Machine Parts Research Articles

Finite element analysis of the thermal and thermo-mechanical coupling problems in the dry friction clutches using functionally graded material

Abstract The friction clutch is an important machine part in the torque transmission system, where it is responsible for gently transmitting the power from the engine to the gearbox and damping the tensional vibration. At the beginning of the engagement between the clutch’s elements, a large amount of heat is released due to frictional sliding between the elements of the clutch system, generating very high temperatures. In this work, the two- and three-dimensional finite element models were developed from scratch to explore the clutch disk’s temperature and contact pressure behaviors using an alternative frictional material such as functionally graded material (FGM). The two assumptions for the thermal loads were considered: uniform wear and uniform pressure assumptions. The thermal–structural problem for the new frictional material was solved numerically and then presented as the temperature distributions and the contact pressure at any instant of sliding time. Also, a comparison was made between the clutch system behaviors when using FGM with different frictional materials. The results showed that the FGM has superior results to the other available frictional materials.

Methodology for determining the durability of soil-cultivating machines working bodies of parts

The development and creation of high-performance machines for agricultural production is in many cases limited by the insufficient wear resistance of individual parts and assemblies. Russian scientists, engineers and technicians working on the problem of increasing the durability of machines have achieved significant results. However, theoretical conclusions and prerequisites for increasing durability and the method of calculating parts of agricultural machines for durability are not enough. The durability calculations of agricultural machine parts used in some cases during their design are imperfect. In addition, in most cases, there are no reasonable calculations of allowable wear that would ensure high quality machine operation, i.e. these calculations are not related to the tasks of preventive maintenance and operation of machines. A number of scientists have been studying the abrasive wear of working parts of soil-cultivating and seeding machines for decades, but this issue has not yet been finally resolved. Until now, there is no clear understanding of the essence of abrasive wear and the factors that determine it. Most of the work carried out on the study of abrasive wear of parts of working bodies of soil-cultivating machines is of a private nature. There are no works covering the study of the complex set of phenomena that occur during abrasive wear. At present, very little has been studied about the wear capacity of soils, there is no criterion that determines it, and there is no connection between the phenomena of wear of the working parts of soil-cultivating machines and the basic theoretical principles of agricultural mechanics. The study of the wear capacity of soils, as well as the determination of the magnitude of pressures that arise during the interaction of the working parts of agricultural machines with the soil, can be used when calculating the working parts of these machines for durability.

Analysis of Heat Transfer for the Copper–Water Nanofluid Flow through a Uniform Porous Medium Generated by a Rotating Rigid Disk

This study theoretically investigates the temperature and velocity spatial distributions in the flow of a copper–water nanofluid induced by a rotating rigid disk in a porous medium. Unlike previous work on similar systems, we assume that the disk surface is well polished (coated); therefore, there are velocity and temperature slips between the nanofluid and the disk surface. The importance of considering slip conditions in modeling nanofluids comes from practical applications where rotating parts of machines may be coated. Additionally, this study examines the influence of heat generation on the temperature distribution within the flow. By transforming the original Navier–Stokes partial differential equations (PDEs) into a system of ordinary differential equations (ODEs), numerical solutions are obtained. The boundary conditions for velocity and temperature slips are formulated using the effective viscosity and thermal conductivity of the copper–water nanofluid. The dependence of the velocity and temperature fields in the nanofluid flow on key parameters is investigated. The major findings of the study are that the nanoparticle volume fraction significantly impacts the temperature distribution, particularly in the presence of a heat source. Furthermore, polishing the disk surface enhances velocity slips, reducing stresses at the disk surface, while a pronounced velocity slip leads to distinct changes in the radial, azimuthal, and axial velocity components. The study highlights the influence of slip conditions on fluid velocity as compared to previously considered non-slip conditions. This suggests that accounting for slip conditions for coated rotating disks would yield more accurate predictions in assessing heat transfer, which would be potentially important for the practical design of various devices using nanofluids.

Analysis of the Impact of Geometry Modifications on the Fit of Splined Shaft Connections Manufactured Using Selected AM Methods

Broadly, understood additive manufacturing techniques expand the spectrum of production of machine parts that are used in various types of devices. However, the requirements to ensure dimensional and shape accuracy require the determination of appropriate material allowances or clearances to enable correct assembly. For the above reasons, the study presents an analysis of the impact of the assumed geometry modifications on the possibility of assembling a splined connection manufactured using selected AM techniques. The work focused on the analysis of changes in geometry resulting from the technology used. Using the Atos II Triple Scan optical measurement system and Gom Inspect software, the possibility of installation was determined for four variants of the splined shaft connection geometry, resulting from the technologies used.

