Overview of a Robotic Arm

Our project aims to increase the efficiency of industries and help to automate the manufacturing process and other day-to-day industrial activities. Right now automation is not that widespread among industries because of cost and other technical issues. We designed an industrial robotic arm. We have used specific materials to give long life and durability to the product. One of the most important motivations to design this product was to make it cost-efficient so that it can be used by small and medium enterprises who have left aside in competition. We have used high modulus carbon fibre, aluminium metal matrix composites, carbon fibre reinforced plastic, and aluminium foreign casting alloy 222. We have designed the model on fusion 360 software with appropriate dimensions. We have also looked carefully at the competitions which we are going to face in near future and have carefully planned the strategy to increase our market share slowly and steadily. Keywords: CAE Analysis, CAD, FMEA, TRIZ, NPD

Effect of the Fibre Orientation Distribution on the Mechanical and Preforming Behaviour of Nonwoven Preform Made of Recycled Carbon Fibres

Recycling carbon-fibre-reinforced plastic (CFRP) and recovering high-cost carbon fibre (CF) is a preoccupation of scientific and industrial committees due to the environmental and economic concerns. A commercialised nonwoven mat, made of recycled carbon fibre and manufactured using carding and needle-punching technology, can promote second-life opportunities for carbon fibre. This paper aims to evaluate the mechanical and preforming behaviour of this nonwoven material. We focus on the influence that the fibre orientation distribution in the nonwoven material has on its mechanical and preforming behaviour at the preform scale, as well as the tensile properties at composite scale. The anisotropy index induced by fibre orientation is evaluated by analysing SEM micrographs using the fast Fourier transform (FFT) method. Then, the anisotropy in the tensile, bending, and preforming behaviour of the preform is inspected, as well as in the tensile behaviour of the composite. Additionally, we evaluate the impact of the stacking order of multi-layers of the nonwoven material, associated with its preferred fibre orientation (nonwoven anisotropy), on its compaction behaviour. The nonwoven anisotropy, in terms of fibre orientation, induces a strong effect on the preform mechanical and preforming behaviour, as well as the tensile behaviour of the composite. The tensile behaviour of the nonwoven material is governed by the inter-fibre cohesion, which depends on the fibre orientation. The low inter-fibre cohesion, which characterises this nonwoven material, leads to poor resistance to tearing. This type of defect rapidly occurs during preforming, even at too-low membrane tension. Otherwise, the increase in nonwoven layer numbers leads to a decrease in the impact of the nonwoven anisotropy behaviour under compaction load.

Investigation into deep hole drilling of austenitic steel with advanced tool solutions

Deep hole drilling processes for high-alloyed materials are characterised by worn guide pads and chatter vibrations. In order to increase feed rates, process stability and bore quality in STS deep hole drilling, various investigations were carried out with adjustments to the tool. First, a new process chain for the production of tribologically optimised guide pads and their effects on the guide pad shape is described in detail. The results of these studies show that the shape change in the area of the axial run-in chamfer through a micro finishing process leads to a better bore hole quality. Furthermore, the influence of guide pad coating and cooling lubricant on the deep hole drilling process was investigated. In addition, the machining of the austenitic steel AISI 304 is analysed by using a conventional steel boring bar and an innovative carbon fibre reinforced plastic (CFRP)-boring bar. While the conventional drill tube oscillates with different eigenfrequencies, the CFRP-boring bar damps chatter vibrations of the drill head and stabilises the process. Even at higher feed rates up to f = 0.3 mm, it is possible to machine austenitic, difficult-to-cut-materials with significantly reduced vibrations.

Mass prediction models for air cargo challenge aircraft

Design/Build/Fly competitions are attracting increased interest in the training of aerospace engineers at academic level worldwide. These competitions entail fundamental activities in aircraft design, optimization and manufacturing which foster student knowledge not possible in classical academic activities. Over the years, the competitiveness of these contests has increased due to the ever-increasing performance that the aircraft exhibit in the flight event. Mass prediction models, specific for competitions such as Air Cargo Challenge (ACC), are presented in this paper. These models are divided into two development methods: statistical and structure-based equations. The statistical mass models are developed based on data collected from past ACC editions where model accuracy is mainly dependent on the amount of data available. Three models are derived, one containing all available aircraft and two more obtained by dividing the aircraft into balsa- or composite-dominated structures. Using the structure-based equations method, where the amount of material required to withstand the stresses that the airplane is subjected to is determined, a model is developed for each one of the three considered wing structural concepts, namely two-cell Carbon-Fibre-Reinforced Plastic (CFRP), CFRP D-box and CFRP tube spar. The tail boom component equation is created independently, while the remaining components masses are determined from coefficients based on geometric characteristics and the computed wing or total masses. The average error associated with these models is inferior to 2% for the total mass. The results obtained from the application to the considered study cases are also presented, and the validity, accuracy, and application in terms of the design phase for each method are discussed.

