2016

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A Case Study on the Successful Implementation of 5s Process and its benefits
(IUT, MCE, 2016-11-20) Hossain, Zilkad; Ashraf, SK. Riad Bin
5S is amongst the first and fundamental steps implemented by an enterprise towards the path of implementing Total Quality Management and continuous improvement at the operation level. 5S is a process designed to organize the workplace, keep it clean, maintain effective and standard conditions. It inspires the discipline required to enable each individual to achieve and maintain a world-class environment. Many enterprises have practiced the 5S and derived significant benefits from it. In particular, this technique has been widely practiced in Japan. Most Japanese 5S practitioners consider 5S useful not just for improving their physical environment, but also for improving their thinking processes too. In Japan it is also called ‘workplace management’.
A comparative study of vibrational characteristics of carbon fiber composite sandwich plates with truss-cores of different lattice structures
(IUT, MCE, 2016-11-20) Hassan, Mehedi; Nayeem, Md. Abu
The effective vibrational characteristics of sandwich plates with truss-cores of pyramidal truss lattice structure and reciprocal double-pyramidal truss lattice structure made of carbon fiber composite have been investigated theoretically in this paper. Analytical models were developed using ANSYS® finite element analysis software. Mode shapes and natural frequencies were investigated in both structures using ANSYS® Modal and a frequency versus mode curve was generated for both of the cases. Modal analysis was also done in both structures at different fiber orientations and a natural frequency versus fiber orientation curve was generated for each cases. Frequency response analysis was done using ANSYS® Harmonic and an amplitude (in decibel) versus frequency curve was generated for both of the lattice structures. At last, all of the results for both pyramidal truss lattice structure and reciprocal double-pyramidal truss lattice structure were compared and a conclusion was drawn depending on the results obtained from the investigation
CFD analysis of steady and transient natural convection in an enclosed cavity
(IUT, MCE, 2016-11-20) Mehedi, Tanveer Hassan; Tahzeeb, Rahat Bin
The research is conducted to find out the critical width of insulation in air insulated walls seen in residential buildings and industrial furnaces. Natural convection between two differentially heated walls have been simulated using ANSYS FLUENT in both steady and transient conditions. To simulate different heat transfer and fluid flow conditions, Rayleigh number ranging from 103 to 105 has been maintained (i.e. Laminar flow.) In case of steady state analysis, the cfd predictions are in very good agreement with the literature reviewed data. Transient simulation process has been performed by, using USER DEFINED FUNCTIONS, where the temperature of the hot wall varies with time in a sinusoidal manner. To obtain and compare the heat transfer properties, Nusselt Number has been calculated at the hot wall at different conditions. The buoyancy driven flow characteristics have been investigated by observing the flow pattern in a graphical manner. The characteristics of the system at different temperature differences between the wall has been observed and documented.
Construction of a plunger type experimental wave tank for validation studies
(IUT, MCE, 2016-11-20) Islam, Md. Ishmam; Islam, Md. Asiful; Asif Hossain, Mohammad
The design and construction of a small wave tank (flume) and associated equipment has been described. The wave tank is equipped with a plunger-type wave generator, capable of producing both regular and irregular waves. A variation of the rack and pinion gear mechanism often known as the reciprocating rack mechanism is utilized to transmit power from the motor to the plunger. A triangular wedge is used as plunger in the setup. Instrumentation includes a vernier depth gauge. The wave-maker is controlled by an induction motor via a Variable Frequency Drive (VFD) or inverter drive. From the survey reports by Khalilabadi et al. of wave absorbers used in different laboratories, a beach was designed for absorbing the waves coming from wave maker. The quality of waves is improved by keeping as little room as possible behind the plunger. The main advantage of this system over previous ones is the novelty of the plunger type wavemaker and low level cost utility.
Cricket bat :
(IUT, MCE, 2016-11-20) Hasan, A. A. Mahmud; Alam, Shariar
In the game of cricket importance of using the right type of bat is very crucial. Boundaries of laws set by the MCC does not permit massive alteration of traditional bat design, materials and its manufacturing process. Yet the performance of the cricket bat can be boosted using FEA method within the limitations of laws. The purpose of this study was to show the presence of sweet spot in cricket bat and its location using modal analysis. The results that were found from the computer simulation showed the natural frequencies and their corresponding mode shapes. From these results verdict can be made about the performance of the cricket bat and how to enhance it. Computer aided modified design was further analyzed which showed improved results in terms of performance.
