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An industrial air compressor is finding a wide range of usage in manufacturing and assembly areas. The intake valve body is one of the major parts in the industrial air compressor which serves numerous functions like regulating the amount of air into the compressor for pressurizing and prevents the backflow of oil. The main intern of our proposed work is to design and conduct Finite Element Analysis (FEA) in air intake valve body casing part with commercially used metallic material of LM6 aluminium alloy and proposed hybrid polymer composite. The proposed polymer material Polyphthalamide (PPA) reinforced with 30wt% glass fiber and 5% Poly tetra fluro ethylene (PTFE) hybrid composites were prepared through the injection moulding route and the obtained tested responses were taken as input data for the further analysis.

The forged connecting rod and pin experience a large amount of stresses due to cyclic load for a long period of time induced by the reciprocating movement of the piston. The proposed work focused to produce lightweight composites with high strength using waste flyash and simple manufacturing process. In this context, the proposed experimental work was formulated to develop aluminium alloy hybrid metal matrix composite of A356 alloy with silicon carbide and flyash processed through stir cum squeeze casting process under optimal parametric condition. The samples were subjected to varying flyash content of 0, 5, 10wt.% and SiC of 5wt.% kept constant. Responses like metallography, hardness, impact strength, flexural strength, fatigue strength were observed for the manufactured hybrid composites. There was a significant improvement in the properties with a higher weight percentage addition of 10wt.% flyash and 5wt.% SiC with A356 hybrid composites.

The 3D Printing (3DP) technology due to its greatest strength, resistance to wear and corrosion to oxidizing agents and has good temperature resistance with durable one. The present article describes the effect of print orientation and infill density of 3DP route on mechanical and tribological properties of PETG filament. The 3DP parameters like layer thickness, slicing, speed, feed are kept as constant and by varying the print orientation (X, Y, Z) with infill density (50%, 75%, 100%) was printed to check the effect of it on mechanical and tribological properties like hardness, impact strength, ultimate tensile strength, flexural strength, wear rate and coefficient of friction. The results shows that all the tested mechanical and tribological properties increase by around 30-60% when the orientation is in the X direction at infill density of 100%.

This limited research was extended to study the modification surface amendment of materials through Friction Stir Process (FSP) with nanoparticle addition followed by the post-processing method. In this paper, strengthened core and surface properties of AA8011 has been enhanced by adding nanoparticles such as Nitinol shape memory alloy (NiTi-SMAs) and silicon nitrate (Si3N4) through FSP followed by two different way of post-processing techniques like case hardening, case harden with shot peening. During FSP the use of NiTi-SMAs and Si3N4 as reinforcement interlocked the grains in hybrid nano composites of the processed zone. Also besides, post-processing promises a performance enhancement of core and surface hardness, ultimate tensile strength, impact strength and homogeneous distribution which was observed through scanning electron microscopic observations.

One of the prominent representatives of heat-resistant polymers was the class of Polyethylene Terephthalate Glycol (PETG) with high-strength, but still lightweight. The carbon fiber with PETG (CFPETG) composites also gives even more resistance to heat and chemical, creating it a demandable choice of application in automotive and other industrial components. This paper aims to study the most significant process parameter of FDM technique for different infill density of 25%, 50%, 75%, and 100% at various sliding load condition and sliding distance on wear and friction characteristics of PETG and CFPETG under annealed condition was investigated via dry sliding tribometer apparatus. The trials were done by applying the load of 10N, 20N, 30N, 40N, with a sliding distance of 1000m, 2000m for the time period of 10 min at room temperature and responses such as wear rate and coefficient of friction were recorded for further analysis.

The Oil Hardening Non Shrinking (OHNS) die steel refers to a variety of carbon and alloy steels that are particularly well-suited for making tools. Though these steels are weldable, there is risk of crack formation. But, this can be avoided with convinced specifications like pre heating, proper choice of electrode etc., In the present work, OHNS die steel is welded with three different electrodes. The chosen electrodes were mild steel electrode, E312-16 chromium based electrode and E-NiCrFe-3 nickel based electrode. The OHNS steel is welded with these three electrodes and the welded specimens were examined for hot cracking tendency and mechanical properties of the joint. The hot cracking tendency was assessed by Houldcroft’s weldability test (Fishbone test). All the three electrodes proved the good results in terms of hot crack resistance and the specimen welded with E312-16 chromium based electrode provides good mechanical properties.

