Table of contents

As the Chair of 2019 6th International Conference on Mechanical, Materials and Manufacturing (ICMMM 2019), I would like to say it is my honor to have been involved with this excellent and exciting conference. Mechanical, materials and manufacturing are three disciplines that are all link directly. A conference that allows this latitude allows for research was success and the edge of knowledge can be pushed fully. This conference was no exception and I would like to thank the prestigious professors that supported the conference and presentations.

Many conferences claim to be international, very few are. In Boston, there were delegates for north and south America, Europe, Africa, middle east, Indian region, South Korea and China. This joining of worldwide researchers allowed for an excellent conference. Furthermore, posters were of a high quality in keeping with the selection process of the work.

Conferences need reviewers, and a thank you to all ours that supplied excellent feedback to maintain our standards. The level of presentation was as I expected, first class. These proceedings are to show the work and depth of research. We hope these will be the seminal work for larger research projects and cited as deserved. Finally, if you are reading and find interesting, submit a paper for next year, if you presented this year return and help us grow to deliver the support these disciplines deserved.

Warmest regards,

Professor Ian R. McAndrew PhD FRAeS

ICMMM 2019 Conference Chair

List of Conference General Chair, Conference Local Organizing Committee, Conference Program Chairs, Conference Program Co-chair, Conference Technical Committees are available in the pdf.

Peer review statement

All papers published in this volume of IOP Conference Series: Materials Science and Engineering have been peer reviewed through processes administered by the proceedings Editors. Reviews were conducted by expert referees to the professional and scientific standards expected of a proceedings journal published by IOP Publishing.

DLC(a-C:H) film are known for their excellent tribological properties however, possess poor adhesion on metallic substrate causing film delamination. Introduction of adhesive silicon interlayer has showed improvement in the adhesion of DLC-H on metallic substrate. In the present study DLC-H was deposited on tappet valve and silicon wafer using PECVD. The as-deposited DLC-H was characterized using XRD, EDS and Raman spectroscopy. SEM was also used to measure the thickness of the DLC-H coating and the average surface roughness (R_a) was measured using 3D Profilometry. Scratch test was used to determine the COF, adhesion and hardness of the DLC-H coating. The DLC-H coating on tappet valve had weak adhesion compared with DLC-H coating deposited on silicon substrate, which had good adhesion. The result of the Raman spectroscopy revealed a sp3 fraction of 0.43 for the DLC-H deposited on silicon substrate. The thickness of the as-deposited DLC-H film was 1.78 µm, which was measured using SEM to view the cross-section of the as-deposited DLC-H coating on the silicon substrate. The surface roughness of the as-deposited DLC-H coating on silicon substrate was 26.59 nm. Silicon substrate coated with DLC-H had the lowest COF, ranging from 0.06 to 0.09.

India embraces wide variety of dimensional stones. It includes granite, marble, sandstone, limestone and slate. Amid all the states, Rajasthan is known as mineral majestic of India, with an abundance of important stones. Rajasthan produces more than 90% of sandstone of all over the country. The total quantity of mined out sandstone is 200.27 million tons per year, out of which 110.25 million tons are accounted as waste during various manufacturing and processing stages of sandstone. An experimental work has been conducted to manufacture self-compacting concrete (SCC) with dry sandstone slurry (DSS) and study the properties of SCC. Seven SCC mixes have been prepared with various percentages of sandstone slurry (i.e. 0, 5, 10, 15, 20, 25 and 30 percent) as partial replacement of pozzolana portland cement (PPC). Compressive, flexure and tensile strength of all SCC mixes up to 180 days curing age and abrasion resistance after 28 days curing age have been found out and presented in this paper. The conclusion of this study draws an idea about the use of SCC mixes made with DSS are in favor of using DSS up to 10% for reinforced cement concrete work and up to 20% for plain cement concrete work.

This study measures the rheological properties of two stainless steel 316L powders which are used for the powder-bed-fusion based additive manufacturing process. The purpose is to evaluate the newly acquired powder in comparison with the used and recycled powder, so that both powders can be mixed with each other to supplement the powder usage. The powder rheology properties, such as dynamic property, bulk property, and shear property, are tested and compared. The results and analysis confirm the compatibility of powder mixing.

Aluminium 1000 alloy has high purity and good electrical conductivity required for high power transmission conductors but lacks adequate thermal conductivity which induces sagging in service. To augment this deficiency, Nb nanopowder was incorporated into it as a reinforcement and consolidated with spark plasma sintering (SPS). The SPS was conducted with pre-optimized processing parameters of 630 °C, 30 MPa, 10 mine and 200 °C/min. The sintering was conducted in a vacuum with graphite die of 20 mm in diameter. Thereafter, the sintered samples were metallographically prepared and subjected to thermal conductivity testing. A laser flash analyzer was used to generate the thermal diffusivity of the samples. Then their thermal conductivities were computed. Results obtained showed that Al-4Nb had the highest thermal conductivity of 115. 95 ± 6.9 W/mK which represented 42% improvement. So, it follows that Al-Nb composite is a better replacement for monolithic Aluminium 1000 alloy in power transmission conductors with a potential property of low sag.

