7 Papers_merged

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 REVIEW ON RESTORATIVE MEASURES TO OVERCOME EFFECTS OF HIGH ENGINE TEMPERATURES ON I.C ENGINE 1Mr. K. Suresh Kumar, 2Matta Venu Gopal, 2Duvva Sagar, 2Gotour Harshvardhan, 2Addula Tharun Reddy, 2Paka Prashanth Kumar 1Assistant Professor, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. 2 Student,Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. Abstract - Since 1876 the IC engines have wide gets temperature beyond the optimum operating applications in the society like transportation, industry etc , the domain of IC engines has huge temperature of engine potential for research and this research study covers various effects of engine high temperature and If engine temperature is beyond the optimum possible solution to overcome the insufficient cooling of engine when vehicle runs at high ambient operating temperature, it can lower the working temperature ,as the engine runs continuously hours together high temperatures obtains in the engine efficiency of engine [1].as low as 1300C is the components and the following effects may occur like evaporation of lubricant oil ,harmful unwanted recommended temperature for smooth running of emissions, decrease in volumetric efficiency, change of metallurgical properties of engine components etc. engine [2] From the above listed problems change of metallurgical properties of engine components due to Fig no-2 insufficient cooling effect is working spot. Keywords: - Radiator, cooling water, ambient air 2. LITERATURE REVIEW temperature etc. In this chapter some major effects of poor cooling are listed like following below 1. INTRODUCTION 2.1 VARIATION IN LUBRICANT VISCOSITY Since the both SI and CI engine are heat engines, they As we know that lot of friction occurs between engine produce lot of heat amount in combustion of fuels and moving parts like piston and cylinder, bearings etc.this removal of liberated heat is serious problem, if heat is friction has to be reduced by lubrication system of not removed by the cooling continuously the engine [2]. With rise in temperature viscosity of temperature of engine components reaches intolerable lubricant oil will decrease. So the operating values and promotes various problems as discussed temperature of should be closer to the cooling water earlier. Generally, IC engines uses the radiator cooling temperature [3]. Due to high temperature of engine if system for heat removal process, in this system it the operating viscosity of oil goes below 10mm2/s then removes heat of engine by running the cool water the oil is too thin to lubricate [4]. through the water jacket and heat which is collected by the water from the engine will be dissipated in to the surrounding atmosphere air while running in the radiator tubes and again circulated through the water jackets. Heat transfer rate in the radiator tubes strongly influence by the surrounding ambient air temperature, in India ambient temperature records 43 to 480C normally in summer spring this leads to poor efficiency of cooling system intern engine components ISBN: 978-93-5620-351-8 88 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 (Viscosity of lubricant vs Engine temperature) [4] Fig:4 (Thermal stress analysis of piston ) [7] 2.2 ANALYSIS OF METULURGICAL 2.3 EMISSION PARAMETERS AT HIGH PROPERTIES OF ENGINE PARTS TEMPERATURES The materials of various engine parts cannot which Operating temperature of engine influences the engine stand at 2700k which is possible temperature of emissions, mainly in the diesel engine the NOX combustion and there is a chance of damage in engine emission levels will increase if the temperature is parts since thermal stresses will be developed at higher above 2000 K in the combustion chamber [10]. temperatures. The charging of fresh air fuel mixture in Reduction in NOX emission is highly required to meet to the cylinder and discharging of combustion gases the pollution control board norms. Maintaining the from the combustion chamber will be done the temperature below the 2000K can reduce the NOX periodic opening and closing of inlet and exhaust emission. valves, and closing of both valves will provide working space for combustion, poor sealing of cylinder head due to damage of valve by thermal stresses leads to low pressure in the combustion chamber and leakage of the air fuel mixture. Figure 3 shows the damage of valves [5] Fig: 3 (Fracture of exhaust valves) [5] Fig:5 (Engine speed vs NOx emissions with variation in temperature) [1] Thermal stress is serious problem in piston because the location of piston is inside the combustion chamber 2.4 ENGINE PERFORMANCE and lack of proper heat dissipation [6].the periodic At high temperatures increase in speed can cause the heat load on the piston can cause surface cracking, reduction in brake power, and knocking tendency will corrosion, wear and even structural damage [7]. As it is observed that in the design of engine piston thermal stress analysis is unavoidable [8]. ISBN: 978-93-5620-351-8 89 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 more if the engine jacket temperature is high[11]. • It is harm full to pets and children if they Fig: 6 (Brake power vs Engine temperature) [8] consume orally In view of insufficient cooling effect at high ambient 2.5 VOLUMETRIC EFFICIENCY temperatures and possible environmental issues the From the basic science we know that air density is low proposed cooling system in this study provides great at high temperature ambience, the poor efficiency of cooling effect even high ambient temperature Asian cooling system cause high temperatures for intake countries with small design modification at the time of manifold and air density decreases when it is passing manufacturing and also it avoids usage of other through it and lowers the volumetric efficiency of chemicals in coolant engine this can be proved from the below formulas. 3 METHODOLOGIES Mass of air in the combustion chamber = Density of 3.1 RADIATOR air X volume of combustion chamber [CC] Radiators are used for cooling internal combustion M=αv In the above equation volume engine is constant engines, mainly in automobiles and also in so density of air of directly influence the mass of air pistonengine aircraft, railway locomotives, present in the combustion in suction stroke, so high motorcycles, stationary generating plants and other temperature of engine reduces volumetric efficiency, places where such engines are used. poor volumetric efficiency leads to low indicated To cool down the engine, coolant is passed through power, high emissions. the engine block, where it absorbs heat from the engine. The hot coolant is then fed into the inlet tank 2.6 EXISTING COOLING SYSTEM of the radiator (located either on the top of the radiator In order to improve cooling effect and avoid the or along one side), from which it is distributed across coolant over consumption problem in simple water the radiator core through tubes to another tank on the cooling system using of nano fluids mainly ethylene opposite end of the radiator. As the coolant passes glycol became regular [10].but ethylene glycol has through the radiator tubes on its way to the opposite significant environmental issues and it is not economy. tank, it transfers much of its heat to the tubes which, in In the view of commercial aspects the existing cooling turn, transfer the heat to the fins that are lodged is got success but it is not recommendable in the view between each row of tubes. The fins then release the of environmental and societal and it is not effective at heat to the ambient air. Fins are used to greatly ambient temperatures especially in Asian countries increase the contact surface of the tubes to the air, thus like Dubai,UAE and India etc. increasing the exchange efficiency. The cooled Disadvantages of Ethylene glycol coolant is fed back to the engine, and the cycle repeats. By the regular and over usage of ethylene glycol the Normally, the radiator does not reduce the temperature following disadvantages my occur [11] of the coolant back to ambient air temperature, but it is still sufficiently cooled to keep the engine from • It is highly flammable overheating. • Chance of mild explosion possibility • It absorbs water rapidly • Difficulty in disposal ISBN: 978-93-5620-351-8 90 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 3.2 SOLENOID VALVE 3.4 TEMPERATURE CONTROLLER AND A solenoid valve is an electromechanically operated THERMOCOUPLE valve. Solenoid valves differ in the characteristics of Temperature controller the electric current they use, the strength of the As the name implies, a temperature controller - magnetic field they generate, the mechanism they use often called a PID controller is an instrument used to regulate the fluid and the type and characteristics of to control temperature. The temperature controller fluid they control. The mechanism varies from linear action, plunger-type actuators to pivoted-armature takes an input from a temperature sensor and has actuators and rocker actuators. The valve can use a an output that is connected to a control element two-port design to regulate a flow or use a three or such as a heater or fan. This temperature controller more port design to switch flows between ports. Multiple solenoid valves can be placed together on a or PID controller is used as controller unit for the manifold. Solenoid valves are the most frequently solenoid valve for opening and closing of the valve. used control elements in fluidics. Their tasks are to It works in such a way that when temperature shut off, release, dose, distribute or mix fluids. They are found in many application areas. Solenoids offer senses high the valve gets automatically opens and fast and safe switching, high reliability, long service simultaneously at medium temperature it closes the life, good medium compatibility of the materials used, low control power and compact design valve automatically. Thermocouple 3.3 SUB ZERO DEVICE A Thermocouple is a sensor used to measure Sub-Zero also has a computer-driven air purification temperature. Thermocouples system that works to circulate fresh air in your fridge. Consist of two wire legs made from different metals. Two separate sealed refrigeration systems are used to control the temperature and humidity in the The wires legs are welded together at one end, refrigerator and freezer. creating a junction. This junction is where the temperature is measured. When the junction experiences a change in temperature, a voltage is created. In this study thermocouple is used to sense the temperature of the outlet coolant temperature. This thermocouple is then connected to the temperature controller where the opening and closing of the valve done. ISBN: 978-93-5620-351-8 91 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 3.5 CONNECTING RADIATOR OUTLET WITH radiator outlet water temperature not in control sub- CAR COOLING SYSTEM zero activates the solenoid The above represents the flow direction of coolant in the proposed cooling system combined with vehicle AC system in this proposed system when the ambient temperature normal and radiator valve then it provides new flow route for the coolant in the direction 1-2-4-3-1,at point 4 excess heat of radiator coolant will be removed with help of car AC system refrigerant. LAYOUT OF DESIGN 4. CONCLUSION The proposed design can give greater relief from 3.6 WORKING: In this design, the solenoid valve is overheating problem of engine and promote good attached between the compressor and evaporator valve efficiency and working of engine at high ambient on the low tape side. This enables a new additional flow route to the cooling gas in A/C circuit. The new temperature Asia countries like India Dubai, U.A.E route is designed in such a way that the coil is merged in radiator outlet pipe and reconnected to the etc, and it is optimum alternative to existed cooling compressor. A sub-zero device is attached to regulate solenoid valve by taking radiator outlet water system in view of economy and environment friendly, temperature as an input.Whenever the radiator outlet water temperature is more than the temperature it by the proposed design cooling system can have should (i.e due to ambient temperature water is not optimally cooled) then the subzero opens solenoid definite control over radiator outlet water which valve which allows the cooling gas to flow and interact with outlet water and cool it optimally. promotes increase in cooling efficiency and improves When again water is adjusted to its optimal temperature the subzero automatically closes the engine performance characteristics. solenoid valve which makes cooling gas not flow from radiator water outlet route. Thus this new automatic 5. REFERENCES cooling setup cools radiator water in necessary times [1]. The Influence of Engine Speed on Exhaust and increases engine performance and life. Emission of Four Stroke Spark Ignition Multi 3.6 FLOW CHART Cylinder Engine, Ajay K. Singh, A. Rehman, ISSN: 2249 – 8958, Volume-2, Issue-4, April outlet water temperature in control, coolant runs in the 2013. route of 1-2-3-1.if ambient temperature is more and [2]. Effects of Lubricant Temperature in a Motorized Engine, A.F.A. Rasid, T.I. Mohamad, M.J. Ghazali and W.M.F.W. Mahmood World Applied Sciences Journal 20 (7): 927-930, 2012 ISSN 1818-4952. [3]. Effect of temperature on lubricating oil and poly(methyl methacrylate) additive M.Sc. Mohammed Faiq Mohammed 1 M.Sc. Muwafaq Mahdi ISSN 1999-8716. [4]. Wear check monitoring and technical bulletin issue 43. [5]. Failure Analysis of Internal Combustion Engine Valves: A Review Naresh Kr. Raghuwanshi, Ajay Pandey, R. K. Mandloi ISSN: 2319 – 875. [6]. The effect of cylinder liner operating temperature on frictional loss and engine emissions in piston ring conjunction R. Rahmani , H. Rahnejat , B. Fitzsimons , D. Dowson Applied Energy 191 (2017) 568– 581. ISBN: 978-93-5620-351-8 92 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 [7]. Analysis of thermal temperature fields and Temperature by Devendra Vashist, Sunny Bhatia, Ashish Kalra. thermal stress under steady temperature field [16]. Dirt analysis on the performance of an engine cooling system,Yashvir Singh, Nishant of diesel engine piston Yaohui Lu, Xing Kr. Singh [17]. The Effect of High Temperature on Engine Performance in Kuwait Conditions Zhang, Penglin Xiang, Dawei Dong Applied Mukhtar M. A. Morad*, Jasem Alrajhi [18]. water-cooled petrol engines: a review of Thermal Engineering 113 (2017) 796–812. considerations in cooling systems calculations with variable coolant density and [8]. The Effect of Engine Temperature on Multi specific heat Tonye. K. Jack, Mohammed M. Ojapah Cylinder SI Engine Performance with [19]. An Overview of Radiator Performance Evaluation and Testing Prof. A. R. Khot , Gasoline as a fuel Sunil Choudhary, A.C. Prof. D.G. Thombare, Prof. S. P. Gaikwad, Prof. A. S. Adadande