Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 increases. From the figure 12, It is observed that, surface roughness is low at moderate depth of cut conditions and increasing for high depth of cut and low depth of cut conditions 4 3 2 1 0 1400 1900 900 Figure No. 9. Ra V/S Cutting Conditions Figure No. 10. Ra V/S Cutting Speed 4 0.125 0.2 3.5 3 2.5 2 1.5 1 0.5 0 0.05 Figure No. 11. Ra V/S Feed rate Figure No. 12. Ra V/s Depth of cut 5. CONCLUSION among used feeds 0.05mm/min, 0.125mm/min, 0.2mm/min. The objective of the project work is to find out the set Depth of cut 0.3mm is the optimum depth of of optimum values for the selected control factors in cut for obtaining optimum valves o surface order to obtain optimum values of surface roughness, roughness in the values 0.2mm, 0.3mm, 0.4mm . n methodology The S/N ratio of predicted value and considering the control factors and steel alloy EN-353 verification test values are valid when work piece. Based on the results of the present compared with the optimum values. It is experimental investigations the following conclusions found that S/N ratio value of verification test can be drawn: is within the limits of the predicted value and the objective is full filled for both The cutting conditions used for this surface roughness . experiment are dry, flooded, MQL, in this Taguchi method has been successfully MQL will give optimum values. applied in optimal output for surface roughness for Turning operation. The speed used for the experimentation 900 rpm, 1400 rpm, 1900 rpm, in this 1400 rpm REFERENCES is the optimum speed for obtaining the optimum value of surface roughness. For obtaining the optimum value of surface roughness, the optimum feed is 0.2 mm/min ISBN: 978-93-5268-241-6 180 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 [1] Nirav M. Kamdar, Prof. Vipul K. Patel, 31 Steel Material Using Taguchi Robust Design of Engineering And Production Engineering ISSN: 2320-2092, Vol.2 Research and Applications (IJERA) ISSN: 2248- Issue 9, September-2014. 9622. Vol. 2, Issue 3, May-Jun 2012, pp.1833-1838. of Different Machining Parameters of En24 Alloy [2] Kaushal Pratap Singh and Girish Dutt of Optimum Machining International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 Parameters for EN36 Alloy Steel in CNC Turning www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.160-164. Scientific & Engineering Research, Volume 5, Issue [8] A.Venkata Vishnu, K B G Tilak, G. Guruvaiah 3, ISSN 2229-5518 March 2004. Machining Parameters on Surface Roughness of EN Different Process Parameters of Aluminium Alloy 6351 in CNC Mill Information Science and Technology (IJAIST) ISSN: International Journal of Engineering Research and 2319:2682 Vol.16, No.16, August 2013. General Science, ISSN: 2091-2730,Nepal, Vol.3 Issue 2, March-April-2015. [4] A .Venkata Vishnu, G. Guruvaiah Naidu, K B G plication of Taguchi American Journal of Engineering and Applied Sciences 2 pp. 421-427 (2009). Method in the Optimization of Turning Parameters for Material Removal Rate of En- [10] K. Adarsh Kumar, Ch.Ratnam, Bsn Murthy, International Journal of Advance Engineering and B.Satish Ben, K. Raghu Ram Mohan Reddy, Research Development E-ISSN (O): 2348-4470 P- ISSN (P): 2348-6406, Volume 2, Issue 8, August- ptimization Of Surface Roughness In Face Turning 2015. Operation In Machining Of En- [IJESAT] International Journal Of Engineering Science & [5] Advanced Technology ISSN: 2250 3676, Jul-Aug Taguchi Method For Design Of Experiments In 2012, Volume-2, Issue-4, pp.807 812. [11]HMT \"Production Technology\", Tata McGraw Engineering Research and Applications (IJERA) Hill, 2004. Vol. 2, Issue 3, May-Jun 2012, pp.1391-1397. [12] Phillip j. Ross \"Taguchi Techniques for Quality [6] G. Guruvaiah Naidu, A.Venkata Vishnu, Engineering\", Tata McGraw Hill, Second Edition, 2005. Parameters for Surface Roughness in Milling of EN- ISBN: 978-93-5268-241-6 181 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 EXPERIMENTAL STUDY ON MECHANICAL PROPERTIES OF FIBRE EPOXY RESIN T.Krishna1, A.Eshwar Sathwik2, D.Anvesh Kumar2, D.Ganesh2, G.Aravind Kumar2, G.Govardhan Reddy2 1Assistant Professor,Student2, Department of Mechanical Engineering ABSTRACT applications. While composites have already proven their worth as weight-saving materials, the current challenge is to Composite are ideal materials for parts which need to be make them cost effective. The efforts to produce strong yet light weight. Composite materials can be tailored economically attractive composite components have resulted to match the precise requirements of the application, by in several innovative manufacturing techniques currently varying the fiber type, orientation and polymer matrix. This being used in the composites industry. It is obvious, achieves a range and combination of properties which often especially for composites, that the improvement in cannot be matched by conventional materials. Composites manufacturing technology alone is not enough to overcome offer many advantages over other materials with in the cost hurdle. It is essential that there be an integrated effort aerospace and automotive applications, where exceptional in design, material, process, tooling, quality assurance, performance is required but weight is critical, composites manufacturing, and even program management for continue to grow in importance. The many advantages of composites to become competitive with metals. composites may be summarized as: stronger and stiffer than metals on a density bases, capable of high continues The composites industry has begun to recognize that the operating temperatures, highly corrosion resistance, and commercial applications of composites promise to offer exceptional formability. much larger business opportunities than the aerospace sector due to the sheer size of transportation industry. Thus the shift In the present work, mechanical and physical properties of of composite applications from aircraft to other commercial the fabrics extracted from the jute fabric are determined and uses has become prominent in recent years. Increasingly compared with silk fabric. The specimen preparation and enabled by the introduction of newer polymer resin matrix testing are carried out as per ASTM standards. And also materials and high performance reinforcement fibers of glass, stacking sequences is adopted. Jute and silk based carbon and aramid, the penetration of these advanced composite material are fabricated using hand lay-up materials has witnessed a steady expansion in uses and technique. Further these jute and silk fabrics were volume. For certain applications, the use of composites rather chemically treated and the effect of this treatment on fabric than metals has in fact resulted in savings of both cost and strength is studied. Composite laminates were prepared with weight. Some examples are cascades for engines, curved one proportion of 50-50%.Tests like tensile test, bending fairing and fillets, replacements for welded metallic parts, test, impact test, The behaviour of the composite under cylinders, tubes, ducts, blade containment bands etc. Further, different tests is analysed with the help of Performance the need of composite for lighter construction materials and curves. As per the results obtained from various tests like more seismic resistant structures has placed high emphasis on tensile test, bending test, impact test. we can replace the the use of new and advanced materials that not only decreases automobile parts like bumpers, doors, and chemical dead weight but also absorbs the shock & vibration through containers by these composite. tailored microstructures. I. INTRODUCTION The most widely used meaning is the following one, which has been stated by Kelly very clearly stresses that the Over the last thirty years composite materials, plastics and composites should not be regarded simple as a combination ceramics have been the dominant emerging materials. The of two materials. In the broader significance; the combination volume and number of applications of composite materials has its own distinctive properties. In terms of strength to have grown steadily, penetrating and conquering new resistance to heat or some other desirable quality, it is better markets relentlessly. Modern composite materials constitute than either of the components alone or radically different a significant proportion of the engineered materials market from either of them. ranging from everyday products to sophisticated niche ISBN: 978-93-5268-241-6 182 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Types of Composites nylon, polystyrene and embedded glass, carbon, steel or Kevlar fibers (dispersed phase). For the sake of simplicity, however, composites can be grouped into categories based on the nature of the matrix The potential applications of polymer composites include each type possesses. Methods of fabrication also vary consumer goods (sewing machines, doors, bathtubs, tables, according to physical and chemical properties of the matrices chairs, computers, printers, etc), sporting goods industry and reinforcing fibers (golf shafts, tennis rackets, snow skis, fishing rods, etc.), aerospace industry (doors, horizontal and vertical stabilizers, A. Metal Matrix Composites (MMCs) wing skins, fin boxes, flaps, and various other structural components), marine applications (passenger ferries, power Metal matrix composites, as the name implies, have a metal boats, buoys, etc.), automotive industry (bumper beam, matrix. Examples of matrices in such composites include seat/load floor, hood radiator support, roof panel and land aluminium, magnesium and titanium. The typical fiber transport systems like cars, trucks and bus bodies, railway includes carbon and silicon carbide. Metals are mainly coach components, containers and two and three wheelers ), reinforced to suit the needs of design. For example, the elastic construction and civil structures (bridges, columns doors, stiffness and strength of metals can be increased, while large windows and partitions and for translucent roofing sheets, co-efficient of thermal expansion, and thermal and electrical prefabricated modular houses and buildings etc.), industrial conductivities of metals can be reduced by the addition of applications fibers such as silicon carbide. Two main kinds of polymers are thermosets and B. Ceramic Matrix Composites (CMCs) thermoplastics. Ceramic matrix composites have ceramic matrix such as alumina, calcium, alumina silicate reinforced by silicon Based on reinforcing material structure carbide. The advantages of CMC include high strength, hardness, high service temperature limits for ceramics, Classification of composites: three main categories chemical inertness and low density. Naturally resistant to high temperature, ceramic materials have a tendency to particle-reinforced (large-particle and become brittle and to fracture. Composites successfully made with ceramic matrices are reinforced with silicon carbide dispersion-strengthened) fibers. These composites offer the same high temperature tolerance of super alloys but without such a high density. The fiber-reinforced (continuous (aligned) and short fibers brittle nature of ceramics makes composite fabrication (aligned or random) difficult. Usually most CMC production procedures involve starting materials in powder form. There are four classes of structural (laminates and sandwich panels) ceramics matrices: glass (easy to fabricate because of low softening temperatures, include borosilicate and alumino Fig.no 1: Classification of Composites silicates), conventional ceramics (silicon carbide, silicon nitride, aluminium oxide and zirconium oxide are fully Particulate Composites: Particulate Composites consist of a crystalline), cement and concreted carbon components. matrix reinforced by a dispersed phase in form of particles. These are the cheapest and most widely used. They fall in C. Polymer Matrix Composites (PMC) two categories depending on the size of the particles: Most commonly used matrix materials are polymeric. The Composites with random orientation of particles. reasons for this are two-fold. In general the mechanical properties of polymers are inadequate for many structural purposes. In particular their strength and stiffness are low compared to metals and ceramics. These difficulties are overcome by reinforcing other materials with polymers. Secondly the processing of polymer matrix composites need not involve high pressure and does not require high temperature. Also equipments required for manufacturing polymer matrix composites are simpler. For this reason polymer composites developed rapidly and soon became popular for structural applications. Polymer composites are used because overall properties of the composites are superior to those of the individual polymers. They have a greater elastic modulus than the neat polymer but are not as brittle as ceramics. Polymeric matrix composites are composed of a matrix from thermoset (unsaturated polyester, epoxy or thermoplastic polycarbonate, polyvinylchloride, ISBN: 978-93-5268-241-6 183 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Composites with preferred orientation of This chapter describes the details of processing of the particles. composites and the experimental procedures followed for their mechanical characterization. The raw materials used in Fibrous Composites : Short fabric reinforced composites: this work are as follows Short-fabric reinforced composites consist of a matrix MATERIALS USED reinforced by a dispersed phase in form of discontinuous fabrics (length < 100*diameter). They are classified as Epoxy resin (LY-556) Hardener(HY-951) Composites with random orientation of fabrics. Natural Fibers (Silk cloth and Jute mat) NaoH Solution Composites with preferred orientation of fabrics. Epoxy Resin (LY-556) Long-fabric reinforced composites:Long-fabric reinforced Features of Epoxy Resin are as follows composites consist of a matrix reinforced by a dispersed phase in form of continuous fabrics. Light weight Resists most alkalis and acids Uni directional orientation of fabrics. Resists stress cracking Retains stiffness and flexibility Bi directional orientation of fabrics. Low moisture absorption Non-staining Laminate Composites: When a fabric reinforced composite Easily fabricated consists of several layers with different fabric orientations, it Hardener (HY-951) is called Multi-layer composite. Hardener is a curing agent for epoxy or fiberglass. Epoxy resin requires a hardener to initiate curing; it is also called as Manufacturing Processes of Composite Material catalyst, the substance that hardens the adhesive when mixed Manufacturing of a composite material is to combine the with resin. It is the specific selection and combination of the polymeric resin system with the fiber reinforcement. Since epoxy and hardener components that determines the final the orientation of the fibers is critical to the end properties of characteristics and suitability of the epoxy coating for given the composite, manufacturing process is utmost important to environment. align the fibers in desired direction. A good manufacturing process will produce a higher, uniform fiber volume fraction Figure 2: Epoxy and Hardener along with a higher production of a large volume of parts Natural fibers economically and have repeatable dimensional tolerances. Fiber-reinforced polymer composites have played a The composite manufacturing techniques can be classified dominant role for a long time in a variety of into two categories: applications for their high specific strength and modulus. The manufacture, use and removal of traditional fiber reinforced Open mould process Hand lay-up process Spray up process Vacuum-bag auto clave process Filament winding process Closed mould process Compression moulding Injection moulding Sheet moulding compound (SMC) process Continuous pultrusion process II. MATERIALS AND METHODS ISBN: 978-93-5268-241-6 184 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 plastic, usually made of glass, carbon or aramid fibers Silk is a protein fabric like wool. This gives it many of its reinforced thermoplastic and thermoset resins are considered characteristics. Out of the numerous species of silk moths, critically because of environmental problems. By natural scientists have enumerated about 70 silk moths, which are of fiber composites we mean a composite material that is some economic value. The four commercially known reinforced with fibers, particles or platelets from varieties of natural silk are; natural or renewable resources, in contrast to for example carbon or aramide fibers that have to be synthesized. 