(I Part) Proceeding of International Conference on Manufacturing Excellence MANFEX 2012

8/9/2019 (I Part) Proceeding of International Conference on Manufacturing Excellence MANFEX 2012

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MANUF

Department ofAmity

International Conferenceon

CTURING EXCELLENCE

ANFEX 2012

29 - 30 March 2012

EditorsProf. Vivek Kumar

Prof. Nitin Kr. Upadhye

Mr. Hemant Chouhan

Ms. Megha Sharma

Organized by

Mechanical & Automation EngineeriSchool of Engineering & Technology,

mity University Uttar Pradesh,

Noida-201303 (U.P), India

g,


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First Impression: 2012

Department of Mechanical & Automation Engineering,Amity School of Engineering & Technology, Amity University Uttar Pradesh

Noida-201303 (U.P), India

International Conference on Manufacturing Excellence

MANFEX 2012

ISBN: 978-93-81583-36-4

No part of this publication may be reproduced or transmitted in any form by any means,electronic or mechanical, including photocopy, recording, or any information storage and

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i International Conference on Manufacturing Excellence (MANFEX 2012)

MANFEX 2012 Organization

Patron-in- Chief Dr. Ashok K. ChauhanFounder President, Amity University

Mr. Atul Chauhan

Chancellor, Amity University Uttar Pradesh

Patron Maj. Gen. K. Jai SinghVice Chancellor, AUUP, Noida

Convener Prof. (Dr.) Balvinder Shukla

Pro-Vice Chancellor AUUP & D.G. ASET, Noida

Co-Convener Prof. Vivek Kumar

HOD (Mechanical & Automation Engg. Dept.), ASET

Prof. P.K. Rohtagi

Head CRC & Prof. MAE Dept.

Organizing Secretary Prof. Nitin Kumar Upadhye

Technical Secretary Mr. Hemant Chouhan

Ms. Megha Sharma


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ii International Conference on Manufacturing Excellence (MANFEX 2012)

CommitteesAdvisory Committee

Prof. Hong Hocheng, National Tsing Hua University, Taiwan, R.O.C.

Prof. L.M. Das, IIT, Delhi,

Prof. S. G. Deshmukh ABV IIITM, Gwalior

Prof. Pradeep Kumar IIT, Roorkee

Prof. I.A. Khan, FIT, Jamia Milia Islamia, Delhi

Prof. Naresh Bhatnagar, IIT, Delhi

Prof. S.K. Garg Delhi Technology University, Delhi

Prof. Mohammad Muzammil, AMU, Aligarh

Dr. Kannan Govindan Associate Professor University of Southern Denmark

Mr. Anant Kishore, CEO, INDO RAMA Synthetics (India) Ltd., Delhi

Mr. Anil Varshney, Addl. V.P., BSES Rajdhani Power Ltd., Delhi

Dr. N. Swaminathan, Technical Architect, MSC Software, Delhi

Dr. Rajkumar P. Singh, Director, Kalyani Centre of Tech. & Innovation, Pune

Dr. Nitesh Jain, Global Chief, Goodyear, Cleveland, Ohio, USA

Mr. N.N Radia, V.P. (Operations), GHCL Ltd., New Delhi

Mr. A. Bali, Vice President, Deki Electronics Ltd., Noida

Mr. Nirmal Tiwari, AVP & Plant Head, Kirloskar Bros. Ltd. Dewas

Mr. R.B. Madhekar, CGM, Maruti Suzuki India Ltd., Gurgaon

Dr. Sanjay Ghoshal, G.M. Samsung Heavy Industries Ltd., Noida

Mr. Sanjeev Paul, Group Head Purchase, Yamha Motors, Noida

Mr. Sandeep Mathur, G.M. (Quality), Precision Industries, Noida

Mr. Manoj Kumar Dora, Scientific Researcher, Ghent University, Belgium

Col. A. Yadav , DGM, Tank Division, Pune


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iii International Conference on Manufacturing Excellence (MANFEX 2012)

Departmental Organizing Committee

1 Mr. R.K. Tyagi 15 Dr. Abhinav Gupta

2 Mr. Gaurav Gupta 16 Mr. Rahul Sindhwani

3 Ms. Nazma Ehtesham 17 Mr. Ravi H.

4 Mr. Manmit Saikia 18 Mr. Harendra Singh

5 Mr. Swet Chandan 19 Mr. Vikas Salyan

6 Mr. Ashok Kr. Dargar 20 Mr. Anoop Kr. Shukla

7 Mr. R.R. Vishwambaram 21 Ms. Punjlata Singh

8 Mr. Ajay Sharma 22 Mr. Kuldeep Kumar

9 Mr. Mahendra Verma 23 Ms. Meeta Sharma

10 Mr. Narendra Singh 24 Mr. Shubham Sharma

11 Col. D.K. Sharma 25 Mr. Ram Pravesh

12 Mr. R.P.S. Sisodia 26 Ms. Medhavi Sinha

13 Mr. Kuldeep Narwat 27 Ms. Anu Kamal

14 Mr. Naveen Kumar

Student Organizing Committee

Ishan Kaushik Student President

Madhur Jain Student Head Coordinator

Abhinav Atreya Student Head Coordinator

Nishant Kaushik Student Co-Coordinator

Tarun Kumar Chenani Student Co-Coordinator

Indraneel Dutta Technical Committee Coordinator

Abhudaya Gupta Registration Committee Coordinator

Prithviraj Singh Registration Committee Coordinator

Siddharth Arora Hospitality Committee CoordinatorRohil Agarwal Hospitality Committee Coordinator

Anuj Nirmal Accommodation Committee Coordinator

Gurbinder Gill Event Management Committee Coordinator


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iv International

Message fr

It is matter of great pride that DeEngineering & Technology, is

(MANFEX-2012) on 29th& 30th M

The theme of the conference M

makers and students working on ad

I am pleased to note that faculty an

Organizations across the world are

Modeling, Rapid Prototyping,

Manufacturing, Quality Function

Processes and many more advanced

With great enthusiasm, organizing

proceeding of MANFEX-2012. I pa

from industry as well as from acade

I am sure that MANFEX-2012 thi

faculty members and young profess

Organizing MANFEX 2012 is a

team who made this research confe

I wish MANFEX-2012 a grand suc

Dr. Balvinder ShuklaConverner, MANFEX 2012

Director General, ASET &

Pro Vice Chancellor, AUUP

Sr. Vice President, RBEF

Conference on Manufacturing Excellence (MANFEX 2012)

m Director General (AS

partment of Mechanical & Automation Engineerirganizing International Conference on Manufa

rch 2012.

nufacturing Excellence is very suitable for the

anced areas of manufacturing and looking new res

d researchers from various reputed Universities, C

presenting their research papers on varied topics su

utomation and Robotics, Lean Manufacturing,

Deployment, Energy Management & Unconventi

areas of manufacturing management

team has put together a rich and varied technical

rticularly appreciate the invaluable contribution of

mia.

s conference would greatly benefit industry profe

ionals. The contents of the proceeding will surely b

ammoth task and my compliments and congratul

ence possible.

ess.

T)

g, Amity School ofcturing Excellence

esearchers, decision

arch directions.

lleges and Research

ch as Finite Element

Six Sigma, Agile

onal Manufacturing

research papers as a

ll the Lead Speakers

sionals, researchers,

helpful.

ations to organizing


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v International Conference on Manufacturing Excellence (MANFEX 2012)

Preface

It is a matter of great pride for us to present the Academicians, Personnel from Industries and R&D Organizations,

Environmentalists, Technocrats, Managers, Research Scholars and students, the proceedings of papers presented at

the two day International Conference on Manufacturing Excellence (MANFEX-2012) held on March 29 & 30,

2012 at Dept. of Mechanical & automation Engineering, Amity School of Engineering & Technology, Amity

University Uttar Pradesh, Noida (India).

Manufacturing is and will remain one of the principle means through which wealth is generated. Rapid

advancements in all branches of Engineering and Technology have posed many challenges as well as opportunities

to organizations in the light of global competition in a complex economic, environmental and social scenario. This

situation has lead to innovation and excellence in the area of manufacturing and its related sub areas like R & D,

development of new material and processes, advanced manufacturing philosophies etc. Mechanical Engineering

begins to merge with other disciplines, as seen in Mechatronics, Multidisciplinary Design Optimization (MDO),

biomechanics and many more.

The international Conference MANFEX 2012is designed with the objective to provide a platform for the industry

personnel, academicians, researchers and the young budding engineers to share their knowledge on the excellence inmanufacturing This knowledge will help them to keep pace with the world to know and learn the advanced

technology & equip them to face the techno-economic challenges of the millennium. The conference aims to provide

an opportunity for students, researchers and engineers:

To interact with key specialists in diversified fields.

To share innovative ideas amongst the participants.

