CAD/CAM, Robotics and Factories of the Future (eBook)

Dr. Dipak K. Mandal Dr Mandal completed his Master’s Degree in Heat Power Engineering from Bengal Engineering and Science University, Shibpur, West Bengal in the year 1999. He obtained his Ph.D in the year of 2010 from the same university. He is currently  Associate Professor and Head of Mechanical Engineering Department at the College of Engineering and Management, Kolaghat, West Bengal. He has worked at the Kolaghat Thermal Power plant. His research fields are computational fluid dynamics and bio-fluid dynamics. He has published several papers in international journals and conference proceedings. He has authored 1 book and is a regular reviewer for several journals. Professor Chanan S. Syan Dr Syan graduated from the University of Bradford, UK in 1983 with a BEng (Hons) in Mechanical Engineering. In 1988 he obtained a doctorate from the University of Hull, UK in Artificial Intelligence in Design for Manufacture. He has over 15 years of industrial experience and over 28 years of academic experience. Presently, he is head of Production Engineering and Management Office (postgraduate office), Leader of Graduate Programmes and Professor at the University of the West Indies. His research specializations include – Brain Computer Interface (BCI), Manufacturing, Design and Manufacture, and Asset Management. He is heading the BCI and Robotics and Automation research groups.

Preface 6
Acknowledgements 7
Contents 8
About the Conference 16
About the Editors 17
1 Design and Development of a Low Cost Automation Injection Molding Machine of 250 g Capacity Using Microcontroller 18
Abstract 18
1 Introduction 18
2 Embedded System 19
3 Interfacing of Driver Circuit with Microcontroller for PC Based Control 22
4 Manual Control 24
5 Conclusion 28
6 Discussion 28
References 28
2 Design, Development and Testing of a Three Component Lathe Tool Dynamometer Using Resistance Strain Gauges 30
Abstract 30
1 Introduction 30
2 Literature Review 31
2.1 Cutting Force Measurement 31
3 Design and Building of a Resistance Strain Gauge Based Dynamometer for Lathe 32
3.1 Fundamental Design Requirement for Dynamometer 32
3.2 Design Standards and Material of Dynamometer 33
3.3 Determination of Measurements of the Cylindrical Bar 33
4 Materials and Method 34
4.1 Dynamometer 35
4.2 Data Acquisition 35
4.3 Estimating Various Parameters Related to Strain Gauges 35
5 Calibrations 36
5.1 Stationary Correction of the Dynamometer 36
6 Conclusion 37
References 38
3 Study of Laser Transmission Welding Process Using a Volumetric Heat Source Model and Experimental Analysis 39
Abstract 39
1 Introduction 40
2 Development of the Model 41
3 Experimental Validation 43
4 Results of Numerical Analyses 44
5 Experimental Investigation and Parametric Analysis 45
6 Conclusion 47
References 47
4 Comparison of Grinding Performance Under Different Eco-Friendly Environment 49
Abstract 49
1 Introduction 50
2 Experimental Procedure 51
3 Results and Discussion 52
4 Conclusion 55
References 56
5 Design of a Maintenance Optimisation Approach for Offshore Oil and Gas Production Systems 58
Abstract 58
1 Introduction 58
2 Review of Maintenance Optimisation Approaches 59
3 Optimisation Framework Review 61
4 Conclusion and Future Recommendations 64
References 64
6 Investigating the Feasibility of BCI-Based Social Media Interaction 66
Abstract 66
1 Introduction 67
2 BCI Experimental Program 67
2.1 Subject Details 67
2.2 Data Recording 68
2.3 Presentation Paradigm 68
Training Trials 68
Testing Trials 69
2.4 Signal Analysis and Pattern Classification 70
3 Results 70
4 Discussion 71
5 Conclusion 72
References 72
7 Virtual Experiments for Integrated Teaching and Learning of Robot Mechanics Using RoboAnalyzer 73
Abstract 73
1 Introduction 74
2 Overview of RoboAnalyzer 76
3 Issues in Teaching and Learning Robot Mechanics 76
3.1 Limited Access to an Actual Robot 77
3.2 Difficulty to Understand the DH Parameters and Coordinate Transformations 77
3.3 Visualizing Simulations 78
3.4 Advanced Calculations and Programming 79
4 Structured Curriculum in Robotics with Practical and Simulation Sessions 79
