i-manager's Journal on Mechanical Engineering (JME)


Volume 8 Issue 3 May - July 2018

Article

Comparative Study on Brake Testing Standards of Trucks and Buses

Yadhu S. Aswan* , Ankit Pandey**, P. V. Srihari***
* Deputy Manager, Volvo Eicher Commercial Vehicles, Indore, Madhya Pradesh, India.
** Deputy Manager, VE Commercial Vehicles Ltd, Indore, Madhya Pradesh, India.
*** Associate Professor, Product Design and Manufacturing, RV College of Engineering, Bengaluru, Karnataka, India.
Aswan, Y. S., Pandey, A., and Srihari, P. V. (2018). Comparative Study on Brake Testing Standards of Trucks and Buses. i-manager’s Journal on Mechanical Engineering, 8(3), 1-8. https://doi.org/10.26634/jme.8.3.14052

Abstract

One of the most relevant parameters for vehicle authentication is the brake performance of the vehicle. Countries follow their own automotive standards for various components manufactured. Criteria put forth by these standards may vary accordingly. The key brake performance parameters considered are its stopping distance, deceleration, and stopping time. This article delivers a comparative study on three brake testing standards: Indian Standard, European Economic Commission, and Federal Motor Vehicle Safety Standards. The article provides an outline to brake testing procedure of service, secondary and parking brakes of automobiles with four or more wheels without trailer. Parameters like Mean Fully Developed Deceleration (MFDD) and Stopping Distance are discussed in detail. Tests prescribed by the three standards like P type test, F type test, H type test, and Burnishing test are detailed. Parameters have been compared according to the specifications as per the standards. This article shall be of assistance to policymakers and industrial experts to select the best criteria out of these three standards while framing revised editions of testing standards.

Research Paper

Surface Finish Achieved in Producing Pneumatic Piston Rod: An Experimental Investigation

Karuppasamy Ramasamy* , Milon Selvam Dennison**, E. Baburaj***
*-** Research Scholar, Department of Mechanical Engineering, Karpagam Academy of Higher Education, Coimbatore, Tamil Nadu, India.
*** Professor, Department of Mechanical Engineering, Karpagam College of Engineering, Coimbatore, Tamil Nadu, India.
Ramasamy, K., Dennison, M. D., and Baburaj, E. (2018). Surface Finish Achieved in Producing Pneumatic Piston Rod: An Experimental Investigation. i-manager’s Journal on Mechanical Engineering, 8(3), 9-16. https://doi.org/10.26634/jme.8.3.14733

Abstract

The objective of this research work is to find the optimal set of process parameters to produce better quality products for pneumatic piston rod application through turning operation. The control factors considered for the study are spindle speed (N), feed rate (f), depth of cut (d) and tool nose radius (r), and the experiments are planned based on Taguchi's L9(34) orthogonal array. The experiments were conducted in a CNC (Computer Numerical Control) turning centre using CNMG TiN coated carbide cutting tool insert of three different nose radius, such as 0.4 mm, 0.8 mm, and 1.2 mm, on AISI 1040 medium carbon steel. The optimal combination of control factors and the corresponding levels were determined for the minimum surface roughness based on signal to noise ratio using MINITAB statistical software and simultaneously, a mathematical model was developed for the surface roughness through regression analysis. The confirmation result revealed the effectiveness of Taguchi's technique by providing better quality product.

Research Paper

Design and Experimental Investigation of a Natural Draft Improved Biomass Cookstove

Vikas Kumar* , Kangkan Jyoti Baishya**, Pankaj Kalita***
* B. Tech Graduate, Department of Mechanical Engineering, National Institute of Technology, Arunachal Pradesh, India.
** B. Tech Graduate, Department of Mechanical Engineering, National Institute of Technology, Silchar, India.
*** Assistant Professor, Centre for Energy, Indian Institute of Technology Guwahati, Assam, India.
Kumar, V., Baishya, K. J., and Kalita, P. (2018). Design and Experimental Investigation of a Natural Draft Improved Biomass Cookstove. i-manager’s Journal on Mechanical Engineering, 8(3), 17-30. https://doi.org/10.26634/jme.8.3.14734