Design and Analysis of a Thermal Control System
(IUT, MCE, 2016-11-20) Hasan, Md. Nahidul; Shaown, Md. Shahriar Hasan; Kassim, Abdulahi Abdirahman
The pressure vessel contains high pressurized fluid so that the selection of material and the design of the pressure vessel are most important. The pressure vessel contains high internal pressure. It must passes the sequence of hydrostatic test this test gives the capability of the construction to survive internal pressure. The analytical design of the pressure vessel is by using as per ASME code sec VIII division I. The dimension and stresses which works on pressure vessel can be found out by ASME code. These stresses are studying by using FEM and equate with theoretical value. We need to write code for the microprocessor .For writing code Arduino IDE was used. For controlling the coils and pump electromechanical relay was used
Design Simulation and Fabrication of vehicle exhaust gases emission control system
(IUT, MCE, 2016-11-20) Mehmood, Aqib; Bilal, Hazrat
Determining factors hampering the implementation of techniques for the reduction of prominent wastes in export-oriented garments factories: a case study
(IUT, MCE, 2016-11-20) Rahman, Hussein Areefur; Islam, Shehroze
In the competitive global market, the position of garments industry, the most important remittance-earning industry, is deteriorating by day due to numerous reasons one of which being increase in cost. To keep up with challenges like increased compliance enforcement and quality demand, the traditional ways are failing to keep a sustainable production environment in this industry. For maintaining a sustainable production environment, it has become an absolute necessary to reduce waste in production system to the minimum. This study concerns with a case study that attempts to address different factors standing in the way of waste reduction in garments industry, the prevalent categories of wastes in the industry and practical measures and guidelines for the solution. Since the study was limited to a single export-oriented garments factory, the findings may not prove accurate for making generalized conclusions. Further study is necessary for determining comprehensive measures.
Effect of rake angle and cutting speed in chip morphology and prediction of tip temperature and cutting forces with FEA software
(IUT, MCE, 2016-11-20) Khalid, Saifullah; Tanzil, Sifat Ullah
To minimize experimental time and expensive experimental test, researchers always refer FEA as most effective system. In this paper, we tried to show the effect of rake angle, cutting speed in chip morphology for different materials. We structured a finite element model for predicting chip morphology in different cutting conditions and then we validated our model with comparison to established papers. Orthogonal cutting methodology has been adopted for analysis. As we know Ti-6Al-4V is most commercially available Titanium alloy. Among the uses of Titanium alloy, 50% of industry uses Ti-6Al-4V. This material is widely known as high strength-weight ratio and excellent corrosion resister. It has 40% lesser density than steel and also having workability at high temperature (600degree).But it has machining problem due to low thermal conductivity and chemically reactivity and our model was able to predict effect of rake angle and effect of cutting speed as well as helped to find out critical rake angle of this material. Our model was able to predict chip type properly and also temperature in the cutting zone and cutting and tangential forces associated to the cutting condition. Every cutting parameter were set from established research works and material specification has been taken from material different material handbook and it has been shown that our FEA model is correct and validates multiple research work with same model in most cases with marginal error.
Effects of magnetism on the roughness of drilled holes of a glass fiber reinforced polymer composite material
(IUT, MCE, 2016-11-20) Shahriar, Md. Ragib; Azam, Md. Firdous
Have superior properties of the glass fiber reinforced polymer (GFRP) composite materials, the use of it is being accelerated recently. That is why the machining of these GFRP materials is a great concern for engineers. It became relevant for the researchers to analyze and introduce to improved machining. One of the most conventional way of machining is drilling process. Drilling is the mostly used in hole creating method in conventional machining. Hole creation in these composite materials is also mostly done by the drilling process. But the laminated structure of the composite material caused several types of damages and other surface irregularities during drilling process. About 60 percent of the rejections in the assembly plant are caused by the defects in the holes. The main contributor for defects in holes in the machining of the composite materials is surface roughness. These defects would create reduction in structural stiffness, which may lead to variation of dynamic performance of the whole structure. Hence, achieving the desired hole quality is of great importance for the functional behavior of the mechanical parts. In this present work, an observation is made on the effect of the permanent magnets of different magnitudes. Experiments are performed under different magnetic drilling conditions of spindle speed, feed rate and drill diameter on CNC drilling machine using three levels of factors with three different magnets of different magnitudes. A procedure has been adopted to assess and optimize the chosen factors by the use of Box-Behnken design to analyze the effects of different parameters. From the experimental results, it has been observed that the technique used is convenient to predict the main effects and their interaction effects of different influential combinations of machining parameters on surface roughness. It has been found that effect of permanent magnets on the guiding mechanism of the drill bit which lead to get improved surface roughness with better circularity ii compared to normal drilling processes and with the increase of the magnitude of the magnets, the results became better. A mathematical model has been developed for the prediction of surface roughness using permanent magnets and normal drilling processes.