1. Mulberry silk Jute fabric 2. Tasar silk Jute is a best fiber obtained from inner best tissues of the 3. Muga silk plant stem. The fibers are bound together by gummy materials which keep the fiber bundles cemented with 4. Erisilk Silk non-fibrous tissues of jute bark. These encircling soft tissues must be softened, dissolved and washed away so that the 5. Spider Silk fiber can be obtained from the stem. This is done by steeping the stems in water and is known as retting. The Properties of silks vary within and between batches. Testing optimum water temperature for retting is 808F. on a single specimen would not provide sufficient and Microorganisms (mainly bacillus bacteria) decompose the accurate estimate of bulk properties. On the other hand, gums and soften the tissues in 5 to 30 days depending upon testing the whole of a production batch of fabric, yarn or temperatures and the type of water used. It has been found garments would be impractical because: some tests are that the presence of higher amounts of calcium and destructive, some tests involve cutting test specimen, and it magnesium tend to increase the tenacity of fiber. would take too much time. Figure 3 : Jute Fabric It is therefore necessary to select one or more samples. A sample may be defined as a small fraction selected to In the present research, hessian yarns which are made from represent the bulk. Factors to be considered when selecting a long jute fibers are used. The yarn is obtained by a spinning sample include: · process which depends upon the class of goods being made; however, there are features common to all systems. Jute Amount and form of textile available, must be softened and lubricated with batch oil so that the fiber may be processed without excessive fiber breakage and Nature of test, waste. The messy nature of the reeds must be split-up and fibers separated as far as possible. Fibers are drawn evenly Type of equipment to be used, into slivers or loose untwisted strands and then drawn out to the desired yarn thickness. At the spinning frame the Information and accuracy required. material is given its final drafting down to the required weight and the fibers are twisted together to form yarn, this In some cases, the test method will specify is then wound on to bobbins. Twisting is done by flyers the type of sample that needs to be taken, and the method to rotating at speeds of 3550 4000 rpm. choose in preparing the specimen(s) for testing Silk fabric: Properties Of Natural Fiber: Table : Properties of Natural Fiber Fibers Density Tensile (Kg/m3) Strength s (MPa) (GPa) 20-55 Jute 1300-1500 200-450 Fiber 5-6.5 Silk 1320-1400 220-300 Fiber NaOH Solution Sodium Hydroxide(NaOH) is a alkaline solution used to enhance the surface morphology of natural fibers. ISBN: 978-93-5268-241-6 185 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Method m f+ f c = f( f/ c) m( m/ c) . Preparation of Composite Boards: Using the definitions of fabric and matrix volume fractions from Equation. The composite is made up of more than one c = fVf+ mVm material; board preparation is important step in this process. Now, consider that the volume of a composite c is the sum Board dimensions depend on the number of specimens that of the volumes of the fabric f and matrix ( m) can be cut. f+ c = m The density of the composite in terms of mass fractions can Board preparation method depends on many factors like be found as application, type of composite, machines used etc. Coupling 1/c = Wf/ f + Wm / m . agents and coating are applied on the fabrics to improve their wetting with the matrix as well as to promote bonding Calculations across the fabric-matrix interference. 1) Jute fiber : Volume Fractions: Volume of composite = 200x200x10 mm = 4,00,000mm3 50% Volume of composite = 2,00,000mm3 This concept is critical because theoretical Volume of one layer =200x200x0.6 = 24000mm3 formulas for finding the stiffness, strength, and No of Layers of jute =200000/24000 = 9Layers. hydrothermal properties of a unidirectional lamina are a function of fabric volume fraction. Measurements of the 2) Silk Fiber : constituents are generally based on their mass, so fabric Volume of composite =200x200x10mm3=4,00,000mm3 mass fractions must also be defined. Moreover, defining the 50% Volume of Composite = 2,00,000mm3 density of a composite also becomes necessary because its Volume of one Layer = 200x200x0.11 = 4,400mm3 value is used in the experimental determination of fabric No of Layers of Silk = 46 Layers volume and void fractions of a composite. Also, the value of density is used in the definition of specific modulus and specific strength. Consider a composite consisting of fabric and matrix. Take the following symbols and notations: Vc, f, m = volume of composite, fabric and matrix respectively Pc, f, m = density of composite, fabric and matrix respectively Now define the fabric volume fraction Vf and the matrix volume fraction Vm as Vf = vf/vc and Vf= vm/vc, 3) Resin Calculations: Amount of resin = volume of comp X resin percentage Note that the sum of volume fraction is Vf +Vm= 1/ Vf+Vm = Vc = 4,00,000 x(50/100) = 2,00,000mm3 = 200ml Density: Resin-Hardener Mixture Preparation: The derivation of the density of the composite in terms of For the making of good composite the measurement of the volume fractions is found f and the mass of c is the sum of samples should be accurate and the mixture should be very the mass of the fabrics as follows. The mass of composite uniform. We take accurate amount of polymer which we mass the matrix have calculated earlier and 10% of its hardener. Then this mixture is stirred thoroughly till it becomes a bit warm. Bit m. f + c = m , ISBN: 978-93-5268-241-6 186 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 extra amount of hardener is taken for the wastage in the process. Hardener should take very minutely because little extra amount of hardener can spoil the composite. III. METHODOLOGY Hand lay-up technique Figure 5: Hand Lay-Up Hand lay-up technique is the simplest method of composite Keep the fabrics straight and press the fabric into the resin processing. The infrastructural requirement for this method while working the resin up through the jute and silk mat. is also minimal. The processing steps are quite simple. First Be careful not to distort the fabrics. Ether brush or a roller of all, a release gel is sprayed on the mold surface to avoid can use to assist in this process. When the layer appears to the sticking of polymer to the surface. Thin plastic sheets have a nice even sheen that is flat, it will have a good are used at the top and bottom of the mold plate to get good lay-up. If do not want any air bubbles, work air bubbles to surface finish of the product. Reinforcement in the form of the edge of the laminate to make them disappear. You can woven mats or chopped strand mats are cut as per the mold also use a brush that has been trimmed to stipple resin into size and placed at the surface of mold after perspex sheet. areas that do not appear to have proper coverage or into Then thermosetting polymer in liquid form is mixed problem areas. The layup assembly was pressed in a press. thoroughly in suitable proportion with a prescribed hardner The excess resin was allowed to squeeze out. The laminate (curing agent) and poured onto the surface of mat already was cured at ambient conditions for a period of about 24 placed in the mold. hours. The laminate so prepared has a size. 200mm X 200mm X 10mm. Figure 4 : Wet Hand lay-up technique Figure 6: After curing specimen is taken out from mould front The Jute, Silk and Lapox epoxy resin composites used in this work is made from the hand lay-up techniques as shown in figure. Pour the calculated amount of resin over the surface where working carrying out. By squeegee and spread the resin over the surface. Then place the reinforcement Jute and Silk fabric in place at the proper orientation called for in the plans. Be very careful not to distort the mats. Protect hands with hand gloves and ensure the mats are in the proper place. Then, using a squeegee begins to press gently from the Centre of the mat making sure that the squeegee moves in the same directions as the fabrics of the mat. ISBN: 978-93-5268-241-6 187 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Figure 7: After curing specimen is taken out from mould Figure 8: Tensile Test Specimen back Specimen size: A mould made of mild steel square rod of dimension of The most common specimen for ASTM D3039 is a constant 200X200 mm was used to prepare the board. In order to get rectangular cross section, 25 mm (1 in) wide and 250 mm required dimension of 200X200X10 mm3 of board, two (10 mm) long. Optional tabs can be bonded to the ends of frames of same dimension were placed adjacently on the the specimen to prevent gripping damage. mould. Thoroughly laminated composite made up of jute and silk fibre and Epoxy resin was taken and placed in the mould Point Bending Testing Composite ASTM D790 uniformly. ASTM D790 is a testing method to determine the flexural (bending) properties of reinforced and unreinforced plastics, Testing S high-modulus composites, and electrical insulation materials. This guide is designed to introduce you to the basic Tensile Testing Composite ASTM D3039 elements of an ASTM D790 flexure test, and will provide an overview of the testing equipment, software, and specimens State-of-the-art tensile properties data generation for needed. However, anyone planning to conduct ASTM D790 reinforced composites materials including tensile strength, testing should not consider this guide an adequate substitute tensile modulus and Poisson's ratio using align-pro, strain for reading the full standard. gages or extensometers performed at ambient, high or low temperatures with or without moisture conditioning. Figure 9: Point Bending Test Specimen Size: ASTM D3039 tensile testing is used to measure the force According to ASTM D 790 the composite specimens were required to break a polymer composite specimen and the prepared for bending test. extent to which the specimen stretches or elongates to that Each test specimen of 30 mm width, length 180 mm and breaking point. Tensile tests produce a stress-strain diagram, thickness 10 mm were prepared. The span (centre to centre which is used to determine tensile modulus. The data is distance between roller supports) for each specimen is 100 often used to specify a material, to design parts to withstand application force and as a quality control check of materials. Since the physical properties of many materials can vary depending on ambient temperature, it is sometimes appropriate to test materials at temperatures that simulate the intended end use environment. ISBN: 978-93-5268-241-6 188 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 mm. The specimen is loaded at the centre of the span through a loading cell. The test is carried until the specimen completely fails. Izod Impact (Notched) ASTM D256, ISO 180 Figure 11: UTM Machine Izod Impact Testing (Notched Izod) ASTM D256, ISO 180 Table : Tensile Test Results is a common test to understand notch sensitivity in plastics. Notched Izod Impact is a single point test that measures a Sno Specimen Break at materials resistance to impact from a swinging pendulum. Point(Mpa) Izod impact is defined as the kinetic energy needed to Modulus(Mpa initiate fracture and continue the fracture until the specimen 1 Sample 1 28.33 ) is broken. 