Abstract The failure of dies and its repairing options are very important in die casting industri... more Abstract The failure of dies and its repairing options are very important in die casting industries. Of all the casting processes available, pressure die casting finds wide applications in large scale production of complex shaped objects with intricate geometries that require good surface finish and dimensional stability. The cooling system employed in the die not only facilitates proper solidification of the cast components but also helps in maintaining the die temperature and controlling the stresses generated during the cyclic operation. The research work focuses on designing a die of H13 material for ADC12 cast part that is to be operated on 160 Tonne Cold Chamber HPDC machine. The effect of cooling system location on the stresses produced in die is analysed and their optimum location is determined by ANSYS. Further, filling simulation of the modified design was carried out and minor modifications are made to optimize the filling operation using MAGMA Software. The research work proves to be useful in increasing the die life by considering the optimization of cooling channel position along with the gating system design in the design stage.
International Journal of Advance Research and Innovative Ideas in Education, 2015
In an internal combustion engine, the cylinder head rests on the top of the cylinder block. One o... more In an internal combustion engine, the cylinder head rests on the top of the cylinder block. One of the parts of head assembly is the valve guide, which is used to orient the valves correctly. Typically valve guide is made up of cast iron and fitted in cylinder head with the use of interference fit. The study aims to find the stress developed due to interference fit in valve guide and cylinder head of air cooled diesel engine. This is done using 3D simulation model and FEA. The investigation aims to provide the design intent to resolve valve guide loosing issue in operating temperature ranges.
Crack is one of the measure catastrophic failure in mechanical machines so it’s necessary to dete... more Crack is one of the measure catastrophic failure in mechanical machines so it’s necessary to detect it in early stage. In this paper proposed a method to identify crack in early stage. The purpose of this study is to describe relation between modal natural frequencies change due to crack in shaft with respective crack parameters like Depth, Location and Width. Analysis is done for Single Crack and is evaluated. Analysis reveals how modal natural frequency decreases with change in crack size. It has been observed that when shaft suffers from a crack or any damage then its dynamic properties changes. Crack causes a reduction in stiffness and ultimately reduction in its modal natural frequencies which leads to change in dynamic response of the shaft. The results of modal analysis using FEA are validated with experimental modal analysis.
International Journal of Scientific & Technology Research, 2019
The noise and vibration analysis plays a major role for determining the root cause for various fa... more The noise and vibration analysis plays a major role for determining the root cause for various faults in a diesel engine. The components of I.C engine produce noise and vibrations due to variation in loads and unbalanced forces which reduce the life of machine. So, it is essential to identify the major sources of vibration and its location and also to reduce the noise to avoid failures in the system. In the present study, experimental modal analysis is carried out for various 3-cylinder engine components to determine resonant frequencies in the system, which have been performed by using roving excitation technique. Then the results of experimental modal analysis are verified by using FEA. The experimental vibration analysis has been carried out at the speed near to the resonance conditions to find out the amplitude of vibrations. A structural borne noise mapping is carried out to know the exact locations of the noise sources. So, based on the results of noise and vibration analysis,...
The major source of noise pollution was an internal combustion engine. Henceforth, the design of ... more The major source of noise pollution was an internal combustion engine. Henceforth, the design of the engine exhaust system was a tough challenge for automotive industries. The mufflers have been used to moderate the exhaust noise from the engine to the neighboring atmosphere. So in domestic as well as the industrial application, it is required to reduce noise levels to prevent human hazards. The performance of muffler is measured in terms of transmission loss. The transmission loss of reactive muffler is depending on its geometry. This article describes the effects of pores at the inlet pipe and outlet pipe of the reactive muffler on its performance capacity at a target frequency. It is found that the muffler performance is dependent on the number and position of pores. The single chamber and double chamber reactive mufflers are used for the study. The numerical analysis is performed by COMSOL Multiphysics software. The numerical analysis result of the different models of the muffle...
