Sathish Kumar | Anna University(Chennai) (original) (raw)

Papers by Sathish Kumar

SAE Technical Paper Series, 2019

T he present work promotes a hybrid composite brake disc for thermal and structural analysis of a... more T he present work promotes a hybrid composite brake disc for thermal and structural analysis of a formula vehicle. In order to reduce the un-sprung weight without compromising the strength, hybrid composite materials were incorporated in the disc plates of the braking system. In the disk brake system, the disc is a major part of a device used for slowing or stopping the rotation of a wheel. Repetitive braking of the vehicle leads to heat generation during each braking condition. Based on the practical understanding the brake disc was remodeled with unique slotting patterns and grooves, using the selected aluminium alloy of (AA8081) with reinforcement particle of 15wt% Silicon carbide (SiC) and 3wt% Graphite (Gr) as a hybrid composite material for this proposed work. By varying slotting pattern and groove angles the transient thermal and structural analysis using ANSYS workbench on the hybrid composite disc plate of disk brake is done. The main purpose of this study is to analyse the ther-momechanical behavior of composite brake disc for a formula vehicle under severe braking conditions. To ensure the braking conditions, the coupled field analysis is done on the disk brake to determine the deformation and the Von Mises stress developed in the disc for both solid disk and disk provided with multiple ventilations (slotting patterns and grooves angles) using the hybrid composite material to improve the performance of the brake disc. Hence the best suitable design of disc plate with the hybrid composite material is recommended based on the performance, strength and rigidity criteria. Also, it will be recommended for fabrication and real-time usage in formula vehicles.

SAE Technical Paper series, 2019

The suspension is an indispensable element of automobiles which plays a crucial role in maintaini... more The suspension is an indispensable element of automobiles which plays a crucial role in maintaining stability and the ride comfort. Helical springs are used in automobile suspension for many decades. The stiffness of the spring and presence of shock absorber plays a major role while negotiating a huge amount of load. Therefore, the cost of the suspension increases proportionally in commercial vehicles. In this present work, a helical and wave spring is designed and static cum dynamic analysis is done by using ANSYS 18.1 for comparing their performance and to eliminate the downside of the suspension. The geometry of the helical spring is designed using the helix curve and wave spring is designed using Sinusoidal equation. Modeling of both the springs is done using Solid works 2018. Chrome silicon and music wire are chosen as a spring material. The responses like stress and deflection of helical spring and wave spring for both the materials under static loads of 3000 N, 3500 N, 4000 N is obtained. Further, the dynamic analysis is conducted on both the springs under transient load conditions to obtain their responses. Output results such as total deformation and von-misses are taken in each loading condition, and the responses are compared. The results show that wave spring of chrome silicon has better properties in both static and dynamic load conditions. From the analysis, it is concluded that the use of helical spring with shock absorber system can be replaced by the newly developed chrome silicon wave spring suspension system. Due to this system incorporation in the vehicles, the free length is reduced.

SAE Technical Paper series, 2019

The connecting rod was manufactured by forging process for enhancing high tensile and compressive... more The connecting rod was manufactured by forging process for enhancing high tensile and compressive load so that it was followed by the machining process and suite the IC engine as a part of the component. The main intern of our proposed work is to manufacture a two set of
composites specimen of A356 alloy with reinforcement of 5 wt.% silicon carbide and 10 wt.% flyash processed through two different techniques like stir casting and stir cum squeeze casting route and obtain better mechanical properties. Further, the same properties were taken for modeling and analysing of the developed connecting rod model. Due
to the commercial demand, the hybrid composite materials take a vigorous role in the analysis part of the connecting rod model. The FEA analysis is done on the connecting rod for a180cc engine by using Ansys 18.1. The static analysis is done by considering four different cases by altering material library property. The output parameter such as total deformation, Von Mises stress, and maximum equivalent elastic
strain are taken in each condition. The analysed results show
that the material property of aluminium alloy A356 reinforced
with 5% SiC and 10% flyash was cast under stir cum squeeze casting condition opt better results when compared with conventional stir casted connecting rod model and also the specimen of A356 alloy with reinforcement of 5 wt.% silicon carbide and 10 wt.% flyash under stir cum squeeze casting will have better material property.A356 reinforced
with 5% SiC and 10% flyash will have better results and
higher material property when compared with previous
similar researchers. So this composites and process were
recommended for manufacturing of connecting rod for
automobile applications.