2 Sample 2 35.41 500 Izod specimens are notched to prevent deformation of the specimen upon impact. This test can be used as a quick and 834 easy quality control check to determine if a material meets specific impact properties or to compare materials for Discussions: The tensile experiments were conducted on general toughness. each jute-silk fabric (60-40) specimen and the results shows that the ultimate stress is around 25 35MPa with 2.5-2.7% Specimen size: The standard specimen for ASTM is 65.5 x 12.9 x 10 mm. elongation at break. The most common specimen thickness is 10 mm (0.125 inch), but the preferred thickness is 6.4 mm (0.25 inch) because it is not as likely to bend or crush. The depth under the notch of the specimen is 10.2 mm (0.4 inches). The standard specimen for ISO is a Type 1A multipurpose specimen with the end tabs cut off. The resulting test sample measures 80 x 10 x 4 mm. The depth under the notch of the specimen is 8mm. Point Bending Testing The following tables provides the details of the Point Bending Testing of the composite results are obtained for two different sample. Figure 10: Impact Test Specimen IV. Results and Discussions Figure 12:Point Bending Testing Table: Point Bending Testing Results Tensile Testing Composite The following tables provides the details of the Tensile Testing of the composite results are obtained for two different sample. ISBN: 978-93-5268-241-6 189 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Sno Specimen Break at Load KN Point(Kpa) 15.23 14.2 1 Sample 1 0.25 2 Sample 2 0.235 Figure 15: Specimen After Impact Test. Discussions: The maximum load at which breaking takes place for sample 1 and sample 2 is given by 1.0024 and 1.004 KJ respectively. Figure 13: Specimun After Bending Test V. CONCLUSION Discussions: The maximum bending strength for composite Natural composites can supplement and eventually replace plate of composition is 15.23KN and 14.2 KN. glass based composite materials in several applications thus offering in automotive industries, manufacturing and Impact Test Results consumer benefits. The test result of jute-silk fabric composite plates indicates that this would be a very promising The following tables provides the details of the Impact test material. The jute-silk fabric composite is found to have good results obtained for various combinations of Natural fibers bending strength and impact strength. Reinforced Composite. Natural fiber composites are based on natural renewable Figure 14: Impact Testing Machine resources usually derived from plants which makes great contribution to the CO2 balance, even if they are thermally Table : Impact Test Results Impact Energy recycled at the end of the life. Additional advantages of the Sno. Specimen Absorbed in Kilo usage of natural fibres as the reinforcement in composites are the added value to the main production of crops and cloths 1 Sample 1 Joules (where the plant stem either is not used or partly used) and 2 Sample 2 better labour conditions (natural composites while machined 1.0024 do not irritate the skin and do not create the hazardous dust). 1.004 The jute fabric , silk fabric composite exhibits an excellent resistance to moisture absorption and is about 8-16% compared to wood based particle boards, which have more than 40-50%. The test results of jute-silk based fabric composite plates indicate that this would be a very promising material for automotive industries, other general structural applications with moderate duration. The jute-silk fabric composite absorbs some amount of moisture present in the compost in the early stages and there is an increase in reaction between the enzymes secreted by the organism and the polymer chains or additives, which make up the compound. It is a very slow process since the jute-silk fabric does not compose at faster rate. Jute-silk fabric reinforced composite are biodegradable and losses its weight. ISBN: 978-93-5268-241-6 190 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 From the above obtained results it is evident that, the [6] Sezgin Ersoy, Haluk Kucuk, Investigation of industrial mechanical and physical properties of jute-silk fabric tea-leaf-fiber waste material for its sound absorption composites can meet the industry specifications used for properties, Applied Acoustics 70 (2009) 215 220. automotive applications. [7] Maryam, Che, Ahmad, Abu Bakar, Investigation and Using jute-silk fabric composites and process technology, the study of Silk reinforced natural composite. Department use of natural fibres can also be expected to extend into of Mechanical and Materials Engineering, Universiti components such as, seatbacks, floor pan, Aircraft industries, Kebangsaan Malaysia, vol. 32,No. 85/2009. Marine industries, Racing Boats and also in several applications. [8] K. Raghu, P. Noorunnisa Khanam and S. Venkata VI. REFERENCES reinforced unsaturated polyester-based hybrid [1] -Mesh Composites, Vol. 29, No. 3/2010. 165 171. [9] Kweon H,Physical properties of silk fibroin/chitosan [2] Shah AN, Lakkad SC. Mechanical properties of jute blend films. Journal of Applied Polymer Science. 2001; reinforced plastics. Fibre Science and Technology 80: 928-934. 1981;15:41 46. [10] Katori S. and Kimura T. Injection moulding of silk [3] fiber reinforced biodegradable composites, WIT Press, Boston, 2002. Section 2: p.97-105. made from pineapple fibers and polyhydyoxybutyrate- [11] Lee S.M., Cho D., Park W.H., Lee S.G., Han S.O. and Materials Science, 34, 1999, pp. 3709-3719. Drzal L.T.. Novel silk/poly (butylenes succinate) biocomposites: the effect of short fiber content on their [4] Mohanty, A.K., M.A. Khan and G. Hinrichsen. 2000b. mechanical and thermal properties. Composites Influence of chemical surface modification on the Science and Technology. 2005; 65: 647-657. properties of biodegradable jute fabrics-polyester amide composites. Composites Part A: Applied [12] Annamaria S., Maria R., Tullia M., Silvio S. and Orio Science and Manufacturing 31(2):143- 150. C., The microbial degradation of silk: a laboratory investigation. International Biodeterior Biodegrad. [5] Ketty Bilba , Marie-Ange Arsene, Alex Ouensanga, 1998; 42: 203-211. Study and investigation of bananaand coconut fiber Botanical composition, thermal degradation [13] Khanam, P. N., Reddy, M. M., Raghu, K., John, K. and andtextural observations, Bioresource Technology 98 Naidu, S. V. (2007). Tensile, Flexural and (2007) 58 68. Compressive Properties of Jute/Silk Hybrid Composites, J. Reinf. Plast. Comp., 26(10): 1065 1070. [14] Bio-Composites. Technologies and Applications. Presentation of Michael Carus, NovaInstitut GmBH, Kemi 26.01.2011 . ISBN: 978-93-5268-241-6 191 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 DESIGN & FABRICATION OF A PROTOTYPE INDUSTRIAL ROBOTIC ARM Mallikarjun B Koujalagi1, J Sai Krishna2, Jammu Anu Naga Chandra Krishna Teja2, Janga Naveen Reddy2, Kirtiranjan Mohanty2, K Shyam Sunder2 1Assistant Professor,Student2, Department of Mechanical Engineering ABSTRACT television camera and a mini computer, this machine was capable of moving and arranging blocks into stacks. In the This project involves designing and fabrication of a 5- axis mid-1970s, General Motors financed a program at the industrial robotic arm prototype to verify the concepts of Massachusetts Institute of Technology (MIT) to develop an forward and inverse kinematics by replicating the exact automated robot for assembly purposes. Researcher Victor movements of a typical industrial pick and place robotic arm. Scheinman invented the Programmable Universal Forward kinematics specifies the joint parameters and Manipulator for Assembly (PUMA), and as such robots computes the configuration of the chain. For serial were introduced in American industries for assemblies. manipulators this is achieved by direct substitution of the joint parameters into the forward kinematics equations for An industrial robot is a robot system used for manufacturing. the serial chain. For parallel manipulators substitution of the Industrial robots are automated, programmable and capable joint parameters into the kinematics equations requires of movement on three or more axis. Typical applications of solution of the set of polynomial constraints to determine robots include welding, painting, assembly, disassembly, the set of possible end-effector locations. Inverse kinematics pick and place for printed circuit boards, packaging and specifies the end-effector location and computes the labelling, palletizing, product inspection, and testing; all associated joint angles. For serial manipulators this requires accomplished with high endurance, speed, and precision. solution of a set of polynomials obtained from the They can assist in material handling. kinematics equations and yields multiple configurations for the chain. For parallel manipulators, the specification of the The setup or programming of motions and sequences for an end-effector location simplifies the kinematics equations, industrial robot is typically taught by linking the robot which yields formulas for the joint parameters. The body controller to a laptop, desktop computer or to a network. and the end effector of the robotic arm are made up of The use of a computer greatly simplifies the programming Polylactic Acid (PLA) filament through 3D printing by process. Specialized robot software is run either in the robot using an FDM printer. The motion of the links of the robot controller or in the computer or both depending on the is controlled by servo motors. The motion commands and system design. There are two basic entities that need to be angular restrictions are given by a code written in Python taught (or programmed): positional data and procedure. language. The computer used for operating the robot is a Raspberry Pi 3B, which operates on Linux. The most essential robot peripheral is the end effector, or end-of-arm-tooling (EOT). End effectors are frequently I. INTRODUCTION highly complex, made to match the handled product and often capable of picking up an array of products at one time. Introduction to Industrial Robotics They may utilize various sensors to aid the robot system in locating, handling, and positioning products. Robots are a segment of the science of automation. Automation uses machines and computers which can learn For a given robot the only parameters necessary to or compensate for varying conditions of operation. In the completely locate the end effector of the robot are the angles late 1960s, the Stanford Research Institute designed and of each of the joints or displacements of the linear axes. built an experimental robot called \"SHAKEY.\" It used a However, there are many different ways to define the points. The most common and most convenient way of defining a point is to specify a Cartesian coordinate for it, i.e. the position of the 'end-effector' in mm in the X, Y and Z ISBN: 978-93-5268-241-6 192 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 directions relative to the robot's origin. In addition, Working of 3D Printer (FDM) depending on the types of joints a particular robot may have, the orientation of the end effector in yaw, pitch, and roll and FDM 3D printing is a technology that works both the location of the tool point relative to the robot's faceplate horizontally and vertically, where an extrusion nozzle must also be specified. For a jointed arm these coordinates moves over a build platform. The process involves the use must be converted to joint angles by the robot controller and of thermoplastic material that reaches melting point and is such conversions are known as Cartesian Transformations then forced out, to create a 3D object layer by layer. which may need to be performed iteratively or recursively for a multiple axis robot. The mathematics of the As the design takes shape, it is clear to the see each layer as relationship between joint angles and actual spatial a horizontal cross section. Following the completion of one coordinates is called kinematics. Positioning by Cartesian layer, the nozzle of the printer is lowered in order for the coordinates may be done by entering the coordinates into next layer of plastic to be added to the design. Once the the system or by using a teach pendant which moves the object has been created, the materials that are used to robot in X-Y-Z directions. When the desired position is support the object can then be removed. reached it is then defined in some way particular to the robot software in use. Introduction to Additive Manufacturing The 3D printing process builds a three-dimensional object from a computer-aided design (CAD) model, usually by successively adding material layer by layer, which is why it is also called additive manufacturing, unlike conventional machining processes, where material is removed from a stock item (subtractive manufacturing) or poured into a mold and shaped by means of dies, presses and hammers. Fig. No 2 Part of a FDM Printer Fig. No 1. Hydra 200 FDM Printer A spool of thermoplastic filament is first loaded into the printer. Once the nozzle has reached the desired 3D printing covers a variety of processes in which material temperature, the filament is fed to the extrusion head is joined or solidified under computer control to create a three-dimensional object, with material being added and in the nozzle where it melts. together typically layer by layer. One of the key advantages The extrusion head is attached to a 3-axis system that of 3D printing is the ability to produce very complex shapes allows it to move in the X, Y and Z directions. The or geometries, and a prerequisite for producing any 3D melted material is extruded in thin strands and is printed part is a digital 3D model or a CAD file. The most-commonly used 3D-printing process is a material deposited layer-by-layer in predetermined locations, extrusion technique called Fused Deposition Modelling where it cools and solidifies. Sometimes the cooling of (FDM). the material is accelerated through the use of cooling fans attached on the extrusion head. To fill an area, multiple passes are required (similar to coloring a rectangle with a marker). When a layer is finished, the build platform moves down (or in other machine setups, the extrusion head moves up) and a new layer is deposited. This process is repeated until the part is complete. ISBN: 978-93-5268-241-6 193 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 by adjusting the extruder temperature depending up on the filament. Depletion of printing material or disrupted material flow - Just by adjust the extruder temperature and bed temperature can rectify depletion of printing material. Lack or loss of adhesion to the print platform - Using a better adhesion bed platform could resolve the problem its one the most important factor too. Fig. No .3. Working of FDM Printer II. METHODOLOGY PROBLEM IN 3D PRINTING DESIGN OF THE ROBOTIC ARM When a physical part is printed, in some cases the material While designing the robotic arm, one of the important things flow can be interrupted due to some special issues therefore considered was the simplicity of the design so that it can be minor and major defects can occur. Minor defects may not easily explainable and can be re- be considered if the previous and/or latter layers compensate purposes. This section covers the designing of the robot arm missing or defected layer.Furthermore, 3D printing process from basic sketch to CAD drawing format. should be understood clearly, and some measures should be taken to avoid these kinds of defects. Otherwise, misprint Sketching the Robotic Arm causesloss of material, time and fund. To begin with the design, the idea was simple; the robot The printing defects can be grouped according to as listed: should have a rotating base, two movable arms with an end effector. Various rough sketches on paper were made and Misalignment of the print platform we came to a conclusion about the final physical appearance of the robot (excluding the measurements of the parts). The Misalignment of the nozzle robot setup consists of two bases, a circular and a rectangular. The circular shaped base was finalised over the Clogging of the nozzle rectangular one due to simplicity of the design. The arm consists of two links, the lengths of the links and positions Depletion of printing material or disrupted material were determined by solving the necessary kinematic flow equations for both forward and reverse transformations respectively. Lack or loss of adhesion to the print platform PROBLEM RECTFICATION Position Representation of the Robotic Arm Misalignment of the Print Platform - Can be solved The position of the end of the arm may be represented in thought some bed leveling techniques like adjusting the bed springs and checking the first layer print. 