The influence of varied process parameters involving three levels of temperature, pressure, heating rate and dwell time on the microstructure, densification and microhardness of spark plasma sintered Ti-6Al-4V/h-BN binary composite was studied. Taguchi design method was adopted to randomize the SPS process parameter levels. The microstructure was analyzed by optical microscopy, densification was determined based on the principle of Archimedes and Vickers microhardness tester was used to evaluate the microhardness of the sintered composite. The consolidation of Ti-6Al-4V powder and nanoparticles of 3 wt.% of h-BN via SPS produced nearly full theoretical densification of 99.77% and the sintered composite gave a microhardness value of 710.37 HV which is more than 200% that of the monolithic alloy. The best combination of relative densification and microhardness were obtained at the sintering parameters of 1000 °C of temperature, 40 MPa of pressure, 100 °C/min heating rate and 15 min of dwell time. Generally, it was found that improved microstructure, densification and microhardness were influenced by the high temperature of sintering and low rate of heating that gave room for adequate diffusional mass transport resulting in solid bonding between the particles of the matrix and the ceramic reinforcement.

Use of cooling media contributes in elevation of desired responses owing to its cooling and lubrication effects especially in case of hard to cut materials like Ti-6Al-4V. This study aims to analyze the effect of cooling media in addition to cutting speed on responses including tool wear and surface integrity during turning. Results highlighted the effectiveness of cooling system in particular that of cryogenic media. Use of cryogenic media and cutting fluid enhanced tool life max by 33% and 21% respectively. At lower cutting speed surface roughness was improved by 13% and 8% by cryogenic media and cutting fluid respectively.

The use of high strength concrete in tall buildings implies less lateral displacement, however, an important question is. In what other measures the seismic behavior of a building improves with high strength concrete (550 kg/cm²). As a result, the material allows the construction of slender structural elements, however we won't be able to know how much the ductility of the structure in front of a seismic event will improve. Therefore, the reason of this study is to analyze the dynamic response of a tall building with different sections and resistance to the compression of its structural elements. The aim of this study is to obtain the curve of capacity and the point of seismic performance of each structural model.

Conversion coating is an effective way to safeguard against corrosion. It is performed on a number of materials inhibiting the surface layer to corrosive attack. In this work surface engineering is carried out on test material ASTM A 516 Grade 70 which is widely used for constructional purposes. During the passivation process samples were given a hot alkaline oxide bath in sodium hydroxide and sodium nitrate. The corrosion resistance was then analyzed using advanced testing procedures. Salt spray test was used as a yard stick in making a comparative analysis of different samples including unpassivated samples, passivated samples and passivated samples with prior surface treatment. Results have shown that mechanical surface treatment improves material life by 3% whereas passivation with prior surface treatment can increase life by 18%.

Pyrene as an important chemical building block has found wide applications in the field of organic electronics. In solution, pyrene and its derivatives are well-known examples for excimer formation. Here, we studied the boron-nitrogen (BN)-substituted pyrene, decorated with thiophene side chain. From density-functional theory (DFT) calculation, this isoelectronic BN substitution maintains the coplanarity of the central motif and the delocalized π-electron distribution, but additionally induces a much stronger permanent dipole moment. Time-dependent DFT indicates a much-reduced oscillator strength for low energy transitions, and surprisingly a forbidden π-π* transition, therefore resulting in a much red-shifted absorption spectrum. Our simulation results call for future experiments to study the photo-excited properties of BN-substituted pyrene and molecular self-assembly through dipole-dipole interaction and π-π* interaction.

In an environment where the international market demands a large amount of fiber, the countries that produce raw material must be prepared to face the fulfillment of exports. However, it must be noted that in majority of the countries, this fiber, such as alpaca, can be found in the mountains at more than 3, 000 MASL where frosts are constant and cause deaths. Likewise, if the collection of feces is not adequate, it can represent an infectious focus which, in addition to the deaths, would reduce the productivity of the fiber. Thus, we can say that the main cause is the incipient knowledge of sanitary practices. This document proposes an alpaca waste management model for the generation of biogas for heating alpacas in frost seasons and obtaining biol for the improvement of pastures. The stages in which the project is carried out include infrastructure of the house, connection of house alpaca and system of drainage, biodigester, improvement of pastures. This model was validated by means of a continuous biodigester prototype supplied with alpaca feces and pig biol achieving 1 of biogas.