Collision-free Tool Motion Planning for 5-Axis CNC Machining with Toroidal Cutters

Collision detection is a crucial part of CNC machining, however, many state-of-the-art algorithms test collisions as a post-process, after the path-planning stage, or use conservative approaches that result in low machining accuracy in the neighborhood of the cutter’s contact paths. We propose a fast collision detection test that does not require a costly construction of the configuration space nor high-resolution sampling of the cutter’s axis and uses the information of the neighboring points to efficiently prune away points of the axis that cannot cause collisions. The proposed collision detection test is incorporated directly as a part of the tool motion-planning stage, enabling design of highly-accurate motions of a toroidal cutting tool along free-form geometries. We validate our algorithm on a variety of benchmark surfaces, showing that our results provide high-quality approximations with provably non-colliding motions.

Performance Assessment of Quenchants on Mechanical Properties of Steel Grade A1046

The main aim of the study is to assess the performance of ghee oil, coconut oil and sea water quenchants on mechanical properties of A1045 steel. The procedures comprise the production of tensile steel specimens, heat-treat them into electrical oven at 850°C for one hour, quench them in ghee oil, coconut oil and sea water separately. The quenched samples were again tempered separately at the temperature of 400°C. Then all the specimens taken for the mechanical tests such as hardness, tensile, impact test and also to calculate the percentage of elongation, having completion of tests, microstructural analysis had conducted to view the structures contain in each specimen. The results obtained on these processes determine whether these oils can be used as local industrial quenchants. The facilities required for the research is include material testing laboratory, heat treatment workshop, machine shop and metallographic laboratory to mentioned but a few. The material selection is steel grade A1045, that have been normally utilize in metal industries for the production of machine parts and structural components

FEATURES OF THE FORMATION OF THE NANOSTRUCTURAL STATE OF THE SURFACE LAYER OF STEEL PARTS DURING PROCESSING AND OPERATION

Considered patterns of formation of the nanostructural state of the surface layer of machine parts during friction under conditions of complex dynamic loading. The results of the complex assessment of the state of the surface layer of samples after friction continuous indentation and scanning methods indenter, an analysis of changes in the work function of the electron from the surface of the samples. Shown that during the friction of steel surfaces, an increase in transverse slippage contributes to the formation of a more uniform surface layer. This decreases its strength, wear resistance, and a more uniform surface microgeometry. This is accompanied by a decrease in the magnitude and spread of the electron work function over the surface. The relationship between the nanostructural state of a polished surface and roughness and reflectivity is presented.

Electric discharge process modelling when piston pins recovery in internal combustion engines

Introduction. The relevance of the topic of the presented article is determined by the improvement of the technology for repairing and restoring machine parts. Currently, the technology of restoring piston pins of internal combustion engines (ICE) by a high-energy method of plastic deformation of metal using the energy of a high-voltage pulse discharge in a liquid is widely used – the electrohydraulic effect, and on its basis electrohydraulic processing. The purpose of the article is to increase the efficiency of the method of restoring piston pins of internal combustion engines due to the use of the electrohydraulic distribution method.Materials and methods. The research methods such as the analysis of the degree of influence of the electrical parameters of the electrohydraulic distribution process on the amount of deformation of the piston fingers depending on the relevant material were used. The article discusses a mathematical model of the electric discharge process when restoring piston pins. The calculation method determines the modes and parameters of the process of electrohydraulic distribution of piston pins while maintaining their fatigue life, static strength and wear resistance.Results. In this work, the degree of influence of the electrical parameters of the electrohydraulic distribution process on the amount of deformation of the piston pins, depending on the product material used, is established. A mathematical model of the electric discharge process during the restoration of piston pins has been developed, and based on them, the modes and parameters of the process of electrohydraulic distribution of piston pins have been determined while maintaining their fatigue life, static strength and wear resistance.Discussion and conclusions. The studies have shown that exploding wires made of iron, copper, and tungsten are not effective in restoring piston pins with an internal radius of up to 10 mm. The pressure in the case of their use does not exceed 100 MPa. Exploding Al wires with a diameter of less than one millimeter have the greatest effect. In this case, the inductance of the circuit should be minimal, because this provides the largest share of the energy released in the discharge channel from all stored in the capacitor. This ensures the highest pressure in the channel. Based on the same considerations, the capacity should be limited to a range of 3-12 UF. This method can be applied to the restoration of other car parts.

