RTIME 2K20 PROCEEDINGS

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 3. EXPERIMENTAL WORKS holder. The blank holder load can be varied by 3.1 EXPERIMENTAL SETUP applying the compressive force over the open coiled helical spring housed over the blank holder by means FIG 6: FOUR PILLAR HYDRAULLIC PRESS of tightening the nut provided for it. As the spring index is known by testing can easily determine the The experimental setup consists of 200T double blank force applied on the blank holder. acting press with in-built load cell for recording of the Steel can be broadly classifed into four groups based punch force . The punch load can be directly recorded on their chemical compositions: under computerized recording system throughout the 1. Carbon Steels process from beginning of the punch while making 2. Alloy Steels contact with the blank till the end of cup formation. 3. Stainless steel Cup drawing tests were conducted using die sets with 4. Tool Steel die profile radius of 9 mm with 72 mm punch Carbon Steels diameter having nose radius of 4 mm. All the tests of Carbon steels contain small amounts of alloying this experiment were conducted while keeping the elements and account for 90% of total steel punch nose radius, percentage of clearance, blank production. Carbon steels can be further classified holder force, friction and other test conditions the into three groups depending on their carbon content: constant. The tool geometric parameters  Low Carbon Steels(or)Mild Steels contain SL. PARAMETER QUANTITY(mm) up to 0.3% carbon NO  Medium Carbon Steels contain 0.3-0.6% carbon 1. Sheet thickness 5  High Carbon Steels contain more than 0.6% 2. Die opening 100 carbon diameter  and sections. These products are commonly used in the automotive and construction 3. Die shoulder 9 units. radius  Flat Products include plates, sheets, coils, and strips are made up of tool steel. These 4. Punch diameter 72 materials are mainly used in automotive parts, appliances, packaging, shipbuilding, 5. Punch nose radius 4 and construction. 6. Die inner 75  Other Products include valves, fittings, and flanges and are mainly used as piping materials. diameter 7. Blank holder 100 3.3 MECHANICAL PROPERTIES The behaviour of materials under external load diameter defines their mechanical properties. Deformations are usually described in terms of stress of force per unit 8. Gap between die 2 area and strain or displacement per unit distance. and blank holder Using the stress-strain relation one can distinguish elastic and plastic regime. At small stress, the This method of rapid determination of LDR(Limiting displacement and applied force obey the Hooke’s law Drawing Ratio) is based on the observation of the and the specimen returns to its original shape upon characteristics limit load at fracture was developed. In unloading. Exceeding the so-called elastic limit, upon this method of testing, experiments were conducted strain release the material is left with a permanent on four different sized blanks, two are of undersized shape. Within the blanks and the two blank is of oversized for deep drawing. The sizes of the blanks, maximum punch Properties Metric Imperial loads recorded are as shown in above table. 3.2 DEEP DRAWING TOOL SETUP Tensile strength 370 MPa 53700 psi The design of deep drawing tool setup is a highly Yield strength 370 MPa 53700 psi specialized task. It consists of number of important Bulk modulus 140 GPa 20300 ksi activities that sequentially starts with determination of blank size, selection of process parameters and tool 80 parameter. The components of deep draw tool setup are die, punch, die holder, blank holder and punch Department of Mechanical Engineering, NNRG. ISBN: 978-93-5268-241-6

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Elastic modulus 190-210 GPa 27557-30458  Gap between die and blank holder Shear modulus 80 GPa ksi =2mm Poissons ratio 0.27-0.30 197 11600 ksi 4.1.2 For circular cup Hardness 65  Thickness of blank Machinability 0.27-0.30 =5mm  Blank diameter 197 =200mm  Die opening diameter 65 =130mm  Punch diameter 3.5 CHEMICAL PROPERTIES =65mm  Depth of cup Element Content =70mm  Die nose radius Chromium 0.8-1.10 =4mm Manganese 0.75-1.10  Blank holder diameter Carbon 0.38-0.43 =130mm Silicon 0.15-0.30  Gap between die and blank holder Molybdenum 0.15-0.20 =2mm Sulphur 0.040 Phosphorus 0.035 4.2 CALCULATION OF DRAWING FORCE Drawing force Iron 96.5 Fd,max= n*π*d*t*UTS Where n= drawing coefficient 3.6 EXPERIMENTAL WORKS d= diameter of blank t=thickness of blank The commercially produced steel alloy of gauge UTS= Ultimate tensile strength 5mm,3mm was utilized in the tests. Firstly, the deep drawing tests were conducted with undersize blanks  For square cup consisting of two blanks in each set. For each size of F= n*π*d*t*UTS d =200mm the blank the punch load verses punch displacement t =5mm readings were made when the work piece under went UTS =370 MPa deep drawing process. The same test were also conducted for over size blank of 200 mm and punch n= 100/200 = 0.5 load verses punch displacement recordings were F = 0.5*π*200*5*370 taken. In the case of 200 mm blank as well as 50mm F = 581194.64 N blank, deep drawing tests were successfully (or) performed and cups of wrinkle free, fully drawn and F = 59.27 Tonnes without necking or fracture were produced. In  For circular cup contrast to the undersize blanks the oversize blanks of F= n*π*d*t*UTS 200 mm diameter yielded better cups. d =200mm t =3mm 4. CALCULATIONS UTS =370 MPa n= 130/200 = 0.65 4.1OBSERVATIONS F =0.65*π*200*3*370 4.1.1 For square cup F = 453331.81 N F = 46.23 Tonnes  Thickness of blank 5. RESULT =5mm In order to better understand the deep drawing  Blank diameter process influenced by different process parameters and the type of defects occur has been studied well in =200mm this work. It is necessary to know the forces and  Die opening diameter stress states that occur during the process. In the following sections some details about the force, =100mm stresses and process parameters are described, mainly  Punch diameter =72mm  Depth of cup =40mm  Die nose radius =4mm  Blank holder diameter =100mm ISBN: 978-93-5268-241-6 81 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 focusing in the analysis of the deep drawing of square Fig 8: Circular cup and circular cups. The main parameters affecting the deep drawing process are given and discussed which 6. CONCLUSION Numerous researchers put their efforts to study the include: the drawing ratio, holding down diameter, deep drawing or warm deep drawing of high strength, punch and die profile radii and their effect on the low formability materials like Al and Mg alloys. Very maximum drawing force and the defects encountered little amount of research work has been carried out in in the process are presented. deep drawing or warm deep drawing of materials like stainless steel, copper, high strength low alloy steels Type of cup Drawing force in tonnes etc. Even though these materials are very extensively Square cup 59.274 used in many industries like automobile, aeronautics, electronics industries and so on. The information Circular cup 46.23 regarding the metallurgical aspects of warm deep drawing is very much limited. In the present work, Fig 7:Square cup steel alloy was used to fabricate square cup, cylindrical cups. The investigation was focused on the process parameters such as punch force, coefficient of friction, die diameter, blank holder diameter etc. The major process parameters which could influence the deep drawing capability of steel alloy square cup, cylindrical cups were punch force and die diameter. To conclude, the effect of die draw radius, sheet thickness, die opening diameter and blank holder force on the material thinning in deep drawing, individually and interactions is analyzed by determining drawing force. In the die dimensions analyses it was observed that only the ironing phase is affected. The increase of force in this stage is due to the decrease of the “Die Opening Diameter”, which causes a variation on the gap between the die and the punch. The increase of this gap results in an increase of the final cups thickness and, consequently, in a decrease of the punch force. It was also observed that before the beginning of the ironing stage the variation of the “Die Opening Diameter” has a negligible effect on the final results. In the global friction coefficient analyses the results show that the punch force increases with the increase of this parameter, both for the models considering isotropic or anisotropic material behaviour. Regarding the thickness evolution along the cups wall, it was observed that in the re-bending and in the wall areas there is a thickness decrease associated with the increase of the global friction coefficient value. Analyzing the contact with friction conditions between the sheet and each tool, it was observed that the contact between the sheet and the die has the most important influence on the forming process. The contact conditions between the sheet and the blank holder seem to have an negligible effect in the variables analyzed, i.e. punch force evolution with its displacement and the thickness evolution along the cups wall. The contact conditions between the sheet and the punch seem to have a small influence on the force evolution in the ironing phase. ISBN: 978-93-5268-241-6 82 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 REFERENCES 1. Jaisingh Amit, Narasimhan K., Date P.P., Maiti S.K., Singh U.P. “Sensitivity Analysis of a Deep Drawing Process for Miniaturised Products”, Journal of Material Processing Technology, vol. 147, pp 321- 327, 2004. 2. Tommerup Soren, EndeltBenny \"Experimental Verification of a Deep Drawing Tool System for Adaptive Blank Holder Pressure Distribution\", Journal of Material Processing Technology, Vol. 212 pp 2529- 2540, 2012. 3. WifiA, Mosallam A, “Some Aspects of Blank- Holder Force Schemes in Deep Drawing Process”, Journal of Achievements in Materials and Manufacturing Engineering, Vol. 24, Issue No. 1, pp 315 – 323, 2007. 4. Volk Mihael, NardinBlaz, DolsakBojan, “Application of Numerical Simulations in the Deep- Drawing Process and the Holding System with Segments’ Inserts”, Journal of Mechanical Engineering, vol. 57, Issue No. 9, pp 697-703, 2011. 5. Zhao S.D., Zhang Z.Y., Zhang Y., Yuan J.H. , “The Study on Forming Principle in the Process of Hydro-Mechanical Reverse Deep Drawing with Axial Pushing Force for Cylindrical Cups”, Journal of Materials Processing Technology, vol. 187-188, pp 300-303 2007. 6. Saniee F. Fereshteh, Montazeran M.H., “A Comparative Estimation of the Forming Load in the Deep Drawing Process”, Journal of Materials Processing Technology, vol. 140, pp 555–561, 2003. 7. Ouakdi E.H., Louahdi R., Khirani D. , Tabourot L., “Evaluation of Spring Back Under the Effect of Holding Force and Die Radius in a Stretch Bending Test”, Materials and Design, vol. 35, pp 106-112, 2012. 8. Kakandikar G.M., Nandedkar V.M., “Optimization of Forming Load and Variables in Deep Drawing Process for Automotive Cup Using Genetic Algorithm”, pp 1-10, 2005. 9. Yang T.S. “Investigation of the Strain Distribution with Lubrication During the Deep Drawing Process”, Tribology International, vol. 43, pp 1104–1112, 2010. 10. Liu Qiqian, Lu Cheng, Fu Wenzhi, Tieu Kiet, Li Mingzhe, Gong Xuepeng “Optimization of Cushion Conditions in Micro Multi-Point Sheet Forming” ISBN: 978-93-5268-241-6 83 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Simulation of Thermal stress of SS316 using ANSYS HARINADH VEMANABOINA Associate Professor, Department of Mechanical Engineering, Sri Venkateswara College of Engineering and Technology, Chittoor, A.P. India Abstract-- Welding is widely used in all the 2. FORMATION & SIMULATION OF fabrication processes for the development of WELDING PROCESS complex structural components. The weld distortion The heat energy equations are referenced in many is one of the major constraints which cannot be including Frewin [5]. For an isotropic, conductive completely avoided irrespective of material type and material with equal coefficient of conductivity kx, ky, kz (W/mK) in all three chosen orthogonal coordinates. thickness. 3D transient thermal finite element model Equation (1) gives the heat energy in the weld area is established to measure the thermal stress and with temperature, T (K) obtained both in spatial, x, y, z (m) and temporal, t (sec), terms. Q (W/m3 or J/m3s) weldments. The temperature stress modeling is one is the net heat from the input and the losses in the of the complex processes which utilize the weld form of convection & radiation. The boundary parameters and material properties at higher conditions given are T0(x, y, z, 0) throughout the body temperatures. A Suitable heat flux is to be given as at time zero or at the starting of the weld, this is an input for the developed model to analyze welding essential boundary condition. In addition, the natural process. The temperature distribution and stress boundary conditions have to apply consisting of analysis have been carried out with developed model normal conduction ������������ ������������ heat flux q, convection h ������������ by using the temperature dependent material (T-T0), and the radiation term,  (T 4  T0 4 ) properties of SS316 using ANSYS. Keywords: Welding, Thermal Stresses ������������ ������������������ + ������������ ������������������ + ������������ ������������������ + ������ = ������������ ������������ − ������ ������������ ������������������ ������������������ ������������������ 1. INTRODUCTION ������������ ������������ Welding is a process used in the fabrication of various steel structures for applications from thin (1) sections to thicker sections in various applications like pressure vessels, chemical plants and nuclear Together, the boundary conditions are summed up as: reactors. The main problem associated with welding is the presence of residual stresses and deformations K n  q  h (T  T 0 )   (T 4  T 0 4 )  0 ----(2) - developed within the sections which may cause the failure at the later stages by Masubuchi [7]. During W---hen symmetric boundary and insulation boundaries the welding process, the material exposed to heat flux causes a phase change of the metal during melting. are considered as adiabatic, with no heat flowing The temperature distribution is non-uniform like fusion zone with molten metal, heat affected zone and through the surface, they are obtained by making the base metal zone. The present study is focused on the understanding of convection zero, and conduction zero from the the heat flux mechanism with heat source used for TIG weld process with developed constant heat surface. Where, Kn is the thermal conductivity normal source model applied to the stainless steel, SS316 to the surface in W/mK, h is the convective heat material by using the temperature dependent transfer coefficient in W/m2K, ε is emissivity of properties and finite element approach. The temperature distribution is estimated which can surface radiating, σ is the Stefan Boltzmann’s further give the estimation of the weld deformations constant, which 5.67*10-8, W/m2K4. When it is and stresses. difficult to use radiation boundary condition, it is combined with convective heat flux by using a modified coefficient, hr, for hot rolled steel plates with an error of about 5% is, ℎ = 2.4 ∗ 10 ∈ ������ . (3) Radiation inclusion will increase solution time by about three times and hence combined with convection. ISBN: 978-93-5268-241-6 84 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 2.1 Finite element for simulation The heat equations (1) can be represented in tensor form so the elemental transient heat equation is obtained and later summed to get the system equation which is analysed with time. ⌊������(������)⌋{������} + [������(������)]{������} = {������(������)} (4) Where K is a temperature dependent conductivity Figure:1(a) model dimesions for simulation matrix. C is the temperature dependent capacitance Figure 1(b): Mesh model used for ansys matrix based on specific heat its product with the rate of temperature gives heat. The above equation can be solved numerically, with standard FEM models with Crank-Nicholson or Euler time integration models. An initial temperature Ti is assumed K, C and Q are calculated at that temperature and the next temperature T at i+1 is obtained. Again K, C & Q are calculated and temperature at next temperature interval is calculated. 2.2 Finite element model The finite element model of dimensions 40mm X 150 mm X 5 mm is used. The AISI 316 austenitic stainless steel material is considered for simulations to be carried out. The convection is applied on all the surface of the plate except on the heat applied area. In the present study AISI type 316 stainless steel is used as it is having many advantages such as low thermal conductivity, the high resistance to corrosion and high stability at elevated temperatures. Thus, SS316 material is widely used in numerous industries, like nuclear industry, chemical plants, aeronautical and specialized pipe industry. 