IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)

2nd National Conference on "Recent Developments in Mechanical Engineering" [RDME-2013]

Voulme 5

Paper Type : Research Paper
Title : Design, Testing and Manufacturing of Decoiler Unit of a Semi-Automated Spooling Machine
Country : India
Authors : K. A. Mahajan, J.M. Solomon, S. J. Sukhu, K. V. Deshpande, L. S. Singh

Abstract: In a boiler cleaning equipment manufacturing unit, the need to spool the wire is quite essential. Ever since the development of wire rope, comprising multiple wire strands, spooling has presented technical challenges. In this paper, a small-scale automated wire spooling machine was designed, tested and fabricated. The machine will replace the current manual machine. The designed machine integrates mechanical, electrical and electronic components so as to automate it as much as possible. Space requirement of the semi-automatic spooling machine is considerably less too, hence improving the machine aesthetics. The spooling patterns are achieved by controlling separately the gear ratio of the reciprocator and speed of the decoiler assembly unit.

Keywords - Decoiler unit , Semi-automatic, Slip/Safety clutch, Solenoid operated brake, Spring steel wire.

[1] Dubbel, Handbook for mechanical engineering, 19.Edition, (Germany, Springer-Verlag, 1994).
[2] E. R. Fernandez, Correlations Among Monotonic Tensile Properties and Simple Approximations that Predict Strain- Controlled Fatigue Properties of Steels, V. SAE, 2013.
[3] N. Rothwell, Technical Information on the Principles Of Spooling, 2001. [4] R. S. Khurmi, Strength of materials (New Delhi, S.Chand Limited, 2008).
[5] S. Mutasher, N. Mir-Nasiri, L.C. Lin, "Small-Scale Filament Winding Machine for Producing fiber composite Products", Journal of Engineering Science and Technology, 7(2), 2012, 156 – 168. [6] PSG, Design Data, (PSG College of Technology, 1966).
[7] V.B. Bhandari, Design of Machine Elements,3e (New Delhi, Tata McGraw Hill Education Private Limited, 1994).
[8] Bolt 3 application notes, Advanced Mechanical Technology Inc. (2008).
[9] S. Singh, Machine Design (Delhi, Khanna Publication, 2004).
[10] J. W. Mar, Statics of Deformable Solids (Canada, General Publishing Company, 1965).

Paper Type : Research Paper
Title : Study of Mechanical Properties of Multiwall Carbon Nanotubes (CNT) Based Polyamide6/Hytrel Polymer Nano Composites
Country : India
Authors : M. Sawant, B. F. Jogi, P. K. Brahmankar1, D. Ratna

Abstract: It was planned to develop polymer matrix composite through polyamide 6 (PA6)/Hytrel blends and multiwall carbon nanotubes (MWNT) by melt-mixing technique with improved mechanical properties which can be utilized for several potential applications. The specific objective of this work is to study the effect of MWNT as nano filler in the presence of polymer matrix on the mechanical properties of the polymer based nano composite materials. It is envisaged that a polymer layer adsorbed on the MWNT surface may improve mechanical properties due to good adhesion between the filler and the matrix material. Few characterization techniques are utilized to study the advanced nano material. Crystallization and phase change behavior of PA6/Hytrel blends and MWNT studies through differential scanning calorimetry (DSC). Mechanical properties are studied with the help of dynamic mechanical thermal analysis (DMTA) and tensile testing methods.

Keywords – Multiwall carbon nanotubes (MWNT), Mechanical properties, Crystallizatiog

[1] S. Bose, A.R. Bhattacharyya, L. Häuβler, P. Pötschke, Influence of multiwall carbon nanotubes on the mechanical properties and unusual crystallization behavior in melt-mixed co-continuous blends of polyamide 6 and acrylonitrile-butadienestyrene, Polymer Engineering Science, 49(8), 2008, 3010-3022.
[2] S. Bose, A.R. Bhattacharyya, R.A. Khare, A.R. Kulkarni, T.U. Patro and P Sivaraman, Tuning the dispersion of multiwall CNTs in co-continuous polymer blends: a generic approach, Nanotechnology, 19, 2008, 3304-3312.

[4] P.M. Ajayan and J.M. Tour, Nanotube composites, Nature, 447, 2007, 1066-1068.

[5] M. Moniruzzaman and K.I. Winey, Review Polymer Nanocomposites Containing Carbon Nanotubes, Macromolecules, 39, 2006, 5194-5205.

