Indo-American Journal of Mechanical Engineering
• Editor- In-Chief: Dr. Wang Chao • Title proper: Indo-American Journal of Mechanical Engineering • Subject: Mechanical Engineering • Publisher: Unicorn Publications • Dates of publication: 2019 • Frequency: Quarterly • ISSN : 2321-9416 • Language: English • Country: India • Medium: Online • Indexed by: CROSSREF • Indexed by: ROAD • Indexed by: THE KEEPERS • Title DOI of the Journal: http://doi.org/10.62645/issn.2321-9416
NUMERICAL INVESTIGATION OF ROTOR–BRAKE ASSEMBLY USING CYCLIC SYMMETRY TECHNIQUES
Brake rotor–pad assemblies exhibit complex vibration behavior due to frictional contact, thermo- mechanical loading, and rotational periodicity. In this study, a quarter-sector finite element model of a rotor–brake assembly is developed using cyclic symmetry theory in ANSYS Mechanical 2025 R2. A sequential multiphysics workflow is implemented, linking steady-state thermal analysis, nonlinear static structural analysis, and pre-stressed modal analysis. Three prestress states corresponding to near contact, sliding, and sticking conditions are examined. The results demonstrate that increasing contact engagement significantly modifies stiffness distribution and shifts natural frequencies. Harmonic index-based modal classification reveals the influence of frictional constraints on symmetric and anti-symmetric mode shapes.
SIMULATION OF BONDED/BREAKABLE CONTACTS IN PCB DROP TEST USING EXPLICIT DYNAMICS
Modeling and simulation of board-level drop tests were conducted for a Flip Chip on Board (FCOB) assembly. The printed circuit board (PCB) specimen measured 185 mm × 150 mm and included large (8 mm × 8 mm) and small (3 mm × 3 mm) flip chips mounted with underfill encapsulation. The PCB was clamped at two edges and subjected to a free-fall drop of 1 meter using a shock test machine. Experimental measurements were obtained using a high-speed camera, accelerometer, and strain gauges. Finite Element Analysis (FEA) was performed using explicit dynamics in ANSYS 2025 R2. Two simulation approaches were implemented: a stress-based breakable model and a non-breakable bonded model. The numerical results were compared with experimental data in terms of displacement, strain, acceleration, and equivalent stress. The study demonstrates that explicit dynamic simulation provides accurate prediction of PCB response during drop impact and allows modeling of bonded and breakable contacts effectively.
PHASE-CHANGE ANALYSIS OF ALUMINIUM FLYWHEEL CASTING USING THERMAL ANALYSIS
Solidification behavior significantly influences the structural integrity and defect formation in cast components. This study presents a transient finite element simulation of the solidification of an aluminum flywheel casting within a sand mold using ANSYS Mechanical (Transient Thermal). A two-dimensional axisymmetric model is employed to represent the rotational symmetry of the flywheel geometry, reducing computational effort while preserving physical accuracy. The enthalpy-based formulation is used to incorporate latent heat effects within a narrow mushy zone (695–697 °C). Temperature evolution, solidification time, and spatial progression of the solid– liquid interface are analyzed.
NON-NEWTONIAN FLOW ANALYSIS OF 3D BLOW MOLDING OF PLASTIC BOTTLES USING POLYFLOW
Blow molding is a widely used manufacturing process for producing hollow plastic products such as bottles and containers. Accurate prediction of wall thickness distribution is critical for ensuring mechanical integrity while minimizing material usage. This study presents a numerical investigation of the stretch–blow molding process of polyethylene terephthalate (PET) bottles using finite element analysis. A time-dependent, non-Newtonian flow model is developed using ANSYS Polyflow, incorporating Lagrangian mesh tracking, contact modeling, and penalty-based mold interaction. Both 2D axisymmetric and 3D shell-based simulations are performed to evaluate deformation behavior, velocity distribution, and final wall thickness. The results demonstrate good agreement with experimentally observed thickness trends and identify critical thinning regions near the bottle shoulder and edges. The proposed approach provides a reliable framework for optimizing preform geometry and process parameters to achieve defect-free bottle production.
