International Journal of Advanced Design and Manufacturing Technology: 43 (2)

Open Access Article

1 - Investigating the Reason for Compressor Gearbox Gear Failure in Arfa Iron and Steel Company using Analytical and Fracture Studies
Mahdi Ebrahimzadeh Ali Galehdari

Given the application of gears in various industries including steel industries, studying the reasons for facture in gears before reaching the end of their lifetime is of great importance. In this study, a gearbox was investigated which included a gear and a pinion. Aft More

Given the application of gears in various industries including steel industries, studying the reasons for facture in gears before reaching the end of their lifetime is of great importance. In this study, a gearbox was investigated which included a gear and a pinion. After four years of use, the teeth of gear and pinion along with the shaft attached to the gear were fractured. The fracture had occurred suddenly and with a lot of noise. The fracture in gear and pinion were in the teeth while the fracture in shaft occurred in the keyway. At the beginning of the study, shaft and gear design equations were used to evaluate the suitability of each of the parts in the system using theoretical equations and then fracture type was determined using fracture studies and the accuracy of analytical results were determined. In the analytical study, the results showed that the fracture is due to improper design for the gear shaft leading to more than one million unites of load on the shaft leading to cracks in the keyway and misalignment between gears causing fracture. In the fracture studies, the fracture type (ductile and brittle) was determined and the accuracy of analytical results was confirmed. In the numerical results, the distribution of static strain in the fractured shaft and a redesigned shaft are investigated. Manuscript profile

Open Access Article

2 - Effect of Burr Grinding on Fatigue Strength of Steel Butt-Welded Connections
Abbas Fadaei Annette Betkhoodu

Among assembling methods, welding is most widely used in various industries. During the welding operation, material is heated to a temperature above the melting point and melted material forms a weld pool. This leads to the formation of tensile residual stresses in the More

Among assembling methods, welding is most widely used in various industries. During the welding operation, material is heated to a temperature above the melting point and melted material forms a weld pool. This leads to the formation of tensile residual stresses in the weld toe. In this paper, effect of burr grinding technique on fatigue strength of butt-welded joint has been evaluated. Burr grinding is one of the weld geometry modification methods that with removing small crack-like defects at the weld toe and increasing weld toe radius leads to reduction of stress concentration factor (SCF) and improvement of fatigue strength of weld. Also, the finite element simulation was performed by using ABAQUS software and stress concentration factor was chosen as a criterion. This factor was calculated using analytical and numerical methods for samples before and after grinding. Burr grinding procedure on welded samples was done using an electric grinder and different conical burrs. Burrs with different radii have been selected in order to provide a better comparison. Fatigue life of samples before and after grinding was determined by fatigue tests under constant amplitude loading. The results show 43.72 percent improvement in stress concentration factor and 50.61 percent improvement in fatigue life of samples. In experimental study, the best result belongs to grinding with a 3 mm tapered burr leading to an improvement of 50.61% in fatigue life while grinding with 1 mm tapered gives the worst result of 8.88% improvement in fatigue life. Manuscript profile

Open Access Article

3 - Development of Thermal and Structural Deformation Model to Predict the Part Build Dimensional Error in Fused Deposition Modeling
K. Chockalingam M. Karthic N. Jawahar

The most common extrusion based technology in rapid prototyping is Fused Deposition Modeling (FDM). In FDM process, widely used materials are Acrylonitrile Butadiene Styrene (ABS) and Polycarbonate. In this study ABS-P430 material is considered. During the part build pr More

The most common extrusion based technology in rapid prototyping is Fused Deposition Modeling (FDM). In FDM process, widely used materials are Acrylonitrile Butadiene Styrene (ABS) and Polycarbonate. In this study ABS-P430 material is considered. During the part build process, the rapid heating and cooling is happening on the build part which leads to high thermal gradient. This thermal gradient causes thermal stress; it will lead to deformation of build parts. In this paper a three dimensional transient thermo-mechanical Finite Element Analysis (FEA) had been used to find out the maximum principal stress and deformation of the build part. This FEA analysis is called as thermal and structural deformation model or 3D FEA model. In this model, the novel technique called Element birth/death is used in ANSYS11 to mimic the FDM process. The most influencing parameters of FDM process called orientation and layer thickness have been considered in a 3D FEA model to calculate the deformation of a part. To validate the work, a standard design which is considered in 3D FEA model is fabricated using dimension 1200es FDM machine using same orientation and layer thickness and deformation is measured. From the results it was observed that the relative error between 3D FEA model and actual fabricated model is found to be 3-6%. This 3D FEA model would be helpful for RP machine users to find the deformation of the build part before making the products. Manuscript profile