Tiwari, Ajay Vardhan, Arvind Kaushal ISSN [20]. Effect of coolant temperature on performance of a si engine Mohammad 2091-2730 Mamun, BDr. Md. Ehsan, [21]. Design and Modification of Radiator in I.C. [9]. The effect of on gas emissions temperature Engine Cooling System for Maximizing Efficiency and Life R. Paul Linga Prakash, Charalampos Arapatsakos, Anastasios M. Selvam, A. Alagu Sundara Pandian, S. Palani and K. A. Harish Karkanis & Stella Maria Strofylla [22]. Improving car radiator performance by using TiO2-water nanofluid Siraj Ali Ahmed, www.arpapress.com /Volumes Mehmet Ozkaymak , Adnan Sözen, Tayfun Menlik, Abdulkarim Fahed /Vol11Issue1/ IJRRAS_11_1_10.pd. [23]. Analysis of IC Engine Performance Using Nano Fluid as Coolant in Radiator – A [10]. Effect of EGR on the exhaust gas Review Prof. Dr. P.P.Rathod, D.B.Lokwani, Prof. A.S.Sorathiya temperature and exhaust opacity in [24]. Advanced Engine Cooling – Components, Testing and Observations John Chastain, compression ignition engines avinash kumar John Wagner and John Eberth [25]. Effect of high engine temperatureon agrawal, shrawan kumar singh, shailendra performance and characteristics of ic engine Suresh konda, P.SaiSrikanth Goud, sinha and mritunjay kumar shuk sadhan¯a M.Narsimha, V.Rupesh Goud, T.Chandra Shekar vol. 29, part 3, june 2004, pp. 275–284. [26]. Investigation of emission characteristics affectedby new cooling system in a diesel [11]. The effect of high temperature of the engine Kyung-Wook Choi, Ki-Bum Kim and Ki-Hyung Lee cyij3vderhead on the knccking tendency of [27]. Design and analysis of a cooling control system of a diesel engine, to reduce an air-cooled engine cylinder E& J. C. emissions and fuel consumption. Marco Antonio Iskandar Sanders and M. D. Peters February 1945 as [28]. An experimental investigation for the coolant temperature effect on the exhaust Advance Restricted Report E29a. emissions for a spark ignition engine fuelled [12]. A Review on Nanofluids: Preparation, Stability Mechanisms, and Applications Wei Yu and Huaqing Xie School of Urban Development and Environmental Engineering, Shanghai Second Polytechnic University, Shanghai 201209, China Correspondence should be addressed to Huaqing Xie, [email protected] [13]. Ethylene glycol: human health aspects First draft prepared by R. Gomes, R. Liteplo, and M.E. Meek, Health Canada, Ottawa, Canada Published under the joint sponsorship of the United Nations Environment Programme, the International Labor Organization, and the World Health Organization, and produced within the framework of the Inter- Organization Programme for the Sound Management of Chemicals [14]. Temperature sensor made of polymer- derived ceramics for high-temperature applications Ran Zhaoa, Gang Shaob, Yejie Caoa, Linan Ana, Chengying Xuc. [15]. Some Studies on the Performance of Automotive Radiator at Higher Coolant ISBN: 978-93-5620-351-8 93 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 with gasoline and CNG, Mina B. R. Abaskharon, Fawzy M. H. Ezzat, Ali M. Abd-El-Tawwab, Mohamed R. El-Sharkawy [29]. Effects of Engine Cooling Water Temperature on Performance and Emission Characteristics of a Compression Ignition Engine Operated with Biofuel Blend, Abul K. Hossain, David I. Smith, Philip A. Davies. [30]. The Effect of Changes in Ambient and Coolant Radiator Inlet Temperatures and Coolant Flowrate on Specific Dissipation, Changhua Lin ISBN: 978-93-5620-351-8 94 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 STUDY OF COMPUTER NUMERICALLY CONTROLLED PIPE BENDING MACHINE 1K. Lakshmi kanth, 2P. Praveen Kumar Reddy 1Student, Dept. of Mechanical, Siddhartha Institute of Engineering and Technology, TELANGANA, INDIA. 2Assistant Professor, Dept. of Mechanical, Siddhartha Institute of Engineering and Technology, TELANGANA, INDIA .Abstract - The first CNC pipe bending machine was divided into CNC pipe bending machines, hydraulic pipe bending machines. Mainly used for electric power invented in 1979. The pipe bending machine construction, public railway construction, boilers, comprises a bending template for bending the pipe bridges, ships, furniture, decoration and other aspects there around. The unbent pipe portion is supported of pipeline laying and repair. CNC bending machines on a pipe supporting rail carrier and being adjustable are developed for high flexibility and low setup times. in height. The height adjustment of the pipe Those machines are able to bend single pieces as well supporting rail is performed by a drive means, suited as small batches with the same precision and efficiency for step less positioning, which sets the pipe as series-produced parts in an economical way. A two- supporting rail to a height predetermined by the CNC plane bend or compound bend is defined as a control unit. Prior to the bending of the pipe, the compound bend that has a bend in the plan view and a height to which the pipe supporting rail is to be bend in the elevation. When calculating a two-plane moved is determined by the working program in bend, one must know the bend angle and rotation dependents on set of tool data which has been input (dihedral angle) into the control unit. The purpose of CNC bending machine is to bend the material in angular, circular 2. LITERATURE REVIEW: directions. All slides guided on linear guide ways. Perishable and non-perishable tooling components: Rapid flow has designed and manufactured the Tube bending components consist of both perishable highest quality machines for tube industry. As a components (those you will eventually have to result, pipe can be bended in any format. replace) and non-perishable components (those you won’t have to replace). 1. INTRODUCTION The first CNC pipe bending machine is made in turkey. The two big pieces of perishable tooling are the wipers At the beginning, the hardness of the operation of and the mandrel (Shank, body, nose, and ball mandrels metal for manufacturing furniture’s generated to all included). The non-perishable components include: motive findings an easier way for bending the pipe. CNC bending machine is a manufacturing process that 1. Bend Dies carried out by CNC press brakes. These machines can 2. Clamp Dies bend sheet metal work from just a few mm across to 3. Pressure Dies sections. Its purpose is to assemble a bend on a work 4. Collet Pads piece. A bend is manufactured by using a bending tool 5. Wiper Holders during a linear or rotating move. NC bending machines 6. Wiper Posts are developed for high flexibility and low setup times . Those machines are able to bend single pieces as well as small batches with the same precision and efficiency as series-produced parts in an economical way. Bending is defined as the straining of metal around a straight axis. The metal on the inside of neutral axis is compressed. The metal on the outside of neutral axis is stretched. Pipe bending machines can be roughly ISBN: 978-93-5620-351-8 95 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 7. Clamp Bolster Tube and pipe bending machines are used to bend 8. Clamp Adjuster tubes and pipes to produce finished parts. Tubes are 9. Bend Die Base (Boss) structural, hollow conduits that are used as flow lines 10. Bend Post (Tool Post) for fluids and gases in pneumatic, hydraulic, medical, and process applications. Tubes are measured by their The Bend, Clamp, and Pressure Dies: outer diameter and are usually smaller and less rigid than pipes. Pipes are vessels that are used in transport The first component to consider is the bend die. A bend systems for fluids and solids. They generally have a die is used to form the tube and determines the radius larger diameter and are measured by their inside of the bend. There are a number of standard die diameter regardless of the wall thickness. Pipe and configurations, as well as pedestal and flange mount tube bending and fabrication equipment is used to bend dies. The application requirements will perform operations such as bending, swaging, flaring determine which style of bend die is appropriate, but and beading. pedestal and flange mount bend dies are used in situations where the height is larger than the width and Types of bending machines: for situations where there is not enough material left There are many different types of tube and pipe for a post through the hole. bending machines. The Wiper Die: The wiper die supports the tube on Computer Numerical Controlled (CNC) benders the inside of the bend to prevent wrinkles. Steel wiper produce tight-radius bends, large-radius bends, and dies are used for bending steel copper, aluminum, and elliptical bends - all on the same part. They are bronze tubing. sophisticated machines that guarantee a high level of productivity and reproducibility. CNC benders are Mandrels used for creating complex tubular parts because they The mandrel is the component that supports the inside can manipulate the tube automatically and position it of the tube, which prevents collapse and wrinkling with precision. They consist of three axels and a during bending. Steel/chrome mandrels are used for servomotor driven carriage, which automatically bending steel, copper, aluminum, and bronze tubing. positions the distance between the bends and its plane. While Aluminum/bronze mandrels are used for CNC benders do not include hydraulic or pneumatic bending stainless, titanium, and in conel tubing. In features, leading to greater repeatability and operation. addition to standard pitch mandrels, close pitch These machines are useful in several industries mandrels can be used for thin wall tubing and tight including automotive, HVAC, ship building and radius bends. railways. There are Types of CNC axle bending machines: Fig. CNC bending machine Fig. Axle bending machine Tube and pipe bending machines: 96 ISBN: 978-93-5620-351-8 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Vector bend tube bending machines come in various Fig. Ram bending models and are designed for automated tube production. They come in various sizes, axis speeds, Heat bending equipment places an induction coil and controllability for acceleration and deceleration. around the tube or pipe and applies a bending force as The high-tech models don't use chains. These the object passes through the heated coil. machines can be used for high strength aircraft tubing Sand packing or hot-slab bending machines fill a and automotive exhaust tube applications. pipe with sand, cap the ends, and apply heat. The pipe Vector bend electric tube bending machines are the is bent around pins using mechanical force. This most advanced, and deliver a high level of process minimizes distortion in the pipe cross section. productivity, quality, and reliability. Electric operation Mandrel benders or rotary-draw benders insert a of the machines saves more energy than conventional mandrel, a stationary counter-bender die, into a pipe or hydraulically operated tube bending machines. These tube during bending so that the shape and diameter is machines are able to reverse the bend head rotation, maintained and the bends are not deformed. The giving the operators flexibility during complex mandrel supports the pipe internally and ensures that bending applications. These machines come with an the interior curvature of the pipe is the best possible advanced touch screen user interface for programing bend and is not deformed. This is the most common and monitoring productivity. bending process. Mandrel bending maintains a good Orbital head bending machines offer significant finish and is best used for handrail, ornamental iron flexibility and can be utilized for complex CNC tube work, exhaust pipes, roll cages and all stainless and bending. These machines effortlessly produce tubular aluminum tubing parts with coils, fittings, and hoses, and can also be easily integrated with automatic loading and offloading equipment. They are used with computer controls on a high resolution touch screen. The advanced features of these machines help to rotate the head and collets simultaneously around the parts, which reduces cycle times and guarantees optimal throughput. The machines are an ideal solution for air conditioning, automotive, truck, and other complex applications. Ram bending and pressure bending machines place a tube or pipe in a die. The tube or pipe is held at two ends and the ram advances on the central axis to bend the pipe. The pipe or tube is deformed inside and outside of the curvature. Depending on the thickness of the pipe or tube material, this process will deform the tube or pipe into an oval shape. This is the easiest and least expensive bending process. Ram bending is best used for electrical conduit and similar light gauge product. ISBN: 978-93-5620-351-8 fig. Mandrel bender 97 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Capabilities: Additional capabilities for tube bending effectiveness and machining or laser operations are machines can include a variety of best for tubular, intricate designs. processes.Annealing and heat treating is the process Notching is a technique which combines a punch press whereby a metal is heated to a specific temperature and with a specialized punch die to reshape the end of the then allowed to cool slowly. Annealing allows the tube. Notching allows for assembly of tubes with a metal to be cut and shaped more easily. tube connector or welder. Buffing and polishing makes a rough surface smooth. Buffing can be done in a cutting motion, which gives a smooth, semi-bright and uniform surface by moving the workpiece against the direction of the wheel with medium to hard pressure or with a color motion to give a bright, shiny, and clean surface by moving the workpiece toward the direction of the wheel with medium to light pressure. Fig .Side notching Dimple hole punching can either be single or double- dimple. The double-dimple style uses two individual punches that travel towards each other during the press cycle. The style punches without a support so they create a dimple. Single hole punches have a punch that ravels from one side through the tube. Support is provided at the bottom of the tube to ensure the second hole is \"clean\" and non-dimpled.. Mandrel hole punching uses an internal support so the outside diameter is not changed when creating a hole. This style is used when the tubes need to fit inside one another because it is more accurate and has tighter tolerances, even though it is more expensive than dimple hole punching. Fig .Two basic buffering motions. End flattening is a punch press operation which produces a flat tube end for tubular assemblies. The specialized die is able to flatten the end of the tube, trim the corners and pierce a hole for fastening the tube . Fig. Dimple hole punching Fig. End flattening Tube and Pipe Characteristics Slotting operations vary by the detail and application The characteristics of the tubes and pipes must be of the slots desired. The process can be done using a considered when selecting a tube and pipe bending punch press, machining, or laser operation. A punch machines. These include tube material and shape, both press is ideal for fabrication due to its cost which can affect the type of equipment required. Material Many bendable tube and pipes are made from materials such as: ISBN: 978-93-5620-351-8 98 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Aluminum Brass plate, when used by wire to the coil is energized, Brass electricity gravitation to the pressing plate is Carbon steel generated, thus realizing the plate and the base plate Stainless steel clamp.Due to the clamping of the electromagnetic Copper force, the pressing plate can be made into various Nickel alloys requirements of the work piece, and the side wall of Polyvinyl chloride (PVC) the work piece processing, the operation is also very Plastics simple. According to the ordinary hydraulic numerical Titanium control bending machines Q235 mold machining sheet Super alloys to do a brief introduction, the first is connected to the power, in the control panel to open the switch, and then Shape start the pump, so that you will hear pump rotation Most tubes and pipes are cylindrical. However, some sound (this time the machine does not operate). processes fabricate products with various cross In 2, stroke adjustment, use must pay attention to sections including: regulating stroke in bending, must be tested before. • Oval The upper die down to the bottom must be guaranteed • Round to have a thickness of the gap. Otherwise to the mold • Square damage to machinery. Adjusting the stroke is a quick • Rectangular electric adjustment. 