Abstract

Cookstove is one of the oldest technologies in the world and is known since 100,000 BC for preparing food. Due to incomplete and poor combustion in traditional cookstoves, it not only consumes a large amount of fuel, but also emits harmful gases which cause severe health problems. Designing a biomass cookstove is dependent mostly on empirical information and hit and trial method of experimentation, influenced by various thermodynamic and heat transfer calculations, which is costly. The proposition is to design a simple yet efficient natural draft biomass cookstove, which is cheap and affordable for all groups of people and should also accommodate their existing cooking practices along with very little or no emission of harmful gases. The performance parameters will be calculated using simulation, and then if found appropriate, fabrication will be done. In this approach, firstly standard Water Boiling Test on two biomass cookstoves available to the team was conducted and various performance parameters of the same were calculated. After experimentation, various important factors required for designing a biomass cookstove were defined and a natural draft biomass cookstove was designed, and detailed Computational Fluid Dynamics (CFD) simulation of the temperature, flame velocity and pressure distribution in the configuration was done using ANSYS Fluent. After the simulation, it was found that the range in which temperature, flame velocity and pressure distribution of the biomass cookstove designed in this research is in good agreement with the results mentioned in literature for free or natural convection. On the basis of results obtained, it was concluded that the design of natural draft improved biomass cookstove is reliable and fabrication of the same will be feasible and will meet the objective set by the team. Here, an idea of the capability of CFD in the field of modelling and analyzing various properties of biomass combustion was known, and it was deduced that ample amount of time and expenses related to experimental investigations can be reduced if CFD is implemented at the proper early stage.

Research Paper

Optimization of Process Parameters on Die-Sinking EDM with Twin Tool Setup Using Taguchi Method

B. Vinod Kumar* , D. J. Jyothsna Devi**, M. Chandra Sekhara Reddy***
* PG Student, Department of Mechanical Engineering, Sri Venkateswara College of Engineering, Tirupati, Andra Pradesh, India.
** Associate Professor, Department of Mechanical Engineering, Sri Venkateswara College of Engineering, Tirupati, Andra Pradesh, India.
*** Professor and Head, Department of Mechanical Engineering, Sri Venkateswara College of Engineering, Tirupati, Andra Pradesh, India.
Kumar, B.V., Devi, D. J. J., and Reddy, M. C. S. (2018). Optimization of Process Parameters on Die-Sinking EDM with Twin Tool Setup Using Taguchi Method. i-manager’s Journal on Mechanical Engineering, 8(3), 31-38. https://doi.org/10.26634/jme.8.3.14736

Abstract

The present research work concentrated on optimization of process parameters to explore the effects of electrode material, Voltage and Duty Cycle in Die-Sinking Electrical Discharge Machine (DSEDM) with Twin Tool Setup. In this experiment, Material Removal Rate (MRR) and Tool Wear Rate (TWR) in machining of Through holes on Copper workpiece, using a couple of copper and steel electrodes with straight polarity have been calculated. In view of the experiments and using Taguchi's design of experiments, response tables and graphs have been made. For high MRR and low TWR, the most significant factor is Voltage. Based on the optimization results from Signal-to-Noise ratios (S/N ratios), it is observed that high MRR is obtained for Copper (Cu) electrode, 55 V and 70% duty cycle, and low TWR for Stainless Steel (SS) electrode, 55 V and 70% duty cycle. Additionally, a comparison is made amongst copper and steel electrodes based on Machining time, MRR and TWR; it is observed that copper electrode is the best material for machining of Through holes on copper workpiece.

Research Paper

Enhancement of Impact Strength of a Car Bumper Using Natural Fiber Composite Made of Jute

P. Ragupathi* , N. M. Sivaram**, Venkatesan***, Kanthimathi****
*,***Assistant Professor, Department of Mechanical Engineering, Karpagam Academy of Higher Education, Coimbatore, Tamil Nadu, India.
** Associate Professor, Department of Mechanical Engineering, Karpagam Academy of Higher Education, Coimbatore, Tamil Nadu, India.
**** Research Scholar,Department of Mechanical Engineering, Karpagam Academy of Higher Education, Coimbatore, Tamil Nadu, India.
Ragupathi, P., Sivaram, N. M., Vignesh, G., and Selvam, M. D. (2018). Enhancement of Impact Strength of a Car Bumper Using Natural Fiber Composite Made of Jute. i-manager’s Journal on Mechanical Engineering, 8(3), 39-45. https://doi.org/10.26634/jme.8.3.14737

Abstract

The primary requirements of the present day automobiles are improved fuel efficiency and reduced emission levels. One way to achieve these two requirements is to decrease the weight of the components in the automobile without compromising on the strength of the components. The reduction in the weight of the components without compromising the strength of the automobile is achieved by using fiber-based composite materials in the automobile. The work reported in this paper compares the impact strength, cost and weight of jute-based composite bumper with that of the existing steel bumper. In this paper, the outline and development of a composite bumper made of jute fiber fortified polymer are explained. Hand lay-up process was utilized to develop the composite bumper and the same is carried out by using jute and epoxy bidirectional laminates. The jute composite bumper was developed by applying a series of jute fiber layers and liquid resin layers. Later, Charpy impact test was carried out to find the impact strength of composite bumper which was observed to be 7.14 J/mm2. When compared with the steel bumper, the composite bumper is 58% less in cost and a weight reduction of 56.1% is achieved.

