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Diss Guide For BITS
Diss Guide For BITS
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE PILANI, RAJASTHAN, 333031 (MAY 2002)
An Informal Guide to All Students of BITS, who are doing their Higher Degree Dissertation Projects in the current semester
Dissert at ion Proj ect s in t his sem est er culm inat e in t o a very im port ant and final st age of your educat ional process of BI TS. This leads t o subm ission of a professional report of a high qualit y st andard, as required of t he BI TS Dissert at ion. A Dissert at ion report is of a higher st andard in it s approach, wider in scope and deeper in t he levels of underst anding t han t hat of a Thesis report . As a BI TS st u de n t , you should take pride in the Dissertation report as well as your work. You should t ake t im e t o read t his not ice carefully t o avoid u n n e ce ssa r y w a st a ge of your hard time and t hat of t he peer reviewers in cor r e spon de n ce . Here are som e of t he suggest ions t o reduce this, and also prevent Dissertation report revision. Take a Look at the following sections:
Why all this? Follow only BITS Standard Format for the Title Pages of Dissertation(S1) Next page that follows is the certificate. (S2) Abstract Page (S3) Expression of gratitude (Acknowledgement), Dedications (S4) List of symbols, List of Figures & List of Tables (S5) Index / Table of Contents (S6) Chapters and their arrangement (Introduction S7) Results & discussion Conclusion (Page /Chapter) S8 Appendices (S9) References(S10,S11) Communications after you submit the Dissertation Self evaluation or checklist before you send the Dissertation Some tips, dos and don'ts
How the Dissertation should be submitted? THE DISSERTATION SHOULD BE SUBMITTED IN A NEATLY TYPED AND BOUND VOLUME ONLY AND IT SHOULD BE COMPLETE IN ALL RESPECTS. Any other form is liable to be rejected / ignored even without notice to you.
Taking int o account all t hese param et ers, it is likely t hat you r fin a l gr a de is lia ble to be revised if the Dissertation falls short of any of the guidelines.
Follow only BITS Standard Format for the Title Pages of Dissertation.
Please do n ot have you r ow n de sign s of t h e t it le a n d in n e r cove r pa ge s. Ot herwise it is not possible t o dist inguish bet ween a report and t he Dissert at ion. Please do not cover t hem by a n y ot h e r blank/ filled pages. See t hat t he t it le of t h e pr oj e ct gives an idea of t he proj ect covered by your Dissertation and it should be consistently be same as approved by your mentor / BITS. See the sample as per the format (S- 1).
Abstract Page
Next is the abstract page. It gives a brief account of the work done by you at your organization in connect ion wit h t he proj ect t aken up by you. Please bind a copy of it in your Dissert at ion. Also a t t a ch t w o se pa r a t e copie s for ou r r e fe r e n ce t o m a k e a com pila t ion of a ll t h e t h e se s in t h e se m e st e r . They can be accessed in BITS library. See the sample as per the format. (S- 3)
Acknowledgement, Dedications
You m ay like t o record t he assist ance / help offered by people associat ed wit h you in m aking t he report . There is no specific form at for t his. You m ay form at it on your own. No grade or evaluat ion component is associated with this page. See the sample as per the format. (S- 4)
it a point t hat no Table goes un- referred in your Dissert at ion and also wit hout any explanat ory not e/ comments/observations/conclusive remarks. See the samples as per the format. (S- 5)
I t is sim ilar t o t he result s and discussion. High- light im port ant rem arks concerning t he result s and t he int erpret at ions --How it has benefit ed t he com pany, how t he result s m ade a difference t o previous situations, etc., See the samples as per the format. (S- 8)
Appendices
This is a part of the Dissertation where you provide material for additional information on the subj ect . For exam ple say you referred a com pany cat alogue of equipm ent specificat ion, or a BI S or BS st andard, you m ay provide pert inent inform at ion. Or you want t he list ing of a com put er program m e you developed for t he purpose. This can be included in t his sect ion. You m ay give num ber for each appended inform at ion in Appendix I , Appendix I I et c., Please do not forget t o num ber t hese pages t oo. See t he samples as per the format. (S- 9)
References
This is an important part of the Dissertation helping you and the reviewer as to see how deep you went int o subj ect m at t er, how t o get a sim ilar or cont em porary report can be referred, how t o compare your results with other research workers in this area etc., It is a code many refereed journals follow. I t is a good pract ice t o follow an order, which is according t o alphabet ical order of t he authors. This is the best among all. I t is a lso possible t h a t you pu blish t h e su bj e ct of t h e D isse r t a t ion in n a t ion a l / in t e r n a t ion a l j ou r n a ls. The list of references t hus help you educat e yourself and also let ot hers t o know where to search and what to search more precisely and quickly. See the samples as per the format. (S10, S11). The sam ple page gives a m et hod how t o writ e t he reference in serial order according alphabet ical list
3. 4.
