Applied Mechanics and Materials Vol. 928

Abstract: The V-bending process is one of the most important operations in sheet formation, which is influenced by a number of different factors. The phenomenon of springback is a well-known issue within the field of sheet metal forming, resulting in compromised dimensional accuracy and reduced operational efficiency. The objective of this research is to analyse and compare the springback properties exhibited by different types of sheet metal alloys (aluminium alloy 6061-T6, stainless steel 304, and low-carbon steel) with thicknesses (0.5, 1, 1.5, 2, 2.5 and 3) mm. The springback angle of each sample is subsequently evaluated quantitatively using a measuring machine of coordinate. A regression model is developed to predict the incidence of springback by using the variables of material properties and forming conditions. The results suggest that there is a significant variability in the springback phenomena, which is influenced by the particular alloy and thickness of the material. Specifically, the low-carbon steel has got the least springback, followed by SS 304, and Al 6061-T6. The thickness of the material has the greatest influence on the process (54%), followed by the type of material (37%). In contrast to the largest thickness of 3 mm, the maximum value of reflectivity is found in all three materials employed in this investigation, the smallest thickness of 0.5 mm provides the least amount of springback.

Abstract: Steel alloys made of sheet metal are important materials because of their high strength applications in construction, automobiles, ships, aircraft, and military products. Among the best and fastest non-traditional ways to cut sheet metal these days is laser cutting. Therefore, it's important to comprehend how the parameters of LC affect the quality of the cut. A thorough analysis was provided to find out which LC parameters have the greatest impact on cutting quality as well as how they affect the kerf quality and cut surface. An overview of the benefits of LC over other machining techniques was provided. Furthermore, an explanation of the various laser sources and the laser cutting technique were given. by eliminating each source's spectrum of cut material thicknesses and their benefits. Graphs and formulae provided a detailed illustration of the cutting performance characteristics. Tables and graphs that display the whole classification of the examined papers were used to utilized to arrange the discussion and analysis of the research into such a detailed discussions. It was discovered that Steel alloys are the most commonly used for laser cutting (59%), followed by aluminum alloys (13%) and titanium alloys (12%). While other subjects constitute 16% of research in this field It was also found that The most common parameters utilized as controls are cutting speed (30%), Laser power (23%), Assist gas pressure (21%), Pulse frequency (9%) and Focal position (7%), in general the ideal parameters to achieve low (SR), small (HAZ) width, small (KW) and small (KT) are low (Pu), high (V), medium (P), high (SOD), medium (PF), medium (PW), small (ND), small (T), and N2 as an assist gas.

Abstract: Magnetic abrasive finishing (MAF) is an advanced surface finishing technology that utilizes magnetic fields to control abrasive particles, enabling precise material removal and superior surface integrity. This review paper comprehensively analyzes MAF research from 2015 to 2024, focusing on key developments, process optimizations, and industrial applications. The study looks at how MAF affects different materials like titanium alloys, stainless steels, and 3D-printed parts, showing how it improves surface smoothness, leftover stress, and resistance to wear and tear. This review paper expands on the experimental investigation of MAF’s efficacy in removing crack fatigue layers for a high-cost product to give it a high performance and longer life, a critical aspect in enhancing the functional performance of components. It is synthesizing various studies that explore the principles of MAF, the preparation of magnetic abrasives, tool design, and the process’s modeling and simulation. It also examines the force measurement and material removal mechanisms, providing a comprehensive understanding of the process parameters and their optimization. It is highlighting the challenges faced ‎in the field and suggests future directions for research, aiming to contribute to the development of more efficient and precise finishing techniques in manufacturing industries. The findings of this study are expected to benefit researchers and practitioners in MAF-related fields, paving the way for innovations in surface finishing technologies.

Abstract: Electrochemical Machining (ECM) is a modern metal working process that make it possible to machine products that are challenging or even impossible to create using traditional machining methods. This study aims to explore how surface roughness and machining rate in ECM are influenced by magnetic field on the metal matrix composite with different machining process input. Neodymium magnets were employed to generate the magnetic field during experiments. The workpiece material used in this experiment is aluminum 6061 alloy, Al-B4C, Al-SiC and the tool material is copper. The input parameter used in this experiment was varying such as electrolyte concentration, voltage, gap, and type of material. Minitab software was used to analyze the results and orthogonal arrays are used in the Taguchi design of the experiment. The results showed that in all experiments, the magneto hydrodynamic effect both reduces surface roughness and increases the machining rate. Furthermore, the Al6061 alloy exhibited the smoothest surface finish and the highest machining rate.

