Engine Manufacturing Industry Research Articles

Advanced Bending and Forming Technologies for Bimetallic Composite Pipes.

Bimetallic composite pipes, as critical components, effectively integrate the superior properties of diverse materials to meet the growing demand for lightweight, high-strength, and corrosion-resistant solutions. These pipes find extensive applications in petrochemical, power generation, marine engineering, refrigeration equipment, and automotive manufacturing industries. This paper comprehensively reviews advanced bending and forming technologies, with a focus on challenges such as wrinkling, excessive wall thinning, springback, cross-sectional distortion, and interlayer separation. The review combines theoretical analysis, experimental findings, and numerical simulations to provide insights into defect prevention strategies and process optimization. It also evaluates emerging technologies such as artificial neural networks and intelligent control systems, which demonstrate significant potential in enhancing bending accuracy, reducing defects, and improving manufacturing efficiency. Additionally, this work outlines future research directions, emphasizing innovations required to meet the stringent performance standards of bimetallic composite pipe components in high-end applications.

Numerical investigation of laser powder bed fusion of glass

Additive manufacturing of glass using laser powder bed fusion has been recently developed, demonstrating its potential to be applied in small scale applications such as flow reactors for the chemical engineering and pharmaceutical manufacturing industries. While previous research demonstrated that complex 3-dimensional shapes can be manufactured, built parts are often brittle, exhibit high porosity and lack transparency. This study employs a transient, heat transfer finite element analysis to shed light on the thermal response of laser—glass powder bed interaction and the impact of processing parameters. Through this understanding, the research seeks to identify practical strategies that can be employed to improve the quality and properties of the built parts. Bulk solid and powder soda lime silica glass properties are used as input in the model, while the laser heat flux and scan strategy, conversion of powder feedstock to bulk solid glass and heat losses from convection and radiation effects are introduced in the model through Fortran coding. The study showed that effective powder consolidation, resulting in well-defined geometrical features, is achieved for temperatures near the glass melting point. Additionally, uniform consolidation depths and widths can be achieved by increasing laser power, elevating substrate temperature and reducing scan speed within certain limits, whilst ensuring hatch spacing is below the corresponding single scan track width for unidirectional adjacent laser trajectories.

Cobalt in the regolith upon Nui Nua ultramafic Massif

Cobalt (Co) Metal plays an increasingly important role in the battery and engine manufacturing industry for electric cars. Previously most of Co was mined as by-product in copper ore deposits in Central Africa. Recently, the proportion of Co extracted from other sources such as weathering-derived mines on ultramafic rocks is increasing. In Vietnam, Cobalt has been discovered in Cu-Ni ore deposits in the Northeast and Northwest Regions. The literature shows that cobalt is found in small amounts in ultramafic rocks. During the weathering process of ultramafic rocks, Co ions will be priority adsorbed in the hydroxide colloids of Mn and Fe (goethite and asbolan). In the regolith upon Nui Nua Masif, Ni content increased dramatically (several times) from 0.19% in bedrocks up to 1% in some locations, while cobalt content just increased only slightly (from 0.02% in bedrock to 0.05 regolith, rarely up to 0.1%). The results of the previous analysis of weathered crust samples of ultramafic rocks of Nui Nua massif by several authors show that, unlike Ni which is presented in both silicate minerals and Fe-Mn oxide/hydroxide, cobalt ions tend to be concentrated in Fe-Mn oxides/hydroxides. Our SEM analyses combined with EDS show some remarkable results: the Co content in some specific minerals is quite high from 1.12÷4.67% (denominator). This is only a preliminary result and it is necessary to conduct more work to further detailed studies defining the Co potential in weathering products of ultramafic rocks of Nui Nua massif as well as in the areas where other ultramafic rocks are developed. Recently, research confirmed that there is a significant Co-Ni occurrence discovered in Mau Lam Valley (Southwest of Nui Nua Massif).