Fire and safety engineering in the garment factory of Bangladesh
(IUT, MCE, 2016-11-20) Arefin, Shamsul; Abedin, Saadman; Azam, Sheikh Shafqat
In Bangladesh businesses are growing at an ever fast rate. New businesses are opening everyday in every possible sector. Taking purchasing power parity into account Bangladesh is the 44th largest economy in the world. Bangladesh is also listed in the N-11 (next 11) by the Goldman Sachs Group, Inc. Among all the industries, at present textiles and readymade garments‟ industry are the top ones. Recently WTO has ranked Bangladesh as the 4th largest exporter of readymade garments‟ in the world. This sector contributes for 75% of foreign currency earning for Bangladesh. Textiles and Readymade Garments‟ sector contributes 13% of GDP and employs more than 3,000,000 people. It has bought benefit and blessings for millions of people in the country. This industry has played a significant role in elevating economic and living standard of millions of families all over the country. Along with bringing blessing for the nation, textile and RMG industry also hold the record of experiencing some worst industrial accidents in the country. Taking advantage of poor surveillance of concerned authorities‟ rules, laws and codes are often violated in construction sector of our country and factory buildings are no exception. It is popularly believed and often proven true by incidences that the building codes are only maintained in paper works and hardly during the construction phase. Later as the owner focuses on the interior works, machine placement etc. the floors are often over loaded with machineries, causing more population load during operational hours, narrowing circulation spaces, thus making it difficult for the people to access the emergency route during an emergency. Many factories do not arrange regular drill; therefore the workers discover themselves in an alien situation whenever an emergency situation arises, causing panic, stampede etc. that further escalate the degree of casualty. On the basis of the situation of most recent Bangladeshi factory fire it is very obvious that any person unconscionably may lose his or her life in the name of garment manufacturing any time. In our presentation we will review the current situation of fire and safety in garment factories with respect of the global parameters, their lacking and the modification that has to be made. The common equipments that are being used in our garment factories are Fire extinguishers, Fire sprinklers, smoke alarms. But the structure of the buildings are so poor that fire escape are not that much effective for large number of workers. Besides they do not follow the building code properly. Even the number of equipment used in a garment factories are not that much. In our presentation we will highlight the lacking of equipment being used and needed for the factories, the solution to this problem on our point of view on the basis of current situation of Bangladesh,
Implementation of nanofluid for heat transfer augmentation and pumping power optimization
(IUT, MCE, 2016-11-20) Salehin, Musfequs
In this project improvement in heat transfer and pumping power optimization by implementing nanofluid through different fluid domains was investigated numerically. Finite Element Analysis (FEA) based software ANSYS- fluent 12.0 was used to analyze the thermo physical and flow behavior by Finite Volume Method (FVM). The fluid domain was selected as circular pipe, corrugated pipe (including sinusoidal, semicircular, rectangle corrugation) and rough parallel plates for different case studies in order to heat transfer enhancement and pumping power optimization using nanofluid. Turbulent flow for wide range of Reynolds number was considered in this project. Al2O3, TiO2, CuO naofluid with 1%-5% volume fraction in concentration was considered as the base fluid. Constant heat flux was subjected to the pipe and plate wall. Improvement in heat transfer was found out using nanofluid as compared with water due to higher thermal conductivity of nanofluids. Pumping power requirements for nanofluids and pumping power optimization was carried out for particular fluid domain and particular nanofluid with specific volume concentration
Investigation of microalgae biomass as a potential source of bio-fuel for Bangladesh
(IUT, MCE, 2016-11-20) Bin Karim, Shabab; Ishmam, Shitab; Rahman, Wasel-Ur-
Fossil fuel energy resources are unsustainable. World reserves are gradually depleting and the greenhouse gas emissions associated with their use are contributing to global warming. Therefore, there are vigorous research initiatives all aimed at developing alternative fuel resources that are both sustainable and carbon neutral. Based on contemporary research, third generation biofuels that are specifically derived from microalgae are considered to be a technically viable alternative energy resource that is free from the major problems associated with the use of fossil fuels. This project investigated the use of microalgae for biodiesel production, including their cultivation, harvesting, and processing. The microalgae species most suitable for biodiesel production in Bangladesh are mentioned as well.
