Near Optimal Grinding Process Design Using Neural Network and Real Coded Genetic Algorithm

A typical grinding process is an essential manufacturing operation and has been considered to be a precise and economical means of shaping the parts into the final products with required surface finish and high dimensional accuracy. The need to economically process hard and tough materials which can withstand varying stress conditions to ensure prolonged service life of parts has become a real challenge for researchers and practitioners. In this context, with the advance development and automation of grinding processes, use of appropriate modelling and optimization techniques has been continually emphasized. In view different types of end product and process requirements in grinding processes, optimization often becomes non-linear, multiple response constrained problem with multi-modal distribution of response quality characteristics. The objective of this study is to apply back propagation neural network modelling technique for prediction of a computer numeric-controlled (CNC) rough grinding process behaviour, and thereby determine overall near optimal process design using real coded genetic algorithm. The study proposes an integrated approach using back propagation neural network algorithm, composite desirability function, and real-coded genetic algorithm. The effectiveness and suitability of the approach is determined based on data analysis of a single-pass 6-cylinder engine liner CNC rough grinding (honing) operation in a leading automotive manufacturing unit in India.

Analysis of a Virtual Prototype First-Stage Rotor Blade Using Integrated Computer-Based Design Tools

The present paper outlines a practical methodology for improved virtual prototyping, using as an example, the recently re-engineered, internally-cooled 1st stage blade of a 40 MW industrial gas turbine. Using the full 3-D CAD model of the blade, a CFD simulation that includes the hot gas flow around the blade, conjugate heat transfer from the fluid to the solid at the blade surface, heat conduction through the solid, and the coolant flow in the plenum is performed. The pressure losses through and heat transfer to the cooling channels inside the airfoil are captured with a 1-D code and the 1-D results are linked to the three-dimensional CFD analysis. The resultant three-dimensional temperature distribution through the blade provides the required thermal loading for the subsequent structural finite element analysis. The results of this analysis include the thermo-mechanical stress distribution, which is the basis for blade life assessment.

Conjugated Heat Transfer in Skirt Hot Box in Pressure Vessels

Pressure vessels are common equipment in oil, gas and petrochemical industries. In a hot containing fluid vessel, excessive temperature gradient at junction of skirt to head (weld line), can cause unpredicted high thermal stresses; Thereby fracture of the vessel may occur as a result of cyclic operation. Providing a hot box (air pocket) in crotch space is a economical, applicable and easy mounted method in order to reduce the intensity of thermal stresses. Natural convection due to temperature difference between the wall of pocket, will absorb heat near the hot wall (head of the vessel) and release that near the cold wall (skirt of the vessel), then the skirt wall conducts heat to the earth as a fin. This conjugated heat transfer removes the temperature gradient boundary at welded junction. This phenomena will lead the temperature gradient on the weld line from a sudden to smooth behavior, thereby the skirt-head junction, that is a critical region, could be protected from excessive thermal stresses. In this paper the profit of hot box and conjugated heat transfer in cavity has been demonstrated experimentally. As a result it is shown that the conductive heat transfer through the skirt (which acts as a fin) ensures the continuation of natural convection in the box. Also the governing equations has been solved numerically and compared with experimental results.

Automatic Procedures as Help for Optimal Cam Design

In this work we suggest a synthesis of recent results obtained on the application of soft-computing techniques to solve typical automatic machines design problems. Particularly, here we show an optimization method based on the application of a specialized algorithms ruled by a generalized software procedures, which appears able to help the mechanical designer in the first part of the design process, when he has to choose among different wide classes of solutions. In this frame, among the different problems studied, we refer here about the choice of the best class of motion profiles, to be imposed to a cam follower, which must satisfy prefixed design specifications. A realistic behaviour of the system is considered and the parameter model identification is set up by a soft computing procedure. The design, based on theoretical knowledge, sometimes is not sufficient to fulfil desired dynamical performances, in this situation, a residual optimization is achieved with the help of another optimizing method. The problem of a cam-follower design is presented. A class of motion profiles and the best theoretical motion profile is selected by an evolutionary algorithm. A realistic model is considered and its parameter identification is achieved by a genetic algorithm. The residual optimization is achieved by a servomotor optimized by another genetic algorithm. Evolutionary approach is used during all the design process and, as was shown, it allows really interesting performance in terms of simplicity of the design process and in terms of performance of the product.