To get exposed to latest trends in Design and Development, Renewable Energy, Thermal Sciences &

Engineering, Industrial Management, Materials and Manufacturing Technology and Engineering to achieve

Manufacturing Excellence.

The proceedings comprises of articles meticulously prepared by leading Academicians, Research Scholars and

Experts from Industries. For the benefit of readers, the research papers have been subdivided into the followingcategories:

1. Design and Development

2.

Industrial Management

3.

Materials and Manufacturing Technologies

4. Thermal Science and Engineering & Renewable Energy

5. Diversified fields of Mechanical Engineering.

Such a proceeding of great proportion is not feasible without the wholehearted support received form various

quarters. We extend our wholehearted gratitude to all the eminent authors for enriching this conference with their

praiseworthy contribution.

We will be failing in our duty if we do not acknowledge the excellent cooperation extended by our colleagues and

experts on the review panel, for their painstaking efforts in reviewing the papers.

We sincerely hope that the entire engineering fraternity will find this publication an invaluable storehouse of

knowledge to decipher the latest trends manufacturing Excellence.

Editors


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vi International Conference on Manufacturing Excellence (MANFEX 2012)

ContentsDesign & Development

1. Creating Microchannels on Polymers Using Underwater Nd: YAG Laser Processing ...................................... 3

Shashi Prakash, Bappa Acherjee, Arunanshu Shekhar Kuar, Souren Mitra

2. Finite Element Modeling of an Improved Extrusion Process for

the Enhancement of the Product Quality ............................................................................................................... 8Atul Suri, K. Hans Raj

3. Finite Element Modelling and Burst Pressure Analysis of

Cylidrical Composite Pressure Vessel ................................................................................................................... 13

Medhavi Sinha, Dr. S. N. Pandit

4. Finite Elemement Based Delamination Damage Analyses of Laminated

FRP Composite Made Bonded Tubular Socket Joints ........................................................................................ 17

R. R. Das, B. Pradhan

5. Detection of Isomorphism among Kinematic Chains by Assigning Type Number of Different Joints ........... 22

Dharmendra Singh, Dr. Aas Mohd, R.A.Khan

6. Micro Pressure Sensors Designing & Optimization Methods .......................................................................... 26

Yogesh Kumar, Ajay Sharma

7. Finite Element Analysis of Disc Brake using RADIOSS Linear......................................................................... 29

Vikas Salyan, G. Bhushan, P. Chandna

8. Use of Electro Mechanical Impedance Technique to Detect Damage ................................................................ 32

Harmohan Singh, Mansi Jain, T.Visalakshi

9. Failure Analysis of Protector Screen Grid ........................................................................................................... 38

M. Tripathi, K.V. Sai Srinadh

Thermal Science & Engineering & Renewable Energy

10. Optimization of Power Generation System Utilizing a Salt Gradient Solar Pond .......................................... 3

Dr. J S Saini, Sanjeev Kumar Joshi, Vivek Kumar

11. Exploration of Emerging Fiscal and Social Benefits through Energy

Efficient Measures and Renewable Energy Resources in Agra Region ............................................................. 12

Anurag Gupta, D. Ganeshwar Rao

12. Energy Conservation by Optimizing Insulation Thickness for Building ........................................................... 16

Subhash Mishra, Dr. J A Usmani, Sanjeev Varshney

13. Experimental Investigation of the Performance and Emission

Parameters of Karanja Oil Blends with Diesel in a CI Engine ........................................................................... 22

Saurabh Kumar Gupta, Dhananjay Singh, Gandhi Pullagura

14.

Low Carbon Future: Challenges and Opportunities for Energy Sector............................................................ 27Iqbal Khan, Ashish Sharma

15. Cogeneration in Cement Industry ......................................................................................................................... 31

Vivek Aggarwal, Suresh Pal

16. Effect of Compression Ratio, Fuels and Reactant Temperature on the

Combustion Irreversibilities in Spark- Ignition Engine ...................................................................................... 38

Munawar Nawab Karimi, Sandeep Kumar Kamboj

17. Energy Audit of a Hospital .................................................................................................................................... 44

Suresh Pal, Vivek Aggarwal


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vii International Conference on Manufacturing Excellence (MANFEX 2012)

18. The Performance and Emission Characteristics of Alcohol-Ether Gasoline Blends on SI Engine ................. 51

K. Chendil Velan, Anuj Raturi

19. Generalized Mechanism to Institute Energy Management System.................................................................... 56

Pankaj Kamboj, Shruti

20. The Futuristic Alternative Fuel- HCNG- A Review ........................................................................................ 60

Anuj Raturi, K. Chendil Velan, Hardik Vala

21. Exergy Analysis of Waste Heat Operated Combined

Power and Ejector Refrigeration Cycle ................................................................................................................ 65

Munawar N Karimi, Basant K Agrawal

22. Feasibility of Starting the Scramjet at Lower Velocities .................................................................................. 70Utkarsh K.K., Sayantan Bhattacharya

23. Development and Test of Low Cost Catalytic Converter from ZnO/CoO in the

Form of Pellet for Petrol Fuelled Engine .............................................................................................................. 79Charula H Patel, Megha Sharma

24. Performance Evaluation of Condenser in a Coal-Fired Power Plant ................................................................ 84Ravinder Kumar, Research Scholar

25. Alternative Fuels Available in India - The Choice of Future Fuel ..................................................................... 91Rajesh Kumar Saluja, Ritesh Kumar, Sudeep Kumar Singh

26. Inverse Heat Transfer ............................................................................................................................................ 99Dhan Raj Thapa, Medhavi Sinha, Sidhant Verma, Vicky Panwar

Materials & Manufacturing Technologies

27. Impact of Machine Vision System in Industrial Automation ............................................................................... 3Tushar Jain, Dr. Meenu

28. A Study of Phase Change Material and Its Applications in Textile Industry .................................................. 11Arbind Prasad, Ashwani Kumar, Amir Shaikh

29.

Study of Influence of Atom Sizes on Martensite Microstructures

in Copper-Based Shape Memory Alloys ............................................................................................................... 18Ashwani Kumar, Arbind Prasad, Amir Shaikh

30. Mechanical and Microstructural Characterization of

Friction Stir Welded Joints of AA7039 ................................................................................................................. 21Chaitanya Sharma, Dheerendra Kumar Dwivedi, Pradeep Kumar

31. Finite Element Analysis of Hard Turning: A Review .......................................................................................... 26Kunal Saurabh, Sudhir Kumar Singh, A.M.Tripathi, Subham Sharma

32. Optimisation of Process Parameter in Ultra-Precision

Diamond Turning of Polycarbonate Mmaterial .................................................................................................. 30V.K. Saini, D. Sharma, S.K. Kalla, Tulsi Chouhan

33. Modification of Hardfacing Alloy of Crusher Used in Sugarcane Industry to Reduce Wear ......................... 38A. Doomra, A.P.S. Sethi, S.S. Sandhu

34. Effect of Weld Groove Design on the Distortion of 304 L Butt Joint in Boiler Drums..................................... 45

A. Sharma, J.S. Oberoi, S.S. Sandhu

35. Predicting Tensile Strength of Double Side Friction Stir Welded 6082-T6

Aluminium Alloy by a Mathematical Model ........................................................................................................ 52S.Gopi, P.Saravanan, K.Manonmani, V.Sritharan

36. Implementation of Green Manufacturing: A review ........................................................................................... 59Ashok Kr. Dargar, Nitin Upadhye, Hemant Chouhan


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37. Current Research Trends in Wire Electric Discharge Machining: An Overview ............................................ 63

Rajeev Kumar, Anmol Bhatia

38. Trends in the Field of Rapid Prototyping ............................................................................................................. 68

Manu Srivastava, Dr. Sachin Maheshwari, Dr. T.K. Kundra

Industrial & Operations Management39. The Practical Application of ISO 9001 and ISO/TS 16949 to the Mass

Production of Motor Industry Components ........................................................................................................... 3

PG Blaine, PJ Vlok, RT Dobson

40. Integration of Design Analysis and Estimation into a Web-Based

Product Lifecycle Management Platform ............................................................................................................. 15S. Jyothirmai, R. Ramesh, K. Ajay, A. Vaidehi, Y. Shashank

41. Effect of Different Mouse Geometries on Human Performance: A Case Study ............................................... 21Taufeeque Hasan, Mohd.Farhan Zafar, Nidhi Singh, Abid Ali Khan

42. Waste Detection and Optimization in Supply Chain Using Value Stream Mapping (VSM) ........................... 27Anil Kumar H Maurya, D. N. Raut, Akshay S. Shrawge

43. Condition Monitoring in Industry......................................................................................................................... 34Dr. S.P.Tayal

44. Improving Quality in Engineering Institute: Six-Sigma Demystified ................................................................ 39Rajender Kumar, Naresh Kumar, Goarav Gera

45. Implementing QFD for an Auto Service Station a Case Study ........................................................................... 48D.Sharma, V.K. Saini, T. Chouhan, N. Upadhye

46. Achieving Quality Goals by Lean Six-Sigma........................................................................................................ 54Piu Jain, Garima Sharma

47. Defect Reduction by Six Sigma Technique ........................................................................................................... 61Surbhi Upadhyay, Rishu Sharma

48.

