The document discusses the design and testing of a 3D printer for additive manufacturing of solid rocket propellant. It describes the project objectives of printing solid propellant and comparing its mechanical properties to traditionally cast propellant. It then outlines the printer design which uses a laser to sinter layers of sucrose and potassium nitrate powder in a powder bed. Test results show the printer can achieve layer thicknesses within specifications but that printed propellant is less dense and more brittle than cast propellant. A thermal model is developed to predict sintering behavior and set safe laser operation settings.
The document discusses a project to 3D print solid rocket propellant using selective laser sintering (SLS). It provides background on solid rocket motors and additive manufacturing. The team has characterized a thermal model for sintering sucrose and validated it for sintering a sucrose-potassium nitrate propellant. Preliminary results show proof of concept for SLS manufacturing of solid propellant. Future work includes printing dynamic grain patterns and motor performance testing.
This document summarizes an experiment that optimized ball burnishing process parameters for hardness of aluminum alloy 6061. A new ball burnishing tool was designed and used to burnish aluminum alloy 6061 test samples. The process parameters investigated were burnishing speed, feed rate, force, and number of passes. Experiments were designed using Taguchi's orthogonal array method. Analysis found the optimal parameters for maximum hardness were 250 RPM speed, 0.06 mm/rev feed rate, 8 Kgf force, and 5 passes. Confirmation tests validated these parameters produced the highest hardness of 126 BHN. Hardness was found to generally increase with speed, force, and passes up to certain levels, then decrease with further increases in those parameters. Hard
Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation u...IJMER
Now-a-days increasing the productivity and the quality of the machined parts are the main
challenges of metal cutting industry during turning processes. Optimization methods in turning
processes, considered being a vital role for continual improvement of output quality in product and
processes include modeling of input-output and in process parameters relationship and determination of
optimal cutting conditions. This paper present on Experimental study to optimize the effects of cutting
Parameters on Surface finish and MRR of 20MnCr5 Steel alloy work material by employing Taguchi
techniques. The orthogonal array, signal to noise ratio and analysis of variance were employed to study
the performance characteristics in turning operation. Five parameters were chosen as process variables:
Cutting Speed, Feed, Depth of cut, Hardness of cutting Tool, Cutting environment (wet and dry). The
experimentation plan is designed using Taguchi’s L9 Orthogonal Array (OA) and Minitab statistical
software is used. Optimal cutting parameters for minimum surface roughness (SR) and maximum material
removal rate were obtained. Finally, the relationship between factors and the performance measures
were developed by using multiple regression analysis
Estimation Of Optimum Dilution In The GMAW Process Using Integrated ANN-SAIJRES Journal
This document presents a study that aimed to optimize process parameters in gas metal arc welding (GMAW) cladding to achieve optimum dilution. Experiments were conducted using a central composite design to develop mathematical models relating welding current, speed, angle, contact tip distance, and pinch to clad bead geometry responses like width, penetration, reinforcement, and dilution percentage. Artificial neural networks and simulated annealing algorithms were then integrated (ANN-SA) to estimate optimal parameters to minimize dilution. The developed models were checked for adequacy and significance. The study aimed to improve corrosion resistance in carbon steel by depositing a corrosion-resistant stainless steel clad layer with minimum dilution.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
We would send hard copy of Journal by speed post to the address of correspondence author after online publication of paper.
We will dispatched hard copy to the author within 7 days of date of publication
Investigations of machining parameters on surface roughness in cnc milling u...Alexander Decker
This document summarizes a study that investigated the effect of machining parameters on surface roughness in CNC milling of H-13 die steel using the Taguchi technique. The parameters examined were spindle speed, feed rate, and depth of cut. Experiments were conducted using an L9 orthogonal array. Surface roughness measurements showed that lower feed rates, higher spindle speeds, and greater depths of cut produced lower surface roughness values. Analysis of variance identified feed rate as the most influential parameter on surface roughness. The optimized parameters determined were a low feed rate of 0.08 mm/tooth, high spindle speed of 358.8 RPM, and high depth of cut of 0.3 mm.
Design and Analysis of fluid flow in AISI 1008 Steel reduction gear boxIRJET Journal
This document summarizes a research paper that analyzes fluid flow in an AISI 1008 steel reduction gearbox using computer simulation. The researchers redesigned the gearbox model in CATIA and analyzed it using casting simulation software to optimize the design and minimize defects from shrinkage, hotspots, and solidification time. They simulated the original design and a modified design with changes to the riser and gating system dimensions. The simulations aimed to improve yield by reducing porosity and defects in the casting.
This document discusses the methodology for conceptualizing the architecture of electronic control unit (ECU) casings. It involves several steps:
1) Layout optimization to meet thermal, vibration, and sealing requirements. This includes optimizing the surface area, isolating components from vibration, and designing effective gaskets.
2) Selection of materials based on a decision matrix comparing properties like structural strength, thermal properties, durability, cost, and weight for materials like aluminum, copper, and cast iron. Aluminum was selected.
3) Selection of manufacturing processes based on decision matrices comparing options for functionality, quality, cost, tooling costs, and lead time. This included comparing casting, machining, and their combinations.
The document discusses a project to 3D print solid rocket propellant using selective laser sintering (SLS). It provides background on solid rocket motors and additive manufacturing. The team has characterized a thermal model for sintering sucrose and validated it for sintering a sucrose-potassium nitrate propellant. Preliminary results show proof of concept for SLS manufacturing of solid propellant. Future work includes printing dynamic grain patterns and motor performance testing.
This document summarizes an experiment that optimized ball burnishing process parameters for hardness of aluminum alloy 6061. A new ball burnishing tool was designed and used to burnish aluminum alloy 6061 test samples. The process parameters investigated were burnishing speed, feed rate, force, and number of passes. Experiments were designed using Taguchi's orthogonal array method. Analysis found the optimal parameters for maximum hardness were 250 RPM speed, 0.06 mm/rev feed rate, 8 Kgf force, and 5 passes. Confirmation tests validated these parameters produced the highest hardness of 126 BHN. Hardness was found to generally increase with speed, force, and passes up to certain levels, then decrease with further increases in those parameters. Hard
Optimization of Machining Parameters of 20MnCr5 Steel in Turning Operation u...IJMER
Now-a-days increasing the productivity and the quality of the machined parts are the main
challenges of metal cutting industry during turning processes. Optimization methods in turning
processes, considered being a vital role for continual improvement of output quality in product and
processes include modeling of input-output and in process parameters relationship and determination of
optimal cutting conditions. This paper present on Experimental study to optimize the effects of cutting
Parameters on Surface finish and MRR of 20MnCr5 Steel alloy work material by employing Taguchi
techniques. The orthogonal array, signal to noise ratio and analysis of variance were employed to study
the performance characteristics in turning operation. Five parameters were chosen as process variables:
Cutting Speed, Feed, Depth of cut, Hardness of cutting Tool, Cutting environment (wet and dry). The
experimentation plan is designed using Taguchi’s L9 Orthogonal Array (OA) and Minitab statistical
software is used. Optimal cutting parameters for minimum surface roughness (SR) and maximum material
removal rate were obtained. Finally, the relationship between factors and the performance measures
were developed by using multiple regression analysis
Estimation Of Optimum Dilution In The GMAW Process Using Integrated ANN-SAIJRES Journal
This document presents a study that aimed to optimize process parameters in gas metal arc welding (GMAW) cladding to achieve optimum dilution. Experiments were conducted using a central composite design to develop mathematical models relating welding current, speed, angle, contact tip distance, and pinch to clad bead geometry responses like width, penetration, reinforcement, and dilution percentage. Artificial neural networks and simulated annealing algorithms were then integrated (ANN-SA) to estimate optimal parameters to minimize dilution. The developed models were checked for adequacy and significance. The study aimed to improve corrosion resistance in carbon steel by depositing a corrosion-resistant stainless steel clad layer with minimum dilution.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
We would send hard copy of Journal by speed post to the address of correspondence author after online publication of paper.
