Journal of Research in Mechanical Engineering and Applied Mechanics ISSN: 3107-4510 (Online)

Authors:  Sreekanth T.G, V.Vijayakumar, M. Senthil Kumar

Abstract: Gears are one among the most critical components in mechanical power transmission system. They have major applications in fields like automotives, industrial rotational machines, watches, lifting devices, etc. Gears are usually subjected to fluctuating loads while in action. Gear tooth mainly fails due to excessive bending stress and excessive contact stress. Thus it is very important to analyze the stresses induced in gear, while designing it for the safety operation. Weight reduction  of gear is also one of the most important design criteria as it has a great role in efficiency of the entire system. Engineering components made of composite materials and plastics find increasing applications nowadays. The components made from composite materials provide reasonable mechanical properties with minimum weight. In this paper, the spur gear and pinion assembly is modeled in “PTC Creo” and imported to “ANSYS Workbench 15.0” for static structural analysis. Analysis is done by considering different materials for gears like Structural Steel, Polycarbonate and AlSiC(20%).

Keywords: Gears, contact stress, Structural Steel, AlSiC-20%

Authors: P.S. Kulat, Suhas Bagmare, Aniket Chourpagar

Abstract: An engineer is always focused towards challenges of bringing ideas and concepts to life. Therefore, sophisticated machines and modern techniques have to be constantly developed and implemented for economical manufacturing of products. At the same time, we should take care that there has been no compromise made with quality and accuracy. In the age of automation machine become an integral part of human being. By the use of automation machine prove itself that it gives high production rate than manual production rate. In competition market everyone wants to increase their production & make their machine multipurpose. The engineer is constantly conformed to the challenges of bringing ideas and design into reality. New machines and techniques are being developed continuously to manufacture various products at cheaper rates and high quality.

 Keywords: Semi-Automatic Slotting Machine, HSS blade, PLC

Author: Dr. KVS Seshendra Kumar

Abstract: This work is carried out on a multi leaf spring having nine leaves used by a commercial vehicle, each leaf length, deformation and bending stresses are theoretically designed. The finite element modeling and analysis of a multi leaf spring has been carried out. It includes two full length leaves in which one is with eyed ends and seven graduated length leaves. Different type of material has chosen like steel, aluminum, carbon epoxy and glass epoxy. The model of the leaf spring has been generated in pro/e 5.0 and imported in ANSYS-12 for finite element analysis, which are most popular CAE tools. The FE analysis of the leaf spring has been performed by discretization of the model in infinite nodes and elements and refining them under defined boundary condition. Bending stress and deflection are the target results. A comparison of different material results have been done to conclude the low weight optimum model.

Authors: Aniket Akhade, Mukund Kavekar, Kamlesh Bachkar

Abstract: Services are much like manufacturing. Therefore, successful implementation of JIT is vital to manufacturing as well as service industries. JIT focuses on the process, not on product. Therefore it can be applied to every process within manufacturing or service industry. The main objective of this research is to make use of a case study to present various issues regarding implementation of JIT for a service industry. This case study also shows the benefits of reduction in waiting period by employing JIT. The conclusion of this research indicates that JIT system is successful and operating JIT system leads to many advantages to the case industry.

Authors: P.S. Kulat, Suhas Bagmare, Aniket Chourpagar

Abstract: An engineer is always focused towards challenges of bringing ideas and concepts to life. Therefore, sophisticated machines and modern techniques have to be constantly developed and implemented for economical manufacturing of products. At the same time, we should take care that there has been no compromise made with quality and accuracy. In the age of automation machine become an integral part of human being. By the use of automation machine prove itself that it gives high production rate than manual production rate. In competition market everyone wants to increase their production & make their machine multipurpose. The engineer is constantly conformed to the challenges of bringing ideas and design into reality. New machines and techniques are being developed continuously to manufacture various products at cheaper rates and high quality.