Effectiveness of Entrepreneurship Development Programme in Jammu & Kashmir

Region: A Study on Jammu & Kashmir Entrepreneurship Development Institute (JKEDI) ......................... 64D. Mukhopadhyay, Pabitra Kumar, Jena Kakali Mazumder

49. Investigation into the Level of Agility in Indian Manufacturing Industry: A Case Study ............................... 71Gaurav Jain, Puneet Jain, Mudit Lamba, Mohit Rathi

50. Exergetic and Economic analysis of Economizer for Waste Heat Recovery in Textile Industry .................... 79

Umesh Kumar, Dr. M.N. Karimi

51. Just in Time Manufacturing and Inventory Management: A Literature Review ............................................ 87

S. Kumar, S. Phogat, Dr AK Gupta, Dr Sultan Singh

52. Barriers to Green Supply Chain Management Practices: A Literature Review ............................................... 94

Mohammad Asim Qadri, Abid Haleem, Mohammed Arif53. Pedestrian Safety Test Procedures and Available Technologies ........................................................................ 99

Devendra Vashist, Mohit Bansal, Lalit Kumar

54. Vendor Selection in Supply Chain Management -An Empirical Model and Case Study............................... 104

Abhishek Jain, Shiv Kumar Sharma, Rakesh Kumar Jain, Ankit Parashar

55. Application of AHP in Selection of Vendor for Manufacturing Industries ..................................................... 111

Mohit Singh, Dr. I. A. Khan, Dr. Sandeep Grover

56. Two Machines Flowshop Scheduling Problem with a Single Transport Agent in Between ........................... 114

Qazi Shoeb Ahmad, M. H. Khan


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ix International Conference on Manufacturing Excellence (MANFEX 2012)

57. Current Status of Extent of Successful Implementation of TPM: A Study

in Context of Developing Nation India ............................................................................................................... 117

Shruti, Pankaj Kamboj, Mudit Lamba, Puneet Jain

Diversified Fields of Mechanical Engineering

58.

Wall Climbing Robot for Rough, Grooved and Smooth Walls ............................................................................ 3Faiz Iqbal, Hemant Chouhan

59. Trends in Cloud-ERP for Small and Medium Sized Manufacturing Industries: A Review .............................. 9

Sapna Shukla, Sugandha Agarwal, Shruti Jain

60. Creative Problem Solving Approach to Enhance Functionality of Vacuum Cleaner ...................................... 14

Tulsi Chouhan, V.K. Saini, D. Sharma, H. Chouhan

61. Advanced Architecture with Hardware Software Cosynthesys for Real Time Embedded Systems ............. 20

Richa Agrawal, Deepika Agrawal

62. The Future of Self Learning Robots through Haptics Technology .................................................................... 24

Dadi Ravi Kanth, Hemant Chouhan

63.

Modified Spoke-Less Bicycle ................................................................................................................................. 28T.Bothichandar, S.Majumder

64. A Riview on Use of Smart Materials to Detect Damage ...................................................................................... 32

R.G Sindhu, Nitya Jain, Talakokula Visalakshi

65. A Review on Permanent Magnet Based PMM & Its Implementation ............................................................... 39

Rajat Saxena, Tulsi Chouhan, Sansar Swaroop Saxena, Dheeraj Chouhan

66. Structural Optimization with Cado Method for a Three Dimensional Sheet Metal Body ............................... 43Shubham Sharma, Ankita Awasthi, Medhavi Sinha, Rohan Kumar

Abstracts

1.

Generalised Formulation of Laminate Theory Using Beam Finite Element

for Delaminated Composite Beams with Piezoactuators and Sensors ................................................................ 3

B. Kavi, B.K. Nanda

2. What Drives the Supply Chain of Manufacturing Organizations? ...................................................................... 4

Dr. Sunil Giri, Rashi Taggar

3. Value Stream Mapping-Its Role and Scope in the Automobile Industry ............................................................ 5

Saif Imam, Ashok Tripathi, Sudipto Sarkar

4. Design and Thermal Analysis of Coronary Stent .................................................................................................. 6Zarna K. Bhavsar, Prof. Ashwin Bhabhor

5. Oxidation and Hot Corrosion Behavior of Nickel-Based Superalloy Inconel 718 .............................................. 7

V. N. Shukla, R. Jayaganthan, V. K. Tewari

6. Designing of Automatic Tool Pickup Machine ....................................................................................................... 8I Kaushik, R Sharma, A Kothapalli, V Khandelwal

7. ECO Friendly Materials-An Overview ................................................................................................................... 9

Goel Neetu, Kumar Sanjay


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DESIGN &DEVELOPMENT


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Creating Microchannels on Polymers Using

Underwater Nd: YAG Laser Processing

Shashi Prakash

1

, Bappa Acherjee

2

, Arunanshu Shekhar Kuar

3

, Souren Mitra

4

1Department of Mechanical & Automation Engineering, ASET, Amity University, Lucknow, U.P., India

2,3,4Production Engineering Department, Jadavpur University, Kolkata-32, India

[email protected]

ABSTRACT

In this research work, a novel technique for creating

microchannels on polymers has been investigated.

Microchannels are used as microfluidic channels in

analytical biological measuring instruments and also as

microchannels in miniature electronic industries. Thesemicrochannels were being created by lithography and

etching techniques in earlier days. However the

slumberness of the process with these techniques resulted

in long manufacturing durations and also precise skills

were required by the worker. The use of lasers as

microcutting tool has been a recent trend in micro

manufacturing arena. Lasers have been widely used for

micro-surgery, micro-cutting and drilling process. In this

research work, Poly-methyl-meth-acrylate (PMMA) has

been used as a workpiece material because of its wide

acceptability in microchannels fabricating industries. Nd:

YAG laser with micro-manufacturing capabilities has been

used in this research work. Since laser processing is a

thermal cutting process and results in large heat affectedzone and burr formations around the microchannels.

Hence underwater processing has been used to create

precise microchannels. Mineral water has been used in this

experiment because of its easy availability as well as its

non-reactive nature towards the workpiece surface. The

process has been investigated using response surface

methods in order to determine the effects of basic input

parameters on the output quality parameter of the

microchannels. Lamp current, pulse frequency, pulse width

and cutting speed has been taken as input parameters while

the burr width has been taken as an indication of quality of

the microchannels.

I. INTRODUCTION

Lasers, being able to cut faster with a higher quality are a

new substitution for traditional cutting processes. However,

its use as a micromachining tool is limited because of its

thermal nature of cutting. As the removal of the material

basically depends upon the thermal energy impinging on

the surface, the defects like heat affected zone (HAZ), burr

formation etc. can not be avoided in usual laser cutting

processes. In this paper an attempt has been made to use

lasers in presence of water in order to realize its

micromachining capabilities. In this research work,

microchannels have been created on Poly-methyl-meth-

acrylate (PMMA). Microchannels are mainly used in

microfluidic devices. The new age biological analytical

instruments utilizes these microfluidic channels to reduce

sample consumption, cost, to yield better results and to

increase portability. Earlier these devices have beenmanufactured by etching and lithography processes, which

were not only expensive but also time consuming and

apart, a level of skill was required. Creating microchannels

using laser microprocessing is a recent trend and have been

studied by various authors. Lim et al. [1], used high

brightness diode pumped Nd:YAG laser with slab

geometry for fabricating multiple level microfluidic

channels on silicon wafers. Choo et al. [2] studied the

micromachining of silicon using a short pulse excimer

laser. Heng et al. [3] fabricated microfluidic channels on a

PMMA sheet of 1.5 mm thickness by using a 248 nm

excimer laser direct writing technique. Tiaw et al. [4] Used

third harmonic diode pumped solid state (DPSS) Nd:YAGlasers to achieve high quality precision cuts of thin polymer

films through micro-drilling and micro-cutting as well as

surface patterning of microchannels through direct beam

scanning. Chen et al. [5] investigated both, the near

ultraviolet and mid UV laser micromachining

systematically. The materials used in their research were

sapphire, silicon and Pyrex glasses.

However, no detailed description of effect of individual

process parameters on microchannel characteristics in

underwater processing is available in the literatures. In this

present research work, microchanneling process by

underwater Nd:YAG laser processing has been investigated

with an aim to determine the effects of various process

parameters on microchannel characteristics.

II.EXPERIMENT METHODOLOGY

In this research work Response Surface Methodology has

been used for design and modelling of the experiment.