1 Misalignment of the nozzle - Just raising the height of 2. This is known as representation in joint space and it the nozzle slightly can often help. Most 3D printers in is defined as: their system settings will allow you to set a Z-axis offset. To raise your nozzle away from the print bed Pj 1 2) value. Clogging of the nozzle - Just by cleaning the nozzle remove the material with in the nozzle if any and also ISBN: 978-93-5268-241-6 194 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Fig.no 4. Position Representation of a 2D manipulator Fig. No 5. Two possible configurations for determining the joint angles Similarly, another way to represent the end position is the representation in world space and it is defined as: 2 is positive as in above figure. Using Pw = (x, y) If one knows the length of the links L1 and L2, it is easy to find the joint angles. Similarly, the length of the links can be The meaning of world space is the use of Cartesian found if the joint angles are known. coordinate system which is external to the robot. Now the robot arm in this project is a 4-Degree of Freedom manipulator in 3-Dimensions. The 4-Degrees of freedom: In order to use both representations one must be able to joint 1 (type T) which allows rotation about z-axis; joint 2 transform joint space into world space and vice-versa. The (type R) allows rotation about an axis that is perpendicular transformation from joint space to world space is known as to z-axis; joint 3 is a linear joint; and joint 4 is a rotational forward transformation and the transformation from world joint which is the end effector and rotates about an axis that space to joint space is known as reverse transformation. is parallel to the joint 2 axis. Forward Transformation of a 2 DOF Arm the length of the linear joint will be L2; and the angle that joint 4 makes with the x-y plane will be called the pitch The position of the end of the arm in world space can be determined by defining a vector for link 1 and link 2 as: below: r1 = [L1 1, L1 2] (Eqn. 1) r2 = [L2 1 2), L2 1 2)] (Eqn. 2) Vector addition of the above two equations yields the coordinates x and y of the end position (Pw) in world space: x = L1 1 + L2 1 2) (Eqn. 3) y = L1 1 + L2 1 2) (Eqn. 4) Reverse Transformation of the 2 DOF Arm In certain cases, it is important to be able to derive the joint angles given in the end position in the world space. There are two possible configurations to do the transformation. ISBN: 978-93-5268-241-6 195 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Fig.no 6. A 3-Dimensional 4- Degree of freedom vertical circular pattern which will hold the arms has the manipulator (Conceptual Representation) inner circle diameter of 18 mm and outer circle diameter of 49 mm. The inner circle is about 13 mm apart from the center and is the distance between the center of the inner circle and the base is 42 mm. A small rectangular slot is provided just apart from the two small circular holes, it is supposed to hold one spring end attached to the arm so that the arm does not fall under its own weight. Fig. No 7. Positioning of Joined Arm Configuration The Arms Designing the Robotic Arm in a CAD software The robotic arm has two arms: primary arm and secondary arm. The primary arm has a total length of 162 mm and the After finalising the sketch and calculating the dimensions of distance between the centres of the circles which holds the the robotic arm, now the same shall be designed in CAD servo motors is 120 mm. The outer circles each have a software, so that after the drawing is complete it can be diameter of 36 mm. The arm also has a cylindrical path converted into suitable file format which is supported by a arrangement for servo wires. It also has a rectangular slot to 3D printer. The software used for this project is AutoCAD hold one of the spring ends for balance. 2020 by Autodesk, Inc. The secondary arm has a total length of around 115 mm. It One needs to have basic knowledge about AutoCAD has one circular hole for holding one servo motor and the commands to draw the objects. These parts were also diameter is same as in the primary arm. The free end of the re-created on other software; Creo Parametric and arm has a small space to house a SG-90 servo, which will Solidworks. hold on to the end effector. The Base Gripper The base has a circular design, the outer circle has a It consists of a base diameter of 98 mm and the inner circle has a diameter of 90 which holds the entire gripper mechanism. It has gear mm. The rectangular slots inside the circle are made to hold mechanism to drive the claws along with the support of the servo motor. The slot which is attached to the circular connectors. The parts of the gripper were designed in Creo wall has the dimensions 26 x 11 mm and the other Parametric. The base has a length of 60 mm. The rear width independent slot has the dimensions of 26 x 8 mm. When measures 43 mm and the front width measures 23 mm. The viewed from side the height of the base is 52 mm excluding supporting connectors each measure 54 mm and the gear the circular disc. Along with the circular disc the total height connectors each measure 52 mm. the gears each has becomes 56 mm. The diameter of the circular disc is 121.25 diameter of around 10 mm. The claws each measure 95 mm. mm. It has four small circular holes for mounting the base; each having the diameter 3.4 mm. FABRICATION OF THE ROBOTIC ARM The Waist After the completion of the designing of the robotic arm now it should be printed via 3D printer. The printer used for The waist is a circular disc cover which mounts a vertical this project is Hydra 200. The drawings done in AutoCAD circular pattern to hold the arms of the robot. The disc has a and Creo are saved in STL format. STL (an abbreviation of diameter of 97 mm. There are two circular holes each \"stereolithography\") is a file format native to the having diameter 3 mm and 7.5 mm apart from the center and stereolithography CAD software created by 3D Systems. An the distance between the two circular holes is 14.5 mm. The STL file describes a raw, unstructured triangulated surface by the unit normal and vertices (ordered by the right- hand rule) of the triangles using a three-dimensional Cartesian coordinate system. STL files contain no scale information, and the units are arbitrary. 3D printers build objects by solidifying one layer at a time. This requires a series of closed 2D contours that are filled in with solidified material as the layers are fused together. A natural file format for such a machine would be a series of closed polygons ISBN: 978-93-5268-241-6 196 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 corresponding to different Z-values. However, since it is Gripper (All parts) 3 hr 45 mins possible to vary the layer thicknesses for a faster though less precise build, it was easier to define the model to be built as III. IMPLEMENTATION a closed polyhedron that can be sliced at the necessary horizontal levels. ASSEMBLY OF THE PRINTED PARTS To properly form a 3D volume, the surface represented by After completion of printing of the parts, those are supposed any STL files must be closed and connected, where every to be installed with the right motors to make the robot work. edge is part of exactly two triangles, and not The motors used in this project are called servo motors. self-intersecting. The closeness only matters insofar as the Unlike the permanent magnet DC motors, servos receive a software that slices the triangles requires it to ensure that desired signal to produce a desired output. the resulting 2D polygons are closed. Sometimes such software can be written to clean up small discrepancies by Servo Motors A brief description moving vertices that are close together so that they coincide. The results are not predictable, but it is often sufficient. A servomotor is a rotary actuator or linear actuator that allows for precise control of angular or linear position, Printing the files velocity and acceleration. It consists of a suitable motor coupled to a sensor for position feedback. It means the After the slicing is done, the files are directly loaded to the rotational movement of the motors can be controlled by 3D printer via computer or USB. According to the infill using a computer. These motors are not a specific class of percentage and support (if enabled), the parts will be printed. motor, although the term servomotor is often used to refer to The time taken for printing a complete part depends on the a motor suitable for use in a closed-loop control system. In selected infill percentage and profile settings. The 3D this project, three types of servo motors are used based on printer used for this project is an FDM printer. their specifications; MG-995, MG-996R, and SG-90. For this project, the following specifications were The MG996R is essentially an upgraded version of the implemented: famous MG995 servo, and features upgraded shock-proofing and a redesigned PCB and IC control system Table-1: PLA Specifications that make it much more accurate than its predecessor. The gearing and motor have also been upgraded to improve dead Material Poly-lactic Acid (PLA) bandwidth and centring. Infill Percentage 30 % Profile 0.25 Support Yes Table-2: Time taken for completion of printing of each part Part Name Time taken for completion Fig. No 8. Robotic Arm complete assembly (with motors) Primary Arm 3 hr 58 mins PROGRAMMING OF THE ROBOTIC ARM Secondary Arm 3 hr 10 mins 6 hr 50 mins The setup or programming of motions and sequences for an Base 4 hr 35 mins industrial robot is typically taught by linking the robot Waist controller to a computer network. Various machines are 'integrated' and controlled by a single computer or PLC. How the robot interacts with other machines in the cell must ISBN: 978-93-5268-241-6 197 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 be programmed, both with regard to their positions in the its own unit testing framework, all of which contribute cell and synchronizing with them. The computer is installed to the increase in its speed and productivity. Python is with corresponding interface software. The use of a considered a viable option for building complex multi- computer greatly simplifies the programming process. protocol network applications. Specialized robot software is run either in the robot controller or in the computer or both depending on the HARDWARE AND OPERATING SYSTEM system design. Instead of going for a general purpose computer, There are two basic entities that need to be taught (or single-board computer (SBC) is used in this project. The programmed): Positional data and Procedure. For example, idea to use an SBC is due to its low cost and portability. An in a task to move a screw from a feeder to a hole the SBC is a complete computer built on a single circuit board, positions of the feeder and the hole must first be taught or with microprocessor(s), memory, input/output (I/O) and programmed. Secondly the procedure to get the screw from other features found on a functional computer. SBCs are the feeder to the hole must be programmed along with any developed for demonstration or development systems, I/O involved, for example a signal to indicate when the educational systems, or for use as embedded computer screw is in the feeder ready to be picked up. The purpose of controllers. Many types of home computers or portable the robot software is to facilitate both these programming computers integrate all their functions onto a single printed tasks. circuit board. In this project, the simulation or offline programming Unlike a desktop personal computer, single board computers method has been used to program the robot. The often do not rely on expansion slots for peripheral functions programming language used is Python. The prime reason for or expansion. Single board computers have been built using using Python programming language is because of the a wide range of microprocessors. Simple designs, such as following reasons: those built by computer hobbyists, often use static RAM and low-cost 8- or 16-bit processors. Other types, such as blade 1. The Python Package Index contains numerous servers, would perform similar to a server computer, only in third-party modules that make Python capable of a more compact format. One of the most popular interacting with most of the other languages and single-board computers used in this project is a Raspberry platforms. Pi. 2. Python provides a large standard library which For this project, a Raspberry Pi 3B+ is used. No special includes areas like internet protocols, string operations, reason behind using this particular model; one can go with web services tools and operating system interfaces. any other model as per their specifications. The key features Many high use programming tasks have already been of the Pi 3B+ is mentioned below: scripted into the standard library which reduces length of code to be written significantly. Table-4: Features of Raspberry Pi Model 3B+ 3. Python language is developed under an OSI-approved CPU type ARM Cortex-A53 1.4 GHz open source license, which makes it free to use and RAM 1 GB SRAM distribute, including for commercial purposes. Further, its development is driven by the community which Integrated Wi-Fi 2.4 GHz and 5 GHz collaborates for its code through hosting conferences Ethernet Speed 300 Mbps and mailing lists, and provides for its numerous Yes modules. PoE 4.2 Bluetooth 4. Python offers excellent readability and uncluttered simple-to-learn syntax which helps beginners to utilize this programming language. The code style guidelines, PEP 8, provide a set of rules to facilitate the formatting of code. 5. Python has built-in list and dictionary data structures which can be used to construct fast runtime data structures. Further, Python also provides the option of dynamic high- level data typing which reduces the length of support code that is needed. 