The position and speed of the piston of pneumatic cylinder are very important parameters in evaluating the pneumatic system performance. Utilization of Pulse Width Modulation (PWM) technique to control the Fast Switching Valve (FSV) usually causes fluctuation in the piston motion and accordingly, the system performance deteriorates. The objective of this work is to introduce a novel PWM control technique considering the suitable duty cycles according to the switching frequency in order to improve the FSV characteristics and reduce piston speed fluctuation. A test rig for a simple pneumatic circuit with an FSV as a control element has been designed and realized. The displacement of the piston is measured using a Linear Wire Potentiometer Transducer (LWPT), while its derivative is used to estimate the speed considering a low pass filter to reduce the effect of piston position signal noise. A nonlinear mathematical model is introduced and experimentally validated. The results of both computer simulation and experimental measurements show that the integration between fast switching valve and PWM control signal leads to a quasi-linear relationship between duty cycle and piston speed. Moreover; results proved the successful control of piston speed based on the correct duty cycle and valve switching frequency.

Labyrinth seals are widely used in turbomachines. In this paper, a transit simulation method is introduced to model the relationship between the journal offset in Labyrinth seals and the system stability based on Fluent UDF. A special dynamic mesh method has been adopted to ensure fine mesh quality during the arbitrary motion of the journal. In each time step, the transient fluid seal force on the journal surface is obtained by the solving Navier-Stokes equations. Then the displacement of the journal in the next step can be numerically solved by the FEM model of the rotor system. For every transient time step, the computed fluid seal force and the rotor motion displacement were coupled by data exchange. The experiment is carried out in a steam turbine with a position adjustable labyrinth seal. The experimental results show that the amplitude of the vibration decreases after the change of the relative position between the journal and the labyrinth seals and the numerical results show that the locus of the journal under different labyrinth seal offsets has some half-frequency components. Both the simulation and the experiment validates that the relative position between the journal and the labyrinth seals can greatly affect the stability in the coupled rotor-seal system.

The four-corner interconnected air suspension can effectively improve vehicles ride comfort, but the opening of the interconnection will intensify the roll or pitch of the car body, reducing the vehicle handling stability when the vehicles are in the turning, acceleration and deceleration conditions. To solve the above problems, an interconnected state control method is proposed for four-corner interconnected air suspension, the interconnection state of the pipeline is determined by the relationship between the torque produced by the air spring and the roll angles or pitch angles of the car body. The parameters of air spring pressure, car body roll angle and pitch angle are used in the control method to obtain the optimal interconnection state of four interconnected pipelines through control algorithm calculation. Finally, the opening and closing of four interconnected pipeline solenoid valves are controlled. In order to verify the effectiveness of the control method, the MATLAB/Simulink model of four-corner interconnected air suspension is established and simulated.

The ultimate load carrying capacity of journal bearings with different materials and surface treatment processes was studied in the present work. The load carrying capacity and backside temperature of bearing were examined using a bearing fatigue test machine (Glacier Vandervel, made in UK). The results showed that the copper-based sputtering bearing has the highest ultimate bearing capacity and the fatigue strength reaches 131.3 MPa. The bearing capacity of copper-based electroplated bearings is 99.7 MPa, which is lower than that of copper-based sputtering bearings. The bearing capacity of high tin aluminum alloy is obviously higher than that of white alloy bearing, and the bearing capacity of the two bearings is 72.7 MPa and 36.3 MPa, respectively. Finally, the mechanisms of fatigue failure of the bearings were analyzed.

Internal combustion engines are the most commonly used engines in the automotive world. However, these engines lack an overheating prevention system against cooling system failures when they exceed their normal operating temperature. Less experienced drivers (users) usually do not notice overheating until the engine stops, generating economic expenses in engine repairs. As such, this paper describes the design and construction of an electromechanical device to prevent engine overheating. This device is installed in a vehicle and operates independently from the electronic control unit (ECU); it records the coolant temperature and controls air admission to the engine of the vehicle in which it is installed. In addition, a new Arduino-based card will receive signals from a temperature sensor as input and process them according to its programming. Then, it will send signal outputs to the actuators: a servomotor, monitor, LED display, and buzzer. To control the intake flow, a butterfly valve is used with the servomotor. This valve partially or totally restricts the engine airflow, based on the temperature programmed for the Arduino, thus protecting the engine from overheating.