LARGE DEFORMATION ANALYSIS OF A RUBBER BOOT SEAL USING NONLINEAR STATIC FINITE ELEMENT METHODS
Rubber boot seals are critical components in mechanical and automotive systems, where they must accommodate large axial and torsional deformations while maintaining reliable sealing performance. This study presents a nonlinear static finite element analysis of a rubber boot seal assembled over a cylindrical shaft. A half-symmetry three-dimensional model is developed in ANSYS Mechanical to capture geometric, material, and contact nonlinearities. The rubber material is modeled using a Neo-Hookean hyperelastic formulation to represent large elastic strains, while the shaft is idealized as a rigid body. Three contact regions are defined: a rigid–flexible frictional interface between the boot and shaft, and two self-contact regions on the inner and outer boot surfaces. The analysis is conducted in three sequential load steps: interference fit, axial compression, and combined axial compression with shaft rotation. Results demonstrate significant nonlinear deformation, stress concentration near geometric transitions and contact regions, and strong coupling between frictional contact and hyperelastic material response. The study confirms the necessity of advanced nonlinear modeling techniques for realistic prediction of rubber sealing performance.
HIGH-VELOCITY BIRD STRIKE ANALYSIS ON AIRCRAFT LEADING EDGE USING SPH METHOD
Bird strike poses a major threat to aircraft structural integrity, particularly during takeoff and landing phases. At high impact velocities, a bird behaves as a soft hydrodynamic body rather than an elastic solid, producing high-intensity, short-duration loads on aircraft structures. This study investigates high-velocity bird strike impact on an aircraft leading edge structure using the Smooth Particle Hydrodynamics (SPH) method. Numerical simulations are performed using ANSYS AUTODYN and explicit dynamic solvers. The bird is modeled as a soft body using an appropriate equation of state (EOS), and the leading edge is modeled using carbon fiber composite material.
FRICTIONAL CONTACT ANALYSIS OF PISTON RING– CYLINDER ASSEMBLY USING DIFFERENT MATERIAL
Friction between the piston ring and cylinder liner significantly influences engine efficiency, fuel consumption, and durability. Optimizing piston ring material and structural performance is essential to reduce frictional losses while maintaining sufficient sealing and heat transfer characteristics. This study presents a finite element-based structural and contact analysis of piston ring materials under static loading conditions using ANSYS. Three materials—Grey Cast Iron, Titanium Alloy, and Elastomer—were evaluated to determine their deformation and stress response under identical boundary and loading conditions. A three- dimensional piston ring model was developed in SpaceClaim and imported into ANSYS for structural analysis. Comparative results indicate that elastomer exhibits minimum deformation but limited structural rigidity, while grey cast iron and titanium alloy demonstrate higher stiffness and acceptable stress levels within material limits.
CFD-BASED ANALYSIS OF COMPLEX FLOW STRUCTURES IN A CENTRIFUGAL PUMP IMPELLER
This project investigates the complex internal flow behavior in centrifugal pump impellers using Computational Fluid Dynamics (CFD). Three different impeller configurations were studied by varying blade angles and rotational speeds. The impeller blade-to-blade plane was modeled and analyzed using ANSYS Fluent to evaluate velocity and pressure distribution. The design was based on required discharge and speed. Euler’s pump equation, velocity triangle analysis, slip factor, and blade blockage were incorporated into the theoretical framework. The CFD results provided detailed insight into flow deviation, reverse flow regions, and performance variation at off-design conditions.
SIMULATION OF UNDERWATER BLAST LOADING ON NAVAL SHIP STRUCTURES USING AUTODYN
Naval vessels are highly susceptible to underwater explosions (UNDEX) generated by torpedoes, mines, and depth charges. Non-contact underwater explosions produce shock wave loading, gas bubble oscillation effects, hull whipping, and structural damage. Due to the high cost and risk of full-scale experiments, numerical simulation is essential for evaluating structural response. This study presents a nonlinear explicit finite element simulation of underwater blast loading on a frigate-class naval vessel using ANSYS AUTODYN. Both the initial shock wave and secondary bubble pulsation phases are modeled, incorporating fluid–structure interaction (FSI). Material behavior is represented using the JWL equation of state for TNT and the Johnson–Cook model for ship steel. Results demonstrate that secondary bubble pulsation significantly contributes to hull whipping and structural stress development. The developed methodology provides a robust framework for naval shock-resistance design.