Volute clapboard and clearance of wear-ring effect on the operation characteristics of canned motor pump

Canned Motor Pump (CMP) is widely used in petroleum, chemical, electric power, aerospace engineering, and military manufacturing industries due to its good sealing performance. In the structure of canned motor pump, the rotor of the motor and the impeller of the pump are fixed on the same shaft. Therefore, balancing the axial force and the radical force of the rotor is a key task for its reliable operation. The numerical simulation study of CMP is carried out in this paper, aiming to improve the pump efficiency and balance the axial force and radial force. The internal flow and rotor force characteristics of CMP under different radial clearances of front or back wear-rings and different volute partitions are studied. The results show that with the increase of wear-ring gap, external performances decline, and the front wear-ring gap contributed the largest influence. Under the working conditions of 0.6QBEP and 0.8QBEP, front wear-rings contributed the largest influence to axial force, and the degree of influence decreases with the rate of flow increase. Radial clearances of front or back wear-rings have less impact on the radial force of the impeller. Adding clapboard for volute has a greater impact on the value and direction of radial force, and it can promote the balance of radial force. However, the effectiveness value will decrease. The research in this paper can provide theoretical basis and reference for performance prediction and hydraulic optimization of CMP.

Testing capability index C pk with its application in automobile engine manufacturing industry

Hypotheses testing is an effective technique for making a decision about the process capability. The adversity to test based on determining the distribution of its natural estimator is very complex, even under the Normal distribution. Thus, the Monte Carlo simulation approach is an executable procedure for the hypotheses testing of based on the natural estimator. The proposed approach is a testing technique to evaluate whether products quality meets the preset specification limits. This procedure implies a Monte Carlo statistical test, which is applicable to Normal processes. A case study in an automobile factory is presented to check out the products, and numerical computations are presented to show the effect of the Monte Carlo critical values for making a reliable decision on the hypotheses testing of

Corrosion behaviour of nickel based abradable coating used in aero engines

The corrosion potential of abradable nickel based coating used for aero engine components (for sealing and clearance control in compressor of aero engines) was explored and the effect of acid rain was observed for varied length of time. Coating plays an important role in aero engine manufacturing industry as it provides surface protection against corrosion, erosion, friction and wear when subjected to harsh conditions viz., high temperature and corrosive environment during service period. The coating deposition was done by using thermal plasma spray method. Porosity was observed to be high at critical plasma spray parameter (CPSP). Phase transformation and interlayer oxide formation were also observed during plasma spray coating. A comparative study was established between acid rain treated and untreated samples by evaluating the corrosion resistance potential, microstructural characterization, composition and phase analysis of coatings of treated samples using Scanning electron microscopy, X-ray diffraction and EDS. The weight gain of coating was also evident after acid rain treatment of up to ten weeks of immersion.

A high-accuracy pose measurement system for robotic automated assembly in large-scale space

Robotic automated assembly in large-scale space is a challenging task both in aerospace engineering and automobile manufacturing industries, which involves several technical metrics, such as accuracy, efficiency as well as stability of the assembly system. In this work, we propose a high-accuracy pose measurement system to tackle this problem. Compared to existing measurement technologies, our system can adequately cover the assembly space and reach a high pose accuracy (<0.2° on rotation and <0.2mm on translation), which meets the requirements of most robotic automated assembly tasks in large-scale space (usually in sub-millimeter). To achieve that, we design a multi-degree-of-freedom measurement platform, which allows the camera to move in the motion space so as to find the best viewpoints to respectively measure the robot end-effector and the assembly target. Another key issue is the localization of the robot end-effector in the assembly space. Traditional calibration methods cannot be applied directly, since the robot and the camera are movable. Hence, we design a practical mechanical tooling which is attached to the sixth axis of the robot. Cubes are uniformly distributed on the tooling, serving for the precise localization of the end-effector. We also propose a novel calibration method to solve the kinematics solution. Moreover, we design a camera-pointcloud collaborative method to effectively compute the accurate 3D coordinates in camera space for sub-pixel marker centers, which can make a significant promotion in measurement accuracy.