3, bending notch, in general to choose the thickness of Fig. Tube shapes. 8 times the width of the notch. Such as bending 4mm sheet, needs to choose 32. Operations In 4, after the expected adjustment generally have Some tube and pipe bending machines can perform electric rapid adjustment method and manual additional operations including: adjustment, with shears. 1. Swaging 5, step on the pedal switch start bending, CNC bending 2. Flaring machines die and cutting plate machine, can release, 3. Notching release the foot stops, in step down. Plastic 4. Fixturing CNC bending machines mold, plastic machine, plastic 5. Assembling board numerical control bending machines mold, 6. Beading plastic plate plastic plate bending bending directly, without splicing, not slotted, not by welding rod, its 3. bending machines working: angular appearance without water leakage, it will The numerical control bending machines mold change into a fully automatic welding machine comprises a bracket, working table and a clamping operation, improve quality, improve labor efficiency, reduces labor costs, shorten the production cycle of the product. Full automatic plastic angle machine which belongs to the electric integration of automatic machinery and equipment. According to the plastic plate heating soft melting welding principle and development, it is suitable for all thermoplastic materials corner. Speed, angle processing the surface appearance, high strength. Hydraulic shearing machine is divided again for tilting and gate type tilting activated carbon due to arc motion arc blade, and make it quite difficult, is generally used by blades do pad iron compensation, so the gap is not accurate, cut out of the sheet metal is not very ideal. Because arc movement, the blade also cannot be made into a rectangle, but should be made into an acute angle, so ISBN: 978-93-5620-351-8 99 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 the blade stress situation is not ideal, the blade damage is badly. 4. Conclusion: Pipe bending is processes are used to make component for automobile, aerospace, households, power plant industries etc. Our pipe bending machine is automatic, program based, it is beneficial when compared to other automatic machines so, it can be preferable for large industry holders, where less manual work required. This type of bending machine is more important for small scale work as well as industrial work in less cost and more precision and accuracy of Different type of pipe bending. The machine capacity can be increased according To the need. Manual bending tends to minimize wrinkles and can reduce Spring Buck. By its design that defects can easily overcome. Simpler design not only Reduces the defects but also contributes to fluid pressure test during bending. It should be noted the tendency to wrinkle and the cross section of the tube deformation Are reduced. Thus, this approach can be used for bending a pipe over cnc pipe bending machine along its radius. References: • Final Working of Rolling Pipe Bending Machine ISSN : 2249-5770 • EXPERIMENTAL DESIGN AND FABRICATION OF A PORTABLE HYDRAULIC PIPE BENDING MACHINE ISSN: 2230-9926 • Design of a Hydraulic Pipe Bending Machine FPL−GTR−148 • Design of a Hydraulic Pipe Bending Machine FPL−GTR−148 • Research Paper of Manually Operated Pipe Bending Machine ISSN - 2250- 1991 • Fabrication of zigzag Bending Machine ISSN No 2277 - 8179 • Design And Analysis Of Portable Rolling And Bending Machine Using ISBN: 978-93-5620-351-8 100 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 INVESTIGATION ON PERFORMANCE OF DIESEL ENGINE WITH TYRE PYROLYSIS OIL K.SURESH KUMAR1 Dr.G.VENKATA SUBBAIAH2 1Asst.Professor, Mechanical Engineering, NNRG, Telangana, India 2 Professor, Mechanical Engineering, MVSR, Telangana, India ABSTRACT: Alternative fuels and advanced technology vehicles are seen by proponents as integral to improving urban air quality, decreasing dependence on foreign oil, and reducing emissions of greenhouse gases. However, major barriers — especially economics — currently prevent the widespread use of these fuels and technologies. Because of these barriers, and the potential benefits, there is continued congressional interest in providing incentives and other support for their development and commercialization. To overcome this problem, it is very important to find alternative fuels. Increase in energy demand, stringent emission norms and depletion of oil resources led to finding alternative fuels for internal combustion engines. Many alternative fuels like alcohols, bio-diesel, liquid petroleum gas (LPG), compressed natural gas (CNG), etc have been already commercialized in the transport sector. The main focus of this review is to shed light on the importance of tyre pyrolysis oil as an alternative fuel for diesel engines. In this context, tyre pyrolysis oil has recently been receiving renewed interest. In the present work performance characteristics and emissions are evaluated on single cylinder four stroke diesel engine fuelling with 10%, 20%, 30%, 40%, 50%, 60%, for tyre pyrolysis oil by volume. Due to high viscosity and soot formation, above 60% was not taken tyre pyrolysis oil- diesel blend. Experiments are carried out on a diesel engine, which is a single cylinder four stroke engine capable of developing a power output of 7.5KW at 1500 rpm. Performance parameters such as Brake Power, Specific Fuel Consumption, Indicated Thermal Efficiency, Brake Thermal Efficiency, Volumetric Efficiency, Mechanical Efficiency, Brake Mean Effective Pressure and Indicated Mean Effective Pressure are calculated based on the experimental analysis of the engine. Emissions such as Carbon Monoxide, Hydro Carbons are measured. KEYWORDS: Emissions, trans-esterification, Internal combustion engine, Tyre pyrolysis oil and Efficiency 1.Introduction Compression ignition engines are employed particularly in the field of heavy transportation and agriculture on account of their higher thermal efficiency and durability. However, diesel engines are the major contributors of oxides of nitrogen and particulate emissions. Hence more stringent norms are imposed on exhaust emissions. Following the global energy crisis in the 1970s and the increasingly stringent emission norms, the search for alternative renewable fuels has intensified. Fast depletion of fossil fuels demands an urgent need to carry out research work to find out the viable alternative fuels; and since atmospheric pollutants are increasing, an eco friendly fuel needs to be developed to meet the fossil fuel depletion. Thus a lot of research has been done to recover energy from waste materials, including materials that are not bio-degradable. Such materials include biomass, municipal solid wastes, industrial wastes, agri- cultural wastes and other low grade fuels, as well as high energy density materials such as rubber and plastics. The tyre and tube wastes pose big environmental problem because rubber is an artificial polymer and also not biodegradable. The photo- degradation of rubber waste takes more time as compared to biomass. 2.LITERATURE SURVEY The gradual depletion of world petroleum reserves, increases in prices of petroleum based fuels and environmental pollution due to exhaust emissions have encouraged studies to search for alternative fuels. In view of these, vegetable oil has been considered as alternative fuels for compression ignition engines. Vegetable oils are renewable, nontoxic, biodegradable, and have low emission profiles. However, there are some drawbacks related to the use of straight vegetable oils in diesel engines primarily due to their high viscosity, lower volatility and lower heat content. The high viscosity causes some problems in atomization of injector systems and combustion in cylinders of diesel engines. Also, in long term operations, high viscosity of vegetable oils may lead to ring sticking, formation of injector deposits, development of gumming, as well as incompatibility with lubricating oils.Different techniques have been developed to solve their high viscosity and low volatility problems of vegetable oils, such as preheating oils, blending or dilution with other fuels, Trans-Esterification and thermal cracking/pyrolysis [1, 2, 10–12]. Trans-Esterification appears to be the most promising technique which is a chemical process of converting vegetable oil into biodiesel fuel. Biodiesel can be used as a blend in diesel engines without modification. Detailed reviews about trans-Esterification process are available in the literature . The price of edible vegetable oils is higher than that of the diesel fuel. Therefore, instead of using such oils, the use of waste vegetable oils and non-edible crude vegetable oils has been considered as potential alternative fuels. ISBN: 978-93-5620-351-8 101 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Research on the pyrolysis mechanism is very important for reactor design and desired product profiles. When tyre particles ar e heated in a pyrolysis reactor, pyrolysis occurs when the par- ticles' surface reaches a certain temperature [7]. There are two stages in pyrolysis: primary pyrolysis and secondary cracking. Vapour or volatile products are first produced from the waste tyres and are made up of a wide variety of hydrocarbons, that can then encounter secondary reactions. For the thermal decomposition of organic polymers, four general mechanisms can be identified:(i) random chain scission; (ii) end chain scission; (iii) chain stripping; and (iv) cross-linking [8].Wey et al. showed that pyrolysis is governed by the following parameters: (i) temperature, (ii) retention time of the volatile at the reaction zone, (iii) pressure and (iv) type of gaseous atmo- sphere. Cracking occurs at higher temperatures and enables pri- mary products to be converted into compounds which may have a higher market value. One method is the aromatization of products generated by primary pyrolysis. Pyrolysis produces maximum yields of aromatic components at temperatures between 700 °C and 800 °C. Fuel oil was produced without much gas at low tem- perature (below 500 °C) and the char fraction was found to decrease as temperature increased from 300 to 720 °C [9].Cui et al. found that the pyrolysis kinetics of the scrap tyre rubbers can be well represented by the first-order irreversible decomposition reactions of its components [10]. Fig. 1(a) and(b) gives some typical curves of derivative thermogravimetry (DTG) and thermogravimetric analysis (TGA) which were found to provide valuable information on pyrolysis kinetics and mechan- isms of scrap tyre rubbers [11]. Heating at a rate of 10 °C/min in nitrogen, the peak at the lower temperature is caused by the decomposition of natural rubber, and that at the higher tem- perature is caused by the decomposition of butadiene rubber (for a trunk tyres) [12]. Reactor Experimental conditions Maximum oil yield References Temperature (°C) Oil (wt%) Char (wt%) Gas (wt%) Fixed, batch 300–700 °C temperature; 15 °C min— 1 heating rate; 700 38.5 43.7 17.8 [37] 175 g tyre 450 ~7 Closed batch reactor 350–450 °C temperature; 30 °C min— 1 heating rate; ~ 63 ~ 30 [37] 20 g tyre 55 36 9 [37] Fixed bed, batch, internal fire 14.8 [21] tubes 375–575 °C; 750 g tyre 475 11.86 [14] 23.9 [49] Fixed bed, batch 300–720 °C temperature; 5 °C–8 °C min—1 heating 720 58.8 26.4 rate; 50 g tyre Fixed bed, batch 400–700 °C temperature 500 40.2 47.88 Fixed bed, batch 950 6 40.7 950 °C temperature (max); ~ 2 °C min— 1 heating 20.9 Fixed bed, batch 500–100 °C temperature; 1200 min— 1 heating rate 500 58.0 37.0 5.0 [41] Fixed bed, batch 375–500 °C temperature; 10 °C min—1 heating rate; 425 60.0 ~30 ~ 10 [18] 10 g tyre Fixed bed, batch 450–600 °C temperature; 5 °C min—1 heating rate; 475 58.2 37.3 4.5 [34] Moving screw bed 3 kg tyre 600 48.4 39.9 11.7 [22] Fluidised bed 600–800 °C temperature; 3.5–8.0 kg h— 1 mass flow 700 26.8 35.8 19 [25] rate Fluidised bed 700 °C temperature; 200 kg h—1 throughput; whole 450 55.0 42.5 2.5 [21] tyres 450–600 °C temperature; ~ 220 g h—1 throughput; Fluidised bed 740 °C temperature; 1 kg h—1 throughput; tyre 740 30.2 48.5 20.9 [25] powder Fixed, wire mesh, fast reactor 390–890 °C temperature; 70–90 °C S—1 heating 860 ~ 5 ~ 22 ~ 73 [30] rate; 0.2 g Vacuum 550 47.1 36.9 16 [28] Vacuum 450–600 °C temperature; batch (100 g) 500 56.5 33.4 10.1 [28] Drop tube reactor 500 °C temperature: pilot scale semi continous 450 37.8 35.3 26.9 [29] Rotary kiln 450–1000 °C temperature; 30 g h—1 throughput 550 49.09 [23] Rotary kiln 550–680 °C temperature; 4.8 kg h— 1 throughput 500 38.1 2.39 [23] Circulating fluidized bed 450 2 41.3 13.6 [26] Conical spouted bed 450–650 °C temperature; 12–15 kg h—1 throughput 500 45.1 ~28 ~15 [24] 360–810 °C temperature; 5 kg h—1 throughput ~35 ~3 425 & 500 °C ~52 ~62 In the present investigation, , Tyre pyrolysis oil was considered as a potential alternative fuel for compression ignition engines. Specifications of the , Tyre pyrolysis oil investigated and compared with other vegetable oils and this was the basic motivation behind the research in this project. The engine tests were carried out on a direct injection diesel engine fuelled with diesel fuel and10%, 20%, 30%, 40%, 50% and 60% , Tyre pyrolysis oil -diesel blends by volume. ISBN: 978-93-5620-351-8 102 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 3. Analysis of Tyre Pyrolysis Oil The Fourier Transform Infrared Spectroscopy (FTIR) offers a quantitative and qualitative analysis for organic and inorganic samples. The spectra produce a profile of the sample a distinctive molecular fingerprint that can be used to screen and scan samples for many different components. It identifies chemical bonds in amolecule by producing an infrared absorption spectrum. The FTIR is an effective analytical instrument for detecting functional groups and characterizing covalent bonding formation. The FTIR test was carried out with Perkin Elmer Spectrum ONE equipment which has a scan range of 450-4000 cm-1with a resolution of 1.0 cm-1. The FTIR analysis of TPO revels that, the functional group present are almost aromatics and hydrocarbons. TABLE NO 1.1 Properties of Tyre pyrolysis oil DIESEL Tyre pyrolysis oil PROPERTIES 2.68 9 823 907 Kinematic viscosity at 40 0C (cSt) 56 40 Density at 15 0C (kg/m3) 10000 10,200 Flash point (0C) GROSS CALORIFIC VALUE ( kcal/kg) 4.SPECIFICATION OF THE PROBLEM In the present work the performance characteristics and emissions are evaluated on single cylinder four stroke diesel engine air cooled, which is capable of developing a power output of 7.5kW at 1500rpm, fuelling with 10%, 20%, 30%, 40%, 50%, 60%, for Tyre Pyrolysis Oil by volume. Due to high viscosity and soot formation, above 60% was not taken in Tyre Pyrolysis Oil- diesel blend. The Performance parameters such as Brake Power, Specific Fuel Consumption, Indicated Thermal Efficiency, Brake Thermal Efficiency, Volumetric Efficiency, Mechanical Efficiency, Brake Mean Effective Pressure, Indicated Mean Effective Pressure are calculated based on the experimental analysis of the engine. Emissions such as Carbon Monoxide, Hydro Carbons are measured. 