Tribological Performance Optimization of Electroless Nickel Coatings Under Lubricated Condition

The present chapter aims to determine optimal tribo-testing condition for minimum coefficient of friction and wear depth of electroless Ni-P, Ni-P-W and Ni-P-Cu coatings under lubrication using grey relational analysis. Electroless Ni-P, Ni-P-W and Ni-P-Cu coatings are deposited on AISI 1040 steel substrates. They are heat treated at suitable temperatures to improve their hardness. Coating characterization is done using scanning electron microscope, energy dispersive X-Ray analysis and X-Ray diffraction techniques. Typical nodulated surface morphology is observed in the scanning electron micrographs of all the three coatings. Phase transformation on heat treating the deposits is captured through the use of X-Ray diffraction technique. Vicker's microhardness of the coatings in their as-deposited and heat treated condition is determined. Ni-P-W coatings are seen to exhibit the highest microhardness. Friction and wear tests under lubricated condition are carried out following Taguchi's experimental design principle. Finally, the predominating wear mechanism of the coatings is discussed.

Lower Body Orthotic Calipers With Composite Braces

Composite based materials are finding application in a large number of research and engineering spectrum due to its better mechanical properties (strength and stiffness), inherent surface finish, easiness in fabrication and installation and corrosion resistant. They are very strong and firm, yet very light in weight due to which lower weight-to-volume ratio can be achieved and stiffness to weight is 1.5 times greater than the non-ferrous materials like Aluminum. The work is undertaken in two parts. First and foremost being modeling and virtual estimation of mechanical properties using CREO and ANSYS for currently used aluminum based calipers and fabrication of the composites and testing of the same. A comparison is performed between the virtual and experimental results and also the effectiveness of composite based calipers over Aluminum ones is studied. Here two polymeric based composites are proposed for fabrication which are thermoplast and thermoset based composites respectively. The braces are modeled using a solid modeling Software, CREO and the same is tested using ANSYS.

Multi-Characteristic Optimization in Wire Electrical Discharge Machining of Inconel-625 by Using Taguchi-Grey Relational Analysis (GRA) Approach

Inconel 625 is a nickel-chromium based super-alloy which is mostly used in high end applications due to its excellent chemical and fabrication properties combined with high strength and outstanding corrosion resistance. Wire EDM is most commonly the used process for machining this material and gives high accuracy and precision in the machined parts. In this paper, an attempt is made to undertake an experimental investigation to optimize the input variables like pulse on time, pulse off time, peak current, and servo voltage in Wire EDM for achieving simultaneous optimization of cutting rate, surface roughness, dimensional deviation, and wire wear ratio. Taguchi's L9 orthogonal array with one replication has been used as an experimental design and then analysis of variance (ANOVA) has been applied to determine the significant parameters and their contributions on response variables. Taguchi method has been combined with grey relational analysis for multi-characteristic optimization. Finally, results are validated with the help of confirmation experiments.

Improvement of Mechanical Properties and Morphological Studies of Friction Stir Processed Composites

Friction-stir processing (FSP) is a property enhancement technique which, not only removes the defects of initial casting process, but also improves the microstructure of the metals and metal matrix composites (MMCs). The process is based on frictional heating which results in a considerable dynamic plastic deformation within the metals. FSP can be specifically applied to develop fine-grained microstructures throughout the thickness of metal surface, to impart super plasticity and ensure homogeneous distribution of reinforced particles, if any. This chapter is a dedicated effort to consolidate the latest developments contributed by different researchers in last few years. The work covers various components and parameters, selected and used, for FSP to obtain specific desired results. Also, it includes past researches to exhibit various changes in mechanical properties with a keen focus on morphological study (by scanning electron microscopy) of these MMCs. In the last, a brief discussion on application and future scope of FSP processed MMC materials, is presented.

Designing of a Twin Tube Shock Absorber

Reverse engineering has become the one of the most relevant concepts in modern design doctrines. Advances in technology demand shorter lead time in the overall product development stage, especially in the automobile sector. Hence as a study in reverse engineering, the author has reverse engineered a twin tube shock absorber. The process involved the obtaining of subassemblies of the damper mechanism to generate a 3D CAD model of the damper in PTC CREO 2.0. The model was used to conduct static structural and CFD analysis of the same using ANSYS 15.0 Workbench. The data obtained was used as the datum for the design modifications and performance enhancement of the part. It was seen that the design of the piston valve was optimum hence modifications to the base valve were done. Following the generation of the datum, similar analyses were conducted on the modified assemblies. The results were compared to the datum for the selection of the most appropriate design. Four designs are analyzed and compared with the datum and the set with four orifices in the valve disk was found to be optimum.

