and objectivity.
Failure analysis and redesign of shaft of overhead craneLaukik Raut
This paper deals with the failure analysis and redesign of shaft of overhead crane having capacity 25 tonne.
There is problem of failure of the shaft in gear box which is mounted on the crane. The shaft breakage occurred
due to dynamic, alternating low tensile– compressive stresses and simultaneous torsional load.
An overhead crane is mechanical equipment for lifting and lowering a load and moving it horizontally, with the
hoisting mechanism which is an integral part of the machine.
To carry out the failure analysis of shaft it is necessary to model the shaft in any modelling software like PROE, CATIA etc. Then analysis of existing shaft is done analytically and with ANSYS11. The shaft is then
redesigned with suitable material available in data book of machine design and then analysis of new design of
shaft is done with the help of ANSYS-11 software.
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.
Abstract:The worm & worm wheel is used in gear box of Winch machine for lifting sand bucket. During working worm wheel fails due to load coming on the teeth. The failure is due to stress concentration. The crack appears at central thickness of tooth. Hence the tooth breaks at the central thickness. The failure of wheel occurs within period of about 20 days. So the company has to replace the worm wheel which is not cost effective. The stress calculation of worm wheel at tooth thickness is a three dimensional problem. This paper represents the review of analysis of stress pattern by using 3D Photo elasticity techniques & FEA technique.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
A Study of Crankpin Failure in I.C. Enginemeijjournal
A detailed study was carried out on crankshafts used in two wheeler made from C45 (EN 8/AISI 1042)
steel. Undesirable noise was heard in crankshaft when the engine is in running. This was stated as failure
of crankshaft. Material has been peeled off and seemed to be scraped at the central portion of the crankpin.
It was the bearing seating place where oil hole also provided. Under analysis the crankpin was identified
as tempered. Chemical composition, micro-hardness and microstructure were studied and compared with
the specified properties of the crankpin material. Reason for failure is identified as wear due to lower
hardness, improper lubrication and high operating oil temperature.
Mechanical Engineering: An International Journal (MEIJ)ECTIJ
Mechanical Engineering: An International Journal (MEIJ) is a peer-reviewed, open access journal that addresses the impacts and challenges of Mechanical Engineering. The journal documents practical and theoretical results which make a fundamental contribution for the development of Mechanical Engineering.
This journal aims to bring together researchers and practitioners in all Mechanical Engineering aspects, including (but not limited to):
A Study of Crankpin Failure in I.C. Enginemeijjournal
A detailed study was carried out on crankshafts used in two wheeler made from C45 (EN 8/AISI 1042) steel. Undesirable noise was heard in crankshaft when the engine is in running. This was stated as failure of crankshaft. Material has been peeled off and seemed to be scraped at the central portion of the crankpin. It was the bearing seating place where oil hole also provided. Under analysis the crankpin was identified
as tempered. Chemical composition, micro-hardness and microstructure were studied and compared with the specified properties of the crankpin material. Reason for failure is identified as wear due to lower hardness, improper lubrication and high operating oil temperature.
