Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 Ahmmad, \"Design and Development of Mopping Robot-'HotBot',\" in In IOP Conference Series: Materials Science and Engineering , vol. 53, 2013, p. 7. [4] Muhammad KashifShaikh Ghaffar, M. Aadil Arshad, Nandkishor S.Kale, Ansari M Bilal, Prof. D. M. Ugle, \"A Research Paper on \"Design and Development of Floor Cleaning Machine\",\" in A National Conference On Spectrum Of Opportunities in Science & Engineering Technology, IJAERD, vol. 5, April 2018, p. 9. [5] Andrew Ziegler, Duane Gilbert, Christopher John Morse, Scott Pratt, Paul Sandin, Nancy Dussault, Andrew Jones, \"Autonomous Surface Cleaning Robot for Wet and Dry Cleaning,\" in Washington, DC: U.S. Patent and Trademark Office, U.S. Patent No. 8,670,866 B2, March 11, 2014, p. 126. [6] Joseph L. Jones, Newton E. Mack, David M. Nugent, Paul E. Sandin, \"Autonomous Floor- Cleaning Robot,\" in Washington, DC: U.S. Patent and Trademark Office, U.S. Patent No. 6,883,201 B2, April 26, 2005, p. 26. [7] Shih-Che Hung, Yao-Shih Leng, \"Cleaning Robot and Control Method Thereof,\" in Washington, DC: U.S. Patent and Trademark Office, U.S. Patent No. 8,788,133 B2, July 22, 2014, p. 12. [8] Michael Dooley, James Philip Case, Nikolai Romanov, \"System and Method for Autonomous Mopping of a Floor Surface,\" in Washington, DC: U.S. Patent and Trademark Office, U.S. Patent No. 8,892,251 B1, November 18, 2014, p. 13. ISBN: 978-93-5268-241-6 30 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 DESIGN AND ANALYSIS OF A SMALL SCALE HELICAL WIND TURBINE FOR STREET LIGHTS V.GURU SHANKER G.SAI TEJA Department of Mechanical Engineering, Department of Mechanical Engineering, Vignan Institute of Technology and Science, Vignan Institute of Technology and Science, Hyderabad, Telangana, India. Hyderabad, Telangana, India. P.VIVEK P.VISHNU SAI Department of Mechanical Engineering, Department of Mechanical Engineering, Vignan Institute of Technology and Science, Vignan Institute of Technology and Science, Hyderabad, Telangana, India. Hyderabad, Telangana, India. ABSTRACT-- The present work is about designing According to James Blyth began a research program a helical wind Turbine and testing its performance. on the use of wind power for electricity generation Throughout the work, it is proven that the turbine is and storage in the garden of his holiday cottage in Scotland. The wind turbine is created by Blyth was much more efficient than its predecessors due to the 10-meter high, cloth-sailed wind turbine and he used nature of it grasping wind, and harnessing its to charge accumulators developed by the Frenchman energy. Conventional sources of power have become Camille Alphonse. Blyth's wind turbine design was 10-meter in diameter and stored the electricity very expensive, common street lights consume a lot generated in 'accumulators' batteries. Blyth used the of energy, this work aims to use the wasted energy generated power to light his cottage, and even offered of the wind to produce renewable energy source to the surplus electricity to the people of the village for produce enough power to light one or more street village people turned down the offer as they thought lights. In the present work we have designed and analysed a helical wind turbine which is to be able to install a larger wind turbine, which was much- improved version of his first at the Infirmary and attached it on one or more streetlights. Dispensary, where it ran successfully for 30 years. [3] KEY WORDS: Helical turbine, Renewable energy, wind The main objective of the present work is to Design velocity, Angular velocity, power co-efficient, static and structural analysis of a small scale wind turbine to produce renewable energy which will reduce the loading, street light. pollution. Cut the cost of Lighting Street especially on highways and remote areas. Decrease the demand 1. INTRODUCTION 31 factor for the whole city. Allow the creation of The present work is intended to design and structural mentioned turbine to be cost effective. Make it analysis of a simple helical wind turbine to be accessible and easy to use by others. attached to streetlights, buildings in order to provide 2. DESIGN METHODOLOGY enough energy to light. A windmill is a type of Turbine sizing and estimation of power, these engine. It uses the wind to make energy. To do this it parameters fall primarily into two categories, those uses vanes called sails or blades. The energy made by are governed by the geometry of the turbine, and windmills can be used in many ways. These include governed by the flow field in which the turbine is grinding grain or spices, pumping water and sawing designed to be placed. wood. Modern wind power machines are used to create electricity. These are called wind turbines. Department of Mechanical Engineering, NNRG. Before modern times, windmills were most commonly used to grind grain into flour. The windmill has been in history for many years. The design consists of a helical wind turbine coupled with an electrical generator, which will be attached to a battery to store the excess energy. The present work aims not only to use a clean source of energy to power everyday needs, but also to provide a cost reduction in the large amount of funds that are spent yearly on generating power. The turbines that are going to be created are safe in nature, and are very cost efficient. The efficacy in cost will allow for many people to easily get a hold of them and for larger scale needs such as to power companies, as well as powering regular everyday things. ISBN: 978-93-5268-241-6
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 equation (2-2): =×××3 = 0.5 1.18×0.7×53=51.625 =× = 51.625×0.55=28.39 Table 1: shows the power at different wind speeds VelocityKm/h Diameter Length Area PTurbine (m/s) (m) (m) (m2) (W) Figure 1: Helical Wind Turbine 5 18 0.7 1 0.7 28.39 6 21.6 0.7 1 0.7 46.9 The dimensions for the turbine are 1 m ×0.7 m, as 8 28.8 0.7 1 0.7 111.4 they are convenient for a small-scale wind turbine. 10 36 0.7 1 0.7 217.5 Moreover, the parameter that the designer has an option to control, here, are some of the formula used to design the turbine and to maximize the efficiency. that no wind turbine could convert more than 59.3% of the kinetic energy of the wind into mechanical energy turning a rotor. This is known as the Betz Limit, and is the theoretical maximum coefficient of The Natural tip speed ratios of the Gorlov helical Graph 1: Power at different speeds turbine were found to fall within the range from 2 to 2.5 in all resources used. Found the range to be just BLADE SHAPE AND PROFILE below 1 to 2.5. If this lower range is considered to be Regarding the blade we decided to go with NACA for not quite optimized circumstances and ignored, 0018 blade profile as it was used frequently in wind the tip speed ratio range of 2 to 2.5 can be used to and marine helical turbine, NACA 0018 blade offers a predict possible expected angular velocities for our medium between the optimized performance of a turbine using the relationship: [10] thin blade and the manufacturability and durability of thick blades profile. There is no need for a special (2.1) cambered blade design because of the good self- start capability of the helical turbine [11]. Where: velocity, : Average air velocity : Angular Rearranging equation (2.1) yields: As mentioned above, r =0.7/2=0.35 , =5 / e= = 2.25 Thus, the equation (2.1) becomes: = = 32.14 / The torque of the turbine can be calculated using the following equation: Where: : = × =1×0.7=0.7 2, : Power coefficient, : Air density, : Wind velocity, : Angular velocity Then the torque becomes: = = 0.88 . Figure 3: NACA 0018 Profile Department of Mechanical Engineering, NNRG. The power of the turbine can be calculated using 32 ISBN: 978-93-5268-241-6
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 According to Battisti, L., Brighenti, A., Benini, E., & : Cross section area of the shaft Castelli, M. R ., the efficiency and controllability are affected by the solidity of the turbine, solidity is = ; =0.025 divided by the swept area of the rotor, it was found = (0.0252)/4=0.0005 2 that at 0.15, as a good compromise between Therefore: controllability and rotor efficiency and it is calculated by using equation (2.5) shown below. A turbine with = =4.86 high solidity allows keeping the optimized turbine rotational velocity relatively low, which minimizes And the rotor vibrations and maximizes the aerodynamic = efficiency. The solidity was chosen to be high, at around 0.15, the solidity then can be calculated using Where: is Weight of the turbine, the equation is Cross section area of the shaft Therefore: = =157 The torsion on the shaft can be calculated using = Where: T: Torque, R: Radius of the shaft, J: Polar moment Where: : The solidity, : Number of blades, of inertia which can be found using equation: : Chord length, : Diameter of the turbine; =( )× 4 rearranging equation (2.5) yields: Therefore: = ( ) ×0.01254= 3.83×10-8 4 = ;= =0.28 The principal stresses then can be calculated using WIND PRESSURE AND STATIC LOADING the equation [2.12]: According to Dyrbye, C., & Hansen, S. O wind pressure can be obtained through figure [12]. Using Hence: wind velocity of 5 / , air density of 1.18 / 3, By taking values from the above equations blade surface area of 0.119528145 calculated sing Catia V5, and with the help of special software linked 1 2= 195.43 kPa to the graph, the wind load on a blade is found to be Using Von Mises Stresses theory to calculate the factor 20.375 / 2[13], therefore the wind load is found of safety: using equation (2.6) = × - (2.6) =20.375×0.119528145=2.43 Note that: 1=371.07 ; 2=0 ; 3 Therefore, using equation (2.13): Therefore, factor of safety can be calculated using equation (2.14): = Graph 2: Wind loads at different speeds Where: =yield strength=1090 a, SHAFT SIZING : Factor of safety The shaft is subjected to two forces and a torque, the Therefore, torque resulting from the rotation of the blades due to Factor of safety=2.14. wind orthogonal to the shaft; the torque is previously calculated in previous section and was found to be MATERIAL SELECTION equal to 0.88 . , the wind load calculated in previous section which is equal to 2.43 , and the Depending on the atmospheric conditions, loads, turbine weight which is obtained through Catia V5, wear & tear a turbine undergoes, We made was found to be 76.5 . subsequent studies on various materials and decided Therefore, the stresses on the shaft are: to go with E-Glass fibre epoxy resin composite for manufacturing of turbine blades, Because it has more strength , low density , high resistance to wear & tear and low cost comparatively to traditional materials. = Where: P : Wind load on the blade, ISBN: 978-93-5268-241-6 33 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 DYNAMIC SIMULATION The dynamic simulation was obtained via ANSYS 16.0 using modal analysis as shown in table 3.1. The frequency number and the rotational speeds corresponding to the modes are mentioned in the table 3.1. Table 3.1: Dynamic simulation frequency modes Figure 4: Final assembly of helical turbine Mode Frequency Rad/sec modeled in Catia 1 10.023 62.97 2 10.101 63.46 SYSTEM TESTING AND ANALYSIS 3 18.806 118.16 4 34.114 214.34 MESH INFORMATION 5 34.538 216.90 6 41.633 261.45 7 44.044 276.60 8 44.37 278.64 9 47.754 300.00 10 83.659 525.40 11 84.423 530.20 12 90.708 570.00 13 90.905 570.88 14 100.02 628.12 A. STATIC SIMULATION: Using ANSYS, we able to predict the static and dynamic behaviour of the turbine by applying flow simulation the static was predicted by applying distributed force on the blades and the shaft as shown in figures 5.a and 5.b. below: Figure 5. a: . Static simulation 1 (Von-Mises stress) Figure 6: Behavior(s) corresponding to various & 5.b: Static simulation 2 (Von-Mises Strain) frequency modes 34 As shown in figures 5.a. and 5.b. the turbine is subjected to Von-Mises stresses at the blades which ISBN: 978-93-5268-241-6 are estimated to reach about 5.97 MPa and the factor of safety is at least to be equal to 4. Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in M24ecthha&ni2c5althEnJugliyn,ee2r0in2g0 determine blade shape especially in areas around the hub which require increased thickness. REFERENCES [1] History of wind turbines. (November 21, Renewable Energy World, 2014).From:www.renewableenergyworld.com/ugc/art icles/2014/11/history-of-wind-turbines [2] AWEA (2013). Wind 101: the basics of wind energy. [3] Price, Trevor J (3 May 2005). \"James Blyth - Britain's First Modern Wind Power Engineer\". Wind Engineering. 29 (3): 191 200. Graph 3: Frequency (x-axis) response for modes (y- [4] Alajmi, Jelowi, Alsayed & Tareq (2014) Design axis) of Airfoils for Wind Turbine Rotors. American As shown in Graph.3, the turbine can sustain a critical speed of 79.34 80 Km/h at a frequency of University, Sharqa, UAE 10.01 Hz. [5] Casini, M., (2016). Small vertical axis wind 3. RESULTS turbines for energy efficiency of buildings. JOCE After completing theoretical calculations and computerised analysis using various tools. We have Vol. 14/254 drawn the following results 1. The designed turbine can generate a power of Optimization of a Vertical Axis Wind Turbine Using 28.4W at a minimum speed of 18Km/hr and FEA, Multibody Dynamics and Wind Tunnel Testing. maximum power of 891W at 58Km/hr of speed Athens Journal of Technology and Engineering X Y 1 2. Under Static load (i.e., Von-misses stress) analysis [7] Weigel, R., Spichtinger, P., Mahnke, C., it was found that the designed turbine can with stand Klingebiel, M., Afchine, A., Petzold, A., ... & a maximum load of 5.9MPa 3. The designed turbine with the constraints taken can Szakáll, M. (2016). Thermodynamic correction of sustain a critical speed of 79.9 80Km/hr at 10.00Hz particle concentrations measured by underwing under 1000N of load. probes on fast-flying aircraft. Atmospheric Measurement Techniques, 9(10), 5135. [2] 4. CONCLUSION 35 Through numerous testing and careful analysis of the Department of Mechanical Engineering, NNRG. vertical wind turbine, we managed to draw up various conclusions on their effectiveness and general importance in the development of clean energy within India. Through careful testing, we compared the different aspects of the vertical turbine with the horizontal, and drew up the following conclusions. A comprehensive look at blade design has shown that an efficient blade shape is defined by aerodynamic calculations based on chosen parameters and the performance of the selected aero foils. Aesthetics plays only a minor role. The optimum efficient shape is complex consisting of aero foils sections of increasing width, thickness and twist angle towards the hub. This general shape is constrained by physical laws and is unlikely to change. However, aero foil lift and drag performance will determine exact angles of twist and chord lengths for optimum aerodynamic performance. A basic load analysis reveals that the blade can be modelled as a simple beam with a built in support at the hub end. A uniformly distributed load can be used to represent aerodynamic lift during operation. The increasing bending moment towards the support indicate that structural requirements will also ISBN: 978-93-5268-241-6
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Experimental Investigation and Analysis of Process Parameters in EDM Drilling with Nickel Alloy G KIRAN KUMAR J. NIKHILESH P B V N SAIKRISHNA Assistant Professor, Student, Student, Department of Mechanical Department of Mechanical Department of Mechanical Engineering, Engineering Engineering Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. B RICKY PUSHPAK P KURUMURTHY SAKI SAIKRISHNA Student, Student, Student, Department of Mechanical Department of Mechanical Department of Mechanical Engineering Engineering Engineering Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Abstract In the field of Production Technologies, generators at short intervals) between a tool called the surface finishing of the product is the most electrode and the work piece in the presence of a importance part there are different types of surface dielectric fluid. This fluid makes it possible to flush finishing methods convectional and unconventional eroded particles (mainly in the form of hollow spheres) machining process. With the increasing demands of from the gap and it is really important to maintain this high surface finish and machining of complex shape flushing continuously. The first EDM application was geometries, conventional machining process are now carried out by Mr. and Mrs. Lazarenko in the Technical being replaced by non-traditional machining Institute of Moscow during the Second World War. The processes. first of the two important improvements, also carried Electrical discharge machining (EDM) is one of the out by these Soviet scientists, which make it feasible to elevate this electrical technique to the category of nontraditional machining processes based on thermo- manufacturing process was the RC relaxation circuit, which provided the first consistent dependable control electric energy between the work piece and an of pulse times. The second innovation consisted of adding a simple servo control circuit in order to find electrode. In this process the material removal is and hold a given gap automatically occurred electro thermally by a series of successive 2. LITERATURE REVIEW T. Muthuramalingam, B. Mohan.