Investigation of Surface Roughness and Burr Height of Al/Al2O3/Gr Metal Matrix Composite for Various Drilling Parameters
(IUT, MCE, 2016-11-20) Saadat, Sadman; Anan, Md. Abid Hasan
Drilling is a simple and common metal removal process and is important for the final fabrication stage prior to application.This paper discusses the influence of cutting parameters on drilling characteristics of pure Aluminium (Al) plate and Aluminium (Al) metal matrix composites (MMCs) reinforced with 3wt% Graphite(Gr) and 5wt%, 10wt%, 15% Alumina (Al2O3). The composites are fabricated using stir casting method. The experiments were conducted to study the effect of spindle speed and feed rate on surface roughness and burr height using high speed steel twist drills of 12 mm diameter having various point angles and lip angles. The results reveal that the alumina- graphite reinforced composites have better surface finish and improved burr heights the than unreinforced sample. Decrement of surface roughness and burr height occur with the increment of the amount of reinforcement. The spindle speed and feed rate extensively affect the surface roughness and burr height of the drilled hole.
Optimisation of Process Parameters using the Hybrid Algorithm of Artificial Bee Colony and Fuzzy Logic Controller
(IUT, MCE, 2016-11-20) Islam, Madani; Rahman, Md. Rizwanur
A hybrid Artificial Bee Colony (HABC) algorithm is proposed based on Fuzzy Inference System for solving fuzzy flexible real life optimisation problem. First, the Fuzzy Logic Control provides multiple parameters to an output of single parameter using the fuzzy logic membership function dependent on the input parameter characteristic and the fuzzy logic rules. Second, this single output from the fuzzy logic is optimised by ABC which utilises multiple strategies in a combined way to generate the initial solutions with certain quality. Third, the algorithm is verified in established set of data which demonstrated the effectiveness of the hybrid Algorithm
Optimization of surface roughness on aluminium milling operation by peltier cooling effect
(IUT, MCE, 2016-11-20) Sanglap, Md. Tanzib Ehsan; Ahnaf, Md. Golam
The ultimate goal in the manufacturing of a part is to achieve an economic production plan with precision and accuracy in the first attempt at machining. A physics-based comprehensive modelling of the machining processes is a fundamental requirement in identifying optimal cutting conditions which result in high productivity rates without violating accuracy throughout the part production process. As technology provides smaller devices with greater heat dissipation needs, cooling systems become essential during machining. The results of manufacturing processes, such as roughness structures on machined surfaces, now play a significant role in milling phenomena. The Main vision of this paper is to facilitate improved machinability that also constitute the reduction of surface roughness and decreasing the temperature at the cutting zone. The conventional milling, in both dry condition and cryogenic cooling that have a lack of getting a smooth surface as well as environmental purpose and costs. Thus for getting a complete cost effective and P a g e | 4 reliable solution, Peltier cooling effect is conducted for the analysis of the influence of the milling parameters on the surface roughness. This also helps to get improved chip formation and chip morphology. The optimum surface roughness obtained in both low and high RPM. In this paper the effect of cutting condition (cutting speed and feed rate) on surface roughness were studied and analyzed using Peltier cooling effect. And the results suggest that using Peltier cooling effect attains more realistic alternative to conventional coolants for milling applications that is not only reduces surface roughness of the machined surface, but also more eco-friendly, provides better chip formation and increases tool life.