Design Evaluation and Optimization of IC Engine Connecting Rods '“ A Reviewijtsrd
Fatigue analysis and Optimization of connecting rod are the modern trend in automotive engineering industry emphasis on many parameters like total deformation, life, factor of safety, stress biaxiality and fatigue sensitivity. The main scope of this work comprises detailed review on various methods and procedures adopted by different researchers in Fatigue analysis of commercially used Engine Connecting rod. The objective of conducting fatigue analysis varies from each other like Weight reduction, Cost reduction, Shape optimization and fatigue life calculation at varying boundary conditions and loads. Fatigue analysis has a very dominant position in product design and development as more than 50% of the products, structural failures are due to fatigue concept only. The review have emphasized the importance of conducting the fatigue analysis of the connecting rod to identity its critical points, fatigue life and factor of safety etc., for its better performance and life period extension. N. Mohammed Raffic | Dr. K. Ganesh Babu | K. N. Arun Kumar"Design Evaluation and Optimization of IC Engine Connecting Rods “ A Review" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-3 , April 2018, URL: http://www.ijtsrd.com/papers/ijtsrd10814.pdf http://www.ijtsrd.com/engineering/mechanical-engineering/10814/design-evaluation-and-optimization-of-ic-engine-connecting-rods--a-review/n-mohammed-raffic
This paper addresses the fracture toughness ( ), or also known as critical stress intensity Factor, according to
conditions of Lineal Elastic Fracture Mechanics (LEFM). The characterization of the mechanical properties in
tensile and fracture toughness of structural steel pipes API-5L used in hydrocarbons transportation was
performed. For fracture toughness, the material was tested through fatigue crack propagation on standardized
compact specimen (CT) according to ASTM E-399 norm. A thickness (B) equal to and a crack size (a) equal
to 0.5w were used. With the porpoise of establishing the adequate conditions at the crack tip, the specimens were
subjected to fatigue pre-cracking by application of repeated cycles of load in tensile-tensile and constant load
amplitude with a load ratio of R = 0.1. The experimental Compliance method was used based on data obtained
from load vs. Crack Mouth Opening Displacement (CMOD). The results show a Stress Intensity factor of 35.88
MPa√m for a 25 mm crack size specimen. The device used for testing is a MTS-810 machine with capacity of
100KN and 6 kHz sampling rate, which meets the conditions of the ASTM E-399 standard. The cracking
susceptibility of steel is influenced by the size, morphology and distribution of non-metallic inclusions,
thermochemical interaction with the environment and microstructure.
Research Inventy : International Journal of Engineering and Scienceinventy
Research Inventy : International Journal of Engineering and Science is published by the group of young academic and industrial researchers with 12 Issues per year. It is an online as well as print version open access journal that provides rapid publication (monthly) of articles in all areas of the subject such as: civil, mechanical, chemical, electronic and computer engineering as well as production and information technology. The Journal welcomes the submission of manuscripts that meet the general criteria of significance and scientific excellence. Papers will be published by rapid process within 20 days after acceptance and peer review process takes only 7 days. All articles published in Research Inventy will be peer-reviewed.
“Comparison of Maximum Stress distribution of Long & Short Side Column due to...IJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
International Journal of Modern Engineering Research (IJMER) covers all the fields of engineering and science: Electrical Engineering, Mechanical Engineering, Civil Engineering, Chemical Engineering, Computer Engineering, Agricultural Engineering, Aerospace Engineering, Thermodynamics, Structural Engineering, Control Engineering, Robotics, Mechatronics, Fluid Mechanics, Nanotechnology, Simulators, Web-based Learning, Remote Laboratories, Engineering Design Methods, Education Research, Students' Satisfaction and Motivation, Global Projects, and Assessment…. And many more.
Contact Pressure Validation of Steam Turbine Casing for Static Loading ConditionIJMER
International Journal of Modern Engineering Research (IJMER) is Peer reviewed, online Journal. It serves as an international archival forum of scholarly research related to engineering and science education.
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to sustainability and efficiency. It is possible to achieve high specific strength and high stiffness of the
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strength and relatively low stiffness. This research focuses on a recipe of multi component alloys of
magnesium with varied percentages of Mg, Al, Cu, Mn and Zn obtained from literature and optimizes the
percentage compositions to obtain for high specific strength and specific stiffness. Relationships among
percentage constituents of the alloy components are examined in Matlab R2022b using multiple linear
regression. Optimization is achieved using genetic algorithm to determine the specific strengths and
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Each material has its own effect and behavior on external impacts like heat, force, tension, compression,
torsion etc. It is important to study and analyze these behaviors before selecting a material for an
engineering application in the design aspects itself. If predicted values analyzed by both mathematical and
software are available it is easy to get the reliable details in the pre design itself. By this one can ensure the
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round shafts with various diameters and lengths have been analyzed. The additional effects like angle of
rotation, rpm and duration also considered to find the optimum predicted value. The data observed by
various experiments are analyzed by design of experiments especially by response surface methodology.
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due to the gradual torsional load performed in the gear box and other rotating components is also studied
for healthy working environment. The nature and characteristics of material also be explained by this noise
analysis.