[1] discrete discharge between electrode and work piece. discussed about having an overview of the EDM This project presents a clear investigation and analysis process, modeling of process parameters, and influence of process parameters such as input carried out for Nickel alloy material worked on Die electrical variables, pulse shape, and discharge energy on performance measures such as material removal sink EDM in Powder mixed EDM, EDM in water and rate, surface roughness and electrode wear rate. From the review results, it has been observed that the Micro EDM. The input parameters consider are efficacy of the machining process can be improved by electrical process parameters, and only less attention current, Pulse on time and Pulse off time whereas has been given for enhancing such parameters. Rajesh Choudhary, Parlad Kumar and Jagdeep Singh output parameters related to material removal rate [2] performed the experiments by using copper silicon carbide (CuSiCp) composite tool electrode on an 1. INTRODUCTION EDM with selected input parameters on AISID3 die Electrical discharge machining is a metal- removal process in which work piece material is removed by electrical erosion. The metal is eroded (removed) in exact amounts under controlled conditions. Electrical discharge machining is a non- traditional manufacturing process based on removing material from a part by means of a series of recurring electrical discharges (created by electric pulse ISBN: 978-93-5268-241-6 36 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Steel workpiece. Micro structure analysis reveals the resistance in relatively large sections with case hardness presence of micro-holes and cavities on machined up to RC64 when carburized, hardened and tempered surface. Depth of re-solidified layer increases with 3.3 DESIGN OF EXPERIMENT: increase of gap current. Total of five process parameters with four levels are Singh Jaspreet, Singh Mukhtar, Singh Harpreet [3] chosen as the control factors such that the levels are investigated comparison of machining characteristics sufficiently far apart so that they cover wide range. The process parameter and their ranges are finalized using of D3 Steel, EN8 Steel and EN31 Steel materials, literature, books and machine op before and after deep cryogenic treatment using taguchi L18 array in EDM. Results of study suggested five control factors selected are cutting condition (A), voltage (B), Current (C) Pulse on time (D).pulse off that best improvement in tool wear and surface time, nickel alloy work pieces are used in roughn ess was reported by D3 Steel followed by EN8 experimentation. The drilling is performed individually. and then by EN 31. Table No. 1: Experimental Design B. Venkatesh, Naveen, Maurya, Shanthi Priya.D [4] discussed the effect of increase in pulsed current on Exp No. Voltage current MRR, TWR, SR in alloy steels viz., EN31, EN8, 1 20 10 HCHCr. The electrode materials viz. copper, brass, 2 20 20 chromium copper. Results of study suggested that SR 3 20 30 4 20 40 increases with increases in pulse current. Chromium Copper electrode has been preferred for highest MRR, Dimensional accuracy and surface finish. 3. EXPERIMENTATION 5 40 10 The aim of the project is to find out the set of optimum 6 40 20 7 40 30 robust design methodology. The work material 8 40 40 selected is n i c k e l a l l o y . The dimensions of the 9 60 10 nickel alloy, selected are of 150mm length 150 mm 10 60 20 breadth 5 mm thickness. The experiments are 11 60 30 conducted using L16 (45) orthogonal array. 12 60 40 This chapter contains the machining aspects and robust 13 80 10 design implementation procedure in drilling of nickel 14 80 20 steel alloy. The work material selected in the present 15 80 30 work is nickel alloy. The drilling operations are carried 16 80 40 out on EDM machine. The machining tests are Accordingly the present study has been done through conducted under the different cutting conditions, the following plan of experiment. speed, feed and depth of cut using L16 (45) orthogonal array. 1. Checking and preparing the EDM machine 3.1 Specifications of EDM Machine: ready for performing the machining operation. The experiments are conducted on EDM Machine 2. A detailed study has been carried out for the selection of the cutting parameters i.e. shown in Figure No.1. Cutting conditions, voltage, current, pulse on time and pulse off time are taken according to the machine standards. Figure No. 1: EDM Machine 3. Selection of appropriate tool depending upon the cutting parameters i.e., speed, feed, depth of cut are changed depending upon the experimental design. 3.2 Work piece Material: 4. Performing operations on specimens and Nickel steel has a carbon content of 0.017% and finding the material removal rate. probably the most usual form of steel, because of the carbon content the material becomes tougher and harder 4. RESULTS AND DISCUSSIONS .generally available in the annealed condition with a Then material removal rate is measured maximum brinell hardness of 270, characterized by high core strength, excellent toughness and fatigue precisely and the results are tabulated in table no 3. For each experiment the corresponding S/N values are also tabulated. Optimization of material removal rate is 37 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 carried out using Taguchi method. Confirmatory test 4.2 Prediction of Process Average for Optimum has also been conducted to validate optimal results. Condition for Cutting Temperature: From table 5, the following calculations are done, for Table No 2: Experimental Data Related To Material all the cases the predicted value is calculated in the same procedure. A4-B2-C2-D1-E4 Removal rate predicted= Y+ (A4-Y) + (B2-Y) + (C2-Y) + (D1-Y) + `Material removal rate (E4-Y) EXP NO. S/N RATIO = A4+B2+C2+D1+E4-4Y MEAN = [(-4.134) + (-5.1962) + (-4.4687) + (-4.918)+(- 2.4267)] [4* (-6.5878)] 1 0.393 -8.112 predicted= 5.2076 2 0.46 -6.74 Therefore, the predicted average for optimum condition 3 0.55 -5.192 of Material removal rate is 5.2076. 4 0.77 -2.270 5 0.79 -2.047 4.3 Performing Verification Test for Cutting Temperature: 6 0.68 -3.349 A confirmation test is performed with the 7 0.43 -7.330 obtained optimum parameters conditions voltage (80), current (20), pulse on time (4) and pulse of time(2) and 8 0.11 -19.172 electrode diameter (1mm). The material removal rate values are taken and the S/N ratio is calculated for thi 9 0.04 -27.958 condition. These values are shown in Table no 6. 10 0.38 -8.404 11 0.7 -3.098 12 0.8 -1.938 13 0.789 -2.058 14 0.768 -2.292 Table No. 5: Comparison of S/N Ratios 15 0.439 -7.150 predicted 5.2076 conformation 8.634 16 0.56 -5.036 Table No 3: Summary of S/N Ratios 4.4 Effect of machining parameter on Material of 4.1 Selection of Optimum Set of Conditions for removal rate: Cutting Temperature: The best condition for material removal rate condition From Figure No 9, it is observed that as MRR increases with increase in servo voltage and then it starts to is level 4 (80 voltage), for current is level 2 (20), for decrease. This is due to increase in servo voltage resulting higher discharge energy per spark because of pulse on time is level 2 (4), for pulse off time is level 1 large ionization of dielectric between working gap. Consequently, the MRR increases. Figure No 10, it is (2). for electrode diameter is level 4(1 mm) Thus, the observed that at low current duration, the MRR is low and nearly constant as low discharge energy is produced optimum conditions chosen were: A4-B2-C2-D1-E4. b/w the working gap due to insufficient heating of work-piece and low pulse duration. Figure No 11, it is observed that the MRR increases when pulse-off time is increased as with long pulse-off time the dielectric fluid produces the cooling effect on wire electrode and work material. From the figure 12, it is observed that as the MRR increases with increase in pulse duration at all value of peak current. The MRR is a function of pulse duration but at low value of peak current Table No 4: Optimum Set Of Control Factors Factors/L Voltage Curre Pulse Pulse Electrode evels nt on on diameter time time Optimum 80 20 4 2 1 value ISBN: 978-93-5268-241-6 38 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Figure No. 9. MRR V/S Voltage 5. CONCLUSION The project gives a study on various machining parameters on EDM. From literature review, It is observed that, there is lot of work done on various work pieces which are difficult to be machined by conventional machining. The electrodes used are copper, aluminium etc. And for optimization purpose. Following results are observed during study, As MRR increases with increase in servo voltage and then it starts to decrease. This is due to increase in servo voltage resulting higher discharge energy per spark because of large ionization of dielectric between working gap. Consequently, the MRR increases. At low current duration, the MRR is low and nearly constant as low discharge energy is produced b/w the working gap due to insufficient heating of work-piece and low pulse duration. Figure No. 10. MRR V/S Current The MRR decreases when pulse-off time is increased as with long pulse-off time the dielectric fluid produces the cooling effect on wire electrode and work material and hence decreases the cutting speed. As the MRR increases with increase in pulse duration at all value of peak current. The MRR is a function of pulse duration but at low value of peak current. As the electrode diameter increases correspondingly the MRR value also increases automatically. Figure No. 11. MRR V/S Pulse on time The S/N ratio of predicted value and verification test values are valid when compared with the optimum values. It is found that S/N ratio value of verification test is within the limits of the predicted value and the objective is full filled the Material removal rate. Figure No. 12.MRR V/s Pulse off time REFERENCES ISBN: 978-93-5268-241-6 [1] T. Muthuramalingam, B. Mohan, A review on influence of .electrical process parameters in EDM process,archives of civil and mechanical engineering 15(2015) 87-94. [2] Rajesh Choudhary, Parlad Kumar and Jagdeep Singh, Analysis of Electro Discharged Machined Surfaces of AISI D3 Steel by Composite Tool Electrode, International Journal of Surface Engineering & Materials Technology, Vol. 2 No. 2 July-December 2012, ISSN: 2249-7250. [3] Singh Jaspreet, Singh Mukhtiar, Singh Harpreet, Analysis of Machining Characteristics of Cryogenically Treated Die Steels Using EDM , 39 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 International Journal of Modern Engineering Technology (IJEAT) ISSN: 2249 8958, Research (IJMER) Vol. 3, Issue. 4, July - Aug. Volume-1, Issue-5, June 2012. 2013 pp-2170-2176. [11] Ajeet Bergaley, Narendra Sharma, Optimization [4] B.Venkatesh, Naveen.P , Maurya.B , Shanthi of Electrical and Non-Electrical Factors in EDM Priya.D, Experimental investigation of EDM for Machining Die Steel Using Copper Electrode using Electrode Materials Copper, Brass and by Adopting Taguchi Technique, International Chromium Copper for alloy steels, International Journal of Innovative Technology and Exploring Journal of Advance Engineering and Research Engineering (IJITEE) ISSN: 2278-3075, Development vol 2,Issue 4, -2015 Volume-3, Issue-3, August 2013. [5] Vikas, Shashikant, A.K.Roy and Kaushik [12] P. Balasubramanian, T. Senthilvelan, Kumar, Effect and Optimization of Machine Optimization of Machining Parameters in EDM Process Parameters on MRR for EN19 & EN41 process using Cast and Sintered Copper materials using Taguchi, 2nd International Electrodes, 3rd International Conference on Conference on Innovations in Automation and Materials Processing and Characterisation Mechatronics Engineering, ICIAME 2014. (ICMPC 2014). [6] Sunil. B. Mishra , Prof. J. K. Sawale , Process [13] G. Bharath Reddy, V.S.P. Vamsi, parameter optimisation in EDM for AISI D3 ParametricAnalysis on Powder mixed Electric steel by grey relational analysis method, discharge machining of various Steels using International journal of innovations in Taguchi method, International Journal of engineering and technology [IJIERT] ISSN: Advance Research In Science And Engineering 2394-3696 VOLUME 2, ISSUE 5, MAY-2015. IJARSE, Vol. No.4, Special Issue (02), February 2015. [7] International Journal of Engineering and Science [14] K.D.Chattopadhyay, S.Verma, P.S.Satsangi ISSN: 2278-4721, Vol. 1, Issue 9 (November ,P.C.Sharma , Development of empirical model 2012), PP 19-22. for different process parameters during rotary electrical discharge machining of copper steel [8] Harpreet Singh, Amandeep Singh, Effect of (EN-8) system, journal of materials processing Pulse On/Pulse Off Time On Machining Of AISI technology 2 0 9 ( 2 0 0 9 ) 1454 1465. D3 Die Steel Using Copper And Brass Electrode [15] V. Muthukuma, N. Rajesh, R. Venkatasamy, A. In EDM , Anand Prakash Dwivedi, IAENG, Sureshbabu, N.Senthilkumar, Mathematical Sounak Kumar Choudhury ,comparative Modeling for Radial Overcut on Electrical assessment of MRR,TWR and surface integrity Discharge Machining of Incoloy 800 by in rotary and stationary tool EDM for machining Response Surface Methodology, 3rd AISID3 tool steel, Proceedings of the World International Conference on Materials Congress on Engineering 2015 Vol II WCE Processing and Characterisation (ICMPC 2015, July 1 - 3, 2015, London, U.K. 2014),V. Muthukumar et al. / Procedia Materials Science 6 ( 2014 ) 1674 1682. [9] Harpreet Singh, Amandeep Singh, Wear Behavior of AISI D3 Die Steel Using Cryogenic [16] Kumar Sandeep, Current Research Trends in Treated Copper and Brass Electrode in Electric Electrical Discharge Machining: A Review, Discharge Machining, International Journal of Research Journal of Engineering Sciences Vol. Modern Engineering Research (IJMER) Vol.2, 2(2), 56-60, February (2013), ISSN 2278 9472. Issue.6, Nov-Dec. 2012 pp-4462-4464. [17] Jeevamalar , S Ramabalan, die sinking edm [10] Pravin R. Kubade, V. S. Jadhav, An process parameters, Int. J. Mech. Eng. & Rob. Experimental Investigation of Electrode Wear Res. 2015, ISSN 2278 0149. Rate (EWR), Material Removal Rate (MRR) and Radial Overcut (ROC) in EDM of High Carbon- High Chromium Steel (AISI D3) , International Journal of Engineering and Advanced ISBN: 978-93-5268-241-6 40 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 A Paper on: Enhancement of Solar Energy in India SUMIT JOSHI Assistant Professor EE, VIET, Jodhpur Abstract - India is highly dependent on the mineral it during energy transport. Although with this, the receives from the womb of the earth for energy consumption of coal can be easily controlled. production. Which mainly consist of coal, oil & natural gas. All of these have high amount of carbon Present Scenario & hydrogen, which produce energy on burning them. At present, most of the energy produce in India is All these minerals are available in a limited amount in through coal which is 63.40% of the total energy the womb of the earth. When coal & oil are burn, produce. Efforts to reduce it are going on a war footing. Sulfur dioxide gas is produce which cause difficulty in Nuclear energy production so far is only 1.93%, which breathing and acidic rain also contributes. For these is very low through it has strong opportunities to reason, we are moving towards the production of increase energy generation capacity in future. carbon free energy, in which solar energy is playing a The production of energy from renewable energy is major role. The production of solar energy is increase being 21.95% of the total production which has grow rapidly in India, one of the reasons is that while very fast in a few years and given this speed, soon we installing solar energy plant then capital cost per can be maximally depend on solar energy. Mega Watt reduced. As of the 31st October 2019, a Table-1:- India- source wise installed power total of 31.696 GW energy plant have been installed in generation capacity as on 31.03.2019 India. Types of Generated Generated Working under govt. of India Energy Power Power S.No. (MW) (%) On 11 January 2010, the meeting of the National Action Thermal Energy Plan on Climate Change (NAPCC) concluded in view 1. 226279 63.40% of climate change. Under which a plan called National Solar Mission (NSM) was formulated to curb carbon 2. Nuclear 6780 1.93% emission and vice-versa to promote solar energy. This Energy scheme was the first plan to produce solar energy based plant in India. The main objective of preparing this plan 3. Hydro 45399 12.72% in this meeting was to make India a global guru in the Energy field of solar energy in future. Under this scheme, the govt. of India load initially set a 4. Renewable 78316 21.95% target of producing 20 GW of solar power by 2022. But Energy the speed of goal is achieving rapidly increased so the govt. of India held a cabinet meeting on 17th June 2015 Total 3,56,774 100% for increasing the target to 100 GW. All thought the pre Energy determined target was completed only in 2018, 4 years ago. According to annual report of the department of New & To produce the solar energy, the govt. of India has set a Renewable Energy, between 1st January 2018 and 31st target of setting up 50 solar parks at various locations in march 2019, 15445.31 MW capacity of renewable India by 2022, with a target of producing 40,000 MW of solar energy. Out of this, 42 solar parks built in 17 energy has been built, which is 19.73% of the total states so far. In these solar parks, the govt. is providing renewable energy so far. Out of this, 11,128.29 MW of the necessary land and other material to private energy is generated by solar energy which is 72.05% of companies for easy installation of solar plant. The govt. also brings some new scheme for rooftop the total renewable energy. Therefore, It prove that the solar power every day. So that energy can be produce production of solar energy in renewable energy is on a small scale without any transmission loses. increasing rapidly. Producing energy at such a small levels eliminates the cost of transportation and maintenance of energy Wind energy has been th most producing energy so far system, there will not be any kind of loss that occurs in the given data in table-2, but by looking at this list, it can be estimated that in the next annual report, the total generation of solar energy will be the highest ever. 41 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 Table-2:- Achievement in Grid Connected 2. 2015- 112953 27069 16 1001022 Renewable Power (in MW) 1087212 3. 2016- 189424 2749798 Achivment Cumulative 17 S.No. Sector 1/1/18- achievement 4. 2017- 330570 18 31/3/19 on 31/3/19 5. 2018- 384539 (MW) (MW) 19 1. Wind Power 2777.51 35625.97 Solar 2. Power(Ground 10314.23 26384.30 Mounted) Solar Hybrid Power System In this system, at least one other power generation 3. Solar Power 814.06 1796.36 energy source is connected together with the solar (Rooftop) power generation. Generally we divide this type of production into two parts. When the energy produce is 4. Small Hydro 175.00 4593.15 sent directly forward without accumulating, such plants Power are called hybrid plant without storage. When the energy produce is easily collected by the battery so that 5. Bio Power 1364.51 9778.31 we can use it later, this type is called hybrid power plant with storage. 