Spare parts warehouse re-layout design with kaizen 5S implementation to reduce wasted time searching for machine parts

Increasing the productivity and efficiency of production machines cannot be separated from the availability of machine spare parts in the warehouse department. Delays in the delivery of spare parts if machine problems occur often become a problem that disrupts efficiency. This delay was caused by the search for engine spare parts in the warehouse taking too long to find. The long search time was caused by the irregular placement of the materials and the messy condition of the warehouse. This research aims to make improvements to the goods search process to make it faster and more effective in the warehouse area and increase warehouse capacity using warehouse re-layout. This research method uses the implementation of warehouse re-layouts combined with the application of Kaizen 5S in controlling the condition of machine spare parts. This research found that the reason for the long search time for machine spare parts was due to the lack of knowledge of warehouse operators and the absence of training regarding the application of the 5S method, as well as the careless placement of spare parts in warehouses that were not neatly arranged. This research has resulted in a reduction in search time for engine spare parts from 6.4 minutes to 4 minutes per spare part unit or a decrease of 36.5%. Meanwhile, the results of the warehouse re-layout resulted in an increase in warehouse capacity from 80 pallets to 316 pallets, an increase of 395%.

Influence of Tool Inclination and Effective Cutting Speed on Roughness Parameters of Machined Shaped Surfaces

Free-form surfaces in the automotive or aviation industry where the future shape of the product will contain complex surfaces raises the question of how to achieve the necessary shape of the required quality in the milling process. One of the methods of their production is the use of 5-axis milling, in which it is necessary to consider not only the input data of the process itself, but also the methodology for evaluating the desired results. Correctly answered questions can thus facilitate the choice of the inclination of the tool when machining parts of the surfaces defined in the experiment. The primary goal of the paper was to monitor the influence of tool inclination on the quality of the machined surface and effective cutting speed by evaluating surface roughness and surface topography. The experiment was designed to show the effect of different tool positions while the feed per tooth fz for the finishing operation remained constant. The best result in terms of surface quality was achieved with a tool inclination of 15° in the cutting process. The most unfavorable result was obtained with a tool axis inclination of zero degrees due to unfavorable cutting conditions.

Multi-objective optimization of wire electrical discharge machining process using multi-attribute decision making techniques and regression analysis

Wire electrical discharge machining (WEDM) is one of the most important non-traditional machining methods that is widely used in various industries. The present research work is concerned with the influences of process variables on quality of machined specimen obtained from WEDM process. The process parameters to manufacture mold structure included wire feed speed, wire tension and generator power, and in the current research, the effects of these variables on the aim factors, namely dimensional accuracy, hardness and roughness of product surface have been investigated, simultaneously. In order to obtain the optimal experiment, the multi-objective optimization with discrete solution area has been employed. Method based on the removal effects of criteria (MEREC) and weighted aggregates sum product assessment (WASPAS) techniques have been used with the aim of weighting the objective functions and discovering the best practical experiment. In the following, the regression analysis has been employed to study the effects of variables on response factors. A good correlation between the results gained from two analysis methods was observed. Based on MEREC-WASPAS hybrid technique, the weights of roughness, hardness and dimensional accuracy of machined part were calculated to about 89%, 9% and 2%, respectively. In the selected optimal experiment, the amount of wire feed speed, wire tension and generator power variables were considered to, in turn, 2 cm/s, 2.5 kg, and 10%.

Recent development in feeding mechanism of sheet metal shearing machine for productivity improvement: A review

Sheet metal working processes find extensive applications in industries such as automobile and aerospace. However, the sharp edges of sheet metal pose a safety hazard to workers, potentially leading to injuries. In response to this concern, we have conceived and developed an automatic sheet metal cutting machine. Feeding mechanism is one of the important part of sheet metal shearing machine. In this paper, recent research papers are reviewed. This papers also reports recent development in feeding mechanism and its role for productivity improvement. Also, proposed innovative feeding mechanism represents a pivotal advancement in the field of mechanical workshops, aligning with industry demands for increased productivity and safety in sheet metal processing. Paper throws lights on benefits of automation into the sheet metal cutting process, which a significantly reduces in labour costs while ensuring precise and efficient cutting operations. Paper also focuses the various parameter such as cutting speed, material properties.