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MODELING, ANALYZING AND SAFETY ASPECTS OF TORSION AND NOISE EFFECTS ON ROUND MILD STEEL SHAFTS BY RESPONSE SURFACE METHODOLOGY
1. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
DOI:10.5121/msej.2016.3302 17
MODELING, ANALYZING AND SAFETY
ASPECTS OF TORSION AND NOISE EFFECTS
ON ROUND MILD STEEL SHAFTS BY
RESPONSE SURFACE METHODOLOGY
N.Boominathan1
, G.K.Vijayaraghavan2
, R.Kathiravan3
1
Research scholar, Periyar Maniammai University, Vallam, Thanjavur, Tamilnadu.
2
Principal, Dhaanish Ahmed college of engineering, Padappai, Chennai 601 301.
Tamilnadu
3
Professor and HoD, Aerospace engineering department, Periyar Maniammai University,
Vallam, Thanjavur, Tamilnadu.
ABSTRACT
Each material has its own effect and behavior on external impacts like heat, force, tension, compression,
torsion etc. It is important to study and analyze these behaviors before selecting a material for an
engineering application in the design aspects itself. If predicted values analyzed by both mathematical and
software are available it is easy to get the reliable details in the pre design itself. By this one can ensure the
safety of the component and the system also. In this investigation, the effects of torsional loads on mild steel
round shafts with various diameters and lengths have been analyzed. The additional effects like angle of
rotation, rpm and duration also considered to find the optimum predicted value. The data observed by
various experiments are analyzed by design of experiments especially by response surface methodology.
Minitab software is used for canalization. The data are tabulated and kept for future reference. Noise effect
due to the gradual torsional load performed in the gear box and other rotating components is also studied
for healthy working environment. The nature and characteristics of material also be explained by this noise
analysis.
KEY WORDS
Torsional load, response surface methodology, noise effect, healthy working environment
Nomenclature
G Modulus of Rigidity, kN/m2
θ Angle of twist, ‘degrees’
l Length of shaft, ‘m’
d Diameter of shaft, ‘m’
γ Shear strain
τ Shear stress, N/m2
R Outer radius, ‘m’
J Torsion constant
r Rotation – in numbers
g Emery sheet grade – in numbers
t Tensile load, kN
2. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
18
1. INTRODUCTION
In material science the torsion is defined as a shear stress produced on metal by applying rotation
or by torque and fatigue is the progressive and localized structural damage that occurs when a
material is subjected to cyclic loading. Most of the shafts with circular cross sections are used for
power transmission. The most common cause of failure in such shafts is fatigue. The rotating
components are susceptible to fatigue by the nature of their operation and the fatigue failures are
generally of the rotating – bending type. For this, experimental study of shafts with various
parameters and analysis are required. Sudden failure leads to Interruption in process, Production
loss, System failure, unnecessary time delay and accident. It develops unsafe working condition.
To avoid the fore mentioned parameters a pre design torsional effects, failure analysis and reliable
data are required. This study implies to evaluate the effect of torsion under repeated cyclic loads
on mild steel shafts. The noise produced during the torsional process is affecting the healthy
working condition and thereby it reduces the productivity of the testing environment in a large R
& D sections. It badly irritates the nearby workers, in smaller working areas.
American society of tool and manufacturing engineers (ASTME) in its Tool Engineer’s Hand
Book [15]
stresses about the importance of the Fatigue failure studies and analysis. It also insists
that these types of study and analysis are required to improve the safety measures and to develop
a safety and noise free environment in the pre design stage itself. R.S. Khurmi [13]
in his ‘Strength
of material book’ explained a sequential procedure for the fatigue test to observe the behavior of
materials under various parameters. The fatigue failure is an unexpected and catastrophic failure
occurs in various stages [6]
. It defines the fatigue and details about the causes for fatigue failures,
its types and fatigue life are available for Engineers end use. It shows the relation between the
stress and the number of cycles in S-N plot for brittle aluminium with ultimate tensile strength of
320 Mpa and explained the probabilistic nature of fatigue failure. It also gives two earlier
accident cases due to fatigue failure – 1842 Versailles train derailment due to axle broken and
1954 De Havilland Comet passenger jet air crash caused by the sharp corners around the plane’s
window openings acted as initiation sites for cracks. The investigation reveals that some
preventing or reducing methods are required for fatigue failures. S.Rusz et al [4]
evaluated the
fatigue properties of micro alloyed steels with a use of samples in initial stage and after selected
heat treatment on stainless steel bar with diameter 11.8 mm and length of 220mm in Universal
bending machine and fatigue testing machine. Fatigue test of micro alloyed 23MnB4 steel was
completed by metallographic and fracture analysis. From this, it can be understood that fatigue
properties of materials is depended on heat treatment.
