Nov'2020

Welcome to The IUP Journal of Mechanical Engineering

Focus

In order to control the lack of fusion, a thorough understanding of the mechanism of development and the influence of welding parameters on the generation of lack of fusion is required. Sumit D Bhatt, Sagarkumar I Shah and G D Acharya, in their paper, "Optimization of Process Parameters Influencing Lack of Fusion Defect in TIG Welding of SS 304 Thin Sheet", have carried out Design of Experiment (DOE) investigation, Radiographic Non-Destructive Testing (NDT) and Tensile Test to predict and reduce lack of fusion with TIG welding process parameters. The authors have proposed 27 different combinations of parameters and investigated the effect of three of process parameters-current, gas flow rate and travel speed-on the tensile stress of the welded joint. They have suggested the optimum value of current, travel speed or welding speed and gas flow rate are 50 A, 6 mm/s and 5 L/min, respectively, for obtaining optimum tensile stress value (672.60 MPa).

In an automobile vehicle, drive shaft or propeller shaft is one of the most important components for transmitting the rotary motion from the front end to the rear end of the vehicle to move the vehicle in forward or backward direction. The shaft should be strong enough to withstand high torsional loads due to constantly changing angles between the transmission and axle. Generally, high quality steel of grade SM45C (an unalloyed carbon mechanical structural steel) is used for manufacturing the drive shafts. To improve the transmission system efficiency, optimum design of drive shaft together with each and every component is needed. R M Shinde and S M Sawant, in the paper, "Optimization of Automotive Drive Shaft for Better Fuel Economy and High Torsional Strength", have carried out analytical studies to determine the torsional strength, maximum shear stress, maximum shear strain and angle of twist of the shaft, and compared with experimental and FEA results. The optimized size generated from shear stress optimization is best suited for propeller shaft with benefits of 7.8% reduction in weight compared to conventional propeller shaft, 7.8% reduction in material cost per propeller shaft and 0.02% increase in mileage. Composites materials, a class of advanced materials made from two or more constituent materials with significantly different physical or chemical properties, is are being extensively used for weight-critical applications in the automotive, aerospace and healthcare sectors. Aluminum (Al)-based Metal Matrix Composites (MMCs) have been extensively studied as an attractive option due to their lightweight, high strength, stiffness and resistance to high temperature. In the paper, "Experimental Investigation and Evaluation of Mechanical Properties of Hybrid Metal Matrix Composites Using Stir Casting Method", the authors, Y Seetharama Rao and Ch Kameswari Chitti, have evaluated the characteristics of aluminum MMC-by varying the weight percentages of aluminum and graphite, and keeping SiC constant as 10%. They have observed significant improvement in the tensile strength, percentage elongation and Brinell's hardness number.

The need for the design and fabrications of flexible prototypes and low-volume component production have resulted in the evolution of Electric Discharge Machining (EDM)-a thermo electric process. In the EDM process, thermal energy is used to erode the unwanted material, thereby producing a critical shape of the desired material. In the paper, "Surface Integrity of EN8 Steel Machined on Electrical Discharge Machine Using Fuzzy Approach: An Investigation", the authors, Chandan Waghmare, M S Sohani and Shailesh Shirguppikar, have studied the influence of parameters used for machining, i.e., discharge current, pulse-on-time and voltage. Fuzzy logic technique has been implemented to convert the multiple responses from the output into a single parameter, i.e., Multi Performance Characteristics Index (MPCI). The study estimated that the different process variables such as White Layer Thickness (WLT), Surface Crack Density (SCD) and Surface Roughness (SR) can be greatly improved using fuzzy logic technique.

Computational Fluid Dynamics (CFD) simulation can be best evaluated using new ANSYS fluent experience. Many researchers have carried out CFD simulation analysis using different versions of ANSYS fluent to understand and optimize the flow characteristics of fluid. In the paper, "Unsteady Analysis of Vortex Generation Phenomenon in Flush Tank Using Ansys", the authors, Sonu Chouhan and Ankur Geete, have presented the design details of flush tank, which utilizes minimum amount of water used without sacrificing the performance. The volume of fluid model has been used to analyze the dynamics of the motion of bubbles and movement over different surfaces by the authors in the process of providing an accurate approach to developing a new water-saving flush tank.

S V Srirama Rao
Consulting Editor

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Article   Price (₹) Buy
Optimization of Process Parameters Influencing Lack of Fusion Defect in TIG Welding of SS 304 Thin Sheet
50
Optimization of Automotive Drive Shaft for Better Fuel Economy and High Torsional Strength
50
Experimental Investigation and Evaluation of Mechanical Properties of Hybrid Metal Matrix Composites Using Stir Casting Method
50
Surface Integrity of EN8 Steel Machined on Electrical Discharge Machine Using Fuzzy Approach: An Investigation
50
Unsteady Analysis of Vortex Generation Phenomenon in Flush Tank Using Ansys
50
     
Contents : (Nov' 2020)

Optimization of Process Parameters Influencing Lack of Fusion Defect in TIG Welding of SS 304 Thin Sheet
Sumit D Bhatt, Sagarkumar I Shah and G D Acharya