Making 3D printing of machine parts more efficient

Identifying potential flaws without having to remove the parts from the manufacturing equipment.

Design and Experimental Tests of a Four-Way Valve with the Determination of Flow Characteristics for Building Central Heating Installations Using Solid Modeling

The article presents the design of a four-way valve, implemented in SolidWorks software (SOLIDWORKS® i 3DEXPERIENCE® Works Simulation) and used for central heating installations in buildings. The project was carried out in order to examine the innovative design of the medium mixing mechanism and to conduct strength and FMEA analysis. The innovative solutions proposed by the authors in this work will allow valves of this type to meet stringent environmental standards. These standards are currently being introduced for this type of structural element of machine parts as part of the energy transformation of buildings. Potential failures occurring in individual elements of the four-way valve were also tested using Failure mode and effects analysis. In addition, strength tests were performed in SolidWorks software using static analysis, and optimization tests were performed on the refrigerant in terms of its impact on the environment. The characteristics of the tested materials in the valve design show that the best materials are brass and stainless steel. Brass has a Poisson’s ratio of 0.33, a tensile strength of 478.4 MPa and a yield strength of 239.7 MPa. In turn, stainless steel is characterized by the following parameters: Poisson’s ratio of 0.27, tensile strength of 685 MPa and yield strength of 292 MPa. The designed valve reduces energy consumption by 30% through a properly designed medium flow with the appropriate selection of materials. Moreover, the design reduces the thickness of the contaminant layer by 0.17 mm, with a capacity factor of −2.50% and an evaporator Δp of 3.10% (53 kPa). The performed research provides knowledge on the subject selection of appropriate material, a description of the potential failures of the structural elements of the designed four-way valve and methods of counteracting these failures. The article presents the optimization role of the tested component in the context of sustainable development.

МОДЕЛИРОВАНИЕ МИКРОРЕЛЬЕФА ПОВЕРХНОСТИ ПОЧВЕННОГО СЛОЯ ДЛЯ УТОЧНЕННЫХ РАСЧЕТОВ РАБОЧИХ ОРГАНОВ НА ПРОЧНОСТЬ

Issues of increasing the reliability of working parts of agricultural machines interacting with the soil surface are discussed in the article. A loading model based on taking into account microroughness of the surface soil layer using a fractal surface model constructed using the diamondsquare algorithm is proposed. It is shown that the parameters of microroughness of the soil surface, calculated using the proposed model, correspond to experimental data obtained by profiling the soil surface during pre-sowing treatment and during the preparation of flax. A comparative calculation of the loading of the needle harrow tooth and the tiller tooth was carried out in accordance with the model of a flat soil surface and a soil surface with a microrelief, modeled according to the proposed model. It is shown that the mechanical stresses in the working bodies interacting with the soil surface, loaded according to the proposed model, are 14% greater during pre-sowing treatment, and 25% greater when preparing flax trust, than when calculated using a model of a flat soil surface. The use of a microrelief model is optimal both when calculating soil tillage machines and when calculating other flax harvesting machines (pulling machines, flax sliver fluffers, balers and other units) that are not intended for direct tillage of the soil, but have contact with it during the technological process.

INVESTIGATION OF CORROSION INHIBITION POTENTIAL OF HYPHAENE THEBAICA SHELLS EXTRACT ON TANNERY MACHINES PARTS IN ACIDIC MEDIUM

Corrosion inhibition potential of ternary machine part was investigated by using ethanoic extract of hyphaene thebaica shells as inhibitor at different temperature of 313K and 333K. The Tannery machines part which are majorly made up of mild steels are subjected to harsh conditions, which include exposure to moisture, air, acid, base, salt and other environmental components that causes corrosion on machines’ parts. The aim of this research was to generate measurable and testable data towards the control of corrosion using plant (hyphaene thebaica shells ethanolic extracts) as inhibitor. This was accomplished through the determination of inhibitor’s performance by weight loss techniques, determination of metal-inhibitor interaction mechanism using kinetic parameters and adsorption isotherms (Langmuir and Temkin), the corrosion process through the use of exposure time, phytochemicals of the shell extracts, inhibitor concentration, media concentration, temperature, initial weight of metal and the weight of the metals in every 2 hours for a total of 6 hours. A weight loss technique was adopted and the weights of the mild steel were recorded every 2 hrs for 6 hrs. The highest inhibition efficiency (78.44%) was attained at 333 K for 0.1 g/dm3 concentration of the plant inhibitor. Inhibition efficiency decreased with further increase in the temperature. The green inhibitor was found to be effective because it is ecofriendly, inexpensive and biodegradable.