6. Waste to 00.00 138.30 Power Total 15445.31 78316.39 According to the annual report of the department of Hybrid power plant without storage In this system, energy needs are met by giving priority New & Renewable Energy, the state of Karnataka is to solar energy and the gap between production and load requirement is bridged by other system used producing the largest amount of solar energy as of together. The investment cost of this system is very low. Solar energy is a volatile energy source with diesel march 2019. gensets generally installed as a stable power source. But a diesel gensets requires a certain time to start, the Table-3:- top 5 state in Solar Capacity (in MW, till only solution is to keep the diesel gensets continuous running at a normal load. March 19) Hybrid power plant with storage S.No. Name of the Solar This plant has few components more than without storage plant. In this, the plant is connected to the State energy battery for energy storage. Hence its main advantage is that the need of continuously run the diesel gensets at generate normal load is eliminated. At this time we can easily store energy. Due to the extra charge of the battery, its ( MW) investment cost is high. In this way, we can easily increasing the production of renewable energy. 1. Karnataka 6095.55 In this system we can make the hybrid power plant of solar photovoltaic cell and diesel generator to generate 2. Telangana 3592.09 energy. In this system photovoltaic cell are prioritized connected to grid and whereas the shortfall between the 3. Rajasthan 3226.79 production of energy and the energy requirement is completed by the use of diesel gensets. 4. Andhra Pradesh 3085.68 Solar-Wind system is also example of a solar Hybrid power plant. Peak operating time of Solar & wind 5. Tamilnadu 2575.22 energy is different so its benefit from the plant and we can easily generate maximum energy. As compare to Other than these state Gujarat, Madhya Pradesh, other type of solar hybrid system this hybrid modal is more beneficial because the minimum variation in load Maharashtra, Uttar Pradesh & Punjab are also introduce requirement. We can also make a hybrid modal of Solar-Wind-Diesel to make a healthy system. to producing maximum solar energy. Solar thermal plant is also example of hybrid power plant. Solar Thermal hybrid power plant working is The many people use the scheme solar rooftop energy based on Rankine Cycle Process. At On-Peak Period we can save the production money and obtain resources of energy on a small scale by using the some kind of scheme solar street light and obtain scheme solar lamp/lanterns. We can promote the production of energy on a small scale use of these devices has increased rapidly in the last five years. The number of solar streets light installed in the year 2104-15 was around 62,968 and this number reached 384,539 in the year 2018-19. Similarly, in the year 2014-15, about 10,000 numbers of solar lamp/lanterns were installed. By the year 2018-19, this number reached 2,749,798 rapidly. Table-4:- installed street light & solar lamp/lanterns S.No. Years Street Light Solar Installed(Nos.) lamp/lanterns installed (Nos.) 1. 2014- 62968 10000 15 ISBN: 978-93-5268-241-6 42 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 store the Solar Energy & at Off-Peak Period we can of land is so high in India we need a huge amount of store the Thermal Energy. In this system we use a parabolic reflector boiler in which water is flow through land to planted a solar plant. The total of land required water tube and heat is collect at the boiler which is for utilities scale power is about 1 (250 acres) for convert the water into steam via heating process. So this reflector converts the hot water into steam energy. This every 40-60 MW Generated. So one alternative is also steam energy is converted into kinetic energy by the use found in which we can use water surface area on canals, of turbine. Turbine is coupled with the alternator so that kinetic energy is converted into potential energy. This lakes, reservoir, farm ponds and the sea for large solar potential energy is used by transformer to bus bar and power plant. In January, 2019 for the development of so on. In this system a magnifier glass is fixed into a parabolic rectifier which converts sun energy into heat solar energy Indian railway announced the plan to and make steam from hot water. installed 4 GW capacity along its track. In one NISE In September 2013, govt. of India converted a 25 year development India possibly will make renewable old solar energy Centre (SEC) into an autonomous institute that is National Institute of Solar Energy resources the strength of its country by 2030. (NISE) under Ministry of New & Renewable Energy in REFERENCE implementing the National Solar Mission and to co- [1] National geographic encyclopedia on fossil fuel ordinate research, technology & other related works. [2] Fossil fuel and nuclear power on bitesize guides This institute is situated at Gurugram-Faridabad Road [3] Physical Program (achievement), ministry of new & and the main working of this institute is maintaining renewable energy. solar photovoltaic module testing in, lightning test, [4] Annual report 2018-19, ministry of new & battery test and etc. facilities available in various renewable energy, chapter -1 laboratories. This institute provides a short technical [5] Annual report 2018-19, ministry of new & training programmed to student for solar energy system after training students are placed at solar power plant renewable energy, chapter -3 easily. [6] Annual report 2018-19, ministry of new & renewable energy, chapter -11 Challenges & Opportunities If we want to planted a solar plant then first problem is - develop against us is land acquisition because the cost gov.DOE.2 July 2012. nt (wind-or- platform for renewable & mining. [10] NISE ISBN: 978-93-5268-241-6 43 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 DESIGN AND ANALYSIS OF EXPANDABLE WHEEL P.SRINIVAS M. POOJITHA MOHAMMED MINHAJ SHAIK ZAFFAR Associate Professor, Assistant Professor, UDDI IBRANI Student, Student, Department of Department of Mechanical Engineering, Mechanical Engineering, Department of Mechanical Department of Mechanical Nalla Narasimha Reddy Nalla Narasimha Reddy Engineering Engineering Group of Instititions, Group of Instititions, Nalla Narasimha Reddy Nalla Narasimha Reddy Hyderabad, Telangana Hyderabad, Telangana of Instititions, Hyderabad, of Instititions, Hyderabad, State, India. State, India. Telangana State, India. Telangana State, India. Abstract Vehicles such as guided vehicles can have While the Umbrella Wheel concept was introduced with a large variety of mechanisms to provide movement, stair-climbing in mind, it can also handle other kinds of such as wheels or caterpillar tracks. The efficiency of obstacle such as open gaps, and even ladders. In the travel, the smoothness of locomotion and the ability to case of open gaps, the gap distance the wheel can cover handle obstacles are among the criteria that can depends on the possible extension of the wheel determine which solution fit best for a specific segments. For the largest reach, two opposite wheel situation. For some applications, production segments will be in contact with the ground (on either considerations can put constraint on the complexity side of the gap). For climbing ladders, the process is level, as a low number of degrees of freedom generally slightly more involved as it requires changing the makes control easier. For vehicles that should operate extension during the climb. To climb a ladder, when in locations designed for people, stair-climbing can be already positioned on a rung, the next wheel segment is a challenge for vehicles, since stairs are designed for positioned above the rung of the ladder and then the the bipedal movement of a human and not for the extension of the segments is lowered, thereby placing mechanically simpler motion of wheels. the piece on the rung and raising the previous segment Keywords- vehicles, stair-climbing, bipedal movement. into the air. 1. INTRODUCTION 2. LITERATURE REVIEW The stair-climbing problem has been under Hybrid systems, where there is a mix of consideration for many years. For hand trucks, earlier designs can, at least, be traced back to as far as 1882, continuous and discontinuous behaviour, are found in where a set of wheels placed around a rotating frame control engineering, economics allows the vehicle to ascender descend a stair-case. in stair-climbing due to the Variations on this design are still among the most popular solutions today. An alternative but common unevenness of the terrain, many of the solutions exhibit solution in the field of robotics is to use caterpillar behavior where there is an impact with the stair surface tracks, which has the advantage of good handling on and therefore can show non continuous behavior [3]. Of most types of difficult terrain, though at the cost of low course some types of stair climbing vehicles do have efficiency on even ground when compared to a wheel. continuous behavior, such as tracked robots [4], [5]. Furthermore, this design can also lead to damage of the Especially when mobile robots using legs [6], [7] are stairs on the edge of the step. To prevent damage to the concerned, modeling without using a hybrid system environment, a design for a stair-climbing wheel chair has been developed, with however considerable climbing additional weight. Other solutions obviously leg-based can easily be studied even if impacts occur [8], but designs, and these are known to be able to handle any often the dynamical behavior is harder to determine. terrain where a stable footing can be achieved, mostly Impact modelling of uniform spheres is a simple and these have four or more legs. However, these are well understood process, but impacts on rigid or semi- generally and comparatively quite complicated to rigid structures are much more complex [9]. construct and control. Flying drones have no problem handling stairs, but lack efficiency, are noisy and cannot 3. EXPERIMENTATION handle heavy cargo. A Scott Russell linkage gives a theoretically linear motion by using a linkage form with three portions of the links all equal, and a rolling or sliding connection. It can be used to form a right-angle change of motion, ISBN: 978-93-5268-241-6 44 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 linear-to-linear. The linkage is named for John Scott A 3D model of the Umbrella Wheel design in a half- Russell (1808 1882), although watchmaker William way position is show sideways views of the wheel in Freemantle had already patented it in 1803.A different these 3d models have been kept at the same scale in form of the linkage has been used in a front-wheel- order to give an idea of the magnitude of the expansion drive vehicle with solid rear axle to control lateral of the wheel segments. In order to see more precisely movement, and with a flexing elastomeric connection how the concept works, let us go back to Fig. 1, where instead of the rolling or sliding connection. A Scott connected with two parts (in Russell linkage on the rear axle of a 2002 Nissan Sentra. The linkage does not share the disadvantages of the asymmetric Panhard rod and although more compact than Watt's linkage has all the forces in one link. As one of the possible ways to extend or retract the Figure No.1: Scott Russel Mechanism umbrella, hence the name of the proposed concept. Note that by having the short arms be half the length of the long arms, there is no movement of the wheel segments in the direction of the axle when the arms extend. Hence the wheel segment rims move only radially away from or closer to the axle. The orange parts (labeled ed by creating a parallelogram. Thus, the strength of the proposed design lies in its relative simplicity. Indeeed the location of the driving force, ie the axle, is essentially the same, no matter what the current geometry of the wheel is. The additional variable is simply the geometry of the wheel. Additionally, the rim of each wheel segment is quite generic and many different types of materials and ensure proper traction. Figure No.2: Kinematic pair in our Design Figure No.3: Isometric view of the Umbrella Wheel in CREO 3.1 Procedure Figure No.4: Isometric view of the Umbrella Wheel The simple idea behind the Umbrella Wheel concept which we designed consists in keeping a perfectly round wheel for travel on smooth ground and then transform the wheel in order to give it the capability of overcoming obstacles such as stairs when necessary. Our design works by having the outer part of the wheel being able to separate into several pieces, referred in the following as wheel segment, each of which extending outwards from the axle to form spokes. ISBN: 978-93-5268-241-6 45 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 3.2Number of wheel segments Figure No.7: Umbrella Wheel with leg segments in our design The Umbrella Wheel concept works with as few as two wheel segments and up to as many wheel 3.4 Different obstacles segments as the designer would like. There are While the Umbrella Wheel concept was introduced with obviously both advantages and disadvantages to stair-climbing in mind, it can also handle other kinds of having more or fewer segments, making the ideal obstacle such as open gaps, and even ladders. In the number different for each situation. A higher number case of open gaps, the gap distance the wheel can cover of segments gives generally smoother stair travel, depends on the possible extension of the wheel while a lower number of segments needs fewer parts segments. For the largest reach, two opposite wheel and requires less arm extension to climb the same segments will be in contact with the ground (on either stair. Conversely, a larger number of segments allows side of the gap) as seen in . For climbing ladders the for a larger wheel in the closed position while fewer process is slightly more involved as it requires changing segments can require a smaller closed-wheel size. the extension during the climb. To climb a ladder, when Implications of the design choices are investigated already positioned on a rung, the next wheel segment is further in Section IV and Section V. Pictures of the positioned above the rung of the ladder and then the 3D model for a three-segment Umbrella Wheel can be extension of the segments is lowered, thereby placing seen in Fig. the piece on the rung and raising the previous segment into the air. The wheel is rotated and once the previous Figure No.5: Umbrella Wheel in the closed position piece is clear of the previous rung, the extension is raised again to allow the next segment to get into 3.3 Overlapping of wheel segment position above the next rung of the ladder. This process Rims Having the wheel segment rims divided into is repeated for each rung of the ladder. Additionally, it strict partitions result in the rims ending in sharp is important for ladder-climbing that the body of the corners, which will serve as the point of contact on the vehicle is capable of ensuring the orientation of the stairs. A sharp corner can result in high contact pressure wheel with respect to the ladder; which is ensured if the that will potentially damage the steps of the stairs, while body extends at least as far back as two rungs of the the corner itself could wear over time. In turn, this wear ladder plus the required extension of the arm when could also lead to an altered and imperfect circle when climbing the ladder. o improve upon this, an overlapping geometry was introduced at the corners of the wheel segment rimes. The overlap continues the outer curve tangentially to the curve of each rim . For comparison, the two kinds of corners (rims sharp corners and corners with overlap) are represented in Figure No.6: Close-up of rim corner overlap CREO 46 Figure No.8: Umbrella wheel in open position Department of Mechanical Engineering, NNRG. ISBN: 978-93-5268-241-6
