Abstract

The aim of this study is fabrication of new design and stress analysis of Ankle-foot orthoses (AFO) on gait parameters of foot drop patients. In the initial phase, patients by age 3-5 years, who are suffering from cerebral palsy and foot drop disease are selected. An AFO is orthosis that is specifically designed to modify the functioning of the ankle and/or the foot. AFOs are produced in various forms composed of different materials, and prescribed with a wide variety of aims. In market, AFOs in polypropylene & polyethylene materials are available which are used by children. The present AFO design is used by patients who are facing excessive heating and sweating problem. After discussing with Patients and Orthotist (who prescribed AFO to patients), the authors have tried to overcome the problem with the new design of AFOs & done the Finite Element Modelling and stress analysis. The result shows that this new design is very close to the actual product.

Abstract

The customers' most specified requirements are surface roughness which is the indicator of surface quality and get the product at minimum cost. In manufactures point of view, maximization of metal removal rate is high priority in order to reduce the manufacturing cost. Hence, it is important to explore the influence of cutting parameters on surface roughness (Ra) and Metal Removal Rate (MRR). In the present paper, AISI 1042 is considered as workpiece material as it has wide applications in manufacturing of Dies, gears, shafts, machine tool parts, etc. Selected tools are PVD (PR1125) and CVD (CR5515), consisting of the coating surfaces of TiA1N and TiCN+Al O +TiN, respectively. The experimentation 2 3 for this work was based on Taguchi's design of experiments (DOE) and orthogonal array. In this work, three cutting parameters, namely, cutting speed, depth of cut, and feed rate were considered as process parameters and responses are Material removal rate and Surface roughness. Experiments were conducted by using Taguchi Design of experiments of L9 orthogonal array for both CVD and PVD tools. The main objective of this paper is to determine the optimum cutting parameters and the tool used in turning AISI 1042 material with multiple output responses using ANOVA and Grey Relational analysis.

Abstract

Cutting fluids are widely used in machining process, to remove heat from the cutting zone. Minimization on usage of cutting fluid is more focused by present day industrialists and researchers for the economical and ecological reasons also. To address the above concern, Minimum Quantity Lubrication (MQL) is one of the techniques, which uses less cutting fluid to maximize the product quality and tool life. The present work reports the experimentations carried out under Minimum Quantity Lubrication and dry conditions in turning of AL 6351-T6 alloy. The samples were turned out at five different spindle speeds (77, 184, 252, 673 and 922 rpm), and the effect of spindle speed on tool temperature and surface roughness are investigated here. It was found that increase in spindle speed in turning of AL6351-T6 alloy by using MQL reduced the surface roughness compared to dry condition.

Abstract

A Camshaft is a shaft on which a cam is fastened or a cam forms as an integral part. It is an important component of an internal combustion engine which plays a major role in operating the valves. 3D printing is a process of making three dimensional solid objects from a digital file. An object is created by laying down successive layers of material until the entire object is created. Hence it is called as 3D printing or additive manufacturing.

The main objective of this work is to produce prototype of two wheeler camshaft and helical camshaft which are designed in Creo Parametric 2.0, analyzed using ANSYS workbench 2016 and 3D printed using Makerbot Replicator Z18. Poly Lactic Acid (PLA) is the material used in 3D printer to produce the camshaft.

3D printing allows innovative ideas into successful end products rapidly and efficiently. 3D printing is still on a developing stage where more research and investigations are being in process. This work concludes that camshaft with helical cam lobe is more favorable as compared to spherical lobe.

Abstract

Micromachining technologies are now being employed in various industries for generation of precise features on engineering components. Among these processes, micro electrical discharge machining is a 'non-contact' machining technology suitable for material removal from electrically conductive materials characterized by considerable wear of the tool used for material removal. This paper presents an investigation involving modeling and estimation of the effect of settings for generation of discharges in stable conditions of micro-EDM on the phenomenon of tool electrode wear. A stable sparking condition during the process is achieved with varying voltage (V), capacitance (C), threshold (T), and discharge frequency (f). The tool electrode wear model has revealed that the energy of the sparks interacting with the tool surfaces control the phenomenon through the settings of capacitance followed by the voltage. The variables controlling the current settings for generation of stable discharges are not found to interact with each other to generate a variation on the tool wear. An increase in feedrate from 2 to 6 μm/s causes a decrease in TWR by 17%. The analysis and modeling approach helps achieve a condition for the minimum tool wear for this micro-EDM process configuration.