Defect detection in high pressure die casting product using image processing technology

In this thesis an Automated Visual Inspection (AVI) system for ckl'eel dL'lc'L'li"i1 ('( 111~h Pressure Die Casting (HPDC) product has been dcveloped, The sy,lelll i, l'i1;lblin~ 1(\ detect external structural defects of the product particularly for crack and Iwk. This lhesi, also describes detailed procedures based on image processing technnl,,~} IIhich include enhancement/preprocessing, segmentation, codingifeature extractinn and I III age analysis/classification/interpretation, The commercial Matlab image processing kls been used to implement these procedures, An intelligent approach based on mllrpllOlog~ and fuzzy logic is proposed to detect such structural defects on the surface. The proposed method has been implemented and tested on a number of 111'1)(' I'rllducl. The results suggest that the method provide an accurate identification tn lhe dekelS and be extended for further application, The results also suggest that the system 1I('rk lIell enough to help die casting manufacturer to improve the value or die Glsling I,rllduc\ lil;11 they can obtain from automated inspection system, A few suggestions have been discussed for future research to address the limiwlillns of this research

The Design of Door Handles for Civil Aircraft Cabin Doors Utilizing Addictive Manufacturing for Aerospace Component Manufacturing

Door handles, usually referred to as "door knobs," are the handles used to open and close a door. On a variety of doors, including the outside doors of homes and businesses, the interior doors of homes, the doors of cupboards and cabinets, and the doors of vehicles, door handles are a common fixture. There are numerous types of door knobs, each of which has a distinct function. Significant numbers of door handles, especially those made for residential and commercial doors, either incorporate latching or locking mechanisms into their design or are manufactured to be compatible with a variety of standard door latching and locking systems. Door handles can be created from a bewildering variety of materials. Brass, porcelain, cut glass, wood, and bronze are examples of various materials. The cabin doors of a civil aircraft serve as the key determinant of the user's first impression because they are the user's first point of contact with the aircraft. Doors must consequently be self-explanatory as to their operability and function. This must not represent the first manual and/or technical difficulty when entering a civil aircraft and ensure that all passengers may board the aircraft safely. The term "additive manufacturing" refers to a variety of techniques that begin with a digital 3D model and result in a three-dimensional object. During these operations, material is mixed, deposited, or created layer by layer under the computer's control. Numerous past studies and research have exclusively focused on prototypes and non-critical components when making aerospace components and parts utilizing additive manufacturing. As the technology of additive manufacturing (AM) has advanced and evolved rapidly, more research is being undertaken on the significance of replacing existing methods of producing key parts and components with AM. This research will heavily rely on SolidWorks software to replicate the existing product into a 3D model, which will then be redesigned to make it easier to produce using the additive manufacturing process so that the product can be used immediately without the need for an assembly process by eliminating all design from the component. The 3D model of the new door handles of civil aircraft designs was analyzed with SolidWorks software and found to perform better compared to the original cabin door handle in terms of the amount of displacement and the value of the safety factor

Simulation and experimental study of double holes film cooling

In the modern gas turbine, film cooling has been widely used to provide thermal protection for the external surface of the gas turbine blades. Numerous number of geometrical arrangement film cooling have been presented for the past 50 years. The main inspiration of the presented geometrical arrangements film cooling are to minimize the effect of lift off phenomena caused by the formation of the Counter Rotating Vortex Pair (CRVP) which commonly discovered in the Single Cylindrical Hole (SCH) arrangement. In order to reduce the CRVP effects, tremendous efforts from the past researchers have been made including the introduction of the Double Cylindrical Hole (DCH). The present study has made use this DCH along with the employment of several geometrical arrangements including pitch distance (POD), length between holes in streamwise direction (LoD), compound angle and upstream ramp. The evaluation of these parameters involved three different blowing ratios, M and two value of the turbulence intensities, Tu. The diameter of the cooling holes in the present study is 4.75mm which taken based on the previous study. The present study has been divided into two major studies namely experimental study and simulation study. The purpose of the experimental study is to validate the present simulation study which making use of an open end wind tunnel. As the validation process shows a good agreement results, 14 more models have been built and tested using simulation study which the total cases considered are 105. As for the result, all the considered cases of DCH shows improvement in comparison with SCH. Each of the considered geometries and flow parameters have their own effects on the film cooling effectiveness which will be elaborate in details in the further chapter. As conclusion, the simulation is having good agreement with the present experimental study and the previous study which is essential to confirm the reliability of the study. Meanwhile, all DCH shows improvement in term of film cooling effectiveness on each of blowing ratio value

Additive manufacturing cost estimation models—a classification review

With the recent evolution of additive manufacturing (AM), accurate cost prediction models are of increasing importance to assist decision-making during product development tasks. Estimating the cost is a challenging task in that it requires a vast amount of manufacturing knowledge that has to be synchronised with many aspects from design to production. As a result, various AM cost models have been developed. This review is performed with the aim of providing an overview of the costing models being developed and utilised associated with the additive manufacturing product development phases. For a better understanding in this field, it is required to become familiar with the various terminologies, perspectives, concepts, techniques, and approaches used in developing these models. It was observed that the contexts and views described during the development of the models were often targeted at specific applications as well as technologies and were classified in many ways. Accordingly, the paper compiles different aspects of the cost estimation classification technique and provides definitions of some of the key terminologies. The main motivation is to provide broad and in-depth reviews of the estimation models developed over the past three decades using a systematic classification approach. From the review, a visualisation of future insights into the AM cost-oriented estimation framework from the perspective of various AM users can be better understood