6. Python has clean object-oriented design, provides enhanced process control capabilities, and possesses strong integration and text processing capabilities and ISBN: 978-93-5268-241-6 198 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Both additive manufacturing and single-board computers are an essential part of Industry 4.0. The main idea of this project was to utilize these concepts both theoretically and practically in order to have a broader sense about their implementation and functionality. Sooner or later, these techniques will change the way an industry works. Fig. No.9. GPIO mapping on Pi Model 3B+ FUTURE SCOPE IV. RESULTS, CONCLUSION AND FUTURE Certain developments and changes can be made to the SCOPE OF THE PROJECT robotic arm to make it more effective. The present design draws the inspiration from a typical industrial robot. RESULTS Further, changes to the gripper can be made to make it more versatile. Also, the robotic arm can be equipped with The manufacturing technique used in this project, that is, 3D sensors and camera to make it complete automatic. printing has proven to be efficient and economical than traditional manufacturing techniques. In 3D printing, a wide V. REFERENCES variety of materials are there to choose from. Wastage of material is very less comparative to traditional techniques. [1] Time constraints in this process totally depend on the build - 2018. and efficiency of the 3D printer. One of the biggest [2] Thabiso Peter Mpofu, Cephas Mawere, Macdonald require any special new tooling to make a part. When making a prototype, this can save a lot of time, money, and IJSR-2014. effort that would normally be spent on tooling the production line and getting an assembly process set up. [3] Vinod G. Gokhare, Dr. D. K. Shinde, Dr. D. N. Raut, - Printing Aspects and Various The use of Raspberry Pi eliminates the necessity of a PC. This saves a lot of space and the Pi is portable enough to be Processes Used in the 3D- carried around in the work space. The programming of the IJERT-2017. comes with a Wi-Fi and Bluetooth module which can be [4] used to control the robotic arm remotely. Transform http://www.designnews.com CONCLUSION [5] The concept of additive manufacturing is still new in the Vol. 4, Issue 6, IJAREEIE-2015. manufacturing and automation industries. Despite having an edge over the traditional techniques there are still some [6] Alexandru Pirjan, Dana- drawbacks. Due to this reason the upcoming manufacturing Impact of 3D Printing Technology on the society and techniques will not replace the traditional techniques in near ms and time. Operations Management, Volume 7, Dec 2013. The performance standard of an SBC is almost similar to a [7] general purpose computer but this technology is also in its budding stage and upgradation of this technology is still an Science and Information Technology Research ISSN ongoing process. 2348- 120X. [8] Richard E. Pattis. Karel the Robot: A Gentle Introduction to the Art of Programming. John Wiley & Sons, 1981. ISBN 0-471-59725-2. [9] https://en.wikipedia.org/wiki/Industrial_robot http://www.madehow.com/Volume-2/Industrial-Robot. html https://en.wikipedia.org/wiki/3D_printing ISBN: 978-93-5268-241-6 199 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 [10] https://en.wikipedia.org/wiki/Fused_filament [12] https://en.wikipedia.org/wiki/Single-board_computer _fabrication#Fused_deposition_modelin g [13] Industrial Robotics: Tecchnology, Programming, and [11] https://en.wikipedia.org/wiki/Industrial_robot# Applications by Groover, Weiss, Nagel, and Odrey Robot_programming_and_interfaces (TATA McGraw Hill Publications) https://en.wikipedia.org/wiki/Raspberry_Pi ISBN: 978-93-5268-241-6 200 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 IMPROVEMENT OF COOLING EFFECT ON IC ENGINE AT HIGH AMBIENCE TEMPERATURES SURESH KONDA1 SATEESH NALLAPU2 D SREEMANNARAYANA REDDY2 RANGENENI DEEPAK2 MUDIGIRI SHANMUKHA 2 1Assistant Professor, Department of Mechanical Engineering, 2Student, Department of Mechanical Engineering . Abstract are difficult to cool because, there location in the In Present technology era IC engine is primary engine does not permit them for proper heat transfer. source for vehicular propulsions so, the study and The design of engine is such that there is not much analysis of IC engine is significant and it has huge space for water jet to cool of the components .The platform to research and this work brings the spark plug is located in the middle and fastened to picture of effects which will evolve in running a chamber. There is no water flow that will aid in the engine at unwanted high temperatures , as the reduction of the temperature. Taking in to account that engine running at high temperatures the following as the engine warms up components expands with difficulties may arise like evaporation of lubricant heat, the engine is designed in such away that, at oil ,harmful unwanted emissions[1] ,variation of optimum operating temperature, components will volumetric efficiency, variations of metallurgical expand to optimum size. If an optimum temperature is properties of engine components etc. Among the not achieved then expansion will be either excessive or above problems variation of volumetric efficiency insufficient and can cause complications in running and variation of metallurgical properties of engine efficiency of the engine [1].Surface temperature may components are the working stock have to limited to temperatures as low as 130 °C [2] Keywords: - High temperatures , Volumetric efficiency, Metallurgical properties, and Lubricant oil Fig: 1 Temperatures of engine components etc. 1.1 Effect on lubricant 1. INTRODUCTION We have two types of engines, the spark ignition All engines require some form of lubrication and this engine (SI) and the compression ignition engine (CI). provided by the oil .This oil is require to carry out Both have there merits and demerits, Heat transfer in numerous different tasks, when the engine is in IC engines is a serious problem, since you need high temperatures to combust the fuel. But you also need to keep the temperature at a controllable level in order to operate the engine safely. Once the temperature in the engine has reached intolerable values the engine block and components may suffer damage. Therefore it is essential to have a heat removal process which will maintain the engine at a safe operating condition. There components in the engine that suffer more from high temperature than others. Therefore, A water jacket or air through fins are the two ways that reduce the temperature in the engine. The components with the highest temperature are Spark plug, the piston face, exhaust valve and a port. The problems with these components are that they are not only the hottest components, but they are also difficult to cool. They ISBN: 978-93-5268-241-6 201 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 operation ,the primary function being to lubricate all Fig:3 ( Fracture of exhaust valves) [5] the components by reducing friction or preventing or As the main heating part in the engine, piston works reducing metal to metal contact[2]. The most for a long time high temperature and high load prominent factor is due to change in temperature environment (maximum gas pressure reaches almost during machinery operation. A lubricant viscosity will 13 MPa). The piston has the characteristics of large decrease with an increase in temperature and will heating area and poor heat dissipation, so the thermal decrease in temperature reduction. These oils are load is the most serious problem [6]. In actual work, designed to function in an optimal way at the normal there are many failure modes due to thermal stress. operating temperature range of the engine. As the Structural design of the piston has a very important general rule of thumb, an engine operating temperature influence on the reliability, emission, economy and life should be approximately 10 C to 15 C and above the of the engine. Under the high temperature condition, cooling water temperature [3]. Keeping this in mind, the piston is subjected to periodic heat load which can the sump operating temperature of engine oil should cause surface cracking, corrosion, wear and even not exceed under normal conditions. Another general structural damage under abnormal temperature or rule that can be applied to the operating viscosity of burning condition [7]. As it can be concluded it is very engine oil is that, if the operating viscosity of oil goes necessary to analyze thermal stress of the piston [8]. below 10mm2/s then the oil is too thin to lubricate [4]. Fig: 2 (Viscosity of lubricant vs Engine temperature)[4] 2. Effect on Engine components The temperature in the combustion chamber of engine goes up to 2700k, and the material used in the engine cannot withstand this. Further, this high temperature destroys the lubricants properties l, of the oil film on the cylinder walls, at the same time, thermal stress will be developed there by destroying the cylinder, head and piston. As the internal combustion engine valves are precision engine components. They open and close as and when needed. The fresh charge (air - fuel mixture in spark ignition engines and air alone in compression ignition engines) is induced through inlet valves and the products of combustion get discharged to atmosphere through exhaust valves. They are also used to seal the working space inside the cylinder against the manifolds [5] Fig:4 (Thermal stress analysis of piston ) [7] ISBN: 978-93-5268-241-6 2.1 Effect on emissions Over recent past years, stringent emission legislations have been imposed on NOx, smoke and particulate 202 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 emissions emitted from automotive diesel engines Fig:6 (Brake power vs Engine temperature ) [8] world wide. Diesel engines are by low f characterized fuel consumption and very low CO emissions [9]. increase in cylinder temperatures increase the However, the NOx emissions from diesel engines still tendency of an engine to knock. Increasing the jacket remain high. Hence, in order to meet the temperature decreased the value of the compression environmental legislations, it is highly desirable to ratio at which knock occurred [11]. 3. Effect on reduce the amount of NOx in the exhaust gas. In diesel volumetric efficiency: Mass flow rate of air may engines, NOx formation is a highly temperature- decrease due to increase in engine temperature; this dependent phenomenon takes place when the may lead to decrease in volumetric efficiency. As we temperature in the combustion chamber exceeds 2000 know that the air densities decrease by the increase in K [10]. Therefore, in order to reduce NOx emissions the temperatures, Due to high temperatures in the in the exhaust, it is necessary to keep peak combustion engine the components such as the inlet manifold get temperatures under control. Formation of NOx is heated to high temperatures, this high temperature inlet almost absent at temperatures below 2000 K. Hence any technique, that can keep the instantaneous local manifold raise the temperature of charge air passing temperature in the combustion chamber below 2000 K, through it . The mass of air induced into the engine will be able to reduce NOx formation. decreases, this can be explaine proportional to the density and volume , the volume of Fig:5 (Engine speed vs Nox emissions with variation the engine is constant ,so when temperature increases in temperature) [1] the air density decreases and which results in the 2.2 Effect on engine performance: decrease in the mass of air supplied. The high temperature in the combustion chamber of 3.Volumetric efficiency: engine not only effects the components but also effects the efficiency and brake Power. The brake Power of engine decreases at high temperatures and speeds [8]. ISBN: 978-93-5268-241-6 203 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 As we know the mass of air supplied decrease, so the Engineering 113 (2017) 796 812 [8]. The Effect of volumetric efficiency also decreases. 4. CONCLUSIONS Engine Temperature on Multi Cylinder SI Engine As the temperature of the combustion chamber in the engine increases above 2000k, the viscosity of Performance with Gasoline as a fuel Sunil lubricant decreases below 10mm2/s, this may lead to insufficient lubrication of components and high Choudhary1, A.C. Tiwari2, Ajay Vardhan3, Arvind temperature may lead to decrease in brake power. Nox emissions increases due to high temperatures in Kaushal4 ISSN 2091-2730 [9]. THE EFFECT OF combustion chamber and also the components in the engine get damaged and lose their properties due to TEMPERATURE ON GAS EMISSIONS thermal stresses induced by the temperatures. The volumetric efficiency decreases with increase in Charalampos Arapatsakos1*, Anastasios Karkanis2 & engine temperatures. REFERENCES Stella Maria Strofylla3 [1]. The Influence of Engine Speed on Exhaust Emission of Four Stroke Spark Ignition Multi Cylinder www.arpapress.com/Volumes/Vol11Issue1/IJRRAS_ Engine Ajay K. Singh, A. Rehman ISSN: 2249 8958, Volume-2, Issue-4, April 2013 [2]. Effects of 11_1_10.pd Lubricant Temperature in a Motorized Engine A.F.A. Rasid, T.I. Mohamad, M.J. Ghazali and W.M.F.W. Mahmood World Applied Sciences Journal 20 (7): 927-930, 2012 ISSN 1818-4952 [3]. EFFECT OF TEMPERATURE ON LUBRICATING OIL AND POLY(METHYL METHACRYLATE) ADDITIVE M.Sc. Mohammed Faiq Mohammed 1 M.Sc. Muwafaq Mahdi Abd 2 ISSN 1999- 8716. [4]. wear check monitoring and technical bulletin issue 43 [5]. Failure Analysis of Internal Combustion Engine Valves: A Review Naresh Kr. Raghuwanshi1, Ajay Pandey2, R. K. Mandloi3 ISSN: 2319 875 [6]. The effect of cylinder liner operating temperature on frictional loss and engine emissions in piston ring conjunction R. Rahmani a, , H. Rahnejat a, B. Fitzsimons b, D. Dowson aApplied Energy 191 (2017) 568 581 [7]. Analysis of thermal temperature fields and thermal stress under steady temperature field of diesel engine piston Yaohui Lu , Xing Zhang, Penglin Xiang, Dawei Dong Applied Thermal ISBN: 978-93-5268-241-6 204 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 FABRICATION OF LIGHT WEIGHT CAR B.NAVEEN1 G.GURUVAIAH NAIDU2 A.VENKATA VISHNU2 1Assistant Professor, Department of Mechanical Engineering Vijaya Engineering College, Khammam, Telangana, India. 