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 3.5 Design & Calculation Choose a scale 1mm = 0.002 m/ Draw the radial component for a length of 50mm Tangential component Acceleration of tangential component BC = = ×BC =0.2×0.1=0.02m/ Hence draw a perpendicular to the radial component of acceleration for a length of 10mm Acceleration of connecting rod Figure No.9: Free body diagram of links in Wheel = /AB = /0.1= 0.06m/ Here we have 3 links AB,AC,CA&BD. At A point we slider, at C we have hinge joint where the angular Liner acceleration of a point AB Measure the length of acceleration of link BC =0.2 rad/sec^2& angular tangential component of A with respect B velocity =1 rad/sec . Where the length of the link 14mm Liner acceleration of AB= 0.028m/ . of lift we will calculate & draw acceleration and velocity diagram and we find the force and then reduce. From the angular velocity we need to find liner velocity of the crank CB, for a velocity diagram Liner velocity of CB = = 0.1 m/sec Following scale 1mm=0.002 m/sec There for in this case 0.1 m/sec is represented with a 50mm line. Figure No.10: Acceleration diagram The liner velocity of = 50 mm= 0.1 m/sec The liner velocity of = 64 mm= 0.128 m/sec Radial component of crank From velocity diagram Liner acceleration of radial component = /CB The liner velocity of = 39 mm= 0.078 m/sec = /0.1 The liner velocity of = 48 mm= 0.096 m/sec = 0.1 m/ Radial component of crank Choose a scale 1mm = 0.002 m/ Liner acceleration of radial component = /CB Draw the radial component for a length of 50mm = /0.1 = 0.1 m/ Tangential component Acceleration of tangential component BC = = ×BC ISBN: 978-93-5268-241-6 47 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 =0.2×0.1=0.02m/ 4. CONCLUSION Hence draw a perpendicular to the radial component of A new design for a stair-climbing wheel, referred to acceleration for a length of 10mm as Umbrella Wheel, has been proposed and Acceleration of connecting rod discussed. The advantage of the concept lies in its = /AB ability to climb up or descend stairs, as well as go = /0.1= 0.1m/ through rough terrain while being capable of length of 50mm regaining smooth displacement conditions on more Liner acceleration of a point AB level terrain. Simple considerations on geometry lead to modeling of the path followed by a single of A with respect B 6mm Liner acceleration of AB= 0.012m/ wheel. Different parameters of the wheel have been FORCE CALCULATION explored with regards to smoothness and versatility. F=M×a Current research includes the construction of an a=acceleration actuating mechanism in order to move the part volume (v)=l×b×h responsible for the extension of each leg segment , as well as the design and development of a suitable =0.1x0.01x0.01 vehicle to test the performance of the design with respect to stair-climbing as well as handling other obstacles and driving on smooth terrain.A hybrid model of the behavioral dynamics of the stairclimbing wheel design called umbrella wheel has been presented and implemented. Both the continuous-time dynamics and the discrete-time dynamics have been explored. A discrete model of the continuous behavior has been developed that allows the use of predictions to detect stair-contact using only measurements of wheel rotation. The results from the detection algorithm give good accuracy and robustness even taking into account real-life measurement limitations. Further research Mass of the crank BC =0.00001x7800 measurement to achieve better results for stair =0.078kg detection as well as construction of a prototype and real-life implementation and testing of the stair Where as acceleration of the crank BC = a=0.1m/ detection method Force f =0.078x0.1=0.0078 N The permissible stress = 70ga pcl REFERENCES Compressive stress = load/area -a Where area Load = 0.078 N stair-climbing and obstacle-handling wheel design 70 = Advanced Mechatronic Systems. [2] J.- International Journal of Robust and Nonlinear Control, vol 11, issue 5, april 2001. [3] C.-T. Chen, H.-V. Pham, C.-J. Lin, C.-H. Cheng, C.H. Wu and Y.C. Ch Analysis of a Robotic Wheelchair on Climbing International Conference on Industrial Informatics Terrain Negotiable Mobile Platform with Passively Adaptive Double-Tracks and Its Application to International Conference on Robotics and Automation. [5] P. Ben-Tzvi, S. Ito and A.A. Goldenberg, ISBN: 978-93-5268-241-6 48 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 ROSE 2007 - IEEE International Workshop on Robotic and Sensors Environments. [6] C. Theeravithayangkura, T. Takubo, Y. Mae Scanning by Limb Mechanism Robot International Conference on Robotics and Biomimetics. [7] W. Zhanhao, H. Dan, L. Ning and L. Shaoyan, Chinese Control Conference. [8] A. Imadu, R. Tanaka, T. Kawai and M. Shibata, -Assisted Luggage Cart with Rotational Arms for Stair [10] R. Goebel, R.G. Sanfelice and A.R. Teel, Control for Systems That Combine Continuous- Time and Discrete- IEEE Control Systems Magazine. [11] P. Tantichattanont, S. Songschon and S. tatic Analysis of a Leg- Wheel Hybrid Vehicle for Enhancing Stair International Conference on Robotics and Biomimetics Versatile Stair-Climbing Robot for Search and IEEE International Workshop on Safety, Security and Rescue Robotics [13] M. Eich, F. Grimminger and F. Kirchner, - International Conference on Robotics and Biomimetics. [14] EBR7912EBI-CA-KA Incremental Sensor SENSITEC. ISBN: 978-93-5268-241-6 49 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 DESIGN AND FABRICATION OF MONO BIKE SWETHA PAVAN KALYAN YAKUB SHAREEF Student, Assistant Professor, Student, Department of Mechanical Department of Mechanical Department of Mechanical Engineering, Engineering, Engineering, Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. LAXMAN MUKESH DEEKSHITH SAI Student, Student, Student, Department of Mechanical Department of Mechanical Department of Mechanical Engineering, Engineering, Engineering, Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Abstract When it comes to self-balancing personal Index Terms - Construction of Monowheel, transportation devices, it looks like the Solo wheel, Specification, Luggage Carrying Capacity Honda U3X, Uno, and Segway could all be in for a I. INTRODUCTION little competition. A monowheel/bike is a one- wheeled single-track vehicle similar to a unicycle. A Mono bike (Monowheel bike) is a single-track vehicle consisting of a single crawler (Wheel). The Instead of sitting above the wheel as in a unicycle, the main aim of Mono bike is that it reduces space occupied rider sits either within the wheel or next to it. Usually when a single occupied vehicle is necessary and for driven by smaller wheels pressing against its inner transportation of short distances. This may sound fictional but as going through history, rim. Most are single-passenger vehicles, though multi- the first mono bike designs appeared as early as the passenger models have been built. The goal of this 1860s. In 1869 the Craftsman Rousseau of Marseilles project is to design, analyze, and build a self- built the first monocycle. Several of these featured a seat for a rider with pedals connected to the outside balancing single wheel bike for use as a transportation wheel. The rider pedals the small wheel, creating tool for someone traveling short distances. The project motion even at that time, the monowheel was consists of a research phase in which similar systems recognized as a difficult means of transportation. The project proposes a monowheel bike, which was the have been investigated to help determine a sensible serious mode of transportation back in the 1800s to design approach and to establish appropriate design 1900s. So we have chosen this idea of a vehicle because of a specifications; a design phase in which a model was very simple thought of that, - designed with certain assumptions to meet the aforementioned specifications and a construction - for example, Back in the days when the mobile phones where invented, the size of the phones phase, in which the vehicle was built and tested. where same as the size which we are using today and Monowheel looks like something out of a science who would have thought that hoverboards will be the fiction movie, but monowheel is, in fact, real, today, future replacing the roller skates. The very common thing we can notice in these inventions is, the design mono wheels are generally built but from the 1860s stayed at the origin but the performance and the high- through to the 1930s, they were proposed for use as serious transportation. The idea may sound extreme, but the science behind monowheels is solid, at present, because of the surging consciousness of pollution and energy shortage crises, automobiles and motorcycles are no longer the best for transportation. As the price of petroleum products growing nowadays, there is a need for a cheaper and more efficient form of transport. ISBN: 978-93-5268-241-6 50 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 power output increased in terms of 100 times better. Hemming's Unicycle, or \"Flying Yankee Velocipede\", This makes us believe in what are we doing now. was a hand-powered monowheel patented in 1869 by Richard C. Hemming. So, with the adaptive idea of design, we have built a B. Steering compact, efficient, powerful and cheaper version, with In a two-wheel mode of transportation, two systems our design and fabrication The Indian version of the (wheels) affect motion. Typically one wheel provides mono bike. We have made this mono bike in an the force to control speed, while the other handles extremely affordable budget where every Indian can get changes in direction: steering. For a monowheel, both hands-on it. direction and speed are controlled through the same physical apparatus; this generally makes steering more It is cheap, efficient and can be built within a short difficult. In a majority of systems, change in direction is time, making its production rate also can be higher, than effected by the rider shifting their weight, or in the any other corporate company is manageable with. sudden movement creating a shearing force between a handhold and the axis that the driver is settled 1.1 LITERATURE REVIEW on. Better control can usually be achieved at lower A. History speeds. Because of the steering problem, monowheels A monowheel is a one-wheeled single-track vehicle have never caught on as a widely accepted mode of similar to a unicycle. Instead of sitting above the wheel transportation. as in a unicycle, the rider sits either within the wheel or next to it. The wheel is a ring, usually driven by smaller 2 CONSTRUCTION PLANNING PROCESS wheels pressing against its inner rim. Most are single- passenger vehicles, though multi-passenger models Figure No.2: Block Chart of Mono bike have been built. The selection of this concept bike is one of our craziest Hand-cranked and pedal-powered monowheels were ideas. Later on, we developed the design by reverse patented and built in the late 19th century; most built in engineering method ie., the Adaptive engineering the 20th century have been motorized. Some modern method (Adaptive manufacturing systems achieve builders refer to these vehicles as mono vehicles, intelligence and adaptation capabilities through the though that term is also sometimes used to describe close interaction between mechanics, electronics, motorized unicycles. control, and software engineering. The results, achieved Today, monowheels are generally built and used for fun by applying the method in reengineering a module of an and entertainment purposes, though from the 1860s automotive sensor manufacturing line, are finally through to the 1930s, they were proposed for use as presented). Therefore the selection of materials that serious transportation. play a crucial role helps the chassis weight through The world speed record for a motorized monowheel is material characterization. And then setting up a plan 98.464 km/h (61.18 mph). according to the schedule. Mapping for 2 stroke engine and crawler(tire) is in repair condition so we turn into Figure No.1: Hemming's Unicycle working condition state. After this as per planning, we need to manufacture Transmission drum, Rollers, and Fabrication of Chassis and the final step is to assemble all of these components into one. ISBN: 978-93-5268-241-6 51 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 2.1 Diagrammatic Construction And Working ends of the roller. Then we inserted deep groove The side elevation of a self-balancing mono bike cut to ensure that it is locked with an external circlip of Diameter 17mm at the ends to an MS rod following the present invention as shown in Fig. In this of Diameter 17mm and length of 400mm into the roller and threaded from end to the middle for the illustrative embodiment, the self-balancing monobike length of 80mm. includes a handlebar, a Fuel tank, Seating, a Crawler 265*R17, a C-frame, a Transmission drum, a 2 Stroke 2.2.2 C- Fame Engine, a Rollers, shock absorbers, a Chain Sprocket, and Chassis facilitates holding, moving, or loading the monobike. A foot platform disposed on a side of Rollers. Figure No.3: Schemetic View of Mono bike 2.2 COMPONENTS OF MONO BIKE 2.2.1Rollers Fig 4 Roller Fig 5 C- Frame Chassis Dimensions Dimensions 1. C- 1. HOLLOW PIPE LENGTH = 160 mm 2. SQUARE BOX PIPE LENGTH= 250 mm ; 40*40 2. SHAFT ROD = 400 MM ; DIA = Ø 17 THICKNESS = 5 mm 3. RUBBER STEEL BEARING = 6203 3. RECTANGULAR BOX PIPE= 270 mm ; 20*40 : 4. FLANGE THICKNESS = 20 mm THICKNESS= 5 mm 5. FLANGE INSERT DEPTH = 6 mm 4. ENGINE PLATE LENTGH = 270 mm : WIDTH= 60 mm ;THICKNESS= 10 mm In this project we have used IDLER type of rollers, 5. U SHAPED HOLDER= W= 50 mm We made these rollers by taking a hollow 90mm 6. H= 60 mm mild steel round pipe and cutting them into 5 equal 7. HOLE RADIUS = R17 FROM MID AXIS pieces over a length of 160mm and then we have created flanges at both ends and drilled to 18mm The c-frame will be the frontier part of a mono bike and bore to the length of 40mm and press- where the three (3) rollers will be placed making it a Deep groove ball bearings 6203 2 RS crucial part of the chassis The c-frame is usually built 17x40x12mm at both ends of 5 pieces with by a process called bending, on a machine called ROLL BENDING MACHINE, where the curvature radius is about 300mm and the distance between two ends when bent 420mm whose OD is 30mm and ID is 24mm of 2 pieces. They are joined together by the two rectangular section pipes of length 270mm. ISBN: 978-93-5268-241-6 52 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 2.2.3 TRANSMISSION DRUM The engine frame consists of an adjustable system with box pipes of MS in which one end 40*40 mm is joined to c-frame and another end 50*50mm welded to the engine cover. It is a very significant element in the chassis where it holds the total seating arrangement, where the rider weight is directly applied to it. It is also a connection between the c-frame and supports the transmission system, making it a vital element. Fig 7 Transmission Drum Dimensions 1. SQUARE BOX PIPE = 50*50 mm : 40*40 mm Dimensions 2. TOTAL LENGTH OF SQUARE BOX PIPE = 1. ROTATING SHAFT DIA = 20 mm 450 mm 2. TRANSMISSION DRUM = Ø190 : 3. THICKNESS OF PIPE = 5 mm 3. LENGTH = 180 mm 4. PILLOW BLOCK BALL BEARING = 6302 2RS 4. TRANSMISSION DRUM TAPER TURNING 5. LENGTH OF PLATE ON BEARING FIXED = THICKNESS = 8 mm 250 mm 5. TOTAL LENGTH OF TRANSMISSION 6. DISTANCE BETWEEN TWO BEARING FIXED SYSTEM = 330 mm PLATES = 330mm 6. FLANGE HUB DIA= 110 mm 2.2.5 Bottom Frame 7. DRUM PLATE DIA = 170 mm 8. DRUM PLATE THICKNESS = 15 mm Fig 8 Bottom Chassis Frame 9. COUNTER SHUNK HEAD SCREW SIZE = M8 10. HEXAGONAL BOLT = M8 The bottom frame carries two rollers in which it also 11. PILLOW BLOCK BALL BEARING SIZE = 6302 connects the c-frame which is the frontier part of the mono bike. The suspension is connected to it. it RS completes the whole chassis. 12. SQUARE KEY SIZE = 6*6 mm The transmission drum is made up of aluminum by a Dimensions 1. PLATE THICKNESS= 5 mm process called casting. The drum rotates the crawler by 2. PLATE TOTAL LENGTH= 500 mm 3. PLATE START AND END RADIUS = 60 mm the use of surface contact friction. It consists of a metal 4. U SHAPED HOLDER= W= 50 mm 5. H= 60 mm plate inside in it with the diameter of 170 mm and 6. HOLE RADIUS= R17 FROM MID AXIS 2.2.6 Engine Specification thickness of 15mm and a 40mm hole is drilled inside in it for placing a shaft of material EN 31 STEEL ALLOY with a diameter of 20mm and length of 330mm, to its both ends a ball bearing 6203 2 RS is connected which is fixed to the chassis. The metal plate is connected to the aluminum drum from the inside at the center, by using countersink screws M 8 of 5. In between the shaft, a sprocket and chain system are connected to the engine transmission system 2.2.4 Engine Frame Fig 6 Engine Frame Fig 9 2 Stroke Engine ISBN: 978-93-5268-241-6 53 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Engine Type 2 Stroke Single Cylinder 3.3 Bottom Frame Displacement 69.9 cc Fig 12 Bottom Chassis frame Cad design model Max Power 3.5 bhp @ 5000 rpm Max Torque 5 Nm @ 3750 rpm Cooling System Air Cooled Starting Kick Start Only Fuel Supply Carburetor Clutch Centrifugal Wet Type Ignition Flywheel magneto 12V, 50W Transmission Automatic Gear Box Automatic 3.4 Engine Model Bore 46 mm Stroke 42 mm The 2-stroke 69 cc (Cubic centimeter) auto Fig 13 Engine Block Cad design model transmission, which was not in the working condition 3.5 Transmission drum model when purchased and was replaced by the essential parts that made the engine alive by making it again into the Fig 14 Transmission System Cad design model working condition 3.6 Assembly of all models 3. CAD Model Preparation AUTO CAD SOFTWARE is mainly used for detailed engineering of 3D models or 2D drawings of physical components, but it is also used throughout the engineering process from conceptual design and layout of products, through strength and dynamic analysis of assembli components. So after completing the production drawing successfully, now it was the time to make a digital design output through CAD model preparation by AUTOCAD. These are the CAD images of the essential components of our project 3.1 Roller model Fig 10 Roller Cad design model Fig 15 Assembly Cad model 3.2 C frame model Fig 11 C frame Chassis Cad design model 54 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 4 PROBLEM STATEMENT by Antilog 4.1 Rollers calculations From bending moment equation Total tension in slack side where z = ( ) M= bending movement = 4.3 Engine frame calculation 1079 N Bending stress of steel pipe is 240 mpa CB Tension in tire = 71612.7 N The tire tension is acting as a load on a pipe so the A Torque = Tension of tire * ½ of the length of pipe Assuming length is 160 mm and outer dia is 90 mm 196 N RB Torque = 5729.01 NM 175 mm Bending moment M = = = 229.1 Nm Di = (( )- ) 450 mm Di = 88 mm Fig 16 Bending Movement From hoop stress The material used in the engine frame is mild steel T = Torque The yield strength of MS is 248 mpa Assuming the factor of safety is 4 Longitudinal stress of a cylinder The allowable stress a = 65 N/mm2 Assuming the engine frame as a simply =T( ) supported beam From the diagram The Bending Movement So the longitudinal stress and hoop do not exceed the M= 20.94*10 N/mm normal stress. Area of cross-section A = 50-44 = 564 mm Hence design is safe Movement of inertia I = 50-44/12 = 208.49*10 mm 4.2 Calculating tension in tire From bending equation Tire dimension M/I = /y w= 0.245 m = bending stress , y = 1/b = 25 mm, = m*y/I = 20.94*10*25/208.49*10 t = 0.02 m l = 4.87 m = 2.51 N/mm Hence the bending stress is not exceeded then Density of rubber 1140 the allowable stress, so the design is safe Allowable stress in rubber N/ Speed N = 837 rpm Drum dia = 0.19n Velocity v = = = 8.33 m/sec Coefficient of friction = 0.54- = 0.275 the angle of contact between the belt and each pulley Fig 17 Cross-section of frame Maximum tension in tight side of the belt T= Mass of the belt per meter length M= a*l* Centrifugal tension = = 1887.3 N Tension in tight side of belt =T- = We know 2.3 log ( ) = ISBN: 978-93-5268-241-6 55 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 5 IMPLEMENTATION 5.4 Fabrication of C-Frame While performing the project it was divided into stages of the procession. The stages are as follows: 1. Making a blueprint Fig 20 C- Frame Chassis after fabrication -info 2. Crawler [2.2.2] 3. Manufacturing of Transmission components 4. Fabrication of Chassis 5.5 Fabrication of rollers 5. Fabrication of rollers 6. Fabrication of engine frame 7. Fabrication of bottom frame 8. Assembly 5.1 making a blueprint Mentioned in fig [2] 5.2 Crawler Fig 18 Crawler (Tire) Fig 21 Fabricated Roller - info [2.2.1] 5.6 Fabrication of engine frame 265/65R17 these are the tire dimension we purchased in the second-hand spare market 5.3 Manufacturing of Transmission Drum Fig 22 Fabricated Engine Frame-info [2.2.4] 5.7 bottom frame Fig 19 Transmission Drum After Casting And lathe Fig 23 Fabricated Bottom Chassis Frame info operations [2.2.5] The transmission drum is made up of aluminum by a 5.8 Transmission shaft assembly process called casting. The drum rotates the crawler by the use of surface contact friction. It consists of a metal Fig 24 Transmission System info [2.2.3] plate inside in it with the diameter of 170 mm and thickness of 15mm and a 40mm hole is drilled inside in it for placing a shaft of material EN 31 STEEL ALLOY with a diameter of 20mm and length of 330mm, to its both ends a ball bearing 6203 2 RS is connected which is fixed to the chassis. The metal plate is connected to the aluminum drum from the inside at the center, by using countersink screws M 8 of 5. In between the shaft, a sprocket and chain system are connected to the engine transmission system. ISBN: 978-93-5268-241-6 56 Department of Mechanical Engineering, NNRG.