3. THERMAL ANALYSIS In the present work Finite Element Analysis of single-pass butt-welding has been carried out with constant heat flux, the load is applied for first 10 sec and allowed to cool to ambient temperature for 1000 sec. For this, a simple Butt-joint welding whose Figure 1(c): Temperature distribution of welding parameters are consistent to those of the weldment Friedman’s model with heat input Q = 1200 W is considered and has been simulated using ANSYS. The temperature distribution was evaluated at various The element can also compensate for mass transport zones i.e. fusion zone, heat affected zone and base heat flow from a constant velocity field. In this plate. The temperature distributions of the weldments analysis, element SOLID70 is replaced with by a are shown in Figs (1a) to (3). Temperature three-dimensional (3-D) structural element SOLID45. measurement studies in various zones of the model The geometry and meshed model with tetrahedral and to understand the distribution. Fig 3. Shows the shape with volume mesh of size 0.02 were shown in temperature versus time distribution graphs in the Fig 1(a) , Fig 1(b).and Fig 1(c). three regions of Fusion zones, Heat Affected zones & Base plate. The temperature is found to vary from 3030K in the base plate and up to 27000K in the fusion zone with the applied heat input parameters in 85 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 the developed model. Fig (2) shows the temperature distribution in the transverse direction on the surface of the weldment. Table: 1 Thermal temperature dependent properties Temperature Density Specific Thermal (K) (kg/m3) heat conductivity (J/kg K) (W/m K) 273 8038.7 456.28 13.29 293 8030.47 464.73 13.63 373 7997.02 494.23 14.99 Figure 3: Temperature distribution of the weldment at fusion zone, Heat affected zone 473 7954.03 522.74 16.62 573 7909.76 543.92 18.19 4. CONCLUSION 673 7864.18 559.87 19.72 FEM simulation by adapting a constant heat flux 773 7817.31 572.69 21.26 873 7769.13 584.49 22.81 analysis has been carried out on SS 316 steel material 973 7719.66 597.38 24.42 for the transient thermal temperature analysis. The 1073 7668.9 613.45 24.09 temperature field at the weld zone was found higher 1173 7616.83 634.82 27.86 at the given constant heat flux input when compared 1273 7563.47 663.58 29.76 with the heat affected zone and base plate regions. This prediction of analysis with reference to the estimation of stress can be useful to predict the weld residual stress status with the heat input parameters which can be used for the experimental application. 1373 7508.81 701.85 31.81 REFERENCES 1473 7452.85 751.72 34.03 [1] Akbari Mousavi. S.A.A, R. Miresmaeili., 2008. 1573 7395.6 815.3 36.46 1643 7354.75 869.09 38.29 Experimental and numerical analyses of residual Figure 2: Transverse Temperature distribution of stress distributions in TIG welding process for 304L the weldment stainless steel, Journal of materials processing technology, 208, 383–394. [2] Amudala Nata Sekhar Babu, et.al. 2012. Finite Element Simulation of HybridWelding Process for Welding 304 Austenitic Stainless Steel Plate, IJRET Vol 1, Issue 3, 101-410. [3]Dean Deng, Hidekazu Murakawa. 2008. “Prediction of welding distortion and residual stress in a thin plate butt welded joint” Computational Material Science 3,353- 365. [4] Dike.J.J, A.R Ortega and C.H. Cadden, .1999. Finite element modelling and validation of residual stresses in 304L girth welds, in Trends in Welding Research, 5th International Conference, ASM International, Materials Park, Ohio, pp.961-966. [5] Frewin m r, Scott d a, “finite element model of pulsed laser welding”, welding j, 1999, 15s – 22s [6] Goldak.J.A, B. Chakravarti and M. J. Bibby. 1984. A new finite element model for welding heat sources, Metallurgical Transactions B, 15, 229-305. [7] Masubuchi.K, .1980.Analysis of Welded Structures. Oxford, Pergamon Press. Mollicone.P, et al,.2006. Simple thermo-elastic-plastic models for ISBN: 978-93-5268-241-6 86 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 welding distortion simulation. Journal of Material Processing Technology,176, 77 – 86. [8] Shan.X, C.M. Davies, T. Wangsdan , N.P. O’Dowd, K.M. Nikbin,.2009. Thermo-mechanical modelling of a single-bead-on-plate element Method, International Journal of Pressure Vessels and Piping 86, 110–121 [9]Taljat.B, B. Radhakrishnan, T. Zacharia, 1998. Numerical analysis of GTA welding process with emphasis on post-solidification phase Transformation effects on residual stresses, Materials Science and Engineering A246 45–54. ISBN: 978-93-5268-241-6 87 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 FABRICATION OF WOOD CUTTING POWERED HACK SAW USING RENEWABLE (SOLAR) ENERGY, RECHARGEABLE BATTERY, D.C. MOTOR AND SLIDER CRANK MECHANISM N.CHANDRA KANTH K.MANOJ KUMAR A.NIRMAL SAI Assistant Professor, Student, Student, Department of Mechanical Department of Mechanical Department of Mechanical Engineering, Engineering, Engineering, Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Society’s Group of Instititions, Society’s Group of Instititions, Society’s Group of Instititions, Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Abstract— The project aims at designing a system 1. INTRODUCTION which makes the Hacksaw Blade cutter based motor A hacksaw consists of toothed blade for cutting running through solar energy.Power plays a great various metals and wood. By There are two types role wherever man lives and works. The living hacksaws will be there one will be handsaw and other will power hack saw. Generally hacksaws will have a standard and prosperity of a nation vary directly C-shaped frame which holds a blade rigidly. with the increase in the use of power. The electricity According to the blade sizes the frame can be requirement of the world is increasing at an alarming rate due to industrial growth, increased adjusted. A screw mechanism will be used to hold the blade firmly and rigidly. Now Power tools like and extensive use of electrical gadgets. According to jigsaws, and angle grinder used cutting long sheet world energy report, we get around 80% of our metals. In hacksaws mostly frame saw, the blade is energy from conventional fossil fuels like oil (36%), natural gas (21%) and coal (23%). It is well known mounted with the teeth facing outwards the handle. The cutting action is done in both the push and pull that the time is not so far when all these sources will stroke. While cutting vertically downwards direction be completely exhausted. So, alternative sources the work is kept in the bench vice and the hacksaw should be used to avoid energy crisis in the nearby future. The best alternative source is solar energy. blades is set to be facing forwards. In some frame A solar panel is a large flat rectangle, typically saws, like Piercing Saws the blades are set to be somewhere between the size of a radiator and the facing the handle because they are used to cut in the size of a door, made up of many individual solar pulled down direction against the horizontal surface. energy collectors called solar cells covered with a protective sheet of glass. The cells, each of which is In multi-operation machine at research areas, there about the size of an adult's palm, are usually are motivated by many question related production. octagonal and colored bluish black. Just like the The hacksaw machine completely changed the cutting cells in a battery, the cells in a solar panel are operation of hand saw hacksaw. The direction of designed to generate electricity; but where a cutting plays the major role for quick cutting. The battery's cells make electricity from chemicals, a perfect cutting dimension is achieved by the solar panel's cells generate power by capturing machining operation. Consider a large work piece is sunlight instead. They are sometimes called to cut with less power than we go for solar hacksaw photovoltaic cells because they use sunlight machine. The main solar renewable energy is (\"photo\" comes from the Greek word for light) to converted in to electrical energy and then to make electricity (the word \"voltaic\" is a reference to mechanical energy is utilized for cutting operation. electricity pioneer Alessandro Volta). This machine is not only use at the hill stations where Keywords- Hacksaw cutter, solar panel, the regular power supply is not available since this Rechargeable battery, DC motor, Slider crank machine is compact in structure and easy movable from place to place. The solar hacksaw machine mechanism ,etc. solves many of the limitations in regular cutting machines. The system depending on the charging circuit the motor can be controlled using relay switch. The solar power stores the energy to a battery and ISBN: 978-93-5268-241-6 88 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 then runs the motor . easy to repair, is less dependent on correct blade Features: tension and less likely to run-out. Furthermore power 1. Utilization of free available source of energy from hacksaws can be left unattended for long periods sun when cutting large diameter bar and require 2. Storage of energy into rechargeable battery. minimum operator skill. Blade replacement is 3. Stored energy is used for running wood cutter relatively cheap and simple. motor. 4. Charging circuit 5. Low Power consumption 2. LITERATURE REVIEW Figure No. 1: Schematic diagram of wood cutting After the study of many literatures about design, powered hack saw construction and working of solar power hacksaw machine, some of them describe the methodology of Solar Power Hacksaws are used to cut large sections solar power hacksaw. Lots of factor have been of wood. Cutting of wood of diameters more than consider for the design, construction and working of twenty millimeters is a very hard work with a normal solar power hacksaw machine such as cutting speed, hand held hacksaw. Therefore solar power hacksaw cutting material, cutting time ,power ,efficiency etc. machine is used to carry out the difficult and time So, lots of literatures have been found which gives consuming work. This power hacksaw machine is the relevance information and methodology of considered as an energy saving machine because the constructing an solar power hacksaw machine. operator need not be there to provide the The problem of cutting-off material to size is reciprocating motion and downward force on the common to practically every industry. Often, sawing work-piece in order to cut it. Once the operator has is the first operation carried out on bar stock. fed the work-piece till the required length in to the Therefore, it is surprising that so little work has been machine and starts the machine, then the machine done to understand the problems of this common will cut until the work-piece has been completely cut operation. Many reasons have been consider better into two pieces. The Solar Power hacksaw machine methods. Often the foreman will assign a new trainee though being able to cut the wood without requiring to a sawing task, on the principle that it is easy to any human effort to cut, it does require a human learn and difficult to foul up. Furthermore cut-off intervention to feed the work-piece many times with machines are frequently housed in stores away from measurements being taken each time before feeding. the main production areas and the operation of the sewing machines appears to be simple. The fact Figure No. 2: Fabrication of wood cutting powered remains that cutting-off operations can account for a hack saw significant part of the cost per piece (Remmerswaa and Mathysen, 1961). 3. EXPERIMENTATION The simple back-and-forth motion of the blade made the hacksaw one of the first types of sawing machines designed for power. The simplicity in the blade motion has kept the price of the saw machine relatively cheaper than other types of sawing machines. The low initial cost coupled with the flexibility and adaptability, has enabled the hacksaw to remain popular in industry. In hacksaw cutting, a single blade is tensioned in the bow, and reciprocated back and forth over the work piece. The cutting action is achieved only during half of the cycle of operation. During the second half of the cycle, the return stroke, the blade is lifted clear of the work piece, giving a discontinuous cutting action, which is considered to be one of the drawbacks of the operation. Despite this disadvantage, As compared to the continuous-cutting action of the band saw, hacksaws remain equally or even more popular alternative machines. As with many other basic processes, hacksaw cutting is a tried and tested method, reliable, consistently accurate, quick and ISBN: 978-93-5268-241-6 89 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Power Hack Sawing The worm (screw) continuously rotates and drives A power hacksaw machine is designed primarily the worm wheel (meshed with it). Worm and worm straight-line sawing. A typical sawing operation is gear form a lower pair as they have sliding contact lined below: Select a hacksaw blade of proper length with each other. for the machine and proper pitch for the material to In a worm gear drive, power is always transmitted be cut. Install the hacksaw blade with the teeth from worm to worm wheel. Power cannot be pointing downward and toward the motor end of the transmitted from worm wheel to worm. This hacksaw machine. Check the alignment of vice and phenomenon is called self-locking. It is highly useful hacksaw blade and mount the work piece in the vice. in many applications. Make the vice holds the work piece securely. Check A screw (worm) is said to have one start if it the stroke of hacksaw machine and adjust if advances one groove (in linear direction), in one necessary. After adjusting the stroke, move the complete revolution. It is said to have two starts if it hacksaw blade and sewing machine frame through advances two grooves (in linear direction) in one one cycle by hand to check the blade clearance at revolution. each end of the work piece. Readjust the position of vice if necessary. Position the hacksaw blade about Figure No. 4: Worm gear ¼ inches above the work piece and set the feed control to its lightest feed setting. Set desired speed Slider crank mechanism: of hacksaw machine. Start the machine and let the The slider-crank mechanism is one of the most blade feed lightly into the work piece for about ¼ useful mechanisms in modern technology since it inch. Readjust the feed to whatever the material will appears in most of the internal combustion engines stand for normal cutting. Permit the hacksaw blade including automobiles, trucks and small engines. to cut completely through work piece. The blade The slider-crank kinematic chain consists of four frame will trip a switch on sawing machine bed to bodies linked with three cylindrical joints and one stop the sewing machine. Cutting diameter is more sliding or prismatic joint. It is used to change than 20 mm is very hard work with a normal hand circular into reciprocating motion, or reciprocating held hacksaw. Therefore power hacksaw developed into circular motion. to carry out the difficult and time consuming work. The heavy arm moves forwards and backwards, cutting on the backwards stroke. The wood to be cut held in machine vice which is an integral part of base. Turning the handle tightens or loses the vice. The vice is very powerful and locks wood in position. SOLAR PANEL Figure No. 3: Solar panel A solar panel designed to absorb the sun's rays as a source of energy for generating electricity. A photovoltaic (in short PV) module is a packaged, Figure No. 5: slider-crank mechanism connected assembly of typically 6×10 solar cells. Solar Photovoltaic panels constitute the solar array Rechargeable battery: of a photovoltaic system that generates and supplies A rechargeable battery, storage battery, or accumulator is a type of electrical battery. It solar electricity to store in battery and run motor. comprises one or more electrochemical cells, and is Working of worm gear: a type of energy accumulator. It is known as a 90 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 secondary cell because its electrochemical reactions 4. DESIGN OF EXPERIMENT: are electrically reversible. Rechargeable batteries schematic diagram and interfacing of circuit with come in many different shapes and sizes, ranging from button cells to megawatt systems connected to each module is considered. stabilize an electrical distribution network. Several different combinations of chemicals are commonly used, including: lead–acid, nickel cadmium (NiCad), nickel metal hydride (NiMH), lithium ion (Li- ion), and lithium ion polymer (Li-ion polymer). The energy used to charge rechargeable batteries usually comes from a battery charger using AC mains electricity, although some are equipped to use a vehicle's 12-volt DC power outlet. Regardless, to store energy in a secondary cell, it has to be connected to a DC voltage source. D.C. Motor: Figure No. 7: Schematic diagram of solar wood A DC motor uses electrical energy to produce cutter mechanical energy, very typically through the interaction of magnetic fields and current-carrying Our project “Solar powered wood cutter” is mainly conductors. The reverse process, producing electrical intended to charge a battery using the solar energy energy from mechanical energy, is accomplished by and also utilized for operating the single phase wood an alternator, generator or dynamo. Many types of cutter dc motor. electric motors can be run as generators, and vice After fully charging the battery, the motor is versa. The input of a DC motor is current/voltage operated by turning the switch. and its output is torque (speed). The motor rotates at 100 rpm and gears associated with it rotate the crank. Here the connecting rod moves in to and fro motion and hence it moves the slider. Thus the hack saw connected to slider cuts the wood which is fixed in bench vice. Figure No. 6: D.C. Motor Figure No. 5: Animated version of hack saw ISBN: 978-93-5268-241-6 Advantages: 1. Conservation of Non Renewable energy sources. 