M.J.Reid [3]
had done his experiments on failures of sugar mill roll shaft due to fatigue.
Theoretical analysis of shaft stresses and fatigue stress concentration factors have been carried out
to determine the parameters such as present shaft design, machine properties, material
specifications and the shell assembly techniques. From the failure investigations it is found that
the fracture always has the appearance of a fatigue failure because of the characteristic clamshell
lines from the point of the initial cracks followed by parallel failure lines similar to the growth
rings on a tree and the initial stress raiser is seldom evident because of subsequent surface
damage in the vicinity of the fracture. Pete Hylton [9]
, in his investigation, stressed that the air
craft experienced loss of one wing due to the fatigue failure of the wing – fuselage interface.
Prop-whirl flutter can cause just such a failure due to an undamped coupling of an engine and
Prop-whirl flutter has always been a difficult phenomenon to analyse. Large finite element
models have been utilized to represent air craft wing and nacelle structures and analyse the
occurrence of Prop-whirl flutters. It reveals that the introduction of readily available, easy to use,
yet highly powerful mathematical analysis tools such as Matlab has changed the analysis process.
The breaking a thin steel rod or wire with hands after bending it back and forth several times in
the same place and an unbalanced pump impeller resulting in vibration that can cause failure are
3. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
19
the examples of fatigue stress creation and its effects on shafts. It also clearly states that the
fundamental requirements during design and manufacturing for avoiding fatigue failure are
different for different cases and should be considered during the design phase itself.
S.K.Bhaumik et al [5]
conducted an experiment on a gear box shaft. They found a micro / hairline
crack on a low speed hollow shaft of a single stage helical gear box during its service. On
observation it was not a catastrophic failure; the shaft was withdrawn from service because of oil
leakage. Subsequent investigation revealed that the crack had initiated by fatigue at one of the
keyway edges. The problem was further aggravated due to in adequate radius at the keyway edges
and rough machining marks. The images, pictures, details of a bolt failure, metal fatigue details, a
pump shaft failure, Lorry steering arm and spring failure and a reversed torsional fatigue failure
details of a splined shaft from a differential drive gear are available in many literature [18]
.
2. EXPERIMENTAL SET UP
Fatigue failure occurs by the application of cyclic loads and an experimental set up is arranged to
observe the data for analysis. Machinery set up with a motor, gear box, sample holding device in
which one end is driving and the other end is driven, the breaking load display unit and then the
speed variation set up is required to conduct this experiments. Three types of emery cloths
(Rough, Medium and Fine) are used to polish the surface of the specimen. A three phase varioc is
also used to vary the speed of the motor.Figure1shows the experimental set up.
Figure 1 Schematic diagram of experimental set up
Though there are numerous ways of fatigue test available in a laboratory, but the basic principle is
the same for all. The most common test is a rotating bar test of cantilever type and beam type. In
this test, a number of identical test piece bars (from 8 to 10mm) are made from the same material
and tests were conducted one by one. The load is gradually applied to the test piece (This load
should not be less than that which can produce a stress equal to ¾ of the tensile strength of the
material up to the elastic limit) by giving rotation. Table 1 gives the details about the machine.
Table 1 Machine Properties
Make : Fuel Instruments and Engineers Pvt.Ltd.
