Fabrication Quality Research Articles

Design, Analysis and Optimization of Composite Propeller Shaft

Most of the automobiles have Rear wheel drive and front engine installation consists of a transmission shaft. Substitution of conventional metallic (SM45C) Propeller Drive Shaft with the composite (CFRP) structure has many advantages. Composite materials have acquired prominence in the engineering industry due to their remarkable strength-to-weight ratio, corrosion resistance, and adaptability. This paper explores the multifaceted process of designing, analysing, and optimizing composite propeller shafts, with a primary focus on their application in marine and automotive industries, aiming to maximize performance while reducing weight. The design phase initiates by establishing precise requirements, encompassing torque loads, rotational speeds, environmental conditions, and safety factors. Material selection is a pivotal decision point, considering factors like fiber type, resin matrix, and layup orientation. Advanced Finite Element Analysis (FEA) technologies are used to simulate the mechanical behaviour of composite propeller shafts under a variety of operational scenarios, assisting in the identification of stress concentrations. Deformations, as well as key failure modes. The design process is iterative. The feedback from these simulations is used to improve the basic design. The analysis phase stress distribution, torsional vibrations, and dynamic behaviour of the composite propeller shaft. A comprehensive study of various layup configurations and boundary conditions is conducted to assess their impact on structural performance and reliability. Additionally, manufacturing considerations, encompassing fabrication techniques, quality control, and cost-effectiveness, are addressed to ensure practical feasibility. The goal of the optimization phase is to lower the weight of the composite propeller shaft while retaining structural integrity and operational reliability. The optimisation outcomes provide information on the best material mix, layup sequence, and geometric factors that achieve the best balance of weight reduction, greater performance and productivity. The findings from this study contribute substantially to the advancement of composite propeller shaft technology, offering engineers valuable insights into the intricacies of design, analysis, and optimization processes. By harnessing the ability of composite materials effectively, industries can realize significant benefits, including reduced fuel consumption, improved efficiency, and enhanced overall system performance, resulting in more sustainable and competitive products for the maritime and automotive sectors.

A novel method of suppressing machining vibration in robotic milling using magneto-rheological foam damper

Owing to their remarkable flexibility and favorable cost-effectiveness, industrial robots have found extensive applications to cutting of materials across sophisticated manufacturing fields. However, the structurally low rigidity of these robots renders the tool tip prone to substantial oscillations during machining processes, significantly impacting product fabrication quality. The objective of this study is to present a novel methodology employing magnetorheological dampers for mitigating vibrations during robotic milling operations. Specifically, a new type of ring nested Magneto-Rheological Foam Damper (MRFD) working in the squeeze mode is developed. Firstly, the MRFD's structure is designed considering the vibrational characteristics of robotic milling. Subsequently, a damping force model of the MRFD is derived. The feasibility of the MRFD’s structural design is validated by the finite element analyses, which is instrumental in comprehending the influence of structural parameters on the electromagnetic characteristics of the MRFD. Next, a prototype of the MRFD is fabricated selecting appropriate parameters. Finally, a series of excitation and milling experiments are conducted on a KUKA KR500 robot. The outcomes demonstrate a substantial reduction (37%-69%) in radial vibration amplitude at the tool tip during robotic milling, highlighting the effectiveness of the developed MRFD. This research endeavor has introduced a pioneering avenue and framework for vibration control in robotic milling, offering a novel paradigm for enhancing the precision of robotic machining.

Design of a Novel Creel Conditioning System for Circular Knitting Machines

Maintaining a certain humidity level of humidity in yarn packages and removing fibre fly from the environment is very important for production efficiency and product quality in textile mills. Humidity has a significant effect on the quality and efficiency of fabrics, especially those made from hydrophilic fibres. The high temperature and low humidity level in the factory environment results in lower yarn strength and higher yarn breakage. The solution is to provide optimum temperature and humidity levels through a central air conditioning system. However, conditioning the entire factory environment is an expensive approach and does not facilitate satisfactory production efficiency. In this study, a new creel system for circular knitting machines was designed to provide excellent yarn package conditioning. More efficient production and economical conditioning were achieved with this new creel system.