2. Maximum workdone can be obtained. 3. It does not cause any environmental pollution like the fossil fuels and nuclear power. 4. Solar cells last a longer time and have low running costs 5. Low power consumption. 91 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 6. Utilization of free available source of energy from 6. CONCLUSION sun Integrating features of all the hardware components 8. Storage of energy into rechargeable battery. used have been developed in it. Presence of every 9. Stored energy is used for using wood cutter motor. module has been reasoned out and placed carefully, 10. High efficiency can be achieved using inverter. thus contributing to the best working of the unit. 11. The electricity generated by the solar cell panel is Secondly, using highly advanced IC’s with the help stored during the day with the help of storage of growing technology, the project has been batteries which give us only direct current. But to successfully implemented. Thus the project has been operate our devices we need alternating current. successfully designed and tested. Therefore we need to convert DC to AC before using any appliance using inverter. REFERENCES [1] R. Mack, R. Mueller, J. Crotts, “A Broderick. Disadvantages: Managing Service Quality,” Managing Service 1. Periodic Monitoring and Maintenance is required. Quality: An International Journal, vol. 10, no. 6, 2. A drastic environmental change cannot be tolerated 2000, pp.339-346. by the equipment. [2] Anna S. Mattila, “The Effectiveness of Service 3. The entire process of manufacture is still very Recovery in a Multi‐industry Setting,” Journal of expensive as silver is used for interconnection of Services Marketing, vol. 15, no. 7. 2001, pp. 583-596. these cells in the panel, which is a very expensive [3] Gordon H. G. McDougall, “Waiting for service: metal. the effectiveness of recovery strategies,” International 4. A practical problem linked with the use of solar Journal of Contemporary Hospitality Management, cell panels is regarding the storage of electricity vol. 11, no. 1, 1999, pp.6-15. general by them. [4] S. Michel, “Analyzing service failures and 5. The conversion of DC to AC uses inverter before recoveries a process approaches,” International using any appliance and thus it increases the cost of Journal of Kinematic Links, vol. 12, no. 1, 2001, such solar panels as the sources of electricity. pp.20-33. [5] Janis L. Miller, Christopher W. Craighead, Kirk Applications: R. Karwan, “Service recovery: a framework and 1. This energy can be utilized for simple house hold empirical investigation,” Journal of Operations appliances. Management, vol. 18, 2000, pp.387-400. 2. This energy can be stored and utilized as backup [6] Chase, Stewart, “Six types of service scotch-Yoke power supply mainly in industries. mechanism and rack and pinion mechanism,” 1994. 5. RESULTS AND DISCUSSIONS The project “wood cutting powered hack saw using solar energy” was designed such that the solar plate generates solar energy and utilizing this energy for running the wood cutter motor. Machine is driven by .67 HP and 70 rpm electric motor. Test was carried out on machine using different metal. For the loaded test, a shaft of diameter 25 mm and length 12 inch and the material of the shaft was mild steel was clamped on the vice of the machine. It took the machine 240 seconds to cut the with a new hacksaw blade. The cut was observed to be neat and straight. The total cost of equipment of the machine is Rs 4280. The total cost of producing the machine was estimated to be Rs10000. Recommendation has been made on the operation and parameters of the machine. Suggestion have been offered on overall machine performance optimization and further work on the machine. Future scope: This project can be extended in a way such that the output from the solar plate is increased. This can be done by increasing the dimensions of the solar plate. The output voltage can be displayed on LCD. ISBN: 978-93-5268-241-6 92 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 CONSIDERATION OF MATERIAL CHANGES IN E NHANCEMENT TO GET UNIQUE SOLUTIONS IN SCREW JACK-SCREW TELKAR MAHESH LAKSHMIGALLA SUNIL KUMAR Assistant Professor, Assistant Professor, Department of Mechanical, , Department of Mechanical, NNRG, Telangana, India NNRG, Telangana, India Abstract-- A power screw is drive utilized hardware to Screw change over a revolving movement into a straight Nomenclature of Thread: movement for power transmission. It produces A screw thread is obtained by cutting a continuous uniform movement and the. Outline of the power helical groove on a cylindrical surface (external thread). screw might be with the end goal that either The threaded portion engages with a relating strung the screw or the nut is held at rest and the other opening (inner string); framing a screwed clasp. Taking member rotates as it moves axially. By analyzing after are the terms that are related with screw threads different parameters in design of different threaded Screw thread nomenclature screw is done to get the most suitable combination of thread profile and there efficiency is calculated by Nomenclature of Thread different nominal diameters and pitch values to get unique solutions by changes the materials for screw. Keywords: Thread Profile, Co-efficient of friction, helix angle, Efficiency. I. INTRODUCTION A screw jack is a reduced contraption involving a screw part used to raise or lower the heavy loads. There are two main applications of screw jack to be particular water fueled and mechanical screw jack. A hydraulic jack consists of a cylinder and piston mechanism. Mechanical jack can be either hand operated or power driven. Screw jacks are made of various kinds of material having distinctive thread profiles square, trapezoidal, acme, buttress, etc. screw jack much of the time utilized as a part of raising autos, mechanical hardware and air planes. Screw jack 1. Major (nominal) diameter: This is the greatest ISBN: 978-93-5268-241-6 separation crosswise over of a screw string, touching the tops on an outside string or the fundamental establishments of an inside Thread. 2. Minor (center) measurement: This is the littlest width of a screw string, touching the roots or center of an outer string (root or center distance across) or the peaks of an inward string. 3. Pitch distance across: This is the breadth of a nonexistent chamber, going through the strings at the focuses where the string width is equivalent to the space between strings 93 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 4. Pitch: It is the separation measured parallel to the III.RESULTS & DISCUSSION hub, between relating focuses on adjoining screw In power transmission a square thread profiles are threads. basically utilized. They assume critical part as 5. Lead: It is the separation a fasten progresses pivotally effectiveness of screw is related with kind of thread one turn. profile and coefficient of rubbing. For power screw 6. Flank: Flank is the straight piece of the surface, on especially for screw jack unmistakable sorts of square either side of the screw Thread. thread profiles are open like square, trapezoidal, 7. Peak: It is the pinnacle edge of a screw string, which summit and support and changed square. In the associates the contiguous flanks at the top. present work, a screw jack is plan logically. In this 8. Root: It is the base edge of the string that associates jack, screw and nut are most noteworthy segments A the contiguous flanks at the base. fix is organized light of most over the top pliant 9. String point: This is the edge included between the anxiety and most important shear push. For most flanks of the string, measured in a hub plane. extreme load it is important to guard both values inside point of confinement for outline. Nut is a Types of Thread Profiles stationary part in which a screw turns. In this way a course weight is likewise considered. For both the II. DESIGN OF SCREW parts, in case we take blend of different materials for The screw is subjected to pure compression and hence each join of screw and nut so we can find better its core diameter is calculated = dc=d-p possible results to get sensible plan. The standard The mean diameter of the screw is given by dm= (d- material blends are (1) Hardened Steel-Bronze, µ= 0.5p) 0.08 (2) Soft Steel-Bronze, µ= 0.10 (3) Hardened Helix angle =tanα = l/π*dm Steel-Cast Iron, µ= 0.15 (4) Soft Steel-Cast Iron, µ= For single –threaded screw the lead is same as the pitch 0.17 .for double threaded screw; the lead is twice of the pitch, and so on IV. CALCULATED VALUES OF For square threaded tanФ = µ PARAMETERS FOR DIFFERENT SCREW For trapezoidal = µsecФ=µ/cos15 COMBINATIONS For acme threads= µsecФ=µ/cos14.5 In the design of screw thread, a square thread Also When Ф > α, screw is self locking. profile is considered for screw . However, the For square standard pitches (5 to 12mm) & standard nominal Torque required to raise the load diameters (24 to 100mm) are taken in order to Mt = W*(dm/2) * tan(Ф+α) calculate efficiency of different types of thread Torque required to lower the load, profiles. Moreover for screw-nut material Mt = W*(dm/2) * tan(Ф-α) combination standard values of coefficient of screw =pi/p=tanα/tan(Ф+α) friction are taken as a reference parameter: In this design a screw is a primary element (i.e. the For trapezoidal&acme most critical part) while a nut is a secondary Torque required to raise the load element. So the stresses developed on these elements are calculated. Moreover, torque transmission and critical load on screw are also found. Eventually, the calculated values and standard values are compared to find out better material for each component. Mt = W*(dm/2) * (µsecФ+ tan α)/1- µsecФtanα Torque required to lower the load, Mt = W*(dm/2) * (µsecФ-tan α)/1+µsecФtanα screw= tan α(1-µsecФtanα)/ µsecФ+ tan α ISBN: 978-93-5268-241-6 94 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Table 1 - Efficiency of different thread profiles Table 3 - Efficiency of different thread profiles For µ= 0.08 (Hardened Steel-Bronze) Hardened Steel-Cast Iron, µ= 0.15 Acme Acme Trapezoidal thread Trapezoidal thread Nominal Square thread η(%) Nominal Square thread η(%) η(%) Pitch diameter thread η(%) Pitch diameter thread (mm) (mm) η(%) (mm) (mm) η(%) 24 48.061 47 47 24 32.66 31.94 31.94 5 28 43.825 43 43 5 28 34.57 33.62 33.62 32 45.149 44.05 44.05 32 30.244 29.77 29.77 6 36 41.85 41 41 6 36 26.64 25.72 25.72 7 40 43.28 42.217 42.217 7 40 28.64 27.66 27.66 44 40.75 40.3 40.3 44 26.63 25.71 25.71 8 48 42.03 41.3 41.3 8 48 27.644 26.82 26.82 52 40.4 39.9 39.9 52 25.90 24.95 24.95 9 55 41.61 40.52 40.52 9 55 27.308 26.65 26.65 60 39.22 38.35 38.35 60 25.55 24.66 24.66 10 70 37.97 36.95 36.95 10 70 24.44 23.84 23.84 80 34.662 33.71 33.71 80 21.91 20.63 20.63 12 90 36.25 35.27 35.27 12 90 23.116 22.74 22.74 100 33.88 32.95 32.95 100 21.33 20.67 20.67 Table 2 - Efficiency of different thread profiles Table 4 - Efficiency of different thread profiles Soft Steel-Cast Iron, µ= 0.17 Soft Steel-Bronze, µ= 0.10 Acme Acme thread Trapezoidal thread Trapezoidal η(%) thread η(%) Nominal Square thread η(%) Nominal Square 28.74 diameter thread 28.74 25.63 Pitch diameter thread η(%) Pitch η(%) 25.63 26.81 (mm) (mm) 29.97 26.81 24.66 (mm) (mm) η(%) 24 26.61 24.66 25.78 5 28 27.57 25.78 23.90 24 42.537 42.211 42.211 32 25.126 23.90 24.52 6 36 26.13 24.52 22.74 5 28 38.43 37.37 37.37 7 40 24.23 22.74 23.63 44 25.18 23.63 22.83 32 39.70 38.61 38.61 8 48 23.55 22.83 21.61 52 24.86 21.61 19.01 6 36 36.65 35.69 35.69 9 55 23.23 19.01 20.11 60 22.18 20.11 18.90 7 40 37.90 36.71 36.71 10 70 19.83 18.90 80 20.95 44 35.49 34.55 34.55 12 90 19.288 100 8 48 36.708 35.81 35.81 52 34.641 33.72 33.72 9 55 36.30 35.88 35.88 60 34.045 33.71 33.71 10 70 32.87 31.9 31.9 80 29.79 29 29 12 90 31.27 30.74 30.74 100 29.07 29 29 ISBN: 978-93-5268-241-6 95 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Efficiency v/s Pitch μ= 0.08 (Hardened Steel-Bronze) Efficiency of different thread profiles Soft Steel-Cast Iron, µ= 0.17 Chart 1- Efficiency v/s Pitch for standard thread Chart 4- Efficiency v/s Pitch for standard thread profiles profiles Efficiency v/s Pitch Soft Steel-Bronze, µ= 0.10 V.CONCLUSION In this work an effective endeavor is made to outline a Chart 2- Efficiency v/s Pitch for standard thread screw jack-screw. The outline is finished by shifting profiles distinctive parameters like string profile, screw material blend, pitch and width. The entire plan concentrates on Efficiency of different thread profiles Hardened how the estimations of effectiveness, fluctuates with Steel-Cast Iron, µ= 0.15 coefficient of contact and pitch. Here, the fundamental idea is built up for picking the best material blend and string profile for given. By this we reasons that Material changes in Upgrade to get Unique Solution in Screw Jack-Screw REFERENCES [1] R.S. Khurmi, J.K. Gupta, \"Machine Design Book\", Fourteenth Edition, S. Chand And Company Ltd., New Delhi. [2] P.S.G. Design Data Book, Second Edition, Koimbtoor. [3] V.B. Bhandari, \"Design of Machine Elements\", Third Edition, Tata McGraw Hill Education Pvt. Ltd. Chart 3- Efficiency v/s Pitch for standard thread profiles 96 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 STUDY OF CNC PIPE BENDING MACHINE K. LAKSHMI KANTH P. PRAVEEN KUMAR REDDY Student, Assistant Professor, Department of Mechanical, Department of Mechanical, Siddhartha Institute of Engineering and Technology, Siddhartha Institute of Engineering and Technology, Telangana, India. Telangana, India. Abstract-- The first CNC pipe bending machine was stretched. Pipe bending machines can be roughly invented in 1979. The pipe bending machine divided into CNC pipe bending machines, hydraulic comprises a bending template for bending the pipe pipe bending machines. Mainly used for electric power there around. The unbent pipe portion is supported on construction, public railway construction, boilers, a pipe supporting rail carrier and being adjustable in bridges, ships, furniture, decoration and other aspects of height. The height adjustment of the pipe supporting pipeline laying and repair. rail is performed by a drive means, suited for step less CNC bending machines are developed for high positioning, which sets the pipe supporting rail to a flexibility and low setup times. Those machines are able height predetermined by the CNC control unit. Prior to bend single pieces as well as small batches with the to the bending of the pipe , the height to which the same precision and efficiency as series-produced parts pipe supporting rail is to be moved is determined by in an economical way. A two plane bend or compound the working program in dependents on set of tool data bend is defined as a compound bend that has a bend in which has been input into the control unit. The the plan view and a bend in the elevation. When purpose of CNC bending machine is to bend the calculating a two planebend, one must know the bend material in angular, circular directions. All slides angle and rotation (dihedral angle) guided on linear guide ways. Rapid flow has designed 2. LITERATURE REVIEW and manufactured the highest quality machines for Perishable and non-perishable tooling components tube industry .As a result pipe can be bended in any Tube bending components consist of both perishable format. components (those you will eventually have to replace) and non-perishable components (those you won’t have 1. INTRODUCTION to replace). 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 metal and the mandrel (Shank, body, nose, and ball mandrels for manufacturing furniture’s generated to motive all included). The non-perishable components include: findings an easier way for bending the pipe. CNC 1. Bend Dies bending machine is a manufacturing process that 2. Clamp Dies carried out by CNC press brakes. These machines can 3. Pressure Dies bend sheet metal work from just a few mm across to 4. Collet Pads sections. Its purpose is to assemble a bend on a 5. Wiper Holders workpiece. 6. Wiper Posts A bend is manufactured by using a bending tool during 7. Clamp Bolster a linear or rotating move.CNC bending machines are 8. Clamp Adjuster developed for high flexibility and low setup times . 