Generative Adversarial Networks (GANs) and large language models (LLMs) are part of the generative AI subset that has shown great promise in many areas, including image production and language translation. Detecting and preventing fraud has recently been a promising use of it.
Climate Change Impact on Agricultural Land Suitability: An Interpretable Machine Learning-Based Eurasia Case Study
Particularly in light of the impact of climate change on the usability of agricultural land, this research tackles the pressing worldwide problem of food security. Predicting the risks of land suitability deterioration and changes in irrigation patterns, which directly affect food security, is the fundamental focus of our study. The fight against hunger and malnutrition is one of the United Nations' sustainable development objectives, and this study fits in with that. Our research focuses on Central Eurasia because it is a prime example of an area dealing with distinct social and economic issues; this makes it ideal for studying how climate change affects food security.
Machine Learning based Energy Management System for Smart Buildings
Research and development on energy management in smart buildings has been of utmost importance in recent years due to the growing need for efficient and sustainable urban settings. By utilizing reinforcement learning to dynamically choose the optimal ventilation equipment (air conditioners, fans, and windows) in response to variable environmental conditions like humidity, temperature, and wind speed, this work fills a gap in the literature on energy management and improves smart building energy management. In order to train the ML model, we used reinforcement learning (RL) with a fuzzy control scoring system that took into account the device's power cost and the consequent user satisfaction as a function of weather conditions (temperature, humidity, and wind speed). In addition, case studies demonstrating its use in both normal and exceptional situations allowed an integrated simulation platform to validate the model's decision-making process.
Automated Fish Species Classification using Convolutional Neural Networks
For the sake of ecological study, fisheries management, and biodiversity conservation, it is crucial to classify fish species appropriately. In this research, we provide a new deep learning approach to automatically classifying aquatic species using convolutional neural networks (CNNs). Classification accuracy reached an astounding 92% when the suggested model was tested on a large-scale and varied dataset of fish. Computational cost and predictability are both taken into account while designing the architecture. In order to generalize, it employs more complex methods including data augmentation, batch normalization, and dropout.
Blockchain-Based Certificate Generation and Validation System for Refugees
Due to inaccurate identification, access to vital services like as education, healthcare, and employment has become more difficult as a result of the extraordinary displacement caused by the worldwide refugee crisis. There are problems with accessibility, loss, and falsification with traditional certification systems. For digital identities, this project employs MetaMask; for certificate creation, it employs the Solidity compiler on Remix IDE; and for development and testing, it employs Ganache and Truffle.
Enhancements to YOLOv5-Based Track Defect Detection
In order to keep the railway infrastructure in good repair and to guarantee the safety of train operations, track fault identification is essential. Using an upgraded version of YOLOv5, we provide a new track defect detection network (DSO-YOLO) to fix the issues with previous methods, such as missing detection, incorrect placement, and an inadequate capacity to identify small-scale objects. For better object recognition performance, this technique uses the full-dimensional dynamic convolution module ODConv and makes use of a decoupling head and a small-object detection layer, all thanks to the YOLOv5s.
Image-Based Weapon Detection Using YOLO v7
Despite the tiny size and possible ambiguity of these weapons, the continuing danger of violence involving firearms and knives is a challenge to worldwide public safety and necessitates robust detection technologies. With the goal of improving public safety in both civilian and military settings, this project aims to design a computerized system that can recognize these common weapons
Secure Cardless Financial Transactions Utilizing Machine Learning and Multi-Factor Authentication
Ensuring safe transactions is of utmost importance in today's fast-paced environment. The article delves into the topic of how cardless transactions may be made more secure by integrating AI with MFA. Machine learning is crucial because it can identify and prevent fraud activities automatically, and multi-factor authentication (MFA) provides additional levels of protection. Algorithms such as Convolutional Neural Networks and Advanced Encryption Standards are included in this study.