Model : TT – 6
Maximum Torque Capacity : 60 Nm
Torque Ranges : 60 – 30 Nm
No. of Div. on Dial : 600
Torsion speed : 1.5 rpm
Clearance between Grips : 0 – 420 mm
Grips for round specimen : 4 – 8, 8 - 12 mm
Motor (400-440V, 3 Phase, 50 Hz) : 0.5 HP
4. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
20
The rotation of the electric motor will sometimes push the test piece downwards and sometimes
pull upwards which will reverse in the upper and lower fibers of the test piece. The speed of the
motor was indicating the frequency of the stress reversal and it kept constant. It has been
experimentally found that after sufficient stress reversals a crack in the form of a ring is formed
on the outer surface of the shaft. This crack further developed and extended towards the centre of
the test piece till it breaks away. It has also been observed that the speed of the motor (or) in other
words the frequency of the stress reversal has no effect on the result.
3. STATISTICAL TECHNIQUE
In order to optimize the process, a Central Composite rotatable Design of second order Response
Surface Methodology, a full factorial design is established which takes into account all the
possible combinations of process parameters. It establishes the mathematical relation of the
response surface using the smallest possible number of experiments without losing its accuracy.
Table 4 shows the parameter settings for performing the statistical test on degree of significance
of process parameters and their interactions. Table 2 shows the specimen details.
Table 2 Specimen Details
MATERIAL
Designation
Chemical composition
Carbon
Manganese
:
:
:
:
Plain Carbon Steel
C 40, cold drawn
0.35 – 0.45 %
0.60 – 0.90 %
SHAPE : Round
SIZE
Diameter
Length
:
:
6mm, 8mm and 10mm
250mm, 300mm and 350mm
The selected design matrix shown in Table 3 is a five factor three level Central Composite
rotatable designs consisting of 54 sets of coded condition respectively.
Table 3 Parameters and Levels Matrix
LEVELS AND VARIABLES OF PARAMETERS
Sl.No Parameter/Notations/Units
Coded
values
Parameter levels
-1 0 1
1 DIAMETER/d/mm 1 6 8 10
2 ROTATION/r/rpm 2 1310 1350 1390
3 LENGTH/l/mm 3 250 300 350
4 GRID/G/Nos 4 20 54 120
5 TENSILE LOAD/t/kN 5 1570 2120 3580
Response Surface Methodology (RSM) explores the relationships between several explanatory
variables and one or more response variables. For five independent variables 1, 2, 3, 4 and 5
response Y can be represented as a function of 1, 2, 3, 4 and 5 as follows.
Y = f ( 1, 2, 3, 4, 5) (1)
5. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
21
The second order RSM model is adequate which can be represented by the following equation.
Y = 0 + ∑ i I + ∑ ii i
2
+∑ ij i j + (2)
Where 1 (i = 0, 1, 2… k) are co – efficient that have to be estimated and represents a normally
distributed random error that accounts for all source of variability. The following equation is
represented the best fit for this experimental data.
Y = E (Y - ) (3)
Y = 0 + i I + ∑ ii i
2
+∑ ij i j (4)
where 0 is the estimator of intercept, 1, 2, ………, k are the linear terms, 11, 22, …………,
kk are quadratic terms and 12, 13, …………., (k-1), k are the second order interaction terms. 54
experimental runs were conducted. A factorial experiment can be analyzed by using ANOVA or
regression analysis. These are relatively easy to estimate the main effect for a factor. Other useful
exploratory analysis tools for factorial experiments include main effects plots, interaction plots
and a normal probability plot of the estimated effects. Analysis of Variance (ANOVA) is a
collection of statistical models and their associated procedures in which the observed variance is
partitioned into components due to different explanatory variables. Table 4 illustrates the
ANOVA values.
Table 4 Analysis of Variance (ANOVA) results for Torque
Sources of Variation DF Seq SS Adj SS Adj MS F-test
Regression 14 348336158 348336158 24881154.2 6454442.67a
Linear 5 348335971 285003 57000.7 14786.60
Interaction 9 188 188 20.9 5.41
Residual Error 39 150 150 3.9 -
Lack of fit 10 73 73 7.3 2.71
Pure Error 29 78 78 2.7 -
Total 53 348336309 - - -
Considering five parameters such as diameter, rotation, length, grid and the tensile load, 54
numerical experiments have been carried out to determine the torque value to the failure of the
particular specimen. The actual values of the parameters, the measured and predicted values of
the torque are tabulated. There is an average error of 0.7465 percent in the predicted value is
observed.