9. Bend Die Base (Boss) Those machines are able to bend single pieces as well 10. Bend Post (Tool Post) as small batches with the same precision and efficiency The Bend, Clamp, and Pressure Dies as series-produced parts in an economical way. Bending is defined as the straining of metal around a The first component to consider is the bend die. A bend die is used to form the tube and determines the radius of straight axis. The metal on the inside of neutral axis is the bend. There are a number of standard die compressed. The metal on the outside of neutral axis is configurations, as well as pedestal and flange mount 97 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 bend dies. The application requirements will determine Computer Numerical Controlled (CNC) benders which style of bend die is appropriate, but pedestal and Produce tight-radius bends, large-radius bends, and flange mount bend dies are used in situations where the elliptical bends - all on the same part. They are height is larger than the width and for situations where sophisticated machines that guarantee a high level of there is not enough material left for a post through the productivity and reproducibility. CNC benders are used hole. for creating complex tubular parts because they can manipulate the tube automatically and position it with The Wiper Die precision. The wiper die supports the tube on the inside of the They consist of three axels and a servomotor driven carriage, which automatically positions the distance bend to prevent wrinkles. Steel wiper dies are used for between the bends and its plane. CNC benders do not include hydraulic or pneumatic features, leading to bending steel copper, aluminum, and bronze tubing. greater repeatability and operation. These machines are useful in several industries including automotive, HVAC, ship building and railways. There are Types of CNC axle bending machines Mandrels Fig. Axle bending machine The mandrel is the component that supports the inside Vector bend tube bending machines of the tube, which prevents collapse and wrinkling Come in various models and are designed for automated during bending. Steel/chrome mandrels are used for tube production. They come in various sizes, axis bending steel, copper, aluminum, and bronze tubing. speeds, and controllability for acceleration and While Aluminum/bronze mandrels are used for bending deceleration. The high-tech models don't use chains. stainless, titanium, and inconel tubing. In addition to These machines can be used for high strength aircraft standard pitch mandrels, close pitch mandrels can be tubing and automotive exhaust tube applications. used for thin wall tubing and tight radius bends. Vector bend electric tube bending machines are the most advanced, and deliver a high level of productivity, Fig. CNC bending machine quality, and reliability. Electric operation of the Tube and pipe bending machines machines saves more energy than conventional Tube and pipe bending machines are used to bend tubes hydraulically operated tube bending machines. These and pipes to produce finished parts. Tubes are machines are able to reverse the bend head rotation, structural, hollow conduits that are used as flow lines giving the operators flexibility during complex bending for fluids and gases in pneumatic, hydraulic, medical, applications. These machines come with an advanced and process applications. Tubes are measured by their touch screen user interface for programing and outer diameter and are usually smaller and less rigid monitoring productivity. than pipes. Pipes are vessels that are used in transport systems for fluids and solids. They generally have a Orbital head bending machines larger diameter and are measured by their inside Offer significant flexibility and can be utilized for diameter regardless of the wall thickness. Pipe and tube complex CNC tube bending. These machines bending and fabrication equipment is used to perform effortlessly produce tubular parts with coils, fittings, operations such as bending, swaging, flaring and and hoses, and can also be easily integrated with beading. automatic loading and offloading equipment. They are TYPES OF BENDING MACHINES There are many different types of tube and pipe bending machines. ISBN: 978-93-5268-241-6 98 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 used with computer controls on a high resolution touch bending process. Mandrel bending maintains a good screen. finish and is best used for handrail, ornamental iron The advanced features of these machines help to rotate work, exhaust pipes, roll cages and all stainless and the head and collets simultaneously around the parts, aluminum tubing which reduces cycle times and guarantees optimal throughput. The machines are an ideal solution for air Fig .Mandrel Bender conditioning, automotive, truck, and other complex applications. CAPABILITIES Ram bending and pressure bending machines Additional capabilities for tube bending machines can Place a tube or pipe in a die. The tube or pipe is held at include a variety of processes.Annealing and heat two ends and the ram advances on the central axis to treating is the process whereby a metal is heated to a bend the pipe. The pipe or tube is deformed inside and specific temperature and then allowed to cool slowly. outside of the curvature. Annealing allows the metal to be cut and shaped more Depending on the thickness of the pipe or tube material, easily. this process will deform the tube or pipe into an oval Buffing and polishing makes a rough surface smooth. shape. This is the easiest and least expensive bending Buffing can be done in a cutting motion, which gives a process. Ram bending is best used for electrical conduit smooth, semi-bright and uniform surface by moving the and similar light gauge product. 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. Ram bending Heat bending equipment Fig .Two Basic Buffering Motions. Places an induction coil around the tube or pipe and applies a bending force as the object passes through the End flattening is a punch press operation which heated coil. produces a flat tube end for tubular assemblies. The Sand packing or hot-slab bending machines specialized die is able to flatten the end of the tube, trim Fill a pipe with sand, cap the ends, and apply heat. The the corners and pierce a hole for fastening the tube pipe is bent around pins using mechanical force. This process minimizes distortion in the pipe cross section. Mandrel benders or rotary-draw benders . Insert a mandrel, a stationary counter-bender die, into a pipe or tube during bending so that the shape and Fig. End flattening diameter is maintained and the bends are not deformed. Department of Mechanical Engineering, NNRG. The mandrel supports the pipe internally and ensures that the interior curvature of the pipe is the best possible bend and is not deformed. This is the mostcommon 99 ISBN: 978-93-5268-241-6

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Slotting operations vary by the detail and application of machines. These include tube material and shape, both the slots desired. The process can be done using a which can affect the type of equipment required. punch press, machining, or laser operation. A punch 1) Material press is ideal for fabrication due to its cost effectiveness Many bendable tube and pipes are made from materials such as: and machining or laser operations are best for tubular, AluminumBrass intricate designs. Brass Notching is a technique which combines a punch press Carbon steel Stainless steel with a specialized punch die to reshape the end of the Copper tube. Notching allows for assembly of tubes with a tube Nickel alloys connector or welder. Polyvinyl chloride (PVC) Plastics Dimple hole Fig .Side notching single or double- Titanium punching can either be Superalloys dimple. The double-dimple style uses two individual 2) Shape punches that travel towards each other during the press Most tubes and pipes are cylindrical. However, some processes fabricate products with various cross sections cycle. The style punches without a support so they including: create a dimple. Oval Round Single hole punches have a punch that ravels from one Square Rectangular side through the tube. Support is provided at the bottom Fig. Tube shapes. of the tube to ensure the second hole is \"clean\" and non- OPERATIONS dimpled.. Some tube and pipe bending machines can perform additional operations including: Mandrel hole punching uses an internal support so the 1. Swaging outside diameter is not changed when creating a hole. 2. Flaring 3. Notching This style is used when the tubes need to fit inside one 4. Fixturing 5. Assembling another because it is more accurate and has tighter 6. Beading Bending Machines Working tolerances, even though it is more expensive than The numerical control bending machines mold comprises a bracket, working table and a clamping dimple hole punching. plate, when used by wire to the coil is energized, electricity gravitation to the pressing plate is generated, Fig. Dimple hole punching thus realizing the plate and the base plate clamp.Due to the clamping of the electromagnetic force, the pressing Tube and Pipe Characteristics plate can be made into various requirements of the The characteristics of the tubes and pipes must be workpiece, and the side wall of the workpiece considered when selecting a tube and pipe bending processing, the operation is also very simple.According to the ordinary hydraulic numerical control bending ISBN: 978-93-5268-241-6 100 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 not be made into a rectangle, but should be made into an acute angle, so the blade stress situation is not ideal, the blade damage is badly. machines Q235 mold machining sheet to do a brief CONCLUSION introduction Pipe bending is processes are used to make component , the first is connected to the power, in the control panel for automobile, aerospace, households, power plant to open the switch, and then start the pump, so that you industries etc. Our pipe bending machine is automatic, will hear pump rotation sound (this time the machine program based,it is beneficial when compared to other does not operate). automatic machines so, it can be preferable for In 2, stroke adjustment, use must pay attention to largeindustry holders, where less manual work required. regulating stroke in bending, must be tested before.The This type of bending machine is more important for upper die down to the bottom must be guaranteed to small scale work as well as industrial work in less cost have a thickness of the gap.Otherwise to the mold and more precision and accuracy of Different type of damage to machinery.Adjusting the stroke is a quick pipe bending. The machine capacity can be increased electric adjustment. accordingTo the need. Manual bending tends to 3, bending notch, in general to choose the thickness of 8 minimize wrinkles and can reduce Spring Buck. By its times the width of the notch.Such as bending 4mm design that defects can easily overcome. Simpler sheet, needs to choose 32. design not only Reduces the defects but also contributes In 4, after the expected adjustment generally have to fluid pressure test during bending. It should be noted electric rapid adjustment method and manual the tendency to wrinkleand the cross section of the tube adjustment, with shears. deformationAre reduced. Thus, this approach can be 5, step on the pedal switch start bending, CNC bending used for bending a pipe over cnc pipe bending machine machines die and cutting plate machine, can release, along its radius. release the foot stops, in step down.Plastic CNC bending machines mold, plastic machine, plastic REFERENCES board numerical control bending machines mold, plastic plate plastic plate bending bending directly, without 1. Final Working of Rolling Pipe Bending splicing, not slotted, not by welding rod, its angular appearance without water leakage, it will change into a Machine ISSN : 2249-5770 fully automatic welding machine operation, improve quality, improve labor efficiency, reduces labor costs, 2. EXPERIMENTAL DESIGN AND shorten the production cycle of the product.Full automatic plastic angle machine which belongs to the FABRICATION OF A PORTABLE electric integration of automatic machinery and equipment.According to the plastic plate heating soft 3. HYDRAULIC PIPE BENDING melting welding principle and development, it is suitable for all thermoplastic materials corner.Speed, 4. MACHINE ISSN: 2230-9926 angle processing the surface appearance, high strength.Hydraulic shearing machine is divided again 5. Design of a Hydraulic Pipe Bending Machine for tilting and gate type tilting activated carbon due to arc motion arc blade, and make it quite difficult, is FPL−GTR−148 generally used by blades do pad iron compensation, so the gap is not accurate, cut out of the sheet metal is not 6. Design of a Hydraulic Pipe Bending Machine very ideal. Because arc movement, the blade also can FPL−GTR−148 7. Research Paper of Manually Operated Pipe Bending Machine ISSN - 2250- 8. 1991 9. Fabrication of zigzag Bending Machine ISSN No 2277 - 8179 10. Design And Analysis Of Portable Rolling And Bending Machine Using 11. CAD and FEA Tool ISSN: 2278-0181 12. SHGawande;P.JAmbhorahttps://en.m.wikipedi a.org/wiki/bending machine 13. V.A Nanhaihttps://en. m.wikipedia. org/wiki/tube bending machine ISBN: 978-93-5268-241-6 101 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 FABRICATION, TESTING AND CALIBRATION OF TWO DIRECTIONAL FORCE SENSOR G.KIRANKUMAR Assistant Professor, Department of Mechanical Engineering, NNRG, Telangana, India Abstract -- Force and Torque sensors are important in static so strain gauge sensor is better for measuring robotic industries for various applications including Force. This paper describes Two Directional Force assembling parts, accepting and rejecting the objects sensors with low cost and minimum numbers strain etc. Force and Torque measurement has become gauge? Forces are measured using strain gauge as a popular area of research has demanded by the sensing element along X and Y axis. It is avoiding the respective applications. Considerable work has been difficulties in the calibration. Here groove making is done on the Force and Torque measurement using needed for increasing the sensitivity. Forces are different techniques like strain gauges and measured in terms of milli volt by using Digital volt piezoelectric sensors mounted on flexible members. meter. In chapter 2 of this paper, the design For specific applications physical models have been requirements of two directional Force sensor, selection proposed with characterization for the Forces and the of materials and the use of strain gauges and Torque. This thesis describes development of Two methodology are described. Chapter 3 describes the Directional Force Sensor for force measuring along X complete hardware design and fabrication, making and Y axis simultaneously using strain gauges. grooves and analysis beam. Chapter 4 Simulation Mechanical structure for the Force sensor has been results of the beam analysis. Chapter 5 describes the developed which contains sensing element mounted experimental results of Simple cantilever beam and near optimize strain region. The identified parameters force sensor. Chapter 6 brings out the Results and are characterized against the loading forces in X and conclusion. Y direction. Generalized equations are developed for this parameters subsequently valuated using soft 2. TWO DIRECTIONAL FORCE SENSOR computing tool i.e., ANSYS software. Results shows DESIGN REQUIREMENTS that the sensitivity of device can be increased by A force sensor measures two components of the force changing physical parameters of sensing element, and along X and Y axis.A force sensor design depends on so as to apply this device for assembling platform or the task it is intended for. In this case, the objective of robotic are configurations. the design is to develop a Two Directional Force Keyword: - Force sensor1 , Force-sensing element2, Sensor, which is capable of sensing force. The design Foil strain gauge3, and Wheatstone bridge4.etc…. also uses bending elastic elements to measure small forces and strain gauges to convert mechanical strain to 1. INTRODUCTION electrical signals. In many manufacturing applications involving A complete design of a force sensor for two directional industrial robots, it is extremely important to be able to force sensor structure requires many stages, which adjust and /or monitor the Force and Torque being begins with the selection of material that is best suited applied to the part. Work has been done on the Force in terms of characteristics, feedback, noise and friction. and Torque measurement using different techniques like Then, it is followed by a proposed design of two strain gauges and piezoelectric sensors mounted on directional force sensor to obtain maximum information flexible members. From many years strain gauges have from the object without much compromising on other been used as the basic sensing element for vast characteristics in order to suit many applications. The applications like pressure sensors, load cells, force construction of the force sensor will be completed by sensors, torque sensor and position sensors etc. from keeping in mind the application that it would be literature review, forces are measured for particular involved and also the way of apply this device for dimensions of the beam sensing element. Wrist force assembling platform or robotic are configurations. sensors are developed for grasping an object with Prior to the design and development of the electronic different degrees of freedom. Piezoelectric sensors are and instrumentation circuits to measure 2D forces, the used for dynamic measurement. It is cannot perform simulations of the beams contribute significantly in static measurements accurately. Work is consider on identifying the placement of the strain gauges. ISBN: 978-93-5268-241-6 102 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 2.1 Fabrication Materials 2) Output Voltage of 1-gage System: Two materials, namely aluminum, steel were In the cited equation for the 4-gage system, the 1- gage system undergoes resistance change, R1, at one side tested. The analysis for the selection of materials are only. Thus, the output voltage is: based on these criteria, which are high stiffness, low friction, noise, immunity and less hysteresis It was found that aluminum is malleable and can have permanent-set if subjected to accidental force. Steel obviously offers a high stiffness and can attenuate force-signal if applied in shape determination. Aluminum is used for fabricating two directional force sensor structures. It is easily available and cheap. 