Data Analysis Tool that Uses Generative AI
Data analysis is a decision-support system in the age of digital transformation, playing a key role in data science and machine learning. It takes a lot of time and effort to get insights from data. Users in need of automated data insights and suggestions from machine learning models are the ones for whom the Automated Data Analyzer was designed. It is constructed using the Streamlit Python Framework and generates insights and algorithm suggestions for the provided dataset using Google Gemini.
An Artificial Intelligence Approach to Multi-Organ Transplantation and Donor Selection in Organ Procurement Organizations
As vital middlemen in the donation process, organ procurement organizations (OPOs) are an essential part of the organ transplantation industry. Despite their critical role, transparency is a major problem in the organ allocation procedure. In addition to reducing OPO efficacy, this opaqueness brings up social and ethical questions about organ allocation.
COMPARATIVE ANALYSIS ON OPTIMIZED PARAMETERS OF HYBRID ALUMINIUM AND COPPER WELDS BY TWO STEP TIG WELDING
TIG welding is well known economical metal fastening process to fulfil industrial needs of present time. Regular metal welds with similar materials can be fastened easily and proved by many researches; dissimilar family welds of making complexity in weld process because of their physical and thermal properties variation. Among that copper hybridized with B4C and aluminium with SiC to elevate the strengthening properties while joining with TIG welding. Present research focused on the hybrid metal welding using Aluma steel weld rods of Ø3mm in two step welding. Initial welding performed at 70A power for alumina side and second step attached with copper hybrid metal. Experimental results given as properties consideration of boundary conditions for simulation for different loads.The model simulated for different thermal load conditions to check the deformation of weld at weld regions.
EXPERIMENTAL INVESTIGATION AND TRIBOLOGICAL PROPERTIES OF METAL MATRIX MATERIAL USING WEAR TEST
Aluminium Metal Matrix composites founds several applications in automobile, aerospace and other engineering application due to its mechanical and tribological properties. To improve wear resistance and mechanical properties has led to design and selection of newer variants of the composite.The present investigation deal with the study of wear behaviour of Al-Sic-mg MMCs for varying reinforcement content, applied load, sliding velocity. Aluminium MMCs reinforced with three different percentages of reinforcement 5, 10, 15% wt. Sic and 3% wt.mg prepared by stir casting method. Wear test was performed by using “pin on disk” apparatus. A plan of experiment based on L9 Taguchi orthogonal array is used to acquire the wear data. An analysis of variance is employed to investigate the influence of three controlling parameters, Sic content, Normal load, sliding velocity on dry sliding wear of the composites. It is observed that Sic content, sliding velocity and normal load significantly affect the dry sliding wear. The optimal combination of the three controlling parameters is also obtained for minimum wear.
Dielectric Properties of Fly Ash-Derived Zeolite: Frequency Response and Conduction Mechanism
This study investigates the dielectric response of zeolite synthesized from fly ash, an abundant industrial byproduct, and compares its performance with conventional zeolites. Pellets prepared with silver electrodes were analyzed using impedance spectroscopy in the frequency range of 1 kHz to 1 MHz. The dielectric constant (ε′) exhibited strong frequency dependence, decreasing with increasing frequency, while the dielectric loss (tan δ) was higher at low frequencies due to space charge effects and stabilized at higher frequencies. AC conductivity (σ_ac) followed Jonscher’s universal power law, confirming hopping conduction as the dominant mechanism. Although the fly ash-derived zeolite displayed slightly lower dielectric constant and marginally higher losses than conventional zeolites A and ZSM-5, its high- frequency dielectric stability and conductivity were nearly identical. These findings demonstrate that fly ash zeolite can serve as a cost-effective, sustainable alternative to conventional zeolites for dielectric and sensor applications.