Statistical package MINITAB

has been used for RSM

modelling and analysis. RSM is a set of mathematical and


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4 International Conference on Manufacturi

statistical techniques that are useful for

predicting the response of interest affected

input variables with the aim of optimizing t

RSM also specifies the relationships amo

measured response and essential controllab

When all independent variables (1, 2,

measurable, controllable and continexperiments, with negligible error, the res

can be expressed by

( ) += kfy ,....,, 21 ;

where the form of the true response functi

and perhaps very complicated, and

represents other sources of variability not

f. Usually includes effects such as meas

the response, background noise, the

variables, and so on. Usually is treated

error, often assuming it to have a normal

mean zero and variance 2.

In the practical application of RSM, it

develop an approximating model for th

surface. The approximating model is bas

data from the processor system and is an e

Usually, a second-order polynomial equa

RSM as given by

211222110 xxxx +++= ;

where parameters 1, 2, etc. are called

coefficients [7].

III.DETAILS OF EXPERI

III.1 Nd: YAG Laser System

A pulsed Nd:YAG laser has been used

research made by M/s Sahajanand Laser T

(figure 1). This CNC Laser machining sy

various subsystems like laser source and

unit, power supply unit, radio frequency

driver unit, cooling unit, compressed air s

CNC controller for X, Y and Z axis movem

The output from the Q-switched Nd:YAG

to the workpiece using a beam delivery s

bends the laser beam at 900, and then focus

spot through the focusing lens. The main p

controls the laser output by controlling the i

emitted by a krypton arc lamp. The coolin

of a three phase chiller unit and a pump, c

by circulating the chilled water to avoid the

laser cavity, lamp, Nd:YAG rod and Q-swit

ng Excellence (MANFEX 2012)

modelling and

by a number of

he response [6].

g one or more

le input factors.

., k ) are

ous in theponse surface y

(1)

nf is unknown

is a term that

ccounted for in

rement error of

ffect of other

as a statistical

istribution with

is necessary to

true response

d on observed

mpirical model.

tion is used in

(2)

the regression

ENTS

in this present

chnology, India

tem consists of

beam delivery

(RF) Q-switch

pply unit and a

ent.

laser is directed

ystem that first

s it on the work

wer supply unit

ntensity of light

unit consisting

ools the system

rmal damage of

ch.

Fig. 1: Photographic view of Nd:

in the present r

III.2 Development of Fixture

In this project underwater machin

on a Nd:YAG laser machine. A fi

to accommodate various sizes of

conditions. Figure 2 shows the p

developed fixture for the present

has been used as water medium be

and its non-reactive nature to wo

higher temperatures. The jammer

jamming the workpiece on the

movement due to water flow or

been attached to measure the wate

Fig. 2: Photographic view of th

the present res

III.3 Input Factors and Proces

A lot of pilot experiments have be

the desired dimensions of microc

After surveying various literatur

some pilot experiments, it has be

YAG laser system used

search

ing has been performed

xture has been designed

orkpiece in underwater

hotographic view of the

research. Mineral water

ause of easy availability

rkpiece material even at

n the fixture is used for

fixture to prevent its

pressure. The scale has

level inside the fixture.

developed fixture for

earch

s Output Factor

en carried out for getting

hannel width and depth.

es available and doing

en found that following


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Creating Microchannels on Polymers Using Underwater Nd: YAG Laser Processing 5

four process parameters affect the laser microchanneling

process significantly and have been taken as input factors

for the present research: (a) lamp current, (b) pulse

frequency, (c) pulse width and (d) cutting speed. Lamp

current in amperage directly relates to total laser fluence or

energy consumed by laser to emit desired pulses. Pulsefrequency or pulse repetition frequency is the number of

pulses emitted by laser per unit time. Pulse width denotes

the percentage of ON time duration per unit time while

cutting speed represents the speed of movement of laser

head with respect to the workpiece or vice-versa. Five

levels of each factors has been identified based on the pilot

experiments in order to find the desired depth and width of

microchannels. Table 1 shows the values of different input

process parameters at different levels.

TABLE 1

PROCESS PARAMETERS AND THEIR LEVELS

Input

parametersDenotes Unit

levels

-2 -1 0 1 2

Lamp current X1 A 13 14 15 16 17

Pulse frequency X2 kHz 1 2 3 4 5

Pulse width X3 % 3 6 9 12 15

Cutting speed X4 mm/s 0.1 0.2 0.3 0.4 0.5

A microchannel is generally specified by its aspect ratio i.e.its width and depth. But if a comparison has to be made

among manufacturing processes utilized for creating the

channel, the cleanliness of the process and product also

have significant effect. So considering both aspects of

process and product, burr width has been taken as an

indication of quality of microchannels. The output

characteristic has been measured by using Olympus-STM-6

optical measuring microscope.

An objective lens of 10X magnification was used for all the

measurements. For reducing the errors during

measurement, the output factor has been measured at three

different locations across the channel and the statisticalaverage has been used for response surface analysis and

modelling.

After conducting various pilot experiments with different

water levels, best results have been found when keeping the

water level just 1 mm above the workpiece for this

experiment. Total thirty one numbers of experiments have

been performed. Figure 3 shows the microscopic view of

the microchannel resulting from experiment no. 23. The

photographs have been taken using the Analysis

software

specially built for this purpose. The uniform distribution of

light at the centre of channels shows that they are uniform

in depth. However, the non-uniformity at the outer edges is

visible in this figure.

TABLE 2: DESIGN MATRIX AND MEASURED

EXPERIMENTAL RESULTS

Exp.

no.

Process parameters Response

X1

(A)

X2

(kHz)

X3(%)

X4(mm/s)

Average Burr

Width

(m)

1 14 2 6 0.2 62.41

2 16 2 6 0.2 59.31

3 14 4 6 0.2 85.40

4 16 4 6 0.2 91.96

5 14 2 12 0.2 44.30

6 16 2 12 0.2 51.09

7 14 4 12 0.2 45.80

8 16 4 12 0.2 61.20

9 14 2 6 0.4 71.0

10 16 2 6 0.4 68.99

11 14 4 6 0.4 77.94

12 16 4 6 0.4 71.80

13 14 2 12 0.4 75.70

14 16 2 12 0.4 90.60

15 14 4 12 0.4 68.58

16 16 4 12 0.4 71.42

17 13 3 9 0.3 58.38

18 17 3 9 0.3 72.44

19 15 1 9 0.3 63.10

20 15 5 9 0.3 74.81

21 15 3 3 0.3 61.21

22 15 3 15 0.3 44.42

23 15 3 9 0.1 70.90

24 15 3 9 0.5 97.30

25 15 3 9 0.3 59.10

26 15 3 9 0.3 57.60

27 15 3 9 0.3 54.60

28 15 3 9 0.3 51.30

29 15 3 9 0.3 55.01

30 15 3 9 0.3 50.60

31 15 3 9 0.3 52.88

Details of the experiment with their corresponding values

of process parameters and responses are given in table 2.

The response values are statistical average of three values

of responses taken across the channel. Input values of


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6 International Conference on Manufacturing Excellence (MANFEX 2012)

process parameters are based on pilot experiments. These

microchannels have been created in single pass

experiments. While conducting experiments normal

atmospheric conditions have been maintained.

Fig. 3: Microchannel resulting from experiment no. 23

IV. MATHEMATICAL MODELLING OF THE

RESPONSE BASED ON RSM

Second-order mathematical models has been developed

using the different values of response obtained as above.

The mathematical correlation for burr width (YBW) is given

by equation (3), where X1denotes lamp current, X2denotes

pulse frequency, X3 denotes pulse width and X4 denotes

cutting speed.

YBW = 54.44 + 5.28X1 + 6.18X2 9.48X3 + 12.28X4 +

11.48X12+ 15.03X2

2 1.11X3

2+ 30.17X4

2+ 0.52X1X2+

11.16X1X3 - 4.01X1X4 20.02X2X3 20.95X2X4 +

20.95X3X4 (3)

IV.1 Analysis of Variance

In order to ascertain fitness of the developed empirical

model for the response of microchannel burr width, the

analysis of variance (ANOVA) test is conducted. The

purpose of ANOVA test is to investigate which design

parameters have a significant effect on the microchannel

characteristics.

Table 3 gives the ANOVA table for burr width. From the

table 3 it is found that the calculated lack-of-fit (1.10) is

less than the tabulated value of F10,14 (2.60) which clarifies

that the effect of lack-of-fit is insignificant. This implies

that all the data has been well fitted in the response curve.

The regression factor on the parameters has more effect on

the process parameter. Hence the developed second order

regression model for burr width is adequate at 95%

confidence level.

TABLE 3:

ANALYSIS OF VARIANCE FOR BURR WIDTH

Source DF Seq. SS Adj. SSAdj.