5.9 After Assembling Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 We are very much obliged to our beloved guide Mrs. T. SWETHA, Assistant Professor for providing the opportunity to undertake this project and encouragement in the completion of this project REFERENCE [1] Sreevaram Rufus Nireekshan Kumar, Bangaru International Journal of Computer Technology and Applications, Volume 4, PP. 29-34. [2] A.Geetha, Vishwanath Kannan, Akhil ELK ASIA PACIFIC JOURNAL OF MARKETING AND Fig 25 Assembled Output RETAIL MANAGEMENT ISSN 0976-7193 (Print) APPLICATION ISSN 2349-2317 (Online); DOI: 1) For sport and adventure purposes. 2) In bigger industries and companies. 10.16962/EAPJMRM/ISSN.2349 3) It is used in Portland Police Department onocycle CONCLUSION Conclusion for the futuristic scope Monowheel or of Electrical and Electronics Engineers, 1066-033X/06 Monobike is a personal transporter that can carry a [4] Mukesh Sahu, Naved Shaikh, S person to move from one place to another within large areas like industries, space centers, shopping complex Journal of areas, etc Engineering and Technology, Volume 4, ISSN: 2395 - We have built a compact, efficient, powerful, and 0056 cheaper version with keeping budget in mind This Monobike is an extremely affordable budget variant and gyroscopes sensors: operation, sensing, and any person can get hands-on it. Since it has fewer -11 components it can be easily dismantled and also less maintenance cost BIOGRAPHIES FUTURE WORK These are the most amazing innovative bikes, here we step into the future with those who love blending style and functionality with pioneering design and technology. They are designed from scratch to inspire awe, keeping production feasibility. Some of them may even hit the roads of reality in the coming future. allow ourselves to be changed by the act of creation. An Engineer's passion is in how the culture we should be building now, might offer the same stability for a wider range of people and manufacturing these concepts into tangibility. ACKNOWLEDGEMENT We would like to express our special thanks & gratitude to Mr. P.Srinivas, Associative Professor & all the Staff members of the Mechanical Engineering ISBN: 978-93-5268-241-6 57 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 STUDY OF WELDING CHARACTERISTICS ON DISSIMILAR METALS USING TIG WELDING J. KUMAR CHANDRA A.VENKATA VISHNU K. ABHIRAMVANJARI K. ABHISHEK REDDY Assistant Professor, Assistant Professor, Student, Student, Department of Department of Mechanical Department of Department of Engineering, Mechanical Engineering, Mechanical Engineering Mechanical Engineering Nalla Narasimha Reddy Nalla Narasimha Reddy Nalla Narasimha Reddy Nalla Narasimha Reddy Instititions, Hyderabad, Group of Instititions, Group of Instititions, Group of Instititions, Telangana State, India. Hyderabad, Telangana Hyderabad, Telangana Hyderabad, Telangana State, India. State, India. State, India. K. MANIKANTA M.PRUDHVI NALLAVINAY REDDY Student, Student, Student, Department of Mechanical Department of Mechanical Department of Mechanical Engineering Engineering Engineering Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Nalla Narasimha Reddy Education Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Hyderabad, Telangana State, India. Abstract For many years, the manufacturing Keywords- Ti6Al4V, INCONEL 625 TIG Welding, industry has shown interest in the advantages and Hardness, thermal conductivity, corrosion resistance opportunities offered by welding of dissimilar metals etc. and effective techniques. It has increased in recent 1. INTRODUCTION decades because of efforts to build light and strong Welding is the coalescence or joining together of vehicles with reduced fuel consumption. In addition, metals, with or without a filler metal, using heat, the thermal conductivity, corrosion resistance, and and/or pressure. Bonding of metals during welding recyclability are other reasons to weld dissimilar non- occurs through localized melting or microstructure ferrous metal. As a reason we have chosen the non changes at the interface between metals. Welding is ferrous metals, those are Ti6Al4V and INCONEL 625 used throughout industry building construction, considering its superior properties which can yield aircraft manufacturing, and for automobile good results in manufacturing field. Considering the production.Welding is used to joint metal of different challenges like intermetallic Properties in welding of type of strength and for joining of commercial metals materials to avoid them TIG Welding is used. In the and alloys. It has become one of the most important project, the welding parameters are kept constant and manufacturing methods as well as the most necessary three combinations of the materials are considered for construction method. Nearly everything made of TIG Welding such as one combination of the metal is welded. Due to its strength and versatility, dissimilar metals and other two combinations of welding is applied in the manufacturing of almost all similar metals of Ti6Al4V and INCONEL 625.The the products used in our everyday life. If there is no project helps to study one of the mechanical test that is welding process, many communities cannot afford Hardness Test. An attempt is made to compare the the cost of the goods and services they need to earn a hardness values of welded specimens of different living. Dissimilar welding of metal joints becomes combinations taking the average values of respective widely accepted as the superior design alternative for trials to find which combination gives the good and manufactured products between their quality, appreciable hardness value. The project information reliability, and serviceability. The advantages of this helps to lay a baseline for the process flexibility and dissimilar welding are; no waste produced and it is adaptability to robotic mass production will allow a cheap. The welding industries are working on in wider range of applications of these metal areas where there is concern on welded joints due to combinations welded using TIG Welding. limitations of materials, process, and ability to ensure quality. Recently, welding dissimilar metal joint promotes a variety of service conditions such as 58 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 resistance to corrosion, heat resistance and magnetic to extensive cracking and failure caused by mismatch properties. A lot of study has been done with the in structural and thermal properties as well as dissimilar welding technology nowadays. formation of the extremely brittle and hard TIG welding is a welding process that electrode is not consumable and electric arc is produced between intermetallic compounds. work piece and tungsten electrode. Filler metal is Two types of cracks were observed in the weld joint, used during welding and it is supplied by hand or namely longitudinal cracks and transverse cracks with metal feeding system. During welding process, electrode, arc and melted pool are surrounded by respect to the weld direction. . The thermal history, inert gas. Inert gas is an inactivated gas that does not i.e. melt pool lifetime and cooling rate of the molten burn and adds nothing to or takes anything from the pool during TIG welding was monitored and a relation metal. Mainly Argon or Helium or both of them are used as shielding gas. The aim to apply gas shielding between thermo-cycle with occurrence of cracks was is to prevent weld from oxidation and it is useful to established. It is inferred that the longitudinal cracks have qualified and clean weld. Tungsten has high are mainly due to the formation of various brittle approximately twice times higher than the melting intermetallic phases of Ti and Ni. The reason of the transverse cracks could be the generation of longitudinal stress in weld joint due to the large difference in the thermal expansion coefficient of Nickel and titanium. temperature of welded metals. The extremely high 3. EXPERIMENTATION melting point of the tungsten allows the formation of The project is done based on experimental method. the arc without causing the electrode to melt. Experimental method enables project to study cause and effect because it involves the intentional Figure No. 1: TIG Welding Process manipulation of one variable, while trying to keep all other variables constant. The experiment is carried to 2. LITERATURE REVIEW analysis the data for the research. The first step A.B. Short et. al attempted to explore the before starting any research is to plan the research - systematically. A specific procedure or methods in methodologies are usually used to solve the problem titanium alloy plates and analysis of microstructure. within the scope. Methodologies show how is to A. Karpagraj et. al performed studies on mechanical conduct the study when carrying out a research. properties and micro-structure characterization of Mostly, the beginning of research is by identifying automated TIG welding of thin commercially pure the main problem and the sequence of systematic titanium sheets. Welding of titanium and its alloys tools to solve the problem. In the project, it has been poses several intricacies to the designer as they are identified that there will be difficulty in the prone to oxidation phenomenon. Jos Mathew et. al dissimilar non ferrous metal welding because of performed investigations into the effects of electron formation of brittle intermetallic layer in the weld beam welding on thick Ti6Al4V titanium alloy. They joint. All the related information was collected from performed all the test to examine the welding strength journals, reference books and internet from reliable and weld quality. Seretsky and Ryba (1976) tried to sources. The collected information will be a characterize the metallurgy of dissimilar welds guideline for the project. Experiments for this produced with laser welding. In their work, they research will be performed using TIG welding. Data wanted to promote the Ti-Ni phase in the weld, which analysis of this project was to identify the is of particular interest because of its ductility, non- mechanical properties and microstructure of the joint magnetic nature,corrosion resistance, and good low- area. The inter metallic phases can be minimized by temperature toughness.In addition, the TiNi phase providing relatively less melt pool lifetime at high exhibits a shape memory effect.The results of their welding speeds. Based on the findings, it can be laser welding experiments were unsuccessful because conjectured that advanced GTAW could be used to of poor microstructures. The cracking could not be attain lower inter metallic thickness with suitable eliminated by changing the laser power. filler metal could be used to improve welded Ti/Ni The combination of Ti6Al4V and Inconel 625 is very properties. Accurate control of the heat input allows difficult to join under conventional fusion process due more effective prediction of the inter metallic properties and better control of post-heat treatments. ISBN: 978-93-5268-241-6 3.1 Work piece Material: The atomic weight of titanium is 47.88.Titanium is lightweight, strong, corrosion resistant and abundant in nature.Titanium and its alloys possess tensile strengths from 30,000 psi to 200,000 psi (210-1380 59 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 MPa), which are equivalent to the strengths found in 3.2 Experimental Procedure most of alloy steels.Titanium is a low-density element (approximately 60% of the density of iron) that can be strengthened by alloying and deformation high melting point of 3135°F (1725°C). This melting Figure No. 4: Experimental Setup point is approximately 400°F above the melting Work pieces which are prepared are placed one over point of steel and approximately 2000°F above that the other with half of its width dimensions that are to of aluminum.Titanium is not a good conductor of be joined to the required Lap joint position on the work table. Required welding parameters are tuned to electricity. setup. Zirconiated tungsten electrode of diameter 2.4 Inconel 625 is a nickel-based super alloy that mm which is reduced to the tip diameter to 2/3 of the possesses excellent resistance to oxidation and original diameter by grinding was taken and fixed to the electrode holder. corrosion in a broad range of environments. Required size of the nozzle is selected and it is fixed Additionally this alloy has outstanding strength and to the torch. The inert gas flow rate to the required toughness at temperatures ranging from cryogenic to rate was adjusted. The filler rod (same as base metals) 2000°F. This alloy possesses a high degree of was selected as per the requirement. formability and shows better weldability than many The work is done in three combinations of the non ferrous metals which are given below. other highly alloyed nickel based materials. It has a density of 0.303 lb/in3 (8.44 g/cm3), specific gravity of 8.44, melting range of 2350 - 2460°F (1280 - 1350°C), specific heat of 410 Joules/Kg. Figure No. 2: Ti6Al4V Specimens Combination-1: Figure No. 3: INCONEL 625 Specimens In the first combination the TI6AL4V and TI6AL4V are taken and they are placed in the lap joint position for welding. Here, the filler rod used for welding is Aluminum and it is held at an angle of 45 on the other side of welding torch. Now, the Electrode is touched to the work, so that current flow will be established and then it is separated by a small distance in order to generate the arc. First tack weld is done on the work pieces. Then the electrode is moved slowly along the length of the joint with the filler rod, so that the filler metal will be deposited in the joint.The operation is repeated for the second time on the other side of the lap joint of work piece in order to make double fillet joint. Thus, the lap joint of Ti6Al4V and TI6AL4V with double fillet Lap joint using TIG Welding was done. ISBN: 978-93-5268-241-6 Figure No. 5: Specimen of TI6AL4V/TI6AL4V after welding 60 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Combination-2: Table No 1: Welding Parameters Here in the combination-2 the INCONEL625 and INCONEL625 are taken for welding. The filler rod TI6 INCO used in this combination is Stainless Steel (SS) of diameter 3mm. The welding is done similarly as PARA AL4 NEL6 TI6AL4 stated above. METE V/ 25 / V/ Combination-3: RS TI6 INCO INCON In the combination-3 the metals taken are TI6AL4V and AL4 NEL6 EL 625 INCONEL 625 and the filler rod used in this is Niobium (Nb) and the welding process is done V 25 Figure No. 6: Specimen of INCONEL625/ Welding 160 160 160 Amps INCONEL625 after welding Current Amps/A Amps/DC /AC C Figure No. 7: Specimen of TI6AL4V/INCONEL625 after welding Welding 2V 2V 2V Voltage Welding 3 mm/s 3 mm/s 3 mm/s Speed Filler Aluminiu Stainless Niobium Rod m (Al) Steel (SS) (Nb) Electrod e 2.4 mm 2.4 mm 2.4 mm Diamete r Dimensi 120×40× 120×40×3 120×40×3 ons 3 mm3 mm3 mm3 6. RESULTS AND DISCUSSIONS In the project, three trials of hardness tests were performed on the three different combinations at different locations of non ferrous metals welded using TIG Welding. Out of them the average value of the hardness is considered for the respective welded specimen combinations. Thus we can able to get the appropriate combination with good and appreciable hardness value. The hardness values of the different combinations are tabulated below: Table No 2: Hardness values of the different combination of metals Welded Brinell Metal ( Trial-( Trial-2) (Trial- Hardnes Combin 1) 3) s Test ation (Avg) TI6AL4V/ 92 BH 94 BH 97 BH 94.3 BH TI6AL4V INCONE 95 BH 99 BH 105 BH 99.6 BH L625/IN 108 BH 104.3 BH CONEL6 101B 104 BH 25 H TI6AL4V / INCONE L625 ISBN: 978-93-5268-241-6 The bead height and bead Width are also measured in the work which is as tabulated below 61 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Table No 3: Bead height and Bead width The Non-ferrous metals are welded successfully using TIG Welding. measurements The Nb was utilized as an interlayer to avoid the S.NO SPECIMEN BEAD BEAD Ti6AL4V alloy and Inconel 625 mixing, which 1 prevented the formations of Ti-Ni, Ti-Cr, and Ti-Fe COMBINATIO HEIGHT WIDTH brittle intermetallics in the Ti6AL4V/Nb/Inconel 625 dissimilar joint. N In the dissimilar joint, the reaction layer that is heat Ti6AL4V - 3.5 mm 4 mm affected zone (HAZ) demonstrated relatively higher Brinell Hardness Value compared to other regions Ti6AL4V and they are tabulated. 2 Inconel 625 - 4 mm 5 mm The bead length and bead Width are measured and the dissimilar metals gave the best results. Inconel 625 As a final result, by using Nb material as a filler rod 3 Ti6AL4V - 3.5 mm 3.8. mm about Ti6AL4V and Inconel625 weld joint gives us maximum hardness results as compared to other two Inconel 625 combinations. As a result of hardness value on the brinell hardness REFERENCES 1. Ahmed N, New developments inadvanced machine we have taken 3 trials on each specimen about three different positions. For the specimen welding, Woodhead Publishing Limited, Ti6AL4V/Ti6AL4V the average hardness value is Abington, 2005. 94.3 BH. And the hardness values for specimens 2. Lucas W &Howse D, Activating flux Inconel625/Inconel625 and Ti6AL4V/Inconel625 are increasing the performance and 99.6 BH and 104.3 BH. productivity of the TIG and plasma process, Welding and Metal Fabrication, For the specimen Ti6AL4V/ Ti6AL4V the bead height 64 (1996)11. and bead width values are 3.5mm and 4 mm. For the specimen Inconel625/Inconel625 the bead height and 3. Lucas W, Howse D, Savitsky M M& Kovalenko I V, A- TIG flux for width values are 4 mm & 5 mm. For increasing the performance and Ti6AL4V/Inconel625, bead height and bead width productivity of weldingprocesses, values are 3.5 mm &3.8 mm. (International Institute of Welding Document No. XII-1448-1996),1996. 4. Lucas W, Welding and Metal Fabrication, 2 (2000)7 5. Gurevich S M, Zamkov V N &Kushnirenko NA, Avtomat, 9 (1965) 1. 6. Lin H L , Wu T M & Cheng C M , J Mater Eng Perform, 23 (2014)125. 7. Shah B & Shah B, A-TIG Welding Process- A Review Paper, International Conference on Ideas, Impact and Innovation in Mechanical Engineering,1-2 June 2017, Pune,India. 8. Singh R A, Dey V & Rai R, Techniques to improveweld penetration in TIG welding (A review), Materials Today: Proceedings, 4 (2017) 1252. 9. Surendhiran S, Kumar K &Jayendran M, Int Res J Eng Technol, 4 (2017) 913. 10. Tanaka M, Weld Int, 19 (2005)870. 11. HowseDS&LucasW,SciTechnolWeldJoi,5(2 000)189. 7. CONCLUSION 12. Tseng K H, Powder Technol, 233 (2013) 72. From the present work the following conclusions are 13. Simonik A G, Weld Prod, 3 (1976)49. 14. Tsai MC &Kou S, Int J NumerMethods drawn Department of Mechanical Engineering, NNRG. 62 ISBN: 978-93-5268-241-6
