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R. S. Agrawa, P. M. Padole, J. F. Agarwal
Measurement of force involved in compression of lint cotton on a mechanical baling press

Cost of processing of lint cotton is very high. In order to optimize this, designing a mechanical press for compressing lint cotton does decentralization of ginnery. This design is carried out after performing extensive experiments on waste cotton pressing machine. During this experimentation it is required to measure the various variables involved in the process. The work presented in this paper reports the experiments carried out and the method used to measure force required for compressing cotton using mechanical press.

S. Sinha, D. B. Pedram, R. G. Gabhale, K. G. Chaudhari
Precision installation of tower structure on concrete foundation

Accurate installation of precisely machined structures on civil foundations maintaining all the required accuracies is an intricate task. In the present case, the interface of the structures is through four numbers of bearing plates and clamping bolts. To keep this bearing plate in position within required alignment is a challenge due to compaction required during concrete casting and drying shrinkage thereafter. Levels of the individual bearing plates can be maintained within 4-5mm at the time of casting the foundation. Due to difficulties in maintaining level and relative position of the bearing plates with clamping bolts, the interface holes of the structure may not match. These inaccuracies in position of clamping bolts and level of bearing plates will lead to deviation in mission critical alignment of structure. A precise method is developed at R&DE(Engrs) for installation of precisely machined structures demanding accurate installation on concrete foundation. The paper elaborates this innovative procedure adopted for installation of such structure with its RCC counterpart to achieve essential stringent alignment accuracy of 5 minutes in azimuth.

B. Prabu, M. Mohanraj, J. Jayakumaran, G. Puruchotaman, D. Peroumal, A. Venkatraman
Design and fabrication of measurement RIG to measure the geometrical imperfections of thin cylindrical shells

It is well known that the buckling strength of thin cylinder shells are mainly depends upon geometrical imperfections present on the thin cylindrical shells induced during manufacturing process. Hence it is necessary to measure these geometrical imperfections accurately, to predict the buckling strength of the cylindrical shells accurately. Using CMM to measure the geometrical imperfections is more accurate but costlier and also measurement depends on the operator’s skill. To overcome this problems an imperfection measurement rig is developed Using this measured imperfections data best fit surface map is generated, which can be used for further analysis.

Sanjay S. Lakade
Differential type high pressure air gauge interfaced to computer: A key instrument in mass production

Air gauging is one of the important instruments used in metal working industry in mass production. Differential type-high pressure air gauge has wide range of applications in automobile industry. An effort was made to interface the differential type-high pressure air gauge to computer to facilitate the gauging. In our experimental setup LVDT is used to sense the displacement of the bellow and the amplified output of LVDT is given to the AD-DA card of the computer. This instrument can be used on critical machines to have data for continuous monitoring and statistical analysis of the process.

V. P. Darji ,P. H. Darji, K. Baba Pai
Quality testing and fracture mode estimation for welded pipes of grade 321 stainless steel

The enormous existing and promising technology have tailored the structural and fractural analysis with measuring means. Stainless steel pipes are welded using tungsten inert gas welding technique. In its very primary stage of preparation only weld bead is removed with bead fitted mills. Welded segments and pipes are also subjected to different heat treatment and mechanical operations. These pipes are used in precise applications in refineries and petrochemical plants where they bear ambient pressure/temperature conditions. Because of heat treatable condition requirement the steel is worked with austenitic phase condition. Stainless steels with γ phase has relatively high ductility, low yielding strength, high tensile strength with ease in fabrication and Ti makes the alloy good corrosion resistant. This may lead to corrosion of welded segments in ambient temperature conditions. Present work deals with the effect of weld gases, alloying element added (Titanium) on the strength and microstructure of the 321 type Stainless Steel. Apart from the benefits of TIG, hot-cracking susceptibility can be industrially exploited and HAZ is satisfactorily would be analyzed using ultrasonic testing. For the present work, we have limited our work up to the spectroscopic chemical analysis of the parent metal and weldment.