Abstract The failure of dies and its repairing options are very important in die casting industri... more Abstract The failure of dies and its repairing options are very important in die casting industries. Of all the casting processes available, pressure die casting finds wide applications in large scale production of complex shaped objects with intricate geometries that require good surface finish and dimensional stability. The cooling system employed in the die not only facilitates proper solidification of the cast components but also helps in maintaining the die temperature and controlling the stresses generated during the cyclic operation. The research work focuses on designing a die of H13 material for ADC12 cast part that is to be operated on 160 Tonne Cold Chamber HPDC machine. The effect of cooling system location on the stresses produced in die is analysed and their optimum location is determined by ANSYS. Further, filling simulation of the modified design was carried out and minor modifications are made to optimize the filling operation using MAGMA Software. The research work proves to be useful in increasing the die life by considering the optimization of cooling channel position along with the gating system design in the design stage.
International Journal of Advance Research and Innovative Ideas in Education, 2015
In an internal combustion engine, the cylinder head rests on the top of the cylinder block. One o... more In an internal combustion engine, the cylinder head rests on the top of the cylinder block. One of the parts of head assembly is the valve guide, which is used to orient the valves correctly. Typically valve guide is made up of cast iron and fitted in cylinder head with the use of interference fit. The study aims to find the stress developed due to interference fit in valve guide and cylinder head of air cooled diesel engine. This is done using 3D simulation model and FEA. The investigation aims to provide the design intent to resolve valve guide loosing issue in operating temperature ranges.
Crack is one of the measure catastrophic failure in mechanical machines so it’s necessary to dete... more Crack is one of the measure catastrophic failure in mechanical machines so it’s necessary to detect it in early stage. In this paper proposed a method to identify crack in early stage. The purpose of this study is to describe relation between modal natural frequencies change due to crack in shaft with respective crack parameters like Depth, Location and Width. Analysis is done for Single Crack and is evaluated. Analysis reveals how modal natural frequency decreases with change in crack size. It has been observed that when shaft suffers from a crack or any damage then its dynamic properties changes. Crack causes a reduction in stiffness and ultimately reduction in its modal natural frequencies which leads to change in dynamic response of the shaft. The results of modal analysis using FEA are validated with experimental modal analysis.
International Journal of Scientific & Technology Research, 2019
The noise and vibration analysis plays a major role for determining the root cause for various fa... more The noise and vibration analysis plays a major role for determining the root cause for various faults in a diesel engine. The components of I.C engine produce noise and vibrations due to variation in loads and unbalanced forces which reduce the life of machine. So, it is essential to identify the major sources of vibration and its location and also to reduce the noise to avoid failures in the system. In the present study, experimental modal analysis is carried out for various 3-cylinder engine components to determine resonant frequencies in the system, which have been performed by using roving excitation technique. Then the results of experimental modal analysis are verified by using FEA. The experimental vibration analysis has been carried out at the speed near to the resonance conditions to find out the amplitude of vibrations. A structural borne noise mapping is carried out to know the exact locations of the noise sources. So, based on the results of noise and vibration analysis,...
The major source of noise pollution was an internal combustion engine. Henceforth, the design of ... more The major source of noise pollution was an internal combustion engine. Henceforth, the design of the engine exhaust system was a tough challenge for automotive industries. The mufflers have been used to moderate the exhaust noise from the engine to the neighboring atmosphere. So in domestic as well as the industrial application, it is required to reduce noise levels to prevent human hazards. The performance of muffler is measured in terms of transmission loss. The transmission loss of reactive muffler is depending on its geometry. This article describes the effects of pores at the inlet pipe and outlet pipe of the reactive muffler on its performance capacity at a target frequency. It is found that the muffler performance is dependent on the number and position of pores. The single chamber and double chamber reactive mufflers are used for the study. The numerical analysis is performed by COMSOL Multiphysics software. The numerical analysis result of the different models of the muffle...
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Papers by Deepak Hujare