% of error =
x 100 (5)
Where τ measured = the experimental value of torque in (Nm) and τ predicted = the calculated
value of torque in (Nm)
The experimental data were analyzed using the Minitab software which gives the output in
tabular form and was used to calculate the values of these co – efficient. For the required
response, all the 54 values for torque mode and the second order general mathematical model for
the five factors are given to the software as input. The significance of co – efficient was
6. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
22
evaluated. The final mathematical model of Torque mode as determined by above analysis in
natural scale is given below
Torque = -9542.91+719.88d+4.24r–2.45l–3.88G+1.71t–0.04dxl+0.21d x G (6)
where d = Diameter (mm), r = Rotation (in numbers), l = Length (mm), G = Grid Number, t =
Tensile load (kN) Significant at 5 percent level, SS – Sum of squares, DF – Degrees of Freedom,
MS – Mean Square F (Table Value) = 2.01
Figure 2 Torque vs Length comparison chart
Figure 2 illustrates the relationship between the length of the shaft and the torque required to
break during torsion. It also shows the variation of torque values as per the diameter of the shafts.
More diameter is needed more torque for break. The length of the shaft plays a vital role in the
requirement of torque to fail. Higher length requires lesser torque than the shorter one.
Figure 3 shows that the rotation of the motor is directly proportional to the torque. The principal
transmission shaft performance specifications are power and speed. The effect of torque is
directly proportional to the angular velocity at the surface. i.e torque T α ω where ω is the angular
velocity. But ω depends upon the speed. So if speed increases correspondingly ω as well as T will
increase. Thus the curve shows the increased slope with the increase in speed
Figure 3 Variation of torque with respect to the rotation of motor
4. SAFETY CONSIDERATION
Any failure analysis ends with a safety consideration. Since fatigue failure is an unexpected,
catastrophic event it is to be considered as one of the major factor in safety aspects. Sudden
failure leads to interruption in process, production loss, system failure, accident and development
of unsafe working condition. To avoid such things a pre design failure analysis is must. Unsafe
act and unsafe condition are the two main causes of accidents. In this, the unsafe condition starts
4200
4400
4600
4800
5000
1310 1350 1390
Torque(kN)
RPM VS TORQUE
RPM VS
TORQUE
LENGTH Vs TORQUE
LENGTH mm
240 260 280 300 320 340 360
TORQUEKg-mm
1000
2000
3000
4000
5000
6000
7000
8000
9000
Dia 10mm
Dia 8mm
Dia 6mm
7. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
23
from the design stage itself. Tool Engineers Hand Book [25]
published by American Society of
Tool and Manufacturing Engineers (ASTME) gives an important note to the Design Engineers as
follows: “Experience has shown that notches, sharp changes of section and other forms of stress
raisers are dangerous to metals in applications involving repeated stress. Some Engineers neglect
to take stress raisers into consideration in design and inspection with the result that a number of
avoidable fatigue failures occur. From this statement it is clearly observed that a pre design
analysis of fatigue failure needs before design”. This research and analysis are the pre design one
and the data are more useful to a Design Engineers for their anytime reference to select an
appropriate and optimum value to improve the factor of safety as well as the safety to provide an
accident free working environment. From the experimental values, it is easily observed that a
6mm diameter mild steel shaft with 300 mm length at 1350rpm withstand to a torque load of 2220
Kg-mm. At the same time an 8 mm shaft with the same parameters can withstand more torque
load i.e. 4595 Kg-mm. So selection of 8 mm instead of 6 mm improves the factor of safety and
ensures the safety in the design stage itself.
