Design of Scaled Bridge Prototype for Energy Harvesting Testing

Energy harvesting from ambient vibration is a promising field, especially for applications in larger infrastructures such as bridges. These structures are more frequently monitored for damage detection because of their extended life, increased traffic load and environmental deterioration. In this regard, the possibility of sourcing the power necessary for the sensors from devices embedded in the structure, thus cutting the cost due to the management of battery replacing over the lifespan of the structure, is particularly attracting. Among others, piezoelectric devices have proven to be especially effective and easy to apply since they can be bonded to existing host structure. For these devices the energy harvesting capacity is achieved directly from the variation in the strain conditions from the surface of the structure. However these systems need to undergo significant research for optimisation of their harvesting capacity and for assessing the feasibility of application to various ranges of bridge span and load. In this regard scaled bridge prototypes can be effectively used not only to assess numerical models and studies in an inexpensive and repeatable way but also to test the electronic devices under realistic field conditions. In this paper the theory of physical similitude is applied to the design of bridge beams with embedded energy harvesting systems and health monitoring sensors. It will show both how bridge beams can be scaled in such a way to apply and test energy harvesting systems and 2) how experimental data from existing bridges can be applied to prototypes in a laboratory environment. The study will be used for assessing the reliability of the system over a train bridge case study undergoing a set load cycles and induced localised damage.

Prediction of surface roughness during hard turning of AISI 4340 steel (69 HRC)

In this study, 39 sets of hard turning (HT) experimental trials were performed on a Mori-Seiki SL-25Y (4-axis) computer numerical controlled (CNC) lathe to study the effect of cutting parameters in influencing the machined surface roughness. In all the trials, AISI 4340 steel workpiece (hardened up to 69 HRC) was machined with a commercially available CBN insert (Warren Tooling Limited, UK) under dry conditions. The surface topography of the machined samples was examined by using a white light interferometer and a reconfirmation of measurement was done using a Form Talysurf. The machining outcome was used as an input to develop various regression models to predict the average machined surface roughness on this material. Three regression models - Multiple regression, Random Forest, and Quantile regression were applied to the experimental outcomes. To the best of the authors’ knowledge, this paper is the first to apply Random Forest or Quantile regression techniques to the machining domain. The performance of these models was compared to each other to ascertain how feed, depth of cut, and spindle speed affect surface roughness and finally to obtain a mathematical equation correlating these variables. It was concluded that the random forest regression model is a superior choice over multiple regression models for prediction of surface roughness during machining of AISI 4340 steel (69 HRC).

Parametric design optimization of hard turning of AISI 4340 steel (69 HRC)

Continuous research endeavors on hard turning (HT), both on machine tools and cutting tools, have made the previously reported daunting limits easily attainable in the modern scenario. This presents an opportunity for a systematic investigation on finding the current attainable limits of hard turning using a CNC turret lathe. Accordingly, this study aims to contribute to the existing literature by providing the latest experimental results of hard turning of AISI 4340 steel (69 HRC) using a CBN cutting tool. An orthogonal array was developed using a set of judiciously chosen cutting parameters. Subsequently, the longitudinal turning trials were carried out in accordance with a well-designed full factorial-based Taguchi matrix. The speculation indeed proved correct as a mirror finished optical quality machined surface (an average surface roughness value of 45 nm) was achieved by the conventional cutting method. Furthermore, Signal-to-noise (S/N) ratio analysis, Analysis of variance (ANOVA), and Multiple regression analysis were carried out on the experimental datasets to assert the dominance of each machining variable in dictating the machined surface roughness and to optimize the machining parameters. One of the key findings was that when feed rate during hard turning approaches very low (about 0.02mm/rev), it could alone be most significant (99.16%) parameter in influencing the machined surface roughness (Ra). This has, however also been shown that low feed rate results in high tool wear, so the selection of machining parameters for carrying out hard turning must be governed by a trade-off between the cost and quality considerations.