Authors: R. N. Khandare, G. S. Dhage

Abstract: In today’s rapidly changing the scenario in manufacturing industries, the metal cutting processes are essential for a manufacturing unit to respond effectively to severe competitiveness and increasing demand for the quality product in the market. Laser Beam Cutting (LBC) is one of the most widely used manufacturing technique for generation of accurate and complex shape geometrical shape on ferrous metal, nonferrous metal, stone plastic and ceramic component with high dimensional accuracy. Fiber laser are solid state laser technologies that offer a combination of high beam quality and a wave length that is easily absorbed by metal surface. This work aim to evaluate the optimization laser beam cutting parameter for 10 mm thickness of mild steel sheets by using fiber laser beam machine of 1000 W power and Nitrogen as assist gas . Focus of work mainly on output response parameter like Material Removal Rate (MRR), Kerf Width (KW), Kerf Deviation (KD), Surface roughness. Results are analyzed using analysis of variance (ANOVA) technique. The effect of different input process parameter like feed rate, laser power , frequency and gas pressure is studied on the output response.

Authors: Kamlesh Bachka, Mukund Kavekar, Aniket Akhade

Abstract: This paper borders around analysis of compressor blade. The Impeller blade is a rotating part which imparts highly pressurized air. Impeller blade is critical part of turbocharger which has shown increasing growth of failure damaging assembly. It deals with Static and thermal analysis of Impeller blade which is made up of INCONEL N06230 to estimate its performance. The causes of failure for blade have also been found out. The investigation has been done using Soild Works 2012 and ANSYS 10.0 software. Solid Works 2012 is used for modeling of compressor blade and analysis has been done by ANSYS10.0 software. An attempt has been made to investigate the effect of induced stresses, pressure and temperature on the Impeller blade. A structural analysis has been carried out to investigate the stresses and displacements of the Impeller blade. A thermal analysis has been carried out to investigate the thermal gradient and thermal stress.

Authors: Nikhil Metange, K. T. Patil

Abstract: Rotary tiller blades are used to prepare or to make a soil bed, the rotary tiller blade works in any type of soil. But, most wear problems occur in the dry soil condition. To find out the solution of problem of wear out the project mostly concentrated about the material and its analysis under the loading condition. In such study, we focus on improving service life of rotary blade and study about its working hours etc. The aim is carried out by means of design and analysis of a blade. To design the efficient blade, we are going to test the blade under different material analysis and test the blade under different load condition. To get the efficient final blade structure we are going to review the different literatures and study different deigns of rotary tiller blades. The blade with the different load conditions will analyze and tested. We are also validating the results with the analytical solution and experimental module of the proved final module. We will test the experimental module under the different load conditions.

Authors: Prachi Bansal, Anshika Jain, Pradeep Khanna

Abstract: Rapid industrialisation and technological advancements in assembly processes and the demand for feeding the components in assembly lines has grown significantly [1]. It, therefore, becomes essential to optimize the assembly process. Automated or mechanized assembly can be achieved by the use of feeders. This paper describes the design and development of a mechanical reciprocatory tube funnel feeder which is suitable for use in any manufacturing system requiring discrete feeding of cylindrical parts. The developed system facilitates feeding of randomly placed heap of parts in a desired orientation and at the desired feed rate.

Author : Rajesh Ghosh

Abstract : The effect of ultrasonic treatment on the mechanical properties of banana fiber reinforced vinyl ester resin composites has been experimentally determined. Banana fibers were initially mercerized. These were then subjected to ultrasonic treatment while preparing the composites. Similar method was followed earlier to study the effect on water absorption property of the composites which showed encouraging results (Ghosh et al, 2013) [1]. Hence these composites were tested for their mechanical strengths. The mechanical strengths were found to be better than the composites made in the general procedure.

Keywords : Alkali treatment, sonication, mechanical strength, banana fiber composites

Authors : S.R.Durairaju, B.Dhanasekar, T.Gilbert, S.Gokul

Abstract : The Aim of this paper is to study and review of Automatic Lubrication System. Any parts in contact with each other may develop certain amount of heat due to friction of the moving parts and as a result, there will be some wear and tear and loss of power. The most effective method of reducing friction to minimum and to save the metals from wear and tear is efficient lubrication and the substance used for this purpose is called lubricant. Optimum lubrication reduces friction and subsequent wear on the material. So proper lubrication system for lubrication is the most important factor for efficient running of machine elements.

Keywords : Automatic Lubrication, Lubricants, Double acting pneumatic cylinder, Solenoid valve, Timer.