Brake pad is considered to be the most essential part of the vehicle. Owing to environmental requirements, natural materials are the raising alternative sources for manufacturing degradable specimens. The main intern of this work was to study the tribological properties of carbon fibre with Cashew Nut Shell Liquid (CNSL) resin, Cashew Nut Shell (CNS) filler, nano Silicon dioxide (SiO2), alumina and graphite. Four samples of varying composition were prepared under optimum process parametric conditions using compression moulding machine. The prepared samples are taken for tribometer test using pin-on-disc apparatus at room temperature. In this load of 10,20,30,40N and sliding distance of 1000,2000 m are applied and responds like wear rate and co-efficient of friction were noted. In addition, the comparisons of hardness of the specimens before and after the tribometer test were also made to note the behaviour of specimens after exposure to thermal and loaded condition.

Friction Stir Process (FSP) was employed for surface modification of steel, titanium, aluminum and magnesium-based alloy has been significantly revised through the last decade. Friction Stir Process can improve surface properties such as hardness, abrasion resistance, ductility, strength, fatigue life, corrosion resistance and formability without upsetting the bulk properties of the material. The aluminum alloy having low ductility and softness characteristics are restricted because of their poor tribological properties. Preliminary studies reveal that, an ideal circumstance is to improve the aluminum alloy material life cycles by the way of strengthening the surface layer which can be modified through reinforcing nanoparticles through FSP. The main objective of the study is to improve the surface properties of AA8011 by adding nanoparticles such as SMA and silicon nitrate (Si3N4) through friction stir process.

This research is limited to study the strength and wear resistance of 20MnCr5 (SAE 5120) alloy steel under monolithic, case hardened and case hardened with shot peening processing condition. Improve the hardness of the material by enhancing the core and surface strength of case hardened with the shot peened sample. The main objective of this proposed work is to conduct the tribometer test by varying the load of 10, 20, 30 and 40N and sliding speed of 193, 386 rpm respectively on wear rate and coefficient of friction be calculated and recorded for this study. Less wear rate and nominal coefficient of friction were observed for case hardened with the shot peened sample. Load increases wear rate increases and the coefficient of friction decreases when sliding distance increases wear rate decreases and the coefficient of friction increases for all the tested samples due to oxide layer formation.

The connecting rod was manufactured by forging process for enhancing high tensile and compressive load so that it was followed by the machining process and suite the IC engine as a part of the component. The main intern of our proposed work is to manufacture a two set of composites specimen of A356 alloy with reinforcement of 5 wt.% silicon carbide and 10 wt.% flyash processed through two different techniques like stir casting and stir cum squeeze casting route and obtain better mechanical properties. Further, the same properties were taken for modeling and analysing of the developed connecting rod model. Due to the commercial demand, the hybrid composite materials take a vigorous role in the analysis part of the connecting rod model. The FEA analysis is done on the connecting rod for a180cc engine by using Ansys 18.1. The static analysis is done by considering four different cases by altering material library property.

The Cardinal goal of this research work is to fabricate hybrid composites of AA8011 with reinforcement particles of Zr2O3 and Al2O3 which was taken in equal (5wt%) weight percentage. The hybrid composites were cast in a square shape (50x50x50 mm size) under the optimal stir casted process parametric condition, further, it was taken for the forging process. The prepared specimens were induced for uni-direction (x), bi-direction (x and y) and multi-direction (x,y, and z) forging route and the response of microhardness of 53, 68, 81 and 96 VHN were obtained respectively due to microstructural phase changes with an even distribution of particles in the matrix. Thus, the tribological properties of prepared specimens were tested using pin-on-disc Tribometer at room temperature under dry sliding condition of load 5,10,15,20 N and by adjusting the sliding speed as 266 and 531 rpm respectively.

The brake pad is one of the foremost imperative parts of the vehicle. Due to the environmental requirement, natural materials were the alternate source for products manufacturing. The product composite made by using hot press techniques with mixing ingredients such as natural fiber (treated sisal), cashew nut filler, graphite and alumina with resin (cashew nut shell liquid - CNSL and epoxy). Two formulas and four samples of each set were composed by varying the resin type of CNSL and epoxy and prepared the test samples with attaining better hardness. The main intern of this proposed effort is to appraise the wear in dry sliding and performance of friction of the prepared composites. The composites are taken for tribo test by varying the load of 10,20,30,40 N and sliding distance of 1000, 2000 m respectively. Experiments were performed at stated process parametric conditions to record the responses.