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Fluids, 9 (1989)1503. 15. Limmaneevichitr C & Kou S, Weld J, 79 (2000)126s. 16. Lowke J J, Tanaka M & Ushio M, J Phys D:Appl Phys,38 (2005)3438. 17. Zhang R H , Pan J I & Katayama S, Front Mater Sci, 5 (2011)109. 18. Berthier A, Paillard P, Carin M, Valensi F &Pellerin S, Sci TechnolWeldJoi,17 ( 2012)609. 19. Ruckert G, Etude de la contribution des flux activantsensoudage A-TIG, These de Doctorat, Ecole Centrale de Nantes et l'Universite de Nantes,2005. ISBN: 978-93-5268-241-6 63 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 DESIGN AND ANALYSIS OF EXPANDABLE WHEEL P. SRINIVAS S. MAHESH Assistant Professor, Student, Department of Mechanical Engineering, Department of Mechanical Engineering Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India Abstract- the expandable Wheel concept consists in keeping a Vehicles such as guided vehicles can have a large perfectly round wheel for travel on smooth ground and variety of mechanisms to provide movement, such as wheels or caterpillar tracks. The efficiency of travel, then transform the wheel in order to give it the the smoothness of locomotion and the ability to handle capability of overcoming obstacles such as stairs when obstacles are among the criteria. For some applications, production considerations can put a necessary. Our design works by having the outer part of constraint on the complexity level, as a low number of the wheel being able to separate into several pieces, degrees of freedom generally makes control easier. referred in the following as wheel segment, each of For vehicles that should operate in locations designed for people, stair-climbing can be a challenge for which extending outwards from the axle to form vehicles, since stairs are designed for the bipedal spokes. The Expandable Wheel concept works with as movement of a human and not for the mechanically few as two-wheel segments and up to as many wheel simpler motion of wheels. We propose a new design segments as the designer would like. A higher number for stair climbing using a wheel that can split into segments and walk upstairs or overcoming other of segments gives generally smoother stair travel, while obstacles often found where humans traverse. Using a lower number of segments needs fewer parts and this change of configuration, staircases with a wide requires less arm extension to climb the same stair. range of dimensions can be covered efficiently and Conversely, a larger number of segments allows for a safely. The designed, Expandable wheel, can consist larger wheel in the closed position while fewer of as many wheel segments as desired, and as few as two. In this design by analyzing the expandable wheel segments can require a smaller closed-wheel size. mechanism as a slide crank mechanism with extended Having the wheel segment rims divided into strict link, find the values of velocity, acceleration, force of partitions result in the rims ending in sharp corners, individual links by giving the inputs as crank angle, crank length, connection rod length and angular which will serve as the point of contact on the stairs. A velocity. The same inputs will be given in ADAMS sharp corner can result in high contact pressure that will Software and doing dynamic analysis of the wheel finally compare the theoretical and practical values of potentially damage the steps of the stairs, while the velocity, acceleration, force and torque. Further corner itself could wear over time. In turn, this wear research includes image processing of the obstacles could also lead to an altered and imperfect circle when and based upon this image processing automatic expansion and closing of the wheel segments will be the wheel in closed. To improve upon this, an done. overlapping geometry was introduced at the corners of Key words: Umbrella wheel, wheel segment, staircase, the wheel segment rimes. The overlap continues the climbing, design outer curve tangentially to the curve of each rim. 1. INTRODUCTION Different obstacles: While the Expandable Wheel Vehicles such as guided vehicles can have a large concept was introduced with stair-climbing in mind, it variety of mechanisms to provide movement, such as can also handle other kinds of obstacle such as open wheels or caterpillar tracks. The stair-climbing problem gaps, and even ladders. In the case of open gaps, the has been under consideration for many years. To gap distances the wheel can cover depends on the prevent damage to the environment, a design for a stair- climbing wheel chair has been developed, with however possible extension of the wheel segments. For the considerable additional weight. Other solutions largest reach, two opposite wheel segments will be in obviously leg-based designs. The simple idea behind contact with the ground (on either side of the gap). For climbing ladders, the process is slightly more involved as it requires changing the extension during the climb. To climb a ladder, when already positioned on a rung, the next wheel segment is positioned above the rung of the ladder and then the extension of the segments is lowered, thereby placing the piece on the rung and raising the previous segment into the air. The wheel is rotated and once the previous piece is clear of the previous rung, the extension is raised again to allow the next segment to get into position above the next rung of ISBN: 978-93-5268-241-6 64 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 the ladder. This process is repeated for each rung of the Velocity analysis: ladder. Additionally, it is important or ladder-climbing that the body of the vehicle is capable of ensuring the Analysis of a mechanism is the study of motions and orientation of the wheel with respect to the ladder; forces concerning their different parts the study of which is ensured if the body extends at least as far back velocity analysis involves the linear velocities of as two rungs of the ladder plus the required extension of various points on different links of a mechanism as well the arm when climbing the ladder. as angular velocities of the links .velocity analysis is the prerequisite for acceleration analysis which further 2. METHADOLOGY leads to force analysis of various links of a Kinematics: It is a branch of science deals with the mechsnism.to explain such study a machine or relative motions of different parts of a mechanism mechanism is represented by a Skelton or line diagram without considering the forces producing the motions. are commonly known as configuration diagrams. Therefore, in geometric point of view it is used to know Velocities and accelerations in machines can be the displacement, velocity and acceleration of a part of determined either analytically or graphically.by using a mechanism.Dynamics: It involves calculations of computers or calculator’s theoretical method is forces impressed upon different parts of mechanism, the convenient to make use of analytical method but forces may be static or dynamic. Dynamics further graphical method is direct and accurate. different types subdivide into kinetics and statics.Mechanism: a of graphical approaches of velocity diagrams namely 1. combination of a number of rigid bodies assembled in relative velocity method 2. instantaneous Centre such a way that the motion of one cause constrained method 3. algebraic method. expectable motion to the others is known as a mechanism. The function of the mechanism is to Fig: characteristics of vector transmit and modify the motion. Machine: a machine is a mechanism or combination of mechanisms which not Length of the vector ab drawn to a convenient scale, only gives the motion to the parts but also transmits and represents the magnitude of the quantity. the direction modifies the available energy from one form into other of the line is parallel to the direction in which the and the modifies the available mechanical energy into quantity acts the initial end a of the line is the tail and some kind of work.Link: we know that mechanism is final end b is the head and arrow end of the line which made up of many numbers of resistant bodies out of indicates the direction.Vector ab also represents a which some may have motion relative to each other, a vector quantity of body B relative to body A such as resistant body or a group of resistant bodies with rigid velocity of B relative to A. If the body A fixed ab connections preventing their relative moment is known represents the absolute velocity of the B. If the both the as a link. A link may also be defined as a member or a bodies A and B are in motion, the velocity of b relative combination of members of a mechanism, connecting to a means the velocity of b assuming the body A to be other members and having motion relative to them. fixed for the movement. The vector ab can also b shown Thus, link may consist of one or more resistant bodies. as Vba.it means that velocity of B relative to A provide a A slider crank mechanism consists of four links those and b are indicated at the ends.Addition of the vectors are frame and guides, crank, connecting road and slider. A link is also called kinematic link or element. Link are Let Va=velocity of A relative to O different types those are binary, ternary and quaternary.Types of kinematic pairs: Lower pair, Vba = velocity of B relative to A Higher pair, sliding pair, turning pair, Rolling pair, Screw or helical pair, Spherical pairDegrees of Vbo= velocity of B relative to O freedom:The minimum number of independent variables required to describe the motion of a body is The law of vector addition states that the velocity of B called degrees of freedom.it also explains about no of relative to O is equal to the Vectorial sum of the constraints present in a body or mechanism. Freely rigid velocity of B relative to A and velocity of A relative to body consist of 6 degree of freedom. Degrees of O.velocity of B relative to O = velocity of B relative to freedom predicts the minimum no of links that should A+ Velocity of A relative to O. i.eVbo= Vba+ Vao , ob = be controlled as input link in order to get a complete oa + abnote that the arrow of the two vectors to be constrained mechanism. That is whose degree of freedom is one. DOF predicts the no of relations that exist between input and output DOF =3(n-1)-2j-h, Where n = no of links J= no of joints h-= higher pair 65 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 added are in the same order and that of the resultant is Vca=Vcb+Vba in opposite order. Any no of vectors canbe added as The velocity of any point relative to any other point on a fixed link is always zero. Thus, all the points on a fixed link are represented by one point in the velocity diagram. The point A and D, both are lie on the fixed link AD. Therefore, the velocity of C relative to A is the same as velocity of D. Addition of the vectors Vcd= Vba+ Vcb i.e. dc=ab + bc take the first vector.at the end of the first vector place the bagging of the second vector, at the end of the Where,Vba =ω×AB; perpendicular to AB second vector place the beginning of the third vector joins of the beginning of the first and end of the last Vcb is known in magnitude; perpendicular to BC vector that represents the sum of the vectors. Vcd unknown in magnitude; perpendicular to DC Motion of a link Intermediate points: The velocity of an intermediate point on any of the link can be found by dividing the corresponding velocity in the same ratio as the point divides the link. For E on the link BC. = Consider a link of OA of length r and rotates around a Offset point: Write the vector equation for point F, fixed-point O with uniform angular velocity w in the counter clock wise direction. When OA turns through Vfb+ Vba= Vfc+ Vcd the angle of del ∅ a in small interval of time del Then A ab + bf = dc + cf will travel to A’ along a length AA’. Then the velocity of the link OA is calculated as The velocities Vba and Vcd are already there on the velocity diagram,Vfb is perpendicular to BF, draw a line Velocity = = ’=r perpendicular to BF through b;Vfc is perpendicular to CF, draw a line perpendicular to CF through c,The When ∆t →0, v = r = r ω intersection of two lines locates the point f.Angular velocity of an unknown link can be found by using a The direction of Vao is along the displacement of A thus formula Linear velocity = angular velocity × length of velocity of A is ω×r and is perpendicular to OA. the link = Acceleration analysis: Rate of change of velocity with respect to time is known as acceleration and it acts in That is b divides the velocity vector in the same ratio as the direction of the change in velocity. Acceleration is B divides the link.Velocity analysis of four bar of two types. Tangential acceleration and Centripetal or mechanism: radial acceleration. Tangential acceleration will act tangent to the link or perpendicular to the link whereas centripetal acceleration will act along the member hence it is also called as radial acceleration. Method to find the acceleration of a link: Consider a link OA of length r, rotates in a circular path in clockwise direction. It is rotating with an instantaneous angular velocity W and angular acceleration α in the same direction i.e. angular velocity increases in the clock wise direction. Tangential velocity of A is Va=ω×r Velocity vector equation Acceleration = ℎ Velocity of C relative to A=Velocity of C w.r.t B + Acceleration = ω×r∆ =ωr.ω = rω2 = v2 Velocity of B w.r.t A ∆ ISBN: 978-93-5268-241-6 66 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 tangential acceleration =f t=α×r.Tangential component of acceleration occurs due to the angular acceleration of the link. Tangential acceleration of B relative to A=ftba=α×a Dynamic Analysis: Dynamic forces are associated with Fig: expandable wheel rings accelerating masses. As all machines have some accelerating parts, dynamic forces are always present when the machines operate. In situations where dynamic forces are dominant or comparable with magnitudes of external forces and operating speeds are high, dynamic analysis has to be carried out. For example, in case of rotors which rotate at speeds more than 80,000 rpm, even the slightest eccentricity of the center of mass from the axis of rotation produced very high dynamic forces. This may lead to vibrations, wear, noise or even machine failure. DESIGN CRITERIA: Theories of failure:When a Fig: line diagram of expandable wheel machine element is subjected to a system of complex Fig:Expandable wheel stress system, it is important to predict the mode of Fig: Wheel Design failure so that the design methodology may be based on a particular failure criterion. Theories of failure are essentially a set of failure criteria developed for the ease of design. In machine design an element is said to have failed if it ceases to perform its function. There are basically two types of mechanical failure: Yielding and Fracture Theories of failure are those theories which help us to determine the safe dimensions of a machine component when it is subjected to combined stresses due to various loads acting on it during its functionality. Various Theories of Failure 1. Maximum Principal Stress theory also known as rankine’s theory 2. Maximum Shear Stress theory or Guest and Tresca’s Theory 3. Maximum Principal Strain theory also known as St. Venant’s Theory 4. Total Strain Energy theory or Haigh’s Theory 5. Maximum Distortion Energy theory or Vonmises And Hencky’s Theory Result: Assumed this expandable wheel mechanism as a slider crank mechanism. Initially taken the data as angle is 20 degrees, crank length as 5.2cm, connecting rod length as 2.7cm, extend link length as 3. 8cm, angular velocity 0.02 red/sec. based upon this data velocity, acceleration, force and turning moment calculated. Fig: Top View and Side View of Umbrella Wheel Vehicle Fig -wheel segment Fig: Final Design of Umbrella Wheeled Vehicle ISBN: 978-93-5268-241-6 67 Department of Mechanical Engineering, NNRG.