5.EXPERIMENTAL SETUP The experimental setup is fabricated to fulfill the objective of the present work. The various components of the experimental set up including modification are shown in fig no.1. Various Parts of Experimental Setup 1. Alamgair Engine 2 Alternator 3. Diesel Tank 4. Air Filter 5. Three Way Valve 6. Exhaust Pipe 7. Probe ISBN: 978-93-5620-351-8 103 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 8. Exhaust Gas Analyser 9. Alternative Fuel Tank 10. Burette 11. Three Way Valve 12. Control Panel a. EXPERIMENTAL PROCEDURE Before starting the engine, the lubricating oil level in the engine is checked and it is also ensured that all moving and rotating parts are lubricated. The various steps involved in the setting of the experiments are 1. The Experiments were carried out after installation of the engine 2. The injection pressure is set at 200 bar for the entire test. 3. Precautions were taken, before starting the experiment. 4. Always the engine was started with no load condition 5. The engine was started at no load condition and allowed to work for at least 10 minutes to stabilize. 6. The readings such as fuel consumption, spring balance reading, cooling water flow rate, manometer reading etc., were taken as per the observation table. 7. The load on the engine was increased by 20% of FULL Load using the engine controls and the readings were taken as shown in the table. 8. Step 3 was repeated for different loads from no load to full load. 9. After completion of test, the load on the engine was completely relieved and then the engine was stopped. 10. The results were calculated theoretically and tabulated. The above experiment is repeated for various loads on the engine. The experimental procedure is similar as foresaid. While starting the engine, the fuel tank is filled in required fuel proportions up to its capacity. The engine is allowed to run for 20 min, for steady state conditions, before load is performed. There was no separation of diesel and Tyre Pyrolysis Oil blends even at B50 and B60. f diesel. Finally, the engine is run by blend (200 atm) at various loads and the corresponding observations are noted. The test is carried on the single cylinder CI Engine for the following fuel blends: 1. 100% Diesel 2. 10% Tyre Pyrolysis Oil + 90% Diesel 3. 20% Tyre Pyrolysis Oil + 80% Diesel 4. 30% Tyre Pyrolysis Oil + 70% Diesel 5. 40% Tyre Pyrolysis Oil + 60% Diesel 6. 50% Tyre Pyrolysis Oil + 50% Diesel 7. 60% Tyre Pyrolysis Oil + 40% Diesel 6.RESULTS AND DISCUSSIONS Experiments were conducted when the engine was fuelled with Tyre Pyrolysis Oil and their blends with diesel in proportions of 20:80, 30:70 and 40:60 (by volume) which are generally called as TPO-20, TPO-30 and TPO-40 respectively. The experiment covered a range of loads. The performance of the engine was evaluated in terms of brake specific fuel consumption, brake thermal efficiency and volumetric efficiency. The emission characteristics of the engine were studied in terms, concentration of HC and CO. The results obtained for Tyre Pyrolysis Oil and their blends with diesel were compared with the results of diesel. TABLE NO 1.2 Performance And Emission Test Results At Pure Diesel Load Speed Time B.P TFC I.P F.P Heat BSFC ηbth ηith ηmech ηvol BMEP IMEP CO HC Input S.N0 kg/s Kg/ kW W Rpm Sec kW *10- kW kW kW h % % % % kN/m2 kN/m2 %vol ppm 4 1 1000 775 8.41 1.28 2.04 2.36 1.27 8.98 0.61 14.63 28.72 51.19 50.90 209.51 414.83 0.109 0 2 2000 734 6.13 2.22 2.84 3.47 1.27 12.36 0.49 18.59 28.06 62.29 54.12 371.17 588.98 0.222 2 3 3000 725 4.33 3.10 4.02 4.33 1.27 17.29 0.47 18.03 25.06 70.69 56.54 528.25 752.56 0.334 6 4 4000 709 3.98 3.89 4.28 4.99 1.27 18.36 0.43 20.01 27.15 75.69 61.14 669.69 895.18 0.096 1 5 5000 705 3.34 4.18 5.31 5.29 1.27 22.77 0.45 18.19 24.07 76.43 63.87 742.12 969.91 0.033 0 ISBN: 978-93-5620-351-8 104 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 TABLE NO 1.3 Performance And Emission Test Results At TPO 10% ηbth ηith ηmech ηvol BMEP IMEP CO HC Heat % %% kN/m2 kN/m2 %vol ppm Load Speed Time B.P TFC I.P F.P Input BSFC 32.42 65 51.97 213.33 302.02 0.171 0 S.N0 kg/s Kg/ kW W Rpm Sec kW *10- kW kW kW h % 4 1 1000 727 8.18 1.14 1.71 1.52 1.05 6.088 0.51 23.37 2 2000 711 6.46 2.03 2.36 2.51 1.05 12.37 0.43 19.21 21.63 79 53.34 363.43 471.44 0.162 0 3 3000 700 5.15 2.82 3.02 3.40 1.05 13.96 0.39 20.92 23.87 81 55.82 521.66 629.82 0.146 0 4 4000 690 4.51 3.37 4.38 4.027 1.05 17.84 0.43 20.07 22.33 83 57.39 647.66 716.09 0.129 0 5 5000 681 3.91 4.28 4.86 4.518 1.05 21.63 0.45 19.35 20.98 88 60.32 753.26 836.47 0.109 0 TABLE NO 1.4 Performance And Emission Test Results At TPO 20% Heat S.N0 Load Speed Time B.P TFC I.P F.P Input BSFC ηbth ηith ηmech ηvol BMEP IMEP CO HC % %% kN/m2 kN/m2 %vol ppm W Rpm Sec kW kg/s kW kW kW Kg/ kW % 21.67 69 53.76 209.58 289.70 0.001 0 *10-4 h 1 1000 735 8.9 1.24 1.88 1.74 1.05 7.79 0.51 15.32 2 2000 724 6.38 2.07 2.63 2.57 1.05 11.08 0.46 18.31 22.88 78 58.39 356.96 439.39 0.003 0 3 3000 712 4.70 2.85 3.61 3.35 1.05 15.14 0.42 18.41 21.73 81 61.19 501.75 585.66 0.005 0 4 4000 699 4.24 3.71 4 4.21 1.05 16.90 0.36 21.71 24.56 85 64.21 661.95 752.50 0.007 0 5 5000 684 3.31. 4.08 5.11 4.58 1.05 21.52 0.44 18.65 20.98 88 60.48 745.16 837.70 0.006 0 TABLE NO 1.5 Performance And Emission Test Results At TPO 30% Load Speed Time B.P TFC I.P F.P Heat BSFC ηbth ηith ηmech ηvol BMEP IMEP CO HC S.N0 Input % %% kN/m2 kN/m2 %vol ppm 23.64 41 47.96 207.70 414.30 0.002 1 W Rpm Sec kW kg/s kW kW kW Kg/ kW % *10-4 h 1 1000 721 6.93 1.01 2.181 2.26 1.15 9.88 0.68 12.12 2 2000 710 6.30 1.91 2.411 3.12 1.15 10.93 0.41 17.75 29.07 58 52.65 361.97 573.76 0.003 2 3 3000 697 4.73 2.65 3.24 4.01 1.15 14.34 0.36 18.76 27.98 63 53.93 509.34 724.97 0.008 3 4 4000 680 3.87 3.40 3.96 4.65 1.15 17.41 0.35 20.34 26.34 71 55.74 658.52 879.97 0.006 2 5 5000 669 3.49 4.10 4.63 5.35 1.15 21.42 0.30 20.15 26.10 75 61.09 799.11 1017.88 0.009 4 TABLE NO 1.6 Performance And Emission Test Results At TPO 40% Load Speed Time B.P TFC I.P F.P Heat BSFC ηbth ηith ηmech ηvol BMEP IMEP CO HC S.N0 Input % %% kN/m2 kN/m2 %vol ppm W Rpm Sec kW kg/s kW kW kW Kg/ kW % 24.92 51 55.86 201.57 372.19 0.001 0 *10-4 h 28.67 59 59.03 354.19 562.30 0.004 0 27.32 65 61.5 470 682.95 0.002 0 1 1000 732 7.09 1.14 2.03 2.14 1 8.75 0.52 13.65 29.39 71 66.7 654.5 870.12 0.034 0 26.55 76 57.3 778.36 1001.91 0.017 0 2 2000 720 6.14 2.01 2.62 3.20 1 11.23 0.41 18.17 3 3000 708 4.84 2.37 3.31 3.93 1 14.13 0.39 19.15 4 4000 697 4.72 3.56 4.02 4.76 1 15.99 0.33 22.76 5 5000 689 3.17 4.21 4.75 5.42 1 19.76 0.31 21.36 ISBN: 978-93-5620-351-8 105 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 TABLE NO 1.7 Performance And Emission Test Results At TPO 50% S.N0 Load Speed Time B.P TFC I.P F.P Heat BSFC ηbth ηith ηmec ηvol BMEP IMEP CO HC Input h W Rpm Sec kW kg/s kW kW kW Kg/ % % % % kN/m2 kN/m2 %vol ppm *10-4 kW h 1 1000 720 8.30 1.11 1.99 2.31 1 8.16 0.51 13.47 27.82 47 51.68 207.84 409.95 0.0019 0 2 2000 709 6.10 2.02 2.52 3.12 1 11.26 0.44 16.66 28.22 60 54.21 371.85 577.03 0.003 0 3 3000 686 5.56 2.75 2.96 4.05 1 12.34 0.34 20.72 31.29 67 56.94 507.92 714.57 0.003 1 4 4000 679 4.35 3.31 3.52 4.65 1 15.44 0.36 22.38 29.30 71 60.20 648.61 833.04 0.004 0 5 5000 666 3.67 4.20 4.15 5.40 1 18.71 0.34 22.99 27.23 75 62.64 802.30 1019.27 0.007 0 TABLE NO 1.8 Performance And Emission Test Results At TPO 60% Load Speed Time B.P TFC I.P F.P Heat BSFC ηbth ηith ηmechηvol BMEP IMEP CO HC S.N0 Input kN/m2 %vol ppm W Rpm Sec kW kg/s kW kW kW Kg/ % % % % kN/m2 466.44 0.001 0 *10-4 kW h 614.18 0.002 0 765.33 0.003 3 1 1000 725 8.32 1.13 1.87 1.73 1.25 8.08 0.51 14.83 32.37 41 55.39 203.19 2 2000 708 6.4 1.91 2.36 2.54 1.25 10.95 0.44 17.16 31.03 52 56.33 349.69 3 3000 710 4.99 2.56 3.17 3.35 1.25 13.32 0.39 20.02 30.93 59 60.75 498.18 4 4000 687 4.31 3.26 3.55 4.19 1.25 15.28 0.35 23.28 32.31 69 61.47 660.23 932.16 0.002 0 5 5000 681 3.66 4.19 4.17 4.8 1.25 17.55 0.31 23.12 31.67 68 63.63 757.81 1032.76 0.001 0 FRICTION POWER LOAD VS MECHANICAL EFFICIENCY Diesel TPO 10 TPO 20 TPO 30 TPO 40 TPO 50 TPO 60 DIESEL TPO 10 TPO 20 TPO 30 6 TPO 40 TPO 50 TPO 60 5 4 100 3 TFC KG/S 2 80 1 0 60 1000 40 20 2000 3000 4000 5000 LOAD KW 0 2000 3000 4000 5000 1000 LOAD VS BMEP LOAD VS BRAKE EFFICIENCY Diesel TPO 10 TPO 20 TPO 30 DIESEL TPO 10 TPO 20 TPO 40 TPO 50 TPO 60 TPO 30 TPO 40 TPO 50 TPO 60 1000 25 800 600 20 400 200 15 0 10 5 1000 2000 3000 4000 5000 0 2000 3000 4000 5000 1000 ISBN: 978-93-5620-351-8 106 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 LOAD VS BSFC LOAD VS INDICATED THERMAL EFFICIENCY DIESEL TPO 10 TPO 20 TPO 30 TPO 40 TPO 50 TPO 60 DIESEL TPO 10 TPO 20 TPO 30 0.8 TPO 40 TPO 50 TPO 60 0.7 0.6 2000 3000 4000 5000 35 2000 3000 4000 5000 0.5 30 0.4 25 0.3 20 0.2 15 0.1 10 0 5 1000 0 1000 LOAD VS IMEP LOAD VS VOLUMETRIC EFFICIENCY DIESEL TPO 10 TPO 20 TPO 30 DIESEL TPO 10 TPO 20 TPO 30 TPO 40 TPO 50 TPO 60 TPO 40 TPO 50 TPO 60 1200 80 1000 70 60 800 50 600 40 400 30 200 20 10 0 0 1000 2000 3000 4000 5000 1000 2000 3000 4000 5000 ISBN: 978-93-5620-351-8 107 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 LOAD VS HC LOAD VS CO DIESEL TPO 10 TPO 20 TPO 30 DIESEL TPO 10 TPO 20 TPO 30 TPO 40 TPO 50 TPO 60 TPO 40 TPO 50 TPO 60 7 0.4 6 0.35 5 0.3 4 0.25 0.2 3 0.15 2 0.1 1 0.05 0 2000 3000 4000 5000 0 2000 3000 4000 5000 1000 1000 • In friction power all blends of tyre pyrolysis oil and diesel performs almost same but with small difference diesel tops the list. • In mechanical efficiency the blends of tyre pyrolysis oil 10 and 20 performs best when compared with all other blends and diesel. • In case BMEP all blends of tyre pyrolysis oil including diesel the performance is almost equal. • From part load 1000 to 3000 tyre pyrolysis oil 10 performs best and at part load 5000 tyre pyrolysis oil 50 serves the best. • At an average the diesel performs best in BSFC but at higher loads tyre pyrolysis oil 10 gives the best. • In indicated thermal efficiency the tyre pyrolysis oil 60 performs the best at all parts load.Even tyre pyrolysis oil 50, 40 and 30 performs better than diesel. • In IMEP expect the blends of tyre pyrolysis oil 10 and 20, all others blends performs better than diesel and tyre pyrolysis oil 60 tops the list. • In volumetric efficiency all blends of tyre pyrolysis oil along diesel performes equally and tyre pyrolysis oil 40 performes best in all till part load 4000. • In emission of pollutants such as CO and HC all blends of tyre pyrolysis oil are very less when compared to diesl in some part loads the emission are zero when tyre pyrolysis oil is used. 7.CONCLUSIONS The conclusions are made from the results obtained in the experiment conducted using diesel engine in which Tyre pyrolysis oil is used as fiel.From the above analysis tyre pyrolysis oil is best substitute for diesel in all formats since performance is almost same in all part loads..Mainly in the case emissions tyre pyrolysis oil is best when compared with diesel.From all the above results tyre pyrolysis oil 60 has best charactersitics it better for the usage as fuel. 8.REFRENCES [1] Murugesan A, Umarani C, Subramanian R, Nedunchezhian N. Bio-diesel as an alternative fuel for diesel engines – a review. Renew Sustain Energy Rev 2009;13:653–62. [2] Wang H, Xu H, Xuan X. Review of waste tire reuse and recycling in china – [3] current situation problems and countermeasure. Nat Sci 2009;2(1). [4] Jang JW, Yoo TS, Oh JH, Iwasakai I. Discarded tyre recycling practices in the United States,Japan and Korea. Resour Conserv Recycl 1998;22:1–14. [5] Harshaft A. Solid waste treatment technology. Environ Sci Technol 1972;6:412–21. [6] Antoniou N, Zabaniotou A. Features of an efficient and environmentally attractive used tyres pyrolysis with energy and material recovery. Renew Sustain Energy Rev 2012:539–58. [7] Lanoir D, Trouve G, Delfosse L. Physical and chemical characterization of automotive shredder residues. Waste Manag 1997;17:1475–82. [8] Yongrong Yang, Jizhong Chen, Guibin Zhao, Technical advance on the pyrolysis of used tires in China. In: Proceedings of the China-Japan International Aca- demic Symposium, 6; 2000. [9] Senneca O, Salatino P, Chirone R. Fast heating-rate thermogravimetric study of the pyrolysis of scrap tyres. Fuel 1999;78:1575–81. [10] Wey MY, et al. Low energy and chemical free activation of pyrolytic tire. J Air Waste Manag 1995;45:855–63. [11] Cui H, et al. Biocrude Production through Pyrolysis of Used Tyres. Chem Ind Eng (China) 1999;50:826–33. [12] Williams PT, Besler S. Pyrolysis-thermogravimetric analysis of tyres and tyre components. Fuel 1995;14:1277–83. [13] Lopez Felix A, El Hadad Amir A, Alguacil Francisco J, Centeno Teresa A, Lobato Belen. Kinetica of the thermal degradation of granulated scrap tyres: a model- free analysis. Mater Sci 2010;9. [14] Williams PT. Pyrolysis of waste tyres: a review. Waste Manag 2013;33:1714– [15] 28. [16] Aydın H, Ilkılıc C. Optimization of fuel production from waste vehicle tires by pyrolysis and resembling to diesel fuel by various desulfurization methods. Fuel 2012;102:605–12. ISBN: 978-93-5620-351-8 108 Department of Mechanical Engineering, NNRG.