4.1 Virtual Experiments for an Introductory Coursework in Robotics 79
4.2 Implementation at IIT Delhi 80
5 Conclusions 81
References 82
8 Fuzzy Based Object Shape Recognition Using Translation, Rotation and Scale Invariant Parameters---An Automatic Approach 83
Abstract 83
1 Introduction 83
2 Proposed Method 84
2.1 Calculation of Object Parameters 85
2.2 Fuzzy Logic Design 86
2.3 Decision Making 86
3 Simulation Results, Comparison and Discussion 87
4 Conclusion 88
References 89
9 Need of Agriculture Hand Tool Design Using Quality and Ergonomics Principles 90
Abstract 90
1 Introduction 90
2 Literature Review 92
3 Framework Development 94
4 Discussion and Conclusion 95
References 96
10 Inverse Dynamics and Feet-Terrain Collision Model for Optimal Distribution of the Contact Forces During Crab Motion of a Hexapod Robot 98
Abstract 98
1 Introduction 99
2 Dynamic Modeling of the Robotic System 100
3 Optimization Criteria for Optimal Distribution of Joint Torques 103
4 Feet-Terrain Interaction Modeling 103
5 Case Study: Robot's Locomotion on Flat Terrain with Wave-Crab Gait (DF = 1/2) 104
6 Conclusion 107
References 107
11 Sensing Human Pulse Bit Using Ionic Polymer Metal Composite (IPMC) 109
Abstract 109
1 Introduction 109
2 Experimental 110
2.1 Fabrication of IPMC Sensor 110
2.2 Sensing Studies Using IPMC Strip 110
3 Results and Discussion 111
4 Conclusion 112
Acknowledgments 112
References 113
12 Order Reduction of Interval SISO Systems Using Least Square Methods with a Linear Shift `a' Obtained by Harmonic Mean 114
Abstract 114
1 Introduction 114
2 Proposed Procedure 115
3 Comparison with Other Existing Methods 119
4 Conclusions 123
References 124
13 Identifying and Updating the Kinematics of KUKA-iiwaR800 in CAD for Accurate Simulation 125
Abstract 125
1 Introduction 126
2 Modeling of Robot 127
2.1 Identifying CAD Model Kinematics 128
2.2 Importing CAD Assembly 128
3 Kinematic Simulation and Validation 130
4 Dynamic Simulation Results Using RA 133
5 Conclusions 135
Acknowledgments 135
References 135
14 Parametric Optimization of Link Lengths of a SCARA Robot for Deburring of Circular Paths 137
Abstract 137
1 Introduction 138
2 Summary of Mathematical Equations Used in the Analyses 140
3 Problem Formulation 141
3.1 Data Used in the Analyses Is as Follows 141
3.2 The Steps Adopted in the Analyses Are as Follows 141
4 Results and Discussions 143
5 Conclusions 145
References 145
15 Integrating Artificial Intelligence and Simulation for Controlling Steady Flow of Fixtures 146
Abstract 146
1 Introduction 146
2 Study Area Description 147
3 Artificial Intelligence and Simulation 148
4 Theoretical Framework 150
5 Conclusions and Suggestions for Future Research 154
References 155
16 Predictions of Hip and Knee Power Consumptions of Patients Having Different Body Heights and Masses During Normal Walking 157
Abstract 157
1 Introduction 157
2 Mathematical Modeling 158
3 Input-Output Modeling by Back-Propagation Neural Network 162
4 Results and Discussion 163
5 Conclusion 164
References 165
17 CFX, Static Structural Analysis of Tractor Exhaust System Based on FEA 166
Abstract 166
1 Introduction 166
2 Establishment of CAD Model 167
3 Materials Mechanical Properties 167
4 FEA Results and Discussion 169
4.1 FEA Results: CFX Pressure Effect 170
4.2 FEA Result: CFX Temperature Effect 173
4.3 FEA Result: CFX Pressure and Temperature Combined Effect 173
5 Conclusion 178
References 179
18 FEA Simulation Based Thermo-mechanical Analysis of Tractor Exhaust Manifold 180
Abstract 180
1 Introduction 180
2 Material Properties 181
3 FEA Simulation 181
4 Computation of Results 183
4.1 Static Structural Analysis 185
5 Modal Analysis 185
6 Conclusion 188
References 188
19 Stress Analysis of a Circuit Breaker Switchgear Mechanism by Using Multi Body Dynamics 189
Abstract 189
1 Introduction 190
2 Analysis Based on Theoretical Equations 191
3 Analysis by Using Multi Body Dynamic Analysis Software Adams 192
4 Results and Discussion 195
5 Conclusions 197
References 199
20 Integration of Fuzzy Logic with Response Surface Methodology for Predicting the Effect of Process Parameters on Build Time and Model Material Volume in FDM Process 200