Abstract: Lower limb exoskeletons assist individuals with mobility impairments by providing support and aiding rehabilitation. However, precise trajectory tracking remains a challenge due to variations in user movement and nonlinear gait dynamics. Traditional control methods, such as PID controllers, require continuous tuning and struggle with long-term adaptability. This study proposes a PID-based Iterative Learning Control (PID-ILC) approach for a 2-DOF lower limb exoskeleton, which refines control inputs over successive gait cycles to improve tracking accuracy. MATLAB simulations demonstrate that the PID-ILC strategy significantly reduces tracking errors over iterations, leading to smoother and more accurate joint movements. The results confirm that iterative learning enhances exoskeleton performance by improving motion precision and adaptability. This approach minimizes manual tuning efforts and provides a more effective solution for rehabilitation applications.

Abstract: An important aspect of warehouse automation is to focus on monitoring products accurately. One of the features of adaptive robotic systems is their ability to perform pick and place operations in warehouses. This work proposed an adaptive system which work autonomously along a predetermined track. Proposed system can visualize objects, precisely pick and place them using a robust PID control algorithm, and ensuring accurate movement. Line following, junction handling, and pick & place operations are performed within warehouse area of 7 × 8 units in an average time of 32 seconds. The performance of the robot shows its ability to work with high accuracy, minimal errors, and precision despite changing working conditions.

Abstract: Piezoelectric materials possess a special property to produce electricity from mechanical motion and are therefore it is suitable for green energy solutions. In our project, we fabricated a flexible piezoelectric device through a simple, non-vacuum process. We prepared the device by a solution casting process with a thin poly (vinylidene fluoride) (PVDF) film. Under mechanical stress, the device shows a clear electrical response, confirming its functionality. This indicates that piezoelectric materials can be fabricated to utilize as a low-cost, eco-friendly, and efficient means to harvest energy. This device can also be used as a sensor in robots and robot-related applications. This device can sense movement, which can be used in autonomous robots to sense movement, feed back, or even to harvest energy to power robotic sensors. In the future, we can improve the device performance by modifying the film thickness, using more efficient electrode materials, and making it stable to operate in different conditions.

Abstract: The world is moving towards the renewable energy generation and utilization. The machinery, tools have been now updated to cope up with the environmental need including sustainability and environmental protection. From Gasoline to hybrid and Electric Vehicles have also been introduced. The material of the vehicles has also been made light weighted so that the efficiency of the vehicle can also be enhanced. On the other side if the vehicle body gets dents, scratches or even bumps so they need to be either repair and mostly new parts are installed like fender, bumper or bonnets and hoods. In this regards a dent remover is designed with the facility to remove the dent even without the removal of the paint that is a paintless dent remover. This Paintless dent remover is also equipped with the ability to work on different angles which another dent remover could not with in the facility. The angular dent removing facility provide a wider span of work and better efficiency respectively. Finite Element Analysis and simulation is also necessary for a successful design, so it is also done and from FEAit was found that the dent remover can easily pulled a dent with a maximum force of 100 kg. After successful simulation and designing the Dent remover is also put forward for fabrication so that it may give a large range of dent removing facility in real time.

Abstract: The PTO (Power-take-off) shaft is an essential rotatory component in agricultural tractor, used for transmitting power to shaft-driven implements such as rotary tiller, thresher, PTO driven pump, etc. During field operations, the PTO is subjected to uneven vibrational loads, which often lead to premature failure. These failures pose significant challenges pertinent to structural integrity, product quality as well as customer satisfaction. The current study conducts static and harmonic analysis to observe failure characteristics of conventional medium-carbon steel shaft under torsional loading. This study also explores the utilization of synthetic, natural, and hybrid-based fiber-based polymer composite to optimize overall weight and evaluate the impact of fiber orientation on stress and deformation behavior. The shaft was made up of unidirectional hemp and carbon-bamboo fiber reinforced epoxy, assuming isotropic characteristics for the fibers and polymer. A Representative Volume Element with a hexagonal array of circular fibers was developed using ANSYS Material Designer, maintaining a fiber volume fraction of 0.3 within the matrix. Laminated composites were then modeled using ANSYS Pre-Post Module with varying ply orientation to obtain an optimum configuration. Compared to the results of baseline steel shaft, Carbon fiber, Hemp fiber and Carbon-Bamboo fiber configurations demonstrated a mass reduction of 75.71%, 80% and 77.5%, respectively. These findings highlight the potential of composite PTO shaft as more economical, biodegradable, sustainable and light weight alternatives to steel in modern agricultural applications.