Fly-Ash-Based Zeolite Beta: A Low-Cost Material for High- Sensitivity Gas Sensors
Zeolite Beta was successfully synthesized from coal fly ash using an alkali fusion– hydrothermal method assisted by tetraethylammonium hydroxide (TEAOH) as a structure- directing agent and evaluated as a gas-sensing material. The crystalline BEA framework was confirmed by X-ray diffraction, while thin films deposited on interdigitated electrode substrates enabled electrical measurements. The fabricated sensor exhibited distinct responses to NH₃, CO₂, H₂, ethanol, and acetone vapors, with ethanol (74% ΔR/R) and ammonia (68% ΔR/R) showing the highest sensitivities. Response and recovery times ranged between 30–55 s and 55–70 s, respectively, indicating fast and reversible adsorption–desorption dynamics. The selectivity towards polar gases and VOCs highlights the role of the BEA framework’s large pore system and surface activity in gas–solid interactions. Compared with other zeolite-based sensors, the fly-ash-derived Zeolite Beta demonstrated superior performance, establishing it as a cost-effective and environmentally sustainable material for gas detection and monitoring applications.
A REVISED FOUR-POST LIFT SYSTEM FOR LIGHT-DUTY VEHICLES: DESIGN AND ANALYSIS
In terms of progress and improvement for any organization, the worth of a human life cannot be understated. Standard and proper tools and equipment are used in several businesses, garages, and workshops to guarantee the safe, effective, and quick completion of tasks while also preventing injuries and fatalities. The use of a car lift is essential for the majority of automotive repair, maintenance, and service tasks. These lifts eliminate back pain, prevent injuries, and make workers more efficient and timely. This paper details the planning and evaluation of an upgraded four-pole lift system that will raise the vehicles off the ground in a safe and efficient manner, allowing access to their undercarriages and bringing them to a more comfortable working height for the operators. Among the many innovative features and capabilities included in the design is the ability to tilt the vehicle from either the front or the back, raise the whole vehicle, or lift either the front or rear end. Additionally, there is a simple mechanical lock at each pole. The device's efficacy in lifting weights up to 7 tons was determined by comparative study after the necessary load capacity and preferred materials—structural steel, cast iron, and carbon steel—were determined. According to the findings of the design's static structural analysis, the corresponding Von-Misses stresses for structural steel, cast iron, and annealed carbon steel are 50.4MPa, 66.9MPa, and 51.4MPa, respectively. When compared to cast iron, structural steel and carbon steel 1020 annealed have the lowest deformation values. Following the imposition of maximum loads without failure that exceed the rated load of light-duty vehicles, the unit is deemed safe for operation.
Four-Post Lift. Redesign, Material Failure, Stress, Deformation, Light- Duty Vehicle
Using finite element analysis, we investigate jute-based composites to learn more about the synergy of natural fiber reinforcement in composite materials.
Composite components made from natural fibers and fillers are all the rage now since they are strong, lightweight, easy to acquire, and good for the environment. In this study, the tensile properties of jute-based composites at various filler content compositions (0, 2.5, 5, 7.5, 10, and 12.5 wt.%) are evaluated using Finite Element Analysis (FEA). This research uses ANSYS R121 software to correlate computational findings with experimental data, proving that FEA is effective in predicting material changes under different conditions. Research shows that jute particle composites (JPC) have an increasing tensile strength with increasing filler content up to a certain limit, but thereafter their strength drops due to reduced stress transfer efficiency. Jute has the ability to compete with synthetic fibers in applications that need lightweight and biodegradable materials, according to the study. Engineers and researchers are also able to make better material choices and constructions thanks to a fifth-order polynomial model that determines composite strength from strain rates and particle proportions. With its informative information on mechanical characteristics, this research emphasizes the significance of natural fiber composites in creating sustainable material solutions for many industrial applications.
Jute particulates, Mechanical strength, FEM, ANSYS.
Investigation of R744/R134a Heat Transfer Properties in a Smooth Horizontal Tube
This study details the heat transfer properties of a refrigerant combination running via a horizontal smooth tube, namely R744/R134a. We test the refrigerant combination under a variety of intake temperature, heat flux, and mass circumstances. Here are the experimental findings for a horizontal smooth tube with an inner diameter of 4 mm, a mass flux ranging from 40 to 80 kg/m2 s, and the heat transfer coefficient, inner wall temperature, and exergy of mass flow. The most efficient heat transfer is achieved with a mixture of R744 and R134a in a ratio of 25:75 with a mass flow of 80 kg/m2 s.