Abstract 200
1 Introduction 201
2 Materials and Methods 202
2.1 Fused Deposition Modelling 202
2.2 Response Surface Methodology (RSM) 203
2.3 Fuzzy Logic Analysis 203
3 Experiments Conducted 204
4 Results and Discussions 206
4.1 Calculation of Responses 206
4.2 Fuzzy Logic Unit (FLU) for Build Time and Model Material Volume Prediction 206
5 Conclusion and Scope of Future Research 210
References 210
21 A Study on State of the Art Technology of Laminated Object Manufacturing (LOM) 212
Abstract 212
1 Introduction 212
2 Basic Works in LOM Development 214
3 3D Metal Printing Project 218
4 Conclusions 220
References 220
22 Design Analysis and Manufacturing of Device for Rehabilitation of Hand Fingers Based on Illusionary Movements by Tendon Vibrations 222
Abstract 222
1 Introduction 222
2 Design and Modelling 224
2.1 Design Equations 224
Cam Design 224
Circuit Design 225
2.2 Device Modelling 226
3 Simulation and Analysis on the 3D Model 227
3.1 Implementing Solidworks Stress Analysis on Parts of the 3D Model 227
3.2 Determining the Torque of the Motor by Trial and Error 228
3.3 Simulation of Actuator Control Circuits Using Proteus 8 229
4 Hardware Implementation 231
4.1 Circuit Construction 231
4.2 Device Construction 231
5 Results 232
Acknowledgments 232
23 Experimental Investigation of Process Parameters for Build Time Estimation in FDM Process Using RSM Technique 234
Abstract 234
1 Introduction 235
2 Literature Review 235
3 Build Time (BT) 236
4 Experimental Design 237
5 Results 241
6 Conclusions 244
References 245
24 Analysis of Prismatic Springs of Non-circular Coil Shape Using Finite Element Method 247
Abstract 247
1 Introduction 247
2 Deflection Analysis of Prismatic Springs with Non-circular Coil Shape 248
3 CAD Modelling of the Spring and Assembly with Base Plates 251
3.1 Assembly of the Spring with Base Plates 252
4 FEA Analysis of the Spring Assembly Using ANSYS Workbench 252
5 Comparison of Various Springs with a Common Cylindrical Spring 253
References 254
25 TiC, W2C Reinforced Ti-W MMC Coating Developed on Ti-6Al-4V Substrate Through Laser Cladding 256
Abstract 256
1 Introduction 257
2 Experimental Details 258
3 Result and Discussions 260
3.1 Microstructure Analysis 260
4 XRD Analysis 261
5 EDS Analysis 262
6 Micro-Hardness and Wear Performance 263
7 Conclusions 264
References 265
26 Motion Programming of SCORBOT ER-4u Using Fusion of Robot Kinematics and Inertial Sensor 266
Abstract 266
1 Introduction 266
2 Methodology 267
3 Experimentation 272
4 Results and Discussion 273
5 Conclusions 275
References 276
27 Trajectory Tracking Control of Three-Wheeled Omnidirectional Mobile Robot: Adaptive Sliding Mode Approach 277
Abstract 277
1 Introduction 277
2 Kinematic and Dynamic Modeling 278
3 Controller Design 281
4 Simulation Results 283
5 Conclusion 287
References 287
28 Point Mass Models for Dynamic Balancing of Industrial Manipulators Using Genetic Algorithm 289
Abstract 289
1 Introduction 290
2 Point---Mass Models 291
2.1 Seven Point---Mass Octahedron Model 291
2.2 Six Point---Mass Hexahedron Model 292
3 Optimization Problem Formulation 294
3.1 Optimality Criteria 294
3.2 Decision Variables and Constraints 294
4 Genetic Algorithm (GA) Technique 295
5 Application Illustration 296
6 Results and Discussion 296
7 Conclusion 298
References 298
29 Application of the Attractive Ellipsoid Methodology to Robust Control Design of a Class of Switched Systems 300
Abstract 300
1 Introduction 300
2 Problem Formulation and Some Basic Facts 302
3 The Attractive Ellipsoid Method 305
4 Robust Control of Automated Continuous Stirred Tank Reactor 308
5 Concluding Remarks 311
References 312
30 A Three Finger Tendon Driven Robotic Hand Design and Its Kinematics Model 314
Abstract 314
1 Introduction 315
2 Proposed Design of the Tendon Driven Robotic Hand 316
3 Kinematic Model of the Proposed Hand 317
3.1 Forward and Inverse Kinematics Solutions 318
3.2 Joint Space to Tendon Space Mapping 319
4 Illustrative Example: Results and Discussions 320
5 Conclusions 321
References 321
31 An Intelligent Methodology for Assembly Tools Selection and Assembly Sequence Optimisation 323