Fabrication, characterization and investigation of flexible light weight nylon-6 based silicon rubber composites for radiation attenuation

Lead, the conventional choice for wearable radiation shielding, faces growing health and occupational concerns. This prompts the search for a lighter, more flexible alternative. Nylon 6, prized for its mechanical prowess, emerges as a reinforcement in wearable composites. This study focuses on creating silicon rubber composites using Nylon 6 reinforcement and varying proportions of Bismuth oxide and aluminium fillers. Mechanical Parameters such as Tensile strength and Elongation at break, are studied and the quality of fabrication is assessed using a Scanning Electron Microscope. Studies on various combinations of nylon 6-based silicon rubber with varying percentages of bismuth oxide and aluminium fillers have been studied and radiation parameters have been assessed. TSN-4 (60% wt. bismuth oxide along with 50% wt. aluminium powder) showed the highest tensile strength of 25.13 MPa having 79.3% of elongation at break followed by TSN-1 & TSN-3. The results reveal good mechanical properties as well as satisfactory radiation attenuation properties. The combination of Nylon 6-based with 60% wt. bismuth oxide along with 50% wt. aluminium powder (TSN4) was considered optimal for the energy range from 140 keV to 511 keV with HVL of 2.06 cm, TVL 6.86 cm, and MAC of 0.093 gm/cm2 and also bearing good mechanical properties. Further, the fabricated samples can be compared with the Monte Carlo Simulation method for further improvements in the fabricated composites. The produced composites have the potential to be used as lead-free protective wearables and wearing devices in nuclear medicine following further investigation.

Analysis of the properties of bast raw materials as a component of fabric for military uniforms

The relevance of the present research is determined by the need to replace imported raw materials for manufacturing military clothing with Ukrainian raw materials of industrial hemp and oilseed flax. The aim was to analyse the quality properties of bast raw materials and determine their potential for use in military uniforms. In the course of solving the set goals, the methods of complex analysis, synthesis, observation, measurement, comparison and generalisation of the obtained results and information were applied, as well as standard methods generally accepted in the light industry were implemented. It is noted that hemp cottonin and oilseed flax fiber, in contrast to other natural fibers, are more durable, resistant to abrasion, decay, and are characterised by sanitary, antistatic, hypoallergenic and antibacterial properties. It has been revealed that fabrics made of these fibers are durable, have high resistance to ultraviolet radiation, hold colour well, do not fade, etc. The academic paper analyses scientific studies on the use of this raw material for various types of military clothing, protective body armour, and gunpowder production. By determining the main properties of the bast raw materials under study, the possibility of using this raw material in some types of military uniforms was established. The main feature of the structure and components of the research was the systematic and comprehensive study of the quality properties of bast raw materials at all stages of its processing. It was proposed to use oilseed flax fibers and hemp cottonin instead of cotton fibers in fabrics for military purposes. This will reduce the state’s material expenditures on the purchase of fabric for the defense sector and, at the same time, it will help bring the Ukrainian light industry to a new quality level and increase the competitiveness of Ukrainian manufactured goods in the global market. Knowledge of the properties of bast raw materials can help manufacturers improve the quality of fabrics for military purposes

A Comparison of the Physical Properties Between Merino Wool and Camel Hair Through Discriminant Analysis

ABSTRACT The applicability of camel hair is still conditioned by a gap in the knowledge about this raw material, which in turn hinders its supply chain, commercial possibilities, and the value that the product reaches in the market. The present research compares the physical-mechanical properties of Canarian camel hair versus Merino sheep wool, the world’s most popular proteinic fabric material, using a discriminant canonical analysis. The attributes that maximized differences between both types of animal-origin fibers were related to average fiber diameter, fineness, length staple, and residual dirt. Although slightly shorter than sheep wool, camel hair can reach a prominent fabric quality and spinning performance given its greater average diameter and its lower variation within small fragments along the snippet, as well as the higher distance from the tip to the finest point in the staple, which is an indicator for the breaking point. Such characteristics are known to increase bending rigidity during the manufacturing process. Residual dirt may be associated with the low-input, extensive exploitation of camels. The present paper provides a reference for maturing pre-process and manufacture techniques for the further valorization of camel hair in the present-day textile industry and, thus, engages income opportunities for this livestock production.

