Development of material selection method for the application children bicycle frame

A bicycle frame is a crucial part for cycling performance, efficiency, comfort, and injury prevention. This is especially true in the case of children cyclists that do not have the necessary cycling experience, balance and the fully developed musculoskeletal system of the adults. The selection of the correct materials for a particular product especially a children bicycle frame is a key step in the design and development process because it will carry the load of the rider during cycling. In the present paper few methods have been developed to select material of a bicycle frame for children and teenagers 7–14 years old. This paper will present the development of the material selection methodology based on Ashby’s material selection chart for the application of bicycle frame purposes. Two quantitative methods are proposed such as cost per unit strength and digital logic model methods. Also mechanical properties, including tensile strength, yield strength, Young’s modulus, toughness, density as well as cost were used as the key parameters in the material selection stage. Among the material selection methods the development of digital logic model is the best suited method which identified that the Kevlar fiber reinforced plastics (KFRP) as the most appropriate candidate material for the application of children bicycle frame

Materials selection of a bicycle frame using cost per unit property and digital logic methods

The aim of this paper is to develop the material selection method and select the optimum material for the application of folding bicycle frame. Two methods are introduced for the selection of materials, such as cost per unit property and digital logic methods. In cost per unit property, only one property (strength) is considered whereas in digital logic method, multiple properties such as tensile strength, yield strength, young’s modulus, toughness and density were considered for the optimum selection of the materials. The Ashby’s material selection chart was used for the initial screening of the candidate materials. The results are presented both in tabular and graphical forms. The materials selection method showed that AISI 1020 steel, Ti-alloy, carbon fiber reinforced polymer (CFRP), kevlar fiber reinforced polymer (KFRP) and glass fiber reinforced polymer (GFRP) are the candidate materials for the design of bicycle frame. From the cost per unit property method it is found that the KFRP shows the least cost material followed by AISI 1020 steel material. The digital logic method also showed the highest figure of merit value for KFRP material followed by AISI steel and Ti-alloy. Based on the developed materials selection method and analysis of the few candidate materials it can be concluded that the KFRP is the suitable material for the design and application of bicycle frame

Reverse engineering of automotive piston

To be aware of the present operating conditions of the automotive piston which are depended on the different mechanical and tribological properties, composition, microstructure and morphologies a comprehensive study of reverse engineering on an automotive piston is very essential. Therefore, the main aim of this work is to investigate and analyze a conventional automotive piston by performing the mechanical test, wear test, and microstructure analysis. A piston was destructed for the various experiments and investigations. Tensile test was performed using universal tensile testing (UTM) machine whereas hardness test was done on Vickers hardness tester. Microstructure and chemical analysis were performed using OM, EDX analyzer respectively. The wear test was performed using pin-on-disk (POD) machine. The tensile test results showed that the ultimate tensile strength and modulus of elasticity of the piston were 215 MPa and 73 GPa respectively, whereas the Vickers hardness number of this material was found to be 155 HV0.5kgf. The micrograph shows the phases of Si plate with ~17% of Si surrounded by α-Al matrix referring to the hypereutectic Al-Si alloy which was proven by the EDX analysis as well and the wear test results showed the moderate specific wear rate (with the range of 1.81 to 3.1 x10-6 mm3/N-m). The current RE analysis provides a guideline to replace or introduce a new material especially metal matrix composite for the application of new generation automotive piston with better properties, lighter weight and higher performance. Keywords: Reverse engineering; automotive piston; tensile strength; microstructure

Design and fabrication of natural woven fabric reinforced epoxy composite for household telephone stand

In the recent era there has been an increasing interest in composite materials for its applications in the field of aerospace, sports, industries, medical, and in many other fields of engineering including household furniture. This paper deals with the design and fabrication of banana woven fabric reinforcement epoxy composite for household telephone stand. A systematic approach of total design process is presented for better understanding of the best design concept for the product. The fabrication process of composite telephone stand using banana woven fabric is also described in this paper

Investigation of the anti-wear characteristics of palm oil methyl ester using a four-ball tribometer test

The aim of this study was to assess the anti-wear characteristics of palm oil methyl ester (POME) in elastohydrodynamic lubrication of EN31 steel ball bearings. A conventional four-ball wear testing machine with different loads was used at 1500 rev miny1 and a test duration of 1 min at ambient room temperature (approximately 28 8C). Optical microscopy of wear worn surfaces revealed the wear mode of mating surfaces. The results provide an nderstanding of the wear characteristics of ball bearings under POME contaminated lubricants. It was found that POME worked as an additive and improved the anti-wear characteristics. The flash temperature parameter (FTP) of the lubricant after each test was also measured

