Optimization of friction stir welding parameters for dissimilar aluminum alloys

Assembly consisting of cast and wrought aluminum alloys has wide spread application in defense and aero space industries. For the efficacious use of the transition joints, the weld should have adequate strength and formability. In the present investigation, A356 and 6061 aluminum alloys were friction stir welded under tool rotational speed of 1000-1400 rpm and traversing speed of 80-240 mm/min, keeping other parameters same. The variable process window is responsible for the change in total heat input and cooling rate during welding. Structural characterization of the bonded assemblies exhibits recovery-recrystallization in the stirring zone and breaking of coarse eutectic network of Al-Si. Dispersion of fine Si rich particles, refinement of 6061 grain size, low residual stress level and high defect density within weld nugget contribute towards the improvement in bond strength. Lower will be the tool rotational and traversing speed, more dominant will be the above phenomena. Therefore, the joint fabricated using lowest tool traversing and rotational speed, exhibits substantial improvement in bond strength (similar to 98% of that of 6061 alloy), which is also maximum with respect to others. (C) 2010 Elsevier Ltd. All rights reserved.

Optimization of Helicopter Rotor Using Polynomial and Neural Network Metamodels

This study aims to determine optimal locations of dual trailing-edge flaps and blade stiffness to achieve minimum hub vibration levels in a helicopter, with low penalty in terms of required trailing-edge flap control power. An aeroelastic analysis based on finite elements in space and time is used in conjunction with an optimal control algorithm to determine the flap time history for vibration minimization. Using the aeroelastic analysis, it is found that the objective functions are highly nonlinear and polynomial response surface approximations cannot describe the objectives adequately. A neural network is then used for approximating the objective functions for optimization. Pareto-optimal points minimizing both helicopter vibration and flap power ale obtained using the response surface and neural network metamodels. The two metamodels give useful improved designs resulting in about 27% reduction in hub vibration and about 45% reduction in flap power. However, the design obtained using response surface is less sensitive to small perturbations in the design variables.

Optimization of Lime Content for Fly Ash

Abundant quantities of fly ash have been produced by thermal power plants situated ail over the world. Many applications of fly ash depend upon its pozzolanic reactivity. This reactivity depends upon many factors, including lime content. Many fly ashes show marked improvement with the addition of lime. However, for every fly ash, there is an optimum lime content for its maximum reactivity. There is no well-established simple test to determine the optimum lime content. In this paper an attempt is made to use a simple physical and physico chemical test to determine the optimum lime content. The principle behind the use of a pH test, liquid limit test, and free swell index test to determine the optimum lime content has been explained. All the methods predict nearly the same optimum lime content and correlate well with that determined by the strength test.

Robust Aeroelastic Optimization Of Composite Helicopter Rotor

A robust aeroelastic optimization is performed to minimize helicopter vibration with uncertainties in the design variables. Polynomial response surfaces and space-¯lling experimental designs are used to generate the surrogate model of aeroelastic analysis code. Aeroelastic simulations are performed at the sample inputs generated by Latin hypercube sampling. The response values which does not satisfy the frequency constraints are eliminated from the data for model ¯tting. This step increased the accuracy of response surface models in the feasible design space. It is found that the response surface models are able to capture the robust optimal regions of design space. The optimal designs show a reduction of 10 percent in the objective function comprising six vibratory hub loads and 1.5 to 80 percent reduction for the individual vibratory forces and moments. This study demonstrates that the second-order response surface models with space ¯lling-designs can be a favorable choice for computationally intensive robust aeroelastic optimization.

Optimization of vibrating structures to reduce radiated noise

In this work, we propose an approach for reducing radiated noise from `light' fluid-loaded structures, such as, for example, vibrating structures in air. In this approach, we optimize the structure so as to minimize the dynamic compliance (defined as the input power) of the structure. We show that minimizing the dynamic compliance results in substantial reductions in the radiated sound power from the structure. The main advantage of this approach is that the redesign to minimize the dynamic compliance moves the natural frequencies of the structure away from the driving frequency thereby reducing the vibration levels of the structure, which in turn results in a reduction in the radiated sound power as an indirect benefit. Thus, the need for an acoustic and the associated sensitivity analysis is completely bypassed (although, in this work, we do carry out an acoustic analysis to demonstrate the reduction in sound power levels), making the strategy efficient compared to existing strategies in the literature which try to minimize some measure of noise directly. We show the effectiveness of the proposed approach by means of several examples involving both topology and stiffener optimization, for vibrating beam, plate and shell-type structures.

