This one-day program is designed to provide introductory information for those organizations who are considering transitioning from the Aeronautic, Space and Defense industry to the Food & Drug Administration (FDA), Medical Device Manufacturing market. Reviewing essential information necessary to understand and successfully begin the journey to FDA Medical Device approval, this course will examine many of the controls between the AS9100 Standard and FDA Regulations and identify the similarities.
In the Aerospace Industry there is a growing focus on Defect Prevention to ensure that quality goals are met. Process Failure Mode & Effects Analysis (PFMEA) and Control Plan activities described in AS13004 are recognized as being one of the most effective, on the journey to Zero Defects. This two-day course is designed to explain the core tools of Process Flow Diagrams, Process Failure Mode & Effects Analysis (PFMEA) and Control Plans as described in AS13004. It will show the links to other quality tools such as Design FMEA, Characteristics Matrix and Measurement Systems Analysis (MSA).
Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. In this two-day seminar, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design!
The objective of the work conducted was to research how sensors can be integrated into the friction manufacturing process to monitor in-brake performance of the brake pad. Can these systems work during standard dyno test programs. As shown by the authors during Eurobrake 2018 and 2019, friction materials custom built for 3D printing can be utilized to die-cast friction materials. A sensor can be placed into a pretreated well-defined area close to the backing plate. After hardening of the compound, the sensor is completely integrated into the friction material. The friction pads are submersed in water to test the tightness of the sealing around the sensor. The cured friction material was dyno-tested in a Golf VI brake and an AK-Master program schedule 4.1 (temperature, pressure and speed) was conducted. Reed-contacts and other sensors can be integrated in friction material during a sequence of a die-casting process with LICFRIC® compounds.
In this study, a model to optimize the friction stir welding parameters which were rotational speed, welding speed, axial force, tool pin profile, and tool material was established. The target of any design is to maximize the welded properties either to get the base metal properties or higher than that. The model constructed is the result of various regression methods which are quantified for adequacy. In this model, we have taken three levels of varying shoulder diameters, rotation speed, welding speed, tilting angles. A mathematical model is developed for the effect of four process parameters at three levels using response surface methodology (RSM). Analysis of variance (ANOVA) technique is used to check the adequacy of the developed mathematical model. The experimental and predicted values of the mechanical properties are correlated.
AA 2014 is a copper based aluminium alloy which is having exceptional mechanical characteristics such as better strength, ductility and lesser fatigue. AA 2014 is most generally employed in various engineering applications such as fabrication of structural components, defense applications and manufacturing of aerospace components. Also, this material possess better resistant to corrosion which makes this material best suitable for numerous engineering applications. Unconventional methods of machining have been evolved for producing intricate shapes in electrically conductive components. Wire Electrical Discharge Machining (WEDM) is one among the unconventional machining method which is used for making intricate shape on any electrically conductive work material. In this work, an experimentation has been carried out on WEDM of AA 2014 alloy, employing Taguchi’s technique.
Inconel 718, a nickel based superalloy is used in all kinds of applications where outstanding strength and corrosion resistance are essential. The Inconel 718 alloys joints from sheets of 1mm thickness are fabricated using a 4 kW Nd: YAG laser welding equipment. The influence of welding speed on the weld bead ripples, weld morphology, defects and the mechanical properties are investigated. Microstructure of the weld fusion zone, Heat Affected Zone (HAZ) and the weld ripple structure were analyzed using optical microscope and the scanning electron microscope. The weldments obtained were with nominal cracks, porosity and shape imperfections that signifying Nd: YAG laser welding as an effective method for fabricating joints of inconel 718 of thickness 1mm. The weld fusion zone consists of fine dendritic structure and HAZ is found with columnar grain structure.
AA2014 Aluminum alloys are most widely used for automobile and aerospace structures where specific strength is important. Hot cracking is a major problem while welding these alloys. In the present investigation, the metallurgical studies, viz, hot cracking sensitivity, microstructure and the mechanical properties, viz, hardness and tensile strength of the 4 mm thickness AA2014 aluminum alloy were studied using two different methods. The first method involves TIG (Tungsten Inert Gas) welding with continuous current process and the second method involves TIG welding with pulsed current process. In the both the process commercial argon pure gas was used as a shielding gas. The results showed that hot cracking sensitivity was decreased when the specimen was welded using pulsed current process compared to continuous current process.
This research work aims to investigate the effect of SiCp and MoS2 lubricant particles on the tribological properties of AlSi7Mg alloy fabricated through stir casting and stir cum squeeze casting process. AlSi7Mg alloy is a supreme favourable industrial aluminium alloy owing to its exceptional casting ability, corrosion resistance and good strength to weight ratio. Stir casting is an effective and capable processing route for making aluminum composites with enhanced properties. Further to obtain improvised properties and pore-free structure aluminium matrix composites were fabricated through stir cum squeeze casting processing route. During the experimental investigation, AlSi7Mg alloy reinforced with 3 wt % MoS2 and 0, 5, 10 wt % of flyash is processed through stir casting and stir cum squeeze casting processing route.