Open Access Article

4 - Preliminary Analysis of the Cladding Mechanical Behavior of a Nuclear Superheat Boiling Water Reactor
Majid Bahonar Gholamreza Jahanfarnia Morteza Gharib

In the present study, investigation of mechanical behaviour of the fuel cladding material for a nuclear superheat Boiling Water Reactor with annular fuel rods, is carried out. In this design, each annular fuel element is cooled internally by steam and externally by wate More

In the present study, investigation of mechanical behaviour of the fuel cladding material for a nuclear superheat Boiling Water Reactor with annular fuel rods, is carried out. In this design, each annular fuel element is cooled internally by steam and externally by water. For the fuel cladding material, radiation embitterment and irradiation-assisted stress corrosion cracking (IASCC) are the most important issues that have to be taken into account. Hence, for cladding, two materials are considered. Preliminary thermal expansion and stress analysis have been done for a fresh (begin of cycle) ASBWR (Annular-fuelled Superheat Boiling Water Reactor) fuel element. The purpose of these analysis is to investigate the stress distribution and thermal expansion of the cladding in the initial phase of operation. The results show that there is a noticeable difference in the axial expansion between the inner and outer claddings. For T91 (modified 9Cr-1Mo steel) cladding, the maximum axial thermal growth of the inner cladding is 22.12 mm, which is about 9.7 mm more than the outer cladding. For Inconel 718 cladding, the results are 27.8 mm and 13.4 mm, respectively. Manuscript profile

Open Access Article

5 - Vibration Analysis of 2-PR(Pa)U- 2-PR(Pa)R New Parallel Mechanism
Mehran Mahboubkhah Sajjad Pakzad Morteza Homayoun Sadeghi Mir Mohammad Ettefagh

Parallel kinematic machines, are closed loop structures which have more accuracy, stiffness and ability to withstand high loads. In this paper the vibration equations of the new parallel mechanism, that has higher stiffness because of parallelogram system and fixed leng More

Parallel kinematic machines, are closed loop structures which have more accuracy, stiffness and ability to withstand high loads. In this paper the vibration equations of the new parallel mechanism, that has higher stiffness because of parallelogram system and fixed length pods, have been derived by analytical approach. Whereas the proposed mechanism is applied as a machine tools, its vibrational behavior investigation has key impact factor. All the kinematic chains of the mechanism have been taken into consideration to achieve the coupled system of equations. To extract mechanism natural frequencies, modal analysis is carried out using three methods including analytical, finite element (FEM) and experimental method on parallel mechanism which has four degrees of freedom including three linear motion along the x, y and z axes and a rotary motion about x axis. Finally the natural frequencies and mode shapes obtained from analytical, experimental and FEM were compared. It is worth noting that all the frequencies obtained from three methods had little differences. Manuscript profile

Open Access Article

6 - An Experimental Investigation on Comparison of the Similar and Dissimilar Resistance Spot Welding of St12 and Galvanized Steel using Design of Experiments
Mahmoud Moradi Hadi Abdollahi Ali Khorram

In the present research, similar and dissimilar resistance spot welding (RSW) process of St12 and galvanized steel sheets with thickness of 0.9 mm was investigated. The experiments were carried out based on the statistical design of experiments (DOE) approach to investi More