Rapid quantitative analysis of cotton-polyester blended fabrics using near-infrared spectroscopy combined with CNN-LSTM

Accurate and rapid quantitative analysis of fiber content is important for blended fabric quality control and supervision. In this paper, a deep learning method based on an improved hybrid network of convolutional neural network (CNN) and long short-term memory (LSTM) to fast and accurate determine cotton content of cotton-polyester blended fabrics using near-infrared (NIR) spectroscopy. The cotton-polyester blended fabric samples were partitioned into training set, validation set and testing set in the ratio of 6:2:2 to develop the quantitative model of cotton content of blended fabric. Firstly, a one-dimensional CNN architecture is designed and modeled to obtain the CNN parameters and to evaluate the spectral preprocessing methods. Then, the CNN structure is modified and improved using LSTM to obtain a CNN-LSTM structure. The root mean square error (RMSE) of the validation set obtained by CNN model is 0.83%, which is 34.03% lower than that of the traditional partial least squares (PLS) model, and the RMSE of the testing set obtained by CNN model is 0.88%, which is 25.88% lower than that of the PLS model. The RMSE of the validation set obtained by CNN-LSTM model is 0.65%, which is 47.85% lower than that of the PLS model, and the RMSE of the testing set obtained by CNN-LSTM model is 0.75%, which is 36.57% lower than that of the PLS model. Compared with PLS and CNN models, the CNN-LSTM model can more accurately analyze the cotton content proportion of cotton-polyester blended fabrics, which provides a new fast and non-invasive method for the quantitative detection of fabrics.

Performance Properties of Swimwear Fabrics Produced from Polyester and Recycled Polyester Fiber

The textile industry is responsible for producing a significant amount of global CO2 emission, which is the biggest contributor to global warming and climate change. Researchers have focused on reducing greenhouse gas emission by recycling textile materials rather than producing new fibers through circular economy approaches. Using recycled fibers or blending new fibers with recycled fibers is becoming an essential approach to strike a balance between textile quality and sustainability. In this study, swimwear fabrics made of 100% polyester, and 50% polyester-50% recycled polyester fiber were investigated in terms of their performance properties including color fastness, abrasion resistance, and seam strength. This study will provide a better understanding of the effect of the polyester fiber and recycled polyester fiber combination on the performance/quality properties of swimwear fabrics.

Characteristics and Quality of Flame-Retarded Ramie Fabrics for the Development of Functional Textiles.

Cellulose fabric testing for flame-retardant studies is frequently necessary in various textile applications. Natural cellulose material from ramie (Boehmeria nivea) is being promoted as an alternative raw material for the development of fire-resistant fabrics. This research aims to optimize the coating process of ramie fabric using a phosphorus-based flame retardant (FR) to enhance its flame-retardant characteristics. The FR treatment involves bleaching the fabric with H2O2; followed by fabric finishing using a formula comprising 3% (v/v) hydroxymethyl resin; phosphoric acid (2%); and two formulations of the flammable agent Flamatic DM-3072N: 40% (v/v) and 50% (v/v), applied using the pad-dry-cure method. The flame-retardant properties of the treated fabric are evaluated through flammability testing based on the ASTM D6413-08 standard, limiting oxygen index (LOI) analysis, and micrograph surface structure analysis with SEM. The results indicate that ramie fabric treated with the FR-50% material exhibits superior fire resistance, preventing fire spread on the fabric with a char length of 15-30 mm and a LOI value of 29. These findings highlight the potential of FR-treated ramie fabrics for various industries, including the automotive and protective clothing industries.

Automated brightfield layerwise evaluation in three-dimensional micropatterning via two-photon polymerization.

Two-photon polymerization (TPP) is an advanced 3D fabrication technique capable of creating features with submicron precision. A primary challenge in TPP lies in the facile and accurate characterization of fabrication quality, particularly for structures possessing complex internal features. In this study, we introduce an automated brightfield layerwise evaluation technique that enables a simple-to-implement approach for in situ monitoring and quality assessment of TPP-fabricated structures. Our approach relies on sequentially acquired brightfield images during the TPP writing process and using background subtraction and image processing to extract layered spatial features. We experimentally validate our method by printing a fibrous tissue scaffold and successfully achieve an overall system-adjusted fidelity of 87.5% in situ. Our method is readily adaptable in most TPP systems and can potentially facilitate high-quality TPP manufacturing of sophisticated microstructures.