MSF P

regress-

ion

14 5662.63 5662.63 404.473 38.69


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Creating Microchannels on Polymers Using Underwater Nd: YAG Laser Processing 7

Fig. 4: (a) Variation of burr width with change in pulse

frequency and cutting speed, (b) Variation of burr

width with change in pulse width and cutting speed

VI. CONCLUSION

It is challenging to fabricate 3D microchannels using

conventional microfabrication technologies such as

photolithography and etching. Multiple exposure andalignment steps required by conventional techniques often

limit the flexibility and size of the fabrication. The pulsed

Nd:YAG laser in underwater conditions has been employed

successfully to produce microchannels for microfluidic and

other applications. From the in-depth experimental

investigation and analysis, it is evident that Nd:YAG laser

microchanneling in underwater conditions is an effective

process.

The underwater laser processing minimizes the heat

affected zone and burr formation in an effective way.

Microchanneling in underwater cutting is far cleaner and

effective process than cutting in assisted air or open airconditions.

Mathematical modelling has been developed for burr width

and the model adequacy has been checked by subsequent

ANOVA analysis. Cutting speed and pulse width are the

most influencing factors for the burr width.. Multipass

processing can be performed to obtain microchannels of

high aspect ratios.

VII. REFERENCES

[1] D Lim, Y Kamotani, B Cho, J Majumdar and STakayama, fabrication of microfluidic mixers and

artificial vasculatures using a high brightness diode-

pumped Nd:YAG laser direct write method, Lab Chip,

2003, 3, 318-323

[2] KL Choo, Y Ogawa, G Kanbargi, V Otra, LM Raffand R Komanduri, Micromachining of silicon by

short-pulse laser ablation in air and under water,

Materials Science and Engineering A 372 (2004) 145

162

[3] Q Heng, C Tao and Z Tie-chuan, surface roughnessanalysis and improvement of micro-fluidic channel

with excimer laser, Microfluid Nanofluid (2006) 2:357-360

[4] KS Tiaw, MH Hong and SH Teoh, Precision lasermicro-processing of polymers, Journal of Alloys and

Compounds 449 (2008) 228-231,

[5] T Chen and BR Darling, Laser micromachining of thematerials using in microfluidics by high precision

pulsed near and mid-ultraviolet Nd: YAG lasers,

Journal of Materials Processing Technology 198

(2008) 248-253

[6] Montgomery DC, (2010), Design and analysis ofexperiments, 5

thed., Wiley New York

[7] B Acherjee, D Misra, D Bose and K Venkadeshwaran,Prediction of weld strength and seam width for lasertransmission welding of thermoplastic using response

surface methodology, Optics & Laser Technology 41

(2009)


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Finite Element Modeling of an Improved Extrusion Process for the Enhancement of the Product Quality 9

also reduces [13]. At the end of the process the force again

increases because the billet is thin and the material must

flow radially to exit the die.

III.TWIST EXTRUSION

Twist extrusion (TE) was proposed by Beygelzimer et al.[14,15] in 1999. The principle of TE is to obtain intense

shear deformation via extrusion of rectangular cross section

billets through a die with a twist channel. The billet is

twisted with an angle about its longitudinal axis as

illustrated in Fig.2, the shape and area of the channel cross

section remain constant[15,18] along the extrusion axis.

The shape of the cross section can be arbitrary [2]. TE

allows repetitive extrusion on a work piece to accumulate

plastic strain [2, 15]. Billet is pushed through the twist die

by an upper die or punch. TE is generally adopted for

metallic materials, however systematic investigation of

material properties and deformation homogeneity is still

needed to establish a basic foundation for this newtechnology.

The principle of TE is shown in fig. 2. Under TE, a billet is

extruded through a twist die. In multi pass TE billets

cross-section may be deformed in different directions.

Opposite route of twist dies for the consecutive passes is

responsible for more severe values of strain in the billet in

comparison to the common route of twist. Amplitude of

deformation in the opposite route is twice as compared to

common route used repeatedly [7]. The simple shear plane

in TE is perpendicular to the longitudinal axis of a

specimen, responsible for the production of new structures

and textures in the material. Similar to HPT its deformationgradient is quite steep causing excessive grain refinement

and improves ductility [15]. Intense flow within the cross

section homogenizes the structure. In twisted region of die

the billet surface expands by 60-70% and returns to

original size. Such change could allow insertion of alloying

elements in the billet surface if need be.

Fig. 2: Twist Extrusion (Beygelzimer et al.)

TE has certain advantages like easy installation of die, less

distortion of billet (unlike ECAP) and uni- axial flow of

metal (unlike ECAP) which allows TE to be easily

embedded on existing industrial lines. Deformation at the

beginning and end of the twisted region gives the strain

values [16], the value of strain in the central core of the

billet is zero. The maximum strain in the billet takes place

at periphery i.e. of the order of 0.5 0.7 where as the value

of equivalent strain in the twisted part is of the order of 0.2-

0.4 which is in most of the volume except 1-2 mm thick

peripheral layer. Maximum equivalent strain in theperipheral layer is of the order of 2.0 which is the highest

of the entire volume

IV. PROPOSED IMPROVED EXTRUSION

Using the concept of Twist Extrusion (TE) a new scheme is

developed for the extrusion process. In improved method

the billet is reduced to a smaller cross section first (as in

simple extrusion), then it passes through the twisted part of

the die providing severe plastic strain in the billet material

causing further grain refinement and improved mechanical

properties. Fig. 3a represents the simple extrusion die and

fig. 3b. Represents the improved die adopted for theproposed method. For the study material of billet is taken

as Al6061. Comparative study of the simple extrusion and

improved extrusion (IE) is done using finite element

modeling.

Fig 3a. Simple extrusion

die

Fig 3b. Improved

extrusion die

V. FINITE ELEMENT MODELING

In this work, the modeling of simple and improved

extrusion processes are done in FORGE environment. This

paper explains the effect of friction on equivalent strain,

forging force and forming energy for both processes.

FORGE is specially intended for 3-D metal forming

process with automatic mesh generation. The software also

takes care of thermal and friction effects.


22/228

10 International Conference on Manufactu

The material is assumed to be homogeneo

incompressible. The elastic strains in comp

plastic ones are considered to be negligibl

behavior is assumed to follow that of Norto

A fully automated remeshing procedure

into the analysis. The material parameters c

k = 1 and m = 1.

Generalized coulomb friction law is use

analysis given by:

n= 3

0 mn V

Vm

=

3

0 n

where, = friction stress tangential to the surface

= coefficient of frictionn

= compressive stress normal to the surf

pressure)

m = Tresca coefficient

The dies are assumed to be rigid. Dimensi

considered as 20 mm (width) X 20 mm (br

(length) and the material was chosen as Al

punch dimensions were considered as 20

20mm (bredth) X 25 mm (height). FE

carried out for simple extrusion and imp

where the die angle () was considere

horizontal, Reduction ratio is taken as 4:1

extrusion the angle of twist (

length of twist is taken as 25mm. The

conducted for both methods considerin

values of friction ranging from 0.5 to 2.5 a

punch velocities 10mm/sec and 15mm/s

drawn are tabulated and compared to show

of improved extrusion method. Adiabatic

considered during the processes and the

maintained at room temperature i.e. 300.

VI. EXPERIMENTAL RES

The FE Simulations are carried out t

importance in developing practical Imp

process. A comparative analysis between

simple extrusion process for = 0.2 is depi

4b The simulation results tabulated in Ta

the improved method incorporates higher

in the workpiece and hence is more effec

deformation, grain refinement and impro

properties. The equivalent strain is comp

pass at two different punch velocities

compared through line graph as shown

Maximum deformation takes place on the

where as minimum deformation takes pla

ring Excellence (MANFEX 2012)

s, isotropic and

arison to visco-

e. The material

n-Hoff law.

is incorporated

osen are:

in the current

3

0

ce (contact

on of billet was

dth) X 105 mm

6061 where as

mm (width) x

simulations are

roved extrusion

as 60O

from

. For improved

90

O

and thesimulations are

the different

nd two different

c. The results

the advantaged

conditions are

temperature is

LTS

illustrate the

oved extrusion

improved and

ted in fig. 4a &

ble1 show that

mount of strain

ive in terms of

ved mechanical

ared for single

and results is

in fig. 5 & 6.

peripheral layer

e in the central

core of the billet. So in order t

grained structure multiple numbers

Simple extrusion

Fig. 4: Comparison in equiv

V=10m

Table 1. Comparison of FE sim

extrusion and improved extrusi

friction and punch

Parameter Simple Extrus

VelocityFrictio

n ()

Avg.

equivalent strain

Fo

E

(

Punch

velocity:10mm/se

c

0.5 2.29 1

1.0 2.46 1

1.5 2.48 1

2.0 2.59 1

2.5 2.64 1

Punch

velocity:15mm/se

c

0.5 2.36 1

1.0 2.41 1

1.5 2.52 1

2.0 2.64 1

2.5 2.67 1

produce homogeneous

of passes are needed.