2.2 Strain Gauge Fig-2: 1-Gauges System 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 e = .∆ .E Gauge length 2mm (3) Measurable strain 2 to 4% Temperature range -30 to 180°C (or) Gauge resistance 350 ohms Gauge factor 2.00 e = . K. ε . E (4) Temperature 0.015%/°C 3) Output Voltage of 2-gage System: Coefficient Two sides among the four initiate resistance change. Fatigue life 10^6 reversals at 1000 Thus, the 2-gage system in the case of Fig.3 provides micro strain the following output voltage: Foil material Copper Nickel alloy Base material 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 Fig-1: 4-Gauges System e= ∆ −∆ .E (5) (or) (6) e = . K (ε − ε ). E When the gages at the four sides have their resistance 3. FABRICATION OF FORCE SENSOR changed to R1 + ΔR1, R2 + ΔR2, R3 + ΔR3 and R4 + STRUCTURE: ΔR4, respectively, the bridge output voltage, e, is: In this section, the details of the proposed e = ∆ − ∆ + ∆ − ∆ E (1) hardware of the two directional force sensor will he discussed If the gages at the four sides are equal in specifications 3.1 A New Mechanical Structure for Force Sensor: including the gage factor, K, and receive strains, є1, є2, A new mechanical structure with two DOF є3 and є4, respectively, the equation above will be: force sensor has been developed. The elastic body of e = . ������ (������ − ������ + ������ − ������ ) ������ (2) the sensor comprises of 4 I-section beams, 8 side plates 103 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 and 3 blocks. The side plates are connected to the 3 3.2. Analysis of I-section Beam. blocks and I-section beams are composed of 4 Analysis of simple cantilever beam is required for Horizontal beams that are connected from side plates. pasting the Strain gauge where the maximum strain is Aluminum material is used for Fabricating Two occurred. Strain is maximum at the place of 38mm distance from fixed end. Strain gauges are pasted at the directional force sensor. As shown in figure 4. place of 38mm distance from both the ends of beam. Fig-4: Mechanical Structure of Force Sensor 3.3. Making Groove Thickness: Groove is made at the place of 38mm distance from 1). Block: both the ends of I-section beam. It will increase the 2). Side Plate: sensitivity of the device. Strain gages are pasted on one Dimensions of block are 126×126×20 as showed in fig side of the beam and grooves are made on other side of 5. Dimensions of side plate are 56×26×12 as shown in the beam. Here groove thickness is taken in incremental fig 6. order with difference of 0.3mm i.e. 0.3mm,0.6mm,0.9mm,1.2mm,1.5mm,1.8mm,2.1mm,2. 4mm,2.7mm and 3mm and then fixing two grooved beams to the setup only in X-axis direction. Grooved beam is shown below. Fig-5: Dimensions of Block Fig-8 Grooved Beam 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-6: Dimensions of Side Plate Fig-9: Fully Assembled Calibration Kit 3) I-Section Beam: Dimensions of I-Section Beam are 130×32×6 as 4. FINITE ELEMENT MODEL OF THE ELASTIC showed in fig 7. BODY: The discretization of the domain into sub-regions is the Fig-7: Dimensions of I-Section Beam first of a series of steps that must be performed for FEM. 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. ISBN: 978-93-5268-241-6 104 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Table 2: 3mm root thickness 3mm root thickness safe load Strain Voltage (V) (kg) Fig-10: Finite Element Model of Force Sensor 0.00021304 0.0021304 1.02 0.00042608 0.0042608 Figure 10 shows a FEM model of the elastic body of the 2.04 0.00063912 0.0063912 2 DOF force sensor with 19527 element nodes and 3.06 0.00085216 0.0085216 7151 elements after mesh generation and Figure 11 4.08 0.0010652 0.010652 shows a FEM model of the Simple cantilever beam with 5.1 0.00127824 0.0127824 4891 element nodes and 1048 elements after mesh 6.12 0.00149128 0.0149128 generation. The material of the elastic body is 7.14 0.00170432 0.0170432 aluminum. 8.16 0.00191736 0.0191736 9.18 0.0021304 0.021304 Fig-11: Finite Element Model of Simple Cantilever 10.2 beam 5. Experimental results: 4.1 Strain analysis under two axis forces. 5.1 Measuring Resistance (1) Boundary conditions Connected the terminals of the strain gauge to the The elastic body is fixed on the shell of the force sensor digital volt meter and then applied load on the pan by through bolts on the base, so the connection between them can be regarded as rigid connection. Therefore the increasing 1kg up to Fx=10.2kg load and note down the total degree-of-freedom of the base of the elastic body variable resistance for each 1kg load from 0kg to can be set as zero. 10.2kg and also for Unloading from 10.2kg to 0kg. Then calculated the equivalent elastic strain from (2) Applied force/torques Each single one of the two axis force is applied to the Resistance by using formulae elastic body on the corner of the beam, respectively. When a single force is applied to the elastic body, the (∆R/R)=K.ℇ (5.1) overall deformation of the elastic body is easy to calculate by using the ANSYS software. 5.2 Measuring output voltage Output voltages are measured by connecting Quarter Strain outputs at the 4 points on the I-section beam, to Bridge, Half bridge and Full bridge .In Quarter bridge which the 4 strain gauges are stuck. The strain of the circuit one strain gauge is active and three strain gauges tensile surface of the beam is defined as positive strain, and the strain of the compressed surface is defined as are dummy(variable resistors are used),in Half bridge negative strain. The measurement range of the analyzed circuit two strain gauges are active and two strain 2 DOF force sensor is designed as Fx = 10.2 N.For the gauges are dummy(two variable resistors).In Full bridge convenience of FEM analysis, the applied force to circuit four strain gauges are active. elastic body is chosen as the maximum 10.2 N. Results are shown in table 2. After connecting Wheatstone bridge circuit, input terminals are connected to constant input voltage circuit board and output terminals are connected to digital volt meter as showed below. Note down the output voltage for each 1kg 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) ������ = (K.V.ε)/2 (5.3) For Half Bridge ������ = K.V.ԑ (5.4) For Full Bridge Where K= Gauge factor ε= Equivalent Elastic Strain V= Constant Input voltage ������ = output Voltage ISBN: 978-93-5268-241-6 105 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Table-3: 3mm grooved beam is fixed to the force 6. CONCLUSION Two directional Force sensors were developed for sensor device and measuring the voltage. calculating sensitivity of the mechanical Force sensor device. Forces are measured in terms of milli volts by Load `Voltage Strain using strain gauges. Sensitivity of the device has been found for different grooved thickness. Resistances and kg Loading Unloading Loading Unloading Voltages are measured by using Digital volt meter. Resistance and voltages are measured by applied load 1 0.001 0.002 1E-4 2.E-04 from 0kg to 10kg with a difference of 1kg load. 2 0.002 0.004 2.E-04 4E-04 3 0.003 0.006 3E-04 6.E-04 REFERENCES 4 0.005 0.007 5.E-04 7E-04 1. Huai-Ti Lin, BarryA.Trimmer,\" A new bi-axial 5 0.006 0.008 6E-04 8E-04 cantilever beam Design for Biomechanics 6 0.007 0.01 7.E-04 1E-03 Force measurements\" Journal of Biomechanics 7 0.009 0.011 9.E-04 1.1E-3 45 (2012), pp. 2310–2314. 8 0.01 0.012 1.E-03 1.2E-3 2. Le Chen, Aiguo Song, \"A Novel Three 9 0.012 0.013 1.2E-03 1.3E-3 Degree-of-freedom Force Sensor\"2009 10 0.014 0.014 1.4E-03 1.4E-3 International Conference on Measuring Technology and Mechatronics Automation. Below the graph is drawn for Load Vs voltage and 3. R. Nagarajan, M.Muralindran\" A Design strain. Methodology of Wrist Force Sensor for a Robot with Insufficient Degree of Freedom\", 0.02 volt loading IEEE conference on robotics and automaton Voltage (V) ,2003, pp 578-83. 0.01 volt 4. Qiaokang Liang a, DanZhangb,d,n, unloading YaonanWanga , \"Development of a touch 0 probe based on five-dimensional force/torque 0 10 20 Linear (volt transducer for coordinate measuring machine Load (kg) loading) (CMM)\" , Robotics and Computer-Integrated Manufacturing 28 (2012) 238–244. Fig-12: Load Vs Voltage 5. Aiguo Song , Juan Wu, Gang Qin, Weiyi Huang, \" A novel self-decoupled four degree- 2.00E-03 of-freedom wrist force/torque sensor\", Measurement, 40 (2007), 883–891. Strain 1.00E-03 strain 6. BaoyuanWua,, JianfeiLuo , FeiShen b, Yang loadi Ren , ZhongchengWub, \"Optimum design 0.00E+00 ng method of multi-axis force sensor integrated in 0 humanoid robot foot system\", Measurement, 10 20 44 (2011), 1651–1660. 7. Chao Yuan, Weijun Wang ,et.al., \"A Three Load (kg) Degree of Freedom Force/Torque Sensor to Measure Foot Forces\" 2012 12th International Fig-13: Load Vs Strain Conference on Control, Automation and Systems Oct. 17-21, 2012 in ICC, Jeju Island, Comparison of analysis and practical voltage values Korea. graph plotted in figure 14. 8. Qiaokang Liang , Dan Zhang,\" Design and fabrication of a six-dimensional wrist Fig-14: calibration of voltage for 3mm root thickness force/torque sensorbased 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 Cambridge, MA, USA, September 13-15, 2010. ISBN: 978-93-5268-241-6 106 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 THERMAL ANALYSIS TO ESTIMATE HEAT TRANSFER FROM HEAT SINK BY NATURAL CONVECTION THROUGH CLOSED ENCLOSURE POOJITHA MADUPU T.SWETHA N.CHANDRA KANTH Assistant Professor, Assistant Professor, Assistant Professor, Department of mechanical Department of mechanical Department of mechanical engineering, engineering, NNRG ,Telangana, India engineering, NNRG ,Telangana, India NNRG ,Telangana, India Abstract -- Electronic devices are strategic devices choice of material, protrusion design and surface such as radars, communication sets, and amplifiers, treatment are factors that affect the performance of a twt’s controls which are used in aircraft, space heat sink. vehicles, missiles and ground stations. The use of Plate fin heat exchanger is significant now-a-days and these devices in strategic and military application is most widely used due to high heat transfer rate. It is rapidly increasing and these equipments are becoming investigated that compact heat exchangers such as plain more and more sophisticated. Plate fin heat sinks are fin strip, offset fin, wavy fin, perforated fin, etc the commonly used devices for enhancing heat transfer in pressure drop decrease with respect to increasing the electronics components. In this thesis, investigations turbulence in working fluid. will be carried out to determine the heat transfer rates A heat sink is usually made out of copper and in a heat sink by means of varying pitch of the fin with aluminum. Copper is used because it has many air as the working fluid. Analysis is carried out for desirable properties for thermally efficient and durable heat sink with closed enclosure constant wall heat heat exchangers. First and foremost, copper is an flux. Analysis is done with Aluminum alloy 6061, excellent conductor of heat. This means that copper's where Aluminum alloy 6061 was having highest high thermal conductivity allows heat to pass through it temperature, heat transfer coefficient and better quickly. Copper is three times as dense and more efficiency values. PRO-E is used for the modeling of expensive than aluminum. Aluminum is used in plate fins. Analysis is performed in ANSYS software. applications where weight is a big concern CFD analysis is performed for different cases to Natural convection heat transfer with heat sink and determine heat transfer coefficient, pressure drop, extended surfaces has been widely used in engineering mass flow rate and heat transfer rate. From the applications [1]. The investigation was done on plate fin analysis done on the mentioned softwares finally we heat sink with consideration of zero equation turbulence get the results of pressure, velocity and heat transfer models to study the heat transfer and fluid flow coefficient values for Reynolds number 8000 and characteristics using fluent [2]. The results are shown 14000 by doing the experiments on circular fin with material Keywords: - Natural convection, FLUENT (14.5), Aluminum Alloy 6061 is better since heat transfer rate, plate-fin heat sink , Heat transfer characteristics . and effectiveness of the fin is more [3]. The laminar natural convection on vertical surfaces was investigated 1. INTRODUCTION computationally. CFD simulations are carried out using Heat transfer by convection may occur in a moving fluent software. Governing equations are solved using a fluid from one region to another or to a solid surface, finite volume approach. Relation between the velocity which can be in the form of a duct, in which the fluid and pressure is made with simple algorithm [4]. flows or over which the fluid flows. In recent years, The natural convection from a radial heat sink was done with the rapid development of electronic technology, experimentally and numerically. Parametric studies promoting the heat transfer rate under the working were performed to compare the effects of the number of process at the desired operating temperature may play fins, fin length, fin height, and heat flux on the thermal an important role to ensure reliable operation of the resistance and the heat transfer coefficient. The thermal electronic components. A heat sink is a passive heat resistance decreased and the heat transfer coefficient exchanger that transfers the heat generated by an increased in proportion to the heat flux applied to the electronic or a mechanical device to a fluid medium, heat sink base [5].Analysis was done to find the often air or a liquid coolant, where it is dissipated away different values of thermal gradient vector sum, nodal from the device, thereby allowing regulation of the temperature and thermal flux vector sum for different device's temperature at optimal levels. Air velocity, 107 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 materials of aluminum, aluminum alloy 2024, copper 3. RESULTS AND DISCUSSIONS: and stainless steel by varying the heat flux values [6] In this present study two case studies were conducted. Design of a heat sink with an open enclosure in Case study 1 studies about the pitch2; height 24 with refrigeration is analyzed for the heat transfer by forced Reynolds number as 8000 and 14000. Case study 2 convection using CATIA V5. Here even designed a studies about the pitch4; height24 with Reynolds modified model also for the heat sink. Design has been number as 8000 and 14000. modified as to compare the results with the original and In case 1 with pitch2; height24 with Reynolds number even to get the better efficiency and even the better heat 8000 and 14000 the various output parameters pressure, transfer rate [7] velocity and heat transfer coefficient were studied. In case 2 with pitch4; height24 with Reynolds number 2. MODELING AND CALCULATIONS 8000 and 14000 the various output parameters pressure, Modeling of plate fin was designed using Pro-E. Two velocity and heat transfer coefficient were studied. different kinds of the models were designed by varying pitch between the fins to know the effect of pitch CASE 1- PITCH2; HEIGHT24: difference on natural convection. Models were designed From the analysis done on the plate fin heat sink with base height of 4mm and width of 100mm and through natural convection, the result of the parameters series of 27 and 18 fins were extruded on base surface obtained for the fin of pitch2 and pitch4 with same with pitch difference of 2mm and 4 mm respectively as height after varying Reynolds number 8000 and shown in figure. 14000 are observed and shown below in detail through the graphs Fig -1:Pitch2; Height24 In graph1, with pitch2; height24 shows the variations of pressure with respect to Reynolds number. The maximum pressure at Re 8000 is 1.697e+000 Pa and at Re 14000 is 4.678e+000 Pa. For graph2, with pitch2; height24 shows the variations of velocity with respect to Reynolds number. The maximum velocity at Re 8000 is 4.951e+000 m/sec and at Re 14000 is 8.667e+000 m/sec. For graph 3, with pitch2; height24 shows the variations of heat transfer coefficient with respect to Reynolds number. The maximum heat transfer coefficient at Re 8000 is 3.619e+001 W/mm2K and at Re 14000 is 5.600e+001 W/mm2K REYNOLDS NUMBER 8000 Fig-2:Pitch4; Height24 Fig -3: Pressure 2.1 VELOCITY CALCULATIONS: Fig -4: Velocity Velocity of the flowing air on the plate fins were Department of Mechanical Engineering, NNRG. calculated for the Reynolds number values of 8000 and 14000 using this equation (1). Theoretically the values 4.86911 m/sec and 8.52095 m/sec rate of velocity were obtain for Reynolds number 8000 and 14000 respectively. Reynolds number, Re = × × ---------------------- (1) Where, ρ=density of air, kg/m3; V=velocity of air, m/s ; L=length of the fin, m; µ=dynamic viscosity of air, kg/m-s The pressure values were found from the known values of velocity. 108 ISBN: 978-93-5268-241-6

