TEQIP-II funded two days FDP on “Practical Durability Assessment of Automotive Structures and welding design” was organized by department of Mechanical Engineering NMAMIT, Nitte during 23-24, December 2016. The FDP was inagurated on 23 rd December 2016 by Dr.G.Ravichandran, additional general manager, welding research institute, BHEL, Trichy. Master of ceremony of the inaugural function, was Mrs Akshatha Manjunath kshatriya, Assistant professor of mechanical engineering. Dr. Shasikantha Karinka, Head, Dept. of Mechanical Engg., welcomed the gathering and gave an overview of the FDP programme. Dr. Mallikappa, Coordinator of the training programme,introduced the chief guest and Guest honor, Dr Sthyaprakash, Chief Technical Officer, Mahesh Software Systems Pvt. Ltd. Dr. Niranjan N.Chiplunkar, Principal presided over the function, , Prof Bhaskara P Achaar gives a vote of thanks. About 44 participants from within and outside Karnataka have participated in the FDP.
At the inaugural function, Dr. G.Ravichandran talked on the importance of welding technology in Industries & Institutions, Dr Sthyaprakash,talked about the durabality test of automotive structures and appreciated the institution for organizing such a workshop.
The first session of the two day program begin with Mr Sthyaprakash talking on the topic Fatigue, Durability and Life Cycle Management, he covers the topics,Customer Usage Monitoring,Vehicle,Health Monitoring and Test Data Management with CAE-based Fatigue Analysis.The fatigue test is usually concerned with the techniques proving ground/flight test, ground Vibration test, road simulator test, Static & fatigue test, Component test, engine & Dynamometer test and shock & vibration test. He also addressed about the simulation driven product development.These are the few aspects he discussed in the session.
The second session on day one continued by Mr Sthyaprakash addressed about fatigue life design (for product competiveness). Fatigue design is not just a simple fatigue life calculation. It is an engineering process and involves many engineering tasks; Different fatigue design methodology has been used in different industries. Fatigue is a process of damage accumulation leading to failure, which may occur even when the nominal stress is lower than the yield stress of material due to the alternating loads. Fatigue usually includes crack initiation and propagation stages. Cyclic plasticity of metal is the main cause. He also discussed about the history of fatigue failures, he told the De Havilland comet story, that the first passenger jet airliner (1949 -1980),suffered two tragic air accidents due to fatigue failure,68 people killed as a result, order books fell by 50 aircraft, ultimately heralded the collapse of the British civil aircraft industry. He also addressed about automotive durability solution, loads measurement and management, road load data acquisition and analysis,
fatigue life prediction – load input, Finite element mesh and stress result, automotive durability solution, laboratory testing.
The third session on Day 1was taken up by Dr.G.Ravichandran, he addressed about welding symbols, (ISO2553)and weld joint design, elementary weld symbols like single bevel groove weld with broad root face, single U groove weld, single J groove weld, backing weld, fillet weld, plug / slot weld, spot weld, seam weld, edge weld surfacing, etc . In his continued talk he presented about supplementary symbols process (as per ISO 4063), acceptance level (as per ISO 5817 or ISO 10042), working position (as per ISO 6947), filler materials (as per ISO 544 or ISO 2560 or ISO 3581), and also he highlighted the examples of application, factors which influence the choice of edge preparation like, thickness, material, welding process, extent of penetration required, welding distortion, cost etc.
Day 2 (24-12-2016) The second day of the first session begun with Mr Sthyaprakash. He addressed about the physics of fatigue-cyclic fatigue loading, fatigue and crack growth are driven by cyclic loading, constant stress will not cause crack initiation or growth, fatigue cycles are defined by the change of stress or strain. He highlighted about the stages of fatigue-crack initiation, cracks usually initiate from, microscopic defects, defects then create persistent slip bands that propagate along the maximum shear plane and material behavior is like a shifting deck of cards. . He gave An Overview of fatigue Analysis, explained how the fatigue analysis roadmap works and highlighted the total fatigue life. Total component life until failure is made up of two stages, 1.Crack initiation starting with the component as-produced and 2.Crack growth from a small crack or flaw until fracture.
The second session on day two was continued by Mr Sthyaprakash He addressed about industrial approach of fatigue analysis. Different industries approach these stages with different design philosophies. Common Philosophies in Different Industries are Ground Vehicles and Aerospace. In ground vehicles-Considerable time is spent initiating a crack, inspections are not economically viable, crack growth, if allowed, can lead to surprises, noticeable cracks are considered failure. In aerospace-many components use tough, crack tolerant materials, growth is designed to be slow and predictable, industry conservatively assumes that cracks are present, frequent inspections are conducted.
The third session Day two was taken up by Dr.G.Ravichandran on the topic of welding design for statically loaded structures. The main Objectives of Welding Design are to provide an assembly that will perform the intended functions, will have the required reliability and safety, is capable of being fabricated, inspected, transported and placed in service at minimum total cost. Total cost includes cost of design, materials, fabrication, erection, inspection, operation, repair, product maintenance. He mentioned about the Knowledge required for welding design and major parameters influence the welding failure. In his presentation he demonstrated the weld size calculation examples for various types of welds.