Mathematical modeling of dynamic yarn input tension on circular weft knitting machine with positive storage feeding

Yarn input tension (YIT) during knitting has a profound impact on fabric quality. Modern high-speed circular knitting machines are mostly equipped with positive feed system, where a predetermined length of yarn is supplied to knitting zone. Several contributing factors affect YIT and keeping YIT in precise setting is a complex phenomenon. A plethora of studies addressed yarn tensile analysis for different knitting systems. However, a comprehensive description of generated YIT for a positive storage feed based circular weft knitting machine is still missing. This study aimed to navigate YIT mathematically through a model development by analyzing yarn tensile forces for different zones of yarn path in dynamic knitting operation. The model revealed several YIT contributing variables. After evaluating the governing equation, the impact of different variables, and their interdependence have also been discussed. The predicted YIT supported the actual YIT with a mean percentage error of around 10%.

Enhancing warp sizing effect and quality: a comprehensive review of the squeezing process and future research

Warp sizing significantly influences both the efficiency of weaving machines and the overall quality of the woven fabric, playing a crucial role in the weaving preparation process. Ensuring precise control of process parameters and equipment status during the sizing process is essential to maintain desirable sizing quality. This paper clarified the research significance of squeezing from the perspective of its application in warp sizing. Moreover, research advances in the squeezing device, including the structure, material, surface state of squeezing and sizing rollers, the configuration of the squeeze and sizing rollers, the spraying device, the pressurization methods for the squeezing roller, and their influence on sizing performance were reviewed in detail. A comprehensive analysis and summary were conducted to explore the correlations between sizing quality and diverse squeezing technical parameters, encompassing squeezing force, surface hardness of rubber-covered sizing and the squeezing roller, squeezing width, warp speed, and immersion time. In addition, this article also outlines the mathematical models related to the squeezing process and the characterization methods of the squeezing effect. Finally, it offers a glimpse into potential future research directions concerning the squeezing process.

Wetting Behavior of Inkjet-Printed Electronic Inks on Patterned Substrates.

In inkjet printing technology, one important factor influencing the printing quality and reliability of printed films is the interaction of the jetted ink with the substrate surface. This short-range interaction determines the wettability and the adhesion of the ink to the solid surface and is hence responsible for the final shape of the deposited ink. Here, we investigate wetting morphologies of inkjet-printed inks on patterned substrates by carefully designed experimental test structures and simulations. The contact angles, the surface properties, and drop shapes, as well as their influence on the device variability, are experimentally and theoretically analyzed. For the simulations, we employ the phase-field method, which is based on the free energy minimization of the two-phase system with the given wetting boundary conditions. Through a systematic investigation of printed drops on patterned substrates consisting of hydrophilic and hydrophobic areas, we report that the printed morphology is related not only to the designed layout and the drop volume but also to the printing strategy and the wettability. Furthermore, we show how one can modify the intrinsic wettability of the patterned substrates to enhance the printing quality and reliability. Based on the present findings, we cast light on the improvement of the fabrication quality of thin film transistors.

Groundwater conservation, and recycling and reuse of textile wastewater in a denim industry of Bangladesh

Bangladesh holds the 2nd position after China in the global apparel market in terms of denim export. In the textile industry clusters of Bangladesh, the groundwater level is depleting at an alarming rate due to overconsumption and mismanagement. The present study evaluates the groundwater conservation potential of a denim facility in Manikganj District through an effluent recycling and reuse approach. In this study, 100% treated wastewater and 10% treated wastewater mixed with softwater were utilized in the wet processing plant to dye and wash sample denim products and investigated for their fabric quality using seven parameters. The test results followed the requirements given by the North American and European fashion brands that source denim products from Bangladesh. The feasibility assessment of groundwater conservation through its high (100%) and low (10%) recycling rates indicated that the studied facility can potentially save around 619,230 m3 and 61,923 m3 of groundwater in a year, respectively.