We will dispatched hard copy to the author within 7 days of date of publication
Investigations of machining parameters on surface roughness in cnc milling u...Alexander Decker
This document summarizes a study that investigated the effect of machining parameters on surface roughness in CNC milling of H-13 die steel using the Taguchi technique. The parameters examined were spindle speed, feed rate, and depth of cut. Experiments were conducted using an L9 orthogonal array. Surface roughness measurements showed that lower feed rates, higher spindle speeds, and greater depths of cut produced lower surface roughness values. Analysis of variance identified feed rate as the most influential parameter on surface roughness. The optimized parameters determined were a low feed rate of 0.08 mm/tooth, high spindle speed of 358.8 RPM, and high depth of cut of 0.3 mm.
Design and Analysis of fluid flow in AISI 1008 Steel reduction gear boxIRJET Journal
This document summarizes a research paper that analyzes fluid flow in an AISI 1008 steel reduction gearbox using computer simulation. The researchers redesigned the gearbox model in CATIA and analyzed it using casting simulation software to optimize the design and minimize defects from shrinkage, hotspots, and solidification time. They simulated the original design and a modified design with changes to the riser and gating system dimensions. The simulations aimed to improve yield by reducing porosity and defects in the casting.
This document discusses the methodology for conceptualizing the architecture of electronic control unit (ECU) casings. It involves several steps:
1) Layout optimization to meet thermal, vibration, and sealing requirements. This includes optimizing the surface area, isolating components from vibration, and designing effective gaskets.
2) Selection of materials based on a decision matrix comparing properties like structural strength, thermal properties, durability, cost, and weight for materials like aluminum, copper, and cast iron. Aluminum was selected.
3) Selection of manufacturing processes based on decision matrices comparing options for functionality, quality, cost, tooling costs, and lead time. This included comparing casting, machining, and their combinations.
APPLICATION OF GREY RELATIONAL ANALYSIS FOR MULTI VARIABLE OPTIMIZATION OF PR...IAEME Publication
The present work deals with a simple approach which predicts the optimum setting
of process parameters of drilling operation on Polymer Based Glass Fiber (PBGF)
composite. The process parameters selected are drill angle (DA), Drill diameter (DD),
Material Thickness (MT), Speed (N) and Feed (f). The output parameters are Thrust,
Torque, Surface Roughness and Delamination. Three levels of each input parameters
are considered. Taguchi’s L27 array is used to set the process parameters. Gray
relational analysis (GRA) is used to find the optimum value of process parameters.
Conduction of ANOVA on GRA shown the significance of each factor on the process
output. A conformation test conducted revealed that the setting of parameters ensures
optimum output
IRJET- Experimental Investigation on the Performance of Calcium Chloride and ...IRJET Journal
The document investigates the effects of adding calcium chloride and geogrid on the compressive and tensile strengths of concrete. Various ratios of calcium chloride (0.2%, 0.5%, and 0.8%) were added to plain concrete and geogrid reinforced concrete. Testing found that the strengths increased with the addition of calcium chloride up to 0.5%, which provided the highest compressive strength of 33.3 MPa in geogrid concrete. Geogrid reinforcement also improved the tensile strength compared to plain concrete. The study concluded that using calcium chloride and geogrid can improve concrete strengths and that 0.5% calcium chloride provides the optimum strength increases.
This document reviews optimization of process parameters for surface roughness and material removal rate (MRR) when machining stainless steel 316 on a CNC machine. It begins with an abstract that describes using design of experiments and grey relational analysis to optimize surface roughness based on data from 27 specimens produced via straight turning. The introduction provides background on the importance of surface roughness and challenges of achieving desired quality features on CNC machines. The literature review summarizes several previous studies on optimizing parameters like speed, feed rate, and depth of cut to minimize surface roughness and maximize MRR using techniques like Taguchi methods. The document aims to identify optimal parameter combinations to simultaneously optimize multiple quality objectives.
IRJET- An Experimental Study on Compression and Flexural Behaviour of Concret...IRJET Journal
This document presents the results of a study on the use of stainless steel scrap as fiber reinforcement in concrete. Concrete mixtures were prepared with 0%, 0.5%, 1%, and 1.5% stainless steel scrap by weight. The mixtures were tested to determine their compressive strength, split tensile strength, and corrosion resistance. The results showed that compressive strength and split tensile strength increased up to 12% and 24% respectively with 1% stainless steel scrap compared to plain concrete. Corrosion testing also showed that stainless steel scrap had much lower weight loss than mild steel when exposed to acids, indicating higher corrosion resistance. The study concluded that 1% stainless steel scrap provided optimal improvement in strength properties while utilizing an industrial waste material
This document summarizes an article from the International Journal of Mechanical Engineering and Technology that discusses optimizing critical processing parameters for plastic injection molding. It begins by stating that determining optimal initial process parameters is important for productivity, quality and costs. It then outlines the objectives of identifying optimized levels for factors like temperature and pressure. The methodology proposed uses Taguchi design of experiments and Moldflow simulation software to optimize parameters for different materials like polypropylene. The scope is to study injection molding parameters for polypropylene and provide recommendations for parameter settings based on material and geometry.
This document provides a dissertation submitted by Kannan P for the degree of Master of Engineering in Mechanical Engineering with specialization in Lean Manufacturing. The dissertation focuses on improving productivity in the manufacturing division of a sheet metal industry located in Coimbatore, India. It involves analyzing the current production process through time studies, layout analysis, and identifying wastes. Based on the analysis, modifications are proposed to the layout and a scrap management system is developed to improve material utilization and reduce waste. The dissertation documents the methodology, analysis of the current state, proposed improvements and their implementation to enhance productivity in the sheet metal manufacturing process.
critique and summary on (1) high speed machining (2) additive manufacturing (...shanjakhrani
This document contains 16 summaries of research papers related to advanced manufacturing systems. The papers cover topics such as high speed machining, sheet metal forming processes, additive manufacturing, and functionally graded materials. Key areas of focus in the critiques include limited analysis of process parameters, material properties, defects, economic considerations, and opportunities for further research.