Improved Extrusion

lent strain at =0.2 and

/sec

lation results of simple

n at different values of

velocity.

ion Improvd Extrusion

rmin

g

ergy

KJ)

Avg.

equivalen

t strain

(KJ)

Formi

ng

Energ

y

.50 2.98 15.53

.51 3.01 15.74

.51 3.13 15.89

.67 3.07 15.97

.74 3.16 15.99

.61 3.12 16.01

.63 3.17 16.23

.81 3.42 16.46

.79 3.51 16.47

.92 3.57 16.73


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Finite Element Modeling

Fig. 5a: Comparison of average equival

Friction for SE and IE Processes at pu

10mm/sec.

Fig. 5b: Comparison of average equival

Friction for SE and IE Processes at pu

15mm/sec

Fig. 6a: Comparison of Forming energy

For SE and IE Processes at punch veloc

2.29 2.46 2.48

2.98 3.01 3.13 3.0

0

0.5

1

1.5

2

2.5

3

3.5

0.5 1 1.5 2

Simpl

Impro

Coefficient of frictio

Eq.

Str

ain

2.36 2.41 2.52 2.6

3.12 3.173.42 3.51

Simple

Improv

Coefficient of friction

Eq.

Strain

12.5 12.51 12.51 12.67

15.53 15.74 15.89 15.97

0

2

4

6

8

10

12

14

16

18

0.5 1 1.5 2

Simpl

Impro

Coefficient of friction

Energy

(KJ)

f an Improved Extrusion Process for the Enhancement of

nt strain with

nch velocity

nt strain with

nch velocity

with Friction

ity 10mm/sec.

Fig. 6b: Comparison of formin

for SE and IE Processes at pun

The value of equivalent strain in

as compared to SE for same fricti

velocity of 10mm/sec. At incre15mm/sec the value of Equivalent

for both the processes. Fig.

representation of forming energy f

in SE and IE. It clearly shows th

higher in IE as compared to SE.

VII.DISCUS

Finite Element modeling of simpl

processes are performed consideri

velocity and different values

observations are made:

Twisted improved extrusion impa

the work piece and hence resp

refinement and enhanced properti

slight increase in forming energy.

Additional forging load and ene

while designing extrusion die

investigation.

Optimal parameters can be chos

depending upon desired properties

VIII.

CONCLU

The study represents a new sc

Deformation (SPD) for the produc

better mechanical properties and i

The method may also be visualiz

bulk ultra fine grained materials

ratio or by processing the bill

comparative study of improved

done using finite element process

Results of Finite element simula

conditions and punch velocities

2.59 2.64

7 3.16

2.5

e Extrusion

ved Extrusion

n ()

4 2.67

3.57

xtrusion

d Extrusion

()

12.74

15.99

2.5

Extrusion

ved Extrusion

()

12.61 12.63 12.

16.01 16.23 16.

I

Coefficient o

Ener

gy(KJ)

the Product Quality 11

energy with Friction

ch velocity 15mm/sec.

E is significantly higher

on conditions and punch

ased punch velocity ofstrain has been increased

shows the graphical

r varying friction values

at the forming energy is

ION

and improved extrusion

g the influence of punch

of friction. Following

ts larger plastic strain to

nsible for better grain

s of the work piece with

rgy must be considered

nd press for practical

n for extrusion process

of the material.

SIONS

eme of Severe Plastic

tion of components with

mproved grain structure.

ed for the production of

y taking high reduction

t for multi passes. A

and simple extrusion is

in FORGE environment.

ions on various friction

are reported and their

81 12.79 12.92

46 16.47 16.73

imple Extrusion

mproved Extrusion

friction ()


24/228


25/228

Finite Element Modelling and Burst Pressure Analysis

of Cylidrical Composite Pressure Vessel

Medhavi Sinha

1

, Dr. S. N. Pandit

2

1Department of Mechanical & Automation Engineering,

Amity School of Engineering & Technology, Amity University Uttar Pradesh, Noida - 201303, India

[email protected] of Mechanical Engineering,

Noida Institute of Engineering & Technology, Greater Noida 201306, India

[email protected]

ABSTRACT

The composite pressure vessels have become very popular

in oil and gas transport industries. These pressure vesselsare subjected to very high internal pressures during their

service. This study is performed on cylindrical shaped

carbon fiber reinforced polymer (CFRP) composite

pressure vessels. The pressure vessel is modeled using the

finite element software ANSYS 11. The step by step

procedure for the finite element modeling of multilayered

composite pressure vessels has been discussed in the

paper. The modeling is performed for both hoop and

helical windings of the fibers. The pressure vessels once

designed and modeled are then subjected to high working

pressures. The stress distributions in the composite

pressure vessel are investigated for various orientations of

fibers in the composite pressure vessel under internal

pressure. Further, the burst pressure for each of the fiberorientations is also calculated based on the Tsai-Wu

failure criteria.

I. INTRODUCTION

Nowadays, the resin matrix composite pressure vessels

have found out there applications in various industrial areas

such as, aerospace, automobiles, aeronautics, chemical

engineering etc [1]. Besides these, the composite pressure

vessels have suddenly become an attraction for the piping

and sewage as well as oil and gas transport industries. This

is all because, in these applications the weight is a very

important concern and the composite pressure vesselsprovides an excellent compromise between high

mechanical properties and low weight [2]. It can be very

well understood that in all of these applications, the resin

matrix composite pressure vessels are subjected to very

high pressures during their service life. Therefore, the

deformation and stress strain analysis becomes a very

important concern must be conducted for every composite

pressure vessel while designing itself. Few researchers

have proposed some methods to study, design and analyze

the resin matrix composite pressure vessels for stress and

deformation under different conditions. For example, R.R.

Chang studied the first ply failure strength of composite

pressure vessels when the fibers were oriented

symmetrically for different number of layers [3]. Levend

Parnas et al. predicted the behavior of a rotating fiberreinforced composite vessel [4]. M.A. Wahab et al.

analyzed composite pressure vessels of five different

polygonal shapes [5]. While, R.M. Guedes evaluated the

performance of a glass-fiber reinforced (GFRP) composite

cylindrical pipe under transverse loading and large

deflections [6]. Also, H. Bakaiyan et al. analyzed

multilayered composite pressure vessels under thermo-

mechanical loadings. The results were evaluated for

various winding angles [7]. Besides these, Frank Ratter et

al. performed finite element analysis for the prediction of

lateral crushing behavior of segmented composite tubes [8].

The design and analysis of a composite pressure vesselconsiders complex decisive factors and for the design to be

accurate the optimum choice of these decisive factors is

necessary. This paper presents a study of the deformation

behavior and the static stress analysis of CFRP (carbon

fiber reinforced polymer) cylindrical, pressure vessel under

internal pressure. The study is performed with the

utilization of the finite element software ANSYS. The

FEM modeling is developed by ANSYS 11. ANSYS 11

features all the capabilities that are necessary for modeling

a system with characteristics of the given problem.

II. THE FINITE ELEMENT MODEL

A. CFRP cylindrical pressure vessel

This study deals with a resin matrix composite pressure

vessel. The composite pressure vessel is cylindrical in

shape and consists of carbon fibers as the reinforcement

material into a polymeric matrix. The Fig. 1. shows the

CFRP cylindrical pressure vessel. The composite materials

are orthotropic in nature and therefore the finite element

modeling of these materials requires the determination of

nine different properties. The material properties of fiber

reinforced composite depends upon the properties of both


26/228


the matrix and the fibers. The angle of or

fibers in the composite also plays a very

determination of the properties and the

composite, since the fibers have super

properties along its length.

B. Selection of appropriate element typ

It is very necessary to select the appropria

before conducting the finite element a

composite pressure vessel. ANSYS 11 prov

shell and solid element types to model la

materials. A solid element can be utilized

layered composites but it requires that the

in thickness directions must be the same a

material layers. This increases the an

calculation time for these elements.

elements does not require the mesh divisi

direction and the calculation as well as the

these elements is much lesser than for theBecause of this property of the shell ele

selected SHELL 99 as the appropriate ele

purpose of our study. SHELL 99 is a

structure shell element. Very thin to m

layers can be modeled with this element. It

the purpose of modeling layered structure

uniform thickness layers can be modeled b

is a 3D shell element and consists of 8 -

degrees of freedom at each node. Among

four nodes are the corner nodes and the re

the mid - side nodes. This element allows t

elastic properties, layer orientation and d

layer.

The finite element model of the composite

shown in Fig. 1. The whole model is esta

finite element software ANSYS 11.