Effects of selective laser melting parameters on relative density of AlSi10Mg

Selective Laser Melting (SLM) is an advance Additive Manufacturing (AM) technique in which a component is manufacturing in a layer by layer manner by melting the top surface of a powder bed with a high intensity laser according to sliced 3D CAD data. AlSi10Mg alloy is a traditional cast alloy that is often used for die-casting. Because of its good mechanical and other properties, this alloy has been widely used in the automotive industry. In this work, the effects on the relative density is investigated for SLM-produced AlSi10Mg parts on one factor at a time (OFAT) basis by keeping constant various parameters such as laser power, scanning speed and hatching distance. It is shown that AlSi10Mg parts produced by SLM having best relative density values are at 350 watt laser power, 1650 mm/s of scanning speed and hatching distance of 0.13mm

Physical and tensile properties of treated/untreated kenaf fiber and pineapple leaf fiber

This paper investigates the effect of alkali treatment on tensile properties of kenaf (Hibiscus cannabinus) fiber and pineapple leaf fiber (PALF) for the development of yarn. Basically, to prepare the biocomposite, this project utilized short kenaf fiber as the main material. The fiber was treated with 3%, 6%, 9% and 12% of different sodium hydroxide (NaOH) concentration. The size and morphology of the obtained fibers were characterized by environmental image analyzer, and the studies showed that the treated and untreated fiber had diameter between 70-100 µm. From this study, it has been found that the tensile properties of the treated fibers for both kenaf and PALF have improved significantly as compared to untreated fibers especially at the optimum level of 6% NaOH. It is also interesting to highlight that, 6% NaOH yields the optimum concentration of NaOH for the chemical treatment

Characteristic of pineapple leaf fibre using different methods at minimum level with the assist of mechanical breaker

Pineapple cultivation has resulted in wastage of pineapple leaf fibre (PALF) where it can be used as renewable natural resources. PALF is able to be used in various textile and non-textile products. However, to gain fibre as raw material requires suitable processing methods. Several methods were used in this experiment to identify suitable process using minimal resources. There were four methods used to produce open PALF which are unchanged extracted PALF, unchanged extracted PALF and going through PALF breaker, extracted PALF going water retting for 4 days and extracted PALF treated with 1% NaOH and going through PALF breaker. All PALFs were opened using Shirley Trash Analyser, and analysed by looking at its trash and microscopy. The results found that the assist of water retting and NaOH treatment and going through PALF breaker give better results for textile and non-textile application

The Thermal Effect of Variate Cross-Sectional Profile on Conformal Cooling Channels in Plastic Injection Moulding

Cooling system is an important role in designing a productive plastic injection moulding (PIM). The selection of geometry and layout for plastic injection moulding cooling channels strongly influences the cooling performance such as cooling time and thermal distribution that leads to shrinkage and warpage. This paper presents the study to determine the best cooling channel layout and cross-sectional profile which include circular straight drilled cooling channels, circular conformal cooling channels, square shape conformal cooling channels, elliptical conformal cooling channels and diamond conformal cooling channels. The cooling time and thermal distribution were simulated by Moldflow Insight (MFI) software. Results are presented based on ejection time and temperature variation by using transient analysis in MFI. The results found the best cross-sectional of cooling channels indicated by square shape conformal cooling channels, compare to others due to the shortest cooling time that recorded from simulation. The conformal cooling channel layout also resulted greater thermal distribution compared to straight drilled cooling channel design. Â

Overhang Analysis Fabricated Using Fused Deposition Modeling Technique

Additive manufacturing (AM) is a process using layer by layer additive technique to fabricate the entire 3D models into a functional component. One of the most popular AM technology is fused deposition modeling (FDM) that utilizes thermoplastic filaments as the materials. AM has the ability to produce complex structure easily without additional tool and fixture, therefore, it can save the overall manufacturing process. However, without optimum design and parameter settings, FDM has a limitation in printing overhang structures. Therefore, this study aims to analyze three types of pass-fail overhang features which are draft angle, overhang length and overhang angle varied accordingly to their respective length and angle. These pass-fail features were fabricated using the FDM 3D printer with standardized 3D printing parameters. The dimensional accuracy of these features was evaluated using an image analyzer. The results showed that the allowable overhang length to be produced is starting from the length of 0.5 mm to 1.5 mm. Meanwhile, for the draft and overhang angles, the allowable angle to be produced is ≥ 50.00 mm and ≤ 45.00 mm, respectively. From this study, it highlights the limitations of the overhang pass-fail features and provide the designer with the design information to help them designing the optimal design solution using FDM

Overhang analysis fabricated using fused deposition modelling technique

Additive manufacturing (AM) is a process using layer by layer additive technique to fabricate the entire 3D models into a functional component. One of the most popular AM technology is fused deposition modeling (FDM) that utilizes thermoplastic filaments as the materials. AM has the ability to produce complex structure easily without additional tool and fixture, therefore, it can save the overall manufacturing process. However, without optimum design and parameter settings, FDM has a limitation in printing overhang structures. Therefore, this study aims to analyze three types of pass-fail overhang features which are draft angle, overhang length and overhang angle varied accordingly to their respective length and angle. These pass-fail features were fabricated using the FDM 3D printer with standardized 3D printing parameters. The dimensional accuracy of these features was evaluated using an image analyzer. The results showed that the allowable overhang length to be produced is starting from the length of 0.5 mm to 1.5 mm. Meanwhile, for the draft and overhang angles, the allowable angle to be produced is ≥ 50.00 mm and ≤ 45.00 mm, respectively. From this study, it highlights the limitations of the overhang pass-fail features and provide the designer with the design information to help them designing the optimal design solution using FDM