S. Vinodh, G. Sundararaj, S. R. Devadasan
DESSAC: A decision support system for agility assessment

This paper traces the origin and development of Agile Manufacturing (AM). The industrial sectors, which have imbibed agility, are today’s winners in the competitive markets. In order to implement twenty criteria AM effectively, the agility level at which currently a company operates needs to be quantified. Hence, a scoring pattern analogous to the one used in Malcolm Baldrige National Quality Award is integrated with the twenty criteria AM model. Applying this quantifying model in real time practice will be a time consuming and tedious process. In order to overcome this difficulty, a Decision Support System named as DESSAC (stands for DEcision Support System for quantifying Agile Criteria) has been developed during the research being reported in this paper.

P. Sasikumar, G. Kannan, V. P. Vinay, A. Noorul Haq, V. Balasubramanian
Application of Quality Function Deployment for recycling of SLI batteries in reverse supply chain

Now a days remanufacturing / recycling has become renowned as a popular option in many reverse logistics settings. In remanufacturing / recycling, firms take back products at the end of their use, disassemble them to obtain components and reassemble these components into a “good as new” remanufactured product. Though the technical solutions for the recovery of products from waste materials become more and more available, it is often imperative to adopt the view point of an individual firm and ask whether it would be wise to engage in product recovery activities or not. In the context of rapidly changing perspectives in the field of reverse logistics, the solution of a great variety of engineering problems calls for innovative application of knowledge and requires logical thinking, analytical capability, reasoning and judgment. In this paper the environmental impact of recycled SLI (Starting, Lighting and Ignition) batteries are considered and used for the disposition of used SLI batteries with the help of reverse logistics. Based on an extensive literature review, it is proposed to use a methodology for applying Quality Function Deployment (QFD) for the development of a new reverse logistics network with the environmental analysis of used SLI batteries. This methodology will incorporate environmental aspects into QFD to handle the environmental and traditional product quality requirements simultaneously.

Z. Humienny, J. Bonarowski, R. Stanczuk, P. Urbaniak, K. Wojtczak
New multimedia training course in geometrical tolerancing

A new multimedia program “Geometrical tolerances – Definitions and evaluation of deviations” developed at Warsaw University of Technology is presented. The animations and multicolor 3-D drawings are used to effectively familiarize the program user with definitions of form, orientation, location and run out tolerances. Deep attention is paid to application of modifiers. In the practice modules a user has interactive opportunity to asses graphically geometrical deviations on actual parts. So, the user can verify whether he completely understands the concepts of particular geometrical tolerances. This chance is a unique feature among software offered to aid the geometrical tolerancing education. The user can also check acquired knowledge in tests. The program is suitable for self study as well as an aid for lectures at universities or trainings for industry.

Sergey V. Muravyov
About reasonable number of rankings in preference profile when measuring quality

To plan the quality measuring in the form of consensus relation determination for the given m weak order relations (rankings) it is necessary to know a reasonable number of the rankings. If a ranking is produced by an expert then the number of rankings is equal to number of experts. It is proposed to estimate the expert number using simple probabilistic Bernoulli model, where m experts reveal defects (demerits) of an object. The model assumes that the more the number of an expert group participants, the less the probability of a new defect revealing. Based on this assumption, the probability decrease have been evaluated and graphically presented. The investigations allow to suppose that the number of rankings in preference profile can be from 4 to 10 for typical applications.

P. V. Kane, V. S. Deshpande
Design of on-line inspection methodology for reduction of cost of internal failure - A case study in sheet metal industry

Industries can endure the superiority over competitors by obtaining proper tradeoff between the quality and cost. One of the alternatives is to reduce the cost of quality. A small-scale unit (SS) in central India engaged in sheet metal working operations has been identified as a potential area for reduction in quality cost. The cost of internal failure has critically analyzed and reduced by eliminating its prominent causes. The critical and frequently occurring defects are targeted for identification at the respective stages of manufacturing process. Accordingly gauges are designed for identification of location error and camber. Inspection by online gauge was incorporated between the straightening decoiler machine and first cropping operation. Since the further processing of defectives is eliminated the cost of internal failures is reduced by about 40%.

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