Optimization of rheological properties of photopolymerizable alumina suspensions for ceramic microstereolithography

Microstereolithography (MSL) is a rapid prototyping technique to fabricate complex three-dimensional (3D) structure in the microdomain involving different materials such as polymers and ceramics. The present effort is to fabricate microdimensional ceramics by the MSL system from a non-aqueous colloidal slurry of alumina. This slurry predominantly consists of two phases i.e. sub-micrometer solid alumina particles and non-aqueous reactive difunctional and trifunctional acrylates with inert diluent. The first part of the work involves the study of the stability and viscosity of the slurry using different concentrations of trioctyl phosphine oxide (TOPO) as a dispersant. Based on the optimization, the highest achievable solid loadings of alumina has been determined for this particular colloidal suspension. The second part of the study highlights the fabrication of several micro-dimensional alumina structures by the MSL system. (C) 2013 Elsevier Ltd and Techna Group S.r.l. All rights reserved.

Optimization of degree of sphericity of primary phase during cooling slope casting of A356 Al alloy: Taguchi method and regression analysis

The present work presents the results of experimental investigation of semi-solid rheocasting of A356 Al alloy using a cooling slope. The experiments have been carried out following Taguchi method of parameter design (orthogonal array of L-9 experiments). Four key process variables (slope angle, pouring temperature, wall temperature, and length of travel of the melt) at three different levels have been considered for the present experimentation. Regression analysis and analysis of variance (ANOVA) has also been performed to develop a mathematical model for degree of sphericity evolution of primary alpha-Al phase and to find the significance and percentage contribution of each process variable towards the final outcome of degree of sphericity, respectively. The best processing condition has been identified for optimum degree of sphericity (0.83) as A(3), B-3, C-2, D-1 i.e., slope angle of 60 degrees, pouring temperature of 650 degrees C, wall temperature 60 degrees C, and 500 mm length of travel of the melt, based on mean response and signal to noise ratio (SNR). ANOVA results shows that the length of travel has maximum impact on degree of sphericity evolution. The predicted sphericity obtained from the developed regression model and the values obtained experimentally are found to be in good agreement with each other. The sphericity values obtained from confirmation experiment, performed at 95% confidence level, ensures that the optimum result is correct and also the confirmation experiment values are within permissible limits. (c) 2014 Elsevier Ltd. All rights reserved.

Optimization of bus allocation to depots by minimizing dead kilometers

In metropolitan cities, public transportation service plays a vital role in mobility of people, and it has to introduce new routes more frequently due to the fast development of the city in terms of population growth and city size. Whenever there is introduction of new route or increase in frequency of buses, the nonrevenue kilometers covered by the buses increases as depot and route starting/ending points are at different places. This non-revenue kilometers or dead kilometers depends on the distance between depot and route starting point/ending point. The dead kilometers not only results in revenue loss but also results in an increase in the operating cost because of the extra kilometers covered by buses. Reduction of dead kilometers is necessary for the economic growth of the public transportation system. Therefore, in this study, the attention is focused on minimizing dead kilometers by optimizing allocation of buses to depots depending upon the shortest distance between depot and route starting/ending points. We consider also depot capacity and time period of operation during allocation of buses to ensure parking safety and proper maintenance of buses. Mathematical model is developed considering the aforementioned parameters, which is a mixed integer program, and applied to Bangalore Metropolitan Transport Corporation (BMTC) routes operating presently in order to obtain optimal bus allocation to depots. Database for dead kilometers of depots in BMTC for all the schedules are generated using the Form-4 (trip sheet) of each schedule to analyze depot-wise and division-wise dead kilometers. This study also suggests alternative locations where depots can be located to reduce dead kilometers. Copyright (C) 2015 John Wiley & Sons, Ltd.

Two-agent cooperative search using game models with endurance-time constraints

In this article, the problem of two Unmanned Aerial Vehicles (UAVs) cooperatively searching an unknown region is addressed. The search region is discretized into hexagonal cells and each cell is assumed to possess an uncertainty value. The UAVs have to cooperatively search these cells taking limited endurance, sensor and communication range constraints into account. Due to limited endurance, the UAVs need to return to the base station for refuelling and also need to select a base station when multiple base stations are present. This article proposes a route planning algorithm that takes endurance time constraints into account and uses game theoretical strategies to reduce the uncertainty. The route planning algorithm selects only those cells that ensure the agent will return to any one of the available bases. A set of paths are formed using these cells which the game theoretical strategies use to select a path that yields maximum uncertainty reduction. We explore non-cooperative Nash, cooperative and security strategies from game theory to enhance the search effectiveness. Monte-Carlo simulations are carried out which show the superiority of the game theoretical strategies over greedy strategy for different look ahead step length paths. Within the game theoretical strategies, non-cooperative Nash and cooperative strategy perform similarly in an ideal case, but Nash strategy performs better than the cooperative strategy when the perceived information is different. We also propose a heuristic based on partitioning of the search space into sectors to reduce computational overhead without performance degradation.