[6] P. M. Ajayan, Nanotubes from Carbon, Chem. Rev. 99, 1999, 1787-1799. [7] C.A. Harper, Handbook of plastics elastomers and composites (McGraw-Hill 2001), 1-90.

Paper Type : Research Paper
Title : Modeling and Simulation of Manufacturing Performances using WITNESS
Country : India
Authors : N. V. Ruikar, M. T. Telsang

Abstract: Production methodology aims to improve overall productivity through elimination of wastes and that leads to improve quality is "Just-In-Time‟. The Simulation is the imitation of operation of the real word process. Integration Just-In-Time with Simulation is beneficial to identify the obstacles in implementation and to take appropriate options to implement successfully. For this integration, there are different Simulation Softwares. To study this integration, with the help of "WITNESS" Simulation Software the model is created. This model is based on literature review. The input parameters are Setup Time, Machine Alteration and Shift Alteration and output parameter is Throughput. With the help of Taguchi Method, Design of Experiment is made and obtained results are used for Statistical Analysis. For this Statistical Analysis, "MINITAB" Statistical Software is used. This analysis concludes the optimal solution to get maximum Throughput.

Keywords - Just-In-Time, Manufacturing Performances, Simulation, WITNESS.

[1] Prof. M. T. Telsang, Production Management (S. Chand Publications).
[2] Sandanayake Y. G. and Oduoza C. F., Dynamic Simulation of performance optimization in JIT enabled manufacturing processes,
International journal of advanced manufacturing technology, 42, 2009, and 372-380.
[3] Selvaraj N., Simulation modeling and analysis of single line multistage manufacturing system, Journal of Scientific and Industrial
Research, 67, April 2008, 277-281.
[4] O‟Kane J. F., Spenceley J. R. and Taylor R., Simulation as an essential tool for advanced manufacturing problems, Journal of
Material Processing Technology, 107,2000,412-424.
[5] Ekren B. Y. and Ornek A. M., A Simulation based experimental design to analyze factors affecting production flow time", Journal of
Simulation Modeling Practice and theory, 16, 2008, 278-293.
[6] Cheraghi S. H., Adashzadeh M., "Comparative Analysis of production control system through Simulation", Journal of Business and
Economics Research, 6(5), May 2008, 87-104.
[7] Law A. M. and McComas M. G., Simulation of Manufacturing System, Proceedings of 1997 Winter Simulation Conference, 1997, 86- 89.
[8] Pisuchpen R., "Integration of JIT flexible manufacturing system, assembly and disassembly using simulation approach", Emerald
Journal of Assembly Automation, 32(1), 2010, 51-61.

Paper Type : Research Paper
Title : A Review Study on Savonius Wind Rotors for Accessing the Power Performance
Country : India
Authors : A. A. Kadam, S.S. Patil

Abstract: Savonius type Small Vertical Axis Wind Turbines (SVAWT) are self-starting, Omni-directional, requires no yaw mechanism to continuously orient towards the wind direction. Savonius wind turbines are viable in low wind speed regimes and which can be fitted on rooftops and also suitable for the urban areas. This paper deals with the review study of Savonius wind rotors and identifying the various performance parameters to increase its power performance. It has been concluded that, the two blades rotor is more stable in operation than three or more rotor blades, the power coefficient increases with increasing the aspect ratio. The rotor blades with end plates give higher efficiency than those of without end plates.

Keywords - Renewable energy, Savonius wind rotor, Vertical axis wind turbines (VAWT), Wind Energ

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[2] Savonius S J. The S-rotor and its applications. Mech. Eng. 1931; 53: 333–8.

[3] B. F. Blackwell, R. E. Sheldahl, L. V. Feltz, Wind tunnel performance data for two- and three-bucket Savonius rotors, SAND76-0131,Unlimited Release, July 1977.

[4] N.H. Mahmoud , A.A. El-Haroun , E. Wahba , M.H. Nasef. An experimental study on improvement of Savonius rotor performance, Alexandria Engineering Journal , ( 51), 2012,, 19–25.

[5] U.K. Saha, M. Jaya Rajkumar, On the performance analysis of Savonius rotor with twisted blades, Renewable Energy (31), 2006, 1776–1788.