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Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 FABRICATION, TESTING AND CALIBRATION OF TWO DIRECTIONAL FORCE SENSOR G Kiran Kumar1, Y. Narsa Reddy2, 1,2Assitant Professor, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. Abstract— Force and Torque sensors are important in robotic groove making is needed for increasing the sensitivity. Forces are measured in terms of milli volt by using Digital volt meter. industries for various applications including assembling parts, II. TWO DIRECTIONAL FORCE SENSOR DESIGN REQUIREMENTS. accepting and rejecting the objects etc. Force and Torque measurement has become popular area of research has A force sensor measures two components of the force demanded by the respective applications. Considerable work along X and Y axis. A force sensor design depends on the task has been done on the Force and Torque measurement using it is intended for. In this case, the objective of the design is to different techniques like strain gauges and piezoelectric develop a Two Directional Force Sensor, which is capable of sensors mounted on flexible members. For specific sensing force. The design also uses bending elastic elements applications physical models have been proposed with to measure small forces and strain gauges to convert characterization for the Forces and the Torque. This thesis mechanical strain to electrical signals. describes development of Two Directional Force Sensor for force measuring along X and Y axis simultaneously using A complete design of a force sensor for two strain gauges. Mechanical structure for the Force sensor has directional force sensor structure requires many stages, which been developed which contains sensing element mounted near begins with the selection of material that is best suited in optimize strain region. The identified parameters are terms of characteristics, feedback, noise and friction. Then, it characterized against the loading forces in X and Y direction. is followed by a proposed design of two directional force Generalized equations are developed for this parameter sensor to obtain maximum information from the object subsequently valuated using soft computing tool i.e., ANSYS without much compromising on other characteristics in order software. Results shows that the sensitivity of device can be to suit many applications. The construction of the force sensor increased by changing physical parameters of sensing element, will be completed by keeping in mind the application that it and so as to apply this device for assembling platform or would be involved and also the way of apply this device for robotic are configurations. assembling platform or robotic are configurations. Prior to the design and development of the electronic and Keywords— Force sensor, Force-sensing element, Foil strain instrumentation circuits to measure 2D forces, the simulations of the beams contribute significantly in identifying the gauge, Wheatstone bridge. placement of the strain gauges I. INTRODUCTION 2.1 Fabrication Materials In many manufacturing applications involving industrial Two materials, namely aluminum, steel was tested. robots, it is extremely important to be able to adjust and /or monitor the Force and Torque being applied to the part. Work The analysis for the selection of materials is based on these has been done on the Force and Torque measurement using different techniques like strain gauges and piezoelectric criteria, which are high stiffness, low friction, noise, immunity sensors mounted on flexible members. From many years strain gauges have been used as the basic sensing element for and less hysteresis It was found that aluminum is malleable vast applications like pressure sensors, load cells, force sensors, torque sensor and position sensors etc. from literature and can have permanent-set if subjected to accidental force. review, forces are measured for particular dimensions of the beam sensing element. Wrist force sensors are developed for Steel obviously offers a high stiffness and can attenuate force- grasping an object with different degrees of freedom. Piezoelectric sensors are used for dynamic measurement. It is signal if applied in shape determination. Aluminum is used for cannot perform static measurements accurately. Work is considered on static so strain gauge sensor is better for fabricating two directional force sensor structures. It is easily measuring Force available and cheap. This thesis describes Two Directional Force sensors with low cost and minimum numbers strain gauge? Forces are 2.2 Strain Gauge measured using strain gauge as a sensing element along X and Y axis. It is avoiding the difficulties in the calibration. Here Strain gauge force sensors have high sensitivity and measurement accuracy requiring relatively simple amplifier circuitries. The specifications of the strain gauge are in Table I. Here, one micro strain is equal to an extension of 0.000 I %. Table 1 Strain gauge specifications Gauge length 2mm Measurable strain 2 to 4% Temperature range -30 to 180°C Gauge resistance 350 ohms Gauge factor 2.00 ISBN: 978-93-5620-351-8 110 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Temperature Coefficient 0.015%/°C 3) Output Voltage of 2-gage System: Fatigue life Foil material 10^6 reversals at 1000 micro strainTwo sides among the four initiate resistance change. Thus, the Base material 2-gage system in the case of Fig.3 provides the following Copper Nickel alloy output voltage: Polyamide 2.3. Wheatstone Bridge: 1)Output Voltage of 4-gage System The 4-gage system has four gages connected one each to all four sides of the bridge. Fig.3 2 Gauge System of Adjacent Connection e =1 (∆R1 − ∆R2). E (5) 4 R1 R2 (6) (or) Fig.1 4-Gauges System e = 1 . K (ε1 − ε2). E 4 When the gages at the four sides have their resistance III. FABRICATION OF FORCE SENSOR STRUCTURE changed to R1 + ΔR1, R2 + ΔR2, R3 + ΔR3 and R4 + ΔR4, In this section, the details of the proposed hardware of the two directional force sensors will he discussed. respectively, the bridge output voltage, e, is: 3.1.A New Mechanical Structure for Force Sensor: e = 1 (∆R1 − ∆R2 + ∆R3 − ∆R4) E (1) A new mechanical structure with two DOF force sensor has been developed. The elastic body of the 4 R1 R2 R3 R4 sensor comprises of 4 I-section beams, 8 side plates and 3 blocks. The side plates are connected to the 3 blocks and I- If the gages at the four sides are equal in specifications section beams are composed of 4 Horizontal beams that are connected from side plates. Aluminum material is used for including the gage factor, K, and receive strains, є1, є2, є3 and Fabricating Two directional force sensor. As shown in fig- 4. є4, respectively, the equation above will be: e = 1 . ������ (������1 − ������2 + ������3 − ������4) ������ (2) 4 2) Output Voltage of 1-gage System: In the cited equation for the 4-gage system, the 1- gage system undergoes resistance change, R1, at one side only. Thus, the output voltage is: e = 1 . ∆R1 . E Fig.2 1-Gauges System Fig.4 Mechanical Structure of Force Sensor (3) 1). Block: 4 R1 Dimensions of block are 126×126×20 as showed in fig 5. (4) (or) 111 e = 1 . K. ε1. E Department of Mechanical Engineering, NNRG. 4 ISBN: 978-93-5620-351-8

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 3.4. Calibration Kit: The calibration kit is specifically designed and fabricated for the purpose of testing and calibration of two directional force sensor. This module consists of pulley holder, base plate, hook and weight holder. The fully assembled calibration kit is shown in Figure 9. Fig 5 Dimensions of Block 2). Side Plate: Dimensions of side plate are 56×26×12 Fig 6 Dimensions of Side Plate Fig 9 Fully Assembled Calibration Kit 3) I-Section Beam: 3.5. Finite Element Analysis Dimensions of I-Section Beam are 130×32×6 Stiffness of the elastic body designed should be Fig 7 Dimensions of I-Section Beam strong enough to take the loads. Forces are applied within the 3.2. Analysis of I-section Beam. elastic limit so that the deformation occurred can be retained back after the removal of force. Finite element modeling is Analysis of simple cantilever beam is required described as the representation of the geometric Model in for pasting the Strain gauge where the maximum strain is terms of a finite number of element and nodes the solution of occurred. Strain is maximum at the place of 38mm distance general problem by finite element method always follows an from fixed end. Strain gauges are pasted at the place of 38mm orderly step-by-step process. Force sensor model and simple distance from both the ends of beam. cantilever beams are made in Pro-e and then import in 3.3. Making Groove Thickness: ANSYS WB with solid bodies and datum lines for the Analysis. Groove is made at the place of 38mm distance from both the ends of I-section beam. It will increase the 3.6. Finite element model of the elastic body sensitivity of the device. Strain gages are pasted on one side of the beam and grooves are made on other side of the beam. The discretization of the domain into sub-regions is Here groove thickness is taken in incremental order with the first of a series of steps that must be performed for FEM. difference of 0.3mm . The subdivision is usually called mesh generation, and a finite number of sub-domains are called elements. The discretization of the body involves the decision as to the element number, size and shape of sub-regions used to model the real body. Fig 8 Grooved Beam Fig. 10Finite Element Model of Force Sensor ISBN: 978-93-5620-351-8 112 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Figure 10 shows a FEM model of the elastic body of the 2 5.1 0.0010652 0.010652 DOF force sensor with 19527 element nodes and 7151 elements after mesh generation and Figure 11 shows a FEM 6.12 0.00127824 0.0127824 model of the Simple cantilever beam with 4891 element nodes and 1048 elements after mesh generation. The material of the 7.14 0.00149128 0.0149128 elastic body is aluminum. 8.16 0.00170432 0.0170432 9.18 0.00191736 0.0191736 10.2 0.0021304 0.021304 IV EXPERIMENTS RESULTS 4.1 Measuring Resistance Connected the terminals of the strain gauge to the digital volt meter and then applied load on the pan by increasing 1kg up to Fx=10.2kg load and note down the Fig. 11Finite Element Model of Simple Cantilever beam variable resistance for each 1kg load from 0kg to 10.2kg and 3.7 Strain analysis under two axis forces. also for Unloading from 10.2kg to 0kg. Then calculated the (1) Boundary conditions equivalent elastic strain from Resistance by using formulae The elastic body is fixed on the shell of the force sensor (∆R/R) =K.ℇ (5.1) through bolts on the base, so the connection between them can be regarded as rigid connection. Therefore, the total degree- 4.2 Measuring output voltage of-freedom of the base of the elastic body can be set as zero. Output voltages are measured by connecting Quarter (2) Applied force/torques Bridge, Half bridge and Full bridge. In Quarter bridge circuit Each single one of the two axis force is applied to the elastic body on the corner of the beam, respectively. When a single one strain gauge is active and three strain gauges are dummy force is applied to the elastic body, the overall deformation of the elastic body is easy to calculate by using the ANSYS (variable resistors are used), in Half bridge circuit two strain software. gauges are active and two strain gauges are dummy (two Strain outputs at the 4 points on the I-section beam, to which the 4 strain gauges are stuck. The strain of the tensile variable resistors).In Full bridge circuit four strain gauges are surface of the beam is defined as positive strain, and the strain of the compressed surface is defined as negative strain. active. After connecting Wheatstone bridge circuit, input The measurement range of the analyzed 2 DOF force sensor is designed as Fx = 10.2 For the convenience of FEM analysis, terminals are connected to constant input voltage circuit board the applied force to elastic body is chosen as the maximum 10.2 N. Results are shown in table 2. and output terminals are connected to digital volt meter as Table 2: 3mm root thickness showed below. Note down the output voltage for each 1kg 3mm root thickness load from 0kg to 10.2kg load and also for unloading from 10k.2g to 0kg. Then calculated the equivalent elastic strain from voltage by using formulae For Quarter Bridge ������������������������ =(K.V.ε)/4 (5.2) For Half Bridge ������������������������ =(K.V.ε)/2 (5.3) For Full Bridge ������������������������=K.V.ԑ (5.4) Where K= Gauge factor V= Constant Input voltage ε= Equivalent Elastic Strain ������������������������ = output Voltage Only 3mm grooved beam is fixed to the force sensor device safe and measuring the voltage. load (kg) Load Volt Strain 1.02 Strain Voltage (V) kg Loading Unloading Loading Unloading 0.00021304 0.0021304 2.04 0.00042608 0.0042608 1 0.001 0.002 1E-4 2.E-04 0.00063912 0.0063912 3.06 0.00085216 0.0085216 2 0.002 0.004 2.E-04 4E-04 3 0.003 0.006 3E-04 6.E-04 4.08 ISBN: 978-93-5620-351-8 113 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 4 0.005 0.007 5.E-04 7E-04 0.025 5 0.006 0.008 6E-04 8E-04 6 0.007 0.01 7.E-04 1E-03 Voltage (V) 0.02 analysis 7 0.009 0.011 9.E-04 1.1E-3 0.015 of 3mm 8 0.01 0.012 1.E-03 1.2E-3 voltage 9 0.012 0.013 1.2E-03 1.3E-3 10 0.014 0.014 1.4E-03 1.4E-3 0.01 0.005 practical of 3mm 0 voltage 0 10 20 values Load (kg) Below graph is drawn for Load Vs voltage and strain. Voltage (V) 0.02 volt 0.015 loading 0.01 Fig.13 calibration of voltage for 3mm root thickness 0.005 volt VI-CONCLUSIONS unloadin 0 g Two directional Force sensors were developed for calculating 0 10 20 sensitivity of the mechanical Force sensor device. Forces are Load (kg) measured in terms of milli volts by using strain gauges. Sensitivity of the device has been found for different grooved Strain Figure 11 Load Vs Voltage strai thickness. Resistances and Voltages are measured by using 2.00E-03 n Digital volt meter Resistance and voltages are measured by load applied load from0kg to 10kg with a difference of 1kg load 1.50E-03 ing REFERENCES 1.00E-03 1.Huai-Ti Lin ,BarryA.Trimmer,\" A new bi-axial cantilever 5.00E-04 beam Design for Biomechanics Force measurements\" Journal of Biomechanics 45 (2012), pp. 2310–2314. 0.00E+00 0 10 20 2. Le Chen, Aiguo Song, \"A Novel Three Degree-of-freedom Load (kg) Force Sensor\"2009 International Conference on Measuring Technology and Mechatronics Automation. Fig. 12 Load Vs Strain Comparison of analysis and practical voltage values graph 3.R. Nagarajan, M. Muralindran\" A Design Methodology of plotted in figure 13. Wrist Force Sensor for a Robot with Insufficient Degree of Freedom”, IEEE conference on robotics and automaton ,2003, pp 578-83. 