Feb'2021

Welcome to The IUP Journal of Mechanical Engineering

Focus

Nanofluids-known for their thermal conductivity-provide significant enhancement in the heat transfer rate, and find application in nuclear and geothermal power plants for enhancing their efficiencies; and in applications of manufacturing-as cutting fluids for metal cutting and machining operations. In the second paper, "A Comparative CFD Analysis of the Flow and Heat Transfer Process of Engine Oil Containing TiO2 and CuO Nano-Additives Inside Steel Piston Cooling Gallery", the authors, Ankitkumar A Modi, Arvind S Sorathiya and Pravin P Rathod, have presented the results of CFD analysis of oil flow with the addition of different percentages of nanoparticles in the engine oil. The study revealed that after entering the cooling gallery, the oil, which is at low temperature, cools down the top domain of the gallery (top wall, inner wall 1 and inner wall 2) within no time. The CFD analysis revealed that the averaged heat transfer coefficients of titanium-oil nanofluids with volume fractions of 1% to 3%, and copper-oil nanofluids with volume fractions of 1% to 3% are found to adequately reduce the piston temperature. The CFD analysis results are in agreement with the obtained empirical data.

AA 6061, the most versatile aluminum alloy known for its strength and workability, finds application in the aviation, aerospace, marine and automobile industries. It is mostly considered for its high specific strength and weight reduction as well as increasing fuel efficiency, good corrosion resistance and weldability. The modified version of TIG welding process is pulsed, in which pulse current alternates between low level and peak level. In the third paper, "Optimization of Pulsed TIG Welding Process Parameters on Mechanical Properties of AA 6061 Alloy Joints", the author, Pratik T Kikani, has varied the input process parameters-peak current, base current and frequency-and determined the tensile strength and hardness of the butt joint. An aluminum/silicon filler metal (4043) is used in the welding process. The author has noticed that the tensile strength and the hardness of the welded joint increase as the peak current and/or frequency increase, whereas base current has an inverse relationship with the tensile strength.

The theory of zero defect ensures no wastage exists in a project. Waste refers to the cost involving the unproductive processes, tools, employees, etc. The zero defect concepts are helpful in eliminating the cause of errors and make the process well organized for time saving, thereby reducing the rejection rate and improving cost saving. The elimination of waste results in the improvement of the process. In the fourth paper, "Implementation of Zero Defect Concept Through Quality Tools for Process Capability Improvement of Diesel Engine Pin", the authors, Rahul H Gandhi and G D Acharya, have collected the data of consecutive machined components for a period of one month to arrive at critical specifications. The authors have carried out root cause analysis and evaluated the critical characteristics of manufacturing process, and thereby reduced non-conformities to achieve zero defect concepts in the performance of process.

Hydraulic machine vice is used to position a workpiece by keeping a firm grip on it during machining or drilling operations, and to restrain the workpiece from spinning due to the pressure exerted by the machine tool's bit. Workpieces differ in size, shape and material. Different workpieces require different forces and sizes of clamping jaws, depending on the requirement. The hydraulic arrangement allows for automatic tightening of the object with the help of the adjustable jaws. The hydraulic vice allows clamping consistency, which results in improvement of the quality and productivity, when a large number of components are required. To overcome a few drawbacks in the existing machine vices, in the paper, "Design and Development of Hydraulic Machine Vice", the authors, Shweta Desale, Gayatri Fegade, Meghana Kakade, Prajakta Bhosale and Priyanka Chavan, have proposed a new design of hydraulic machine vice. Based on the ANSYS results, the authors have observed that the deformations undergone and the stresses induced due to the loads acting on the vice are within the safe limits, and found that the proposed design is quite robust.

S V Srirama Rao
Consulting Editor

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Article   Price (₹) Buy
Experimental Investigation and Optimization of Wire Drawing Process Parameters
50
A Comparative CFD Analysis of the Flow and Heat Transfer Process of Engine Oil Containing TiO2 and CuO NANO-Additives Inside Steel Piston Cooling Gallery
50
Optimization of Pulsed TIG Welding Process Parameters on Mechanical Properties of AA 6061 Alloy Joints
50
Implementation of Zero Defect Concept Through Quality Tools for Process Capability Improvement of Diesel Engine Pin
50
Design and Development of Hydraulic Machine Vice
50
     
Contents : (Feb' 2021)

Experimental Investigation and Optimization of Wire Drawing Process Parameters
Gangurde S R, Pawar P J and Paraskar C B

Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through die. Steel, copper and aluminum are commonly used wire materials. Wire drawing has many important parameters like die angle, bearing length, coefficient of friction, percentage reduction, lubrication, surface roughness, tensile strength, etc. Die angle is the most affecting parameter on wire drawing. At higher die angle, percentage reduction increases with drawing load and friction and vice versa. Bearing length should be equal or higher than the wire radius to eliminate the elastic recovery effect. Also, type of lubricant affects the surface qualities of wire. In this paper, die angle, bearing length and lubrication are selected as input parameters, and energy consumption, speed of wire drawing and surface roughness of wire are selected as output parameters. The experiments are conducted on copper wire of 18 gauge (1.219 mm), which is reduced to 19 gauge (1.016 mm). The experimentations are performed by considering three levels of three input parameters. Taguchi method is used to optimize the process parameters of wire drawing. The optimal parameters are found as die angle 80 and bearing length 0.3 mm with oil as lubricant.


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Article Price : Rs.50

A Comparative CFD Analysis of the Flow and Heat Transfer Process of Engine Oil Containing TiO2 and CuO NANO-Additives Inside Steel Piston Cooling Gallery
Ankitkumar A Modi, Arvind S Sorathiya and Pravin P Rathod

This paper presents a comparative study on oil fill ratio and heat transfer coefficient within the steel piston cooling gallery for engine oil containing TiO2 and CuO nano-additives, respectively, by using Ansys fluent package. Both nano-additives of 50 nm diameter are added individually in engine oil in proportion of 1%, 2% and 3% for CFD analysis of oil flow and heat transfer process. The evaluation is carried out considering 2100 rpm engine speed. Also, the empirical value of heat transfer coefficient has been calculated.


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Article Price : Rs.50

Optimization of Pulsed TIG Welding Process Parameters on Mechanical Properties of AA 6061 Alloy Joints
Pratik T Kikani

The study pertains to the improvement of mechanical properties of aluminum alloy welds through pulsed Tungsten Inert Gas (TIG) welding process. The study aims at selecting optimum parameters on Pulsed TIG welding aluminum alloy 6061 butt joint. Input process parameters (peak current, base current and frequency) are varied, and tensile strength and hardness are determined. Full factorial method is employed to optimize the pulsed TIG welding process parameters of aluminum alloy welds for increasing the mechanical properties. Optimization of selected parameters is done by response optimizer. After optimization, the results are validated.


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Implementation of Zero Defect Concept Through Quality Tools for Process Capability Improvement of Diesel Engine Pin
Rahul H Gandhi and G D Acharya

We live and work in a hyper competitive world. Competing and winning in today's global marketplace require products and services of high quality developed with short lead times with minimum waste and optimum use of resources. This requires very robust processes; for that, zero defect is a quality concept to survive in this market with continuous improvement in process. The paper presents a study of zero defect concepts through application of quality tools to improve process capability and obtain quality product. It takes advantages of Failure Mode Effective Analysis (FMEA), Statistical Process Control (SPC) and Measuring System Analysis (MSA) to adapt innovative technologies integrated with the operational aspects in order to prevent failure in diesel engine pin. The process validation is carried out through SPC to validate the process. The study concludes with the development of process improvement activities with reduction in non-conformities to achieve zero defect concepts.


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Article Price : Rs.50

Design and Development of Hydraulic Machine Vice
Shweta Desale, Gayatri Fegade, Meghana Kakade, Prajakta Bhosale and Priyanka Chavan

During machining, holding the component firmly is always a crucial task. Workpiece never has the same size, shape and material. It requires different forces and different sizes of clamping jaws. In an ordinary vice, the human power requirement is more to tighten the heavy jobs, but in the machine vice, the hydraulic arrangement is used to tighten the job automatically. In this paper, reduction of human effort and enhancing safety play a vital role while designing and fabricating the machine vice, which is used to hold the components during heavy machining works. In normal machine vice, the human labor involved in operating the handle to grip the component tightly is more. Excess amount of human effort generally results in damage to the workpiece. This may be avoided using hydraulic machine vice, in which the workpiece cannot be damaged while clamping the job, as only adequate amount of pressure is exerted to tighten the job. In this vice, we can also hold components of different shapes with the help of the adjustable jaws that can be provided if needed. A lever slides the movable jaw, using a lead screw for forward and reverse movement of the movable jaw. Hydraulic machine vice can be used for all types of machines.


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Article Price : Rs.50

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