The validectory function was held at th end of second day at end of sessions and lab visits, at phalguni seminar hall. Dr.G.Ravichandran, Additional General Manager, Welding Research Institute, BHEL, Trichy. was the chief guest for the function. Mrs Akshatha Manjunath kshatriya presented a brief report on the FDP programme on “Practical Durability Assessment of Automotive Structures and welding design”. Head of department Dr. Shasikantha Karinka presided over the function. The certificates were distributed to the participants in the valedictory function. The feedback about the FDP were received from the participants during the function. Dr Mallikappa Coordinator of the training programme closed in the training program giving thanks.
At the inaugural function, Dr. G.Ravichandran talked on the importance of welding technology in Industries & Institutions, Dr Sthyaprakash,talked about the durabality test of automotive structures and appreciated the institution for organizing such a workshop.
The first session of the two day program begin with Mr Sthyaprakash talking on the topic Fatigue, Durability and Life Cycle Management, he covers the topics,Customer Usage Monitoring,Vehicle,Health Monitoring and Test Data Management with CAE-based Fatigue Analysis.The fatigue test is usually concerned with the techniques proving ground/flight test, ground Vibration test, road simulator test, Static & fatigue test, Component test, engine & Dynamometer test and shock & vibration test. He also addressed about the simulation driven product development.These are the few aspects he discussed in the session.
The second session on day one continued by Mr Sthyaprakash addressed about fatigue life design (for product competiveness). Fatigue design is not just a simple fatigue life calculation. It is an engineering process and involves many engineering tasks; Different fatigue design methodology has been used in different industries. Fatigue is a process of damage accumulation leading to failure, which may occur even when the nominal stress is lower than the yield stress of material due to the alternating loads. Fatigue usually includes crack initiation and propagation stages. Cyclic plasticity of metal is the main cause. He also discussed about the history of fatigue failures, he told the De Havilland comet story, that the first passenger jet airliner (1949 -1980),suffered two tragic air accidents due to fatigue failure,68 people killed as a result, order books fell by 50 aircraft, ultimately heralded the collapse of the British civil aircraft industry. He also addressed about automotive durability solution, loads measurement and management, road load data acquisition and analysis,
fatigue life prediction – load input, Finite element mesh and stress result, automotive durability solution, laboratory testing.
The third session on Day 1was taken up by Dr.G.Ravichandran, he addressed about welding symbols, (ISO2553)and weld joint design, elementary weld symbols like single bevel groove weld with broad root face, single U groove weld, single J groove weld, backing weld, fillet weld, plug / slot weld, spot weld, seam weld, edge weld surfacing, etc . In his continued talk he presented about supplementary symbols process (as per ISO 4063), acceptance level (as per ISO 5817 or ISO 10042), working position (as per ISO 6947), filler materials (as per ISO 544 or ISO 2560 or ISO 3581), and also he highlighted the examples of application, factors which influence the choice of edge preparation like, thickness, material, welding process, extent of penetration required, welding distortion, cost etc.
Day 2 (24-12-2016) The second day of the first session begun with Mr Sthyaprakash. He addressed about the physics of fatigue-cyclic fatigue loading, fatigue and crack growth are driven by cyclic loading, constant stress will not cause crack initiation or growth, fatigue cycles are defined by the change of stress or strain. He highlighted about the stages of fatigue-crack initiation, cracks usually initiate from, microscopic defects, defects then create persistent slip bands that propagate along the maximum shear plane and material behavior is like a shifting deck of cards. . He gave An Overview of fatigue Analysis, explained how the fatigue analysis roadmap works and highlighted the total fatigue life. Total component life until failure is made up of two stages, 1.Crack initiation starting with the component as-produced and 2.Crack growth from a small crack or flaw until fracture.
The second session on day two was continued by Mr Sthyaprakash He addressed about industrial approach of fatigue analysis. Different industries approach these stages with different design philosophies. Common Philosophies in Different Industries are Ground Vehicles and Aerospace. In ground vehicles-Considerable time is spent initiating a crack, inspections are not economically viable, crack growth, if allowed, can lead to surprises, noticeable cracks are considered failure. In aerospace-many components use tough, crack tolerant materials, growth is designed to be slow and predictable, industry conservatively assumes that cracks are present, frequent inspections are conducted.
The third session Day two was taken up by Dr.G.Ravichandran on the topic of welding design for statically loaded structures. The main Objectives of Welding Design are to provide an assembly that will perform the intended functions, will have the required reliability and safety, is capable of being fabricated, inspected, transported and placed in service at minimum total cost. Total cost includes cost of design, materials, fabrication, erection, inspection, operation, repair, product maintenance. He mentioned about the Knowledge required for welding design and major parameters influence the welding failure. In his presentation he demonstrated the weld size calculation examples for various types of welds.
The validectory function was held at th end of second day at end of sessions and lab visits, at phalguni seminar hall. Dr.G.Ravichandran, Additional General Manager, Welding Research Institute, BHEL, Trichy. was the chief guest for the function. Mrs Akshatha Manjunath kshatriya presented a brief report on the FDP programme on “Practical Durability Assessment of Automotive Structures and welding design”. Head of department Dr. Shasikantha Karinka presided over the function. The certificates were distributed to the participants in the valedictory function. The feedback about the FDP were received from the participants during the function. Dr Mallikappa Coordinator of the training programme closed in the training program giving thanks.
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