2 Assistant Professor, Department of Mechanical Engineering State, India. ABSTRACT- cycle, has been the most successful for Passenger transportation accounts for 60 to automobiles, while diesel engines are widely 70% of energy consumption from used for trucks and buses. transportation activities. The private car is the The gasoline engine was originally selected for dominant mode but has a poor energetic the automobile due to its flexibility over a wide performance/ efficiency, although this range of speeds. Also, the power developed for a performance has seen substantial given weight engine was reasonable; it could be improvements since the 1970s, mainly due to produced by economical mass-production growing energy prices and regulations. Only methods; and it used a readily available, 12% of the fuel used by a car actually provides moderately priced fuel--gasoline. Reliability, momentum, this is purely because of heavy compact size, and range of operation later design of vehicles. Heavy design and less become an important factor. occupancy of the car is also one of the major reasons for traffic jam in major cities. In most 2. PROBLEM DISCRIPTION of the cities heavily designed cars (size & mass In general the presently using wise) are being used by a single person to reach his work place, where most of the energy being automobiles has more weight and has more generated by the engine/ motor is used to drag rotating, reciprocating parts, by this disadvantage self weight of the car itself and also the efficiency of automobiles is decreasing and contributing to traffic conge station on roads. there by the consumption of fuel is increasing. By replacing heavily designed cars with small As the world is now facing fuel deficiency so it cars designed for a single/ two persons, can is important to reduce the consumption of fuel Increase the fuel efficiency of the car by and also by the more consumption of fuel it increasing the ratio of mass of human to car releases the harmful gases into the air where it is and can also reduce traffic problems. This in increases the pollution in air. So by reducing the turn results in less dependence on foreign import fuels and less vehicular pollution in of material of cities. The project involves Design, the vehicle and r Procurement, Fabrication, Painting and 10 percent can improve fuel economy by 6 to 8 Testing of a small (single seater) car body, percent. By keeping above problems our steering gear, seats, break system etc., which is objective is to suitable for Electric / Solar energy drive system. Reduce self weight of the car. KEYWORDS: Fabrication, Design, Electric Having less rotating and reciprocating energy, solar energy, Brake system etc. parts where it decreases the energy consumption which causes less harm 1. INTRODUCTION to pollution compared to presently using fuel propelled vehicles. An automobile or car is a wheeled Reduce the drag force. vehicle that carries its own power generator and Reduce the frictional force. transports passengers. Automotive production Reducing the required power down the ages has required a wide range of energy-conversion systems. These include Estimation car weight is 150kg electric, steam, solar, turbine, rotary, and different types of piston type internal combustion engines. The reciprocating piston internal combustion system, operating on a four stroke ISBN: 978-93-5268-241-6 205 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 200GPa Fig. No. 1 General Car Weight Fig.No.3. Frame structure Fig. No.2 Estimated Car Weight .3 EXPERIMENTAL PROCEDURE 3.1. CHASSIS: Fig.No.4.Chassis structure A vehicle without body is called Chassis. The components of the vehicle like Power, Transmission System, Axles, Wheels and Tyres, Suspension, Controlling Systems like Braking, Steering etc., and also electrical system parts are mounted on the Chassis frame. It is the main mounting for all the components including the body. So it is also called as Carrying Unit. MAIN COMPONENTS OF CHASSIS: The following main components of the Chassis are Frame Power source Transmission system Steering system Breaks Wheels 3.1.1. Frame: It is made up of long two members called side members riveted together with the help of number of cross members. Fig.No.5.Chassis Construction Specifications: 3.1.2 Power Source: The vehicle can be propelled either by heat Table No.1: Specifications of Frame engine or by the electricity. In heat engines the vehicle is propelled by converting chemical Material used Mild Steel 206 Cross section L Department of Mechanical Engineering, NNRG Cross sectional 40*40 dimensions ISBN: 978-93-5268-241-6
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 energy into mechanical energy. In electrically Fig.No.7 Shunt Motor powered vehicles the electric power stored in batteries is converted into mechanical energy by using motor. Batteries: A battery is a device consisting of one or more electrochemical cells that convert stored chemical energy into electrical energy. Here Dry batteries are used in the present work. Table No.2Motor Specifications Motor (DC shunt motor) Description Voltage 24 volts Current 12 amps Power ½ hp . Chains and Sprockets: Fig.No.6.Batteries Speed ratio calculations: 3.1.3. Transmission system-Motor: The Motor or an electrical motor is a Pitch circle diameter of the sprocket mounted on device that has brought about one of the biggest the motor shaft (d3) = 5cm advancements in the fields of engineering and technology ever since the invention of electricity. Pitch circle diameter of the sprocket mounted on A Motor is nothing but an electro-mechanical device that converts electrical energy to the shaft (d2) = 25cm mechanical energy. No.of teeth on the sprocket mounted on the In shunt motor the field winding is connected in parallel with the armature . the motor shaft (T1) = 12 current through the shunt field winding is not the same as the armature current. Shint field No.of teeth on the sprocket mounted on the shaft windings are desingned to produce the necessary m.m.f. by means of a relatively large number of (T2) = 60 turns of wire having high resistance. Therefore, shunt field current is relatively small compared Speed ratio = T1/T2 =60/12 with the armature current. Speed ratio = 5 Fig.No.8 Sprockets and Transmission system Length of chain calculations (L) = kP Where k =No.of chain links P = pitch of the chain K= (T1+T2)/2+ (2x)/p+ ((T2- 2P/x Where x=center distance between the sprockets X=27cm ISBN: 978-93-5268-241-6 207 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 K= (12+60)/2+(2*27)/0.6+((60- 2*0.6/27 Fig.No.9. Steering Rod K=127.298 Length of the chain = k*p =127.29*0.6 Length of the chain =76.38cm 3.1.4. Steering Mechanism: Fig.No.10 Steering Gear Rack and Pinion Generally, lighter, sportier cars have lower steering ratios than larger cars and trucks. The lower ratio gives the steering a quicker response you don't have to turn the steering wheel as much to get the wheels to turn a given distance which is a desirable trait in sports cars. These smaller cars are light enough that even with the lower ratio, the effort required to turn the steering wheel is not excessive. Fig.No.10. Hooke's joint showing the speed irregularities across a Checking for correct steering: a=wheel track=640mm b =wheel base=925mm c= distance between the pivots A and B of the front axle=610mm IP=925mm BP=1045mm AP=BP+BA =1045+610 AP=1655mm, now from triangle IBP , from triangle IAP, cotØ = AP/IP, cotØ= 1655/925 cotØ=1.78, c/b=610/925 =0.65 cotØ- -1.12 cotØ- cotØ- If the above condition is satisfied, there will be no skidding of the wheels, when the vehicle takes a turn. This geometry results in the inside wheel turning through a smaller radius than the outside wheel. This allows the vehicle to travel around a curve without scrubbing the tyres. In Fig.No.8.Steering Geometry produce true Ackerman. It is achieved by a ISBN: 978-93-5268-241-6 combination of the steered angle and the slip angle produced by the cornering force.The slip angle on the outside wheel is greater than that of the inner and this produces varying degrees of dynamic Ackerman effect. Steering gear specifications: Type of gear = helical gear 208 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 Teeth profile = involute teeth 3.1.6. Wheels: Wheel specifications: Helix angle = 200 Size: 2.15×16 Outer Diameter: 433mm Pitch of the teeth = 0.5cm Wheel Weight: 1,250g No of revolutions for complete rotation = 2½ rotations Distance moved by the rack for 2½ rotations =10cm Steering ratio: The steering ratio is the ratio of how far Fig no. 11 Wheels you turn the steering wheel to how far the wheels turn. For instance, if one complete revolution 3.2. MATERIAL FOR CAR BODY: (360 degrees) of the steering wheel results in the wheels of the car turning 20 degrees, then the ALUMINIUM steering ratio is 360 divided by 20, or 18:1. A higher ratio means that you have to turn the Physically, chemically and steering wheel more to get the wheels to turn a given distance. However, less effort is required mechanically aluminium is a metal like steel, because of the higher gear ratio. brass, copper, zinc, lead or titanium. It can be Rotation of steering wheel =3600 melted, cast, formed and machined much like Rotation degrees made by wheels =300 these metals and it conducts electric current. In Steering ratio = 30/360 fact often the same equipment and fabrication Steering ratio = 1:12 methods are used as for steel. Table No. 3 General Steering Gear Specifications APPLICATION DISCRIPTION Fig no. 12 Car Body with Al Sheet Type Rack and Pinion Tooth profile Involute Type of Gear Helix Angle Helical Gear Total No.of 200 steering wheel 2½ rotations rotations Steering Ratio 1:12 3.1.5. Brakes: Table No. 4. Specifications of the car: The material used for the brake lining should have the following charecteristics: Description Values 1600/820/80 mm It should have high coefficient of Vehicle Dimensions friction with minimum fading. In other L/W/H 90kg words, the coefficient of friction should Weight 150kg remain constant with change in temperature. Maximum load 30kmph It have low wear rate. No Emissions It should have high heat resistance. capacity Front wheel drive It should have high heat dissipation Rack and Pinion s capacity. Maximum speed DC shunt motor (1/2 It should have adequate mechanical hp) strength. Emission Wet cell batteries 12v It should not be affected by moisture and oil. Drive Type Steering Gear Drive motor Batteries ISBN: 978-93-5268-241-6 209 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 Distance between 2 925mm turning forces from one side of the other. If clockwise bending moments are taken as wheels negative, then a negative bending moment within an element will cause and a clockwise moment Brakes Internal Expanding will cause & it is therefore clear that a point of zero bending moment within a beam is a point of Brakes (Drum Brakes) contra flexure - that is the point of transition. Here the calculations are done manually to get Man to Car Ratio 1.5 the Moment of Inertia; other load calculations are also performed. 4. RESULT Fig No.13 Load Diagram on frame 4.1 Test for Bending moment: Fig No.14 Bending Moment Diagram Loads Acting on the beam: A beam is normally horizontal and the Name Weight (kg) Driver 60 loads vertical. Other cases which occur are Wheels 12 considered to be exceptions. A Concentrated Steering 2 load is one which can be considered to act at a Motor 7 point, although in practice it must be distributed Battery 12 over a small area. A Distributed load is one Body 31 which is spread in some manner over the length, Frame 26 or a significant length, of the beam. It is usually Total Weight 150 quoted at a weight per unit length of beam. It may either be uniform or vary from point to The calculated Factor of safety =5 point. When applied loads act along a beam, an internal bending moment which varies from point to point along the axis of the beam is developed. A bending moment is an internal force that is induced in a restrained structural element when external forces are applied. Failure by bending will occur when loading is sufficient to induce a bending stress greater than the yield stress of the material. Bending stress increases proportionally with bending moment. It is possible that failure by shear will occur before this, although while there is a strong relationship between bending moments and shear forces, the mechanics of failure are different. A bending moment may be defined as "the sum of turning forces about that section of all external forces acting to one side of that section and quota;. The forces on either side of the section must be equal in order to counter-act each other and maintain a state of equilibrium. For systems allowed to rotate, then the equivalent force would be referred to as torque. Moments are calculated by multiplying the external vector forces (loads or reactions) by the vector distance at which they are applied. When analyzing an entire element, it is sensible to calculate moments at both ends of the element, at the beginning, centre and end of any uniformly distributed loads, and directly underneath any point loads. Of course any within a structure allow free rotation, and so zero moment occurs at these points as there is no way of transmitting ISBN: 978-93-5268-241-6 210 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 5. CONCLUSION Table No. 5. Components of the drag of a body The original vehicle weight producing and their reduction same power is 130kg-150 kg, was reduced to 90 kg, which is decreased to 19-percent. structural Drag % of Caused by Way of performance of light weighted vehicles can be type Cp reduction summarized as: Fore body 65% and From this experiment we are able to drag measures reduce the original weight of the vehicle to 10%. So that we are able to increase Overpressur Reduction fuel economy to 6-8%. e on the of The deceleration of a vehicle was more front face. likely to be dependent on the vehicle overpressur stiffness and crash mechanisms, rather e by than vehicle mass reduction. The best material for the car body is accelerating aluminum that is because of the the flow: reasonable price, there is possibility to repair the car in case of any accidents. It rounding up is light weight material and handling of upper and forming aluminum is relatively horizontal easy. The most significant drag reduction can and vertical be achieved by rounding up the vertical leading and upper horizontal leading edges on the front face. edges, Relatively small amendments can result slanting the considerable drag reduction. front face. The drag reduction of front spoiler is large if its use is combined with Base drag 34.9 Depression Increase of rounded leading edges. % on the rear pressure: To have a 30-percent content of plastics boat-tailing, and composites in the development of a, end. tapering the additional applications of plastics and rear part of composites to the vehicle structural components, the body, especially occupant compartment and closures, rounding up would be required. Investigation of of trailing Opportunities for Lightweight Vehicles Using Advanced Plastics and Composites Based on the edges. front NCAP simulations of five light weighted vehicles, Side wall, 0.1% Shear Decrease of roof and stresses over shear 6. REFERENCES underbod 1. Mechanics of materials by Timeshenko y drag the walls, stresses: & Gere. roof and reduction of 2. Production engineering by S.Chand. underbody roughness, 3. Electrical Engineeing and Eletronics by decrease of V.K.Mehta and Rohit Mehta the velocity 4. Elle Kalm Master of Science Program Ergonomics and Production in the Engineering underbody 5. Kinematics and Dynamics of Machinery by Kurmi. gap. 6. Handbook of Composites, Lubin, G., editor, Society of Plastics Engineers ISBN: 978-93-5268-241-6 211 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 Technical Monograph, Van Nostrand Reinhold Co., Inc., New York, 1982. 