IRJET- Effect of Fly Ash on Fiber Reinforced Concrete-A Durability ApproachIRJET Journal
The document discusses an investigation into the durability of steel fiber reinforced concrete with fly ash when subjected to chemical attack by sulfuric acid. Concrete cubes were prepared with and without fly ash replacement and steel fibers. The cubes were tested for compressive strength after 28 days of curing and after 30 days of immersion in sulfuric acid. Results showed that steel fiber reinforced fly ash concrete exhibited the lowest loss of compressive strength of 15.4% after acid exposure, indicating it has better durability compared to the other concrete mixtures tested.
A Review on Various Approach for Process Parameter Optimization of Burnishing...ijsrd.com
The aim of this paper is review for different optimization methods used for process parameter optimization of roller burnishing process and Taguchi approach used for process parameter optimization for various processes. The quality of burnishing processed parts are highly depends upon various process parameters of burnishing process. Hence optimization of burnishing process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of burnishing process and application of Taguchi approach for design of experiments.
Study of Influence of Tool Nose Radius on Surface Roughness and Material Remo...IRJET Journal
This document presents an experimental study that investigates the effects of cutting speed, feed rate, depth of cut, and tool nose radius on surface roughness and material removal rate during turning of Inconel 718. An L9 orthogonal array was used to design experiments with the four machining parameters each set at three levels. Turning experiments were conducted on a CNC lathe using different carbide inserts with nose radii of 0.4mm, 0.8mm, and 1.2mm. Surface roughness was measured and material removal rate was calculated for each experiment. Signal-to-noise ratios were determined using Taguchi's smaller-the-better and larger-the-better approaches for surface roughness and material removal rate respectively
Experimental Stress Analysis and Optimization of Connecting RodIRJET Journal
The document discusses experimental stress analysis and topology optimization of a connecting rod. It begins with modeling the existing connecting rod using CAD software and performing finite element analysis to determine stresses and deformation. Topology optimization is then used to remove material from low-stress regions to reduce weight without compromising strength. The optimized model is again analyzed using FEA. Finally, the optimization results are implemented on the physical connecting rod using EDM machining. Strain gauges are mounted and experimental testing is conducted to correlate results with the FEA analysis. The optimization reduced the connecting rod weight from 2.351kg to 2.240kg while von Mises stresses and deflections remained within acceptable limits.
of flux cored arc welding process parameters ond duplex stainless steel clad q...A X.S
This document summarizes an experimental study that analyzed the effects of flux cored arc welding (FCAW) process parameters on clad quality when duplex stainless steel is used to clad low carbon structural steel plates. Experiments were conducted using a central composite design with four welding parameters (current, speed, nozzle distance, angle) and responses (bead width, penetration, reinforcement, dilution). Mathematical models were developed to relate the parameters to the responses using multiple regression analysis. The models can help select welding parameters to achieve desired clad quality.
Design of experiments using Moldflow Analysis.Nilesh Nevrekar
The document discusses using Design of Experiments (DOE) in Moldflow to analyze injection molding processes. It describes different types of DOE analyses including Taguchi screening analysis, factorial analysis, and Taguchi followed by factorial analysis. Input parameters for DOE in Moldflow include mold temperature, melt temperature, injection time, and others. Reasons to perform DOE include optimizing part thickness and cycle time. The document provides steps to conduct each type of analysis and interpret their results.
Moldex3D, Structural Analysis, and HyperStudy Integrated in HyperWorks Platfo...Altair
In recent years, with the increasing variety, complexity, and precision requirement on plastic products, CAE tools have been widely used for solving product design and manufacturing issues. The structural designs or molding process parameters for products can be optimized efficiently through CAE analyses. Plus the reliable and correct verification with experiments, the directions or guidance in designs or process condition settings can be provided prior to the real moldings. However, sometimes it is not efficient to find an optimized set of parameters through traditional CAE analyses. A novel integration between Moldex3D and HyperStudy allows for more quick and efficient parameter optimization which will save time, increase product quality, and increase productivity.
Also, traditional CAE analyses do not consider the molding properties influence on structural analysis, such as material property variations caused by fiber orientation and residual stresses. Accordingly, an integrated technology is proposed to bridge molding and structural analysis. Through the integration of Moldex3D and structural analysis in HyperWorks platform, the important effects from molding process can be transferred to structural analysis for more accurate and realistic predictions of the product behaviors. This integration provides a virtual product development platform for users to increase profits as well as enhance productivity.
“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
IRJET- Optimization of Minimum Quantity Lubricant (MQL) Conditions in Milling...IRJET Journal
This document describes an optimization study that used the Taguchi method to determine the optimal minimum quantity lubrication (MQL) conditions for milling mild steel. The study considered three MQL parameters - lubricant type, fluid flow rate, and nozzle distance from the machining zone. Experiments were conducted using an L9 orthogonal array with different settings for each parameter. Surface roughness and maximum temperature generated during machining were measured. Statistical analysis was performed to determine the most influential parameters and their optimal levels for improved surface finish and reduced temperature.
Study on Microstructure and machining characteristics of 7% B4Cp reinforced i...IJTET Journal
The document discusses a study on the microstructure and machining characteristics of an aluminum 6061 metal matrix composite reinforced with 7% boron carbide particles produced by stir casting. The microstructure of the composite showed a homogeneous distribution of boron carbide particles in the aluminum matrix. Tests were conducted to analyze the effects of varying cutting speed, feed rate, and depth of cut on the cutting forces and surface roughness when machining the aluminum-boron carbide composite.
Optimization of Material Removal Rate & Surface Roughness in Dry Turning of M...IJERA Editor
Optimization of machining parameters is valuable to maintain the accuracy of the components and to minimize
the cost of machining. Surface finish is an important measure for the quality of the machined parts. The present
work is an experimental investigation to study the effect of machining parameters on Material Removal Rate
and Surface Roughness in dry turning of medium carbon steel EN19. Taguchi’s single objective optimization
method was used to find the effect of input parameters on the responses. The experiments were conducted as per
Taguchi’s L9 Orthogonal Array on CNC lathe under dry conditions. Cutting parameters of speed, feed and
depth of cut were taken as inputs and machining was done by PVD TiAlN tool. Regression models for the
responses were prepared by using MINITAB-16 software. Analysis of variance (ANOVA) was used to find the
influence of machining parameters on the responses. From the ANOVA results, it is clear that speed has high
influence followed by feed and depth of cut has very low influence in achieving the optimum values for both
Material Removal Rate and Surface Roughness. Finally, experimental and Regression values of responses were
compared. From the results, it is found that both the values are close to each other hence, the regression models
prepared were more accurate and adequate. Percentage of errors between experimental and regression values
were calculated and they found in the range of ±0.20.
This document summarizes a critical design review for a project to develop an additive manufacturing system for printing solid rocket propellant. It outlines the project background, functional requirements, critical elements, and safety considerations. Key aspects of the design include the laser system selection, thermal modeling of the sintering process, powder bed subsystem, and implementation of safety systems to address the fire and explosion risks of the propellant materials. The goal is to 3D print complex grain shapes for solid rocket motors and compare the mechanical properties to those of traditionally cast propellant.
