In this paper, a methodology is proposed which can be used to predict the crack growth and fatigue life of a cantilever beam made of Acrylonitrile Butadiene Styrene (ABS) manufactured with fused deposition modeling Three beam configurations based on length (L=110 mm, L =130 mm, and L=150 mm) are considered. Empirical relationships are formulated between the natural frequency and the crack growth. The analytical and experimental results are found in good agreement for all configurations. Using the experimental data, global relation is formulated for the crack depth prediction. This global relation is useful for an in-situ crack depth prediction with an error of less than10%. Later a residual fatigue life of these specimens is compared with metallic structure (Aluminum 1050) of similar configuration available in the literature. It is found out that the ABS material has more residual fatigue life compared to the metallic structure at the same frequency drop. Based on remaining fatigue life, ABS material can be a potential material to manufacture machine components under cyclic loads.

Autonomous underwater vehicle (AUV) is an unmanned tether-free vehicle which is powered by battery or fuel cell. The weight of the AUV is a major issue to be decided when considering its performance. To manufacture a propeller that is lighter in weight and able to carry the pressure applied to the blades is an involving process. The present study investigates the performance of the propeller of an AUV, manufactured by additive manufacturing, using ABS plastic material. The propeller blade designed in SolidWorks was transferred to the CUBPRO (DUO), followed by setting the parameters for a 3D printing machine. A comparative study was carried out for ABS (Acrylonitrile Butadiene Styrene) material between the required dimensions and a 3D printed model dimension propeller blade. An error analysis was carried out and we observed that ABS material is the most suitable for an AUV propeller. A stress-strain analysis for the propeller was carried out using the Finite Element Method.

Friction Stir Processing (FSP) was used to fabricate metal matrix composite, based on steel and reinforced with nano-sized yttrium oxide powder. The powder was packed in a narrow longitudinal groove of 2 mm depth and 1 mm width cut in the steel plate’s rear surface. Different rotation speeds of 500–1500 rpm were used, at a fixed traveling speed of 50 mm·min−1. Single-pass and two passes, with the same conditions, were applied. The direction of the second pass was opposite to that of the first pass. After the first pass, complete nugget zones were obtained when the rotation speeds were more than 700 rpm with some particles agglomeration. The added particles showed as narrow elliptical bands, with a band pitch equal to the rotation speed over traveling speed. Performing the second FSP pass in the opposite direction resulted in better particles distributions. Almost defect-free composite materials, with homogenously distributed yttria nano-sized particles, were obtained after two passes when rotation speeds more than 700 rpm were used. The resulting steel matrix grains were refined from ~60 μm of the base metal to less than 3 μm of the processed nugget zone matrix. The hardness and the tensile strength of the fabricated materials improved almost two-fold over the base metal. Uniform microhardness values within the nugget areas were observed at higher rotational speeds. The ductility and toughness of the fabricated composites were reduced compared to the base metal.

Finite Element Method based techniques apply to a wide spectrum of engineering applications including manufacturing. The flexibility to achieve optimized results by simulations adds another dimension to process-development. The efficiency due to simulation is enhanced many folds for developing desired components by reducing the cost as well as time. This paper investigates cold forging process to be adopted to produce camshafts with a target to minimize flash as well as under filling. These two factors being major problems encountered when cold forging is to be adopted for complex shaped products. The current work is primarily concerned with the development of an optimized preform design for a V8 engine camshaft. The work involved the Solid modeling of the camshaft on AutoCAD and further analyzing the developed model through finite element analysis using Deform 3D. The analysis involved understanding of metal flow, volumetric analysis and die stresses in the forging process. The materials considered for the work-piece and the dies are AISI 8620 and AISI-H-26 respectively. The sample camshaft was taken from a standard Dodge Challenger V8 engine. 10 different cases are analyzed to find out the best possible scenario. It is fund that the stress level for the developed model was very much within the design limit of the material.

The recent developments in the additive manufacturing to manufacture complex cost effective profiles is gaining popularity to test the strength of developed products through finite element method (FEM). Finite element analysis (FEA) is a potent tool for mechanical analysis. The combination of 3D printing and FEA is opening new opportunities to go further in the complexity of the product geometry. The autonomous underwater vehicle (AUV) propeller blade has a complex profile with multi-directional gradient and twist, which requires a multi-stage operation to manufacture, including the hubs. The AUV propeller is required to withstand the applied load and generate the required thrust to move AUV at the desired speed. The current study explores the performance of AUV propeller prepared by additive synthesis using Nylon 6 material. The design of the propeller blade was developed using SOLID WORKS and integrated to the CUBPRO (DUO) to obtain the required 3D printing parameters. A comparative investigation is made for Nylon material within the dimensional conformance with the 3D printed propeller blade. The stress-strain analysis of the Nylon AUV propeller is carried with the FEM. The analysis of error and the stress show that the Nylon material meets the performance criteria for AUV propeller.