Stress and Strain Distribution in the Upsetting Process

Numerical simulation of metal flow behaviour was studied using DeformTM3D software. The simulation process was done on X20 steel taken from the software database at 1073-1273K temperature, 10mm/s die speed, and 67% height reduction. From the simulation results, forging load, damage, and stress/strain distributions were obtained. The results show that the forging load increased with a decrease in temperature or decreased with an increase in temperature. The maximum damage values increased as the temperature increased. The obtained maximum damage values were 0.42 (1073K), 0.43 (1173K), and 0.45 (1273K). The damage distribution was inhomogeneous in the deformed cylinder. The stress/strain distributions were inhomogeneous in the deformed cylinder. The location of the maximum strain was at the centre of the deformed cylinder while the maximum stress occurred at the die-cylinder contact surfaces. The study showed that flow stress behaviour can be predicted using finite element method. This shows the feasibility of applying the finite element analysis to analyse the forging process.

Simulation of a Hydropneumatic Suspension for Agricultural Working Vehicles

The chapter shows the study and simulation of a hydropneumatic suspension to be adopted for a telescopic handler vehicle. The hydropneumatic suspension system with independent wheels and with quadrilateral architecture has been studied to improve comfort and productivity of the existing vehicle, which has a suspended rigid axle on the front and a rigid axle on the rear, limiting the comfort and the grip. After the choice of the architecture and the kind of suspension, the chapter shows the design of the suspension kinematics. The optimization of the characteristic angles of the suspension has been performed using Adams/Car and Adams/Insight. The kinematic model optimized is subsequently reproduced in Adams/View to simulate the dynamics of the complete vehicle. Simulation results are used to evaluate vehicle performance in terms of comfort and stability according to the methods proposed by the standards.

Material Selection Considerations for Lightweight Automotive Bodies

Lightweight is a trend of new vehicle development, driven by government regulations, environmental concerns, and customer needs. A major effort in the automotive industry is on light weighting vehicle bodies. This chapter reviews the various materials, their characteristics, weight reduction potentials, and costs for light weighting vehicle bodies. The chapter also exams the joining technologies on their principles, applications for the lightweight materials, and influencing factors for choosing a joining process. Furthermore, this chapter discusses the development trends of material selection and joining technology applications.

Biodegradable Acoustic Proficiency in Sound Absorption Capacity After Water Treatment and Testing by Impendence Tube Method

The present research investigation aims to fabricate a new class of fiber reinforced composite material by using biodegradable materials with epoxy as the strengthening agent. In order to explore the possibilities of using the new class of composite material in required application areas, the research work is carried out mainly in the field of the acoustic absorption properties of these bio fibers as an alternate building material. Also, the utilization of these materials as sound insulation will also provide a good solution to the waste management.

Advancements in Manufacturing Technology With Additive Manufacturing and Its Context With Industry 4.0

Additive manufacturing (AM) is also known as 3D printing and classifies various advanced manufacturing processes that are used to manufacture three dimensional parts or components with a digital file in a sequential layer-by-layer. This chapter gives a clear insight into the various AM processes that are popular and under development. AM processes are broadly classified into seven categories based on the type of the technology used such as source of heat (ultraviolet light, laser) and type materials (resigns, polymers, metal and metal alloys) used to fabricate the parts. These AM processes have their own merits and demerits depending upon the end part application. Some of these AM processes require extensive post-processing in order to get the finished part. For this process, a separate machine is required to overcome this hurdle in AM; hybrid manufacturing comes into the picture with building and post-processing the part in the same machine. This chapter also discusses the fourth industrial revolution (I 4.0) from the perspective of additive manufacturing.

Structure Properties Relationship Studies of Vinyl Ester Hybrid Syntactic Foam

Syntactic foam is the porous composite produced by mixing prefabricated hollow spherical particle into the matrix. Syntactic foams are used as energy absorption sandwich core for several applications like marine, automotive, and aerospace. In this work, low density hollow glass microspheres are hybridized with fly ash cenosphere in Bisphenol-A epoxy-based vinyl ester matrix. Hybrid syntactic foams is created with 60% total filler content. Within these hybrid systems internal composition of two fillers were varied in a step of 25 vol% with respect to each other. Hybrid syntactic foams are prepared by the hand lay-up (molding) method. The physical characterization parameter contains density and matrix porosity whereas tensile, quasi-static compression, flexural (3-point bending), Izod impact, and micro Vickers hardness are grouped as mechanical characterization parameters. Scanning electron microscopy was performed on fractured surfaces to examine deformation and fracture mechanisms related with each loading condition.

Control Optimisation of Overhead Gantry Cranes via Fuzzy Controllers

This study considers a fuzzy logic-based reasoning approach for control and optimising performance of overhead gantry crane. The objective of this study is to minimise load swing and to stabilise the crane in the least possible time. The fuzzy controllers were designed using nine Gaussian and triangular shape membership functions. The results clearly confirmed the effect of shape of memberships on performance of fuzzy controllers. Performance of overhead crane was measured in terms of settling time and overshoot ranges. The study also demonstrates the influence of varying mass of the load, mass of crane, and length of crane bar on stability of the crane. A mathematical model of the crane system has been derived to develop a simulink model of proposed system and performing simulations.

Optimization of Seat Frame With Dissimilar Materials for Lightweight Materials

High-strength and lightweight methods for vehicle parts include methods such as optimization and application of lightweight materials by reflecting load or material characteristics. Safety regulations have been established in accordance with the loads affecting the vehicle to secure the safety of the vehicle. In order to reduce the weight, high strength materials such as high strength steel (HSS) or high tensile strength steel (AHSS) have been studied. In addition, research on additional lightweight optimization is actively performed by removing parts that do not require high strength or replacing them with plastics. The process of designing a vehicle or part with different properties and considering various loads is costly and time consuming. In order to secure safety and light weight, the authors propose an approximate model for the optimal design of the seat frame that has a direct impact on occupants among the parts of the vehicle, and reduces the development cost, time, and intuitive design through the procedure.

Static and Dynamic Analysis of Deformable Fractal Surface in Contact With Rigid Flat

The chapter consists of static and dynamic analyses of a fractal rough surface in contact with a rigid flat. The fractal surface is constructed using modified Weierstrass-Mandelbrot function. A rigid flat surface touches the topmost point of the rough surface, which moves towards the rough surface and deforms it. Different contact parameters (e.g., contact force, contact area, contact stress, etc. for varying fractal and material properties are obtained through finite element based static analysis. A parameter denoting the degree of nonlinearity of the contact system is extracted from the force-displacement plot of the surface. This parameter is utilized to explain the dynamic behaviour of the fractal surface which vibrates under the influence of the externally excited rigid flat surface. The dynamic analysis of the contact system is carried out by modelling the contact interface as a single degree of freedom (SDOF) spring-mass-damper system. The dynamic behavior of the system is investigated in terms of frequency response curves, time-displacement plots, and phase plots.

IDI Engine With Alternate Fuels

A plethora of experiments were conducted on IDI engine with various biodiesels (e.g., methyl esters of mahua, jatropha, rice bran, pongamia, palm, beef tallow, and waste cooking oils). Review of the results of these endeavors with various additives and blends with or without super charging of the engine are presented in this chapter. All these attempts have been concentrated to arrive at the best yield from a single cylinder engine. The recorded pressure changes during combustion, the derived heat release rates, and exhaust emissions are presented in the form of plots at various loads and at a constant speed. Engine cylinder vibrations (reflect combustion excitation) in the form of FFT and time waves were recorded at radial points and vertical on the cylinder body to assess the combustion propensity in all cases of studies. The results with relative benefits are enumerated.