This document discusses spray modeling for lean NOx trap aftertreatment system design. It presents Eaton Corporation's aftertreatment system for reducing NOx and PM emissions. Computational fluid dynamics (CFD) was used to optimize fuel preparation and distribution through injection modeling. Both test-based and CFD-based injection modeling were performed and validated. CFD results showed that smaller droplet sizes and optimized mixer placement improved fuel uniformity and vaporization. CFD modeling aided in comparing injector performances and selecting mixers for the aftertreatment system design.
This document summarizes a study on 3D printing applications for aerospace components. Key findings include:
- 3D printing allows integrating multiple parts into one to reduce weight and volume for unmanned aerial vehicles.
- Design considerations like minimum thickness and angles are important for metal 3D printing.
- Properties of 3D printed parts like yield strength and hardness are lower than wrought parts but provide design flexibility.
- Further research on machine parameters and post-processing could improve mechanical properties of 3D printed metal parts.
six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
APPLICATION OF GREY RELATIONAL ANALYSIS FOR MULTI VARIABLE OPTIMIZATION OF PR...IAEME Publication
The present work deals with a simple approach which predicts the optimum setting
of process parameters of drilling operation on Polymer Based Glass Fiber (PBGF)
composite. The process parameters selected are drill angle (DA), Drill diameter (DD),
Material Thickness (MT), Speed (N) and Feed (f). The output parameters are Thrust,
Torque, Surface Roughness and Delamination. Three levels of each input parameters
are considered. Taguchi’s L27 array is used to set the process parameters. Gray
relational analysis (GRA) is used to find the optimum value of process parameters.
Conduction of ANOVA on GRA shown the significance of each factor on the process
output. A conformation test conducted revealed that the setting of parameters ensures
optimum output
IRJET- Experimental Investigation on the Performance of Calcium Chloride and ...IRJET Journal
The document investigates the effects of adding calcium chloride and geogrid on the compressive and tensile strengths of concrete. Various ratios of calcium chloride (0.2%, 0.5%, and 0.8%) were added to plain concrete and geogrid reinforced concrete. Testing found that the strengths increased with the addition of calcium chloride up to 0.5%, which provided the highest compressive strength of 33.3 MPa in geogrid concrete. Geogrid reinforcement also improved the tensile strength compared to plain concrete. The study concluded that using calcium chloride and geogrid can improve concrete strengths and that 0.5% calcium chloride provides the optimum strength increases.
This document reviews optimization of process parameters for surface roughness and material removal rate (MRR) when machining stainless steel 316 on a CNC machine. It begins with an abstract that describes using design of experiments and grey relational analysis to optimize surface roughness based on data from 27 specimens produced via straight turning. The introduction provides background on the importance of surface roughness and challenges of achieving desired quality features on CNC machines. The literature review summarizes several previous studies on optimizing parameters like speed, feed rate, and depth of cut to minimize surface roughness and maximize MRR using techniques like Taguchi methods. The document aims to identify optimal parameter combinations to simultaneously optimize multiple quality objectives.
IRJET- An Experimental Study on Compression and Flexural Behaviour of Concret...IRJET Journal
This document presents the results of a study on the use of stainless steel scrap as fiber reinforcement in concrete. Concrete mixtures were prepared with 0%, 0.5%, 1%, and 1.5% stainless steel scrap by weight. The mixtures were tested to determine their compressive strength, split tensile strength, and corrosion resistance. The results showed that compressive strength and split tensile strength increased up to 12% and 24% respectively with 1% stainless steel scrap compared to plain concrete. Corrosion testing also showed that stainless steel scrap had much lower weight loss than mild steel when exposed to acids, indicating higher corrosion resistance. The study concluded that 1% stainless steel scrap provided optimal improvement in strength properties while utilizing an industrial waste material
This document summarizes an article from the International Journal of Mechanical Engineering and Technology that discusses optimizing critical processing parameters for plastic injection molding. It begins by stating that determining optimal initial process parameters is important for productivity, quality and costs. It then outlines the objectives of identifying optimized levels for factors like temperature and pressure. The methodology proposed uses Taguchi design of experiments and Moldflow simulation software to optimize parameters for different materials like polypropylene. The scope is to study injection molding parameters for polypropylene and provide recommendations for parameter settings based on material and geometry.
This document provides a dissertation submitted by Kannan P for the degree of Master of Engineering in Mechanical Engineering with specialization in Lean Manufacturing. The dissertation focuses on improving productivity in the manufacturing division of a sheet metal industry located in Coimbatore, India. It involves analyzing the current production process through time studies, layout analysis, and identifying wastes. Based on the analysis, modifications are proposed to the layout and a scrap management system is developed to improve material utilization and reduce waste. The dissertation documents the methodology, analysis of the current state, proposed improvements and their implementation to enhance productivity in the sheet metal manufacturing process.
critique and summary on (1) high speed machining (2) additive manufacturing (...shanjakhrani
This document contains 16 summaries of research papers related to advanced manufacturing systems. The papers cover topics such as high speed machining, sheet metal forming processes, additive manufacturing, and functionally graded materials. Key areas of focus in the critiques include limited analysis of process parameters, material properties, defects, economic considerations, and opportunities for further research.
IRJET- Effect of Fly Ash on Fiber Reinforced Concrete-A Durability ApproachIRJET Journal
The document discusses an investigation into the durability of steel fiber reinforced concrete with fly ash when subjected to chemical attack by sulfuric acid. Concrete cubes were prepared with and without fly ash replacement and steel fibers. The cubes were tested for compressive strength after 28 days of curing and after 30 days of immersion in sulfuric acid. Results showed that steel fiber reinforced fly ash concrete exhibited the lowest loss of compressive strength of 15.4% after acid exposure, indicating it has better durability compared to the other concrete mixtures tested.
A Review on Various Approach for Process Parameter Optimization of Burnishing...ijsrd.com
The aim of this paper is review for different optimization methods used for process parameter optimization of roller burnishing process and Taguchi approach used for process parameter optimization for various processes. The quality of burnishing processed parts are highly depends upon various process parameters of burnishing process. Hence optimization of burnishing process parameters is necessary in order to improve the quality of parts. The purpose of this paper is to explore the reviews for various optimization methods used for process parameter optimization of burnishing process and application of Taguchi approach for design of experiments.