On The Genealogy of Knowledge Management &amp; Automated Systems in Engine Manufacturing Industry &amp; Perception of BS III and BS IV Heavy Vehicle Drivers in Pune, Maharashtra: A Qualitative Study

On The Genealogy of Knowledge Management &amp; Automated Systems in Engine Manufacturing Industry &amp; Perception of BS III and BS IV Heavy Vehicle Drivers in Pune, Maharashtra: A Qualitative Study

Pressure control strategy for high-pressure tubing

The entry and ejection of fuel into and out of high-pressure oil tube are the basis of many fuel engines. However, the intermittent working process of fuel entering and exiting will be leading to pressure changes in high-pressure oil tube. Furthermore, it will affect the efficiency of an engine. Therefore, it can be seen important to control high-pressure oil tube effectively. Also, it will be increasing the efficiency of an engine, while having a greatly impact on the development of engine manufacturing and energy industry. This paper is to focus on solving pressure control under high-pressure oil tube. The problems are stable pressure at the inlet of the high-pressure tubing and high-pressure oil tube with no pressure reducing valve and only one nozzle. Regarding the first one, we used the least square method to fit an elastic modulus and pressure data. Then, a differential equation model of pressure and time were set inside high-pressure oil tube. Meanwhile, we also worked on a delayed injection strategy and traversal search algorithm to have results. So, the optimal delayed injection time is 0.23 ms while the one-way valve opening time is 3.06 ms . The maximum offset pressure is about0.3 MPa. The second case which is based on the first case. In order to achieve pressure control, linking the pressure at the inlet of high-pressure oil tube to a cam and using the principle of mass conservation. So, it is stated that the pressure can be stabilized as much as possible when the angular velocity is 0.0275 rad/ms. Finally, we verified the feasibility of the model through simulation analysis.

Under the “Belt and Road” initiative, the China and Ukraine governments should assume greater responsibility to promote trade

Purpose: Ukraine is located in Eastern Europe, has a good geographical location, and has good bilateral relations and traditional economic exchanges with China, especially agriculture, high-tech, and existing and ongoing cooperation projects with China. "There are also difficulties in construction: Ukraine's economy has been in a difficult period since independence, its economic structure is very uneven, and its economic relations with Eastern European and CIS countries, as well as Russian economic relations, need to be improved. Ukraine needs to restore its national strength. China's "Belt and Road" initiative and the diplomatic concept of building a community of shared future for mankind have determined that the Chinese government is willing to help Ukraine restore its strength and restore normal political, economic, and diplomatic relations with neighboring countries. It will benefit the people through the improvement of the national economy This article aims to analyze how the two sides can use the "Belt and Road" platform to develop economic relations and strengthen cooperation to achieve mutual benefit results.&#x0D; Methodology: This article uses the literature research method, the combination of analysis and synthesis methods, observation method, investigation method.&#x0D; Originality: Since the Soviet Union, Ukraine has started friendly exchanges with China. After the founding of New China in 1949, Ukraine, as a part of the Soviet Union, made a greater contribution to China establishment of its national steel, machinery, agriculture and other basic industries. After Ukraine's independence, China-Ukraine relations have entered a new stage. China was the first country to recognize Ukraine's independence and established diplomatic relations with it on January 4, 1992. In the past 30 years of Ukraine's independence, the two countries have not had any conflicts of interest and no serious political and economic contradictions. The "Belt and Road" initiative proposed by Xi Jinping in 2013 provided a new platform for bilateral relations and created unprecedented opportunities for the development of bilateral relations. In the "Belt and Road" construction, Ukraine should play a greater role.&#x0D; Practical value: Participating in the "Belt and Road" construction is also a very important opportunity for Ukraine, helping the Chinese people to have a more comprehensive and clearer understanding of Ukraine, and more importantly, it is conducive to the trade between the two countries to bring more Ukrainian enterprises Trade exchanges to drive the economic development of Ukraine. Politically, Ukraine and China have good bilateral relations；On June 20, 2011, the two sides signed the "China-Ukraine Joint Partnership on the Establishment and Development of Strategic Partnerships. Economically, Ukraine and China have complementary economies. Economic exchanges have been established since the Soviet Union. In recent years, the existing and ongoing cooperation between Ukraine and China has continued to develop in high-tech fields such as agriculture, machine manufacturing, and aviation. More and more Ukrainian experts have pointed out that developing relations between Ukraine and China should become a priority direction of Ukraine's current foreign policy. Ukraine has a strong advantage in agriculture, military industry, and manufacturing, especially the engine manufacturing industry, and can develop machine manufacturing; Ukraine can provide transportation for China “Belt and Road” Convenient conditions.