Among all metal matrix composites, A356 is the most applicable matrix due to its low density and exhibits nominal strength with soft nature. This proposed study is concerned with examination of mechanical and tribological behaviour of virgin A356 alloy and A356 reinforcement with 10wt.% power plant waste flyash particles composites were processed by liquid metallurgy stir casting technique. The fabricated composites expose enhanced higher hardness and compare the virgin A356 alloy due to presents of flyash particles in the matrix. The wear and friction behaviour of casted samples was tested in pin on disk tribometer apparatus under dry and wet sliding environment at the presence of lubricant (SAE 80W-90) by varying sliding load of 10N-40N and sliding velocity of 1-3 m/s respectively. Wear rate increase with the increasing load and sliding velocity. The usage of lubricant tends to decrease the wear rate by reducing the friction when compared to dry sliding method.
Friction stir processing (FSP) is a typical process for refinement changes of microstructure, upgradation of material’s mechanical properties and fabricating of surface layer composites. The effect of cast A356 surface composites were fabricated through Friction Stir Processing (FSP) route to appraise the metallurgical and mechanical properties were considered in the present research study. The three combination of test samples of FSP’ed cast A356 alloy, FSP’ed cast A356 FSP with tungsten nano particle addition (5 and 10 vol%) were considered to fabrication under fixed parametric conditions like tool rotational speed of 1000 rpm, load acting 9 kN, tool travel speed of 20 mm min−1 through four number of tool travel passes respectively. Obtained FSP’ed samples were exposed to microstructural, tensile strength tests and fracture surface morphology analysis were carried out to record the responses.
In industry, productivity is based on various manufacturing processes. Bending the Sheet metal process is a type of forming process that has been used by the wide range in industries. There are several tangible and intangible factors affecting the production rate during the bending process. Spring back is one of the severe factors which affects the production rate, especially in stainless steel material. The spring back is mostly affected by material properties, sheet thickness, bending radius, die sizes and component geometry. In this paper, the spring back is studied by the effect of various parameters such as rectangle / oblong slots with varying pitch distance and without slots and bending time in the stainless steel material 304 grade in V-air bending machine. The experimental data are evaluated by using the Response Surface Method and conclusions are drawn. Finally found that explored results have the betterment of the production rate with connection to spring back.
Primary objective of this research work is to study the effect of heat treatment and heat treated cum shot peening processes on the tribological properties of squeeze casted A356 Alloy. The proposed alloy has wide range of applications in automobile industries due to its appreciable mechanical and tribological properties. Squeeze casting is an efficient economic and promising processing route for fabricating aluminum alloy with improved properties and pore free structure. Further the properties can be improvised through post processing technique like heat treatment and heat treated cum shot peening approach and also residual stresses are removed as a result of heat treatment process. So, this research work aims to investigate the effect of post processing approach on the tribological properties of squeeze casted A356 alloy.
This research is contracted to study the impact of post processing routes like heat treatment and heat treated cum shot peening approach on the mechanical characteristics of A356 alloy. A356 alloy composed of aluminium, silicon, magnesium, iron and copper act as a most promising aluminium alloy due to its phenomenal cast ability, corrosion resistant and great strength to weight proportion. A356 is a common industrial alloy due to its great mechanical properties, reduced weight and capability to be casted into complex designs. However, in order to display good static mechanical properties, it must be heat treated. The prime objective of this research work is to compare the mechanical attributes of squeeze casted pure A356 alloy with the samples processed through T6 heat treatment and heat treatment cum shot peening approach. Mechanical responses like hardness, tensile strength and impact strength were measured for the fabricated post processed samples.
Fused deposition Modeling (FDM) is one of the 3D techniques which are mainly used to fabricate the three-dimensional object directly and it is more economical method. The objective of this investigation is to primarily as-build and annealed polymer associated composites of carbon fiber Polyethylene Terephthalate Glycol (CF-PETG) material by FDM with the effect of different raster angle and layer thickness were consider for the prime parameters. The test specimen was prepared by FDM process with different raster angle (00/900, -450, +450, -450+450) and layer thickness (100, 400 microns) with other parameters were kept constant. The study of the mechanical properties such as hardness, tensile and impact test of the as-built and annealed CF-PETG were studied. The best results obtained for annealed specimens printed with raster angle of 00/900 and layer thickness of 100 microns produced more influence in all the mechanical properties.
For bolted joint design, the accuracy of decision made depends on several parameters like bolt pretension force used, 1D vs 3D bolt model, submodel vs full model and contact settings used for analysis. This paper discusses the effect of the above-mentioned parameters on bolts, thumb rules that can be used for designing and the parameters to be considered for decision making on the bolted joint design. The fatigue life of bolts subjected to all modelling techniques are calculated in this work and is used to compare between two different scenarios. All bolts are modelled with pretension. 3D bolts are modelled with surface to surface contact at the head and nut region. Among the 3d and 1d bolts, it was observed that the 3d bolts have a lesser change in pretension reaction force compared to 1d bolts. When the entire assembly model was compared to a sub-model including the bolts under consideration, it was found that both models have a close correlation with each other.