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Pressure,Pa 5.00E+00 4.00E+00 3.00E+00 2.00E+00 1.00E+00 0.00E+00 8000 14000 Reynolds number Fig -5:Heat transfer co-efficient Graph 1 REYNOLDS NUMBER 14000 Velocity, m/s 1.00E+01 8.00E+00 6.00E+00 4.00E+00 2.00E+00 0.00E+00 8000 14000 Fig -6: Pressure Reynolds number Graph 2 Fig -7: Velocity Heat transfer co- 6.00E+01 efficient, w/mm2K 4.00E+01 2.00E+01 0.00E+00 8000 14000 Reynolds number Fig-8: Heat transfer co-efficient Graph 3 ISBN: 978-93-5268-241-6 CASE 2 -: PITCH4; HEIGHT24: In graph 4, with pitch2; height24 shows the variations of pressure with respect to Reynolds number. The maximum pressure at Re 8000 is 1.703e+000 Pa and at Re 14000 is 4.677e+000 Pa. In graph 5, with pitch2; height24 shows the variations of velocity with respect to Reynolds number. The maximum velocity at Re 8000 is 4.958e+000 m/sec and at Re 14000 is 8.666e+000 m/sec. In graph 6, with pitch2; height24 shows the variations of heat transfer coefficient with respect to Reynolds number. The maximum heat transfer coefficient at Re 8000 is 3.624e+001 W/mm2K and at Re 14000 is 5.600e+001 W/mm2K 109 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 REYNOLDS NUMBER – 8000 Fig -13: Velocity Fig -9: Pressure Fig -10: Velocity Fig-14: Heat transfer co-efficient Fig -11: Heat transfer co-efficient Pressure,Pa 5.00E+00 REYNOLDS NUMBER 14000 4.00E+00 3.00E+00 Fig -12: Pressure 2.00E+00 ISBN: 978-93-5268-241-6 1.00E+00 0.00E+00 8000 14000 Reynolds number Graph 4 Velocity, m/s 1.00E+01 8.00E+00 6.00E+00 4.00E+00 2.00E+00 0.00E+00 8000 14000 Reynolds number Graph 5 110 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Heat transfer 6.00E+01 Innovative Technology (IJEIT) Volume 3, coefficient, w/mm2k 5.00E+01 Issue 2, August 2013 4.00E+01 3.00E+01 6. Ankit Mayank , Rajvinder Singh , J.P. Singh , 2.00E+01 Ashok Singh Yadav\" , Design and Analysis of 1.00E+01 0.00E+00 Extended Surfaces with Different Thermal Conductivity Using ANSYS 12\", International 8000 14000 Journal of Innovative Research in Science, Reynolds number Engineering and Technology(An ISO 3297: 2007 Certified Organization) Vol. 5, Issue 4, Graph 6 April 2016 7. J Veerababu ,Sanmala Rajasekhar , V.V 4. CONCLUSIONS Ramakrishna ,Y.Dhana Sekhar, “Thermal The values of pressure drop, velocity and heat transfer coefficient values are compared in this analysis. Analysis to Estimate Heat Transfer From Heat Sink By Forced Convection Through Open Through this analysis, it was concluded that the values of pressure drop, velocity and heat transfer coefficient Enclosure”, International journal of Science engineering and Advance Technology, values were increased with the increasing of Reynolds IJSEAT, Vol.3, Issue 12 number. Finally it can be concluded that for the heat transfer of natural convection through closed enclosure, for getting highest values of the result parameters Reynolds number with greater value is considered. 5. REFERENCES: 1. Han -Taw Chen, Tzu-Hsiang Lin, Chung-Hou Lai, \"Study of Natural Convection Heat Transfer of Plate-Fin Heat Sink in a Closed Enclosure\", International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering Vol: 9, No: 7, 2015 2. H.T. Chen, C.H. Lai, T.H. Lin, G.J. He, “Estimation of natural convection heat transfer from plate-fin heat sinks in a closed enclosure”, International Conference on Mechanical, Aeronautical and Manufacturing Engineering (ICMAME), London, United Kingdom, 2014, August 21-22. 3. P. Sai Chaitanya, B. Suneela Rani, K. Vijaya Kumar,\" Thermal Analysis of Engine Cylinder Fin by Varying Its Geometry and Material\", IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278- 1684,p-ISSN: 2320-334X, Volume 11, Issue 6 Ver. I (Nov- Dec. 2014), PP 37-44 4. Mahdi Fahiminia, Mohammad Mahdi Naserian, Hamid Reza Goshayeshi1, Davood Majidian, “Investigation of Natural Convection Heat Transfer Coefficient on Extended Vertical Base Plates”, Energy and Power Engineering, 2011, 3, 174-180 5. M. Patil, P.D. Kabudake,\" Analysis of Natural Convection around Radial Heat Sink\", International Journal of Engineering and ISBN: 978-93-5268-241-6 111 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Performance Analysis on Rate of Heat Transfer for Shell and Tube Heat Exchanger by Increasing Number of Tubes in Parallel & Counter Flow KALERU APARNA CHINTIREDDY SHARATH REDDY Department of Mechanical Engineering Department of Mechanical Engineering JNTUH College of Engineering Sultanpur Chaitanya Bharathi Institute of Technology (A) Sangareddy, Telangana, India Hyderabad, Telangana, India [email protected] [email protected] Abstract - The present work deals with the heat for shell and tube heat exchanger with different number transfer analysis of a shell and tube heat exchanger of tubes (5, 25), to find the LMTD, overall heat transfer and simulation through Computational Fluid coefficient and heat transfer area through CFD Dynamics (Fluent) by varying number of tubes. The simulation which are useful for calculating Rate of Heat design consists of a simple shell and tube heat transfer and to draw the temperature contours for exchanger with five tubes and also consist the same different cases of shell and tube heat exchanger design modified with more number of tubes i.e. (Counter flow& Parallel flow) [3]. twenty five, for which temperature, pressure and velocity profiles are simulated. The variation in heat II. METHODOLOGY AND GEOMETRIC MODELING transfer in two of these cases both in parallel & counter flow were calculated by using the overall A. Case 1; Modeling of simple Shell and Tube Heat heat transfer coefficient, heat transfer area obtained from solution report of CFD-Post and LMTD can be Exchanger with Five Tubes: calculated from the drawn plots for parallel and counter flow through CFD simulation. This study In this case modeling of shell and Tube Heat Exchanger also shows the LMTD of counter flow heat exchanger is greater than the parallel flow case, and with five tubes is done using the following dimensions it can also be observed that with increase in number of tubes, surface area of heat transfer increases due and the design software Ansys14.5 [4]. to which the rate of heat transfer also increases. Index Terms - Shell and tube heat exchanger, TABLE I Computational Fluid Dynamics, LMTD, Overall Heat Shell Diameter 80mm transfer coefficient, Rate of heat transfer. Working fluid Water Pipe diameter 10 mm inner, 20 mm outer Cold water temperature 27 0C (300K) Hot water temperature 87 0C (380K) Length of tube 700mm Number of Tubes 5 I. INTRODUCTION Heat Exchanger devices have its application in various fields from petrochemical industries to power plants and everything in between. Some of the other areas where heat transfer must be regulated include heat engines, heat pumps, fuel cells, gas turbines, electronic packaging systems and food processing [1]. There are different types of heat exchanger available in market as per their application such as such as plate fin, shell and tube, double pipe, plate and shell, pillow plate, etc. are a few types of heat exchangers used on an industrial scale Fig. 1 Modelling of simple shell and tube heat [2]. Among which shell and tube heat exchanger exchanger with five tubes (STHX) were used in industries mostly. Shell and tube heat exchangers mostly used in industries because of they can easily cleaned up, lower cost, more flexible adaptability compared with other heat exchanger. The objective of this study is to analyze the heat transfer rate ISBN: 978-93-5268-241-6 112 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Fig. 2 Meshing of simple shell and tube heat Fig. 4 Front view of the Shell and Tube Heat exchanger with five tubes Exchanger designed with number of tubes as twenty Mesh details of the Shell and Tube Heat Exchanger is five. reported in Table II TABLE II Number of nodes 176987 umber of elements 898271 Tetrahedron 898271 B. Case 2; Modeling of Shell and Tube Heat Exchanger with Number of tubes twenty five: In this case Modeling of Shell and Tube Heat Exchanger with twenty five tubes is done using the following dimensions and the design software Ansys14.5. TABLE III Fig. 5 Mesh generation of shell and tube heat exchanger with number of tubes twenty five. Shell Diameter 110mm Working fluid Water Pipe diameter 10 mm inner, 20 mm Mesh details of the Shell and Tube Heat Exchanger outer with Number of tubes Twenty five is reported in Table 27 0C (300K) Cold water IV. temperature 87 0C (380K) TABLE IV Hot water Number of 1516813 temperature nodes Length of tubes 700mm Number of 7575217 Number of Tubes 25 elements Tetrahedron 7575217 C. Boundary Conditions TABLE V Boundary Conditions of hot water and cold water (number of tubes 5, 25). Material Hot water Coldwater Inlet type Velocity inlet Velocity inlet Temperature 300K 380K Velocity 0.55m/s,11m/s 0.44m/s,10.5m/s Pressure 101325 Pa 101325 Pa Fig. 3 Modelling of shell and tube heat exchanger Outlet type Pressure Pressure Outlet with number of tubes as twenty five. Outlet ISBN: 978-93-5268-241-6 113 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 III. CALCULATIONS A. RATE OF HEAT TRANSFER AND LMTD[5] Q = UA ∆Tm U= Overall Heat Transfer coefficient in W/������ ������ A= Area of Heat transferred in ������ ∆Tm=Logarithmic Mean Temperature Difference (LMTD) We have taken same temperature limits in 2 cases; A. TEMPERATURE CONTOUR-COUNTER FLOW hence LMTD for two cases (shell and tube with 5, 25 tubes) is same. 1) Parallel flow: ( )( ) ∆Tm= ( ) ( )( ) = ) ( =22.12 0C 2) Counter flow: ( )( ) Fig. 6 Temperature Distribution in the center plane of the counter ∆Tm = () flow shell and tube heat exchanger with number of tubes five. ( )( ) In Fig.6, Exchange of heat between the hot fluid = and cold fluid is shown. It is observed that in ( ) counter flow case effective heat transfer took place compare to the parallel one. In this case hot fluid = 22.45 0C temperature totally reduced and it reached the cold fluid temperature. It can be observed through the Thi, Tho - Hot inlet& outlet temperatures change of colour from Red to Blue. Tci, Tco - Cold inlet& outlet temperatures B. TEMPERATURE CONTOUR- PARALLEL FLOW NOTE: Area of heat Transfer (A), Overall Heat Transfer Coefficient (U) values for two cases are obtained from CFD-post (Simulation Results). IV. RESULTS AND DISCUSSIONS Case 1: Shell and tube Heat Exchanger with 5 tubes Case 2: Shell and tube Heat Exchanger with 25 tubes  For ∆Tm=22.13 0C TABLE VI  For ∆Tm=22.45 0C Fig. 7 Temperature distribution in the center plane of the Parallel flow shell and tube heat exchanger with number of tubes five. ISBN: 978-93-5268-241-6 C. TEMPARATURE PLOTS Plots are drawn below for counter flow and parallel flow respectively, by taking length of the tube as position in mm in the X-axis (0 to 700 mm) where as the Temperature in Kelvin (300K to 380K) in the Y- 114 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 axis. LMTD can be easily calculated from the temperature limits, which are directly taken from the plots drawn below. Fig. 8 Temperature Plot for counter flow shell and Fig. 10 Temperature distribution across the center plane of the tube heat exchanger with five tubes. Counter flow shell and tube heat exchanger with number of tubes NOTE: In Fig. 8, White colour shows decrease in Twenty five. Temperature of Hot fluid from 380K to 300K and the Red colour shows increase in temperature of the Cold Exchange of heat between the hot fluid and cold fluid from 300K to 380K. fluid is shown here in the Fig. 10. It can be observed that in counter flow case effective heat transfer took place compare to the parallel one. Fig. 11 Temperature distribution in the center plane of the parallel flow shell and tube heat exchanger with number of tubes Twenty five. Fig. 9 Temperature Plot for parallel flow shell and tube heat exchanger with five tubes. NOTE: In Fig 9, White colour shows decrease in Temperature of Hot fluid from 380K to 300K and the Red colour shows increase in temperature of the Cold fluid from 300K to 380K. Fig. 12 Temperature Plot for counter flow shell and tube heat exchanger with 25 tubes ISBN: 978-93-5268-241-6 115 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 At the inlet we can observe high pressure and as the flow goes the pressure drop occurs, So that we get low pressure at the outlet. Fig. 13 Temperature Plot for parallel flow shell and tube heat exchanger with 25 tubes. Fig. 17 Velocity contour for a Counter flow Shell and tube heat exchanger with five tubes. Here we have high velocity at the inner tube, because it has the smaller diameter and the outer tube has the low velocity. Fig. 14 Pressure contour for a parallel flow Shell and tube heat exchanger with five tubes. At the inlet we can observe high pressure and as the flow goes the pressure drop occurs, So that we get low pressure at the outlet. Fig. 18 Pressure contour for a parallel flow Shell and tube heat exchanger with Twenty five tubes At the inlet we can observe high pressure and as the flow goes the pressure drop occurs, So that we get low pressure at the outlet. Fig. 15 Velocity contour for a parallel flow Shell and tube heat exchanger with five tubes. Here we have high velocity at the inner tube, because it has the smaller diameter and the outer tube (shell) has the low velocity. Fig. 19 Velocity contour for a parallel flow Shell and tube heat exchanger with Twenty five tubes. Fig. 16 Pressure contour for a counter flow Shell and tube heat Here we have high velocity at the centre tubes, exchanger with five tubes. because it has the smaller diameter and the outer tube has the low velocity. ISBN: 978-93-5268-241-6 116 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 the smaller diameter and the outer tube has low velocity (0.5 m/s). In Pressure Plot-Counter Flow case Pressure variation across the centre plane of a counter flow concentric tube heat exchanger is plotted by taking position or length of the tube on x-axis and Pressure on y-axis. The points are taken from the pressure contour as shown in Fig. 23. Fig. 20 Pressure contour for a Counter flow Shell and tube heat exchanger with Twenty five tubes. At the inlet we can observe high pressure and as the flow goes the pressure drop occurs, So that we get low pressure at the outlet. Fig. 21 Velocity contour for a Counter flow Shell and tube heat Fig. 23 Pressure Vs Length of the Tube exchanger with Twenty five tubes The trend shows decrease in pressure along the length Here we have high velocity at the centre tubes, of the tube in inner tube as well as outer tube. It can be because it has the smaller diameter and the outer tube observed that from inlet to outlet, high pressure i.e. 1.5 has the low velocity. K Pa at the inlet and as the flow goes the pressure drop occurs, So that we get low pressure i.e.-5 K Pa at the D. PRESSRE AND VELOCITY PLOTS outlet. 