4. Qiaokang Liang a, DanZhangb, YaonanWanga , \"Development of a touch probe based on five-dimensional force/torque transducer for coordinate measuring machine (CMM)\" , Robotics and Computer-Integrated Manufacturing 28 (2012) 238–244. 5. Aiguo Song, Juan Wu, Gang Qin, Weiyi Huang, \" A novel self-decoupled four degree-of-freedom wrist force/torque sensor\", Measurement, 40 (2007), 883–891. ISBN: 978-93-5620-351-8 114 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 6. BaoyuanWua,, JianfeiLuo , FeiShen b, Yang Ren , ZhongchengWub, \"Optimum design method of multi-axis force sensor integrated in humanoid robot foot system\", Measurement, 44 (2011), 1651–1660. 7. Chao Yuan, Weijun Wang, et.al., \"A Three Degree of Freedom Force/Torque Sensor to Measure Foot Forces\" 2012 12th International Conference on Control, Automation and Systems Oct. 17-21, 2012 in ICC, Jeju Island, Korea. 8. Qiaokang Liang , Dan Zhang,\" Design and fabrication of a six-dimensional wrist force/torque sensor based on E-type membranes compared to cross beams\" Measurement 43 (2010) 1702–1719. 9. Andrew J. Fleming, Kam K. Leang, \"High Performance Nano positioning with Integrated Strain and Force Feedback\" Preprints of the 5th IFAC Symposium on Mechatronic Systems Marriott Boston Cambridge, MA, USA, September 13-15, 2010. 10. A.O. Kocaeli, CenesuyuKarsisi, \"Design criteria for electro-mechanical transducers and arrangement for measurement of strains due to metal cutting forces acting on dynamometers\" Materials and Design 28 (2007) 496–506. ISBN: 978-93-5620-351-8 115 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Design and Fabrication of Multipurpose Agri Robot Mr. Y. Narsa Reddy1 Vudayana Srinivas Rao2 Busiraju Praveen2 Akka Karnakar Reddy2 Anandula Rathan Reddy2 Syed Arbaaz2 1 Assistant Professor, Department of Mechanical Engineering Nalla Narasimha Reddy Education Society group of Institutions, Hyderabad, India 2Student, Department of Mechanical Engineering Nalla Narasimha Reddy Education Society group of Institutions, Hyderabad, India ABSTRACT More than 60% of the population in the India do agriculture as the primary sector occupation. At present, due to increase in shortage of labour interest has raised for the development of the autonomous vehicles like robots in the agriculture field. A robot called Agri robot has been designed to minimize the labour of farmers in addition to increasing the speed and accuracy of the work. The Proposed system aims at designing multipurpose autonomous agricultural robotic vehicle which can be controlled through IOT for seeding and pumping of water depending upon soil. These autonomous vehicles are implemented to reduce human intervention, ensuring high yield and efficient utilization of resources. I. INTRODUCTION Agriculture is India's backbone. Agriculture has a long history in India, dating back to the Indus Valley Civilization and even earlier in certain regions of Southern India. India is now the world's second-largest producer of agricultural products. Special vehicles are used in a variety of industries, including industrial, medical, and military purposes. In the agricultural sector, the special vehicle field is progressively expanding its production. In India's agricultural sector, growing input prices, a scarcity of qualified labour, a shortage of water resources, and crop monitoring are all key issues. Automation technologies were applied in agriculture to solve these issues. The agricultural census provides crucial data on the distribution of land ownership in our nation. According to the census, the majority of farmers own less than one hectare of land. This is one of the most significant disadvantages of agricultural mechanisation in India. Ploughing, seed planting, levelling, and water spraying are among the operations for which vehicles are being designed. All of these tasks have yet to be completed with a single vehicle. The robots in this project are being designed to focus in an effective way and to conduct activities independently. The suggested concept uses a vehicle to do tasks including ploughing, seeding, mud levelling, and water spraying. These duties may be combined and executed in a single vehicle. Many countries in Asia including India are agrarian economies and most of their rural populations depend on agriculture to earn their livelihood. Aimed at increasing the productivity and reducing the labour involved, this robot is designed to execute the basic functions required to be carried out in farms The robot starts its function by ploughing the field, then sows the seeds in the ploughed area and ends the process with covering the seeds sown with soil. It uses basic components like DC motors, stepper motor, relay and PSoC as the main controller. The mechanical design of the robot is also simple. It is programmed to carry out the above functions simultaneously. To perform the function of ploughing it is equipped with spiked wheels which are fixed in the anterior end of the robot, to sow seeds it has a container with seeds and its bottom contains a perforation to drop the seed and finally the posterior end of the robot has a sloping metal sheet touching the ground to cover the sown seeds with soil as it moves ISBN: 978-93-5620-351-8 116 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 forward. Why to use Agri-robots? Autonomous agricultural robots are an alternative to the tractors found on fields today. Cultivation tasks like seeding, spraying, fertilizing and harvesting may be performed by fleets of autonomous agricultural robots in the future. Independent of the actual design a serious agricultural robot will be a complex and expensive vehicle – the challenge is therefore to prove that it is competitive to traditional technology and may even bring a decisive lead. Construction: The chassis of the robot is fixed to two wheels and the movement of these wheels is controlled using DC motors as shown in Fig. 1. An additional DC motor is also can be done in two ways: It can be controlled using stepper motor or it can be done using a relay. A tough metal sheet is attached at the end of the robot to cover the seeds with soil. To enable this function the metal sheet is attached such that its slope touches the ground. The robot is placed in the field and is switched on. This enables the movement of its wheels. To start ploughing another switch is turned on. This starts the rotation of spiked wheels (shown in Fig. 2) and thus starts ploughing which is done simultaneously as the robot moves forward. As the spiked wheels are in the front, a container is used for holding the seeds. A hole is drilled in the bottom of this container and that is covered with a small metal sheet. This sheet acts as a flip-flop and caters to the dropping of seeds at periodic intervals. Using stepper motor: The flip-flop metal sheet is connected to a stepper motor. As the stepper motor rotates to a specific angle the flip-flop opens and a seed is dropped. Then, immediately it rotates the same angle in reverse direction thus, closing the flip-flop. Using a relay: A relay can be used instead of a stepper motor. Whenever the coil terminals are excited, the soft iron surrounded by coil acts as electro magnet and it attracts the moving armature to connect to Contact terminal B. Whenever there is no excitation the moving armature is held at contact A due to the spring action. As soon as there is an excitation the coil acts as an electromagnet and pulls the armature towards itself, thus causing the function of opening the lid. The above concept can be co-related to the dropping of seeds. The excitation can be used to attract the metallic lid of the container and hence drop the seed in the required place. ISBN: 978-93-5620-351-8 117 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 II. LITERATURE SURVEY 2.1. Vishnu Prakash, Sathish Kumar, Venkatesh P, Chandran A: presents a project aimed at designing, implementing, and testing an autonomous multipurpose vehicle with safe, efficient, and economic operation. This autonomous vehicle moves through the crop lines of an agricultural land and performs tasks that are tedious and/or hazardous to the farmers. First, it has been equipped for spraying, but other configurations have also been designed, such as: a seeding, plug platform to reach the top part of the plants to perform different tasks (pruning, harvesting, etc.), and a trailer to transport the fruits, plants, and crop waste. 2.2. Burra Hymavathi, J Hariharan, K Mandeep, D V Srikanth: presents a project on Agricultural multipurpose robot aimed at designing, implementing and testing an autonomous multipurpose vehicle with efficiency and economic operations for tilling, sowing seeds, spraying fertilizers, and sprinkling water simultaneously. It operates on solar power and is fully automated and can be used in arid and semi-arid lands with ease by single individual. This vehicle moves through the crop lines and performs tasks, thus reducing requirement of manual intervention. 2.3. Chetan Patil, Vishal Deshmukh, Shailesh Deshmukh, Govind rai, Parag Bute: develop a robot capable of performing operations like automatic ploughing, seed dispensing and pesticide spraying. It also provides manual control when required and keeps tabs on the humidity with the help of humidity sensors. The main component here is the microcontroller that supervises the entire process. Initially the robot tills the entire field and proceeds to ploughing, simultaneously dispensing seeds side by side. 2.4. Gowtham Kumar S N, Anand G Warier, Chirag B Shetty, Gerard Elstone Shawn D’Souza: presents about the multiple agricultural tasks done by the single robot. To develop the efficiency of the agricultural tasks we have to find the new ways. This project deals with a novel approach for cultivating lands in very efficient way. The distinctiveness of this agriculture robot system is it is multitasking abilities which can drill, pick and place, seeding, pumping water & fertilizers, weather monitoring to work in both agriculture, afforestation and gardening platform. The project aim is design, development and the fabrication of the robot which can dig soil, put seeds, roller to close the mud and sprayer to spray water, this whole system of robot works with the help of battery and solar power. More than 40% of the population in the world chooses agriculture as the primary occupation, in recent years the development of the autonomous vehicles in the agriculture has experienced increased interest. 2.5. Gaurav Lohakar, JiwanUjwalkar, Subhash Chikankar, Rupesh Kumar.D. Suryawanshi: Developed agriculture needs to find new ways to improve efficiency. One approach is to utilize available information technologies in the form of more intelligent machines to reduce and target energy inputs in more effective ways than in the past. Precision Farming has shown benefits of this approach but we can now move towards a new generation of equipment. The advent of autonomous system architectures gives us the opportunity to develop a completely new range of agricultural equipment based on small smart machines that can do the right thing, in the right place, at the right time in the right way. III. DESIGN OF AGRI ROBOT SOLIDWORKS Solid works is a solid modelling computer aided design and computer aided engineering computer program that runs on Microsoft window. Solid works is published by Dassault Systems. ISBN: 978-93-5620-351-8 118 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Solid works corporation was founded in December 1993 by Massachusetts institute of technology graduate Jon Hirschtick. Solid works currently markets several versions of the solid works CAD software in addition to Drawing, a collaboration tool, and Draft sight, a2D CAD product. MODELING TECHNOLOGY Building a model in solid works usually starts with a 2D sketch (although 3D sketches are available for power users). The sketch consists of geometry such as point, lines, arcs, conics (except the hyperbola), and splines. Dimensions are added to the sketch to define the size and location of the geometry. Relations are used to define attributes such as tangency, parallelism, perpendicular, and concentricity. The parametric nature of solid works means that the dimension and relations drive the geometry, not the other way around. The dimensions in the sketch can be controlled independently, or by relationships to another parameter inside or outside of the sketch. ASSEMBLY In an assembly, the analog to sketch relation are mates. Just as sketch relation define conditions such as tangency, parallelism, and concentricity with respect to sketch geometry, assembly mates define equivalent relations with respect to the individual parts or component, allowing the easy construction of assemblies. Solid works also includes additional advanced mating features such as gear and cam follower mates, which allow modelled gear assemblies to accurately reproduce the rotational movement of an actual gear train. Finally, drawing can be created either from parts or assemblies. Views are automatically generated from the solid model, and notes, dimensions and tolerances can then be easily added to the drawing as needed. The drawing module includes most paper size and standards (ANSI, ISO, DIN, GOST, JIS, BSI and SAC). File format Solid works files (previous to version 2015) use the Microsoft structured storage file format. This means that there are various files embedded within each SLDDRW (drawing files), SLDPRT (part files), SLDASM (assembly files) file, including preview bitmaps and metadata sub files. Assembly of Multipurpose machine ISBN: 978-93-5620-351-8 119 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Assembly of Multipurpose machine IV. METHODOLOGY The basic aim of this project is to develop a multipurpose machine, which is used for digging the soil, seed sowing, and leveller to close the mud and water sprayer to spray water with least changes in accessories with minimum cost. This whole system of the robot works with the battery and the solar power. The project aims on the design, development and the fabrication of the robot which can dig the soil, leveller to close the mud and turn on and turn off the motor depending on water level in the ground and this whole system of the robot works with the battery and the solar power. The language input allows a user to interact with the robot which is familiar to most of the people. The advantages of these robots are hands-free and fast data input operations. In the field of agricultural autonomous vehicle, a concept is been developed to investigate if multiple small autonomous machines could be more efficient than traditional large tractors and human forces. Keeping the above ideology in mind, a unit with the following feature is designed. Robot has rotor which will destroy the unwanted grasses while moving and also level the ground. All the operations are performed with the help of microcontroller. DESIGN ANALYSIS AND TESTING 4.1 Design Calculation for Shaft Power of the engine, P = 10.297 kW Displacement = 149 cc Power, P = 2πNT/60 10297= (2 * 3.14 * 8000 * T)/60 Torque, T = 13.4 Nm = 13400 N-mm Now T is the maximum torque among all shaft, checking the shaft for failure T= (π/16) * 135 * d3 13400= (3.14/16) x135xd3 D = 7.96 = 8 mm But in this project, the diameter of the shaft is 35mm. So the design is safe. 4.1.1 Bending Stress Calculation of the Axle Shaft Consider the weight of 1500 N is acting on the shaft, 120 Induced stress, σ = M/Z Department of Mechanical Engineering, NNRG. ISBN: 978-93-5620-351-8