7. ASM Handbook Volume 21 Composites, ASM International, Material Park, OH, 2001. Ganster, J., Fink, H. and Pinnow, - Tenacity Man-made Cellulose Fibre Reinforced Thermoplastics Injection Moulding Compounds with Polypropylene and Alternative Composites Part A, 37, 2006, 1796-1804. ISBN: 978-93-5268-241-6 212 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 CFD Simulation of Down Drought Biomass Gasifier R.Ravi kumar1 K.Suresh Kumar2 1Assistant Professor, Department of Mechanical Engineering, MVSR Engineering College, Nadergul Hyderabad. 2Assistant Professor, Department of Mechanical Engineering Nalla Hyderabad, India. Abstract- Biomass is considered to be one of the most the gasifier, they are classified according to the way air or promising renewable energy sources in the present scenario. oxygen is introduced in it. There are three types of gasifiers. Due to stringent policy on emission reduction, biomass has become a centre of attention worldwide as a source of green Downdraft gasifier, energy. The gasification technology is now considered to be Updraft gasifier in an advanced stage of development. Hence there is huge Cross draft gasifier. expectation from the user industry for its application. The present work has been carried out in order to perform CFD Downdraft gasifier simulation in Biomass Gasification process, for this purpose Downdraft gasifier has air passing through the biomass from a down draft biomass gasifier system is designed using the tuyers in the downdraft direction. And the combustible empirical data and derived quantities in CATIA, changes gases come out from the bottom of the gasifier. made in the Model of reduction chamber with 30° inclination angle considering 4 number of nozzles. In this paper airflow analysis and temperature distribution across the chamber of gasification products has been analyzed by CFD method using ANSYS CFX 11.0 software. I. INTRODUCTION Figure No. 2: Down Draft Gasifier The production of generator gas (producer gas) called Figure No. 3: Various Zones in downdraft Gasifier gasification, is partial combustion of solid fuel (biomass) and takes place at temperatures of about 1000°C. The reactor is called a gasifier. The combustion products from complete combustion of biomass generally contain nitrogen, water vapor, carbon dioxide and surplus of oxygen. However in gasification where there is a surplus of solid fuel (incomplete combustion) the products of combustion are (Figure No. 1) combustible gases like Carbon monoxide (CO), Hydrogen (H2) and traces of Methane and non useful products like tar and dust. The production of these gases is by reaction of water vapor and carbon dioxide through a glowing layer of charcoal. Thus the key to gasifier design is to create conditions such that Biomass is reduced to charcoal and, Charcoal is converted at suitable temperature to produce CO and H2. Process Zones Four distinct processes take place in a gasifier as the fuel makes its way to gasification. They are: Drying of fuel Pyrolysis a process in which tar and other volatiles are driven off Combustion Reduction Though there is a considerable overlap of the processes, each Figure No. 1: Production of Gasification. can be assumed to occupy a separate zone where fundamentally different chemical and thermal reactions take 1.1 Types of Gasifiers place. Since there is an interaction of air or oxygen and biomass in 213 ISBN: 978-93-5268-241-6 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 Figure No. 3 shows schematically a downdraft gasifier with transient one-dimensional model is developed for the different zones and their respective temperatures. In the throated close-top downdraft biomass gasifier. The model downdraft gasifiers there are two types: takes into account of the pyrolysis, secondary tar reactions, Single throat and, homogeneous gas reactions and heterogeneous combustion/gasification reactions. Double throat (Figure No. 4) The developed model is divided into three parts according to Single throat gasifiers are mainly used for stationary applications whereas double throat are for varying loads as three prevailing zones in the gasifier: well as automotive purposes. (1) Pyrolysis, (2) Oxidation and (3) Reduction. The drying zone is indirectly incorporated in the developed model. The experimental data obtained in the earlier study [18] are used to validate the simulation results of the combined transport and kinetic model. III. DESIGN OF FIXED BED DOWN DRAFT BIOMASS GASIFIER Figure No. 4: Single and Double Throat Gasifier Design of gasifier essentially means obtaining the dimensions of the various components of it. Design of Advantages: gasifier is largely empirical. Design of gasifier is carried out Flexible adaptation of gas production to load Low sensitivity to charcoal dust and tar content of fuel partly through computations and partly using empirical relations and using some experimental data. The principal design parameters are specific gasification rate (SGR), gas resistance time (GRT) and area of air nozzles. The derived parameters are diameter of hearth and throat, total length of combustion and reduction zone, air velocity, diameter of nozzles and number of nozzles etc. Disadvantages: Design tends to be tall Not feasible for very small particle size of fuel II. LITERATURE SURVEY Various models that have been reported for different gasifier Figure No. 5: Experimental setup scheme configurations include: Figure No.5 setup of down draft biomass gasifier. Figure 1. Unsteady one-dimensional model for stratified No.6 shows the schematic design of the down draught gasifier. Firing nozzle is used start the combustion process. downdraft gasification [4], Ash and gases will pass through the grate region. Ash will be collected in the ash pit and producer gas will leave the 2. Transient single particle and fuel bed model for gasifier through the gas outlet. A close up view of the combustion zone is shown in the Figure No.7. crosscurrent moving bed furnace [5]. 3. Steady-State reduction zone model for downdraft gasification [3] and 4. Steady state fluid flow and heat transfer model for open top throat-less downdraft gasification [7]. However, for throated close-top downdraft biomass gasifier, commonly known as an Imbert downdraft gasifier, a complete model including pyrolysis, combustion and reduction zones has not been reported in the literature. In a survey of gasifier manufacturers, it is reported that 75% of gasifiers offered commercially were downdraft, 20% were fluid beds (including circulation fluid beds), 2.5% were updraft, and 2.5% were of other types [11] [13]. Taking into account of the importance of downdraft biomass gasifier and its commercial applications, it is essential to have a complete model for such a configuration. In the present study, a ISBN: 978-93-5268-241-6 214 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 Phase 2 : (Modified Model) 3D Model generation based on CFD results of Initial Model Mesh generation Solution Post Processing 4.1 Model of the chamber with Zero Nozzle Inclination Angle Figure No. 6: Setup of down draft biomass gasifier The nozzle inclination angle is the angle between the radial line connecting the nozzle with the center and the center line of nozzle and angle being measured in clockwise sense. In the first case, 4 nodded tetrahedral elements are used to mesh the model. Airflow analysis is same as that of the model without the wall, because the flow region is same and there is no property change as far as the flow analysis is concerned. The air flow has not reached the wall efficiently and the Gasification in this zone is poor. The temperature is maximum at the reduction zone and in the wall region it varies from 1220 K to 1349° K. The maximum temperature of 1478° K is very well coincides with the theoretical maximum of 1200° C (1573° K). The temperature at the outlet where the producer gas leaves the gasification chamber is about 700° C [18]. 4.2 Model of a reduction chamber with 30° inclination angle Figure No. 7: Schematic design of downdraft gasifier The model is analyzed considering the wall of the reduction chamber. The model is shown in Figure No. 8; the effect of The main components of the gaseous mixture leaving the wall is neglected in the place of nozzles. Also the wall shown combustion zone are carbon dioxide, water vapor, inert nitrogen, carbon monoxide, hydrogen and some amount of above the nozzle is not considered for the analysis. Thus the low molecular weight hydrocarbons such as methane, values in that region that we will get from the analysis are not ethane, ethylene etc. In the reduction zone, the gaseous true values. This portion of the wall is not considered for the mixture passes through the hot porous charcoal bed resting above the grate. The reduction zone is often referred as analysis, because the combustion starts only from the region gasification zone. where the air enters into chamber and the flow is downwards chamber. IV. DESIGN AND ANALYSIS USING CFD Figure No. 8 Shows model of a reduction chamber with 30° to analysis the temperature and air flow velocity of the inclination angle by considering four nozzles. It is modeled producer gas. in CATIA and imported in to ANSYS CFX 11.0. Figure Tools used: No. 9, Shows model with volume mesh with nodes 15081 CAD: CATIA and elements 76724. Preprocessor: ANSYS CFX 11.0 Solver: ANSYS CFX Post Processor: ANSYS CFX Steps followed during the execution of project: Figure No. 8: Model with wall of the Reduction chamber Phase 1: (Initial Model) 3D Model generation Mesh generation Solution Post Processing ISBN: 978-93-5268-241-6 215 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 Figure No. 9: Model with mesh Figure No. 12a: Top View Figure No. 10: Boundary conditions Figure No. 12b: Bottom View Figure No. 12, Shows air flow velocity across the reduction chamber with inlet velocity 6 m/s and outlet velocity 30 m/s. Figure No. 11: Stream lines across the Reduction chamber Figure No. 10, Shows boundary conditions of a reduction chamber with initial velocity and temperature V=6 m/s and T=298°K and outlet mass flow rate and temperature T=523°K. Air flow velocity across the Reduction chamber Figure No. 13: Temperature around the wall ISBN: 978-93-5268-241-6 216 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 S.No Temperature(K) Reference line Z(m) Table No.2: Readings of temperature (K) and Reference line Z (m) 1 322 -0.04 2 320 -0.025 3 320 -0.008 4 321 0.005 5 322.7 0.025 6 324.8 0.042 7 325 0.05 8 327.4 0.075 Figure No. 14: Pressure around the wall Figure No. 13, Shows temperature contours around the Figure No. 16: Temperature (K) Vs Reference line Z (m) reduction chamber wall with an inlet temperature 2980 k and The airflow rate is drastically reduced in the central outlet temperature around 5230 k. region. When the inclination angle forms 0° with wall and Figure No. 14, Shows pressure contours around the reduction the air velocity ranges from 0.75 m/s to 1.5 m/s in the central region and from 3 m/s to 6 m/s near the wall. maximum at the reduction zone and in the wall region it varies from1220 K to 1349° K. This maximum temperature Air reaches all regions in the reduction zone efficiently of 1478° K is very well coincides with the theoretical when the nozzle inclination angle forms 30° with wall and maximum of 1200° C (1573° K). The temperature at the outlet where the producer gas leaves the gasification the chamber is about 523° K. average air velocity ranges from 5 m/s to 7 m/s. V. RESULTS AND CONCLUSIONS The comparison of all the cases reveals that the choke Table No.1: Readings of velocity in m/s and Reference line Z plate design with 4 nozzles and 30° inclination angle is (m) much better than the other designs considered in the work. S.No Velocity(m/s) Reference line Z(m) Gasification is almost complete and the gasification 1 12.5 -0.04 takes place throughout the reduction chamber when the 2 6.4 -0.024 nozzle 3 19.5 -0.008 4 21 0.01 inclination angle forms 30° with wall and the maximum 5 20 0.025 temperature produced is 1483° K. 6 17.9 0.042 7 17.9 0.059 The gasification is effective only at the narrow region 8 16.5 0.075 near the wall and it is poor at the central region when the inclination angle forms 30° with wall. The comparison of temperature distribution for all the models also indicates that the choke plate design with 4 nozzles and 30° inclination angle is better than the other models. However this 30° inclination angle may not be the optimum and the optimum angle may lie between 10° to 25°. This has been arrived from the fact that for zero inclination angle the gasification and air flow is more at the central region and that for the 30° inclination angle it is near the wall of reduction chamber. In order to get the optimum inclination angle, we have to carry out the analysis for the choke plate designs with nozzle Figure No. 15: Velocity (m/s) Vs Reference line Z (m) VI. FUTURE SCOPE ISBN: 978-93-5268-241-6 The future scope of the work, is the Approach of CFD analysis can be vary the inclination angle of the nozzle from 00 to 450 . i.e. 100, 150 , etc. At the same time we change /increase the number of nozzles. i.e. 2, 4 and 6. 