1) Case 2 shell and tube heat exchanger with five tubes In Velocity-Parallel Flow case velocity variation across In Velocity Plot-Counter Flow case velocity the centre plane of a Parallel flow shell and tube heat variation across the centre plane of a counter flow Shell exchanger is plotted by taking velocity on x-axis and and tube heat exchanger with five tubes is plotted by taking velocity on x-axis and position or length of the position or length of the tube as y-axis. The points are tube as y-axis. The points are taken from the velocity taken from the velocity contour as shown in Fig. 24. contour as shown in Fig. 22. Fig. 22 Velocity Vs Length of the Tube Fig. 24 Velocity Vs Length of the Tube. The trend shows increase velocity in the inner tube The trend shows increase velocity in the inner tube along the length of the tube and low velocity in the along the length of the tube and low velocity in the outer tube. It can be observed that from inlet to outlet, outer tube. It can be observed that from inlet to outlet, high velocity (2.5 m/s) at the Inner tube, because it has high velocity (2 m/s) at the Inner tube, because it has the smaller diameter and the outer tube has low velocity (0.5 m/s). In Pressure Plot-Parallel Flow case Pressure variation across the centre plane of a counter flow concentric tube heat exchanger is plotted by taking position or length of the tube on x-axis and Pressure on y-axis. The points are taken from the pressure contour as shown in Fig. 25. ISBN: 978-93-5268-241-6 117 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Fig. 25 Pressure Vs Length of the Tube The trend shows decrease in pressure along the The trend shows decrease in pressure along the length of the tube in inner tube as well as outer tube. It length of the tube in inner tube as well as outer tube. It can be observed that high pressure i.e. 1.5 K Pa at the can be observed that high pressure i.e. 1.5 K Pa at the inlet and as the flow goes the pressure drop occurs, So inlet and as the flow goes the pressure drop occurs, So that we get low pressure i.e.-5 kpa at the outlet. that we get low pressure i.e.-6 K Pa at the outlet. In Velocity Plot-Counter Flow case velocity 2) Case 2 Shell and Tube Heat Exchanger with variation across the centre plane of a counter flow shell and tube heat exchanger with number of tubes twenty Twenty Five Tubes five is plotted by taking velocity on x-axis and position In Velocity Plot-Parallel Flow case velocity or length of the tube as y-axis. The points are taken variation across the centre plane of a Parallel flow shell from the velocity contour as shown in Fig. 26. and tube heat exchanger with twenty five tubes is plotted by taking velocity on x-axis and position or length of the tube as y-axis. The points are taken from the velocity contour as shown in Fig. 28. Fig. 26 Velocity Vs Length of the Tube Fig. 28 Velocity Vs Length of the Tube The trend shows increase velocity in the inner tube The trend shows increase velocity in the inner tube along the length of the tube and low velocity in the along the length of the tube and low velocity in the outer tube. It can be observed that from inlet to outlet, outer tube. It can be observed that high velocity (2 m/s) high velocity (2.5 m/s) at the Inner tube, because it has at the Inner tube, because it has the smaller diameter the smaller diameter and the outer tube has low velocity and the outer tube has low velocity (0.5 m/s). (0.5 m/s). In Pressure Plot–Counter Flow case Pressure In Pressure Plot–Parallel Flow case velocity variation across the centre plane of a counter flow variation across the centre plane of a Parallel flow shell concentric tube heat exchanger is plotted by taking and tube heat exchanger with twenty-five tubes is position or length of the tube on x-axis and Pressure on plotted by taking Position or length of the tube in x-axis y-axis. The points are taken from the pressure contour and Pressure in y-axis. The points are taken from the as shown in Fig. 27. Pressure contour as shown in Fig. 29. Fig. 27 Pressure Vs Length of the Tube Fig. 29 Pressure Vs Length of the Tube ISBN: 978-93-5268-241-6 The trend shows decrease in pressure along the length of the tube in inner tube as well as outer tube. It can be 118 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 observed that from inlet to outlet, high pressure i.e. 1.5 The calculated LMTD for Counter flow is 22.45 0C and K Pa at the inlet and as the flow goes the pressure drop for Parallel flow is 22.12 0C which is same for two occurs, So that we get low pressure i.e. -6 K Pa at the outlet. cases. It is observed that LMTD of counter flow heat NOTE: From the pressure and velocity plots which are drawn for TWO cases shows that the obtained Pressure exchanger is greater than parallel flow. Effective Heat drop is optimum in three cases. Maximum allowable transfer also took place in counter flow heat pressure drop is 10 psi (1 psi is 6894.757 Pa). Among exchangers. all, Case 2 gives reduced pressure drop because increasing the shell diameter, increases flow area due to Heat transfer area of Shell and tube Heat Exchanger increased number of tubes and, thereby, reduces flow with five tubes and with 25 tubes are obtained from velocity and, hence reduces pressure drop, it also means CFD-simulation Results. Those are 0.003563 m2, reduced length too, leads to reduced pressure drop. 0.059024 m2 and 0.260837 m2 respectively. The overall Heat transfer coefficient obtained for three cases from CO-ORDINATES FOR TEPERATURE PLOTS simulation results are 600 W/m2, 800 W/m2 and 1200 The above Temperature plots are drawn by taking x, y, W/m2 respectively. z coordinates as lines in the hot fluid zone and cold fluid zone. The white & red lines shown in graph are The calculated Rate of Heat Transfer for two cases is hot fluid, cold fluid respectively, and it shows that 1044W and 6926.78W respectively. It is observed that temperature of the hot fluid decreases and temperature with increase in number of tubes heat transfer area of the cold fluid increases. increases, through which the rate of heat transfer increases. TABLE VIII The Pressure drop in the Heat exchanger can be estimated through the pressure contours and plots obtained for two cases. The practical simulation of a designed model is very expensive, hence CFD is a tool which helps to simulate the process and thus eliminating the cost, for the development of a prototype based on study and also the Practical simulation of shell and tube heat exchanger with more number of tubes is complicated [6,7]. CFD simulation directly gives all the parameters which are required for calculating rate of heat transfer and it saves time. REFERENCES [1] Digvendra singh, Narayan Das Pal, “Designing and Performance Evaluation of a Shell and Tube Heat Exchanger using Ansys (Computational Fluid Dynamics)”, International Journal of Scientific Engineering and Applied Science (IJSEAS) – Volume-2, Issue-3,March 2016. V. CONCLUSIONS [2] Jian Wen, Huizhu Yang, Simin Wang, Yulan Modeling of Shell and Tube Heat Exchanger with Xue , Xin Tong, “Experimental investigation five tubes and with 25 tubes is done using Ansys. CFD simulations are carried out to the two cases. on performance comparison for shell-and-tube Temperature, Velocity and Pressure Plots are drawn for both the cases. Temperature, pressure and Velocity heat exchangers with different baffles”, distributions across the center plane of shell and tube International Journal of Heat and Mass heat exchanger with number of tubes five and twenty- five are obtained and the variation of temperature in Transfer, 84 (2015) 990–997. case of parallel and counter flow heat exchangers is [3] Santosh Kansal, Mohd. Shabahat Fateh, studied. LMTD is calculated from the Temperature limits taken from the drawn plots, for counter flow and “Design and Performance Evaluation of Shell parallel flow heat exchangers. Area of Heat transfer and and Tube Heat Exchanger using CFD Overall heat Transfer coefficient is obtained from the CFD-post (simulation Results). Rate of Heat Transfer is Simulation”, International Journal of also calculated for two cases. Engineering Research & Technology (IJERT), Vol. 3 Issue 7, July – 2014. [4] Divi Venkata Prashanth, Goroginam Santhi, “Cfd Analysis Of Double Pipe Parallel Flow Heat Exchanger”, International Journal Of Professional Engineering Studies, Volume Vii /Issue 1 / Sep 2016. ISBN: 978-93-5268-241-6 119 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 [5] Swathi Juturu, J. Kishore, “Comparison of Effectiveness of Two Different Setups of Double Pipe Heat Exchangers”, International Journal for Research in Applied Science & Engineering Technology (IJRASET), Volume 3 Issue IX, September 2015. [6] BENGT SUNDE´N, “Computational Fluid Dynamics in Research and Design of Heat Exchangers”, Heat Transfer Engineering, 28(11):898–910, 2007. [7] B. Alma, U. Imke, R. Knitter, U. Schygulla, S. Zimmermann, “Testing and simulation of ceramic micro heat exchangers”, Chemical Engineering Journal, 135S (2008),179–184. ISBN: 978-93-5268-241-6 120 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 DESIGN AND FABRICATION OF BELT CONVEYOR SYSTEM FOR WEIGHT T. MAHESH V.NARESH Assistant Professor, Student, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Department of Mechanical Engineering, Group of Instititions, Nalla Narasimha Reddy Education Society’s Hyderabad, Telangana State, India Group of Instititions, Hyderabad, Telangana State, India ABSTRACT-- In any handling of rice bags, the bags e. Slat Conveyor f. Flat Belt Conveyor being passes through long distance and it needs to be g. Magnetic Belt Conveyor transported from place to place. This could involve h. Troughed Belt Conveyor i. Bucket Conveyor processes such as transporting of rice bags from store BELT CONVEYOR SYSTEMS: to vehicles and vehicles to store. The bags are shifting Belt Conveyors can be used for different from the one station to another station and finally to applications of conveying Raw materials to finished the store or warehouse. For low volume and small goods; and at Dynamic Industrials these are distance of handling of bags is to take from one place specifically designed according to your specific needs. to another place with the help of worker. In large travelling setups, where the transfer rates are high Fig:1.1 Trough Belt Conveyors for Bulk Material and the bags to be handled is difficult. In such cases Handling this system is used to reduce man power. This project attempts to discuss the generalized design INCLINED BELT CONVEYOR SYSTEM: consideration for adjustable height and maximum Fig: 1.2Inclined Belt Conveyor Systems load transfer belt conveyor. in first stage collecting the VARIABLE SPEED BELT CONVEYORS: data from the different vehicles. In next stage belt Fig:1.3 Variable Speed Belt Conveyors conveyor consists of an endless belt of a resilient material connected between two pulleys and moved by rotating one of the pulleys through a drive unit which is connected to an electric motor. Motor can rotate in both directions to clockwise and anti-clockwise directions. Conveyor mechanism is used in the system. Height of the conveyor system is adjusted by the pin type. In next stage preparing software model by CREO software. PROBLEM DEFINATION: The roller conveyor assembly normally involves the use of channels, rollers and shaft that are heavy by virtue of their structure and the material used as iron, aluminium pulleys. OBJECTIVES OF THE WORK The main objective is to suggest the alternative material for roller used in roller conveyor for weight optimization. The following are important points regarding this objective of study –: 1. Study existing roller conveyor system and its design. 2. Geometric modelling of existing roller conveyor. 3. Recommendation of new solution for weight optimization TYPES OF CONVEYORS Conveyors are again classified into different categories those are as follows: a. Chute Conveyor b. Wheel Conveyor c. Roller Conveyor d. Chain Conveyor 121 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 SIDEWALL &CLEATED BELT CONVEYORS conveyors. Available in two models namely Motorized Roller Conveyor and Gravity force roller Conveyors; these are economical solutions for carrying heavy weight material. BEND ROLLER CONVEYOR SYSTEMS: Fig:1.4 Sidewall & Cleated Belt Conveyors Fig:1.8 Bend Roller Conveyor Systems TELESCOPIC ROLLER CONVEYORS: GRAVITYROLLER CONVEYOR SYSTEMS: Roller Conveyors are an integral part of the material handling industry due to its high load carrying capacities and sturdiness. It's a series of rollers supported in a frame over which objects are advanced manually, by gravity or by power. Fig:1.5 Gravity Roller Conveyor Systems Fig:1.9 Telescopic Roller Conveyors DYNAMIC RANGE OF ROLLER CHAIN CONVEYORS: CONVEYORS: As the name suggest, chain conveyors are equipped Powerised Roller Conveyors: with interlinked chains, selected /manufactured Here all the rollers are power according to the customer specific needs. These run- Gravity Roller Conveyors on custom-made sprockets on each end. The Gravity roller conveyor system is a declining sort of conveyor system, whereby the weight of the product drives the product to the point of discharge with help of Gravity Fig:1.6 Manual Push Roller Conveyor System POWERISED ROLLER CONVEYOR Fig:1.10 Chain Conveyors Fig:1.7 Powerised Roller Conveyor BALL TABLES: We manufacture a precision engineered range of roller Ball tables or Ball transfer units are also conveyors which are also termed as mono rail sometimes known as Ball transfer conveyors. Here the material is pushed manually / through gravity over a series of free balls fixed over metal tables. This is also very effective where the material size is big & needs to be pushed manually over short / long distance. ISBN: 978-93-5268-241-6 122 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 OVERHEAD CONVEYORS: SUSHI CONVEYORS: The conveyors installed in a hanging position with minimal use of the ground area are denominated as Overhead conveyors¸ The use of overhead conveyor systems in factory settings is a great way to conserve space and man power. Fig:1.11 Overhead Conveyors Fig: 1.17 Sushi Conveyors SLAT CONVEYORS: DESIGN OF BELT CONVEYOR SYSTEM Fig:1.12 Slat Conveyors It is necessary to have design related basic information The Slat Chain systems are highly used in about various components of belt conveyor before bottling, packing, Aluminium Cans, PET & HDPE attempting to design belt conveyor. The design of belt Bottles in Dairy Food, Food processing & packing, conveyor is depends upon design/construction of Beverages, Pharmaceuticals, Consumer Durables and individual component. more. MODULAR CONVEYORS: INTRODUCTION The Belts or Ropes are used to transmit power from one Fig:1.13 Modular Conveyors shaft to another by means of pulleys which rotate at the MODULAR PLASTIC BELT CONVEYORS: same speed or at different speeds. The amount of power transmitted depends upon the following factors: There are a lot of industrial and food 1. The velocity of the belt. applications, which the belt conveyors and other 2. The tension under which the belt is placed on the types of conveyors are unable to cater to. Our pulleys. Modular conveyors have an answer to a lot of 3. The arc of contact between the belt and the smaller those. Plastic Modular Belts offer highly rugged pulley. yet flexible design choices. These are used is 4. The conditions under which the belt is used. It may Food Processing & packing, Bakery and snack be noted that food application, freezers, engineering industry, Packing lines, Dip tank applications and a lot SELECTION OF A BELT DRIVE more. Following are the various important factors upon which GRIPPER CONVEYORS: the selection of a belt drive depends: 1. Speed of the driving and driven shafts, Used for empty product / filled product 2. Speed reduction ratio, conveying to the filling machine / vice versa. 3. Power to be transmitted, Special attachments are provided to the belts to hold 4. Centre distance between the shafts, different types of products for conveying. 