Design of Impeller Blade of Mixed Flow Pump

Mixed flow pumps have got a wide range of application such as that in irrigation, flood control, dewatering and power station cooling systems. A number of design templates have been in use to design the mixed flow pump impeller blades including free vortex theory and mean stream line theory. Here blade of the impeller of the mixed flow pump has been designed using Mean stream line theory and the free vortex theory and stresses arising due to static loading conditions has been obtained for both the cases. Comparison analysis for the equivalent stresses developed due to structural loading using various materials for the blade was undertaken. It was found that the stress for the blade designed using mean stream line theory is always on the higher side in comparison to that designed using free vortex theory. Further, out of the four materials of construction, titanium and copper were found to be suitable for blade designed using free vortex theory and the mean stream line theory respectively.

Development of Liquid Composite Moulded Thermoset Composite Automotive Parts Using Process Simulations

Hand layup method is normally used for manufacturing composite parts with large and complex geometry where as Resin Transfer Moulding (RTM) process is a better substitute, but is sparingly used due to lack of proper manufacturing technology. Developments of RTM manufacturing process always requires a proper mould design. In addition, difficulty in the tooling design and mould fabrication cost increases with increase in size and complexity of the component. The scale down strategy of full scale product avoids bigger size mould requirements, prototype bulk production for product testing and quality check at the starting phase of product development. Moreover, the mould scale down strategy can be used to validate the process and the product with less capital input. In this work, a methodology to develop a RTM technology for manufacturing a complex and large composite structure utilizing the process simulation were demonstrated using high speed cab front as selected component.

A Conceptual Analysis on the Different Approaches to New Product Development and the Variables Associated With Modelling the Process

Globally, new products are launched daily. They provide answers to common or specialised problems, enrich lifestyles, provide alternatives to old solutions, amuse us etc. Companies that develop, design, manufacture, market and sell these products seek commercial compensation in the short, medium or long term “success”, however you measure it. Subsequently, New Product Development is a major issue for most companies as they seek to reduce time to market, reduce the development cycle, access new technologies and develop more and better products and services. New products that can successfully compete in local, national and global markets are a key concern for the majority of companies, so successful NPD is fundamental to both stimulating and supporting economic growth. It is a subject, which has received and continues to receive much attention, particularly in seeking to improve its effectiveness and efficiency. This chapter reviews the NPD process and considers the variables associated with the different approaches, which may be needed when developing a new product.

Functionally Graded Varying Geometry Annular Fins

The research work aims at investigating the performance of functionally graded annular fin. The work involves computation of efficiency and effectiveness of such fins and compares the fin performances for different geometry and grading parameters. It is also assumed that the temperature gradient only exists in one direction i.e. along the radius. A general second order governing differential equation has been derived for all the profiles and grading. The thickness of fin is considered to be a power function of radial co-ordinate. The functional grading of thermal conductivity is assumed to be a power function of radial co-ordinate and also consists of parameters, namely grading parameters, varying which different grading combinations can be carried out. The efficiency and effectiveness of the annular fin of different geometry and grading combinations have been calculated and plotted. The performance analysis reveals the dependence of thermal behaviour of annular fins on geometry and grading parameter.

Development of Natural Bio-Filler-Based Epoxy Composite for Wind Turbine Blade Application

Nowadays, the research and engineering attention stimulated towards development of environmentally gentle materials to satisfy the energy needs of the society through renewable resources. The growing cognizance in the production and consumption of renewable energy for civilization necessities has directed towards the growth in the wind energy utilization. The wind energy is a leading renewable and sustainable energy resource and key answer to the global energy problem. The rotor blades of wind turbines are its integral parts and traditional materials used for blade manufacturing are carbon or glass fibre reinforced polymer composites owing to their low density and high strength to stiffness ratio. But the non renewability and adverse environmental effect during their processing and disposal forced the researchers to look out for some biodegradable and light weight natural plant fibres for reinforcement in polymeric resin to produce required polymer composites. In the present work, application of bio filler based epoxy composite is proposed to be used as wind turbine rotor blades.