SAE Technical Paper series, 2019

The Cardinal goal of this research work is to fabricate hybrid composites of AA8011 with reinforc... more The Cardinal goal of this research work is to fabricate hybrid composites of AA8011 with reinforcement particles of Zr 2 O 3 and Al 2 O 3 which was taken in equal (5wt%) weight percentage. The hybrid composites were cast in a square shape (50x50x50 mm size) under the optimal stir casted process parametric condition, further, it was taken for the forging process. The prepared specimens were induced for uni-direction (x), bi-direction (x and y) and multi-direction (x,y, and z) forging route and the response of microhardness of 53, 68, 81 and 96 VHN were obtained respectively due to microstructural phase changes with an even distribution of particles in the matrix. Thus, the tribological properties of prepared specimens were tested using pin-on-disc Tribometer at room temperature under dry sliding condition of load 5,10,15,20 N and by adjusting the sliding speed as 266 and 531 rpm respectively. The outcomes uncovered all the specimens that the wear rate increments with an increase in load and coefficient of friction show an increase at most extreme load conditions. Wear rate increments with increment in the sliding distance and Coefficient of friction also increment in sliding speed. As a result, it was concluded that multi-directional forged hybrid metal matrix composite was far better than uni and bi-directional forging specimens. The prepared specimen was prescribed for high precision parts inferable from its better tribological executions.

SAE Technical Paper Series, 2019

The restrictor is a component which controls the mass flow of air passing to the engine. The prop... more The restrictor is a component which controls the mass flow of air passing to the engine. The proposed work focuses on design and analysis of air intake restrictor of Duke 390cc engine which is used in formula vehicles. As an constrain of this system, the air flows through a single circular throat of diameter 20mm. In past decades conventional venture nozzles were used as a restrictor but it leads to nominal press drop. A de lavel nozzle is a tube pinched in the middle, making an asymmetric hourglass shape. It is used to accelerate a higher supersonic speed in the axial direction. The main objective is to utilize De-Laval Nozzle for the minimal pressure drop. The change in pressure will increases the engine power output. The analysis is done by varying design conditions such as three levels of convergent (12,14 and 16 degrees) and three levels of divergent angles (4, 6 and 8 degrees) are taken into consideration. After numerous CFD Simulations, it is inferred that the optimal angles of 14 and 4 degrees for convergent and divergent angles have found the minimum delta pressure. On the other hand, further analysis was carried out on the throttle body valve angle of the optimal restrictor. The throttle body is the part of the air intake system that controls the amount of air that flows into an engine combustion chamber. It consists of a housing unit that contains a throttle plat (butterfly valve) that is rotated by a shaft. In this case, the four different positions such as 5, 45, 75 and 90-degree valve angles are chosen for simulation. From the analysis, the valve angle of 75 degrees is the optimal angle as it provides greater efficiency to the engine. The restrictor with the optimal angle is recommended for use in formula vehicles

Maple tree Publication House, 2019

The principle part for a vehicle suspension is the compression spring system, which is fabricated... more The principle part for a vehicle suspension is the compression spring system, which is fabricated for arresting shock impulse. Suspension system work on the principle of fluid transformation between compression and expansion cycle. Mostly the suspension system is used in motorcycles for providing better handling, prompt braking, safety, and comfort by keeping the passengers isolated from road noise, bumps, and vibration. The shock absorbers duty is to absorb or dissipate energy. In a vehicle, it reduces the effect of traveling over rough ground, leading to improved ride quality, and increase in comfort due to the substantially reduced amplitude of disturbances. In most of the cases, the spring which is used in the scooter suspension system is made up of beryllium copper, phosphor bronze and titanium, but in this research paper a scooter suspension system is designed and the designed suspension system is analyzed using ansys with different material properties. The composite material gives less deformation because of the high stiffness to load carrying capacity. So the Composite suspension system is recommended for two and three-wheeled vehicles.

Blue Eyes Intelligence Engineering & Sciences Publication, 2019

The air-fuel mixture is the important source in engine combustion, the transfer of air-fuel mixtu... more The air-fuel mixture is the important source in engine combustion, the transfer of air-fuel mixture is done by intake manifold in the intake system of the automobile. So due to improving the efficiency of the engine most of the automobile manufacturing industry is mainly focused on the intake manifold design for better performance. This project investigates about flow analysis taken in the different cross-section of an intake manifold. The main goal of our work is to change the cross-section of the intake manifold and analysis the model. In this paper, the manifold is designed by considering two different cross-section one is the circular outlet and the other is the convergent-divergent outlet and the created model is analyzed. The flow analysis is carried by using CFD and the values are compared and the best cross-section is concluded. The manifold with a convergent-divergent outlet has high velocity when compared with the circular outlet. The intake manifold can be used in automobile industries.