Research Paper

A Study on Influence of Inlet Pressure and Fiber Architecture on The Quality of Sample Made From VARTM

L. Ramesh* , A. M. K. Prasad**, G. Chandra Mohan Reddy***, D. V. Ravi Shankar****, M. A. Mateen*****
*Research Scholar, Department of Mechanical Engineering at Osmania University, Hyderabad, Telangana, India.
** Retired Professor, Department of Mechanical Engineering, Osmania University, Hyderabad, Telangana, India.
*** Principal and Professor, Department of Mechanical Engineering, Mahatma Gandhi Institute of Technology, Hyderabad, Telangana, India.
**** Professor and Principal, TKR College of Engineering & Technology, Hyderabad, Telangana, India.
*****Associate Professor, Department of Mechanical Engineering, Nizam Institute of Engineering and Technology, Hyderabad, Telangana, India.
Ramesh, L., Prasad, A. M. K., Reddy, G. C. M., Shankar, D. V. R., and Mateen, M. A. (2018). A Study on Influence of Inlet Pressure and Fiber Architecture on the Quality of Sample Made From VARTM. i-manager’s Journal on Mechanical Engineering, 8(3), 46-52. https://doi.org/10.26634/jme.8.3.14182

Abstract

Fiber reinforced polymers are used extensively in various engineering applications due to their advantages such as producing any component with any form and shape. Resin infusion process is the most effective technique being employed in processing of components with intricate geometric details. However, the mechanical behavior is affected by various parameters in such production process. The present study aims at understanding the effect of parameters such as fiber architectures, number of layers, and inlet vacuum in the mould on the mechanical properties of the e-glass/polyester composites. Two different fiber architectures (i) chopped strand and (ii) Unidirectional (UD) mat are selected where the number of layers are varied as 4 layers, 5 layers, and 6 layers. Three different vacuum pressures (i) 200 mm of Hg, (ii) 300 mm of Hg, and (iii) 400 mm of Hg are selected in the present study for preparation of samples. The results indicate that there is a considerable effect of the above said parameters on the mechanical behavior of the material.

Research Paper

Optimization of Process Parameters by ANN and Taguchi Analysis on M2 Tool Steel With Versatile Electrodes during EDM

Dinesh Kumar* , Naveen Beri**
* Dean Academics (Associate Professor), Tawi Engineering College, Pathankot- IKGujral Punjab Technical University, Punjab, India.
** Associate Professor, Department of Mechanical Engineering, Beant College of Engineering Technology, Gurdaspur, Punjab, India.
Kumar,D., and Beri, N. (2018). Optimization of Process Parameters by ANN and Taguchi Analysis on M2 Tool Steel With Versatile Electrodes during EDM. i-manager’s Journal on Mechanical Engineering, 8(3), 53-58. https://doi.org/10.26634/jme.8.3.14738

Abstract

Artificial Neural Network (ANN) analysis is used for the prediction of Material Removal Rate (MRR), Tool Wear Rate (TWR) and Surface Roughness (SR) in Electrical Discharge Machining(EDM) process of M2 tool steel, followed by a Matlab program.Taguchi's L36 mixed orthogonal array was used to optimize the input parameters, such as polarity, electrode type, and concentration of abrasive powder, discharge current, voltage and duty cycle. Taguchi technique individually is not effective for multiple performance characteristics, so ANN is applied for this experimental study for converting process parameters into single performance characteristics which allows for a potential economical experimentation. The outcome analysis shows that the suggested ANN models can predict the acceptable optimum machining parameters for Electrical Discharge Machining, and has been verified experimentally as well as graphically by adopting Back-Propagation Neural Networks (BPNN) model.

Research Paper

Designing of Various Parts of CNC Setup

Pretesh John* , Rahul Davis**
* M. Tech. (Production & Industrial Engineering) Research Scholar, Department of Mechanical Engineering, SIET-SHUATS, Allahabad, Uttar Pradesh, India.
** Assistant Professor, Department of Mechanical Engineering, SIET-SHUATS, Allahabad, Uttar Pradesh, India.
John, P., and Davis,R. (2018). Designing of Various Parts of CNC Setup. i-manager’s Journal on Mechanical Engineering, 8(3), 59-67. https://doi.org/10.26634/jme.8.3.13996

Abstract

Control of Dimensional accuracy with good surface finish is the most important requirement of the manufactured parts because it is a kind of measuring parameter to determine the reliability. The accuracy can be attained by the automation of the tool by removing the human error possibilities, and here comes the role of CNC (Computer Numeric Control) system. Use of CNC Machining in the manufacturing sector involves control of machine tools with the help of computers. The tools that can be controlled in this manner include lathes, mills, routers and grinders, etc. In this article, the designing of the various parts of CNC setup is shown by SolidWorks 2017 Student Addition with simple static simulation. The simulation results show the limits of stress, strain, and displacement in the designed setup.