Abstract 323
1 Introduction 323
2 Proposed Methodology for Assembly Sequence Planning 324
2.1 Knowledge-Based System for Selection of Tools and Grippers 324
2.2 Genetic Algorithm Based Approach for Assembly Sequence Optimisation 326
Selection 327
Crossover 327
Mutation 328
Fitness Function 328
3 Illustrative Example 328
4 Results and Discussions 329
5 Conclusions 331
References 332
32 Alignment Based Inspection Framework for Additive Manufactured Parts 334
Abstract 334
1 Introduction 334
2 Methodology 335
3 Case Study 338
4 Non-Contact Digitization 338
5 Results and Discussion 340
6 Conclusion 342
References 343
33 An Investigation on Slab Milling Operation to Find Out Optimum Cutting Parameters 344
Abstract 344
1 Introduction 345
2 Materials and Methods of Experimentation 346
3 Results and Discussion 346
4 Conclusion 354
References 354
34 Recognition of Force Closed Point Grasp for 2D Object 356
Abstract 356
1 Introduction and Background 356
1.1 Frictionless Grasps on Four Edges 357
2 Proposed Methodology 361
3 Results and Discussions 362
4 Conclusions 363
References 364
35 Developing a GUI for Optimization of Acoustic Enclosure of a Compressor Chamber 365
Abstract 365
1 Introduction 366
2 Theory 367
2.1 Acoustic Enclosure 367
2.2 Parallel Baffle Muffler 368
3 Formulation for the Design of Acoustic Enclosure and Muffler 368
3.1 Design of Acoustic Enclosure 369
3.2 Design of Parallel Baffle Muffler 370
4 Problem Definition 372
4.1 Developing GUI for the Design of Enclosure and Muffler 372
5 Results and Discussions 372
6 Conclusions 375
References 375
36 A Pilot Study of Sustainable Machining Process Design in Indian Process Industry 376
Abstract 376
1 Introduction 376
2 Literature Review 377
2.1 Vegetable Based Cutting Fluid (SMPD1) 377
2.2 Utilization of Cryogenic Machining (SMPD2) 378
2.3 Machining Process Utilisation (SMPD3) 378
2.4 Waste Minimization (SMPD4) 378
2.5 Energy Efficiency During the Process (SMPD5) 379
3 Research Methodology 379
4 Data Collection and Analysis 379
5 Conclusion 381
37 Sagittal Position Analysis of Gait Cycle for a Five Link Biped Robot 383
Abstract 383
1 Introduction 383
2 Trajectory Generation 385
2.1 Science of Walking 385
2.2 Foot Trajectory 385
2.3 Hip Trajectory 387
3 Joint Profile Generation 388
3.1 Joint Trajectory in DSP 388
4 Numerical Example 389
5 Discussion 391
6 Conclusion 392
References 392
38 A Note on Mechanical Feasibility Predicate for Robotic Assembly Sequence Generation 393
Abstract 393
1 Introduction 393
2 Assumptions 394
3 Mechanical Feasibility Representation 395
4 Case Study 397
5 Validation 398
6 Conclusion 398
39 Weld Seam Tracking and Simulation of 3-Axis Robotic Arm for Performing Welding Operation in CAD Environment 401
Abstract 401
1 Introduction 401
2 Analytical Kinematic Models of 3-Axis Manipulator 402
2.1 Forward Kinematic Model 403
2.2 Inverse Kinematic Analysis 405
3 Sewing Technique for Obtaining Seam Path 406
4 Simulation of Welding Operation 407
4.1 Comparison with Previous Work 409
5 Conclusion 410
References 410
40 A Comparative Performance Analysis of Discrete Wavelet Transforms for Denoising of Medical Images 412
Abstract 412
1 Introduction 412
1.1 Discrete Wavelet Transform (DWT) 414
2 Image Denoising 414
2.1 Thresholding 415
3 Performance Analysis 416
4 Experimental Results 416
5 Conclusion 418
41 Deterministic Model for RF Hot Spots Location and Probability Within Empty Rectangular Structures 420
Abstract 420
1 Introduction 420
2 Ionizing Radiation 422
3 Non-ionizing Radiation 423
4 A Deterministic Model for RF Location 424
5 Hot Zone Areas 424
6 Hot Spot Location 425
7 Analysis 426
8 Discussion 427
9 Conclusion 428
References 429
42 Heat Stress in the Workplace: A Case Study of a Cement Manufacturing Facility in Trinidad 430
Abstract 430
1 Introduction 430
2 Literature Review 431
3 Heat Illnesses 432
4 Heat Strain 433
5 Methodology 433
6 Data Collection and Analysis 434
7 Environmental Monitoring 434
8 Characteristics of Participants 435
9 Discussion 436
10 Conclusions 437
43 Modeling and Simulation of a Near Omni-Directional Hexapod Robot 439
Abstract 439
1 Introduction 439
