Metal additive manufacturing techniques typically operate using powders with limited particle size ranges, but atomisation processes produce significant amounts of particles outside these ranges, resulting in an accumulation of out-of-size specification metal powders without a clear use case. Field assisted sintering technology (FAST) can provide an alternative, solid-state processing route to consolidate these powders into billets for subsequent processing, or directly into near-net shape components. In this study, surplus powders of A20X, an aerospace approved aluminium alloy developed by Aluminium Materials Technologies (ECKART GmbH), were processed using FAST and subsequently hot rolled to produce sheet material. Tensile properties were similar to hot rolled conventional cast material and comparable to additively manufactured product. This indicates that FAST is an effective option for processing surplus metal powders, whilst improving sustainability in the additive supply chain.
This paper provides a review of the literature on designing and analysis of a gearbox casing. Gearbox is an important machinery component in any industry. Helical gears are widely used in numerous engineering applications. Industry is facing the problem of higher disassembly time and difficulty in maintenance. As a solution, split casing needs to be developed. Stress analysis is engineering discipline that determines the stress in materials and structures subjected to static and dynamic forces or loads. Vibrational analysis of casing also plays a vital role in proper working of the gearbox. Gearbox with moving parts gives rise to noise and vibration, which reveals the gearbox condition. FEA method is used for static and vibration analysis. In this paper, we have reviewed the current research state of modal analysis and harmonic frequency response on gearbox casing and also an insight into future research and challenges in this field of study.
Planetary Gear System is an assembly of gears where one or more planet gears revolve around a gear placed at centre named Sun gear and a ring gear encircles the whole system. It is capable of achieving high reduction ratios in a very compact package. Large number of manufacturing errors can influence the stresses induced onto the gear system. In this paper, a detailed study of the design of a planetary gearbox is done at first. After designing, this research utilizes the finite element method to investigate the variation of stresses occurring due to misalignments. Here, the stresses analyzed are occurring due to misalignments resulting from the tolerances on centre distance between gears and also from the tol erances on parts. In this paper, we have reviewed the research papers mainly dealing with the designing and analysis of a planetary gearbox.
This research presents a comprehensive dynamic finite element analysis (FEA) of a cryogenic fuel tank made from an innovative aluminium/lithium–graphene nano-composite material, assessing its suitability for aerospace launch vehicles carrying cryogenic hydrogen and oxygen. The study focuses on the effects of lightweighting, utilizing 0.5 wt.% reinforced graphene in the Al 2195 matrix, a material poised to revolutionize the aerospace industry. Objectives include developing a digital twin of the fuel tank, CAD modeling to aerospace standards, and conducting ANSYS simulations under launch conditions to evaluate stress, strain, and deformation. Numerical results reveal a significant weight reduction of approximately 19,420 kg and a notable maximum stress reduction of 1.3% compared to traditional Al 2195 alloy tanks. The novelty of this research lies in its pioneering analysis of aluminium/lithium–graphene composites for lightweighting in cryogenic fuel tanks under space launch conditions. Conclusions affirm the composite’s viability, advocating for the development of lighter yet robust aerospace structures and fostering innovation in spacecraft design and materials science.
The air classifier is an equipment that finds its major applications in mineral processing plants. One of its utility is to separate the finer particles from the coarse particles to provide the required size of particle output. Air classifiers use various principles of operation depending on their prerequisite and usage. Various running parameters of the air classifiers can be varied to obtain the desired output particle sizes which are governed by specific particle size distribution curves. The air classifier considered in the paper is based on a 'deflector wheel' principle. These deflector wheels are the rotors. During a trial run on a dynamic balancing machine the rotors failed structurally resulting in their permanent plastic deformation. This indicated a fault in the design; thus requiring failure analysis and restructuring of the same. This research paper points out an alternative to the current design keeping in mind the constraints of the system. The authors have employed the procedure of calculating the failure manually by an analytical approach. Later on, the design was examined and verified using a well-known Finite Element Analysis software followed by the development of conceptual designs and then choosing the most optimum one. The optimized design offered structural integrity to the rotor with minimal reduction in area, and hence the performance.
Purely phase-sampled fiber Bragg gratings are optimized to produce accurate dispersion compensation for the ITU-50 grid. We report limited penalty by using a cascade of six gratings in a 540 km 40 Gb/s DPSK system.
Abstract: Bearing is moving object, so friction force of comes into play, and must be surpassed to move the Bearing. Various types of bearings are used to reduce this friction force for moving mechanism. The bearing named from the fact that it bears a turning axle or shaft. Rolling bearings use balls, or rollers so it’s called rolling elements. If the operating loads and speeds are known then you can calculate bearing life expectancy based on material fatigue. These calculations must assume that the bearing is correctly mounted, lubricated and otherwise properly handled. It cannot take into consideration the effect of adverse operating conditions. Bearing failures have great impact on industry and economy. The aim of the present work is to study and spot the major causes that limit bearing efficiency, thus leading to bearing failure.
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