5. NOISE ANALYSIS
Moving parts in a torsion testing machine release tolerable noise level on nil loads. They produce
gradually developed noise and vibration depending upon the material, size and length of the rod
which is loaded for torsion testing. Table 5 illustrates the rotation requirements for shear, noise
level measurements and torque levels
Table 5 Rotation requirements for shear, noise level and torque values
Diameter
(mm)
Length
(mm)
Rotation required
for break (degrees)
Number of
rotation
Noise level
(dB)
Torque
Kg - mm
10 250 2710 7.52 98 8603
10 300 2460 6.83 85 8320
10 350 2230 6.19 83 8023
Number of rotation increases according to the characteristics of the material to break. It may vary
by the chemical composition, heat treatment through which the material is formed, the nature of
material, surface condition and physical and chemical properties of the material. In this study the
behavior of three mild steel round rod samples with same diameter (10 mm) and different lengths
(250 mm, 300 mm and 350 mm) has investigated for noise effect. The samples required several
rotations for break and the noise produced in gear box is gradually increases with increase of
rotation. Noise level is measured for each rotation and tabulated.
6. RESULTS AND DISCUSSIONS
Three samples were experimented for noise effects with increase in number of rotations up to the
failure level. Figure 3 reveals that the noise effect on number of rotations which are the major
factors for shear of material in torsion process and also gave a comparison illustration with other
results. Rotations vary with the material characteristics and sizes. Figure 4 shows the results of
three samples of 10 mm diameter with various lengths namely 250mm, 300mm and 350 mm were
illustrated. Curves show that the noise level slowly increases per rotation and increased randomly
after fourth rotation because the work piece tried to resist the torsion effect.
8. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
24
Figure 4 Rotation vs Noise level
At the end of the process in 250mm sample gives the high noise level. This shows there is a
sudden increase of noise level when shear off takes place. It is observed that if the work piece is
tough in nature it develops more noise intensity when it shears. So the end shape of the shaft I
curve indicates that the work piece is tough in nature and its usage should be restricted in the
working environment because it creates high noise and it affects the nearby worker’s health. Like
this the material quality of the other shafts can be identified as coarse for shaft II and smooth for
shaft II. From this method one can easily identify the shafts material quality.
Figure 5 Noise level variations with Torque
From the figure 5 it is observed that the noise level produced is increased by torque required to
break the rod during torsion. The noise level shows a sudden increase in beginning and gradually
increases afterwards as per the material size especially the diameter. The same experiment may
extend to other ferrous and non ferrous materials with different diameters, lengths for analysis.
The capacity of the machine and the maintenance details also get from the plots. If the machine
has more capacity than the required one, there is a chance for reduction in number of rotation and
the noise level production. If the maintenance schedule and the procedure are followed strictly
then the nature of working capacity of the machine parts are smooth and this will help to reduce
the noise level as well as the number of rotations considerably. Table 6 gives the noise level
details.
Table 6 Noise measurement
Number of
rotation
Length (mm)
Shaft I (250) Shaft II (300) Shaft III (350)
1 62 61 62
2 68 67 66
3 78 76 78
4 87 86 84
5 92 88 86
6 96 90 86
6.19 - - 83
6.83 - 85 -
7 96 - -
7.52 98 - -
ROTATION vs NOISE LEVEL
ROTATION in numbers
0 1 2 3 4 5 6 7 8
NOISELEVELindB
50
60
70
80
90
100
SHAFT I
SHAFT II
SHAFT III
SHAFT I
SHAFT II
SHAFT III
NOISE LEVEL vs TORQUE
NOISE LEVEL (dB)
82 84 86 88 90 92 94 96 98 100
TORQUE(Kg-mm)
7900
8000
8100
8200
8300
8400
8500
8600
8700
Noise level vs Torque
9. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
25
CONCLUSIONS
Torque values required to break mild steel round shafts with various diameters and lengths has
been studied, analyzed and recorded in this research. A design Engineer can use these values for
his design calculations to improve the safety aspects of his design. By this, the life of the
equipments as well as the performance of the process and outputs can be improved in the pre
design itself. A noise analysis with number of rotations helps to predict the quality of the
material, machine capacity and its working condition and maintenance details. Comparison study
between various ferrous and non ferrous materials is also possible.
REFERENCES
[1] A.H. Bonnett (2000) ‘Root cause AC motor failure analysis with a focus on shaft failures’, IEEE
Trans. Industry Application, Vol 36, Issue 5, pp 327-331.
