Engineering Headway Vol. 41

Abstract: To meet the rising demand for both more strength and less weight, Aluminium alloys are regarded as most appropriate in global development of novel metallic materials. In the present work, the effect of different rotational speeds and depth of penetration on 6082-T651 aluminium alloy through conventional friction stir welding and underwater friction stir welding (UFSW) were studied. Various rotational speeds of 800, 1000 and 1200 rpm, depth of penetration such as 5, 6 and 7mm have been used. In UFSW complex intermetallic compounds and welding defects were reduced due to low heat generation. Mechanical properties such as tensile strength and hardness have been compared in both FSW and UFSW. The weld behavior and failure during mechanical testing were influenced by a variation in the ductility of the Heat Affected Zone (HAZ) due to variations in the heat distribution within the weld area caused by the change in rotating speed. The 6082-T6 aluminum alloy plates that were utilized in this study were welded at an appropriate rotational speed. The weld area's average hardness distribution was higher in the optimal speed range when it came to hardness. Tensile testing showed that the ductility in Heat Affected Zone (HAZ) changed due to heat distribution in the weld area. Variations in the hardness of the base metal and the weld area have been detected by hardness throughout the weld area. Changes in tensile strength due to variations in rotational speed are also observed and documented. For the entire welding process, the tilt angle and welding speed were maintained at the same levels so that the comparison and analysis of welded aluminum alloy plates become easy.

Abstract: This study investigates the optimization of machining parameters for fabricating micro-holes in Wire Arc Additive Manufactured (WAAM) Inconel 625 using Micro Electric Discharge Machining (Micro EDM). An experimental design based on the Taguchi L9 orthogonal array was employed, focusing on the effects of input current (Ip), pulse-on time (Ton), and pulse-off time (Toff). Using copper electrodes, 800 µm diameter micro-holes were machined, and responses such as Material Removal Rate (MRR), Tool Wear Rate (TWR), and dimensional accuracy (DA) were analyzed. Signal-to-Noise (S/N) ratio analysis was used to determine optimal machining conditions, achieving maximum MRR, minimum TWR, and enhanced DA. The results revealed that the optimal parameters for achieving these objectives were Ip = 2 A, Ton = 5 µs, and Toff = 9 µs. This research highlights the effectiveness of the Taguchi method and S/N analysis in enhancing machining performance for WAAM Inconel 625, contributing to improved precision and efficiency in manufacturing processes.

Abstract: This paper experimented with aluminum grade 6500 to predict surface roughness based on the projected workpiece on a CNC lathe machine. The operation used a 50 mm diameter solid bar, 240 mm long, divided into six equal segments. Each segment was machined at depths of 0.25 mm, 0.5 mm, 0.75 mm, 1.0 mm, 1.25 mm, and 1.5 mm. The actual cutting depths were analyzed based on SolidWorks G-code. Under constant feed rate and spindle speed, the sound chatter was recorded for machine learning. The librosa library enhanced the sound chatter utilizing 50 neurons and a 71051 input shape. In parallel, a batch size of 32 and the 10-epoch training over a 9-layer model achieved 50.4% accuracy. Besides, the spectrogram’s purple color indicated significant signal energy between 0 Hz to 64 Hz and 4096 Hz to 8192 Hz, while lighter color intensity showed weaker energy. The peak intensity of energy represents high vibration, and the weak intensity of energy is linked to the low vibration. Additionally, the Abacus simulation showed cutting depths of 0.25 mm and 0.75 mm, resulting in deformations between 8.713e^-08 mm and -1.176e^-00 mm. The higher deformation values corresponded to less chatter, while lower values indicated low vibration. Overall, deeper cuts on the aluminum grade resulted in peak frequencies associated with a smoother surface finish, whereas shallower cuts produced rougher machined surfaces.

Abstract: The V-bending process is crucial in sheet metal forming, but the improper combination of process parameters can lead to issues such as spring-back and dimensional inaccuracies, affecting the quality and precision of formed components. Spring-back is a phenomenon where the material slightly returns to its original shape after bending, which compromises the desired geometry. Dimensional inaccuracies can result in assembly problems, reduced structural integrity, and increased manufacturing costs due to rework or scrap. In this study, the influence of key process parameters—punch radius, die opening, and sheet thickness—on spring-back in V-bending of SS304 stainless steel is investigated using a Design of Experiments (DoE) approach. Classical DoE methods are employed to analyze the effects of these factors and identify the optimal process parameters. The findings indicate that sheet thickness has the most significant impact on spring-back, followed by die opening and punch radius. The optimal combination of parameters for minimal spring-back is found to be a punch radius of R6 mm, a die opening of 20 mm, and a sheet thickness of 0.5 mm. These insights, derived from ANOVA calculations and main effect plot analysis, provide a pathway for improving dimensional accuracy and reducing spring-back in the V-bending process, ensuring consistent quality in sheet metal forming applications.

Abstract: The development of a robotic cat leg inspired by biomimicry was executed with subtractive rapid prototyping technique. The design emulates the proportions and functions of a natural cat's hind leg, with the femur, tibia, and metatarsal scaled for relative precision. Plywood was selected as the principal material due to its lightweight and economical characteristics, making it appropriate for iterative prototyping. The manufacturing method entailed accurate 2D schematics converted into tangible components via CNC routing. The constructed robotic leg exhibited fundamental locomotor abilities, emulating the lifting, extending, and retracting motions characteristic of a cat's normal walk. Although the prototype demonstrated functionality, issues such as joint rigidity and material degradation underscored opportunities for enhancement. This study demonstrates the promise of subtractive prototyping in the development of biomimetic robotic systems and establishes a basis for future improvements in joint flexibility, material selection, and movement accuracy.