CALCULATIONS: Proceedings of RTIME-2K20 Velocity calculations: 4th National Conference on Recent Trends & Innovations in Mechanical Engineering Acceleration calculations: 24th & 25th July, 2020 =0.0375 kg cm2/s2 CONCLUSION A new design referred as Expandable wheel for a stair climbing has been proposed and discussed. This expandable works similar to the umbrella, when the obstacle’s come it opens the wheel segment and gives the motion to the mechanism and when the obstacle is not means it goes smooth as the normal wheel goes,obstacle are stairs, rough terrains, ladder are considered. On this expandable wheel theoretically calculated the values of velocity, acceleration, force and torque by taken the input as angular velocity, crank length, connecting rod length and angular acceleration. All this analysis done assuming expandable wheel as slider crank mechanism with extended link. Finally, by giving the same input to ADAMS software dynamic analysis is done and compared the results. Further research includes image processing of the obstacles and based upon this image processing automatic expansion and closing of the wheel segments will be done. ACKNOWLEDGMENT I am thankful to Nalla Narsimha Reddy Group of Educational Society, Dr. G Janardhan Raju, Dean school of engineering &HOD-Mechanical department and my guide Mr. P Srinivas Associate professor. REFERENCES [1] R.C. Luo, M. Hsiao and T. Lin,” Erect Wheel- Legged Stair Climbing Robot for Indoor Service Applications”, 2013 IEEE/RSJ International Force and torque calculations: Conference on Intelligent Robots and Systems (IROS Input data ������ = 20������ [2] P. Ben-Tzvi, S. Ito and A. Goldenberg,” ������ = 42������ Autonomous Stair Climbing with Reconfigurable Mass (m) = 2 Kg Tracked Mobile Robot”, ROSE 2007 - IEEE ω = 0.02 rad/s International Workshop on Robotic and Sensors Crank length (r) = 5.2 cm Environments [3] Y. Sugahara, N. Yonezawa and K. Kosuge,” A n= = 1.342 Novel Stair-Climbing Wheelchair with Transformable piston effort f=mrω2[cost ������ + ] Wheeled Four-Bar Linkages”, The 2010 IEEE/RSJ = 2×5.2×0.022[cos 20+ ] International Conference on Intelligent Robots and = 6.093×10-3 kg cm/s2 . = 0.006093 kg cm/s2 Systems Force (thrust) along the connecting rod [4] D. Lu, E. Dong, C. Liu, M. Xu and J. Yang,” Design Fc= and Development of a Leg-Wheel Hybrid Robot” HyTRo-I””, IROS 2013 [5] C. Theeravithayangkura, T. Takubo, Y. Mae and T. =. × ^ Arai,” Stair Recognition with Laser Range Scanning by = 8.1989×10-3 kg cm/s2 Limb Mechanism Robot” ASTER- ISK””, International = 0.0082 kg cm/s2 Crank effort(fc) Conference on Robotics and Biomimetic 2009 Ft=Fc × sin (������ + ) = 8.1989×10-3×sin (62) [6] European Patent number EP2003039B1,” Trolley = 7.2392×10-3 = 0.00723 kg cm/s2 for ascending/descending stairs” by AlanLiva Turning moment(T) T=ft × r [7] A. Imadu, R. Tanaka, T. Kawai and M. Shibata,” = 7.23923×10-3×5.2 kg cm/s2 Study on Design Methodology of Power-Assisted Luggage Cart with Rotational Arms for Stair Climbing”, SICE Annual Conference 2011 [8] Danish building regulations 01.01.2016 - 30.06.2016 paragraph 3.2.2 [9] The Building Regulations Document K, 2013 ISBN: 978-93-5268-241-6 68 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 [10] Branicky MS. Studies in hybrid systems: modelling, analysis and control. 1hesis, MIT,1995. [11] Cardaliaguet P, Quincampoix M, Saint-Pierre P. Temps optimum pour des problem’s avec contraintes et sanscontro(labiliteH locale. Comptes-Rendus de l1AcadeHmie des Sciences,SeHrie 1, Paris, 1994; 318:607}612. [12] Johanson KH, Lygeros J, Egerstetdt M, Sastry S. Regularization of Zeno hybrid automata. Systems Control Letters, to appear. ISBN: 978-93-5268-241-6 69 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 DESIGN AND FABRICATION OF LIFTING MECHANISM T. MAHESH K. BALACHANDER Assistant Professor, Student, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Department of Mechanical Engineering, Instititions, Hyderabad, Telangana State, India Nalla Narasimha Reddy Education Society’s Group of K. ROHIT REDDY Instititions, Hyderabad, Telangana State, India Student, I. THARUN REDDY Department of Mechanical Engineering, Student, Nalla Narasimha Reddy Education Society’s Group of Department of Mechanical Engineering, Instititions, Hyderabad, Telangana State, India Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India ABSTRACT-- This model proposes a new design for of degrees of freedom generally makes control easier. stair-climbing using a wheel that can split into For vehicles that should operate in locations designed segments and walk upstairs or surmount other obstacles often found where humans traverse, while for people, stair-climbing can be a challenge for still being able to retain a perfectly round shape for vehicles, since stairs are designed for the bipedal traveling on smooth ground. Using this change of movement of a human and not for the mechanically configuration, staircases with a wide range of simpler motion of wheels. dimensions can be covered efficiently and safely. The stair-climbing problem has been under The design, named Umbrella Wheel, can consist of consideration for many years. Where a set of wheel as many wheel segments as desired, and as few as segments placed around a rotating frame allows the two. A smaller or higher number of wheel segments vehicle to ascend or descend a stair-case. Variations has advantages and disadvantages depending on the specific situation.The parts are designed by CREO on this design are still among the most popular latest version in 3d form. This design is converted solutions today, an alternative but common solution into (STL) file by using the external application in the field of robotics is to use caterpillar tracks, called CURA. The body parts are made up of which has the advantage of good handling on most Polylactic Acid (PLA) filament through 3D printing by using an FDM printer.Here we used Scott types of difficult terrain, though at the cost of low Russell mechanism to create a straight-line motion. efficiency on even ground when compared to a wheel. The motion of the links is controlled by nut Bolt Furthermore, this design can also lead to damage of mechanism modelling the trajectory of the wheel the stairs on the edge of the step. To prevent damage when as it ascends or descends stairs is given and the results are analysed. to the environment, a design for a stair-climbing wheelchair has been developed, with however I. INTRODUCTION considerable additional weight. Other solutions Vehicles such as autonomous robots or guided obviously leg-based designs, and these are known to vehicles can have a large variety of mechanisms to provide movement, such as wheels or caterpillar be able to handle any terrain where a stable footing tracks. The efficiency of travel, the smoothness of can be achieved, mostly these have three or more locomotion and the ability to handle obstacles are legs, however, these are generally and comparatively among the criteria that can determine which solution quite complicated to construct and control. Flying fits best for a specific situation. For some applications, production considerations can put a drones have no problem handling stairs, but lack constraint on the complexity level, as a low number efficiency, are noisy and cannot handle heavy cargo. Finally, some vehicles separate the stair-climbing from general locomotion to achieve the ease and efficiency of wheeled travel while still being able to overcome stairs, for example by having rotating arms that can lift the vehicle onto a step this allows for ISBN: 978-93-5268-241-6 70 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 simpler mechanisms since it no longer has to handle general locomotion. II. CONCEPT The simple idea behind the Wheel concept consists in keeping a perfectly round wheel for travel on smooth ground and then transform the wheel in order to give it the capability of overcoming obstacles such as stairs when necessary. Our design works by having the outer part of the wheel being able to separate into several pieces, referred in the following as wheel segment, each of which extending outwards from the axle to form spokes. A. Number of wheel segments Figure 2. Stair-climbing with the umbrella wheel The stair-climbing problem has been under design. consideration for many years.The wheel works by Steps have to be known. Adding contact sensors that having the segments of the otherwise round wheel detect the stair surface to the rotating pieces of a able to separate and extend out from the axle on arms wheel can be challenging, since any wires would get that then can grip onto stairs and obstacles. Fig. 1 wrapped up in the mechanism of the wheel while shows a 3D CAD model of the wheel design with adding complexity and cost to the product. three-wheel segments and an umbrella-inspired mechanism for arm extension. The arms extend radially outward when the green pieces are pushed together, the front one sliding on the axle, the back one being fixed to the end of the axle. . B. Overlapping of wheel segment rims Figure 1. 3D CAD model of an expanding wheel Having the wheel segment rims divided into strict segment partitions result in the rims ending in sharp corners, which will serve as the point of contact on the stairs. In Fig. 2 depicts how the umbrella wheel design A sharp corner can result in high contact pressure that climbs stairs as well as the path it follows going up will potentially damage the steps of the stairs, while the stairs. the corner itself could wear over time. In turn, this wear could also lead to an altered and imperfect circle when the wheel in closed configuration. To improve upon this, an overlapping geometry was introduced at the corners of the wheel segment rimes. The overlap continues the outer curve tangentially to the curve of each rim (the overlap is made circular for design simplicity). For comparison, the two kinds of corners (rims sharp corners and corners with overlap) are represented in Fig.3 The extension of the arms lets the umbrella wheel adjust itself to fit any dimension of stair within its range perfectly. To calculate a fitting arm extension that allows the wheel to hit the same point on each step, the height of the stair. Fig. 3: Close-up of rim corner overlap ISBN: 978-93-5268-241-6 71 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 III. MECHANISMS USED 1. Scott Russell mechanism A Scott Russell linkage gives a linear motion by using a linkage from with three portions of the links all equal and a rolling or sliding connection. It can be used to form a right-angle change of motion linear to linear. Here we use this mechanism to create a straight segment motion Fig 4: Scott Russell mechanism Fig 6: schematic diagram of nut 2. Nut bolt mechanism A link diagram is shown in the below figure which is A nut is a type of fastener with a threaded hole. Nuts having a length 125mm are almost always used in conjunction with a mating bolt to fasten multiple parts together. The two parts Link length from sliding pair to point E is 250mm as will move together and away by combination of their shown in Scott Russell mechanism figure. And threads. This mechanism will help to move sliding smaller link which is fixer at the one end link length pair up to required distance is 125mm IV. 3D DESIGNING USING CREO A sleeve with external threading will work like a bolt to move sliding pair. The below figure shows the schematic diagram of sleeve with their dimensions (all dimensions are in mm) Fig 7: schematic diagram of link The below part is mounted on shaft or rod which is a fixed link it is having number of supports are three ant an angle of 120o Fig 5: schematic diagram of sleeve A nut is used as a sliding pair. A nut with internal treading with three supports at an angle of 120o to each support as shown in bellow figure 72 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 is also outside the reach of the wheel, otherwise the wheel might rotate with the body due to gravity. Additionally, the Wheel requires knowledge about its own position as well as the position and dimensions of obstacles to be able to handle them optimally, so sensors are needed for a successful implementation of a vehicle using our concept. Fig 8: schematic diagram of fixed support Size limitations To ensure that the stair-climbing works, it is The design of wheel segment without overlap. Three recommended that the radius of the wheel should be segments are used to create a complete wheel. Each sufficiently small so that the wheel pieces fit on as segment consiststheir separate link mechanism to lift many stairs as possible. The ground of a stair in the segment publicly accessible areas has to, by the Danish building regulations, be a minimum of 250mm, the American International Residential Code state a minimum ground of 10in = 25 .6mm. The English Building Regulations have a minimum of 220mm in private areas and minimum of 250mm for all public access stairs. Hence the following inequality should be fulfilled: r· 2π/ n +2ro + πro<Gmin= 250mm although it can be recommended to have an extra margin for safety. Note that while there is an upper limit for step height, there is none for the ground and as such, any finite range of required extension cannot be given, though through modelling it can be tested beforehand we there specific staircase can be climbed satisfactorily. For a ladder-climbing scenario, it is important that the ladder does not prevent the wheel from turning. As such, the wheel must be small enough so that the widest part of the wheel segment is smaller than the gap between the rungs of the ladder. The following should be true if ladder-climbing is intended: gap > 2ro +2(r−ro)·sinπ /n VI. FABRICATION USING 3D PRINTER Fig 9: schematic diagram of wheel segment V. IMPLEMENTATION CONSIDERATIONS For the Wheel to work properly, it is important that the vehicle that uses this concept is large enough so that it has a body that extends back from the wheel at least as far as the maximum extension of the arms (plus the radius of the wheel). Without this constraint there is a risk of the body spinning freely instead of Fig.10: 3D Printer turning the wheel. For smooth motion it is further more required that the centre of gravity for the robot 3D printing, or additive manufacturing, is the construction of a three-dimensional object from 73 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 a CAD model or a digital 3D model. The term \"3D files can be combined with other parts into an printing\" can refer to a variety of processes in which assembly file material is joined or solidified under computer 3D printable models may be created with CREO control to create a three-dimensional object, with package, via a 3D scanner, or by a plain digital material being added together (such as liquid camera and photogrammetry software. 3D printed molecules or powder grains being fused together), models created with CREO result in relatively fewer typically layer by layer. errors than other methods. Errors in 3D printable models can be identified and corrected before In the 1990s, 3D printing techniques were considered printing. The manual modelling process of preparing suitable only for the production of functional or geometric data for 3D computer graphics is similar to aesthetic prototypes, and a more appropriate term for plastic arts such as sculpting. 3D scanning is a it at the time was rapid Prototyping. As of 2019, the process of collecting digital data on the shape and appearance of a real object, creating a digital model precision, repeatability, and material range of 3D based on it. printing has increased to the point that some 3D printing processes are considered viable as an FABRICATION PARTS DONE BY OUR TEAM industrial-production technology, whereby the term additive manufacturing can be used synonymously with 3D printing. One of the key advantages of 3D printing is the ability to produce very complex shapes or geometries that would be otherwise impossible to construct by hand, including hollow parts or parts with internal truss structures to reduce weight. Fused deposition modelling, or FDM, is the most common 3D printing process in use as of 2018. Fig. 13: Threaded sleeve with nut Fig. 11:3D printing filament material Fig. 14: fixed nut without links connected. Fig. 12: Fixed Rotational Support to Specimen 3d Fig. 15: fixed rotational support to specimen. Part. Department of Mechanical Engineering, NNRG. A PRT file is a part file created by PTC CREO 74 Parametric, a CAD program part of the CREO suite that is used to design manufactured parts and assembly processes. It contains part information, including a 3D model and part structure. PRT ISBN: 978-93-5268-241-6