Characterisation of a Simplified Aeroengine Casing Subjected to a Radial Loading Condition Using FE and Approximate Methods

In general, aeroegine casings may experience an axial force, a bending-moment and radial loading. Under these loads, the high stress regions of these complex aerongine casings will experience local stress and strain concentrations, with various load combinations. The stiffness will also depend on the loading mode. Hence, careful design is required to avoid the various types of failure such as buckling, crack initiation and propagation must be taken into account when designing an aeroengine casing structure. In addition, aerongine casings require extremely high reliability in service and adequate strength under extreme load conditions, i.e. Fan-Blade-Off (FBO) condition, must be demonstrated. Under radial loading of aeroengine casings, which have spoke to shell connections, these are the most likely sites for plastic deformation to occur and cracks to initiate. Also, the load path for each spoke to shell connection within the casing structure changes during loading. Based on these observations, this paper concentrates on the behavior which occurs in spoke to shell connections, referred to as local joints. The intention is first to characterize the local joint behavior and then to incorporate this into a global casing model. The work reported in this paper includes studies of mesh sensitivity, predictions of load path at each local joint under radial load, FE failure loci, upper bound techniques for predicting limit loads and stresses-strains predictions at local casing notches under elastic-plastic and creep situations using approximate notch methods. Hence, the global responses of a casing structure were predicted by utilizing a “repeated local joint” technique in conjunction with simplified global models.

DNC Method for Flatness Reduction by Machine Tool Error Compensation in Planning Processes

Milling is a widely used manufacturing process with the main purpose of generating high precision mechanical components of shapes and sizes given by the numerical control programmed cutting tool trajectory. These mechanical components frequently needs the application of milling operations in order to satisfy the technical specifications that corresponds to their dimensional, geometrical and surface quality requirements. For that reason, the effects of different factors such as cutting tool dynamics, fixturing system design, workpiece material behaviour and applied cutting forces on the desired dimensional precision must be studied, as well as cutting tool and machine tool performance. In this work, the relation between machine tool inaccuracies and geometrical tolerances is analyzed, and a methodology is proposed for improving flatness in planing operations by the correction of imperfections detected in cutting tool displacement according to machine tool axis. These machine tool error correction methodology could be implemented in the current CAD/CAM/CAPP techniques as a means of increasing the milling process performance by identification and correction of CNC milling machine imperfections. The deviations in machine tool displacement during cutting process are identified by metrological analysis, and a modified trajectory for cutting tool is defined by direct numerical control (DNC) from systematic error compensation in machine tool.

On the Use of Fast-Response Pressure Transducers in a Common-Rail Diesel Injection System

The aim of this paper is to investigate the use of fast-response pressure transducers for measuring the instantaneous pressure in different sections of a common-rail diesel injection system, both for a single injection and for multiple injections. The influence of the pressure transducer onto the measured pressure is evaluated numerically by comparing the pressure history computed without the pressure transducer and that computed with the presence, and thus with the disturbance, of this sensor. A new electric circuit is proposed in substitution of the standard electronic central unit, which allows to modify the injection parameters and to perform injections on a test rig, as done in the automotive applications. Experimental results are provided both for a single injection and for multiple injections, to demonstrate the capabilities of the proposed test bench for the unijet injectors.

Synergy-Based Approach to Bad Engineering

In the present paper unique data about initial shortcomings in the design and application of different industrial and consumer products are presented. The research area covers all of the products’ development stages beginning with factory automation and equipment control systems, and continuing with the design and realization of light fittings up to follow-up on the product development of office machines. The statistical results of this research are presented. Further the essence of the synergy-based approach to the design process, focussing on the most common human faults/mistakes, is clarified. Evidence is presented to show that the reason for human shortcomings is either the lack of synergy in teamworking or problems in inner personal communication. A detailed definition of the concepts of positive and negative synergy, with examples from both categories is given. Guidelines are given to reduce human risks at the conception of interdisciplinary systems design to avoid bad engineering. A framework for the synergy-based design of interdisciplinary systems is presented capable of adapting to the competences of the design team.

Washers to Reduce Vibration and Noise From the Injection Molding Process

The noise and vibration problems created by injection molding machines can be moderated by the installation of absorbers. The pull rods of the machine, which are guided to the molding movements, might be a better location for mounting a spring, rubber or hybrid elastomer for energy absorption and reduction of noise and vibration. In this paper, some special washers are designed to fit the guide rods and performance tests are carried out. The results show that noise and vibration decreased over 10 dB and 2 times, respectively.

Thermomechanical Model and Experimental Analysis of Progressive Fatigue Damage in Steel Specimens

This paper presents a thermomechanical model to predict the surface temperature evolution of a specimen during a fatigue test. In particular, the aim of this theoretical approach is to evaluate the amount of accumulated fatigue damage in the material, on the basis of its temperature growth indicated as damage parameter. To do that, a thermomechanical model has been developed and applied to a unidimensional steel specimen, with rectangular cross-section, fatigued by alternate axial stresses. Temperature variation along the thickness of the specimen has been disregarded. Thermomechanical differential equation has been integrated by applying both initial and boundary conditions. Temperature evolution of steel specimens measured during fatigue tests by means of thermographic techniques has been compared to the corresponding predicted by the theoretical model.