Study of Influence of Tool Nose Radius on Surface Roughness and Material Remo...IRJET Journal
This document presents an experimental study that investigates the effects of cutting speed, feed rate, depth of cut, and tool nose radius on surface roughness and material removal rate during turning of Inconel 718. An L9 orthogonal array was used to design experiments with the four machining parameters each set at three levels. Turning experiments were conducted on a CNC lathe using different carbide inserts with nose radii of 0.4mm, 0.8mm, and 1.2mm. Surface roughness was measured and material removal rate was calculated for each experiment. Signal-to-noise ratios were determined using Taguchi's smaller-the-better and larger-the-better approaches for surface roughness and material removal rate respectively
Experimental Stress Analysis and Optimization of Connecting RodIRJET Journal
The document discusses experimental stress analysis and topology optimization of a connecting rod. It begins with modeling the existing connecting rod using CAD software and performing finite element analysis to determine stresses and deformation. Topology optimization is then used to remove material from low-stress regions to reduce weight without compromising strength. The optimized model is again analyzed using FEA. Finally, the optimization results are implemented on the physical connecting rod using EDM machining. Strain gauges are mounted and experimental testing is conducted to correlate results with the FEA analysis. The optimization reduced the connecting rod weight from 2.351kg to 2.240kg while von Mises stresses and deflections remained within acceptable limits.
of flux cored arc welding process parameters ond duplex stainless steel clad q...A X.S
This document summarizes an experimental study that analyzed the effects of flux cored arc welding (FCAW) process parameters on clad quality when duplex stainless steel is used to clad low carbon structural steel plates. Experiments were conducted using a central composite design with four welding parameters (current, speed, nozzle distance, angle) and responses (bead width, penetration, reinforcement, dilution). Mathematical models were developed to relate the parameters to the responses using multiple regression analysis. The models can help select welding parameters to achieve desired clad quality.
Design of experiments using Moldflow Analysis.Nilesh Nevrekar
The document discusses using Design of Experiments (DOE) in Moldflow to analyze injection molding processes. It describes different types of DOE analyses including Taguchi screening analysis, factorial analysis, and Taguchi followed by factorial analysis. Input parameters for DOE in Moldflow include mold temperature, melt temperature, injection time, and others. Reasons to perform DOE include optimizing part thickness and cycle time. The document provides steps to conduct each type of analysis and interpret their results.
Moldex3D, Structural Analysis, and HyperStudy Integrated in HyperWorks Platfo...Altair
In recent years, with the increasing variety, complexity, and precision requirement on plastic products, CAE tools have been widely used for solving product design and manufacturing issues. The structural designs or molding process parameters for products can be optimized efficiently through CAE analyses. Plus the reliable and correct verification with experiments, the directions or guidance in designs or process condition settings can be provided prior to the real moldings. However, sometimes it is not efficient to find an optimized set of parameters through traditional CAE analyses. A novel integration between Moldex3D and HyperStudy allows for more quick and efficient parameter optimization which will save time, increase product quality, and increase productivity.
Also, traditional CAE analyses do not consider the molding properties influence on structural analysis, such as material property variations caused by fiber orientation and residual stresses. Accordingly, an integrated technology is proposed to bridge molding and structural analysis. Through the integration of Moldex3D and structural analysis in HyperWorks platform, the important effects from molding process can be transferred to structural analysis for more accurate and realistic predictions of the product behaviors. This integration provides a virtual product development platform for users to increase profits as well as enhance productivity.
“Gray Relational Based Analysis of Al-6351”iosrjce
IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) is a double blind peer reviewed International Journal that provides rapid publication (within a month) of articles in all areas of mechanical and civil engineering and its applications. The journal welcomes publications of high quality papers on theoretical developments and practical applications in mechanical and civil engineering. Original research papers, state-of-the-art reviews, and high quality technical notes are invited for publications.
IRJET- Optimization of Minimum Quantity Lubricant (MQL) Conditions in Milling...IRJET Journal
This document describes an optimization study that used the Taguchi method to determine the optimal minimum quantity lubrication (MQL) conditions for milling mild steel. The study considered three MQL parameters - lubricant type, fluid flow rate, and nozzle distance from the machining zone. Experiments were conducted using an L9 orthogonal array with different settings for each parameter. Surface roughness and maximum temperature generated during machining were measured. Statistical analysis was performed to determine the most influential parameters and their optimal levels for improved surface finish and reduced temperature.
Study on Microstructure and machining characteristics of 7% B4Cp reinforced i...IJTET Journal
The document discusses a study on the microstructure and machining characteristics of an aluminum 6061 metal matrix composite reinforced with 7% boron carbide particles produced by stir casting. The microstructure of the composite showed a homogeneous distribution of boron carbide particles in the aluminum matrix. Tests were conducted to analyze the effects of varying cutting speed, feed rate, and depth of cut on the cutting forces and surface roughness when machining the aluminum-boron carbide composite.
Optimization of Material Removal Rate & Surface Roughness in Dry Turning of M...IJERA Editor
Optimization of machining parameters is valuable to maintain the accuracy of the components and to minimize
the cost of machining. Surface finish is an important measure for the quality of the machined parts. The present
work is an experimental investigation to study the effect of machining parameters on Material Removal Rate
and Surface Roughness in dry turning of medium carbon steel EN19. Taguchi’s single objective optimization
method was used to find the effect of input parameters on the responses. The experiments were conducted as per
Taguchi’s L9 Orthogonal Array on CNC lathe under dry conditions. Cutting parameters of speed, feed and
depth of cut were taken as inputs and machining was done by PVD TiAlN tool. Regression models for the
responses were prepared by using MINITAB-16 software. Analysis of variance (ANOVA) was used to find the
influence of machining parameters on the responses. From the ANOVA results, it is clear that speed has high
influence followed by feed and depth of cut has very low influence in achieving the optimum values for both
Material Removal Rate and Surface Roughness. Finally, experimental and Regression values of responses were
compared. From the results, it is found that both the values are close to each other hence, the regression models
prepared were more accurate and adequate. Percentage of errors between experimental and regression values
were calculated and they found in the range of ±0.20.
This document summarizes a critical design review for a project to develop an additive manufacturing system for printing solid rocket propellant. It outlines the project background, functional requirements, critical elements, and safety considerations. Key aspects of the design include the laser system selection, thermal modeling of the sintering process, powder bed subsystem, and implementation of safety systems to address the fire and explosion risks of the propellant materials. The goal is to 3D print complex grain shapes for solid rocket motors and compare the mechanical properties to those of traditionally cast propellant.
This document discusses spray modeling for lean NOx trap aftertreatment system design. It presents Eaton Corporation's aftertreatment system for reducing NOx and PM emissions. Computational fluid dynamics (CFD) was used to optimize fuel preparation and distribution through injection modeling. Both test-based and CFD-based injection modeling were performed and validated. CFD results showed that smaller droplet sizes and optimized mixer placement improved fuel uniformity and vaporization. CFD modeling aided in comparing injector performances and selecting mixers for the aftertreatment system design.
This document summarizes a study on 3D printing applications for aerospace components. Key findings include:
- 3D printing allows integrating multiple parts into one to reduce weight and volume for unmanned aerial vehicles.
- Design considerations like minimum thickness and angles are important for metal 3D printing.
- Properties of 3D printed parts like yield strength and hardness are lower than wrought parts but provide design flexibility.