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Put ������ in eq (1) pcos������=������(psin������ + wcos������)+ ������������������������������ pcos������- ������psin������ = ������wcos������ + ������������������������������ p(cos������- ������sin������)=w(������cos������ +������������������������) P= ( ) But ������ = ������������������∅ ∅ = Friction angle P= ( ∅ ) ∅ P= ( ∅ ∅ ) ∅ ∅ ) ( P= ( ∅∅ ) ∅ ∅) ( P= ������ ( ∅) ( ∅) P= ������tan (������ + ∅) P= ������ [ ∅] ∅ From the above equations actual effort applied to raise the load can be calculated torque required to rotate the screw T = P× T= ������ [ ∅]× Diameter ������ = 300������������ ∅ Pitch P = 20������������ Weight W = 400������ Fig. 16: sleeve Assuming friction ������ = 0.15 = ������������������∅ VII. CALCULATION D =������ − Tan������ = Where = 300− = 290mm P = Pitch of screw thread (mm) Tan ������ = D = mean diameter of screw thread (mm) Diameter = Resolving forces along the plane for equilibrium conditions × ∑������ = 0 = 0.021 pcos������ = ������������ + ������������������������������---- (1) Resolving forces perpendicular to the plane Effort P = ������ [ ∅] Torque ∑������ = 0 ∅ ������ = psin ������ + wcos������ ----- (2) ISBN: 978-93-5268-241-6 = 400 . . . ×. P = 68.61N T = ������ × T = 68.61× T = 9948.45N-m VIII. CONCLUSION A new design for a stair-climbing wheel, referred to as Umbrella Wheel, has been proposed and discussed. The advantage of the concept lies in its ability to climb up or descend stairs, as well as go through rough terrain while being capable of regaining smooth displacement conditions on more level terrain. Simple considerations on geometry lead to modelling of the path followed by a single wheel. Different parameters of the wheel have been explored with regards to smoothness and versatility. 75 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 Current research includes the construction of an Transformable Wheeled Four-Bar actuating mechanism in order to move the part Linkages”, The 2010 IEEE/RSJ International responsible for the extension of each leg segment, as well as the design and development of a suitable Conference on Intelligent Robots and vehicle to test the performance of the design with respect to stair-climbing as well as handling other Systems obstacles and driving on smooth terrain. 9. D. Lu, E. Dong, C. Liu, M. Xu and J. Yang,” A hybrid model of the behavioural dynamics of the stair climbing wheel design called umbrella wheel has Design and Development of a Leg-Wheel been presented and implemented. Both the continuous-time dynamics and the discrete-time Hybrid Robot” HyTRo-I””, IROS 2013 dynamics have been explored. A discrete model of the continuous behaviour 10. C. Theeravithayangkura, T. Takubo, Y. Mae hasbeen developed that allows the use of predictions and T. Arai,” Stair Recognition with Laser to detect stair-contact using only measurements of wheel rotation. The results from the detection Range Scanning by Limb Mechanism algorithm give good accuracy and robustness even taking into account real-life measurement limitations. Robot” ASTERISK””, International Further research includes the introduction of filters Conference on Robotics and Biomimetics for the measurement to achieve better results for stair detection as well as construction of a prototype and 2009 real-life implementation and testing of the stair detection method. 11. European Patent number EP2003039B1,” Trolley for ascending/descending stairs” by Alan Liva REFERENCES 1. Imadu, R. Tanaka, T. Kawai and M. Shibata,” Study on Design Methodology of Power-Assisted Luggage Cart with Rotational Arms for Stair Climbing”, SICE Annual Conference 2011 2. P. Ben-Tzvi, S. Ito and A. Goldenberg,” Autonomous Stair Climbing with Reconfigurable Tracked Mobile Robot”, ROSE 2007 - IEEE International Workshop on Robotic and Sensors Environments 3. Y. Sugahara, N. Yonezawa and K. Kosuge,” A Novel Stair-Climbing Wheelchair with Transformable Wheeled Four-Bar Linkages”, The 2010 IEEE/RSJ International Conference on Intelligent Robots and SystemsR.C. Luo, M. Hsiao and T. Lin, ”Errect Wheel-Legged Stair Climbing Robot for Indoor Service Applications”, 4. 2013 IEEE/RSJ International Conferrence on Intelligent Robots and Systems (IROS)] 5. US Patent Nr.: US255693 by J. G. TAUBER 6. R.C. Luo, M. Hsiao and T. Lin,” Errect Wheel-Legged Stair Climbing Robot for Indoor Service Applications”, 2013 IEEE/RSJ International Conferrence on Intelligent Robots and Systems (IROS) 7. P. Ben-Tzvi, S. Ito and A. Goldenberg,” Autonomous Stair Climbing with Reconfigurable Tracked Mobile Robot”, ROSE 2007 - IEEE International Workshop on Robotic and Sensors Environments 8. Y. Sugahara, N. Yonezawa and K. Kosuge,” A Novel Stair-Climbing Wheelchair with ISBN: 978-93-5268-241-6 76 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 DEEP DRAWING OF 5 MM & 3MM THICKNESS STEEL BLANK T. MAHESH K. ANAND KUMAR Assistant Professor, Student, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India Instititions, Hyderabad, Telangana State, India Abstract-- Deep Drawing is the process in which a require redrawing process using progressive dies. The punch forces a flat sheet metal blank into a die deep drawing process had prominently acquired its cavity. work is available in the applications of Deep popularity due to rapid press cycle times, requirement Drawing processes at elevated temperatures which is of semi skilled labor and simplicity of the process. going to be a very important manufacturing The desired shape of the component can indeed be application in the coming decades. Deep Drawing is stored in the shape of punch and die and can be one of the sheet metal forming processes widely imparted the same to the blank when it passes through used in automobile, aerospace, electronics and other the clearance between the punch and die. In essence, industries to produce the hollow parts. The punch forces the blank through the clearance between improvement in the deep drawing manufacturing punch and die with or without the presence of blank process with modern methodologies leads to holder force. Indeed a blank holder with suitable developments in the automobile and other sheet applied force or pressure can essentially postpone for metal industries. Until today, this process of analysis initiation in wrinkles formation or tearing by and design is an art. Presently, the deep drawing suppressing these failures operation is carried out at room temperature in industries. Although the deep drawing process of 1.2PRINCIPLE OF DEEP DRAWING A flat blank of sheet metal is formed into a high strength metals has an extensive industrial application area. Deep drawing at room temperature cylindrical cup by forcing a punch against the centre has serious defects because of the large amount of portion of a blank that rests on the die ring. The blank deformations revealed and high flow stresses of the may be circular or rectangular or more complex materials. The present report gives an overview of outline. Blank holder is loaded by a blank holder deep drawing process, its classification along with force, which is necessary to prevent wrinkling and to advantages, limitations and applications. The control the material flow into the die cavity. The optimum process parameters were calculated based punch is pushed into the die cavity, simultaneously on their influence on the thickness transferring the specific shape of the punch and the die to the blank sheet. The material is drawn out of 1. INTRODUCTION the blank holder die region during the forming stage Deep drawing process of sheet metal is an essential and the material is subjected to compressive and means for forming of cup shaped components often tensile stresses in this portion. The principle of deep having ample applications in automobile, beverage, drawing is schematically shown in Figure 1. aerospace, kitchen utensils, cartridge bases and zinc dry cells. At the outset, deep drawing process underwent lot of research in last two decades. In essence the competitive environment is still demanding further for high strength and light weight metal parts. It is seldom sought for careful and improved further study of deep drawing process with advanced methods of analytical, experimental as well as numerical methods such finite element methods. Deep drawing process can also be used as an assessment test of sheet metal formability. In general, deep drawing process can be used to produce from simple cylindrical, conical, box-shaped to even complicated intermediate shapes which normally FIG 1. 77 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 1.3 CLASSIFICATION OF DEEP DRAWING circular open die. The diameter of the blank is The deep drawing may be broadly classified as a denoted by Do. Blank is a sheet metal in deep drawing process, it is a sheet metal forming process conventional deepdrawing and a non-conventional deep drawing depending on the method of operation. in which a sheet metal blank is radially drawn down The detailed classification of various deep drawing into a forming die by the mechanical action of a processes is shown in the figure 2. punch. FIG.2 FIG:3 1.4 PARTS USED 1.5 WORKING PROCESS punch The blank is placed in an open circular die with the help of blank holder. The blank holder provides a blank holder necessary force to hold the blank. The punch which is blank attached with a mechanical or hydraulic press moves die downward and provide a necessary drawing force to blank. This force tends to deform metal sheet and forces it into the die cavity and convert it into a cup shape structure. If this force is high, it causes elongation of cup wall to thin and if excessive, it causes tearing of sheet metal. So the punch force should remain a certain limit to avoid tearing during operation of deep drawing. 1.6 BLANK HOLDER PRESSURE If the blank holder pressure is too small, it create wrinkling problem and if it is too high, it causes the cup wall tear. So this pressure remains in a certain limit which allows proper operation of blank holding. Normally it is taken as 0.7 % to 1 % of the sum of the yield strength and the ultimate tensile strength of the sheet. PUNCH 1.7 CLEARANCE BETWEEN PUNCH AND DIE Punch is a forming process that uses a punch press Clearance between punch and die should be taken as to force a tool, called a punch, through the work 7 to 14% greater than sheet thickness. If this is too piece to create a hole via shearing. The punch often small it sheared or pierced the sheet blank. passes through the work into a die cavity. A scrap slug from the hole is deposited into the die in this Corner Radius of Punch and Die process. This part provides necessary downward force Corner radius can cause of wrinkling if it is too large at the blank. It travel downward and forces the blank and can causes fracture if it is too small. So this into the die cavity to form a cup shape. The diameter of the punch can be denoted by Dp radius should take between these two limits. BLANK 1.8 FORMULAS USED The sheet metal cut piece which is used for deep DRAWING FORCE drawing is known as blank sheet. It is placed over an Drawing force Fd ,max= n*π*d*t*UTS Where n= drawing ratio d= diameter of blank t=thickness of blank UTS=ultimate tensile strength . ISBN: 978-93-5268-241-6 78 Department of Mechanical Engineering, NNRG.
Proceedings of RTIME-2K20 4th National Conference on Recent Trends & Innovations in Mechanical Engineering 24th & 25th July, 2020 DEFECTS IN DEEP DRAWING (i) Blank holder force (BHF) and optimization BHF. Bottom fracture (ii) Punch force and punch speed Wrinkling (iii) Friction Orange peeling (iv) Blank shape Stretcher strain (v) Forming Limits Earring (vi) Stress and Strain Distribution for drawing operations (vii) Thickness variation (viii) Wrinkling (ix) Some other defects FIG:4 2.2.1 Blank Holder Force (BHF) and Optimization BHF Fig 5: Defects in deep drawing Higher BHF (Blank holder force) is always desirable 2.1 LITERATURE SURVEY to eliminate wrinkling in deep drawn cup shaped product, but always there have been attempts made to The earlier research work published by various authors on LDR revealed that the punch load is predict a minimum BHF. A lot of research work has proportional to blank size. Influence of geometry been reported to investigate the effect of BHF on variations in micro deep drawing were conducted by product quality, material flow, strain path, stress ACS Reddy et.al and revealed that drawing force distribution, thinning (at wall) and thickening (flange) increases with increase in die shoulder radius. The deep drawing tests show that the limiting drawing of sheet metal, defects in product. Jai singh et. al. [1] ratio increased as temperature rose to 200o C and has suggested that the blank holder force has the huge decreased afterwards . effect on the thinning strain, the coefficient of fiction, 2.2 LITERATURE SURVEY OF VARIOUS plastic strain ratio. Also the strain-hardening PARAMETERS Literature review has been categorized on the basis of exponent depends on BHF. Tommerup et. al. [2] has the parameters which control forming process, the investigated the effect of blank holder pressure on quantities which decide successful execution of the strain path in the sheet during forming process. A process and the quality of the product. The important tooling system has been developed to investigate parameters and factors are: material flow, which is capable of controlling the distribution of blank holder pressure. This tooling system was integral to press and capable to run eight different pressure schemes. The tooling system consisting of a controller to regulate the process parameters, an actuator system to control BHF, in conducting parametric studies on the different parameters which are affecting the process. Volk et. al. [4] has simulated deep drawing process to investigate, optimized blank holder force (BHF) for an asymmetrical work piece from household appliances industry. In this research work the specific blank holder forces have been identified for minimum wrinkling and for the improve quality product. It has been suggested that the quality of a work piece can be improved with a better holding system. It is evident that even small changes in BHF can lead to failure during the process. These failures can be avoided if a variable BHF is applied, but the correct trajectories need to be chosen. ISBN: 978-93-5268-241-6 79 Department of Mechanical Engineering, NNRG.
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