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Moment, M = (WL)/4 Where, W = load; L = Length M = (1500 * 1100)/4 M = 412500 N/mm Section modulus, z = (π/16) * d3 Z = (3.14/16) * 353 Z = 8414.21 mm3 σ = (412500/8414.21) σ = 49.02 N/mm2 Therefore, Induced stress < Allowed stress 49.02 N/mm2 < 270 N/mm2 (Hence the design is safe). 4.2 Calculation for Cutter P = 2πNT/60 watts P = Power N = Speed of motor T = Torque Then, P = V * I V= Voltage I= Current Power input to the motor, Pin = I * V Pin = 8*12 Pin = 96W (1) Power output from motor to shaft, Pout = T * ω (2) Motor Efficiency, From equation1 &2, E = Pout / Pin 0.36 = [T * (2π * N/60)] / 96 T * (2π * 65/60) = 34.56 T = 5.0773Nm Here, the power, torque and speed generated on the motor shaft is transmitted wholly to the crank of the crank and slotted lever mechanism. The cutting velocity of the blade can be determined by the relation between lever speed and the stroke length of the blade. Here, β = Cutting Angle α = Return Angle In ACB2, Cos (������/2) = CB2/AC =0.0750.08807 α = 63.23 Also, β = 360 – α β = 360 – 63.23 β = 296.77 Scotch Yoke Mechanism Quick Return Ratio or Time ratio, β/α = 296.77/63.23 β/α = 4.9635 Stroke length, ISBN: 978-93-5620-351-8 121 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 R1R2 = P1P2 = 2P1Q Here, P1Q = AP1 * Sin (90 – ������/2) P1Q = 176.14 * Sin (90 –63.23/2) P1Q = 150mm Therefore, R1R2 = 2 * 150 R1R2 = 300mm 31 Now, Cutting speed of the blade, Vc = (s∗ Ns/1000) (1+1/QRR) Where, S = Stroke Length Ns = Number of strokes per minute. QRR = Quick Return Ratio Vc = 0.300 ∗ 251000 (1+14.9635) Vc = 0.0075 * 1.2015 Vc = 0.00901103 m/min Vc = 1.5018 x 10-4 m/s Vc = 1.5018 x 10-4 x 3600 x 103 Vc = 540.648 mm/hr Now, Volume of grass cut per hour is given by, Vg = Vcx Clearance Area Vg = 540.648 x 3 x 800 Vg = 1297555.2 mm3/hr Vg = 0.0012975552 x 109 m3/hr 4.3 Calculation for Plough Depth of cut= 5 cm Speed of the tool= 2.5 km/hr = 41.66 m/hr No. of tool= 4 Feed rate= Rpm x N x CL FR= 41.66x4x0.05 Feed rate, FR= 8.332 m2/min 4.3.1 Tool Life Calculation From Taylor’s tool life equation, vTn= C Where, v= velocity T= tool life C, n= Taylor coefficient For HSS, n=0.2 V= 41.6 m/min 41.6xT^n=100 T= 2.4x10^20cycles for mild steel, T= 2.4x10^10 cycles 3.4 Calculation for seed sowing: Speed of the motor= 30 rpm ISBN: 978-93-5620-351-8 122 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Row spacing= 22 cm Seed sowing time= 2 sec/per seed No. of openings = 4 Seed dropping per minute = 30x4 = 120 seeds If the speed of the wheel is 42 m/min, then for 42-meter 120 seed is dropped. V. FUTURE SCOPE • The Present project aims at designing an intelligent robotic vehicle which can be controlled by mobile. • The main aim of our project has been to develop a solar operated digging machine, which is solar powered. • In this machine we used a solar panel to capture and convert solar energy into electrical energy which in turn is used to charge a battery, which then gives the necessary power to a DC motor. This power is then transmitted to the rear wheel through gear drives. • In this project an attempt is made to make the mechanical systems that shares their powers in an efficient way. VI. ADVANTAGES • The vehicle can be easily assembled and disassembled so that ease in handling and carrying it. • Will be operated by the mobile so that no need of more workers. • Installation of components for fertilization and pesticides is easy. • More efficient vehicle hence increases output. • Less cost and easy to handle technology. VII. CONCLUSION This project entitled Design and Fabrication of Multipurpose Agri Robot is successfully completed and the results obtained are satisfactory. It will be easier for the people who are going to take the project for the further modifications. It will very useful for small scale farmers. The cost can be reduced by using this type of vehicle. The agricultural operations are made easier. The reduction in cost of the plough tool is done and the life time is also increased. The seed sowing machine is made with simple mechanism. The cutter blade is design from the principle of scotch yoke mechanism. VIII. REFERENCES [1] Vishnu Prakash K, Sathish Kumar V, Venkatesh P, Chandran A: “Design and fabrication of multipurpose agricultural robot”, International Journal of Advanced Science and Engineering Research, Volume: 1, Issue: 1, June 2016, ISSN: 2455 9288. [2]Ankit Singh, Abhishek Gupta, Akash Bhosale, Sumeet Poddar: “Agribot: An Agriculture Robot”, International Journal of Advanced Research in Computer and Communication Engineering Vol. 4, Issue 1, January 2015 ISSN (Online): 22781021 ISSN (Print): 2319-5940. ISBN: 978-93-5620-351-8 123 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 [3]Mr. Sagar R. Chavan, Prof. Rahul D. Shelke, Prof. Shrinivas R. Zan war: “Enhanced agriculture robotic system”, International journal of engineering sciences & research technology, ISSN: 2277-9655. [4] Nithin P V, Shivaprakash S: “Multipurpose agricultural robot”, International Journal of Engineering Research, ISSN: 2319-6890) (online),2347-5013(print) Volume No.5 Issue: Special 6, pp: 1129 - 1254. [4]Ms. Aditi D. Kokate, Prof. Priyanka Yadav: “Multipurpose Agricultural Robot”, International Advanced Research Journal in Science, Engineering and Technology National Conference on Emerging trends in Electronics & Telecommunication Engineering, (NCETETE 2017), ISSN (Online) 2393-8021 ISSN (Print) 2394-1588. ISBN: 978-93-5620-351-8 124 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 STUDY ON EXPERIMENTAL INVESTIGATIONS OF ALLOY STEEL USING SUSTAINABLE MANUFACTURING TECHNIQUES Telkar Mahesh1, A. Sai Nitheesh,2 M. Akhilesh2, S. Naveen Kumar2 1Assistant Professor, Mechanical Engineering, NNRG, Telangana, India, 2Student, Mechanical Engineering, NNRG, Telangana, India, ABSTRACT techniques like cryogenic cooling, dry Machining operations are very common cutting, solid lubricants, air/vapor/gas for the production of auto parts, i.e., cooling, and cryogenic treatment. connecting rods, crankshafts, etc. In Cryogenic treatment on tools and the use machining, the use of cutting oil is very of vegetable oils or biodegradable oils necessary, but it leads to higher machining instead of mineral oils are used as primary costs and environmental problems. About techniques to enhance the overall part 17% of the cost of any product is quality, which leads to longer tool life with associated with cutting fluid, and about no negative impacts on the environment. 80% of skin diseases are due to mist and To further help the manufacturing fumes generated by cutting oils. community in progressing towards Environmental legislation and operators’ industry 4.0 and obtaining net-zero safety demand the minimal use of cutting emissions, in this paper, we present a fluid and proper disposal of used cutting comprehensive review of the recent, state oil. The disposal cost is huge, about two of the art sustainable techniques used for times higher than the machining cost. To machining steel materials/components by improve occupational health and safety which the industry can massively improve and the reduction of product costs, their product quality and production. companies are moving towards sustainable INTRODUCTION manufacturing Manufacturing products while conserving This review article emphasizes the natural resources and causing no negative sustainable machining aspects of steel by environmental impacts is called employing techniques that require the sustainable manufacturing. Manufacturing minimal use of cutting oils, i.e., minimum industries create products for fulfilling quantity lubrication, and other efficient human needs; however, this includes the consumption of huge amounts of raw ISBN: 978-93-5620-351-8 125 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 resources and the generation of wastes dispose of into the environment without which are increasing day by day and can any prior treatment. be very detrimental for our environment. The need for sustainable manufacturing To avoid the using resources needed by techniques is also depicted by the three future generations, it is necessary to use pillars of sustainable manufacturing. One fewer natural resources and reduce of these is the need for improvement from negative environmental impact caused by an economic, social, and environmental manufacturing systems. Early ideas about point of view. It brings balance between sustainable manufacturing is first appeared social, economic, and environmental in 1970s and 1980s. in all machining aspects. This technique mainly deals with operations, cutting fluid plays a vital role the minimal usage of cutting fluids. It does in reducing the machining cost by not mean just stopping the supply of increasing tool life. About 7-17% of the cutting oils to make the environment cost incurred in machining of a part is better. Cutting oils serve many purposes associated with cutting fluids, and tooling like lubrication and temperature reduction cost is about 2-4%. The usage of cutting in the cutting zones. fluids causes health diseases like skin Aluminium (Al) is the third problems, allergies, eyes problems and most abundant metal in the earth’s crust cancer in workers. Vegetable oil-based and and in its natural form is combined with metal working liquids have been proven to oxygen and other elements. It is a face- be environmentally sustainable in the die centered cubic (FCC) structure, is electric regime. relatively easy to machine and has high Strict environmental regulations demand ductility at ambient temperature. the cutting oil used during machining Compared to other engineering metals, process should be recycled or disposed in aluminium has a low melting temperature such a way that it will not spoil the about 660 °C. Alloys can be formed environment and will be harmless for all through reaction with chemical elements interested parties. the cost is double the such as copper, zinc, manganese, silicon, machining cost is depending on the cutting magnesium, iron, etc. to give primary fluid which is going to be used. mineral oil aluminium new mechanical properties. used as cutting fluids are difficult to Aluminium alloys have been employed in ISBN: 978-93-5620-351-8 126 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 aircraft construction since 1930, mainly applied in the machining zone, it leads to those of classes 2xxx, 7xxx, and 6xxx. process improvement. Several studies These alloys are responsible for most of related to the lubrication properties of the machining activities in the aerospace Vegetable oils are carried out over the past and automotive industries, since they several decades. The growing demand for present a high strength-to-weight ratio and higher productivity, product quality and can advantageously substitute steel and overall economy in manufacturing by cast iron in the fabrication of parts. Their machining, insists high material removal low weight reduces the environmental rate and high stability and long life of the impact caused by energy consumption. cutting tools. But machining with high Among the main applications of cutting velocity, feed rate and depth of cut aluminium alloys are the fabrication of car is inherently associated with generation of wheels, panels, and structures using 6061 large amount of heat and high cutting alloy, pistons, brake discs, brake drums, temperature. Such high cutting and piston sleeves using Si-C (silicon temperature not only reduces dimensional carbide hard particle) or Al2O3 accuracy and tool life but also impairs the (aluminium oxide hard particle) reinforced surface integrity of the product by 6061 aluminium alloy or aluminium- inducing tensile residual stresses, surface silicon alloys containing up to 20 % Si. A and subsurface micro-cracks in addition to thorough study of literature suggests that rapid oxidation and corrosion. Vegetable the machining of Aluminium Alloy 6061 oil is an environmentally acceptable is difficult and most application oriented lubricant. Vegetable oil will yield the compared to other Al alloy materials. lowest manufacturing cost of any fluid as found by Jung Soo, et al. (2011) for the Application of vegetable oil lubrication in selected control parameters. Orthogonal cutting has proved to be feasible Array and Signal to Noise Ratio are alternative to cutting oils, if it can be employed to study the performance applied properly. If the friction at the characteristics for the selected process machining zone can be minimized by parameters. The turning operations providing effective lubrication, the heat (facing) are carried out on CNC lathe at generated can be reduced to some extent. Balanagar, Hyderabad and the machine If a suitable lubricant can be successfully ISBN: 978-93-5620-351-8 127 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 used is WASINO LJ-63m CNC Turning Machine LITERATURE SURVEY Title of the paper Author Names Remark • The methodology we used is Experimental M. Rakesh Babu, Taguchi robust design methodology. investigation of alloy steel A. Venkata • Orthogonal Array, Signal to Noise Ratio and ANOVA are employed using sustainable Vishnu, M. to study the performance characteristics for the selected manufacturing techniques Narendhra Baba, process parameters • Turning of EN-24 steel was carried B. Naveen out on HMT NH26 lathe machine. MQL setup consists of a mixing Experimental Archana Thakur, chamber, oil container, nozzle, pressure gauges and air investigation of nanofluids Alakesh Manna, compressor. • The mixture of compressed air and in minimum quantity Sushant Samir cutting fluid were supplied to cutting zone through nozzle to lubrication during turning provide needed cooling and lubricating action. All these of EN-24 steel components essentially required ISBN: 978-93-5620-351-8 128 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 Energy-Efficient Lorena Caires good surface finish. machining process Moreira, WD Li, • Due to the complexity of analysis and optimization