217 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 Experimental results can be extracted in order to [10] further validate the presented numerical results. Stratified DowndraftGasification of In VII. REFERENCES Proc. Of the Fifteenth Biomass Thermo [1] and Estimation of Optimum Parameters in Pyrolysis chemicalConversion Contactors Meeting, Atlanta, of 44 (2135 2158), 2003. GA, pp. 217-254. 1983. [2] [11] Bridgwater, A. of Reduction Zone of Downdraft Biomass Gasifier: Feasibility of Biomass Gasification for Power Conversion and Management, 47 (2602-2611), 2006. [3] -653. 1995. Steady State Model of Gas-Char Reactions in a Down [12] Reed TB, Das A Handbook of biomass downdraft -91, gasifier engine system. Golden, CO: SERI, 1988 2003. [4] [13] Bridgwater, A. Downdraft Gasifie Feasibility of Biomass Gasification for Power Science, 55, 2931-2944, 2000. [5] Wurzenberger, J.C., Wallner, S., Raupenstrauch, H., 631-653. of Biomass: [14] Bhattacharya, S. C., Hla, S. S., Pham, American Institute of Chemical Engineers Journal, on a Multistage Hybrid Gasifiers- 48, 2398-2411, 2002. [6] Biomass and Bioenergy, Vol. 21, pp. 445-460. 2001. in the Reactive, Porous Bed of Downdraft (Biomass) [15] Flow, 28, 1518 1530, 2007. [7] Bridgwater, A.V., Bio-Energy Research Group, Aston Gasification in a Laboratory- Scale AFBG: Influence University, Birmingham B47ET, UK, (2002). of the location of the Feeding Point on the Fuel-N [8] Iyer, P. V. R., Rao, T. R., Groover, P. D., Singh, N. -1378. 2000. P., [9] Z. A. Zainal, A. Rifau, G. A. Quadir, and K. N. [16] P.P.Parikh,A.G.Bhave,D.V.Kapse&Shashikantha, Bioenergy, vol. 23, pp. 283 289, 2002. Study of Thermal and Emission Performance of Small Gasifier-Dual- Fuel Engine Systems, Biomass 19 75-97. 1989. [17] Dasappa, S., Paul, P. J., Mukunda, H. S., -A Renewable Bangalore. 2000. [18] and Analysis of down Draft Biomass Gasifier using Gate.Net.2006. [19] Ratnakar Chodapaneedi, Narsimhulu Sank, Civil Engineering (IOSR-JMCE) ISSN: 2278-1684, PP: 42-48. ISBN: 978-93-5268-241-6 218 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24etchha&ni2c5atlhEJnugliyn,ee2r0in2g0 INVESTIGATION OF PROCESS PARAMETERS FOR THE WELDABILITY OF THE MATERIAL Dr.K.Harinarayana Professor, Department of Mechanical Engineering CMR Engineering College, Kadlakoya (V), Medchal Road, Hyderabad 501401 Email: [email protected] Abstract In this paper, the effect and optimisation of various generated at each pole is the same and hence changing over welding process parameters on the weldability of Mild Steel the connections to the electrode does not have any effect. specimens having dimensions 50mm× 50mm× 6 mm welded by metal arc welding will be investigated. The welding current, arc But the polarity of D.C has greater effect on electrode voltage, welding speed, heat input rate are chosen as welding performance. With a D.C source, if the work piece is parameters. The depth of penetrations are to be calculated for connected to the positive terminal and the electrode holder each specimen after the welding operation on closed butt joint and is connected to the negative terminal of a welding machine, the effects of welding speed and heat input rate parameters on then the welding set up is said to have straight polarity. depth of penetration will be estimated and then investigated by applying optimization and regression modelling Usually D.C. Arc welding machines are D.C generators which are driven by electric motors where as A.C. Welding Keywords Welding Current, Heat Input, Optimization, machines are transformers. Depth of Penetration Both consumable and non consumable electrodes are I. INTRODUCTION (HEADING 1) used in arc welding. In the past bare electrodes were used 1.1. Arc Welding: but with bare electrodes it was found difficult to control the arc and to protect the molten metal from atmospheric Electrical arc is used as the main source of heat in arc oxygen and nitrogen which produces oxides and nitrides and welding. Electrical arc is produced when two conductors i.e. makes the weld bead brittle and weak. Therefore modern Anode and cathode of an electric circuit are brought electrodes are mostly coated. During welding the coatings together and then separated slightly so that an air gap is on the electrode burns as the electrode melts and covers the established such that the current continues to flow through molten metal from contamination. the gaseous medium. This arc produces temperatures of about 6000-7000 degrees. Various arc welding processes are as follows: a) Metal arc welding b) Carbon arc welding c) TIG welding d) MIG welding e) Submerged arc welding 1.2. Metal arc Welding: This is conventional welding process where metal rod is used as electrode (consumable) and the work piece is used as another electrode. Figure 2 shows the conventional metal arc when the electric arc is struck between the electrodes, the base metal melts due to the heat of the arc. The consumable metal electrode will also melts and enters in to the molten metal. Fig.1. Schematic diagram of arc welding Figure 1 shows schematic diagram of an arc welding process. Either from an A.C or a D.C source supply electric current. With A.C due to the reversal of the current, the heat 219 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 Fig.2. Metal arc welding performance of a component when it is welded because its metallurgical structure was modified by the process. The depth to which the base metal is melted and The re-design is very costly since that happen late in deposited is called the penetration of the joint. The amount the development cycle of the product. It is now of penetration depends upon the cross sectional area of the possible to avoid this by anticipating the undesirable weld bead, the current and the voltage. Penetration increases effects of the manufacturing process early in the design with increase in current. stage, by using numerical simulation, numerical optimization and AI tools. This shows how much A crater (small depression in the base metal ) is virtual welding formation due to the action of the electric arc. This arc crater should be avoided always otherwise it will become the weak process can be important in the development of a new point in the welded structure. component. Welding simulation utilize to optimize process parameters during the earlier stages of a new design This process is also called as shielded metal arc welding cycle avoiding expensive errors that could occur later. The (SMAW) because as the electrode coating burns it gives off industrial benefits of using welding simulation and an inert or protective gas which shields the arc and the optimization are: molten metal from the atmospheric oxygen and nitrogen. Both A.C. And D.C. Current source may be employed in i) Minimize distortions: Simulation allows to predict this method. the distortions and to minimize them by optimization. The effects are of increasing the overall quality of the Overall Classification of Welding processes are further product and of reducing the costs. Increase in heat input classified as shown in Fig. 3. during welding can cause the problems of fracture resistance and deformations. The welding cost increases Fig.3 Classification of welding processes with the increase of welding volume. 2. LITERATURE SURVEY IN WELDING ii) Residual stresses: The goal is to minimize the DOMAIN gradient and to have a smooth distribution of the residual stresses resulting from the welding process. By acting on Welding process is an important domain of activity of to- the welding process, one can have compressive stresses day industry, especially in the sector where a lot of on the surface of the component, which improves its assembly of structures has to be done. Generally, the quality and avoids corrosion due to tensile stresses. initial design of industrial parts requires revisions, because Residual stresses can be optimized by applying design of unpredictable changes occur in the shape or the experiments and simulations. iii) Knowledge of welding process: Welding analysis by ANOVA and simulation allows to define the best welding sequence and to control all the parameters of the welding process. It is important to optimize the amount of heat input brought by the heat source during the process to maximize the weld strength and minimize the deformations. By mastering the process involved, one can use the right parameters to achieve the desired response, and the productivity is improved by applying process knowledge base. 3. EXPERIMENTAL PROCEDURE: In this analysis, metal arc welding is used. It is a process which yields coalescence of metals by heating with a welding arc between a continuous filler metal electrode and the workpiece. 20 specimens of dimensions 150mm × 50mm× 6 mm are prepared, then closed butt joint are made by these specimens. Before welding, edges of the work pieces are suitably prepared. The edges and the area adjoining them is cleared of dust using wire brush and cloths. Afterwards, the work pieces to be welded were positioned with respect to each other and welding process was performed. During the welding process, following data are chosen: M.S. (Mild Steel) Workpiece ISBN: 978-93-5268-241-6 220 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Electrode (E 6011) of 3mm & 4mm 5. 440 200 103.86 50837.66 3.19 diameter 6. 440 220 104.19 55744.31 2.85 Current (3mm electrode) =120-180 Amp 7. 440 230 104.85 57911.30 2.34 Current (4mm electrode) =160-240 Amp 8. 440 240 109.19 58027.29 1.42 Terminal voltage = 440 V Chemical Composition of M.S.Plate are shown in the 4. RESULTS AND DISCUSSIONS following sequence: 4.1.Effect of welding speed on depth of penetration: Chemical composition of Workpiece : Readings of depth of penetration obtained through measuring instrument after cutting all the welded specimens Mild steel plate. perpendicular to the direction of welding are shown in the table 1 and 2.Penetration Ratios are analyzed with the help C% Si% Mn% P % S% of graph which is plotted between Welding current, Welding (0.250) (0.035) (0.95) ( 0.014) (0.0081) Speed and penetration as shown in Fig 4 and 5. Cr% Ni% Mo% Al% It can be seen from Fig 4, As Welding Current (0.019) (0.019) (0.012) (0.00) increases, Penetration Ratio also increases slightly then it shows rapid growth with Welding Current. Further increase Only arc time was varied during the welding. Welding in welding current, a maximum value of 150 amps shows speed is calculated for each welded specimen. After the maximum value of Depth of Penetration 2.66 mm. finishing the welding processes, in view of measuring the Afterwards, increase of Welding current decreases Depth of depth of penetration, weld pieces were cut perpendicular to Penetration. the direction of welding on power hacksaw. Then with the help of measuring instrument, depth of penetration of welded specimens was measured. Different values of Depth of Penetration are tabulated with input parameters like Welding Current, Welding speed and Heat Input as shown in Table 1 for 3 mm electrode and Table 2 for 4 mm electrode TABLE 1: Process parameters of Depth of Penetration for 3 mm electrode S. Welding Welding Welding Heat input Penetrati No voltage current speed (J/mm) on ratio (v) (A) (mm/min) (mm) 1. 440 120 101.07 31344.61 1.96 2. 440 130 101.60 33779.52 2.01 3. 440 140 102.22 36157.30 2.22 Fig 4. Relationship between Welding Current and Penetration Ratio 4. 440 150 101.71 38934.22 2.66 5. 440 160 103.85 40674.04 2.58 6. 440 170 104.28 43037.97 2.09 7. 440 180 104.92 45291.65 1.85 8. 440 180 109.01 43592.33 1.45 TABLE 2: Process Parameters of Depth of Penetration for 4 mm Electrode S. Welding Welding Welding Heat input Penetrati No voltage current speed (J/mm) on ratio (v) (A) (mm/min) (mm) 1. 440 160 101.19 41743.25 1.98 2. 440 170 101.76 44103.77 5.66 3. 440 180 102.34 46433.45 2.96 Fig 5 . Relationship between Welding Speed and Penetration Ratio 4. 440 190 101.86 49244.06 3.28 From the graph it can be found that the increase in ISBN: 978-93-5268-241-6 221 Department of Mechanical Engineering, NNRG
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Welding speed first increases depth of penetration then 2. Microstructure consists of tempered martensite in the further increase in speed , penetration ratio will not change matrix. much. Instead it decreases enormously. Hence an Optimum 3.HAZ is well fused and consists of tempered and needle value of 2.66mm Depth of Penetration is recorded at 101.71 martensite in the matrix. mm/min of Welding speed. 4. Maximum Depth of Penetration of 2.66mm is possible at 4.2.Microstructural analysis: optimum values of Welding Current 150 amp with welding speed of 101.71mm/min is possible which clearly indicated Microstructure for 5MM that the weldability is maximum at this point. It is due to the weldability of any material is proportional to Depth of Penetration. 5mm HAZ@100x REFERENCES 5. CONCLUSIONS [1]. A text book of Production Technology by R.K.Jain 1. Depth of Penetration can be achieved by considering the [2]. A Text book of Production Engineering by P.C.Sharma welding parameters as welding speed, 101.71 mm/min with [3]. A Text book of Manufacturing Science by Amitabh Ghosh and current 150 Amp, arc voltage 440V which is taken as constant with size of the electrode(E 6011) diameter 3mm. Malik [4]. Biswajit Das1, B. Debbarma2, R. N. Rai3, Influence of Process parameters on Depth of Penetration International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308 [5]. Pranesh B. Bamankar, Dr. S.M. Sawant Study of effect of Process parameters on Depth of Penetration, International Journal of Advanced Engineering Research and Studies ISBN: 978-93-5268-241-6 222 Department of Mechanical Engineering, NNRG
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