Authors : Md. Shahidul Islam, Hideo Koguchi

Abstract : In recent years, intelligent or smart structures and systems have become an emerging new research area. Piezo-ceramics material, due to its characteristic direct-converse piezoelectric effect, has naturally received considerable attentions. The stress concentrations caused by mechanical or electric loads may lead to crack initiation and extension, and sometimes the stress concentrations may be high enough to fracture the material parts. Stress singularity of bonded joints is one of the main factors responsible for debonding under loading. However, the stress singularity for transversely isotropic piezo-ceramic bonded joints has not been made clear until now. In this paper, order of singularity and intensity of singularity in piezo-ceramic bonded joints is analyzed. Eigen analysis based on finite element method is used for order of singularity analysis of the joints. The distributions of stress and electric displacement in the singular field for the piezo-ceramic bonded structure are obtained by using the boundary element method. It is shown from the numerical result that the stress and electric displacement increase with the thickness of upper material and have larger value near the vertex of the interface. Therefore, there is a highest possibility to debond and delamination occurs at the corner of thick transversely isotropic piezo-ceramic bonded joints.

Keywords : Bonded joint, Boundary element method, Eigenanalysis, Piezo-ceramic, Stress singularity.

Authors : Mangesh G. Deokar, Vijaykumar S. Ghorade

Abstract : This report is based on Electronic Control Unit (ECU)’s validation process for Input (crank signal) and Output Drivers (injector and ignition coil signals) characteristics, because of the code flashed on ECU using IDE for particular microcontroller that controls the injector driver and ignition driver pulses respectively. Based on the given PWM Input signal (crank signal) it will give injector and ignition pulses , which is used to obtain ECUs best result using generated and flashed code on microcontroller on virtual environment setup. Hardware-in-loop setup is act as a virtual engine setup, which gives the input sensor signals to ECU for their best performance under test on bench or in lab testing. Design of a fully programmable, ECU must make use of all the temperature, pressure, position and speed sensors as well as the original injectors and ignition coils that are already available on the engine. The ECU must provide the user access to all the maps and allow their full customization simply by connecting it to a PC. This will provide the user with the capability to adjust the engine’s performance to its needs quickly and easily.

Keywords : Electronic Fuel Injection, Engine Control Unit, embedded

Authors:Edwin Raja Dhas.J, Pon Sudhir Sajan. S. S

Abstract: Composite materials are playing effective role in the development of automotives and aeronautical structural parts. Due to its flexibility and damping qualities and its easy approach of study and development, number of investigation and researches nowadays increases a lot. In this study, basics about Metal matrix composites with aluminium base are briefed. The nature and properties of boron carbide is also discussed effectively. Among many processing technique of AMC’s, a best adoptive technique of microwave sintering methodology for Al-B4C is discussed.

Keywords: Microwave sintering, Boron Carbide, Aluminium matrix Composites, Ceramics.

Author : Prof. Arun Bhattacharya

Abstract : The integration of IoT into industrial process monitoring has transformed traditional systems by enabling real-time data acquisition and remote accessibility. This paper presents an IoT-based framework designed for seamless integration with existing industrial setups. The system employs sensors, cloud computing, and analytics to monitor processes and send alerts in case of anomalies. Implementation results show significant improvements in operational efficiency and decision-making.

Keywords : IoT, remote monitoring, industrial processes, cloud computing, real-time data.

Authors: Dr. Neha V. Kulkarni , Prof. Arjun R. Menon

Abstract : Vibration analysis plays a crucial role in monitoring the health and performance of rotating machinery. With the growing complexity of mechanical systems and the increasing demand for reliability, predictive maintenance, and performance optimization, vibration analysis has emerged as a key diagnostic tool. This paper provides a comprehensive overview of vibration analysis in rotating machinery, including the theoretical foundations, advanced techniques, practical applications, common challenges, and future directions. Emphasis is placed on condition monitoring, fault detection, and maintenance strategies in industries such as manufacturing, aerospace, power generation, and automotive.

Keywords : Vibration Analysis, Rotating Machinery, Condition Monitoring, Predictive Maintenance, Fault Diagnosis, Signal Processing, Modal Analysis

Authors : Dr. Kavita Ramesh , Mr. Ankit Sharma

Abstract : Composite materials are increasingly used in a wide range of engineering applications due to their superior mechanical properties, corrosion resistance, and low weight. However, when exposed to thermal gradients or temperature fluctuations, these materials are subjected to thermal stresses that can compromise their structural integrity. The complex interaction of thermal conductivity, expansion coefficients, and phase mismatch between constituent materials introduces additional challenges in the accurate modeling of heat transfer and thermal stress distribution. This paper aims to investigate the fundamentals of thermal stresses and heat transfer mechanisms in composite materials. It explores the thermomechanical behavior under varying environmental conditions, highlights the analytical and numerical models used to predict performance, and discusses current challenges and future scope in enhancing thermal reliability.