This research document on technological development is aimed at workers in small companies, those that are developing well and soon to emerge as companies that will be positioned at the top of their labor sector. Starting from the problem at present with respect to the bad manipulation of loads it is arranged to solve the problem with established objectives to try to correct the corporal posture at the time of lifting an object with a machine that replaces the functions of the worker. The design and the solution was made based on the requirements of the worker, workers who have the need to load objects at a certain height, here the man-machine relationship, demands and desires that help to achieve the general objective are analyzed. In addition, it has the main function of this machine: to lift heavy objects of up to 150 kg of mass, this due to the implementation of a hydraulic piston in the lifting platform. The appropriate solution is an adaptation of a platform in the form of a truck forming an angle of 47.17 between the structure of the truck and the horizontal surface, this position is the most adequate so that the back does not suffer injuries during the handling of loads at work. The results give assurance that it is a machine of reliability and easy handling since it only requires an operator to control the objects and a flat position on the back without damaging the spine.

This research project modeled and simulated a ventilation system at a Mining Concession, obtaining real-time information regarding the fans used to ventilate the mine. The simulation was developed using the VENTSIM 5 software, which also helped define the number of fans and the operating parameters required, field information, mine dimensions, the mining method, production, geothermal gradient, gas emission, air stream, and air pressure. In addition, the results from software operation revealed the need to open chimneys and use fans. Furthermore, the results also suggest that a specialist dedicated to ventilation and fan maintenance must be hired to formalize mining operations as per the Occupational Safety and Health Mining Regulations from Executive Action No. 024-2016-EM as this Mining Concession is currently operating without license.

This paper presents a blasting method called controlled trim blasting, in which the rock mass of an unstable gallery where high levels of vibration have been detected is analyzed. This methodology comprises a drilling mesh with two-contour gallery assessment, producing its drilling machines and determining the type of explosive used and burden and spacing, which will be detonated after the internal blasting. Further, the internal blasting will possess its drilling machines, burden, spacing, and a second type of explosive. The separation of the gallery into smaller parts will improve the blasting, as verified in the recorded simulation. In addition, the rock-mass stability improves because the explosives used in the perimeter of the gallery are low-power with mild detonation pressure, which does not generate high levels of vibration. This is a practical and efficient method in areas where the rock mass is not good or there is a mixture of rock types.

The application of rigid transformations matrices in variation propagation has a long tradition in manufacturing community. However, the matrix-based modeling of variation propagation in multistage machining processes is complicated. Moreover, there is a need to improve the computational efficiency of manipulation of geometrical models for variation analysis purposes. This paper introduces the representation of rigid transformation by dual quaternions, which have a computational advantage and mathematical elegance compared to matrices. In comparison to a commercial tool, the implementation of the purposed method predicted parallelism with an average error of 4.3 % in a hypothetical two stage machining process. The proposed approach has a potential to be an alternative to matrix based rigid transformation practices in variation and tolerance analysis.

In the present scenario, lean manufacturing techniques are the most successful improvement concepts that many companies can apply in order to eliminate waste and non-value-added activities related to the manufacturing process. This paper discusses the implementation of lean manufacturing tools and an integrated framework between production planning and quality in a SME dedicated at a production of kitchen equipment. Studies of the company processes showed that the cutting and bending processes tend to create the most amount of sheet metal waste and non-value-added activities. The main objectives of the research were to standardize work, reduce waste, eliminate machine failures and develop the guidelines for a correct planning that meets quality requirements. The improvement results have shown a positive impact reducing the waste ratio and this has meant a saving of 13% in the manufacturing cost.

3D printing is an additive manufacturing process that has an untold number of applications in fields as diverse as medical prostheses to military vehicle manufacturing not to mention its long term use in component prototyping [1][2]. With the creation of robotic arm based printers, the 3D printing process can be improved in terms of flexibility and time-efficiency, but with the potential trade-off being lower resolution in some areas of printer workspace. To counteract the resolution reduction, we are studying the use of continuously variable transmissions (CVTs) coupled to the robot's traditional revolute joints [3]. This paper will show that CVTs allow our SCARA-based robotic printer called DEXTER to achieve a resolution as good or better than a traditional desktop style 3D printer.

Aviation manufacturing is at the leading edge of technology with materials, designs and processes where automation is not only integral; but complex systems require more advanced systems to produce and verify processes. Critical Infrastructure theory is now used to protect systems and equipment from external software infections and cybersecurity techniques add an extra layer of protection. In this research, it is argued that Artificial Intelligence can reduce these risks and allow complex processes to be less exposed to the threat of external problems, internal errors or mistakes in operation.

This paper proposed a multi-scale retrieval framework to help optimize manufacturability. The case based workflow integrates both geometry and rules with model-based definition. At conceptual stage, defect models are categorized and global retrieval is initialized to narrow down cases as defects references. At detail stage, local feature retrieval finds similar defect feature with pre-defined rules, to adapt to manufacturability optimization. Intersection feature detection and decomposition are explored to improve generality.