Wear behavior of as-cast and heat treated triple particle size SiC reinforced aluminium metal matrix composites

Purpose – The purpose of this paper is to study the wear behavior of as-cast (AC) and heat treated (HT) triple particle size (TPS) silicon carbide (SiC) reinforced aluminum alloy-based metal matrix composites (SiCp/Al-MMC). Design/methodology/approach – Al-MMCs were prepared using 20?vol.% SiC reinforcement into aluminum metal matrix and developed using a stir casting process. Stir casting is a primary process of composite production whereby the reinforcement ingredient material is incorporated into the molten metal by stirring. The TPS composite consist of SiC of three different sizes viz., coarse, intermediate, and fine. The solution heat treatment was done on AC composite at 540°C for 4?h followed by precipitation treatment. The wear test was carried out using a pin-on-disc type tribo-test machine under dry sliding condition. A mathematical analysis was also done for power factor values based on wear and friction results. The wear morphology of the damaged surface was also studied using optical microscope and scanning electron microscope (SEM) in this investigation. Findings – The test results showed that HT composite exhibited better wear resistance properties compared to AC composite. It is anticipated that heat treatment could be an effective method of optimizing the wear resistance properties of the developed Al-MMC material. Practical implications – This paper provides a way to enhance the wear behavior of automotive tribo-components such as brake rotor (disc and drum), brake pad, piston cylinder, etc. Originality/value – This paper compares the wear behavior of AC and HT TPS reinforced Al-MMC material under dry sliding condition

Tribological behavior of dual and triple particle size SiC reinforced Al0MMCs: a comparative study

Purpose- The aim is to study the tribological behavior of dual particle size (DPS)and triple particle size (TPS) SiC reinforced aluminium allloy based metal matrix composites - MMCs (Al/SiCp MMC)SiCp/Al-MMC). Design /methodology /approach- Al-MMCs were prepared using 20 vol% SiC reinforcement into aluminum metal matrix and developed using a stir casting process. Stir casting is a primary process of composite production whereby the reinforcement ingredient material is incorporated into the molten metal by stirring. The triple particle size (TPS) composite consist of SiC of three different sizes viz., coarse, intermediate and fine. The solution heat treatment was done on as cast (AC) composite at 540 0C for four hours followed by precipitation treatment. The wear test was carried out using a pin-on-disc type tribo-test machine under dry sliding condition. A mathematical analysis was also done for power factor values based on wear and friction results. The wear morphology of the damaged surface was also studied using optical microscope and scanning electron microscope (SEM) in this investigation. Findings- The test results showed that heat treated composite exhibited better wear resistance properties compared to as cast composite. It is anticipated that heat treatment could be an effective method of optimizing the wear resistance properties of the developed Al-MMC material

Energy efficient lighter weight aluminium matrix composite automotive brake motor

With 75 percent of fuel consumption relating directly to vehicle weight, potential weight reductions that can result in improved performance ratio and reduce CO2 emissions stimulate the application of lightweight materials. The substitution of aluminium matrix composite (AMC) for structural component of brake rotor is quite effective in lightening, energy efficiency and hence mitigation of global warming. Mathematical models are used to evaluate the influence of light weight material on energy and the environment. This study attempts to predict the effect of weight reduction on energy consumption and CO2 emissions by replacing conventional materials for light weight AMC. The study found that a weight savings of 50 to 60% from the AMC brake rotor can translate to an energy savings of 16-18% in energy usage and hence reduction in CO2 emission in the environment. This study will facilitate a cleaner and healthier environment for human life in the society

Tribological properties of surface coated duplex stainless steel containing SiC ceramic particles

This paper presents an experimental investigation on the tribological properties of coated duplex stainless steel (DSS) containing SiC ceramic particles. The preplaced SiC powder with 20 µm particle size and TIG torch surfacing was conducted with energy inputs of 480, 768 and 1440 J/mm. The comparisons of the room temperature wear behavior of substrate DSS and coated SiC duplex stainless steel was carried out against alumina ceramic ball. The effects of the process parameters on the hardness and wear behavior were analyzed in this study. The coated surface of DSS produced hardness about 2~4 times higher than uncoated DSS. It was revealed that coated surface was improved significantly with lower wear weight loss and coefficient of friction (about 2 times lower) than the substrate material. The embedded SiC into the surface of steel has improved the wear behaviour of DSS. This is due to SiC dendrites structure that strongly bonded to the steel resulting the reduction of the friction between coated surface and the alumina ball. The wear worn surface was observed under SEM with a very mild abrasive wear for coated surface compared to severe abrasive wear for substrate DSS surface. The coated surface has showed lower surface roughness and wear depth penetration indicated that the presence of the SiC reduced the wear of the material