[6] M.A. Kamoji, S.B. Kedare, S.V. Prabhu, Performance tests on helical Savonius rotors, Renewable Energy ,(34), 2009, 521–529.

[7] Kunio Irabu, Jitendro Nath Roy, Characteristics of wind power on Savonius rotor using a guide-box tunnel ,Experimental Thermal and Fluid Science( 32), 2007, 580–586.

[8] R. Gupta, R. Das, R. Gautam, S. S. Deka, CFD Analysis of a Two bucket Savonius Rotor for Various Overlap Conditions, ISESCO JOURNAL of Science and Technology, 8 ( 1 3), 2 0 1 2, 67-7 4

[9] J. V. Akwa, G. A. da Silva Júnior, A. P. Petry Discussion on the verification of the overlap ratio influence on performance coefficients of a Savonius wind rotor using computational fluid dynamics. Renewable Energy, 38, 2012, 141-149

Paper Type : Research Paper
Title : Shrinkage Analysis of Wax Patterns For Aerospace Components in Investment Casting Process
Country : India
Authors : B.Y. Chaudhari, N. Kanoongo, S. Sulakhe, S. D. Pathak

Abstract: Investment casting has been the most widely used process for several centuries for producing components of excellent surface finish, dimensional accuracy and complex shapes. In the present study, work has been done to select a correct wax type with minimum shrinkage for further investment casting process of aerospace components. Wax Patterns were made with different types of waxes namely Pattern Wax, Sprue wax and machine wax. In each case, linear shrinkage was determined. The experimental setup for building the silicone rubber mould is explained, by which different wax are used and aerospace parts are made. The selection of wax is shown by using graphical representation and inspection results of linear shrinkage of no of wax patterns. Accuracy of dimension is the main aim achieved in this paper by shrinkage analysis to get an accurate final product.

Keywords: Shrinkage, Silicone rubber mould, Selection of wax, Pattern wax, Investment casting

1] P. R. Beeley and R. F. Smart, Investment Casting, The Institute of Materials Carlton House Terrace London 1995, 77-135
[2] R. J. Spinosa, Investment castings. The McGraw-Hill Companies, 2004, 1-13.
[3] K. B. Rundman, Metal casting, Dept. of Materials Science and Engineering, Michigan Tech. University, 30-40.
[4] S. Sabau and S. Viswanathan. Prediction of Wax Pattern Dimensions in Investment Casting. Metals and Ceramics Division, 2002.
[5] C.Yanfei, X. Shulong, T. Jing, X. Lijuan, K. Fantao and C. Yuyong. Improvement in collapsibility of ZrO2 ceramic mould for investment casting of TiAl alloys. Harbin Institute of Technology, Harbin February 2011.
[6] O. Bemblage and D. Benny Karunakar, A Study on the Blended Wax Patterns in Investment Casting Process. World Congress on Engineering London, 1, U.K., 6-8, 201.1

Paper Type : Research Paper
Title : Effect of Tool Design and Process Variables on Mechanical Properties and Microstructure of AA6101-T6 Alloy Welded by Friction Stir Welding
Country : India
Authors : L.V. Kamble, S.N. Soman, P.K. Brahmankar

Abstract: Friction stir welding (FSW) has a potential for wide-spread applications. However, it is necessary to overcome some challenges for its wide-spread usage. Tool design and selection of process variables are critical issues in the usage of this process. This paper tackles the same issues for AA6101-T6 alloy (material used for bus bar conductor, requiring minimum loss of electrical conductivity and good mechanical properties). Two different tool pin geometries (square and hexagonal) and three different process variables, i.e. rotational speeds and welding speeds were selected for the experimental investigation. The welded samples were tested for mechanical properties as well as microstructure. It was observed that square pin profile gave better weld quality than the other profile. Besides, the electrical conductivity of the material was maintained up to 95% of the base metal after welding.

Keyword: FSW, Microstructure analysis, Mechanical properties, Electrical conductivity

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[2] C. J. Dawes and W. M. Thomas, Friction stir process welds of aluminium alloys, Welding Journal 75, 1996, 41-44.

[3] R. Nandan, T. DebRoy and H. K. D. H. Bhadesia, Recent advances in friction stir welding process, weldment structure and properties, Progress in Material Science, 53, 2008, 980-1023.

[4] R. Rai, A. De, H. K. D. H. Bhadesia and T. DebRoy, Review: friction stir welding tools, Science and Technology of Welding and Joining, 16(4) 2011, 335-341.