Productivity and quality enhancement through implementation of Total Productive Maintenance (TPM) in a manufacturing plant
(IUT, MCE, 2016-11-20) Rashid, Md. Mynur; Alam, Rabiul
Plant and equipment maintenance is a vital issue in manufacturing. The cost of regular maintenance might be low but the major breakdown of a machine can halt the entire production line. On the other hand effective machine maintenance would enable a plant to increase productivity, efficiency, quality operations, various flexibility, and responsive to customer service. Most importantly, this may prolong the life of machines. In order to measure performance of a maintenance system, the overall equipment effectiveness (OEE) is a summarized metric of several performance measures used to determine a machine’s or plant’s performance and its impact on productivity. The purpose of OEE is to assist an organization with improved productivity, reliability, maintainability for both short term and long term effectiveness, and low cost yet quality product at the best value. To evaluate the OEE, research framework has been designed through interview-for initial assessment, observation of shop floor, collecting breakdown and repair data and analyzing those with statistical tools. After the documentation and analysis of data, findings are represented in graphical forms such as Pareto chart, cause effect diagram, and process flow diagram. Very little research is conducted about Total Productive Maintenance (TPM) implementation Bangladeshi manufacturing plant; so this thesis going to add value to that cause. Bangladesh spends significant portion of foreign currency to import industrial machineries. Understanding the reasons of machine breakdowns, failures, quality defects, reduced speed, setup and adjustment losses are vital for plants. Actual capacity of production line can be enhanced by understanding the big losses and evaluating OEE. Otherwise to meet the extended demand of a product, a plant has to spend more money on buying new equipment. Many Japanese and the USA manufacturing plant incorporated TPM few decades ago but this practice seems to be absent here. Practical implication of this study is that manufacturing plants needs to improve its maintenance policy.
Redesigning of a warehouse facility layout for improving the inventory management system: a case study
(IUT, MCE, 2016-11-20) Razee, Syed Muqsit
Warehouse layout is a classical production problem in engineering environment. Warehouse design often has a significant impact on the performance of a manufacturing plant. In modifying the warehouse floor layout, main issue that needs to be concerned is the impact on system performance due to the changes made. Improvements in terms of time delays, frequency of material flows and efficiency of line will contribute to the reduction of production cost. Neither an algorithmic nor a procedural layout design approach is usually an effective way in solving a practical layout problem. This paper applied the simple procedural methodology for the generation of suggested system, namely Systematic Layout Planning (SLP) approach. This approach analyses the layout problems through the usage of easy understanding analytical tools. The suggested system focuses on the redesigning of the workstations for more visible value adding workstation arrangement in the warehouse. The system was evaluated through the line balancing issue and space distribution. Changing material handling equipment and space arrangement of all the equipment directly improves of flow within the warehouse. Implementation of a new layout is a time consuming process and a big investment is required for making the changes. Even no practical analysis is possible for observing the improvement(s) made, hence the improvement was proved through a heuristic way in this project
Study of environmental pollution by Petrol engines
(IUT, MCE, 2016-11-20) Mohammed, Hammam Ali; Idris, Abdullahi; Mohammed, Abdallah
Study of the effect of external vibration on surface roughness after burnishing by a vibration assisted flexible burnishing tool
(IUT, MCE, 2016-11-20) Rahman, Wahidur; Chowdhury, Asif Alam; Tousif, Rahat Latif
Burnishing is a very simple and effective method for improvement in surface finish and can be carried out using existing machines, such as lathe. Quality of Surface is an important factor to decide the performance of a manufactured product. For better quality surface finish the main factor is surface roughness. On account of its high productivity, it saves also more on production costs. Moreover, the burnished surface has a high wear resistance and better fatigue life. The lower value of roughness gives higher surface finish for the manufacture red product. Now in present scenario different processes like grinding, honing, super finishing, polishing, burnishing, etc. are used to reduce the value of surface roughness. Burnishing is one of the process which majorly effect the surface roughness. The levels of input process parameters are selected on basis of one factor at a time. Experiment of depth of cut, burnishing feed, burnishing speed and number of process. Burnishing process has many advantages over the other finishing processes, the improvement of the surface roughness through the burnishing process generally ranged between 40% and 90% [11-13]. Compressive stresses are also induced in the surface layer, giving several improvements to mechanical properties. Burnishing can improve both the surface strength and roughness [14].