Xin Lu, ME based on BS EN24T alloy Fitzpatrick machining parameters, it is steel as case studies challenging to develop effective modelling and optimization Eco-Friendly Cutting Brinayak Sen, approaches to implement energy- Fluids in Minimum Mozammel Mia, efficient CNC machining. Quantity Lubrication GM Krolczyk, • Case studies and algorithm Assisted Machining: A Uttam Kumar benchmarking have been Review on the Perception Mandal, Sankar conducted to validate the of Sustainable Prasad Mondal effectiveness of the optimization Manufacturing approach. • The relationships between energy consumption and key machining parameters (e.g., cutting speed, feed, depth, type of tool) have been analyzed. • The requirement to stir towards sustainability motivated the researchers to revise the effects of substitute lubrication methods on the machining. • In actual, the definite principle of this manuscript is to re-examine modern advancements in the MQL technique and also explore the benefits of the vegetable oil and nanofluid as a lubricant ISBN: 978-93-5620-351-8 129 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 Optimization of Process A. Venkata • Taguchi’s orthogonal arrays are Parameters in Turning of Vishnu, highly fractional designs, used to En-353 for Material J. Ramakrishna, A. estimate main effects using only Removal Rate Vishnu Teja, few experimental runs. B. Madhusudhan, D. Sai Kiran • These designs are not only applicable to two level factorial experiments, but also can investigate main effects when factors have more than two levels. • The experiments designed using Taguchi Robust Design Methodology with four control factors i.e. cutting speed, feed rate, depth of cut and types of tool selected with three levels and the corresponding orthogonal array are chosen with respect to its degrees of freedom [2,5]. CONCLUSION • The main aim is to study the Taguchi’s techniques with the help sustainable manufacturing techniques using EN 353 material. ISBN: 978-93-5620-351-8 130 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 DESIGN VALIDATION AND ANALYSIS OF THEMAGWHEEL FOR DIFFERENT SPOKES Mr. P. Srinivas1 Mr. T. Mahesh1 Mr. Omnath3 1.Associate Professor, Mechanical Engineering, NNRG, Telangana, India, 2 Assistant Professor, Mechanical Engineering, NNRG, Telangana, India, 3.PG Scholar, Mechanical Engineering, NNRG, Telangana, India, ABSTRACT Alloy wheels are automotive wheels that are formed from an alloy of aluminium or magnesium metals. Alloy wheels are lightweight and durable. Or, on sometimes, a combination of the two. Alloy wheels vary from conventional steel wheels in that they are lighter in weight, which enhances the handling and acceleration of the vehicle. When compared to a vehicle equipped with ordinary steel wheels, a vehicle equipped with alloy wheels will have a lower unstrung weight. Because of the decrease in unstrung weight, more accurate steering is possible, as well as a little reduction in fuel consumption. As an efficient heat conductor, alloys aid in the dissipation of heat generated by the brakes, minimising the likelihood of brake failure under difficult driving circumstances. In addition to aluminium and magnesium alloy wheels, Magnesium alloy wheels, also known as MAG wheels, are often used on racing vehicles in favour of heavier steel or aluminium wheels in order to achieve higher performance. In our project, we have modelled parts of the original modal and slot types. Using the Catia programme, we were able to create models of alloy wheels for two- wheeled vehicles. Every design is checked for strength under various loads in the analytical programme, taking into account both the vehicle weight and the weight ofthe driver and a second passenger. ALUMINUM [201.T43 Insulated mould casting] and MAGNESIUM [ZK60] are two of the materials under consideration. We may monitor the behaviour of the wheel under a variety of load scenarios via analysis, and we can use this information to confirm the most appropriate wheel design. 1.0 INTRODUCTION An axis-rotating circular device that facilitates movement or transit while supporting a weight (mass) or doing labour in machines is known as a wheel. Examples of this may be found in transportation-related applications. A wheel and an axle work together to overcome friction by allowing for more movement while rolling. The application of a moment to the wheel around its axis, whether by gravity or by the application of another external force, is required in order for wheels to revolve. In a broader sense, the phrase is also used to various circular items that spin or revolve, such as a ship's wheel, steering wheel, and flywheel, among other things. At this point, just a few different kinds of wheels are still being used in the automobile industry. They differ widely in terms of size, form, and materials employed, yet they all adhere to the same fundamental principles.The first sort of wheel worth noting is the steel wheel, which is also by far the most often seen. This kind of wheel is made up of numerous sheets of steel that have been pressed into shape and then commonly welded together to form the wheel. This sort of wheel is durable, but it is also hefty. They may be seen on a variety of vehicles, ranging from sports cars to huge pickup trucks; while the wheels seem to be different, they are fundamentally the same technology. The rally wheel is the second sort of wheel that has to be discussed. These are basically steel wheels, but they are constructed in a slightly different manner and are often composed of a higher gauge of steel. While the inner piece of a steel wheel is often welded to the rim throughout its full circumference, the inner portion of a steel wheel is chopped to mimic the spokes of a mag wheel and then welded in place. Magnesium alloy wheels, sometimes known as \"mag wheels,\" are occasionally used on racing vehicles to improve performance by replacing heavy steel or aluminium wheels with lighter magnesium alloy wheels. The wheels are made from a magnesium alloy known as ZK60, AZ31, or AZ91, which is formed in a single step by hot forging. Magnesium alloy research and development has generally been driven by the aerospace industry's need for lightweight materials that can perform under more demanding operating environments. The low density of magnesium alloys, which is just two-thirds that of aluminium, has traditionally made them appealing to designers. This has played a significant role in the widespread usage of magnesium alloy castings and wrought products in a variety of applications. 131 ISBN: 978-93-5620-351-8 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 In recent years, there has also been a need for improved corrosion resistance, and new magnesium alloys have exhibited substantial gains in this area. Increased interest in magnesium alloys for aerospace and specialist applications has resulted from improvements in mechanical qualities and corrosion resistance, and alloys are now being required on projects such as the McDonnell Douglas MD 500 helicopter, whichis now under development. Fig: 1 Magnesium alloy wheel on a Porsche Carrera GT 2.0 LITERATURE SURVEY HIGH CYCLE FATIGUE OF A DIE CAST AZ91E-T4 MAGNESIUM ALLOY M.F. Horstemeyer a,*, N. Yang b, Ken Gall c, D.L. McDowell d, J. Fan e, P.M.Gullett b. 3 July 2003; accepted 11 November 2003 AZ91E-T4 Mg component fatigue crack nucleation and growth was studied in this work. The processesof fatigue crack nucleation and growth in this component were revealed. Engineered casting specimens with total strains of 0.02 percent to 0.5 percent were used for mechanical fatigue experiments under R 14 1 conditions. Witha scanning electron microscope, specimens with lifetimes spanning two orders of magnitude were analysed for fracture surfaces. Nucleation site sizes varied from a few hundred lm's to several millimetres in the Mg specimens, which accounted for the disparity in life expectancy between the two groups Average secondary dendrite arm spacing and average grain size may also havean impact as a secondary effect. Because undamaged particles and borders operate as fatigue crack propagation barriers at low crack tip driving forces (Kmax 3:5 MPa), fractures avoidedinterdendritic areas and progressed through cells instead, generating a fine striated pattern in this single-phase portionof the experiment. Cracks followed the interdendritic areas, producing serrated marks as they travelled through this heterogeneous zone under high driving forces (Kmax> 3:5 MPa), creating weak routes for fatigue crack development. It is explained how the findings would affect future modelling attempts. Under entirely reversed cycling in laboratory air at ambient temperature, samples ofcast Mg machined from commercial high-pressure automotive die-casting were tested until failure at strain amplitudes ranging from 0.02 percent to 0.5 percent. SEM was used to study the failed samples' initialmicrostructures and fracture surfaces, and the results show that these major hypotheses are supported. WHEELS AUTO MODELING USING FINITE ELEMENT METHOD Amalia Ana DASCĂL, 2.Daniel CĂRĂULEANU Year 2011. There's always the debate over \"steel or alloy wheels?\" when it comes to purchasing rims. In addition to their aesthetic appeal, alloy steel wheels provide a number of practical advantages, including less weight, better starting and braking,more stiffness, and faster cooling. Construction trucks and the stresses they put on their tyres dictate the wheel shape, which may be made from sheet steel or cast alloy. When a wheel is exposed to aerodynamic loading conditions, we investigated the stresses that emerge and tried to identify the optimum locations in which attention should be increased in order to avoid early destruction. A light idea was developed in CATIA V5 and tested using a finite element approach with varying forces and acceleration constraints in regions where issues arise during usage. The results were encouraging. This method of calculating diagrams allows us to see how material behaviour changes under 132 ISBN: 978-93-5620-351-8 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 tension, allowing us to make corrections when needed. It is possible to make a conclusion that proves the concept's viability, as well as create new technologies for observing and verifying components or assemblies at the end of the method's implementation phase. Class A-surface product development may benefit from this method. CATIA V5 customers don't need to buy any new hardware to utilise the same approach. Furthermore, I believe that as time passes, the necessity to create a new model of the Rimin can only be met via the use of computers and specialised software designed for these committed experts. impact test and so enhance the design of a wheel with the mechanical performance necessary for the application. The lug area of the wheel was found to have the most stress, as shown by the findings. Because of the complicated and uneven geometry created by the lug hole, this is the case. When the striker's momentum is measured along an axis that passes through the lug area, the moment created is the largest. As a consequence, nonlinear simulation is a valuable tool in the wheel design optimization process. PROBLEM DESCRIPTION: Alloy wheels, which have a higher melting point and are more difficult to forge, have replaced steel wheels in the construction of automobiles because of their greater strength. Mileage is affected greatly by a person's weight as well. Afterwards, aluminium and magnesium were used to manufacture alloy wheels, however these alloy wheels had a poor compressive and yield strength, resulting in a short life expectancy. For the same reasons why aluminium and magnesium wheels are prone to yielding (bending) over time and aren't suitable for carrying big loads, 3.0 METHEDOLOGY: ❖ As shown in the issue and literature study above, new alloy wheels are not able to handle bigloads and also bend (give) during bumps and pits in the long term. ❖ As a result of this project's utilisation of geometric and material optimization, these issues were addressed. ❖ This thesis introduces a new form of composite zk60. 3.1. CAD & CAE MODEL Part ModelingMODELLING SCREENS Modeling of original wheel Modeling of modified wheel Wheel with slots ISBN: 978-93-5620-351-8 133 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 3.2. INTRODUCTION TO ANSYS ANSYS is a multi-purpose FEA software suite, which may be used for a variety of different tasks. Numerical decomposition of a complicated system into tiny, discrete components (of a user-specified size) is termed Finite Element Analysis (FEA). Equations governing the behaviour of various components are implemented and solved by the software, resulting in a thorough description of how the system operatesas a whole.. After then, the data may be shown graphically or in a table format. Use this form of study when designing or optimising a system that is too complicated to evaluate manually. Due to the complexity of their geometry, size, or governing equations, systems that may fall into this category fall short. Many universities' mechanical engineering departments use ANSYS as their primary FEA teaching tool. Also utilised in Civil and Electrical Engineering, as well as Physics and Chemistry. Cmposites, fatigue, p-Method, and beam analyses are all aspects of fracturemechanics. LOAD CALCULATIONS Type of vehicle: Honda City Car weight – (wc) = 1090 kg’s 5 passengers + luggage - (wp) = 500 kg’sArea (A) = 272511.58 mm2 Pressure = WC /A = 1590 X 9.81/272511.58 = 0.0572 N/mm2 MASS PROPERTIES Properties of Original Wheel Volume = 8.48710462 mm^3 ; Mg= 1.7 Kg / mm^3 Surface Area = 85.2914.55 mm^2 ; Mg= 15.416 Kg Density of, AL = 2.8 Kg / mm^3 Mass of, AL = 23.744 Kg Modeling of Modified Wheel (With Slot) Volume = 8.39634022 mm^3 ; Mg= 1.7 Kg / mm^3 Surface Area = 80.724275mm^2 ; Mg= 14.263 Kg Density of, AL = 2.8 Kg / mm^3 Mass of, AL = 23.49 Kg 4.0 RESULTS & DISCUSSIONS 134 ISBN: 978-93-5620-351-8 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 STATIC ANALYSIS OF ORIGINAL MODEL MAGNESIUM ALLOY (ZK60) Imported Model from CATIA Element Type : Solid 20 node186 Material Properties: Youngs Modulus (EX) : 45000 N/mm2 : 0.35 Poissons Ratio (PRXY) Density : 0.0000017 kg/mm3 Yield Strength : 382 N/mm2 Meshed Model Loads 135 Pressure – 0.0572 N/mm2 Department of Mechanical Engineering, NNRG. ISBN: 978-93-5620-351-8

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 Solution Solution – Solve – Current LS – ok General Post Processor Displacement Vector Sum Von Misses Stress ISBN: 978-93-5620-351-8 136 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Mechanical Engineering 6th & 7th May, 2022 Strain ISBN: 978-93-5620-351-8 137 Department of Mechanical Engineering, NNRG.