The present work promotes a hybrid composite brake disc for thermal and structural analysis of a formula vehicle. In order to reduce the un-sprung weight without compromising the strength, hybrid composite materials were incorporated in the disc plates of the braking system. In the disk brake system, the disc is a major part of a device used for slowing or stopping the rotation of a wheel. Repetitive braking of the vehicle leads to heat generation during each braking condition. Based on the practical understanding the brake disc was remodeled with unique slotting patterns and grooves, using the selected aluminium alloy of (AA8081) with reinforcement particle of 15wt% Silicon carbide (SiC) and 3wt% Graphite (Gr) as a hybrid composite material for this proposed work. By varying slotting pattern and groove angles the transient thermal and structural analysis using ANSYS workbench on the hybrid composite disc plate of disk brake is done.

The essential target of this examination is to compare the morphological and thermal properties of two different polyamide composite blends with inventive thermal properties. The polyamide-6 (PA6) reinforced with 10, 20 and 30 wt. % glass fiber (GF) and PA6 reinforced with 10, 20 and 30 wt. % glass beads (GB) are the two different polyamide composite blends extruded in form of wire by twin screw extrusion process. The experimental study illustrates to print the specimens by means of Fusion Deposition Modeling (FDM) based Three-Dimensional (3D) printer. The responses like morphology, Thermal Conductivity (TC) and Heat Distortion Temperature (HDT) of composites were observed. From the scanning electron microscope (SEM) analysis equal distribution of higher 30wt% GF and GB in the PA6 matrix was observed. The results compare the increasing thermal properties of the 3D printed specimen like TC and HDT with the enhancement of beads content during the investigation.

The restrictor is a component which controls the mass flow of air passing to the engine. The proposed work focuses on design and analysis of air intake restrictor of Duke 390cc engine which is used in formula vehicles. As an constrain of this system, the air flows through a single circular throat of diameter 20mm. In past decades conventional venture nozzles were used as a restrictor but it leads to nominal press drop. A de lavel nozzle is a tube pinched in the middle, making an asymmetric hourglass shape. It is used to accelerate a higher supersonic speed in the axial direction. The main objective is to utilize De-Laval Nozzle for the minimal pressure drop. The change in pressure will increases the engine power output. The analysis is done by varying design conditions such as three levels of convergent (12,14 and 16 degrees) and three levels of divergent angles (4, 6 and 8 degrees) are taken into consideration.

The enormous need of effective transportation creates an unavoidable situation in automobile industries to improve and maintain safety systems in vehicles. In crisis, brake disc of the braking system plays a vital role in effective braking of the vehicle. The main objective of this proposed study is to design a disc with two different groove patterns and a material with two different compositions. By using solidworks, a brake disc with proper slots and groove pattern (J hook and square groove) was designed for improved bite, debris, clearance, reduced distortion / vibration and effective heat transfer through convection process. In which two different materials namely zinc based Aluminium Alloy (AA8011) and its composite (AA8011 (5 wt% B4C +3 wt% Gr)) are considered after heat treatment (T6) as disc materials. The properties are measured and given as input data set in ansys workbench for further processing.

Formula vehicles (FSAE) is confronting to increase vehicle performance by reducing the weight of the various components. In consideration of weight, knuckle is one of the serious things to look over it. Steering knuckle is a nonstandard or non-catalog component hooks up with the constraint wishbones, suspension, brake disc and wheel hub. It undergoes alternating loads subjected to different conditions. In this study we aim in reduction of weight in the knuckle with concession in the yield strength. Design a two different type of compact knuckle by using the solidworks software. The compact knuckle also provides desired direction to the vehicle and also reduces the unsprung mass. To make a compact knuckle enrich a rib in less stress areas. The difference in two knuckles is that the length of model 2 knuckle is more. If the length of the knuckle increases the stress acting on upper arm will be less when compared to the model 1.

The steering knuckle is an essential component in All-Terrain Vehicle (ATV) which withstands alternating loads subjected to different conditions without affecting the vehicle performance. The main objective of the proposed work was to design and analysis the steering knuckle under static conditions to observe stress, total deformation and factor of safety for proposed materials. In this present investigation, Aluminium alloy (AA7075) was chosen as it exhibits good ductility, high strength, toughness and high resistance to withstand impact load. The prime objective of this work was processed under three different conditions like virgin AA7075, AA7075 with T6 heat treatment and AA7075 with T6 heat treatment followed by shot-peening post processed technique was completed and to attain diverse strength of the samples were tested and noted appropriate responses. The secondary objective of our proposed work, an optimum knuckle design was modeled using Solidworks.