Thermodynamics of solvent sorption by layers of carbon-chain polymers in damping rubber blankets

The paper addresses the study of the thermodynamic compatibility of carbon-chain polymer compositions of offset rubber blankets with low-molecular-weight liquids, paint solvents and care agents for rubber damping machine parts used in transport, mechanical engineering and printing industries. The Flory-Huggins parameters χ were determined by inverted gas chromatography and calculation performed using the mathematical model of sorption, and the correlation between χ obtained by these two independent methods was found. The excess thermodynamic characteristics of the studied systems G E, H E and S E were calculated to predict the compatibility of components in these systems. The relationship was found between χ that characterizes the thermodynamic quality of the solvent and the equilibrium swelling index of polymer networks.

Rancang Bangun Mesin Penggiling Sambel Pecel dengan Penerapan Antropometri Guna Meningkatkan Efisiensi dan Kepuasan Pengguna (Studi Kasus: UMKM Warung Pecel dan Rujak 46)

The sambel pecel grinding machine is a machine used to smooth the ingredients of sambel pecel. The ingredients for making sambel pecel consist of fried peanuts, brown sugar, red chili, garlic, lime leaves, and other ingredients. All these ingredients will be ground to make sambel pecel. UMKM pecel and rujak coffee shop 58 in the process of grinding sambel pecel still requires services from other places, so that condition causes the production process to be less efficient. The purpose of this research is to make a sambel pecel grinding machine part of the transmission system.The results of the design of the resource and transmission parts of the sambel pecel grinding machine are: the resource used is an AC electric motor with a power of 0.268 Hp and a rotation speed of 2900 rpm, the transmission used is a pulley and a type A V-belt to drive the grinder, the diameter of the drive pulley used is 65 m, the driven pulley is 130 mm, the length of the V-belt circumference is 711 mm, number of belts required 1 piece, and uses a WPA 40 gearbox with a ratio of 1: 20.

Proposed Improvements to Reduce the Risk Work Accidents on CV HB with FMEA and HAZOP Method

A company called CV HB makes socks based on what its customers want. Bandung is home to CV HB. Several machines, including Santoni, Dakong, Obrass, Stock Steam, and others, are employed in CV HB's sock production process. Numerous personnel who are in charge of running the machinery and performing other production tasks are also a part of the production process. The execution of health and safety protocols has yet to be well-executed in the production sector. The organization saw 24 workplace accidents between 2019 and 2023, including injuries from needles and blades, hands stuck in machinery, brain injuries from machines, slipping down stairs, and many more incidents. In order to address health and safety concerns at CV HB, the research attempts to pinpoint the root causes of workplace mishaps and offer suggestions for enhancement. Hazard and Operability Review (HAZOP) and Failure Mode and Effects Analysis (FMEA) were the methodologies used in the investigation. A few suggestions for improvement for the chosen departments are using material handling tools during the material retrieval process, posting warnings about machines with sharp parts, requiring protective gear like masks and gloves, designing foam padding for sharp machine parts, and installing fans.

Artificial intelligence and edge computing for machine maintenance-review

Industrial internet of things (IIoT) has ushered us into a world where most machine parts are now embedded with sensors that collect data. This huge data reservoir has enhanced data-driven diagnostics and prognoses of machine health. With technologies like cloud or centralized computing, the data could be sent to powerful remote data centers for machine health analysis using artificial intelligence (AI) tools. However, centralized computing has its own challenges, such as privacy issues, long latency, and low availability. To overcome these problems, edge computing technology was embraced. Thus, instead of moving all the data to the remote server, the data can now transition on the edge layer where certain computations are done. Thus, access to the central server is infrequent. Although placing AI on edge devices aids in fast inference, it poses new research problems, as highlighted in this paper. Moreover, the paper discusses studies that use edge computing to develop artificial intelligence-based diagnostic and prognostic techniques for industrial machines. It highlights the locations of data preprocessing, model training, and deployment. After analysis of several works, trends of the field are outlined, and finally, future research directions are elaborated