The Engine is one of the important component in an automobile which is subjected to high temperat... more The Engine is one of the important component in an automobile which is subjected to high temperature and thermal stresses. In order to cool the engine the fins are another component which are used to dissipate the heat from the Engine. Fins are generally used to increase the heat transfer rate from the system to the surroundings. By doing computational flow analysis on the engine cooling fins, it is helpful to know about the heat dissipation rate and the Principle implemented in this project is to increase the heat transfer rate, so in this analysis, the fins are modified by putting different types of notches and are of same material. The knowledge of efficiency and effectiveness of the fins are necessary for proper designing of fins. The main objective of our
analysis is to determine the flow of heat at various notches available and the analysis is done by using ANSYS – CFD Fluent software.

The use of methods serving for determination of metallurgical, foundry and other causes of castin... more The use of methods serving for determination of metallurgical, foundry and other causes of casting defects is an inseparable part of the complex system of securing the production of high quality castings. Expert systems become a powerful tool for foundry men for identification, analysis and diagnosis of casting defects and they are also one of several possibilities how to secure higher quality of castings and lower costs for rejects. At present casting defect analysis, diagnosis and reventions are carried out using Knowledge based engineering module, WebCADAS, ESVOD, etc. In this paper an attempt has been made to list different expert systems for casting defects analysis, diagnosis and preventions. This paper also aims to provide correct guideline to quality control department to identify casting defects which are not desirable.

Keywords: ESVOD, WebCADAS, Web-based systems, analysis, diagnosis

ABSTRACT The objective of this work is to automate the conventional power hacksaw machine in orde... more ABSTRACT
The objective of this work is to automate the conventional power hacksaw machine in order to achieve high productivity of workpieces than the power hacksaw machine using pneumatic power. Pneumatic is a huge topic of science and engineering dealing with the mechanical properties of air. In our project we take this pneumatic and a hacksaw for cutting purpose, The pneumatic reciprocating high-speed hacksaw machine has an advantage of working in high pressure , the hacksaw used in this is reciprocate such that required shape can be cutted according to the requirement. The hacksaw is the metal cutting machine tool designed to cut metal by applying pneumatic pressure. Hacksaws are used to cut thin and soft metals the operation of the unit is simplified to a few simple operations involving a cylinder block and piston arrangement. There are numerous systems in hacksaw machine .

Key Words: Automation, power hacksaw, Solenoid valve, Pneumatic cylinder and Pneumatics .

Nano machines play a major role in the country development. Now a day’s nano are most faster tech... more Nano machines play a major role in the country development. Now a day’s nano are most faster technology in the developing country. So the uses of nano machines are most important in the faster world. The nano machines are very small in size and it can be used for various fields. And because of the very small size it’s working speed is high. So when we manufacture machines in nano size we can achieve most accuracy and easy production. Since the nano machines are using the planet's resources as raw material with which to replicate, the danger is that the planet could
eventually be transformed into a seething mass of nanomachines.

Keywords:
Nanotechnology, IC engine, Nano spanner, Backplate Potential applications

In this paper we have improved OEE (Overall Equipment Effectiveness) by using Kaizen methodology ... more In this paper we have improved OEE (Overall Equipment Effectiveness) by using Kaizen methodology and we use different layout to improve the productivity in the manufacturing industry by embellishing the concepts of TPM. Today the competition has been increased dramatically, customers focused on quality of product. Because of these, the organization should introduce a quality and productivity continuously. The OEEE is product of equipment availability, performance efficiency of process and quality performance of manufacturing operations. This research aims to improve the plant layout of manufacturing industries to make the optimum space utilization, eliminate the rejection of components and thus by increasing the maximum productivity. The suitable new plant layout eliminates the transportation waste and improves the material flow, which in turn increases the productivity.

Keywords— Plant layout, Total productive maintenance, Overall Equipment Effectiveness, Performance efficiency

The purpose of this research is to apply the lean tools towards reduction of lead time in a compr... more The purpose of this research is to apply the lean tools towards reduction of lead time in a compressor manufacturing industry. The study is done on the 2 Hp air compressors. Value stream mapping (VSM) technique is applied in order to create an overview of the entire production flow in manufacturing process, visualize non value added activities and identify process waste. Then suitable Lean tool is used to eliminate the non value added activities. The standard operating procedure is developed and training is given to operators. Line balancing technique is used to
balance the total work content among different work stations. It is concluded that with the implementation of lean tools, lead time is reduced and overall equipment effectiveness is improved.

KEYWORDS: VSM, Kaizen, 5S, Overall equipment effectiveness, Lead time, Line balancing.