Multi-objective multi-model assembly line balancing problem: a quantitative study in engine manufacturing industry

This paper deals with multi-model assembly line balancing problem (MuMALBP). In multi-model assembly lines several products are produced in separate batches on a single assembly line. Despite their popular applications, these kinds of lines have been rarely studied in the literature. In this paper, a multi-objective mixed-integer linear programing model is proposed for balancing multi-model assembly lines. Three objectives are simultaneously considered in the proposed model. These are: (1) minimizing cycle time for each model (2) maximizing number of common tasks assigned to the same workstations, and (3) maximizing level of workload distribution smoothness between workstations. Performance of the proposed model is empirically investigated in a real world engine assembly line. After applying the proposed model, possible minimum cycle time is attained for each model. All common tasks are assigned to the same workstations and a highest possible level of workload distribution smoothness is achieved. It is shown that the best compromise solution has led to the best value of the first and second objective functions with a slight distance from the best value of third one.

Mediation analysis of multiple constructs in the relationship between manufacturing and technology and environmental constructs in structural equation model for sustainable manufacturing

Sustainable Manufacturing (SM) has been a buzzword for manufacturing industries in present state of intense competition but the research in this field needs to be enhanced towards developing an integrated and comprehensive approach for its adoption. The main objective of this study is to address this need by identifying and quantifying the mediating effects in complex causal structures of various domains by means of path modeling. A partial least square–structural equation modeling (PLS–SEM) is proposed and tested using survey data of Indian engineering manufacturing industries, collected using SurveyMonkey platform by sending emails to 999 organizations. Actual responses received were 87 with 15 incomplete responses giving finally 72 responses with no missing data. The p value for social to environmental domain of 0.640 did not show satisfactory performance at 1% confidence level and indicated a need to address the activities under social domain. For rest hypothesis, the results indicated satisfactory performance of the model, even for “manufacturing and technology” domain which is the endogenous variable. The results of mediation analysis showed a p value of 0.645 for the mediation effect of social domain which is not satisfactory, implying no mediation effect whereas economical domain has a partial mediation effect at 1% confidence level, in the relationship between exogenous construct and target endogenous construct. This research is expected to provide a systematic approach for the enhancement of SM practices in manufacturing firms for further improving decision-making towards controlling environmental impacts of their activities.

A phase-wise approach to implement lean manufacturing

PurposeToday, manufacturing companies are facing a fierce competition and are under great pressure to cut costs for survival in the market. So emphasis is given to enhance quality, minimize waste, customer delight and increasing productivity through reduction in wastage of resources. But, most companies hesitate to implement all measures simultaneously to acquire lean manufacturing because of some practical/ capital constraints. Therefore, the purpose of this paper is to develop a phase-wise approach to implement lean manufacturing.Design/methodology/approachThe paper opted for an exploratory study using the qualitative flexible system methodology framework proposed by Sushil (1994) and options field methodology proposed by Warfield (1982, 1990) including rigorous group discussion comprising the employees representing middle and senior management with productivity improvement backgrounds. The response of experts was recorded using a specially designed instrument in the light of the parameters suggested in group discussion. The measures/ actions were arranged in the decreasing order of their cumulative score.FindingsThe paper provides a phase-wise approach to implement lean manufacturing. Mixed approach is preferred over the other three approaches to implement lean manufacturing. Thirty measures/actions contributing to mixed approach are identified to implement lean manufacturing in three phases. A three-phase approach is developed: 10, 14 and six measures in the first, second and third phases, respectively, are identified to implement lean manufacturing after considering the practical constraints faced by the companies.Research limitations/implicationsAll the measures/actions suggested to implement lean manufacturing are focused on the engineering manufacturing industry. Thus, the research results may lack generalizability and are limited to engineering manufacturing industry. The model developed in this research is based upon experts’ opinions. The experts’ opinion may be biased. The results of the model may vary in the real-world setting.Practical implicationsThe present paper provides guidelines to practitioners for implementing lean manufacturing in phases. Hopefully, this study will motivate the firm’s management for implementing lean manufacturing and limiting the effect of practical constraints and scarcity of resources.Originality/valueThis paper fulfills and identifies the need to develop an approach to implement lean manufacturing phase wise because of practical constraints.