Abstract: The usage of ordinary brakes in today’s brake applications has many challenges such as skidding, wear and tear, increased fuel consumption due to power assistance, requirement for anti-lock controls, insufficient braking force at high speeds. This diminishes the safety and efficiency of the braking application. To overcome these problems, Eddy Current Braking system which is responsive and low maintenance has been developed as a contactless and wear-free system using the reverse effect of eddy current. This braking system uses electromagnetic induction phenomenon that can provide frictionless braking for vehicles, including trains. Compared to traditional friction brakes, eddy current brakes can reduce the need for periodic replacement of braking components and lower braking costs. Additionally, this technology can help to reduce toxic smells caused by friction brakes while the vehicle is in motion. When a conductor is subjected to a time varying magnetic field, localised currents called Eddy Currents get induced. The integrated eddy current braking mechanism is combined with a power generation spur gear arrangement for bicycle. This a self-sustaining and eco-friendly solution which can proficiently manipulate braking force. This brake provides an advanced, reliable brake with both protective features and less wear performing part distortion which is great for bicycles, bikes and trains as well as those who seek modern vehicles. The interaction between the eddy currents and the magnetic field generates a resistive force that slows down the wheel. The braking force generated by the system will depend on the strength of the magnets, the speed of the wheel, and the conductivity of the material.The objective is creating a braking system that uses the principle of eddy currents to provide non-contact, smooth and adjustable braking. This system should be designed to use the same generator components, effectively turning the motor into a brake by short-circuiting its terminals, which creates a resistive load that slows down the wheel. This system will also serve as a method for controlled energy recovery.

Abstract: The role of Heat exchanger’s in the present scenario of Industries and production applications is growing in a rapid manner. Heat Exchanger types such as shell and tube, plate type, are the most used one at present. Heat Exchanger’s major problems are generally deposits of flowing mixture, increased pressure in the shell, efficient performance and poor design. To solve this issues regarding the heat exchanger we are willing to develop an optimised standard design of shell and tube heat exchanger. This design will enhance the previous results by the usage of base fluid water blended with ethylene glycol 16A. Considering the fluid flow through the heat exchanger with varying volume fraction from 0.40% to 1%. Based on the few of the previous results that could be enhanced with slight modification in the design of shell, we are analysing for an optimised valuation that could give similar effectiveness as expensive fluid that is 60% to & 70% with pressure under 1 bar and temperature limited up to 160 degree Celsius which is obtained in our optimised analysis. This design is maintained as the best possible valuation validated by a practical experiment which could feasibly be the solution for most of the problems and that can be used for long run usage.

Abstract: Additive Manufacturing (AM) has transformed modern engineering by enabling the creation of complex and customized components with exceptional precision and minimal material wastage. This innovative manufacturing technique is increasingly applied in the automotive industry, where it plays a key role in producing lightweight, efficient, and high-performance parts, such as brake systems, engine components, and structural elements. AM offers unmatched flexibility, allowing engineers to move beyond the limitations of traditional manufacturing methods and develop designs that enhance both performance and sustainability. This work leverages AM to design brake caliper and brake pads with vent holes, which are essential for improving heat dissipation and braking efficiency. The process begins with the design phase, where the brake caliper and several brake pad models, featuring unique vent hole geometries, are developed using SolidWorks. These designs are then subjected to motion studies to evaluate their performance in conjunction with rotating disc brakes, ensuring optimal functionality under dynamic conditions. Finally, Structural Finite Element Analysis (FEA) for brake caliper is performed to assess stress distribution and deformation under braking loads. This analysis identifies the most robust and effective designs, ensuring they can withstand operational forces while maintaining reliability. This study demonstrates how advanced technologies like AM, combined with design and simulation tools, can lead to significant innovations in automotive braking systems. By integrating cutting-edge techniques, this work covers the way for creating more efficient, sustainable, and high-performing components in the automotive sector.

Abstract: The gear is a toothed rotating mechanical device that engages another gear to transfer motion and torque. Gears are used extensively in machinery, automotive vehicles, and industry for power transmission and speed regulation. The aim of this study is to enhance the properties and performance of spur gears using three material types: pure metals like steel or brass, metal matrix composites, and hybrid materials. The study contrasts particularly the mechanical performance of spur gears produced with Steel Matrix Composites (SMC), SAE 8620, Iron Matrix Composites, and Aluminium Matrix Composites. To evaluate the efficiency and feasibility of this production process, the gears will be manufactured through additive manufacturing (3D printing). The main aim is to study the effect of material choice on deformation behaviour and failure modes under different loading conditions and constraints. Important performance parameters like durability, efficiency, and mechanical properties will be compared to identify the best material to employ for spur gears. Finite Element Analysis (FEA) will be employed to model stress distribution, strain distribution, overall deformation, and failure mechanism under working conditions. The simulation will be followed by experimental testing to establish performance under real conditions. This research will advance mechanical engineering and gear design by establishing the most appropriate combination of material and manufacturing process for spur gears.