Assessing the urbanization-induced impact on environmental parameters of a city from a remote-sensing perspective

An unplanned urban sprawl is a significant challenge for cities in developing nations. Such growth damages the environmental fabric (quality) of the city. The environmental parameters that are mainly affected due to urbanization need to be monitored for sustainable urban development. Hence, it becomes essential to adopt a sustainable framework for a thorough critical examination of environmental parameters that are altered due to urbanization as its consequence. Thus, this paper analyses the spatial-temporal changes that occurred in three vital environmental parameters: Land Surface Temperature (LST), Vegetation Cover (VC), and Particulate Matter (PM2.5), due to unplanned urbanization in the Bhopal city of Madhya Pradesh state in India. The study evaluates the relationship among these parameters. Then, an Environmental Quality Index (EQI) is quantified from 2000 to 2020 to analyse the environmental quality of the city. Further, a trend analysis for these parameters and the EQI is done. Based on the results of EQI, the city's environmental quality is classified. The findings show that in various parts of the city, LST and PM2.5 were found to be increased by 1–2 °C and 23–25 μg/m3, respectively. The severity analysis of the EQI revealed that environmental quality was found to be good to moderate in 2005 whereas, it deteriorated to poor and very poor levels by the year 2020. Overall results show that severe environmental degradation was significant in some specific locations in dense urbanization, heavy traffic areas, industrial zones, and major highways. The research reveals the environmental consequences of unplanned urbanization, offering valuable insights for policymakers and urban designers to improve the quality of urbanization and advance sustainable development. It also suggests strategies and policy interventions for managing industrial and vehicular pollutants and advocates the vital role of urban greening, which can aid in raising the quality of the urban environment.

Detection of Microdefects in Fabric with Multifarious Patterns and Colors Using Deep Convolutional Neural Network

Automatic detection of fabric defects is important in textile quality control, particularly in detecting fabrics with multifarious patterns and colors. This study proposes a fabric defect detection system for fabrics with complex patterns and colors. The proposed system comprises five convolutional layers designed to extract features from the original images effectively. In addition, three fully connected layers are designed to classify the fabric defects into four categories. Using this system, the detection accuracy is improved, and the depth of the model is shortened simultaneously. Optimal detection rates for testing dirty marks, clip marks, broken yams, and defect-free were 88.01%, 90.15%, 98.01%, and 97.73%, respectively. The experimental results show that the proposed method is effective, feasible, and has significant potential for fabric defect detection.

A proposed method for quality evaluation of COVID-19 reusable face mask

During the time of COVID-19, the use of face masks has become an essential control and prevention measure. The wide usage of disposable face masks has presented a great challenge to governments to face the impact of plastic waste on humans health and the environment. The quality of reusable face masks was assessed in previous research based on general measures such as the fabric, size fit, arrival time, price, and convenience, and based on more-specific measures related to the number of layers and the included filters. However, as the quality of reusable face masks includes several other dimensions, the general measures cannot be enough to ensure a comprehensive evaluation of these products during the COVID-19 outbreak. Nowadays, however, digital social media has provided venues and convenient tools for users to share their opinions, preferences, and experiences on the quality of reusable face masks. Considering reusable face masks, several types have been launched on online platforms to meet the increasing demand during COVID-19. The main goal of this study is to investigate how reusable face masks can be evaluated through online customers’ reviews. This study proposes a combination of qualitative (text mining) and quantitative (survey-based analysis) approaches to provide the researchers with a method of data analysis to inspect the most influential quality factors for the evaluation of reusable face masks. We performed a literature review on the previous works and also collected online customers’ reviews from Amazon.com to find the quality factors of reusable face masks. The review of previous literature on reusable face masks and the result of online reviews analysis indicated that several factors impact customers’ experiences, including filteration efficiency, fabric quality, breathability, design, functionality, environmental impact, comfort, easy to use, easy to clean, economic impact, donning/doffing, quality of seal, vision, communication and safety protection. The presented framework can be complementary to the existing evaluation research methods, which use the strengths of one method to overcome the shortcomings of the other.