Authors: Babu E R, G V Gnanendra Reddy

Abstract: Pulsating heat pipe is an effective method of heat transfer through passive two phase mechanism. In the present research work, experimental studies were performed on pulsating heat pipe made up of copper tube having inner diameters of 1, 1.5, 2 and 2.5 mm respectively. The pulsating heat pipe is charged with acetone as working fluid with different filling ratios of 50%, 60%, 70%, 80%, and 90% of its volume. The evaporator zone is electrically heated by means of mica heater with a range of 20 to 80W and condenser section is cooled by means of constant flow cooling water. The effect of filling ratio and tube diameter on thermal performance of closed loop pulsating heat pipe was investigated and the results shows that, for 2 mm and 1.5 mm inner diameter gives better performance compared to other tube diameters. The thermal resistance obtained have a lower value of 0.40 0K/W and 0.45 0K/W for 2 mm and 1.5 mm diameter respectively. It is also observed that the operation of pulsating heat pipe enhances at a filling ratio of 60% for all the tube diameters considered.

Keywords: Heat pipe, Acetone, Filling ratio, Tube diameter and Heat input.etc

Authors: Gautam Yadav, Garima Julaniya, M.L. Jain, S. Tiwari

Abstract: Ploughing wear is the micro-level abrasive wear and in this type of wear material shifted to the sides of the wear surface. In this research work, 10015 grade mild steel and 6000 grade aluminum sample were experimentally investigated for ploughing and cutting wear. This experimental investigation for ploughing wear of (mildsteel and aluminum) under the effect of scratching/cutting at different forces which responsible for roughness and damage of surface and this rough motion of parts of machine decrease the efficiency and working life of machine such as parts of IC engine and compressors. A setup has been made on shaper machine on the place of clapper box and ploughing wear rate was estimated experimentally at various different operating parameters. The spring force was calculated with the help of stiffness and displacement of the spring and the cutting force was calculated by ultimate stress with the help of spring force. Ploughing wear was calculated by the cutting and spring force. The experimental results showed that ploughing wear directly proportional to the force and loss of material of specimen. The ploughing wear and coefficient of friction found minimum in mild steel sample in comparison of aluminum sample within the observed range of sliding velocity and force.

Authors: Dr. Meenal Raghav, Mr. Arvind Chakole

Abstract: In the context of escalating environmental concerns and resource depletion, the integration of sustainable materials into mechanical design has become a vital area of research and development. This paper explores the application of a mechanics-based approach to integrating sustainable materials in mechanical systems. It emphasizes the mechanical performance, lifecycle analysis, environmental impact, and economic feasibility of alternative eco-friendly materials. A structured methodology is provided to guide mechanical engineers in incorporating sustainability without compromising structural integrity and efficiency. The paper highlights the challenges, scope, benefits, and real-world implications of embracing sustainable materials in modern mechanical engineering.

KEYWORDS: Sustainable Materials, Applied Mechanics, Biodegradable Polymers, Structural Design, Mechanical Properties

Authors: V. V. Shukla

Abstract: The Finite Element Analysis presented in this investigation demonstrates the feasibility of employing an anatomically realistic finite element eye model with 8 components. 3-D model of the human eye which closely resembles the dimensions of the actual human eye was modeled in ANSYS®. The human eye is modelled as comprising of eight distinct regions, namely the cornea, the aqueous humor, the lens, the ciliary body, the iris, the vitreous humor, the choroid and the sclera. Intraocular pressure (IOP) is the pressure of fluid inside the eye. The average value of intraocular pressure within the human eye is 15.5 mmHg with fluctuations of about 2.75 mmHg. An increase in blood pressure is called hypertension similarly an increase in intraocular pressure is called ocular hypertension. An eye is considered to have ocular hypertension if intraocular pressure is consistently 21 mm Hg or above. In some typical physiological cases, a traumatic situation is reached when the eye is subjected to external pressure in addition to IOP. These typical cases are challenging and important for ophthalmologists. The stress distribution over all the eight components of the eye are presented and compared with multiple combinations of IOP and external pressure. The worst case has been observed at highest IOP and highest wind pressure situation yielding a highest stress of 29.883 kPa at the junction of sclera and cornea. This could be eliminated by proper precaution and utilization of protection gear operating in similar work conditions.

