ORCID Profile
0000-0003-1623-5317
Current Organisation
Air University
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Publisher: MDPI AG
Date: 30-08-2021
DOI: 10.3390/PR9091547
Abstract: Selective laser melting (SLM), a metal powder fusion additive manufacturing process, has the potential to manufacture complex components for aerospace and biomedical implants. Large-scale adaptation of these technologies is h ered due to the presence of defects such as porosity and part distortion. Nonuniform melt pool size is a major cause of these defects. The melt pool size changes due to heat from the previous powder bed tracks. In this work, the effect of heat sourced from neighbouring tracks was modelled and feedback control was designed. The objective of control is to regulate the melt pool cross-sectional area rejecting the effect of heat from neighbouring tracks within a layer of the powder bed. The SLM process’s thermal model was developed using the energy balance of lumped melt pool volume. The disturbing heat from neighbouring tracks was modelled as the initial temperature of the melt pool. Combining the thermal model with disturbance model resulted in a nonlinear model describing melt pool evolution. The PID, a classical feedback control approach, was used to minimize the effect of intertrack disturbance on the melt pool area. The controller was tuned for the desired melt pool area in a known environment. Simulation results revealed that the proposed controller regulated the desired melt pool area during the scan of multiple tracks of a powder layer within 16 milliseconds and within a length of 0.04 mm reducing laser power by 10% approximately in five tracks. This reduced the chance of pore formation. Hence, it enhances the quality of components manufactured using the SLM process, reducing defects.
Publisher: MDPI AG
Date: 05-05-2021
DOI: 10.3390/EN14092642
Abstract: The process of material removal from a workpiece to obtain the desired shape is termed machining. Present-day material removal technologies have high spindle speeds and thus allow quick material removal. These high-speed spindles are highly exposed to vibrations and, as a result, the accuracy of the final workpiece’s dimensions is compromised. To overcome this problem, the motion of the tool is restricted, and multiple degrees of freedom are given through the motion of the workpiece in different axes. A machining bed configured as a parallel manipulator capable of giving six degrees of freedom (DOF) to the workpiece is proposed in this regard. However, the proposed six DOF machining bed should be energy efficient to avoid an increase in machining cost. The benefit of using the proposed configuration is a reduction in dimensional error and computational time which, as a result, reduces the energy utilization, vibrations, and machining time in practice. This paper presents kinematics, dynamics and energy efficiency models, and the development of the proposed configuration of the machining bed. The energy efficiency model is derived from the dynamics model. The models are verified in simulation and experimentally. To minimize error and computation time, a PID controller is also designed and tested in simulation as well as experimentally. The resulting energy efficiency is also analyzed. The results verify the efficacy of the proposed configuration of the machining bed, minimizing position error to 2% and reducing computation time by 27%, hence reducing the energy consumption and enhancing the energy efficiency by 60%.
Publisher: MDPI AG
Date: 29-04-2021
DOI: 10.3390/EN14092565
Abstract: As non-renewable conventional fossil fuel sources are depleting day by day, researchers are continually finding new ways of producing and utilizing alternative, renewable, and reliable fuels. Due to conventional technologies, the environment has been degraded seriously, which profoundly impacts life on earth. To reduce the emissions caused by running the compression ignition engines, waste cooking oil (WCO) biodiesel is one of the best alternative fuels locally available in all parts of the world. Different study results are reviewed with a clear focus on combustion, performance, and emission characteristics, and the impact on engine durability. Moreover, the environmental and economic impacts are also reviewed in this study. When determining the combustion characteristics of WCO biodiesel, the cylinder peak pressure value increases and the heat release rate and ignition delay period decreases. In performance characteristics, brake-specific fuel consumption increases while brake-specific energy consumption, brake power, and torque decrease. WCO biodiesel cuts down the emissions value by 85% due to decreased hydrocarbon, SO2, CO, and smoke emissions in the exhaust that will effectively save the environment. However, CO2 and NOx generally increase when compared to diesel. The overall economic impact of production on the utilization of this resource is also elaborated. The results show that the use of WCO biodiesel is technically, economically, environmentally, and tribologically appropriate for any diesel engine.
No related grants have been discovered for Hafiz Zia Ur Rehman.