2 Configuration of the System 440
2.1 Kinematics of Legs 442
2.2 Gait 443
3 Simulation and Results 444
4 Conclusions and Future Work 446
References 447
44 Optimization of Vibration of Collecting Plates of Electrostatic Precipitator Through FEA 448
Abstract 448
1 Introduction 448
2 Details of ESP System 449
3 Analysis Methodologies 449
4 Load Calculations 451
5 Result and Discussion 452
6 Conclusion 452
References 452
45 Full Aperture Optical Polishing Process: Overview and Challenges 454
Abstract 454
1 Introduction 455
2 Workpiece-Polisher Interface (WPI) 456
3 Material Removal and Effects of Process Parameters 457
4 Discussion and Conclusion 460
Acknowledgments 461
References 461
46 Stability Analysis of Haptic Virtual Environment Systems for Active Interactions in Surgical Robot Simulators 464
Abstract 464
1 Introduction 464
2 Modeling of HVE Syetm 466
3 Modified Stability Model 467
3.1 Active Operator Without Time Delay 468
3.2 Active Operator with Time Delay 469
4 Simulation Studies 469
4.1 Active Operator Without Time Delay 470
4.2 Active Operator with Time Delay 470
5 Conclusions 472
References 472
47 Synchronized Optimization of Injection Moulding Parameters for Higher Acceptance of Polypropylene Products 474
Abstract 474
1 Introduction 474
2 Machining and Measuring Tabs 475
3 Process Parameters and Responses 476
4 Grey Relational Analysis 477
5 Results and Discussion 478
6 Conclusion 481
References 482
48 Use of Visual Analytics and Durometer in Risk Reduction of Foot Problems in Diabetes 483
Abstract 483
1 Introduction 483
2 Foot Ulcer 484
3 Hardness of Footwear 484
4 Durometer 485
5 Visual Analytics 486
6 Research Objective 487
7 Methodology 488
8 Results and Discussion 488
9 Conclusion 489
References 489
49 On the Complexities in Machining Titanium Alloys 491
Abstract 491
1 Introduction 491
2 Complexities Involved in Machining Titanium Alloys 492
2.1 Discontinuous Chips with Variable Thickness 492
2.2 Thermal Stress 493
2.3 Intense Mechanical Pressure on Tool 494
2.4 Elastic Bouncing Effect 494
2.5 Microstructural Alterations and Residual Stresses 495
2.6 Strong Chemical Affinity 495
2.7 Elevated Temperature Strength with Strain Hardening 496
2.8 Poor Surface Quality and Machining Parameters 496
3 Summary and Research Need 497
50 Modeling, Analysis and Trajectory Planning of a 5 Degree of Freedom Robotic Arm for a Transmission Line Crossing Robot 500
Abstract 500
1 Introduction 501
2 Modeling of the Robotic Arm 503
2.1 Kinematic Modeling 505
2.2 Inverse Kinematic Modeling 506
2.3 Workspace of the Arm 507
2.4 Dynamic Modelling 507
2.5 Trajectory Planning 508
3 Result and Discussion 509
3.1 Workspace Analysis 509
3.2 Dynamic Modeling 509
3.3 Trajectory Planning 511
4 Conclusion 512
References 513
51 Design and Modelling of Dual Faceplate Centrifugal Casting Equipment for Manufacturing of Turbine Bearing 514
Abstract 514
1 Introduction 514
2 Literature Review 515
3 Proposed Design 516
4 Design and Selection of Components 517
4.1 Selection of Motor, Gearbox and Output Shaft 517
4.2 Design of Gear and Pinion 518
4.3 Design of Shaft, Phi 90 519
4.4 Hollow Shaft at Tailstock 520
4.5 Bearing Selection for Shaft, Phi 70 520
4.6 Bearing for Shaft, Phi 90 521
4.7 Bearing for Hollow Shaft 521
4.8 Leadscrew and Gearbox to Rotate Leadscrew 522
4.9 Design of Gear and Pinion for Lead Screw 522
4.10 Halfnut 523
4.11 Bearing for Leadscrew 523
4.12 Integral Flat Slideway 523
5 Conclusion and Future Scope 523
Acknowledgments 524
References 525
52 Design and Control of Tendon Driven Robotic Hand for Prosthesis Applications 526
Abstract 526
1 Introduction 526
2 Mechanical Design and Manufacture of the Robot Hand for Upper Limb Prosthesis 527
3 MATLAB Simulation and Hardware Control Interface 529
4 Conclusion 533
53 Stabilization of Posture of Humanoid Using PID Controller in Gazebo Simulator Using Robot Operating System (ROS) 534
Abstract 534
1 Introduction 534
2 Methodology Adopted 536
3 Experiment/Test Conducted 539
4 Results and Discussion 540
5 Conclusion 541
6 Ongoing Work 542
References 543
54 Robotic Picking of Cylindrical Fuel Pellets from a Boat Using 3D Range Sensor 544