Finding Meaning, Application for the Much-Discussed “Digital Twin”

Among the many buzzy, digitally related words or terms bandied about the industry over the past year or two, “digital twin” serves as something of a confluence of them all. Populating many industry conference agendas are high-level presentations and discussions with descriptors such as digitization, digitalization, digital transformation, and the digital disruption, which involve big data, data analytics, advanced analytics, artificial intelligence (AI), machine learning, automation, the Internet of Things (IoT), and the ever-important, abundantly abstract cloud. Some of those terms are used rather broadly and inter-changeably, leading many to wonder: What exactly are we talking about here? The definition of a digital twin is similarly less finite, but it is rather easy to conceptualize at a basic level. The technology links the physical world with the digital world, providing a digital model of a physical asset or process. It serves as a real-time data hub for its owner, allowing for reference to designed or expected performance and continuous offsite monitoring. Roots of the idea can be traced back to a similarly challenging sector that is tasked with exploring and operating in harsh environments normally inaccessible by humans. Successful space travel requires complex modeling and simulations, which NASA for decades has employed from its field centers on the ground. Michael Grieves, currently executive director of Florida Institute of Technology, brought the term to the fore during the early 2000s while working in the University of Michigan’s college of engineering, but he credits the coinage to his one-time NASA colleague and technologist John Vickers. Multinational conglomerates such as GE and Siemens have deployed the twin in everything from jet engines to power plants. The architectural engineering and automotive manufacturing industries are also mature in their use of digital twin. The digital twin in the building industry is referred to as the building information model. Traditionally slow on the uptake when it comes to implementing new technologies, the oil and gas industry is beginning to put the twin to work on its equipment, facilities, and wells with the promise of more efficient engineering, procurement, construction (EPC), and operations. The virtual hub is envisioned as a way of breaking down silos between work phases, operators and contractors, and the different industry disciplines—such as geophysics and reservoir engineering—required to carry out upstream projects.

A principal component analysis based three-dimensional sustainability assessment model to evaluate corporate sustainable performance

Abstract Corporate sustainability assessment involves two procedures including quantification of the upstream/downstream impacts generated during the company’s activities and integration of these impacts into a single metric. In order to achieve a desirable balance among the economic growth, environmental friendliness, and social equity, it is essential to scientifically manage and monitor the corporate sustainability. This paper proposes a three-dimensional (economic, environmental, and social) sustainability assessment model to analyze the corporate sustainable performance based on principal component analysis. An effective evaluation indicator system for cooperate sustainability assessment is provided after conducting reliability and validity analysis. Considering the coordination degree of sustainable development among the three dimensions, the corporate sustainability index is used to express the overall sustainability performance of a company. A case study on the internal combustion engine manufacturing industry in China has been conducted to verify the validity and practicability of the proposed method. A questionnaire survey was conducted at 52 companies to collect the economic, environmental, and social indicators data during 2010–2012. A total of 49 companies responded, yielding a total of 103 economic samples, 102 social samples, and 79 environmental samples. The results of this investigation show that a large gap exist in the reported enterprises in their sustainability, and most of them are recommended to take measures to improve the sustainability performance. At the end, a specific company is selected to illustrate how to identify the strengths and weaknesses of its sustainability performance.

Symbiotic Relationship between Higher Engineering Education and Manufacturing Industry in China

According to the requirements of the current “knowledge economy era” background, to explore the harmonious symbiosis between higher engineering education and manufacturing industry with the state space model, the results show that: the investment of higher engineering education has obvious influence on the factor of “higher engineering teachers’ input”, and the intermediary effect of “higher engineering teachers’ input” is obvious.