Fig. 1: Finite Element model o

composite pressure vessel

C. Defining the layered configuration

The layered configuration is the

characteristic of a composite material

configurations are determined by specif


ientation of the

important role

ehavior of the

ior mechanical

e

te element type

nalysis of the

ides the various

ered composite

to model thick

mesh divisions

s the number of

alysis and the

hile, the shell

ns in thickness

nalysis time for

solid elements.ments we have

ent type for the

linear layered

oderately thick

may be used for

and up to 250

this element. It

nodes, with six

the 8 nodes,

aining four are

e user to define

ensity for each

pressure vessel

blished through

the

ost important

. The layered

ying individual

layer properties and therefore

composite as a whole depends

configuration. The material proper

angle, the layer thickness and th

points per layer must be speci

definition of the layered configurat

The CFRP layers in the compos

assumed to be orthotropic. T

properties are required for the pur

material properties for CFRP are li

The cylindrical composite pressu

various fiber orientations. The m

the CFRP cylindrical pressure vess

the helical windings of the car

windings of the carbon fibers, the

angle of 0 with the axis of the cy

The fibers are also oriented hel

orientations such as 35, 45,The Fig. 2. shows the stacking s

orientation.

Table 1. Material prop

Ex (MPa)

Ey (MPa)

Ez (MPa)

Gxy (MPa)

Gyz (MPa)

Gzx (MPa)

xy

yz

zxThe cylindrical composite pressu

six uniform thickness layers and t

points are taken as three to define

completely.

Fig. 2: The stacking sequence fo

the properties of the

greatly on its layered

ties, the fiber orientation

e number of integration

fied for individual the

ion to be complete.

ite pressure vessels are

herefore nine material

pose of the analysis. The

sted in Table 1.

e vessel is designed for

deling is performed for

el for both, the hoop and

on fiber. For the hoop

fibers are oriented at an

lindrical pressure vessel.

ically for various fiber

55, 65 and 75.equence for 35 fiber

rties of CFRP

127700

7400

7400

6900

4300

4300

0.33

0.188

0.188

e vessel is modeled for

e number of integration

he layered configuration

35 fiber orientation


27/228

Finite Element M

III. ANALYSIS

The CFRP pressure vessel is analyzed by lo

internal pressures. The Tsai-Wu failure crit

for the purpose of analysis. The analysis i

two different cases. In the first case n

pressure of 35 MPa is applied for hoop asfiber orientations of 35, 45, 55,

The stress distributions for these various

then predicted.

While, the second case involves the calc

pressure for the pressure vessel. The burst

pressure vessel is predicted by increasi

pressure from the working value of 35 MP

burst pressure step by step. For every i

internal pressure, the value of maximum st

compared with value of ultimate stress f

vessel. The maximum stress and the ulti

satisfy the relation given by the Eq. 1.

max u (Eq. 1)

Where, max , u are the maximum stress an

of the pressure vessel, respectively. The v

stress for the CFRP pressure vessel is 1210

The Fig. 3. And Fig. 4 gives the stress dist

pressure vessel for hoop and 35 fiber ori

Fig. 3: Stress distribution for hoop fibe

composite pressure vessel

Fig. 4: Stress distribution for 35 fibe

delling and Burst Pressure Analysis of Cylidrical Compos

ading it by high

erion is utilized

s performed for

ormal working

well as helical65 and 75.

orientations are

lation of burst

pressure for the

ng the internal

to the value of

crement in the

ress obtained is

or the pressure

ate stress must

ultimate stress

alue of ultimate

MPa.

ribution for this

ntation.

r windings in

r orientation

IV. RESULTS AND

After the analysis of the stress dis

fiber orientations, the maximum

composite pressure vessel is foun

45 fiber orientation and maxi

orientation in the composite presshows the graph between the

angles of fiber orientations when

vessel is subjected to the working

graph gives a decreasing slope fro

slope further increases drastically

orientations.

The burst pressure is calculated i

analysis. The Fig. 6 shows the

pressure and the different fiber

gives an increasing slope from ho

decreases from 45 to 65 fib

further predicted that the pressur

maximum internal pressure of 59orientated at 45, which is rega

at 45 fiber orientation. The

distribution in the composite pres

orientation angle when, the pressu

its burst pressure of 59 MPa. It ca

that, the maximum stress obtaine

than 1210 MPa.

Fig. 5: Variation of the maximu

angles of fiber ori

Fig. 6: Variation of the burst p

angles of fiber ori

ite Pressure Vessel 15

ISSCUSSION

ribution for the different

stress in the cylindrical

d to be minimum for

mum for 65 fiber

sure vessel. The Fig. 5aximum stress and the

the composite pressure

pressure of 35 MPa. The

m hoop to 45 and the

rom 45 to 65 fiber

n the second part of the

raph between the burst

orientations. The graph

p to 45 and the slope

er orientations. It can be

vessel can sustain the

Pa when, the fibers areded as its burst pressure

ig. 7 shows the stress

ure vessel at 45 fiber

re vessel is subjected to

be seen from the figure

d is 1178 which is less

m stress with different

ntations

ressure with different

ntations


28/228


V. CONCLUSION

In this study, the finite element model of C

composite pressure vessel is establishe

element software ANSYS 11. The mode

various fiber orientations are meshed using

structure shell element, SHELL 99.

The study discusses a step by step method

of cylindrical composite pressure vessel w

to internal pressure loading. The maximum

burst pressures for various fiber orientatio

using the Tsai-Wu failure criteria. The o

angle is obtained 45 for the composite

subjected to internal pressure. At 45 fibe

maximum stress in vessel is found minimu

pressure for the vessel is found maximum.

Fig. 7: Burst stress at 45 fiber or


RP, cylindrical

d using finite

ls obtained for

a linear layered

for the analysis

ich is subjected

stresses and the

s are predicted

timum winding

pressure vessel

r orientation the

m and the burst

ientation

REFERE

[1] Buarque, E.N., and Almeidacylindrical defects on the t

fiber/vinyl-ester matrix reinf

Composite Structures, 79 (20

[2] Duell, J.M., Wilson, J.M. andof a carbon composite o

system, International Journal

Piping 85 (2008) pp. 782788

[3] Chang, R.R., Experimental afirst-ply failure of laminat

vessels, Composite Structure

[4] Parnas, L. and Katrc, N., Dcomposite pressure vessels

conditions, Composite Struct

[5] Wahab, M.A., Alam, M.S., PJones, R.A., Stress analys

composite pipes, Composite

125132.[6] Guedes, R.M., Stressstrain

pipe subjected to a transvers

tions, Composite Structures,

[7] Bakaiyan, H., Hosseini, H. anmulti-layered filament-woun

combined internal pressure

loading with thermal variation

88 (2009) pp. 532541.

[8] Ratter, F., Lueddeke, D., aElement Analysis of the Late

Segmented Composite Tubes

Technology and Education, V

pp. 1-16

[9] Nagesh, Finite-element APressure Vessels with Pr

Defence Science Journal, V

2003, pp. 75-86.

CES

, J.R.M., The effect of

nsile strength of glass

rced composite pipes,

7) pp. 270279.

Kessler, M.R, Analysiserwrap pipeline repair

of Pressure Vessels and

.

d theoretical analyses of

ed composite pressure

,49 (2000), pp. 237-243.

esign of fiber-reinforced

under various loading

res, 58(2002) pp. 83-95.

ng, S.S., Peck, J.A., and

is of non-conventional

Structures, 79 (2007) pp.

analysis of a cylindrical

load and large deflect-

8(2009) pp.188194.

Ameri, E., Analysis of

composite pipes under

and thermomechanical

s, Composite Structures

d Huang, S.C., Finite

al Crushing Behavior of

, Journal of Engineering

ol. 6, No.1, March 2009,

nalysis of Composite

gressive Degradation,

ol. 53, No. 1, January


29/228

Finite Elemement Based Delamination Damage

Analyses of Laminated FRP Composite Made Bonded

Tubular Socket JointsR. R. Das

1, B. Pradhan

2

1Associate Professor, KIIT-University, Bhubaneswar, Odisha, India

[email protected] Professor, Department of Mechanical Engineering, IIT, Kharagpur, West Bengal, India

Presently Director, Gandhi Institute of Education and Technology, Bhubaneswar, India

[email protected]

ABSTRACT

Finite Element Method (FEM) based modelling andsimulation of through-the-circumference delamination

damage analyses of a Tubular Socket Joints (TSJ) made

with laminated FRP composites is the major concern of the

present research. Numerical analysis of the bonded TSJ

has been carried out using ANSYS 12.0 a Finite Element

(FE) based software. Three-dimensional non-linear FE

analyses have been carried out to study the effects of

through-the-circumference delaminations on interlaminar

stresses in the bonded TSJ.

Stress analyses revealed that the interface of surface ply (in

contact with the adhesive) with the next ply i.e. first ply-

interface of both the adherends shows maximum intensity

of interlaminar out-of-plane stress concentration, which is

gradually reduced for the subsequent ply-interfaces.