Abstract 544
1 Introduction 545
2 Related Work 545
3 Description of Bin Picking System 546
4 Methodology for Pose Estimation 547
4.1 Building Cylinder with Two Sample Points 547
4.2 RANSAC and O-RANSAC Algorithms 548
5 Results and Discussion 549
6 Conclusion 551
References 552
55 Swachh-Bharat Bot: A Sweeping Robot 553
Abstract 553
1 Introduction 553
2 Swachh-Bharat Bot: Design and Fabrication 554
3 Conclusion and Future Work 557
Acknowledgment 558
References 558
56 Force Sensitive Robotic Gripper 559
Abstract 559
1 Introduction 559
2 Implementation 560
3 The Gripper Design 562
4 The Gripper Control System Hardware 565
5 Conclusion 567
Acknowledgments 568
References 568
57 Electron Beam Melting of Steel Plates: Temperature Measurement Using Thermocouples and Prediction Through Finite Element Analysis 569
Abstract 569
1 Introduction 569
2 Mathematical Formulation 570
3 Experimental Procedure 572
4 Finite Element (FE) Analysis 573
5 Results 576
6 Conclusion and Scope for Future Work 577
References 578
58 Design and Analysis Towards Successful Development of a Tele-Operated Mobile Robot for Underground Coal Mines 579
Abstract 579
1 Introduction 580
2 Design of the Concept Model 581
3 Operation of the System 583
4 Approximate Mathematical Modeling of the Robot 584
5 Kinematic Model 585
6 Dynamic Modeling 586
7 Simulation and Analysis 587
8 Results and Discussions 588
9 Conclusion 589
Acknowledgments 591
References 591
59 Design-of-Experiments (DOE) to Compute the Effect of Chromium Abrasives in Kerosene Oil as Dielectric of EDM of OHNS Die Steel 593
Abstract 593
1 Introduction 594
2 Materials and Equipment 594
3 Experimental Procedure 595
3.1 Design of Experiments 595
3.2 Screening Formula 596
3.3 Analysis of Variance and F-Test 596
3.4 MRR Measurement 597
4 Results and Discussion 597
5 Conclusions 602
References 602
60 CFD Modeling for Slurry Flow Through Bends and Straight Pipe Line 604
Abstract 604
1 Introduction 604
2 Laboratory Setup of Experiment 605
3 Basic of Mathematical Modeling 605
4 Governing Equations for Multiphase Flow in Eulerian Model 607
4.1 Basic Continuity Equation 607
4.2 Basic Momentum Equations 607
5 Criteria of Selection of Suitable Model 607
6 Numerical Solution for Simulation 608
7 CFD Modeling Results 608
8 Conclusions 611
References 612
61 Role and Significance of Visualisation in Product Design at Prototyping Stage 613
Abstract 613
1 Introduction 613
2 New Product Development Phase (NPD) 614
2.1 Geometric Forms 615
2.2 Unity and Order 616
2.3 Physical Properties 616
2.4 Weight & Stability
2.5 Visual Balance 617
2.6 Internal Design 617
2.7 Movement 618
3 Scanning Technology for Virtual Product Realization 618
4 Advancement 619
5 Conclusion 623
References 624
62 Positional Analysis of a DC Brushed Encoder Motor Using Ziegler-Nichols Algorithm 625
Abstract 625
1 Introduction 626
2 Block Diagram of the System with the Problem Description 628
3 Hardware Description 629
3.1 Arduino Board 629
3.2 DC Encoder Motor 629
4 System Information with and Without Control Approach 630
4.1 Steady State Analysis 631
4.2 Transient Analysis of the System 631
4.3 MATLAB Simulation for Without Controller, P, PI and PID Controllers 632
4.4 Ziegler-Nichols Algorithm for P, PD and PID Controller 633
4.5 Applying Z-N Algorithm to Without Controller, P Controller, PI and PID Controller 634
5 Results and Discussion 634
6 Conclusion and Future Scope 636
References 637
63 A Hybrid Approach to Motion Planning for Stepping over and Obstacle Avoidance in Humanoids 639
Abstract 639
1 Introduction 639
2 Motion Planning 641
2.1 Stance Leg Trajectory Generation 642
2.2 Swing Leg Trajectory Generation 642
3 Optimum Step Length 643
3.1 Kinematic Modelling 644
3.2 Dynamic Analysis 645
3.3 Power Consumed and Optimum Step Length 645
4 Obstacle 646
4.1 Lateral Shift in Path Planning for Obstacles with an Axis of Revolution 647
4.2 Fuzzy Inference System 648
Rule Base 649
Hybrid Control 649
5 Conclusion and Future Scope 650
References 651
64 Web Based Simulation and Remote Triggered Laboratory for Robots 653
Abstract 653
1 Introduction 653
2 Software Tools Used 655
2.1 Back End Tools Used at Server Side 655