[2] Cyndi Nyberg, (2007) ‘Understanding Factors That Cause Shaft Failures’, Electrical Apparatus Service
Association, Inc. Vol 6, pp 24-27.
[3] M. I. Reid (1988) ‘Analysis of the causes of recent roll shaft failures in natal sugar mills’, The South
African Sugar Technologists' Association pp 74-78.
[4] S. Rusz, L. Cizek, P. Filipec, M. Pastrnak (2008) ‘Fatigue failure of micro-alloyed 23MnB4 steel
Journal of Achievements in Materials and Manufacturing Engineering,’ volume 31 issue 2, pp 243-
247.
[5] S.K. Bhaumik et al (2002) ‘Fatigue failure of a hollow power transmission shaft’, Engineering Failure
Analysis, Vol 9, pp 457–467.
[6] Shine U P, EMS Nair. (2008) ‘Fatigue Failure of Structural Steel – Analysis Using Fracture
Mechanics’, World Academy of Science, Engineering and Technology, Vol 46, pp 616-619.
[7] T.Nimali Medagedara (2004) ‘Comparison of experimental and Finite Element results for Elastic-
Plastic Stress/Strain behavior of notched shaft under multi axial loading’, International Symposium of
Research Students on Materials Science and Engineering Chennai, India, pp20-22, 2004,
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[9] Pete Hylton (2006) ‘Analyzing a simple prop-whirl-flutter model using modern analysis tools’, IJME-
INTERTECH Conference 2006.
[10] Paul Dvorak (2001) ‘How to get a better handle on fatigue’, Published on Machine Design Created
07/12/2001 - 02:00
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[12] M. M. Khonsari, E. R. Booser (2008) ‘Avoiding Stick-Slip Chatter in Low-Speed Bearings’, Published
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[13] R.S.Khurmi (2010) ,’Strength of Materials,’ S.Chand Publications reprint 2010 Multicolor Edition pp
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[14] Shaft Analysis - Lecture 18 (2009), Martin School of Engineering, pp 473 - 478.
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[18] Material Engineering Component failure museum website
[19] www.Wikipedia.com - the free encyclopedia.
10. Advances in Materials Science and Engineering: An International Journal (MSEJ), Vol. 3, No. 3, September 2016
26
Authors
N.Boominathan has completed his B.E , Mechanical engineering degree in
Thiagarajar college of engineering, Madurai and M.E., Industrial safety
engineering in Bharatth Niketan engineering college, Aundipatti. Now he is doing
his research work in the field of Industrial noise at Periyar Maniammai university,
Thanjavur. He has 25 years industrial experience and 9 years teaching experience
G.K. Vijayaraghavan, B.E, M.Tech, PhD is currently working as Adviser,
Dhaanish Ahmed College of Engineering, Padappai, Chennai. He has obtained his
M.Tech from IIT Madras and PhD from NIT, Durgapur in the area of
Thermography NDT. He has been in the teaching field for more than 18 years. He
is one of the editorial board members of 3 international journals and has reviewed
many journal papers. He has authored more than 16 textbooks in the area of
Mechanical Engineering which are being well received. He has received the “Best
Educationalist Award” from International Institute of Engineering & Management,
New Delhi in 2014; “The Best Principal in Engineering College 2014 Award” from
Education Today Publications, Chennai.
Dr. R. Kathiravan is presently working as a Professor in Aerospace Engineering
department and Director for Center of Excellence for Training and research in
Automation Technology (CETAT) in Periyar Maniammai University, Vallam,
Thanjavur. He received his Doctorate degree from Indian Institute of Technology
Roorkee (IIT Roorkee) and obtained master degree in Thermal Power Engineering
from Annamalai University, Chidambaram and Bachelor degree in Mechanical
Engineering from Madurai Kamaraj University, Madurai, Tamilnadu state, India.
He is having 20 years of experience in both teaching as well as Industry. He was
given a special training on Industrial Automation Technology by M/S Bosch
Rexroth India at their Mysore centre. He published his 10 research papers on well
refereed international journals like ASME transactions, Elsevier and Taylor & Francis Publications etc.,
and 2 in national Journals. He is a life member of IAENG, ISTE, and SSWR