In the present research, similar and dissimilar resistance spot welding (RSW) process of St12 and galvanized steel sheets with thickness of 0.9 mm was investigated. The experiments were carried out based on the statistical design of experiments (DOE) approach to investigate the effect of RSW parameters on the welding quality, achieving the mathematical regression equations and predicting the new results. Welding time and electrode force were considered as the input process variables while the tensile-shear strength of the joints was considered as the process response. By comparing three RSW types, galvanized steel has the highest tensile-shear strength. Statistical analysis shows that tensile-shear strength is increased with increasing electrode force and welding time. Verification experiments for three types of RSW joints were carried out in order to analyse the obtained results via software. Good agreement between the verification tests and the optimization results revealed that the statistical modelling would be appropriate for RSW process. Welding time (T)  = 5 s and electrode force (P)  = 925 N, welding time (T) = 5 s and electrode force (P) = 1100 N and welding time (T) = 3 s and electrode force (P) = 925 N were obtained as the optimum settings for similar RSW of St12, dissimilar RSW of St12 to galvanized steel and similar RSW of galvanized steel, respectively. Manuscript profile

Open Access Article

7 - Experimental Investigation of Maximum Achievable Convolution Height of Metallic Bellows in Hydroforming Process
Mehdi Safari Younes Ghadiri

The manufacturing of metal bellows with high ratios of crown-to-root diameters is very sensitive to design parameters such as internal pressure inside the tube, axial force and movement, die-stroke length (distance of the dies) as well as the initial tube length. In thi More

The manufacturing of metal bellows with high ratios of crown-to-root diameters is very sensitive to design parameters such as internal pressure inside the tube, axial force and movement, die-stroke length (distance of the dies) as well as the initial tube length. In this paper, hydroforming process of a metallic bellows is investigated experimentally. For this purpose, the effects of internal pressure and die stroke on the maximum achievable convolution height and thickness distribution of hydroformed bellows is studied. The experiments are performed with different internal pressures such as 90, 110 and 130 bars and also in different die strokes such as 10, 12 and 14 mm. The results show that by increasing the die stroke, the range of allowable internal pressure to produce a metallic bellows without wrinkling or bursting decreases and manufacturing of the bellows becomes more difficult. It is extracted from results that with holding the die stroke value, very low internal pressures leads to wrinkling in the hydroformed bellows while very high internal pressures cause the excessive thinning. Also, it is concluded that by increasing both internal pressure and die stroke the convolution height of manufactured bellows is increased. It is proved that the maximum thickness reduction is occurred at the crown point of hydroformed bellows. Manuscript profile

Open Access Article

8 - Forecasting Operational Parameters of a Solar Space Heating System using a Novel Multistage Artificial Neural Network
Farnaz Jamadi Behnam Jamali

In this study, several operational parameters of a solar energy system are predicted through using a multistage ANN model. To achieve the best design of this model, three different back-propagation learning algorithms, i.e. Levenberg-Marquardt (LM), Pola-Riber Conjugate More

In this study, several operational parameters of a solar energy system are predicted through using a multistage ANN model. To achieve the best design of this model, three different back-propagation learning algorithms, i.e. Levenberg-Marquardt (LM), Pola-Riber Conjugate Gradient (CGP) and the Scaled Conjugate Gradient (SCG) are utilized. Further, to validate the ANN results, some experimental tests have been done in winter 2016 on a solar space heating system (SSHS) equipped with a parabolic trough collector (PTC). In the proposed model, ANN comprises three consecutive stages, while the outputs of each one are considered to be the inputs of the next. Results show that the maximum error rate in Stages 1, 2, and 3 has occurred in the LM algorithm with respectively 10, 6, and 10 neurons. Moreover, the best obtained determination coefficient of all stages belongs to the total system efficiency and has the value 0.999934 for LM-10. As a result, the multistage ANN model can simply forecast operational parameters of the solar energy systems with high accuracy. Manuscript profile

Open Access Article

9 - The Aerodynamic Effects of the Blade Lean on a High-Aspect-Ratio Transonic Axial Flow Rotor
Mansour Asghari Mohsen Agha Seyed Mirzabozorg Mahmood Adami

In this study, the effect of tangential blade lean on the aerodynamic characteristics of low-transonic, high-aspect-ratio axial flow compressor rotor has been investigated by using the computational fluid dynamics. The B-Spline curvature with four control points of 25%, More

