Automotive design with economy, safety and aesthetics have been a great challenge to design engineers. Augmenting to these factors today environment impact is an upcoming research area. The safety of the passengers during vehicle crashes can be ensured to a certain limit by using good bumpers. At the same time these automotive parts should not be massive in terms of weight contributing to the increase in total the weight of the vehicle. In this work, a bumper used for low passenger vehicle, Ambassador car is modelled by using the software CATIA V5R18. Then this model is imported into FEM package of ABAQUS 6.10 impact as well as static analysis. Again modal analysis and analysis under dynamic loading done for the same model using ANSYS Workbench 11.0. The materials used for these analyses are Aluminum B390 alloy, Chromium coated mild steel and carbon composite. During static analysis, Carbon composite shows the lowest deformation and maximum von mises stress value. After the impact analysis, the composite shows the highest stress value, lowest deformation and the lowest strain value on compared with above materials. The analysis under the dynamic loading shows this carbon composite has the maximum stress value and it having the highest strength to weight ratio and producing low deformation. From all these analysis, it can concluded that carbon composite is the best material which can use as the bumper material among all the other materials used here.
Welding of ferritic steel tube material T91 (9Cr-1Mo), was used because of high temperature withstanding, mechanical properties, compatibility with chemicals and adequate weldability. The main objective of this project is to find out near optimum welding parameters with appropriate shielding gas in gas tungsten inert gas welding (GTAW) of T91 tube. The quality and productivity of the weld joint strongly depends on welding parameters. The perfect arc during welding is produced when the welder uses the optimum welding parameters. The composition of shielding gas plays an important role ensuring sound quality of welds. The composition of shielding gas with the molten pool has a marginal influence in the depth of penetration. The optimized parameters with three samples were prepared with different purging gases Viz. 100% helium, 100% Argon, Argon 50% plus Helium 50% for welding of 2.9 mm thick T91 tube with ER 505 filler wire.
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