Study of thermophysics during diamond drilling of fibreglass and carbon fibre-reinforced polymer composites

This paper examines thermophysics of the drilling process of polymeric composite materials, such as carbon-fibre-reinforced plastics (CFRP) and fibreglass by tubular diamond drill bits. Features of the COMSOL Multiphysics engineering software package were used. We employed Fourier heat equations, which express the intensity of heat gain by a mobile source in a moving coordinate system. The research was performed using the proprietary method of modelling spatial thermal action upon drilling polymer composite materials (fibreglass and carbon-fibre-reinforced plastics) in the COMSOL Multiphysics software environment. A tubular diamond drill bit with a diameter of 10 mm with two slots was chosen as a model cutting tool. Solid plates with a thickness of 5.5 mm made of layered fibrous polymer composite materials (fibreglass, carbon-fibre-reinforced plastic) were used as a preform. As a result of computer calculations, we obtained temperature fields of fibreglass and carbon-fibre-reinforced plastic during diamond drilling with a tubular tool. When studying the thermal behaviour of fibreglass and carbon-fibre-reinforced plastics, maximum temperature fields were located. The study revealed that the temperature reaches 413.6 and 448.7 K during CFRP and fibreglass drilling, respectively. It was shown that the distance of heat transfer from the edge of the hole into the preform was 6.42 and 6.40 mm for CFRP and fibreglass, respectively. A method of modelling the thermal effects when cutting polymer composite materials developed in the COMSOL Multiphysics environment allows complex analytical calculations of temperatures induced by drilling to be simplified. In addition, its use prevents overheating of a preform during drilling, allows assessing the depth of heat distribution inside the preform from the edge of the formed hole in different polymer composite materials. These measures increase the machining quality of polymer composite materials.

Studying a grinding method of sapphire pipes using two grinders

This paper examines the thermophysics of a drilling process of polymeric composite materials such as carbonfibre-reinforced plastics (CFRP) and fibreglass by tubular diamond drill bits. Features of the COMSOL Multiphysics engineering software package were used. We employed Fourier heat equations, which express the intensity of heat gain by a mobile source in a moving coordinate system. The research was performed using the proprietary method of modelling spatial thermal action upon drilling polymer composite materials (fibreglass and carbon-fibre-reinforced plastics) in the COMSOL Multiphysics software environment. A tubular diamond drill bit with a diameter of 10 mm with two slots was chosen as a model cutting tool. Solid plates with a thickness of 5.5 mm made of layered fibrous polymer composite materials (fibreglass, carbon-fibre-reinforced plastic) were used as a preform. As a result of computer calculations, we obtained temperature fields of fibreglass and carbon-fibre-reinforced plastic during diamond drilling with the tubular tool. When studying the thermal behaviour of fibreglass and carbon-fibre-reinforced plastics, maximum temperature fields were located. The study revealed that the temperature reaches 413.6 K and 448.7 K during CFRP and fibreglass drilling, respectively. It was shown that the distance of heat transfer from the edge of the hole into the preform was 6.42 and 6.40 mm for CFRP and fibreglass, respectively. A method of modelling the thermal effects when cutting polymer composite materials developed in the COMSOL Multiphysics environment allows complex analytical calculations of temperatures induced by drilling to be simplified. In addition, it helps avoid overheating of a preform during drilling, allows the depth of heat distribution inside the preform from the edge of the formed hole in different polymer composite materials to be assessed. These measures lead to increasing the machining quality of polymer composite materials.

An integrated decision-making model for wind turbine blade material

Wind turbines are the devices used to harness wind energy. The turbine blades are one of the components which directly confront the wind and convert it into mechanical energy. Various material composites are used in the turbine industries to manufacture wind turbine blades but it is hard to select the best material composite along with the choices. In this study, an MCDM technique named Measurement of Alternatives and Ranking according to Compromise Solution (MARCOS) method is applied to select the best material composite among the set of materials for manufacturing of the blades. The weights of the criteria are determined by the Best Worst (BWM) method. Around 9 criteria such as the ultimate tensile strength, stiffness, cost of the materials, panel stability parameter of the material etc. are used to rank the best alternative among the blade materials. The carbon fibre reinforced plastic is seen to be the best material among the other materials composite by applying the MARCOS method.

IMPLEMENTATION OF CIRCULAR DISCONTINUITIES IN CFRP BUMPER BEAM FOR MATERIAL SAVING: A CASE STUDY

An automotive bumper system consists of an energy absorber, fascia and bumper beam. Among them, the bumper beam is the main component contributing to the overall weight of the vehicle. The bumper beam absorbs the kinetic energy during an accidental collision by deflection in low speed impact and by deformation in high speed impact. Carbon Fibre Reinforced Plastic (CFRP), being an extremely strong and lightweight composite, is a good candidate for bumper beam material. Earlier used in high performance cars CFRP is nowadays being promoted to be used in passenger cars also. The reinforcement beam is the vital part which ensures safety and needs to be validated through Finite Element Analysis (FEA). Therefore, the double hat bumper beam is impacted with a cylindrical impactor and analyzed in Abaqus. In this paper the bumper beam is analyzed after weight reduction by putting circular holes for material saving. Further the effect on cost of production is calculated. Above all, material saving reduces carbon footprint.