Keywords: Human Eye Model, Intra-Ocular Pressure (IOP), Ocular hypertension,

Authors: Ajit Lohote, S.S.Kelkar

Abstract: The use of honeycomb composite structure continues to increase rapidly due to the variety of their application, for example: satellites, aircraft, ships, automobiles, transportation rails, etc. The sandwich composites are multi-layered materials made of bonding stiff, high strength skins facings to low density core material. In structural components high stiffness to weight ratios is the major benefit of the honeycomb sandwich concept. In this study a honeycomb structure is evaluated. Static behavior of sandwich is investigated for permissible load. Then a fatigue analysis is carried out to investigate for its life prediction. The objective of the project is to find number of cycles a structure sustains at a particular load. If a structure fails at early stage, efforts will be taken to increase its stiffness and strength as design parameters .A Finite element analysis of honeycomb structures is to be carried out with ANSYS Workbench as both preprocessor and post processor. The finite element analysis results compared with the experimental results.

Keywords: Finite element analysis, Honeycomb, Fatigue analysis.

Authors: Jagannatha GupthaV L, Ramesh S Sharma

Abstract: This paper presents, by experimentally investigating, the effect of notch dimension and fiber orientation on the tensile strength of laminated CFRP composites. In the present study, notch tensile strength of unidirectional CFRP laminated composites with epoxy matrix is evaluated. Three fiber orientations viz 0o, 45o and 90owith two central circular holes/notches of 6 mm and 10 mm diameter are considered. An experimental program has been carried out to investigate their effect on the tensile strength of laminated composites in the presence of central circular notch. Investigations on the tensile strength of composite laminates containing circular holes show that there is a large difference in failure stress and mode of failure mechanism. It has been observed that the notch tensile strength decreases with increase in whole diameter/notch size and with the increase in fiber orientation. Considerable variation in strength has also been observed between 0o and 45o fiber orientations as compared to that between 45o and 90o which is very small. In addition to the variation in strength, two different failure mechanisms are observed: fibre pull out in 0o loading condition, debonding along the fiber orientation with matrix damage in other two conditions. It is observed that the damage propagated across the gauge section via delamination at the hole, which is controlled by the ply direction.

Authors: Dr. Ramesh Ayyanar

Abstract: The increasing demand for high-speed vehicles in both terrestrial and aerospace transportation has led to significant research efforts aimed at reducing aerodynamic drag. Drag is a primary force that opposes motion through a fluid medium, contributing to energy loss, reduced speed, and increased fuel consumption. This paper discusses the principles of aerodynamic drag, its impact on high-speed vehicles, and various strategies employed for drag reduction. Emphasis is placed on passive and active control techniques, surface modifications, vehicle body design, and emerging technologies such as plasma actuators and morphing surfaces. Case studies of high-speed trains, race cars, and aircraft are examined to illustrate practical implementations. The paper concludes by identifying current challenges and potential future research directions for sustainable, efficient, and high-performance vehicle design.

Keywords: aerodynamic drag, drag reduction, high-speed vehicles, turbulence control, surface modification, vehicle aerodynamics, energy efficiency.

Authors: Swati Menon, Manisha Rani

Abstract :Gears are fundamental mechanical components in various industrial and automotive systems, requiring both high surface hardness for wear resistance and a tough core for load-bearing. Surface hardening processes are designed to meet these dual requirements by modifying only the surface properties of the gear material. This paper explores the various surface hardening techniques employed in gear manufacturing, including carburizing, nitriding, carbonitriding, induction hardening, flame hardening, and laser hardening. Each technique is analyzed in terms of working principles, applicable materials, advantages, limitations, and suitability for different gear types. A comparative analysis is presented to highlight selection criteria based on gear size, material, and application environment. The paper also discusses the challenges in surface hardening processes such as distortion, cost, and crack formation, while outlining the scope for future research in advanced and eco-friendly surface treatment methods.

Keywords: Surface Hardening, Gears, Carburizing, Nitriding, Induction Hardening, Laser Hardening