Tsai-Wu coupled stress criterion has been used to identify

the location of delamination damage initiation in the

adherends. Accordingly, free edges of the first ply-

interfaces of both the adherends showing maximum values

of failure index are simulated with delamination damages

using sub laminate technique. Contact FE analyses have

been performed in order to avoid interpenetration of

delaminated surfaces.

Strain Energy Release Rate (SERR), a Fracture mechanics

based parameter has been used in the present analyses to

characterize the growth of the delamination failures.

Modified Crack Closure Integral (MCCI) vis--vis Virtual

Crack closure Technique (VCCT) has been implemented to

calculate the three components of SERR (GI, GII, and GIII)

numerically.

Keywords: Delamination damage; FEM; Fracture

Mechanics; FRP composites; MCCI; SERR; VCCT

I. INTRODUCTION

In response to significant corrosion problems with metallic

pipes in the chemical processes in pulp and paperindustries, composite piping systems were developed using

fibre glass reinforced thermoset plastics. With

advancement of material science and manufacturing

processes, the mechanical properties of composite pipes

have been dramatically improved. Limitations of

component size imposed by manufacturing processes and

requirement of inspection, assembly, repair and

transportation necessitate provision of some load carrying

joints in most piping systems. The overall system

performance usually comes from the capacity of these pipe

joints, and hence they play a critical role in the overall

integrity of most piping systems. The estimation that one

joint is to be installed for every 4 ft of composite pipe formarine applications further emphasizes the importance of

efficient design of composite pipe joints.

Adhesive bonding is the most attractive connection method

in composite pipe joints because it can effectively lower

the stress concentration through smoother load transfer

between the connecting members. In addition to this,

adhesive bonds are generally corrosion free as compared to

mechanical fasteners.

When the adherends are laminated FRP composites, they

are vulnerable for various types of failures, viz.

interlaminar failure and delaminations, etc., besides theconventional failures like cohesion and adhesion failures.

Fracture mechanics parameters such as SERR, J-integral

and SIF can be used to characterize the propagation of such

failures or damages. Although literature [1-6] is available

for the adhesion and/or delamination damage prediction

and its propagation in adhesive bonded flat laminated FRP

composites, only a few have been devoted to the adhesive

bonded TSJ. Also, the literature contains very limited

research on the calculation of SERR which is one of the

key parameters for the study of adhesion or/and

delamination damage peropagation. Raju et al., [7]


30/228


emphasized on SERR for the problem wi

debonding. The importance of SERR to

delamination damages are discussed in de

and Chakraborty [8-9] and Pradhan and Pan

Interlaminar or interply delamination is

mode in the adherends of a FRP composiAs a result of this, the structures havin

reduce their strengths and stiffness and thu

structures are limited. Due to the low tr

strength, the TSJ experiences peel loadi

adherends are likely to fail in transverse te

adhesive layer fails. Like the shear stresse

the peel stresses are the highest at the o

hence can induce adherend failures due to

strength in the circumferential direction. A

of joint failure would be enhanced

eccentricity in case of Single Lap Joints

cases, even though the remote loading is

the local loading effect near the discontinaround the overlap portions of the joint

plane type. Although work has been don

and predict the failure behaviour of lamina

3] to understand the effect of presence of th

delamination when embedded in the

delamination propagation parameters. But

based upon the assumptions of presuming

the delamination damages without taking in

the exact location in the adherends prone

damages under the remote tensile loading c

However, the present work is based upon a

analyses to evaluate the interlaminar streadherends of the bonded TSJ. Tsai-Wu

criterion has been used to calculate the

based on which the locations prone to dela

initiation under tensile loading conditions

Study of effect of through-the-circumferen

damage propagations on the strength of

main concern of the present study.

II. FINITE ELEMENT ANA

The geometry, configuration, loading

conditions of the TSJ specimen analyzed

finite element mesh used to discretize the

been shown in Fig. 1. The adherends an

bonded TSJ are made with GR/E [90]4composite and epoxy is used as the adhesi

the socket and adherends are oriented in

applied tensile load ([90]4), as recomm

Pradhan [18] for increasing the resistance

against the interfacial failures. The geo

conditions, material properties along wit

values for the adhesive and the laminated

adherends have been taken from the anal

Pradhan [18]. The applied tensile load at t


h skin stiffener

haracterize the

tail by Pradhan

da [10].

a major failure

e bonded joint.bonded joints

the lives of the

ansverse tensile

ng, and so the

sion before the

s, the values of

erlap ends and

the low tensile

lso, the severity

ue to loading

(SLJ). In such

f in-plane type,

ities prevailingmay be out-of-

to understand

ed FRP SLJ [1-

rough-the-width

adherends on

these works are

the location of

to consideration

to delamination

nditions.

complete stress

ses for variouscoupled stress

failure indices

ination damage

are identified.

ce delamination

the joint is the

LYSES

and boundary

along with the

onded TSJ has

socket of the

laminated FRP

ve. The plies of

the direction of

nded Das and

of the structure

etry, boundary

their strength

FRP composite

sis of Das and

e far end of the

inner tube is equivalent to a unifor

MPa.

Fig.1: Adhesive bonded TSJ al

considered for delamination

oriented in the direction o

In order to facilitate the extractio

from different ply interfaces of th

modelling of the delaminations at

adherends the adherends in the b

separately with SOLID 46 elem

defined as a real constant. Howev

has been modelled using Solid 45

Crack growth studies in ortho

complex in nature due to the

properties at the interface. The s

field at the tip of the delamination

and at the tip of the delaminagenerally more complex than thos

in homogeneous medium. Oscill

interface were observed by Rice [

Tay et al., [12] have discussed th

tip mesh sizes in greater details. T

extreme fine mesh could result i

the region enters the zone of osci

FE work of Raju et al., [13] sugge

size or characteristic length betwe

thickness evaluates the component

m loading of intensity 10

ng with the FE mesh,

analyses with plies

applied loading.

of interlaminar stresses

adherends and for easy

the ply interface of the

nded TSJ are modelled

nts with a single layer

r, the isotropic adhesive

lements.

ropic media are quite

mismatch of material

ingularities of the stress

in laminated composites

tion damage zones aree associated with cracks

tory stress fields at the

11]. To account for this,

adequacy of local near-

ey also observed that an

non-convergence when

llatory stress fields. The

ts that choosing element

en 0.25 to 0.5 of the ply

s of SERR well.


31/228

Finite Elemement Based Delamination Da

Accordingly, a mesh pattern of

(circumferentially) x 1 or 2 elements (radi

elements (axially) have been adopted t

adherends and adhesive in the overlap reg

TSJ under consideration. Such a mesh de

yield stress values in the mid-surface of the

compares well with the available literatureisotropic [14] and FRP composite adhere

are shown in Figs. 2(a) and 2(b), respectivel

(a)

Fig. 2: Normal and shear stress distribu

adhesive mid-plane in TSJs with, (a

adherends and (b) composite adherends

uniform tension.

III.

CRITERIA FOR ONSET AN

OF FAILURES IN BOND

Onset of Failures in Bonded TSJ

The delamination damage failures at th

generally can be evaluated by the Tsai-Wutakes into account the interaction of

components at the critical and ply-interfac

by:

............2

11111

2

2

2

2

2

2

2

2

2

2

2

2

ezzfrzzrfrrf

TZz

CTCRTRr

zS

z

zrS

zr

rS

r

TZ

z

TTR

r

=++

+

+

++++++

where, RT, T, ZT are the allowable tensil

RC, C, ZC are the allowable compressive

three principal material directions, respecti

Sz are the shearing strengths of the orth

various coupling modes. The coupli

reflecting the interaction between r, and

given by fr, fzr and fz, respectively. Fail

defined as the parameter to evaluate the co

the structure is likely to fail or not. If e

else there is no failure. Generally, the out-

e

fai

mage Analyses of Laminated FRP Composite Made Bon

120 elements

ally) x (5 x 2c)

discretize the

ion (2c) for the

nsity is seen to

adhesive which

for the cases ofds [15]. These

y.

(b)

ions along the

isotropic

, subjected to

GROWTH

D TSJ

ply-interfaces

FC [16] whichall six stress

es and is given

)1...(..................

1

C

+

e strengths and

strengths in the

ely. Sr,Szrand

tropic layer in

ng coefficient

z directions are

re index (e) is

ndition whether

1 failure occurs,

f-plane stresses

are responsible for the initiation

and hence only the interlaminar s

and the radial stress or peel str

predict the damage initiation.

equation is:

222

eSSR zr

zr

r

r

T

r =

+

+

where, RT is the interlaminar nor

Szrare the interlaminar shear stren

the two orthogonal shear coupli

composite laminates considered in

Szr, because of material symmetry.

Cohesion failure is the inability

internal separation. The failure in

adhesive layer is formulated

philosophy. Following the paraisotropic materials proposed by

identification of location of cohe

the adhesive bonded

Documents

(I Part) Proceeding of International Conference on Manufacturing Excellence MANFEX 2012