Tungsten Inert Gas (TIG) welding or Gas Tungsten Arc Welding (GTAW) process is widely used in many appliances due to its versatility in industry. For GTAW process, metal like stainless steel is widely used in all positions. Butt joint, lap joint, T-joint, edge joint and corner joint are the common types of joints used in welding. The incompletely fused spot ike porosity that occurs after welding is known as lack of fusion that leads to undesirable results, and to overcome this, changes in welding techniques and parameters within the limits are required. Nowadays, a large number of resources are used for reworking the welds. But it causes higher cost of production and delay in completing the work. Higher amount of rejection of product may occur if lack of fusion is not controlled physically during welding. The paper aims at predicting and reducing lack of fusion with TIG welding process parameters. Using design of experiment method, straight and indirect effects of the process parameters can be determined and process parameters can be optimized.


© 2020 IUP. All Rights Reserved.

Article Price : Rs.50

Optimization of Automotive Drive Shaft for Better Fuel Economy and High Torsional Strength
R M Shinde and S M Sawant

Drive shaft is the most important component in transmission system which needs to be designed for high torsional strength. While designing the drive shaft for high shear strength, weight of the shaft is increased which reduces the efficiency of transmission system. Transmission system efficiency plays a crucial role in fuel economy and performance of vehicle. So for improving the transmission system efficiency, optimum design of each and every component becomes a need. Optimum design of drive shaft for less weight with strength constraint has greater impact on vehicle performance. In this paper, the drive shaft of light motor vehicle is selected for optimization. Based on the maximum torque needed to propel the vehicle, the torsional strength required at propeller shaft is calculated. The existing propeller shaft is investigated analytically for its torsional strength, maximum shear stress, maximum shear strain and angle of twist. These analytical results are compared with experimental and Finite Element Analysis (FEA) results. For FEA, the model required is developed in CATIA V5 R20. This 3D model is analyzed using Altair Hyper works. The shear strength obtained is used as constraint and thickness of the shaft is optimized in Altair Hyper works using optistruct solver. The optimization of propeller shaft has been carried out for reducing its weight and cost. Comparative reduction in material cost per car and improvement in fuel economy per kilometer are investigated.


© 2020 IUP. All Rights Reserved.

Article Price : Rs.50

Experimental Investigation and Evaluation of Mechanical Properties of Hybrid Metal Matrix Composites Using Stir Casting Method
Y Seetharama Rao and Ch Kameswari Chitti

The paper prepares Al-SiC and graphite in particulate Metal Matrix Composites (MMCs) using stir casting technique. The additional level of graphite varied from 3-6 wt% in steps of 1 wt% and the percentage of SiC is constant. For each composite, reinforcement particles were preheated and dispersed in steps for the molten aluminum alloy to improve weldability and distribution. The microstructure of the hybrid composites was investigated and experimental results showed a nearly uniform distribution of aluminum particles and good dispersion of SiC, and it is within the aluminum metal matrix, although some small clusters were found in the matrix. The mechanical properties like tensile strength and Brinell hardness number were improved significantly compared to that of pure alloy.


© 2020 IUP. All Rights Reserved.

Article Price : Rs.50

Surface Integrity of EN8 Steel Machined on Electrical Discharge Machine Using Fuzzy Approach: An Investigation
Chandan Waghmare, M S Sohani and Shailesh Shirguppikar

Electrical Discharge Machine (EDM) is one of the non-traditional machining processes used to produce a critical shape on hard or brittle conductive material and it can also be successfully applied on material that is extremely difficult for traditional machining processes. The experimental investigation of EDM processes and parameters is of utmost importance in order to improve the surface integrity and quality characteristics. The paper investigates the influence of different process variables on various aspects of surface integrity such as Surface Roughness (SR), Surface Crack Density (SCD) and White Layer Thickness (WLT). The effect of input parameters such as discharge current, discharge voltage and pulse-on-time on SCD, WLT and SR is studied.


© 2020 IUP. All Rights Reserved.

Article Price : Rs.50

Unsteady Analysis of Vortex Generation Phenomenon in Flush Tank Using Ansys
Sonu Chouhan and Ankur Geete

The study changes the design of water tank and proposes minimizing the amount of water used without sacrificing the performance. By modification of the design of water tank, the amount of water used inside the tank can be decreased. The realizable k-e double equation model and Volume of Fluid (VOF) method for multiphase flow with free surface are suitable for simulating and analyzing the flushing flow of tank based on 3D unsteady 1st order implicit equation. The performance of flush can be evaluated with the three-dimensional flushing flow simulating method through the distribution of the two-phase flow field, total flow pressure, flow speed at the surface and siphoning bent tube. It is observed that while considering one-way coupling analysis, vortex generation is more near the lower surface of tank and at the pipeline outlet. While considering two-way coupling analysis, even if the air volume fraction is maximum at U-Tube inlet, air and water are almost in equal amount after 0.5 s.


© 2020 IUP. All Rights Reserved.

Article Price : Rs.50

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