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six sigma DMAIC approach for reducing quality defects of camshaft binding pro...Niranjana B
Data collection for 11 months revealed that 26% of the defects are due to improper camshaft binding. The six sigma approach involves DMAIC approach with statistical tools involved in each stage. The main root are identified and improvements are implemented. The quality is improved by reducing the number of defects
Kedar Ratnakar is a mechanical engineer passionate about product design, controls, and manufacturing. Their portfolio highlights projects including developing an innovative multi-material 3D printer and bringing a 3D printer concept to production. They have experience with CAD software, finite element analysis, bill of materials generation, cost analysis, and computer integrated manufacturing. Kedar has also designed robotic systems, generated 3D models for manufacturing, and developed Arduino applications for electro-mechanical systems.
This document is an engineering design portfolio for Tsuyoshi Yokoyama. It includes contact information, education background, and details of various mechanical engineering and design projects completed. Projects include designs of a motor performance testing platform, 5-axis CNC milling machine, wine opener, tensile members, fluid dynamics analysis, robot programming, and closed-loop quadcopter control. For each project, the document describes the objectives, design features, and conclusions. The portfolio demonstrates Yokoyama's skills in CAD, FEA, mechatronics design, and passion for practical engineering challenges.
This document provides details on the conceptual design of a screw conveyor assembly. It includes information from the house of quality, product design specifications, and morphological analysis conducted during the conceptual design phase. The house of quality outlines customer requirements and engineering characteristics. Product design specifications define functional requirements, key performance targets, and manufacturing specifications. Morphological analysis was used to generate concept solutions by breaking the problem into subsystems and combining solutions.
TO DOWNLOAD THE PRESENTATION DROP US A LINE AT mkt@moldex3d.com
Cars are becoming lighter and more environmentally friendly. Producers need to stay ahead with their part designs technology and delivering to the competitive automotive market. Discover how Moldex3D team solves pressing issues and helps reach those goals by using CAE technology!
For the recorded webinar please go to our YouTube channel:
https://www.youtube.com/watch?v=ISFHmv1cLWk
Thank you for watching!
Blow Hole Defect Analysis in Die CastingRamesh Raja
This document summarizes an analysis of blow hole defects in die casting. The objectives were to minimize defects using design of experiments. Process parameters like metal temperature, die temperature, and die holding time were identified as factors affecting blow hole defects. Experiments were conducted using a Taguchi design with three factors at three levels. Analysis of variance showed die temperature was the most significant factor. Optimization found the best parameters were a metal temperature of 700°C, die temperature of 300°C, and die holding time of 75 seconds. This was predicted to increase casting density by 4.13% and reduce blow holes.
Tolcap training material:
Demonstrating the importance of tolerance allocation and process capability in design and manufacture.
Introducing the Tolcap methodology and software, and its role in engineering capable products.
The document discusses the design of a forging die for a planetary gear blank. It begins with an introduction to forging as a metalworking process and advantages it provides over other manufacturing methods. It then outlines the objectives and methodology for the die design project. The methodology involves designing the final gear part geometry, determining stock size requirements, and designing the forging die. Key die design considerations discussed include parting line selection, drafting angles, fillet and corner radii, flash and gutter design, and shrinkage allowance. The document concludes with CAD drawings of the designed forging die.
On July 10th Innovate UK and the KTN held a business innovation day to showcase 30 of the Innovate UK projects that are currently active in the area of Additive Manufacturing. The presentations and pitches made on the day are now available to download. Topic 3 focuses on Post Processing
Design for Manufacturability Guidelines Every Designer should FollowDFMPro
The document discusses design for manufacturability guidelines for sheet metal parts. It outlines several key DFM parameters like minimum bend radius, hole placement, cutout distances, notches and reliefs. Ignoring these guidelines can cause issues like cracks, deformation and breakage. Traditional DFM methods are manual and problematic. Automating DFM checks in a software tool called DFMPro allows early validation of designs and avoidance of costly rework. A case study of a hi-tech manufacturer found annual part cost savings of over 2 million euros through use of DFMPro's automated DFM analysis and guidelines.
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This document discusses using AutoForm to optimize sheet metal part quality through die optimization. It aims to improve simulation accuracy, standardize simulations, and transition die quality improvement to earlier design stages. This helps decrease part development time and costs. The document outlines past issues, optimization methodology, effective simulation parameters, verification of simulation results against experiments, and examples of optimized sample parts showing quality improvements and successful high production rates after die surface optimization based on simulations.
IRJET- Optimization of Plastic Injection MoldingIRJET Journal
The document discusses optimization of plastic injection molding process parameters using Taguchi methods and Moldflow simulation software. It analyzes the effect of melt temperature, cooling time, injection pressure, and mold temperature on the warpage of a honey cup part made of polypropylene. An L9 orthogonal array experiment is designed using the Taguchi approach to study these four parameters at three levels each. The results show that melt temperature has the most significant effect on warpage, followed by mold temperature, injection pressure, and cooling time. The optimal parameter settings found to minimize warpage are a melt temperature of 180°C, cooling time of 15 seconds, injection pressure of 90MPa, and mold temperature of 50°C.
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BAHIR DAR UNIVERSITYBAHIR DAR INSTITUTE OF TECHNOLOGY (BiT)FACULTY OF MECHANICAL AND INDUSTRIAL ENGINEERING Rapid Prototyping & Reverse Engineering [MEng6123]
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts
Post processing of AM parts Preparation for use as a Pattern Often
Guidelines for process selection
Guidelines for process selection Approaches to Selection
Guidelines for process selection Selection Example
Guidelines for process selection - Selection Example
In this example, it is decided to allow customization of certain features.
Only standard 12 mm diameter x 100 mm length bolts will be used for the inner bore, therefore, these dimensions will be constrained.
Customers will be allowed to customize all other features of the caster wheel
within allowable ranges for this model wheel, as displayed in the table below.
Guidelines for process selection - Selection Example
Guidelines for process selection Selection Example
In this example, we examine two weighting scenarios (relative importance ratings).
Scenario 2
All selection attributes were equally weighted.
Guidelines for process selection Selection Example
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Topology Optimization for Additive Manufacturing as an Enabler for Robotic Ar...piyushsingh376
The current research is intended to minimize the mass of T shaped joint by using lattice structure and topological optimization tool.
The stresses, deformation, safety factor of generic and optimized design is evaluated on the basis of these mentioned parameters. The findings have shown that topological optimization method is best as compared to lattice structure method for weight minimization.
Topology Optimization for Additive Manufacturing as an Enabler for Robotic Ar...