Pengaruh Jenis Mordan Dan Lama Waktu Pencelupan Terhadap Kualitas Warna Kain Batik Dengan Pewarnaan Alam Kulit Bawang Merah Menggunakan Proses Post-Mordanting

Red onion skin is one of the wastes that can be used as a natural dye because it contains anthocyanins which are one of the natural color pigments. The availability of red onion skin waste is very abundant, especially from household waste and industrial waste which has not been optimally utilized. The purpose of this study was to determine the effect of fixation type with different dyeing times on the color quality of batik fabric. This research method is an experiment by varying the fabric treatment in the pre-mordanting process, time variations of 30 and 60 minutes, and fixation variations, namely alum, arbor, and quicklime. The results of the study obtained that red onion skin extract is very good as a natural dye for dyeing batik fabric, the value of the color fastness test at 40 ℃ soap washing and cloth rubbing (wet) shows good quality with an average value of 4 and 4 - 5. The value of the L *, a *, b * color difference test and the results of visual observations on the pantone color produce an orange-red color that contains dominant color elements towards reddish and yellowish.

Enhancing heat transfer in MHD Falkner's‐Skan flow with thermal radiation, free convection and dusty fluid between parallel plates

AbstractFalkner's‐Skan flows are one‐dimensional flows widely used in fluid dynamics and boundary layer theory. They optimize heat exchangers and cooling systems, enhance turbine and compressor blades in turbomachinery, and provide consistency and quality in semiconductor fabrication. Additionally, they assist in pollution management and environmental impact assessments. The variety of Falkner's‐Skan flows clarifies fluid flow phenomena and their practical applications. This article aims to explore the impact of surface temperature on the flow behavior of dusty fluid in Falkner's‐Skan flow. The study focuses on the flow of dust particles in a channel formed by two infinite parallel plates. The study assumes that the particles are round and uniformly dispersed in the fluid. Furthermore, the article takes into account the effect of radiation on the energy equation. With the findings of this study, we hope to gain a better understanding of the dynamics of Falkner's‐Skan flow and contribute to the development of effective strategies for managing the flow of dusty fluids. The right plate's movement at free stream velocity causes the fluid to flow. Partial differential equations are used to represent the behavior of the flow. The Poincare‐Light Hill Technique yields exact answers. Visual representations of the temperature and velocity curves show the effects of different factors. It is possible to create graphic pictures of the fluid and dust particles using Mathcad‐15. Furthermore, critical fluid characteristics for engineers, such as skin friction and heat transfer rate, are analyzed and tabulated. These evaluations include the heat transfer rate at the wedge surface and the influence of this enhancement on surface viscous drag forces.

A Systematic Review of Natural Fiber-Reinforced Polymer Composites in Prosthetic Socket Fabrication

This review systematically examines the burgeoning field of natural fiber-reinforced polymer (NFRP) composites in prosthetic socket fabrication. The review begins by exploring the historical context and recent shift towards sustainable and biocompatible materials in prosthetics, with a specific focus on NFRP. It delves into the composition and properties of NFRP, detailing the types of natural fibers used and the characteristics of these innovative composites. The review highlights the advantages of NFRP in prosthetics, notably their biocompatibility, sustainability, and mechanical properties that are pertinent to prosthetic applications. The technical aspects of fabricating prosthetic sockets with NFRP are examined, discussing both traditional and advanced manufacturing techniques and design considerations that take into account anatomical and biomechanical factors, as well as the need for customization. The clinical outcomes and user experiences with NFRP prosthetic sockets are evaluated, focusing on their durability, functionality, and comparison with traditional materials. User-centric perspectives, including comfort, satisfaction, and adaptation challenges, are also considered. Crucial challenges and limitations in the field are identified, such as technical and fabrication complexities, consistency and quality control issues, as well as clinical and practical barriers like accessibility, cost, and the necessity for specialized training. The review outlines future directions and research needs, emphasizing potential innovations in NFRP, integration with emerging technologies, and the importance of translational research and interdisciplinary collaboration. The review underscores the significant role NFRP could play in advancing prosthetic technology, envisioning a future where prosthetic design is not only user-friendly and functional but also sustainable