5. Positive drive requirements, 6. Shafts layout, 7. Space available, and 8. Service conditions. Circular belt or rope: The circular belt or rope as shown in Fig. (c) Is mostly used in the factories and The leather belts must be periodically cleaned and dressed or treated with a compound or dressing containing neats foot or other suitable oils so that the Density of Belt Materials: The density of various belt materials is given in the following table. Table. Density of Belt Materials Hinged joint Sometimes, metal hinges may be fastened to the belt ends and connected by a steel or fibre pin as shown in Fig. (d). ISBN: 978-93-5268-241-6 123 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 DESIGN OF BELT CONVEYOR SYSTEM: Effective tension (Te) = total empty friction + load Input data used for designing the belt conveyor system are: friction + load slope tension (3) Material density=1600 kg/m3, Return side tension= Fe x W x L x 0.4 x 9.81 x10-3 Belt speed v = 0.02m/s, Length of conveyor L = 1.5 meter, For horizontal and elevating conveyors, Fe = 0.020 Height of conveyor, H = 2.5 meter, Inclination angle = 10.36°, W=weight of material + weight of belt, kg/m Material Size =850 x 395 x 268 mm, Weight of material, Design procedure for belt conveyor system The following procedure is followed to design present Wm= (C x 2000)/(60xv) belt conveyor system Wm= (1081x 2000)/ (60x0.02) BELT CAPACITY: Belt Capacity c = 3.66 x load cross section area Wm=500 perpendicular to belt x belt speed x material density(1) C = 3.66 x 850 x 395 x 0.02x 0.044 Weight of belt, C = 1081kg/hr Wb=16.6 lbs/ft, BELT WIDTH: Belt width = (T1(kg) / Belt strength (kg/inch)) (2) W=weight of material + weight of belt, kg/m Live load = C / (3.6 x v) =1081/ (3.6 x v0.02) =15.013 kg/m W= 516.33 kg/meter Total live load (A)=live load x conveyor length=120 kg Return side tension = Fe x W x L x 0.4 x 9.81 x10-3 Dead Load (B): This load consists of weight of roller, =0.020 x 516.13 x8x 0.4 x 9.81 x 10-3 belting and drive pulley, therefore B=58 kg = 0.32KN Belt Pull Total empty friction = Fe (L+ tf) x W x 9.81x10-3 = (A+B) coefficient of friction for roller bed belt conveyor coefficient of friction= 0.05 Standard edge distance=0.055b+0.9 inch Belt pull (c) = 135.42kg Inclines/declines (D): =0.0899meter Tangent of angle =33 x product length / product height =930 For standard edge distance 0.0899 tf=60 meters Additional belt pull=total live load x sine of angle =119 kg Total empty friction= 5.06 KN Additional belt pull =average live load rise in elevation = 15.03 x 1.825 = 27 kg Carrying side empty friction = Total empty The maximum of above two is consider, D=119kg friction -Return side tension Deflectors (E): There are no deflectors in our system, E=0 = 5.06 - 0.32 Transition point (F): Additional belt pull= total live load x 0.05 = 4.75 KN F=6 kg Load friction = Fl x (L+ tf) xc/ (3.6 x v) x 9.81x10-3  Effective belt pull= total belt pulls (C+D+E+F) For horizontal and elevating conveyor, x 1.25 Fl = 0.025 =325kg T1=effective belt pulls x T1factor Load friction =2.5 KN From table T1factor = 1.42, Load slope tension= (C x H) / (3.6 x v) x 9.81x10-3 therefore T1= 461.5kg Therefore, =2.459 KN Belt Strength= 1.02 kg/mm3 Substitute the value of belt strength and T1in equation Effective TensionTe = Total empty friction +load (2) Belt Width = (T1(kg) / Belt strength) friction+ load slope tension = 461/1.02 Te= 5.06 + 2.5 + 2.459 Belt Width =452.45 mm BELT TENSION: Te = 10.019 POWER CALCULATION: Power HP= (Te x v) / 33000 Power= (250190 x 0.02) / 33000 Power =1.52 x 1.4 Power = 2 HP IDLER SPACING: Idler Spacings = (8 x Te x Sag) / (W x 9.81 x 10-3) Where, Sag = 0.02 (2%), Si = (8 x 10.017 x 0.02) / (516.13 x 9.81 x 10-3) Si=0.32 Meters MOTOR RPM CALCULATION: Motor RPM, N = (9550 x 1000 x 1.42 KW) / Mt Here torque is not known and hence it can be calculated by following method. For belt conveyor application, Mt =1/2 x D x (F+ μWg) To find out the diameter of roll Material weight density=1600 kg/m3. From table of bulk material handling handbook, for weight density of material Wmand belt width, the diameter of pulley D =0.630 meters. According to CEMA (Conveyor Equipment and ISBN: 978-93-5268-241-6 124 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Manufacturers Association) the coefficient of friction Fig: Roller with shaft μ=0.35 Substitute the values of F, μ,W, and g Torque Mt = 1/2 x 0.63x (0.02+ 0.35 x 1600) Fig: Belt Mt= 176 Nm Mt = 176000 Fig: Stand Substitute the value of Mtin N WORKING MODEL: N = (9550 x 1000 x 1.42 KW) / 176000 Motor RPM, = 808.4 RPM THE SPECIFICATIONS GOT AFTER DESIGN ARE AS FOLLOWS: Belt width=452.4mm, Effective belt tension Te=10KN, Power=2.1hp, Idler spacing, Si=0.31meter, Motor rpm=808, Shaft diameter d=138.24mm, Pulley diameter=636.19mm LITERATURE REVIEW Design and Analysis of Roller Conveyor for Weight Optimization by Using Composite Material: In the present work, an attempt is made to reduction in weight of existing roller conveyor by optimizing the critical parts of (e.g. Roller,) conveyor without hampering its structural strength. The existing Roller conveyor designed is considered for this project work. The dimensions being 6000 mm length, 34 inch above ground and inclined at 6 degree with the ground and the weight to be carried by Design and Optimization of Roller in Belt Conveyor System for Weight Reduction: The aim of this paper is to study existing Belt conveyor system and optimize the critical parts like Roller, L channels and ADVANTAGES OF CREO PARAMETRIC SOFTWARE 1. Optimized for model-based enterprises 2. Increased engineer productivity 3. Better enabled concept design 4. Increased engineering capabilities 5. Increased manufacturing capabilities 6. Better simulation 7. Design capabilities for additive manufacturing MODELS OF CONVEYOR SYSTEM Fig:Conveyor System Model Belt conveyor Design in CREO ISBN: 978-93-5268-241-6 125 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Belt conveyor (Proto type) CONCLUSION To load or unload rice bags, cement bags, carton boxes man power is required. In higher transfer rates, more man power is required. In this project we have designed a belt conveyor system to load or unload in order to reduce the man power. And also, this system is easily disassembled and variable to the required places at less cost. In this we have calculated Belt width, Effective belt tension, Power, Motor rpm, Shaft diameter and Pulley diameter. The 3D models of the conveyor system are done in CREO. We have fabricated a prototype model of the conveyor system. REFERENCES 1. Ogedengbe, T. I. (2010). Lecture Note on Applied Techniques of ProductionManagement. pp. 16-20. 2. 2nd integrated design project conference (IDPC) 2015, Improvement of mechanism of conveyor system part 5 M.A.MUDA*, F.I.MALEK, M.MUAZ, S.RUBIAH, M.N.MANSOR 3. Richardson, J. F., Harker, J. H. and Backhurst, J. R. (2002). Particle Technology and Separation Process. Vol., 2, 5th Edition, Elsevier publisher, New Delhi, India. Pp. 29-35. 4. Vanamane, S. S., Mane, P. A. and Inamder, K. H. (2011). Design and its Verification of Belt Conveyor System Used for Mould Using Belt Comp Software. Int. Journal of Applied Research in Mechanical Engineering. Vol. 1(1) pp. 48-52. 5. Taiwo, A., Jekayinka, S. O. and Onawumi S. A. (2005). Mechanical Maintenanceand Repairs. Orsome Ventures Ltd, Ibadan. Pp. 50- 70. 6. Anath, K. N. and Rakesh, V. (2013). Design and Selecting Proper Conveyor Belt. Int. Journal of Advanced Technology. Vol. 4(2) pp. 43-49. ISBN: 978-93-5268-241-6 126 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Study on chemical dehumidification and cooling D.B. Jani GEC, Dahod, Gujarat Technology University GTU, Ahmedabad. Email: [email protected] Contact: +91-9428044640 Abstract- A new technique to reduce latent heat to improve A desiccant material can be described as a material that energy consumption in air-conditioning is by using naturally attracts moisture from both gases and liquids. desiccant assisted chemical dehumidification. The aim of This moisture is then adsorbed or retained within the dehumidification process is to remove the water vapor desiccant and can be released again when heated. There from the processed air to desiccants. Dehumidification is are various types of desiccant materials available on the considered as a key feature of HVAC systems for thermal market, but silica gel as common desiccant within the comfort. Chemical dehumidification is removing the water drying wheels. The internal structure of each silica vapor from the air by transferring it towards a desiccant granule is made up of a network of interconnecting material (adsorption or absorption). It shows that the microscopic pores, which by a process called physical application of desiccant dehumidification in air adsorption or capillary condensation, attract and holds conditioning can improve indoor air quality, reduce moisture within each granule. This trapped moisture can energy consumption and bring environmentally friendly then, with the addition of heat, be released from the products, also. Cost saving increased rapidly with an desiccant. This desiccant can then be used again and invent of newer desiccant material which regenerate at again. As low ambient temperatures do not restrict the lower temperature to save heat supply. Therefore, material, it makes it a more all season drying system. A desiccant air conditioning systems are drawing more and thermal wheel, also known as a rotary heat exchanger, more attention in recent years. or rotary air-to-air enthalpy wheel, or heat recovery wheel, is a type of energy recovery heat exchanger Keywords: Chemical dehumidification, desiccant positioned within the supply and exhaust air streams of materials, regeneration heat, thermal comfort. an air handling system, or in the exhaust gases of an industrial process, in order to recover the heat energy. I. INTRODUCTION Other variants include enthalpy wheels and desiccant wheels [1-3]. Aconventional air conditioner consumes large In recent years, the use of desiccants for amount of electrical energy especially in hot and dehumidification in air-conditioning applications has humid climatic conditions due to high latent load which been on the rise, and their capital cost has been on the is decide by the outside contents. Desiccant wheel decline. The supermarket industry was the first to based hybrid air conditioning system is one of the realize the potential of desiccant dehumidification, and promising alternative to handle the high latent load there are currently supermarkets that use desiccant efficiently where sensible and latent heat of air are dehumidification packages integrated with electric- being removed separately. A desiccant wheel is very driven refrigeration systems. In these integrated similar to a thermal wheel, but with a coating applied designs, the desiccant system works as a pre- conditioner for outside (ventilation) air to remove the stream. The desiccant is normally Silica Gel. As the latent load. Other applications of desiccant wheel turns, the desiccant passes alternately through the dehumidification are in ice rinks, hotels and motels, incoming air where the moisture is adsorbed, and office buildings, full-service and fast food restaurants, medical facilities, and retirement homes. The benefits dried and the moisture expelled. The wheel continues to of desiccant dehumidification are better humidity rotate and the adsorbent process is repeated. control, more efficient latent load removal, and Regeneration is normally carried out by the use of a reduction of peak electric demands. In regions of the heating coil, such as a water or steam coil, or a direct- country where the electric utilities are having trouble fired gas burner. Thermal wheels and desiccant wheels servicing their peak air-conditioning loads, this energy- are often used in series configuration to provide the efficient technology can assist in meeting that demand. required dehumidification as well as recovering the heat from the regeneration cycle. ISBN: 978-93-5268-241-6 127 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 II. CHEMICAL DEHUMIDIFICATION TYPES processed air from the dehumidification chamber enters into the conditioned space. The desiccant, Air dehumidification can be achieved by two methods: leaving the dehumidification chamber containing (1) cooling the air below its dew point and removing absorbed moisture, goes through a heat exchanger moisture by condensation or (2) sorption by a desiccant and down to the regenerator, where heat is added material. Desiccants in either solid or liquid forms have to remove the moisture. The liquid desiccant is a natural affinity for removing moisture. As the pumped continually between the two chambers desiccant removes the moisture from the air, desiccant when dehumidification is needed [8-9]. releases heat and warms the air, i.e., latent heat becomes sensible heat. The dried warm air can then be cooled to desired comfort conditions by sensible coolers (e.g., evaporator coils, heat exchangers, or evaporative coolers). To re-use the desiccant, it must be regenerated or reactivated through a process in which moisture is driven off by heat from an energy source such as electricity, waste heat, natural gas, or solar energy [6]. For industrial applications, solid desiccant cycles use dual-column packed-bed dehumidifiers; however, the most appropriate dehumidifier configuration for air- conditioning applications is the rotary wheel (see Fig. 1). The air to be dehumidified enters the system, comes into contact with the desiccant wheel, and exits the dehumidifier hot and dry. The wheel is then rotated so that the desiccant portion that has picked up moisture is exposed to hot reactivation air and its moisture removed [7]. Since the air leaving the desiccant is heated because of Fig. 2. Working of liquid desiccant dehumidifier. the release of heat adsorption, there is a need for cooling the dried air in cooling applications. This can be accomplished with a sensible heat exchanger such as a heat pipe or with a standard vapor-compression cooling coil. The schematic diagram and the pictorial view of solid desiccant and vapor compression hybrid air- conditioning system have been shown in Fig. 1. The return room air first passes through the rotary desiccant dehumidifier. Its moisture is adsorbed significantly by the desiccant material and the heat of adsorption raises its temperature slightly warmth. The hot and dry air is first sensibly cooled in an air-to-air heat exchanger and then in cooling coil of VCR system up to room supply design conditions. In the regeneration air line, ambient Fig. 1. Working of rotary dehumidifier. air first enters the air-to-air sensible heat exchanger and cools the supply process air. Consequently, its Fig. 2 is a schematic of a liquid-desiccant temperature rises when exiting from sensible heat dehumidification system. In a liquid system, there exchanger. At this point, it is heated to reach are two separate chambers one to perform the temperature which is high enough to regenerate the desiccant material. Moist air at the outlet of dehumidification (or conditioning) and the other to dehumidifier is exhausted to atmosphere. reactivate (or regenerate) the desiccant. The . The rotary desiccant dehumidifier used is 360 mm diameter and 100 mm width. Rotational speed of 128 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 the dehumidifier is kept constant as 20 rph. Synthesized consumes most of the power in closed cycle metal silicate is the desiccant material used in desiccant refrigeration. wheel. No special III. APPLICATIONS OF CHEMICAL DEHUMIDIFICATION refrigerants, such as ammonia, sulphur or CFCs, are used that could be toxic, Desiccant systems are especially useful when the latent expensive to replace, contribute to ozone load is high (i.e., when the latent-to-sensible heat ratio depletion and/ or be subject to stringent is high), because they remove moisture more licensing and environmental regulations. economically than they remove sensible heat. Another desirable situation is when the cost of dehumidification 3. Unmatched dehumidification efficiency. with a desiccant is lower than the cost of 4 Temperature-neutral operation provides dehumidification with a refrigeration system. This is where thermal energy comes into the picture: there are effective refrigeration capacity. instances where desiccant regeneration done by waste 5. Capable of lower dew points than heat, natural gas, or off-peak electricity is more economical compared to regular electric refrigeration. conventional technology. Because there is no need for reheating with desiccant 6. Prevents mould, mildew and dust mite dehumidification systems, another appropriate use is when conditioned air must be reheated after coming out growth. of a coil to reach a comfortable dry-bulb temperature. 7. Independent humidity control maintains Finally, the use of a desiccant is well-suited to the case where dehumidification is required at levels below comfort at higher dry-bulb set point. freezing dew-point temperatures. For example, an ice 8. Preserve building materials by lowering arena has is a great deal of humidity, but the cooling coil has to cool below the freezing point. In such an equilibrium moisture content. environment, dehumidification with desiccants can play 9. Eliminating condensation or other collected a major role [10-13]. water. Desiccant dehumidification is an established technology that has been used successfully for many years in V. LIMITATIONS OF DESICCANT COOLING institutional and industrial applications. Commercial applications are now gaining acceptance. Desiccant Thermal wheels are not suitable for use where systems have been applied successfully in supermarkets separation of supply total and exhaust air streams is and ice rinks. Hotels and motels, office buildings, and required, since air will bypass at the interface between restaurants provide the next opportunity [14-18]. the air streams at the heat exchanger boundary, and at the point where the wheel passes from one air stream to the other during its normal rotation. Matrices made from fibrous materials, or with hygroscopic coatings, for the transfer of latent heat, are far more susceptible to metal or plastic materials, and are difficult or impossible to effectively clean if dirty [19-20]. IV. ADVANTAGES OF DESICCANT COOLING VI. CONCLUSION 1. Less expensive to install: Lowering the cost of chemical dehumidification systems and improving their performance will clearly that of central refrigerated air conditioning. provide more opportunities for desiccant 2. Less expensive to operate: dehumidification technology. Currently, a number of cost-effective applications in the market will result in operation is 1/4 that of increased sales during the next several years; but as in refrigerated air. other technologies, further research will enhance broader applications of the technology. Low water pump. Because the water vapor is not temperature desiccants can effectively use waste heat recycled, there is no compressor that from electric air conditioners and improve their efficiency and effectiveness-an area that need to participate for further development. ISBN: 978-93-5268-241-6 129 Department of Mechanical Engineering, NNRG.