In this study, the effect of tangential blade lean on the aerodynamic characteristics of low-transonic, high-aspect-ratio axial flow compressor rotor has been investigated by using the computational fluid dynamics. The B-Spline curvature with four control points of 25%, 50%, 75% and 100% of span have been used to define the blade stacking line. Various leaned rotors have been created by rotating the circumferential position of control points and they have been simulated by Computational Fluid Dynamics (CFD). At the best state, the leaned blade improves the adiabatic efficiency and total pressure ratio of compressor about 0.55% and 0.75%, respectively. The results show that, lean angle at 100% span has most effect in the peak adiabatic efficiency rather than lean angle at other control points. Also, the results indicate that, in low-transonic, high-aspect-ratio rotor blades, the tangential change of the stacking line only causes the reduction of secondary flow, while the previous studies on high-transonic low-aspect-ratio rotor blades, such as NASA Rotor 37 and NASA Rotor 67 revealed the movement of shock wave toward the downstream and the reduction of the secondary flow. Manuscript profile

Open Access Article

10 - Application of Topology Optimization in Design of Stem Profile in Hip Implants Using Finite Element Method
Mohammad Reza Niroomand Farzad Boroomand

Appropriate design of stem shape is an important factor in total hip replacement. It affects the attachment of the implant to the bone and the stability of the implant. Using topology optimization, this study has been an attempt to propose an optimized model of the stem More

Appropriate design of stem shape is an important factor in total hip replacement. It affects the attachment of the implant to the bone and the stability of the implant. Using topology optimization, this study has been an attempt to propose an optimized model of the stem profile of the hip implants. In this regard, a three-dimensional finite element model of the implant has been combined with a stiffness-based topology optimization algorithm to reduce the relative motion between the implant and the bone. The objective function in the optimization problem is the compliance of the structure which should be minimized. Also, a constraint on usable volume is applied to the structure. Then smoothing process has been done on the optimal model to prevent its geometric complexities. Results show that the final model has a smaller weight, less displacement, and more uniform stress distribution. In addition, using conventional production methods, this model can be easily produced. Manuscript profile

Open Access Article

11 - Novel Aspect of Composite Sandwich Fairing Structure Optimization of a Two Stages Launch Vehicle by Using MDO Independent Subspace Approach
Foozie Morovat Jafar Roshanian Ali Mozaffari Hadi Zaare

In this paper, a novel composite sandwich structure analysis of Launch Vehicle (LV) fairing is considered and proposed by a new Multidisciplinary Design Optimization (MDO) for a two-stage launch vehicle. Accordingly, “Multidisciplinary Design Optimization based on More

In this paper, a novel composite sandwich structure analysis of Launch Vehicle (LV) fairing is considered and proposed by a new Multidisciplinary Design Optimization (MDO) for a two-stage launch vehicle. Accordingly, “Multidisciplinary Design Optimization based on Independent Subspaces” (MDOIS) is employed using the “Fixed Point Iteration” (FPI) method to achieve the best convergence at system level (SL) to segregate the disciplines. Therefore, two proposed subspaces overcome difficulties of common mentioned MDO of LVs. Hence, the first subspace is a MDO which includes propulsion, aerodynamics, weight and trajectory disciplines and the second one, includes the novel composite fairing structure optimization as the other single discipline optimization that considered as a compact problem analytically and numerically and it is one of the novelties of this work. By considering variables as propulsion, trajectory and also composite sandwich fairing structure design regarding to the variables of designing and the performing optimization process, the fairing mass has been reduced more and considerable with respect to the common two stages LVs. In addition, due to the global optimization of LVs this weight reduction caused in reduction of the total gross weight of LVs. This system engineering proves the high sufficiency of MDO in complicated designing and it can be a roadmap for the future space vehicles designers especially who want to consider the composite structure optimization in LVs. Manuscript profile

Open Access Article

12 - The Effects of Joint Clearance on the Dynamics of the 3-RPR Planar Parallel Manipulator
Seyyed Mojtaba Varedi-Koulaei Mahdi Bamdad

In reality, clearances in the joints are inevitable due to the defects arising from manufacturing process, design tolerances, and wearing after a certain working period. It leads to a chaotic behaviour including the impact loads which results in an unpredictable respons More