2.2 Front End Tools Used at Client Side 656
3 Requirements for a Typical Robotics Course 656
3.1 Puma 560 & Movemaster RM-501
3.2 Forward Kinematics of a 6R Robot Manipulator 657
3.3 Forward Kinematics of a 4R Robot Manipulator 657
3.4 Multi DOF Customized Manipulator 658
3.5 Inverse Kinematics 659
4 System Architecture of Online Simulator and Remote Triggered Lab 660
5 Implementation of Online Simulator and Remote Triggered Lab 661
6 Conclusion 664
References 665
65 Modular Robotic Assistance in Cluttered Environments: A Broad-Spectrum of Industrial Applications 666
Abstract 666
1 Introduction and Background 666
2 Modular-Design and Planning 667
2.1 Parameters Based Modular Architecture 667
2.2 Design Strategy and Assembly Planning 668
3 Multi Layer Approach to Modularity 669
4 Results and Discussion 670
5 Conclusion 673
Acknowledgements 673
References 673
66 A Benchmarking Model for Indian Service Industries 675
Abstract 675
1 Introduction 675
2 Literature 677
3 Benchmarking Classification 677
4 Analytical Network Process (ANP) 678
5 Intensity of Critical Success Factors 679
6 Implementation of Benchmarking Model 680
7 Results and Conclusions 681
References 682
67 Optimal Design of a Production System 683
Abstract 683
1 Introduction 684
2 Optimization Techniques Used 684
2.1 Genetic Algorithm 684
2.2 Simulated Annealing 685
3 Model Formulation 685
3.1 Minimize the Mean Flow Time 685
3.2 Maximize Throughput 686
3.3 Combination of Minimization of Mean Flow Time & Maximization of Throughput
4 Result and Discussion 686
4.1 Comparison Between Genetic Algorithm and Simulating Annealing 688
5 Conclusions 689
References 689
68 Modelling and Analysis of a Novel Ancillary Braking System for All Terrain Vehicle 690
Abstract 690
1 Introduction 691
2 Theoretical Consideration 691
3 Experimental 692
3.1 Rotor Modeling and Manufacturing 692
3.2 Brake System Fabrication 692
3.3 Testing 693
4 Results and Discussion 693
4.1 Brake Rotor Analysis 693
4.2 Brake Actuation Mechanism Analysis 696
4.3 Brake Performance Analysis 697
Over Steering 698
Under Steering 698
5 Conclusion 699
Acknowledgments 699
References 699
69 Nonlinear Tracking Control of Parallel Manipulator Dynamics with Intelligent Gain Tuning Scheme 700
Abstract 700
1 Introduction 700
2 Dynamics of Planar Parallel Manipulator 702
3 Design of Controllers 704
3.1 Computed Torque Control 704
3.2 Design of Hybrid Sliding Mode Control 705
3.3 Design of Intelligent Gain Tuning Technique 706
3.4 Stability Analysis 707
4 Simulations 708
4.1 Tracking Control Without External Disturbances 708
4.2 Tracking Control with External Disturbances 709
4.3 Experimental Results 711
5 Conclusions 713
References 713
70 Study of Joining Different Types of Polymers by Friction Stir Welding 715
Abstract 715
1 Introduction 715
2 Literature Review 718
2.1 Methods of Polymer Welding 718
2.2 FSW of Polymer Materials 718
Polyethylene (PE) 718
Polypropylene (PP) 719
Acrylonitrile Butadiene Styrene (ABS) 719
Polyvinyldeneflouride (PVDF) 720
Polyethylene Terephthalate Glycol (PETG) 720
Nylon (Polyamide) 720
Teflon (PTFE) 720
2.3 FSW of Polymers with Aluminium 721
3 Conclusion 721
References 722
71 Single Point Incremental Forming Using Flexible Die 724
Abstract 724
1 Introduction 724
1.1 Incremental Sheet Forming 725
1.2 Geometric Accuracy of Parts 725
2 Methodology 726
3 Experiments Conducted 727
4 Results and Discussions 728
5 Conclusions 731
Acknowledgments 731
References 731
72 Hilbert Curve Based Toolpath for FDM Process 733
Abstract 733
1 Introduction 733
2 Methodology 734
2.1 CAD Model Preparation 735
2.2 Hilbert Curve Generation 735
2.3 Part Fabrication 736
2.4 Implementation of Hilbert Curve on Object 736
2.5 Trimming the Hilbert Curve 737
2.6 CNC-Milling Assisted Fused Deposition System 739
3 Results and Discussions 740
3.1 Validation 740
4 Conclusion 740
Acknowledgments 741
References 741
73 Development of Edge Processing and Drawing Algorithms for a 6 Axis Industrial Robot 742
Abstract 742
1 Introduction 742
2 Literature Survey 743
2.1 System Design 744
Robot Manipulator 744
Flex Pendent 744
IRC 5 Controller 744
End Effectors 745
