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A Comparative Study on Optimizing CNC Milling Operation Using Simulated Annealing and
Genetic Algorithm
--R Saravanan and V Janakiraman
In this paper, a component from automobile industry is considered for optimizing the end milling
operation. The objective function is to minimize the total production cost subject to machine constraints such
as cutting power, cutting force, tool life, surface finish of the product and the range of the operating
parameters. For solving the above problem, optimization procedures were developed using Simulated Annealing
(SA) and Genetic Algorithm (GA). Generally, industries use cutting parameters from the range given
by machine/tool suppliers. But it is required to find the optimum point in the given range in order to
reduce the cost of production. By implementing the procedures developed in this work, an average of
24.48% reduction in manufacturing cost is indicated. The optimization problem is solved very efficiently using
the above procedures. They can be easily modified to suit other machining operations such as turning,
cylindrical grinding, surface grinding and nontraditional machining processes.
© 2009 IUP, All Rights Reserved.
Application of Predictive Maintenance Program
in Cooling Tower Fans: A Case Study
-- Rupinder Singh
Predictive Maintenance (PDM) program is an important philosophy, which can be applied to
effectively manage plant maintenance. Under PDM program `Signature Analysis' technique is widely used to
study the vibration behavior of machines. Cooling towers in process industry are mainly engaged for
evaporation of water to reject heat from processes (such as cooling the circulating water used in oil refineries,
chemical plants, power plants and building cooling). In the present study, PDM program has been applied in
these cooling tower fans of a process plant as a case study to reduce the severity of their vibrations. The
outcome of the present research work is, reduced vibration of fans, thereby improving the fan reliability.
The results of study suggested that vibration level of the fans could be reduced by 63%.
© 2009 IUP, All Rights Reserved.
Effect of Finite Element Mesh Orientation on
the Solution Accuracy of Torsion Problems
--Yatheshth Anand, Sarbjeet Singh and Sunand Kumar
In mechanical systems there are numerous applications of torque, which result in the failure of a
component due to shear stress if not properly designed. It becomes essential to examine the amount of torque, so
that the component can be sustained without failure. The Finite Element Method (FEM), which is now
increasingly becoming an integral tool for CAD due to the ongoing revolution in computer field, is used for
the analysis of torque by a number of researchers. The FEM orientation has an effect on the accuracy of
the solution. The present work describes the effect of triangular FEM orientation with regard to torsion.
© 2009 IUP, All Rights Reserved.
Estimation of Thermal Stresses by Finite
Element Analysis in a Weld Zone During Atmospheric Cooling
--S P Tewari, B Agrawal and N K Samria
Welding is globally used as the most versatile means of joining all commercial metals. In fusion
welding, a weldment is locally heated by the welding heat sources. Due to the nonuniform temperature
distribution during the thermal cycle, incompatible strain leads to thermal stresses, the main source of
problems. Thermal stresses in the weld may lead to formation of hot cracks. Therefore, it becomes necessary
to develop a model for the welding process, which would produce not only qualitative but also
quantitative information on thermal stresses. In the present work, a finite element simulation of the welding
process, yielding the welding induced thermal stresses in rectangular weld pool, is presented.
© 2009 IUP, All Rights Reserved.
Studies on Deformation and Failure Behavior of
Ti-6Al-4V Alloy for Aircraft Structures
--P S Ranjit and A Chennakesava Reddy
The dynamic response of Ti-6Al-4V alloy at high strain rate is investigated with
tensile split Hopkinson bar test using plate type of specimens. High strain rate tensile tests are
then performed with the above said material in order to construct their appropriate constitutive models
for use in aircraft structures under dynamic conditions.
© 2009 IUP, All Rights Reserved.
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