In reality, clearances in the joints are inevitable due to the defects arising from manufacturing process, design tolerances, and wearing after a certain working period. It leads to a chaotic behaviour including the impact loads which results in an unpredictable response in the system. Since clearance introduces an additional uncontrollable degree of freedom to the manipulator, it causes error and could not be neglected in the manipulator design or analysis. In this study, the dynamic behavior of a planar mechanism with revolute joints, in the presence of clearances is investigated. The planar 3-RPR parallel manipulator with six revolute clearance joints is modelled in MSC.ADAMS software and the simulation results are presented. Moreover, the effects of clearance size on the dynamic characteristics of a planar mechanical system are analysed and compared. What is found out is the prediction of the dynamic error due to the joints clearance for this parallel robot. Manuscript profile

Open Access Article

13 - Experimental Study on Magnetic Abrasive Honing of Inner Surface of Tube AISI304
Hamzeh Shahrajabian Masoud Farahnakian Payam Saraeian

To overcome the limitation of honing process, the present work proposes magnetic abrasive honing (MAH) process whereby abrasive stones are replaced by magnetic abrasives. This process is combination of magnetic abrasive finishing (MAF) and honing. MAF which is one of th More

To overcome the limitation of honing process, the present work proposes magnetic abrasive honing (MAH) process whereby abrasive stones are replaced by magnetic abrasives. This process is combination of magnetic abrasive finishing (MAF) and honing. MAF which is one of the finishing processes can improve the quality of workpiece surface with various geometries, removing the chips in micrometer scale by magnetic field forces. This study set to apply longitudinal vibration to the tube workpiece in MAF process; hence, this process is called MAH. The effects of rotary speed of workpiece, cross-hatch angle, and mesh number were investigated on the surface roughness of AISI 304. Magnetic abrasives were combination of SiC particles as abrasives and iron particles as ferromagnetic particles in lubricant of SAE 40 oil. The results revealed that the longitudinal movement of workpiece is effective on MAH, as the surface roughness decreased with increasing the cross-hatch angle. Surface roughness decreased with increase of rotary and mesh number. The major changes in surface roughness (58%) were obtained in cross-hatch angle of 45º rotary speed of 800 rpm and mesh size of 400. The microscopic picture showed that three-body wear mechanism is dominant for fine grits. Manuscript profile

Open Access Article

14 - Optimization The High Speed Machining of Hardened AISI 4140 Steel Using Vapor Deposited Cutting Tools (Wear and Roughness)
Mehdi Jalali Azizpour Ata Fardaghaie

In this study, the main cutting parameters of high speed machining (HSM) including cutting speed, feed rate, depth of cut as well as deposition method were optimized using genetic algorithm considering the average surface roughness (Ra) of work piece and flank wear (Vb) More

In this study, the main cutting parameters of high speed machining (HSM) including cutting speed, feed rate, depth of cut as well as deposition method were optimized using genetic algorithm considering the average surface roughness (Ra) of work piece and flank wear (Vb) of CVD and PVD coated tool criteria in high speed turning of hardened AISI 4140 Steel. Standard L18 orthogonal array has been used for the design of experiment (DOE) applying Taguchi approach. Multiple linear regression model applying Minitab, was used to determine the relationship and interaction between machining parameters and outputs. For genetic algorithm(GA) optimization, the average was applied as a functional output of design of experiments. The results of GA for smaller- the better quality characterization shows the optimum roughness of 1.107 mm and optimum flank wear of 0.461mm. The conﬁrmation tests were carried out in order to validate the response of predicted optimum condition. The results of validation test show a good agreement between obtained optimum condition and the results of genetic algorithm. The analysis of variance was used in order to obtain the contribution of each factor on the output statistically. ANOVA results indicated that the cutting speed and cut depth are the most effective factors on the flank wear by 37.02 and 27.80 percent contribution respectively. The most effective factors on surface roughness were feed rate and cutting speed by 82.49 and 10.50 percent contribution respectively. Stereoscopy and Scanning electron microscopy was used to evaluate the wear mechanism and topography of worn surface. Manuscript profile

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