Modelling and optimization of injection molding process for PBT/PET parts using modified particle swarm algorithm

603-615In the present study, a systematic methodology has been presented to determine optimal injection molding conditions for minimizing warpage and shrinkage in a thin wall relay part using modified particle swarm algorithm (MPSO). Polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) have been injected in thin wall relay component under different processing parameters: melt temperature, packing pressure and packing time. Further, Taguchi’s L9 (32) orthogonal array has been used for conducting simulation analysis to consider the interaction effects of the above parameters. A predictive mathematical model for shrinkage and warpage has been developed in terms of the above process parameters using regression model. ANOVA analysis has been performed to establish statistical significance among the injection molding parameters and the developed model. The developed model has been further optimized using a newly developed modified particle swarm optimization (MPSO) algorithm and the process parameters values have been obtained for minimized shrinkage and warpage. Furthermore, the predicted values of the shrinkage and warpage using MPSO algorithm have been reduced by approximately 30% as compared to the initial simulation values making more adequate parts

Modelling and optimization of injection molding process for PBT/PET parts using modified particle swarm algorithm

In the present study, a systematic methodology has been presented to determine optimal injection molding conditions for minimizing warpage and shrinkage in a thin wall relay part using modified particle swarm algorithm (MPSO). Polybutylene terephthalate (PBT) and polyethylene terephthalate (PET) have been injected in thin wall relay component under different processing parameters: melt temperature, packing pressure and packing time. Further, Taguchi’s L9 (32) orthogonal array hasbeen used for conducting simulation analysis to consider the interaction effects of the above parameters. A predictive mathematical model for shrinkage and warpage has been developed in terms of the above process parameters using regression model. ANOVA analysis has been performed to establish statistical significance among the injection molding parameters and the developed model. The developed model has been further optimized using a newly developed modified particle swarm optimization (MPSO) algorithm and the process parameters values have been obtained for minimized shrinkage and warpage. Furthermore, the predicted values of the shrinkage and warpage using MPSO algorithm have been reduced by approximately 30% as compared to the initial simulation values making more adequate parts

Elastic properties of graphene-reinforced aluminum nanocomposite: Effects of temperature, stacked, and perforated graphene

In this article, the elastic and shear moduli of the graphene sheet-reinforced aluminum nanocomposite have been investigated by molecular dynamics simulations. Different models have been simulated to study the effect of multilayer graphene sheet, perforation of GS, and temperature on the elastic and shear moduli of resulting nanocomposite. The simulation results show that the elastic and shear moduli of graphene sheet-reinforced aluminum are sensitive to the temperature changes, multilayer, and perforated graphene sheets. The temperature and perforation of graphene sheets exert adverse effects on the elastic and shear moduli of graphene sheet-reinforced aluminum nanocomposites. However, the multilayer graphene sheet leads to favorable effects on the stiffness properties of the nanocomposite. It is also observed that there is only a marginal effect of the chirality of graphene sheet on the out-of-plane shear moduli of the nanocomposite. </jats:p

A critical review on tribological properties, thermal behavior, and different applications of industrial waste reinforcement for composites

Industrial wastes such as marble dust, fly ash, and red mud have progressed as an environmental hazard that needs to be disposed or utilized for minimizing the ecological pollution problems and manufacturing costs. Over the years, there is an increasing interest among researchers in utilizing these industrial wastes as reinforcement for developing economic and lightweight monolithic or hybrid composites. In the same context, this paper presents a comprehensive review on the aspects of tribology and thermal performance of industrial waste such as marble dust, fly ash, and red mud as reinforcement for different monolithic and hybrid composites. The review also describes different applications for industrial waste material reinforced composites. Finally, the paper concludes with authors’ perspective of the review, conclusion summary, and future potential of industrial waste filled composites in different industries for obtaining a sustainable and cleaner environment. </jats:p

Preliminary evaluations on development and material selection of high temperature vacuum casted marble dust-reinforced silicon-bronze alloy material for bearing applications

Development and selection of an adequate bearing material with distinct characteristics for wear resistant applications is one of the most crucial tasks. Inappropriate selection of material may cause hindrance and result in failure of components during its functioning. To this end, this research focusses on fabrication of bearing materials reinforced with varying weight percentages of industrial waste, i.e. marble dust, and the physical, mechanical and tribological characteristics were determined. The proportions of marble dust were varied from 0 wt. % to 10 wt. % with a gap of 2.5 wt. % and filled in a silicon-bronze alloy. The physical and mechanical properties were realized by the Archimedean principle, micro-hardness tester and Instron 3369 universal testing machine respectively. The tribological properties such as friction and wear behaviour were determined utilizing pin-on-disk tribometer under different condition at normal room temperature. Due to the conflicting nature of desired properties in a bearing material, the Vise Kriterijumska Optimizacija Kompromisno Resenjemeaning under fuzzy environment was applied to rank and select the optimal composite among available alternatives because it can obtain compromise solution considering overall satisfaction and regret of the selection of the wrong provinces. From the analysis of the results, it was found that silicon-bronze-3 marble dust bearing material containing 7.5 wt. % marble dust achieved the best possible set of the properties for wear resistant applications. </jats:p

Investigating Alignment Effect on Inspection Accuracy of AM Part Using 3D Scanner

Presently, parts having intricate custom-made profiles are mostly fabricated using additive manufacturing (AM) processes. It becomes an essential task to verify the accuracy of AM parts so that they meet customer’s need and requirement. In product quality control, quick error comparison of manufactured part and an original CAD model is usually laborious but still a critical issue. Noncontact inspections using 3D scanners were preferred over conventional coordinate measurements, due to the significant amount of point data capturing in very short span of time. One of the important step of the noncontact inspection procedure using the 3D scanner is the correct localization of the datum reference frame. This step would help in the effective alignment of the digitized point data. This paper takes into consideration various 3-2-1 alignment approaches and investigates their influence on the inspection results. The result provides an evidence that an incorrect description of the product reference frame can lead to erroneous estimation of actual part deviations. The results show higher distance distribution for most of the point data of third alignment as the distance distribution is influenced by the worst description of the part reference frame. On the contrary, second alignment shows least distance distribution among point data due to correct reference frame definition. </jats:p