SPAM_Spring_Final_Review
1. Cameron Brown, Erick Chewakin, Max Feldman,Tony Lima
Nick Lindholm,Caleb Lipscomb, Ryan Niedzinski, & Jon Sobol
Solid Propellant Additive
Manufacturing
Printing Solid Rocket Motors
1
2. 2
Agenda
• Project Purpose and Objectives -> Ryan
• Design Description -> Jon
• Test Overview -> Erick
• Test Results
o Powder Bed -> Nick
o Sintering Results -> Caleb,Tony
• Systems Engineering -> Max
• Project Management -> Cameron
5. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Field of Application
Solid Rocket Motors
• Cylinders of solid rocket propellant (fuel +
oxidizer) with different cross sectional grain
shapes
• Grain shape determines thrust profile through
available surface area to burn
o Higher surface area -> Higher thrust
• Normally made by casting
o Propellant cures in a cylindrical tube
o Desired grain shape is bored through the
middle
5
Example Grain Shapes andThrust Profiles1
6. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
• Problems withTraditionalCasting:
o Limited number of grain shapes
o Air bubbles in cast
o Nonuniform setting
• Impact of 3D Printing on SRM Manufacturing:
o Produce complex grain shapes and new
thrust profiles
o No need to manufacture a different cast for
each design
o Consistent material properties in each layer
6
Example complex shape produced from
SLS printing
Casting vs. Additive Manufacturing
8. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
8
Level Description Status
1.1 Design 3D Printing System for Sucrose-KNO3 Achieved
1.2 Characterize aThermal Model for Propellant Achieved
1.3 UseAnalogous Method to form Solid Propellant Achieved
2.1 Compare Material Properties (Casted vs Printed)
Not
Achieved
2.2 Print a Solid Rocket Motor Cylinder Achieved
3.1 Manufacture 5 Different Grain Shapes
Not
Achieved
Levels of Success
19. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
19
Designation Requirement Description Verified
FR 1
The project shall produce a printer capable of
automated 3D additive manufacturing.
Provisionally
FR 2
The rocket propellant shall be a solid composite
propellant consisting of oxidizer and fuel.
Yes
FR 3
The printer shall have a mechanism to transport the
mixed fuel and oxidizer to the manufacturing area.
Yes
FR 4
The printed propellant properties shall be compared
to traditionally cast propellant material properties.
Provisionally
FR 5
Safety shall be the primary concern in every aspect of
the project.
Yes
Functional RequirementsOverview
23. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Requirements Fulfillment: FR 4
• The printed propellant properties
shall be compared to traditionally
cast propellant material
properties.
o Printed propellant less dense, less
homogeneous, more brittle
o Tensile/Compression testing
incomplete
Printing process too unstable to
manufacture dogbones
Sample cast is too small for brittle
propellant
23
Printed (top) vs.
Cast (bottom)
27. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Powder BedToleranceTesting Results
27
Trial Command [mm] Actual [mm] Error [%]
1 1.98 1.9558 -1.22
2 1.98 1.9431 -1.86
3 1.98 1.905 -3.79
4 1.98 1.9812 0.06
5 1.98 1.9177 -3.15
6 1.98 1.9304 -2.50
7 1.98 1.9558 -1.22
8 1.98 1.905 -3.79
9 1.98 1.9558 -1.22
10 1.98 1.9431 -1.86
11 1.98 1.8923 -4.43
… … … …
• 77 Steps/trial commanded
• Bias towards loss suggests steps are smaller
or are being skipped
• Error is within 30% at all times
*All distances are downward
Error bars based on
DR 1.4
28. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Powder BedToleranceTesting Results
28
Theoretical:
∆𝑍 = 38.88 𝑠𝑡𝑒𝑝𝑠/𝑚𝑚
Actual (77 steps/trial):
Even when under load pistons behave
as expected
Actual height is less than commanded
height by ~2%, well within the
requirement of 30%
Thinner layers allow for sintering
between layers
Requirement ID Description
1.4 Layers shall be 1+0.3mm
∆𝑍 𝑎𝑣𝑔 = 1.934 𝑚𝑚/𝑡𝑟𝑖𝑎𝑙
= 39.81 𝑠𝑡𝑒𝑝𝑠/𝑚𝑚
Error bars based on
DR 1.4
30. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Sintering Model: Assumptions
30
• Laser sweeps out a rectangle of area as it moves
• Layer depth is variable
• All laser energy is deposited uniformly into the
layer
• No heat loss to surroundings
o Model limited to fast slew rates
𝑄𝑖𝑛 = 𝐶 𝑝 ∗ 𝑚 ∗ ∆𝑇
𝑄𝑖𝑛 = 1 − 𝑎𝑙 ∗ 𝑃𝑜𝑤𝑒𝑟 ∗ ∆𝑡
𝑚 = 𝑚 ∗ ∆𝑡
𝑡𝑙𝑎𝑦𝑒𝑟 =
1 − 𝑎𝑙 ∗ 𝑃𝑜𝑤𝑒𝑟
∆𝑇 ∗ 𝐶 𝑝 ∗ 𝑑𝑙𝑎𝑠𝑒𝑟∗ 𝑟𝑠𝑙𝑒𝑤
𝑚 = 𝑡𝑙𝑎𝑦𝑒𝑟 ∗ 𝑑𝑙𝑎𝑠𝑒𝑟∗ 𝑟𝑠𝑙𝑒𝑤
L
A
S
E
R
Slew Rate
Propellant Layer that receives
Laser energy
45. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Propellant Heat Model: Lumped Capacitance
• Assume: All heat is absorbed uniformly at in a cylinder with radius of laser
beam and depth of optical depth
• Equation: gives time over spot as a function of laser power
• 𝑑𝑡 =
𝜋∗𝑟𝑙𝑎𝑠𝑒𝑟
2
∗𝑑 𝑠𝑖𝑛𝑡∗𝜌∗𝐶𝑝∗𝑇
𝐴∗𝑃 𝑙𝑎𝑠𝑒𝑟
• Time over spot converted to slew rate:
• 𝑠𝑙𝑒𝑤 𝑟𝑎𝑡𝑒 = 2 ∗
𝑟 𝑙𝑎𝑠𝑒𝑟
𝑑𝑡
45
58. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Requirements Definition
• FR 1:The manufacturing system shall be capable of
manufacturing at least two layers of solid propellant
• FR 2:The manufacturing system shall be capable of
automated additive manufacturing
• FR 3:The manufacturing system shall be verified
through testing
• FR 4:The entire system shall be safe under normal
operation
58
Clear and
continued
communication
with SAS facilitated
sound Functional
Requirements
throughout the
project
64. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Project Management
Approach
• More laid-back approach to try
to reduce micromanaging
o Main management focus was on
meetings, client interaction, and
communication between
members
• Systems leads were designated,
but team members tended to
move to work on multiple
systems as needed
64
Successes
• Followed schedule fairly well
• Powder bed worked
great/tolerances met
• 3D SRM was printed
• Happy customer/2nd gen project
requested
65. Purpose
Design
Description
Test
Overview &
Results
Systems
Engineering
Project
Management
Key Lessons Learned
• Communication can make or break a project
o Action items help but only if they’re utilized
o The PM can help with communication, but it takes effort from the whole team
• Tasks rarely get done on time, always plan with margin
• Its important to understand problems from other team members’
perspectives
• Nature of the project held it back initially
o Research based
o First-generation
o Lack of direction/concept is new
65
68. 68
Acknowledgements
Team SPAM would like to thank
everyone who made this project
possible:
-Special Aerospace Services
-Dr. Ryan Starkey
-CU Boulder Aerospace PAB
-Ifuzion 3D Printing
-Andreas Bastian (OpenSLS)
-Richard Nakka Rocketry
-Frontier Astronautics
69. References
• 1Braeunig, Robert A. “Space Pictures”. Rocket and Space Technology. Accessed October 2015. Available:
• http://www.braeunig.us/space/pics/fig1-14.gif
• 2”Saltpetre”. The Ingredient Store.com Accessed October 2015. Available: http://store.theingredientstore.com/saltpetre-food-gradepotassiumnitrate.aspx
• 3“Sucrose Advanced Inorganics”. India Mart. Accessed October 2015. Available: http://dir.indiamart.com/impcat/sucrose-powder.html
• 4Miller, E., “Rapid Prototyping Technology Animations,” PADT, Inc Available: http://www.padtinc.com/blog/the-rp-resource/rapid-prototyping-technology-animations
• 5“Selective Laser Sintering (SLS),” MakeAGif Available: http://makeagif.com/cpjtel
• 6Sher, D., “Using SnowWhite to Laser Sinter Sugar,” 3D Printing Industry Available: http://3dprintingindustry.com/2014/09/26/sharebot-used-snowwhite-laser-sinter-sugar-worked-
perfectly/.