[5] H. Uzun, C. D. Donne, A. Argagnotto, T. Ghidini and C. Gambaro, Friction stir welding of dissimilar Al6013-T4 to X5CrNi18-10 stainless steel, Materials and Design, 26, 2005, 41-16.

[6] C. Hamilton, S. Dymek, and M. Blicharski, Mechanical properties of al 6101-T6 welds by friction stir welding and metal inert gas welding, Archives of Metallurgy and Materials, 52, 2007, 67-72.

[7] K. Elangovon, V. Balasubramanian and S. Babu, Prediction tensile strength of friction stir welded 6061 aluminium alloy joints by mathematical model, Materials and design, 30, 2009, 188-193.

[8] K. Elangovon and V. Balasubramanian, Influence of pin profile and rotational speed of the tool on the formation of friction stir processing zone in AA2219 aluminium alloy, Materials Science and Engineering A 459, 2007, 7-18.

[9] M. W. Mahoney and R. S. Mishra, Friction Stir Welding and Processing, ASM International, Ohio,USA, 1 2007.

[10] Annual Book of ASTM standards, section 3,vol 3.01 metals –mechanical testing, elevated and low temperature tests, ASTM E8, 1983.

Paper Type : Research Paper
Title : Review Article: Evolution of a Stair-Climbing Power Wheelchair
Country : India
Authors : G. S. Modak, M. M. Bhoomkar

Abstract: The goal of this article is to review the state of the art in the technology for Stair-Climbing Power Wheelchair for people with disabilities, with a particular focus on the technology that is loosely referred to as assistive devices. In the process, we review research that has been done by different groups on Stair-Climbing Power Wheelchair for manipulation and locomotion. We will be less interested in examples of devices that simply perform the mechanical function of a person's limb further therapeutic applications are beyond the scope of this article. Main goal is to provide the reader with an understanding of how the technology and science can be used to develop assistive devices for people with manipulative and locomotive disabilities. Also the analytical work carried out so far in this context is reviewed and discussed.

Keywords: Staircase Climbing Wheelchair, Impaired Mobility, Low Cost Design.

[1] G. Verburg, H. Kwee, A. Wisaksana, A. Cheetham and J. van Woerden, Manus: The evolution of an assistive technology. Technology and Disability, 5(2): 217-228, 1996.
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[5] People Weekly, Tom Houston is a real stand-up guy, thanks to the versatile vertical wheelchair he devised. 32: 91-2, August 28, 1989.
[6] IMEX Riser Wheelchair. Product Literature, Imex Medical Inc., San Jose, CA.
[7] Standup Wheelchairs. Product Literature, Levo Inc. Switzerland.
[8] H. F. M. Van der Loos, S. J. Michalowski and L. J. Leifer, Development of an omni-directional mobile vocational assistant robot, In Proceedings of the 3rd International Conference of the Association of Advanced Rehabilitation Technology, Montreal, P. Q., Canada, June 1988.
[9] R. Walli, DOE technology to develop TRANSROVR --Omnidirectional wheelchair, DOE News Brief, October 10, 1996.
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Paper Type : Research Paper
Title : Depassivation Method of Hard Passive Alloys by Electrochemical Machining
Country : India
Authors : W. G. Kharche, D. S. Bilgi, S. H. Surekar, S. G. Bhatwadekar

Abstract: Recently numbers of materials are discovered for industrial applications. Those materials are having very high hardness and difficult to machining. Such materials are widely used in aerospace, automobile as well as in electronic industries. For mechanical machining purpose the first requirement for the cutting tool is its hardness must be higher than the workpiece. Therefore for machining of such materials non contacting non mechanical machining method or processes are used. In all non contacting methods electrochemical machining process is one of the best alternatives for machining hard passive alloys as well as composite materials. For electrochemical machining process the important requirement for the workpiece material is, 'it must be electrically conductive. Hard passive alloys such as Nickel base Superalloys and composite materials which are electrically conductive are machined by electrochemical machining process irrespective of their hardness. In this paper difficulty in machining hard passive alloys regarding the passivation effect and the economical method of depassivation is studied.

Keywords: Depassivation, Electrochemical machining process, hard passive alloys, passivation, pulse ECM

[1] American Society for Metals, MACHINING-HANDBOOK, Page No.149-155 VOL- 3,9th Edition.
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