heat flux, mass flux, refrigerant mixture
A STUDY OF THE 8-UPS PARALLEL MANIPULATOR'S EFFICACY
When doing research and designing parallel manipulators, evaluating their performance is a top priority. The manipulators' efficiency is evaluated based on properties like manipulability and minimal singular value. By using the performance indices, the singularity and its surrounding configurations are eradicated. This study examines the 8-UPS spatial parallel manipulator and finds its performance indices for various architectures, including condition number, manipulability, and minimal singular value. The best way to set up the manipulator is decided upon by looking at the performance indicators. The analysis is carried out using MATLAB code that is written. The findings are shown visually.
Performance Index, Manipulability, Minimum Singular Value.
ELECTRONIC HORIZONTAL FIRE TUBE BOILER DESIGN FOR INDIAN FOOD COMMERCIAL COOKING
In order to facilitate the industrial preparation of Indian cuisine, this article seeks to provide the specifications for a horizontal fire tube two pass boiler. This boiler can produce 300 kg of steam per hour. Pure mild steel is used to construct the boiler tank. Boiler components including the fire tubes, furnace, and return chamber are made of mild steel. For this boiler, the fuel of choice is Indian coal. When heated at 1500 degrees Celsius and pressurized to 5 bars, the boiler produces dry saturated steam. Commercial kitchens, food processing plants, dairies, and restaurants may all benefit from this boiler's ability to cook Indian cuisine.
Fire tube boiler, Coal fired boiler, sake of the commercial cooking of Indian food, Indian food cooking.
Predicting the Axial Steam Turbine's Performance using 3D Computational Fluid Dynamics
To generate electricity, steam turbines are the primary prime movers. With horsepower ratings exceeding 10,000 HP, these turbines discover significant uses for naval propulsion in addition to electricity production. We use Ansys-CFX CFD software to model and analyze the performance of a single axial turbine stage, which has 58 blades in the rotor and 60 blades in the stator. The working fluid for the turbine stage was determined to be superheated steam with temperatures of 500 K and 600 K at 2 & 3 pressure, respectively. The working fluid's thermodynamic characteristics are sourced from the IAPWS97 database. When designing turbo equipment, it is essential to first do thorough simulation studies to identify potential issues, and then determine the best operating conditions. Under both inlet situations, the turbine is operated at various speeds, varying between 6,000 and 12,000 rpm. At a greater pressure of 3 bar, the power output more than doubles, but the efficiencies remain almost the same, exceeding 90%, regardless of the input circumstances. Maximum efficiency were achieved at 8000 rpm at 2 pressure and 10000 rpm at 3 bar, which ranged by 15 to 20%. Stator blades exhibit a significant rise in kinetic energy, suggesting a highly efficient nozzle. Due to the fact that the relative mach number is dependent on the rotor speed and since the sonic velocity decreases as temperatures fall, it is seen that both the temperatures and the relative mach number drop as the speed increases.
Prime movers, Ansys, CFX, CFD, IAPWS97, Turbo Machinery, Nozzle Efficiency, Kinetic Energy.
DUFOUR AND SORET EFFECTS ON UNSTEADY MHD FREE CONVECTION AND MASS TRANSFER FLOW OVER AN IMPULSIVELY STARTED VERTICAL POROUS PLATE CONSIDERING THE VISCOUS DISSIPATION
The Soret and Dufour effects on unsteady free convection and mass transfer flow past an impulsively started vertical porous plate of a viscous incompressible and electrically conducting fluid, in the presence of a uniform magnetic field by taking into account the viscous dissipation has been analyzed in this paper. In this analysis, the local similarity solutions of the transformed dimensionless equations for the flow with appropriate transformations, the governing boundary layer equations are transformed into non-linear ordinary differential equations and the numerical solution is obtained by using the implicit finite difference method. The solution at each time step has been found to reach the steady state solution properly. Representative results for the fluid velocity, temperature and concentration profiles for various parameters are presented graphically and the effects of pertinent parameters on the local -Skin friction coefficient (Viscous drag), local-Nusselt number (rate of heat transfer) and the local- Sherwood number are also calculated and presented in the tabular form.