Cerium Oxide Nanoparticles are More Toxic than Equimolar Bulk Cerium Oxide in Caenorhabditis elegans

Engineered cerium oxide nanoparticles (CeO2 NPs) are widely used in biomedical and engineering manufacturing industries. Previous research has shown the ability of CeO2 NPs to act as a redox catalyst, suggesting potential to both induce and alleviate oxidative stress in organisms. In this study, Caenorhabditis elegans and zebrafish (Danio rerio) were dosed with commercially available CeO2 NPs. Non-nano cerium oxide powder (CeO2) was used as a positive control for cerium toxicity. CeO2 NPs suspended in standard United States Environmental Protection Agency reconstituted moderately hard water, used to culture the C. elegans, quickly formed large polydisperse aggregates. Dosing solutions were renewed daily for 3 days. Exposure of wild-type nematodes resulted in dose-dependent growth inhibition detected for all 3 days (p < 0.0001). Non-nano CeO2 also caused significant growth inhibition (p < 0.0001), but the scale of inhibition was less at equivalent mass exposures compared with CeO2 NP exposure. Some metal and oxidative stress-sensitive mutant nematode strains showed mildly altered growth relative to the wild-type when dosed with 5 mg/L CeO2 NPs on days 2 and 3, thus providing weak evidence for a role for oxidative stress or metal sensitivity in CeO2 NP toxicity. Zebrafish microinjected with CeO2 NPs or CeO2 did not exhibit increased gross developmental defects compared with controls. Hyperspectral imaging showed that CeO2 NPs were ingested but not detectable inside the cells of C. elegans. Growth inhibition observed in C. elegans may be explained at least in part by a non-specific inhibition of feeding caused by CeO2 NPs aggregating around bacterial food and/or inside the gut tract.

Modern Machining of Advanced Aerospace Alloys - Enabler for Quality and Performance

Advanced Aerospace alloys are designed to withstand high loads at extreme temperature conditions in their specific applications. These advanced alloys are more demanding in terms of machinability as their structure and material properties are focused on improved resistance to dwell crack growth, environmental damage (hot corrosion and oxidation) and creep strain, as well as higher levels of microstructure stability and high temperature yield stress. Machining of these alloys therefore focuses on high stock removal rates in roughing processes as well as in high surface finishing rates and good surface finish and surface integrity in finish machining. High performance machining methods will enable the aero engine manufacturing industry to meet increasing future requirements supported by an improved understanding of processes and process control factors. In addition to the technical challenges a number of other elements have to be considered to meet future business requirements, which include robustness of machining solutions and control of boundary conditions to be met in order to ensure acceptable surface and subsurface conditions in machining. Modern machine tool concepts, advanced machining processes and methods are key enablers to achieve overall quality and productivity goals to meet future market requirements.

Surface strength of silicon nitride in relation to rolling contact performance

Silicon nitride material has been traditionally used as bearing material due to its superior performance against bearing steel. Its successful application as a bearing element has led to the development of rolling contact applications in turbomachinery and automotive industries. In the case of latter, this is especially true for the engine manufacturing industry where its excellent rolling contact performance can make significant savings on warranty cost for engine manufactures. In spite of these advantages, the remaining limitation for their broader application is the high component machining cost. Further understanding of rolling contact performance of silicon nitride in relation to its surface integrity will enable engine manufacturers to produce components that meet the design requirements while at the same time reduce the machining cost. In the present study, the relationship between the C-sphere strength of a silicon nitride and its rolling contact fatigue life is investigated. The C-sphere test is used here to compare the strengths of three batches of sintered reaction-bonded silicon nitride (SRBSN) specimens with different subsurface quality induced by variation of machining parameters. In parallel, the rolling contact fatigue (RCF) performance of those machining conditions is studied on a modified four-ball tester. The results show that the most aggressively machined specimens have the weakest C-sphere strength and the shortest RCF life. This positive relationship can give component manufacturers a valuable reference when they make selections of candidate material and finishing standards.

Future aircraft greener by design?

Air Travel - Greener by Design is an initiative of the UK civil aviation community, embracing the aircraft and engine manufacturing industry, the airline and airport operators, the research community and government departments. Its primary objective is to identify and promote options for reducing the environmental impact of air travel. This paper considers what might be achieved within the next 50 years by advances in aircraft and engine technology and by a shift in design priority from minimising costs to minimising environmental impact. The emphasis of the paper is on climate change and it is suggested that, in the medium term, a substantial reduction in climate impact per passenger kilometre is potentially achievable. Present understanding of the effects of aviation on the atmosphere is, however, not yet sufficiently robust for this to be asserted with confidence. Atmospheric research, focussing on those effects of aviation which it may be possible to mitigate by design and operational changes, therefore remains a high environmental priority.