2.2 System Implementation 745
System Description 745
Problem Definition 745
Lab VIEW 745
Computer Imaging 746
Direct Acquisition Method 746
3 Results and Discussions 747
3.1 Edge Detection 747
3.2 Coordinates Transformation Algorithm 747
3.3 Conclusion and Future Enhancement 749
References 749
74 Experimental Investigation and Fuzzy Modelling of Flatness and Surface Roughness for WCB Material Using Face Milling Operation 750
Abstract 750
1 Introduction 750
2 Experimentation 751
2.1 Work Piece Material 751
2.2 Machine Tool and Cutting Tool 752
2.3 Experimental Procedure 752
2.4 Measuring Techniques 753
3 Development of Fuzzy Logic Model to Predict Flatness and Surface Roughness 753
3.1 Membership Functions of Inputs and Outputs Fuzzy Variables 754
3.2 Fuzzy Rules 754
3.3 Defuzzyfication 755
3.4 Prediction of Flatness and Surface Roughness for WCB Material 756
4 Validation of Developed Fuzzy Logic Model 756
5 Conclusion and Future Scope 757
References 757
75 A Retrospective Investigation of Different Uncertainty of Measurement Estimation Approaches 759
Abstract 759
1 Introduction 759
2 Uncertainty of Measurement 760
3 LPU Method for Uncertainty Evaluation 760
4 Limitations of LPU Approach 762
5 Monte Carlo Method 762
6 Conclusions 764
References 764
76 Design of Automatic Fuel Filling System Using a Mechatronics Approach 765
Abstract 765
1 Introduction 766
1.1 Literature Review 766
1.2 Need 767
2 Design Proposals 767
2.1 Assumptions in the Design 767
2.2 Proposed Designs 768
Proposed Design 1 768
Proposed Design 2 768
Proposed Design 3 769
Proposed Design 4 769
Proposed Design 5 770
3 Measurement of Car and Fuel Box Dimensions 771
4 Conceptual Mechanism and Working 771
4.1 Mounting of Components and Its Function in the System 772
4.2 Working Methodology of Automatic System 773
5 Conclusion and Future Scope 774
References 774
77 A Framework for Evaluation of Environmental Sustainability in Pharmaceutical Industry 776
Abstract 776
1 Introduction 776
2 Methodology 777
3 Results and Discussion 777
3.1 Environmental Metrics in Pharmaceutical Industry 777
3.2 LCA of Pharmaceutical Products 778
3.3 Framework to Evaluate Sustainability of Formulated Pharmaceutical Products 779
4 Conclusion 783
References 783
78 Aero-Structure Interaction for Mechanical Integration of HP Compressor Blades in a Gas Engine Rotor 786
Abstract 786
1 Introduction 786
2 Problem Definition, Objectives and Design Considerations 787
2.1 Problem Definition 787
2.2 Objectives 788
2.3 Design Considerations 788
3 Descriptions of Vibration Characteristics in Rotating Machines 789
3.1 Stress Stiffening 789
3.2 Spin Softening 789
3.3 Mechanical Efficiency 790
3.4 Blade Geometry 790
4 Results and Discussion 794
5 Conclusion 797
References 798
79 Appraisement of Mass Customization Capability Level Using Multi-grade Fuzzy Approach 799
Abstract 799
1 Introduction 800
2 Literature Review 800
2.1 Literature Review on Mass Customization Capability and Its Appraisement 801
2.2 Literature Review on Fuzzy Logic 802
3 Development of Conceptual Model 802
4 Appraisement of MCC Using Fuzzy Logic 804
4.1 Primary Appraisement Calculation 806
4.2 Secondary Appraisement Calculation 806
4.3 Tertiary Appraisement Calculation 807
4.4 Mass Customization Capability Index I = W x R 807
5 Results and Discussions 807
References 807
80 Analysis of Solar Ejector--Jet Refrigeration System Using Eco-Friendly Material R1234yf 809
Abstract 809
1 Introduction 809
2 Materials and Methods 811
3 Analysis 812
4 Results and Discussion 814
5 Conclusion 815
References 815
81 Numerical Investigation of Thermohydraulics Performance in Elliptical Twisted Duct Heat Exchanger 817
Abstract 817
1 Introduction 817
2 Model and Governing Equations 819
3 Numerical Solution and Boundary Conditions 821
4 Result and Discussion 822
5 Conclusion 826
References 827
82 Erratum to: TiC, W2C Reinforced Ti-W MMC Coating Developed on Ti-6Al-4V Substrate Through Laser Cladding 828
Erratum to: Chapter 25 in: D.K. Mandal and C.S. Syan (eds.), CAD/CAM, Robotics and Factoriesof the Future, Lecture Notes in Mechanical Engineering, DOI 10.1007/978-81-322-2740-3_25 828
Author Index 829