• 7“Selective Laser Sugar Snowflakes,” Collected Edition Available: http://blog.collected-edition.com/post/41556924865/slssnowflakes.
• 8“EngArc - L - Stress-Strain Diagram,” EngArc - L - Stress-Strain Diagram Available: http://www.engineeringarchives.com/les_mom_stressstraindiagram.html.
• 9“Fracture Toughness,” Fracture Toughness Available: https://www.nde-ed.org/educationresources/communitycollege/materials/mechanical/fracturetoughness.htm.
• 10“Part 3: How to Build a High Power Rocket - Casting the Fuel into BATES Grains,” YouTube Available: https://www.youtube.com/watch?v=dfrnimt2bu4
• 11“HD How to make & cast R-Candy Fuel ( BEST RESULTS ),” YouTube Available: https://www.youtube.com/watch?v=uhm7nrv3bs8
69
70. References
• 12“Sucrose,” National Institute of Standards and Technology Available: http://webbook.nist.gov/cgi/cbook.cgi?id=c57501&mask=80
• 13“AC110V 1’ Solid Coil Electric Solenoid Valve Gas Water Fuels Air Solid Coil,” Amazon Available: http://www.amazon.com/ac110v-solid-electric-solenoid-
valve/dp/b00lap0cie/ref=pd_sim_60_21?ie=utf8&refrid=1wa1qjzcp57mkscsykh7
• 14Shoberg, R., “Engineering Fundamentals of Threaded Fastener Design and Analysis”. PCB Load & Torque, Inc. Accessed Oct. 2015. Available:
http://www.hexagon.de/rs/engineering%20fundamentals.pdf
• 15“Dissecting the Nut Factor”. Archetype Joint. Accessed Oct. 2015. Available: http://archetypejoint.com/?page_id=135
• 16“Joint1.gif”. Bolt Science. Accessed Oct. 2015. Available: http://www.boltscience.com/pages/nutorbolttightening.htm
• 17Herder, G., Weterings, F. P., and de Klerk, W. P. C., “MECHANICAL ANALYSIS ON ROCKET PROPELLANTS,” Journal of Thermal Analysis and Calorimetry, vol. 72, 2003, pp. 921–929.
18“Stereolighography,” Wikipedia Available: https://en.wikipedia.org/wiki/stereolithography. 19“Testing – Testing?,” IMPRESS Education:
Mechanical Properties, Testing Available: http://www.spaceflight.esa.int/impress/text/education/mechanical properties/testing.html. 20Tussiwand, G. S., Saouma, V.,
Terzenbach, R., and Luca, L. D., “Fracture Mechanics of Composite Solid Rocket Propellant Grains: Material Testing,” Journal of Propulsion and Power, pp. 60–73.
21Bastian, Andreas. “R2 Final Assembly”. RepRap Wiki. Open Source CAD Files. Modified 7 December 2013. Accessed October 2015. Available:
http://reprap.org/wiki/File:R2_final_assembly.png
• 22Kodikara, J., “Tensile strength of clay soils,” Tensile strength of clay soils Available: http://eng.monash.edu.au/civil/research/centres/geomechanics/cracking/tensile-clay.html
• 23“What is a Creep Test?,” What is a Creep Test? Available: http://www.wmtr.com/en.whatisacreeptest.html .
• 24Jacobsson, L., and Flansbjer, M., “Uniaxial compression tests,” Uniaxial compression tests Available:
http://www.sp.se/en/index/services/rockmechanicaltesting/uniaxial/sidor/default.aspx .
• 25Full Spectrum Laser, “Hardware Setup and Operation,” FSL 40w Hobby Laser Manual
• 26 Laser Institute of America, “American National Standard for Safe Use of Lasers,” ANSI Z136.1, published 2007
• 27 Occupational Safety & Health Administration, “Laser Hazards,” OSHA Technical Manual, Section III: Chapter 6
• 28 CU Boulder Environmental Health and Safety, “Hazardous Materials & Waste Management,” http://ehs.colorado.edu/about/hazardous-materials-and-waste-management/
[retrieved 15 November 2015]
• 29 National Fire Protection Agency, “NFPA 704: Standard System for the Identification of the Hazards of Materials for Emergency Response,” http://www.nfpa.org/codes-and-
standards/document-information-pages?mode=code&code=704 [retrieved 20 November 2015]
• https://www.rocket.com/article/aerojet-rocketdyne-completes-successful-leo-46-rocket-motor-test
70
74. Project Overview Testing & Results Project Management
Powder BedToleranceTesting Results (BACKUP)
74
Slow increase of actual
position relative to
commanded position suggests
the system has a harder time
moving up than down
Relative error can be as high as
37%
The system does not rely on up
and down motion, only
continuous motion in one
direction (see main slides for
results)
*Positive down, negative up
75. Project Overview Testing & Results Project Management
Requirement 2.4.1.2/2.4.2.2: Pistons shall
support 2.5kg + own weight (BACKUP)
75
• Scrap metal taken from machine shop and massed:
Description MASS (kg)
Hexagonal steel 0.47
Short round copper 0.62
Tall round copper 1.02
Round brass 0.45
TOTAL 2.56
• Empirical evidence shows pistons support the load and
can lift without difficulty
76. Project Overview Testing & Results Project Management
Requirement 2.4.5: Each cycle shall take less
than 5 minutes (BACKUP)
76
Nominal engrave job:
~195 second
5 min = 300 sec
Time left = 300 – 195 = 105
Nominal PB cycle << 105 sec
Depends heavily on
geometry and cutter DPI but
is generally less than 5 min
77. Project Overview Testing & Results Project Management
Requirement 2.4.1.4: Reservoir shall deliver
150% of powder needed (BACKUP)
77
150% by volume.
Volume is driven by vertical motion of the pistons.
Software has a variable that controls how much more vertical distance the reservoir covers.
For most prints this is set at 1.3 (130%) but there is no limitation on how large this value can be.
This value can be fully controlled by the user.