The project is mainly concentrated about the analysis of a shaft with the help of a ANSYS softwar... more The project is mainly concentrated about the analysis of a shaft with the help of a ANSYS software under workbench. In this the shaft is taken from the head stock of the lathe machine. In this analysis the shaft is connected with bearing and gear. This is the major important component to be taken into account while designing. The objective is to build a model and assemble the part files and to analyze the various stress and deformation. The part files and assembly are done by using CREO software and the analyzing are done by using a ANSYS software. The static analysis is used to analyze the stress and deformation of the shaft when it is subjected to a particular load and the modal analyze is executed to govern
the vibration features (mode shapes and natural frequencies) of shaft. The results obtained by the stress analysis is found to be good agreement and modal analysis i.e., vibration characteristic like frequency and mode shapes are presented are
within the limit

Keywords: shaft, bearing, gear and pinion, static stress analysis, FEA, CREO, modal analysis, natural frequency, mode shapes.

Lean manufacturing is a process of eliminating non value added activities in an Industry. Non val... more Lean manufacturing is a process of eliminating non value added activities in an Industry. Non value added activities (NVA) are the activities, which does not add values to the products made in the industry. Industry uses either lean team or external lean consultant to carry out the lean manufacturing process. Lean
manufacturing software is a web based application which helps the lean team as well as lean consultant to carry out their process in faster, reliable way of approaching their results. The Database Management System connected to web application stores, calculate and manipulate the data which are collected from data
collection process and provide statistical data output which are further carried to decision phase by the lean team. An idea to make the lean implementation process
go lean.

Keywords—Value stream mapping, Process flow Analysis, Value added ratio, Overall Equipment Effectiveness, Database Management System, Asp.Net.

In this Paper the stress distribution is evaluated on the four stroke engine piston by using FEA.... more In this Paper the stress distribution is evaluated on the four stroke engine piston by using FEA. The finite element analysis is performed by using FEA software. The couple field analysis is carried out to calculate stresses and deflection due to thermal loads and gas pressure. These stresses will be calculated for two different materials. The results are compared for all the two materials and the best one is proposed. The materials used in this project are aluminium alloy, and SiC reinforced ZrB2 composite material. In this project the natural frequency and Vibration mode of the piston and rings were also obtained and its vibration characteristics are analyzed. With using computer aided design (CAD), CREO software the structural model of a piston will be developed. Furthermore, the finite element analysis performed with using software ANSYS. SiC reinforced ZrB2 : Silicon carbide reinforced Zirconium diboride is a ceramic matrix composite (CMC) material is also used.

Keywords - Stress distribution, Four stroke engine piston, Finite element analysis, Aluminium alloy and SiC, Natural frequency, Vibration mode, Computer aided design (CAD), Ceramic matrix composite (CMC) material, Ansys.

The OHTC (Over Head Travelling Cleaner) is a textile cleaning unit which is used in all textile f... more The OHTC (Over Head Travelling Cleaner) is a textile cleaning unit which is used in all textile frames such as spinning, speed frame, weaving, roving, winding etc. The main function of the OHTC unit is used to clean the cotton waste, bluffs and prevents them entering into the frames of
the machines to produce fine threads for different application purpose. The Belt Shifter assembly is considered as the heart of OHTC unit, which is used to shift the belt frequently for to and fro motion of the unit. Polyurethane is the material used in Belt shifter unit. Material breakage, breakdown of the whole unit, frequent belt damage are some of the problems faced in using the polyurethane material. The analysis of the above material was carried out based on the properties
and some design modification was done. A new material (Nylon) was selected based on the drawback of the old material and design modification was done on the material for rigidity and strength to resist high shear stress on the material. The 3-D modeling was carried out by CATIA V5R20 the analysis of shear force between the belt shifter and the reversing spring were carried out by means of ANSYS 14.5.

Key Words:
OHTC, PU,Nylon,Weaving,Roving.

Books by Sathish Kumar

Lap Lambert Academic Publication, 2018

The Engine is one of the important component in an automobile which is subjected to high temperat... more The Engine is one of the important component in an automobile which is subjected to high temperature and thermal stresses. In order to cool the engine the fins are only component which are used to dissipate the heat from the Engine. Fins are generally used to increase the heat transfer rate from the system to the surroundings. By doing computational flow analysis on the engine cooling fins, it is helpful to know about the heat dissipation rate and the Principle implemented in this project is to increase the heat transfer rate, so in this analysis, the fins are modified by putting different types of notches and are of same material. The knowledge of efficiency and effectiveness of the fins are necessary for proper designing of fins. The main objective of our analysis is to determine the flow of heat at various notches available and the analysis is done by using ANSYS – CFD Fluent software.