5. 6. 7. 8. 9.
Please not e t hat all t he com m unicat ions will be sent t o t he la st k n ow n e m a il a ddr e ss a n d post a l a ddr e ss give n by you in you r e va lu a t ion for m s. Dissert at ion revision advises will be sent t o t hese addresses only. Hence it is all t he m ore im port ant t hat you should inform us your lat est address ( em ail / Post al / Telephone / and Fax) in order t o help us ( t o help you) . BI TS, Pilani will not be responsible for t he loss of m ail/ m ail not being delivered/ delayed m ail in any form . However we will t ake all t he st eps t o cont act you in case any need arises based on t hese address inform at ion pr ovide d by you in t h e evaluation forms.
Grade your own Dissertation (Self evaluation) before you submit: Use it as a checklist
Check list\ grade Front cover page Inner cover page Certificate Acknowledgement Abstract Index or Table of contents List of symbol/notations List of figures/photos List of Tables Chapter 1 (introduction) Chapter 2 --- etc Chapter x Discussion Chapter x+1 Conclusions References Appendices 1,2,3 etc Excellent BITS Format BITS Format BITS Format NA BITS Format BITS Format All page nos given BITS Format BITS Format BITS Format BITS Format BITS Format BITS Format BITS Format BITS Format BITS Format Poor/un- acceptable Company format Company format Company format NA No signatures No page numbers No list /numbers given No list/numbers given No tables/numbers given No introduction/abrupt beginning No chapters/freestyle No discussion chapter No conclusion Title of book only Every thing jumbled in main Dissertation
WHAT A DISSERTATION IS NOT? Please remember that a Dissertation is not any of the following:
A compilation of Power Point Presentations of a seminar A text book or a Manual A Days report, nor a report of what you are doing in the organization Companys Marketing report or Companys Quality Control records A compilation of Companys drawings A set of compilation of quotations for a contract
1.
A D isse r t a t ion is n ot a com pila t ion of Pow e r Poin t Pr e se n t a t ion s. Ple a se be a r it in m in d t h a t t h e y w ill n ot be a cce pt e d e ve n w it h ou t a n y n ot ice t o you . Th e y ca n r u n t h e RI SK OF BEI N G IGNORED. Th e y m a y be im pr e ssive for a se m in a r , bu t n ot for a D isse r t a t ion . Th e y a lso con t r ibu t e t o w a st in g pa pe r w it h la r ge n u m be r of pa ge s w it h lit t le in for m a t ion h ow t h e subject has been chosen, how analyzed, how experiments were conducted, etc.,
2.
Ple a se r e m e m be r t h a t you a r e n ot w r it in g a Te x t book or a M a n u a l. Ple a se con fin e t o you r su bj e ct . Ch oose t h e su bj e ct of you r D isse r t a t ion spe cific t o you r a ssign m e n t . Usu a lly it sh ou ld be t h e w or k ca r r ie d ou t a t you r or ga n iz a t ion / or a t ot h e r pla ce on be h a lf of you r parent company. 3. D o h a ve a com pr e h e n sive pla n for you r D isse r t a t ion . I t is n ot a da y's r e por t . W r it e e a ch chapter and review entirely and examine the continuity of subject to the next chapter and a logical conclusion 4. D o n ot r e pr odu ce t h e pa ge s of a t e x t book . A r e fe r e n ce n u m be r sh ou ld be in dica t e d if it ca lls for t h e discu ssion . Sim ply pu t , D o n ot follow a be a t e n t r a ck w h ich is a lr e a dy a va ila ble in standard literature and textbooks
5.
6.
Com pa r ison of you r da t a w it h ot h e r pr e viou s r e cor ds ( in a sim ila r sit u a t ion or in con t r a st ) is encouraged. D o n ot ge n e r a liz e you r D isse r t a t ion t it le ( For e x a m ple do n ot ch oose t it le s lik e Tot a l Qu a lit y M a n a ge m e n t , Six Sigm a , Ope r a t ion a l m e t h ods, Fin it e Ele m e n t a n a lysis, En vir on m e n t a l pollu t ion , or ca t ch y Bu t u n - u n de r st a n da ble t it le s lik e ...KKL- SIP- ESFD- M ACRO e ve n if it is justified and meaningful from your angle.) I n st e a d For e x a m ple you m a y ch oose t it le s lik e : Pa in t - sh op qu a lit y m a n a ge m e n t in FORD I n dia / Fin it e Ele m e n t analysis of a le a f spr in g, D e ve lopm e n t of an in ve n t or y management software based on MS Access etc. D o n ot sim ply a t t a ch t a ble s t o in cr e a se t h e bu lk of you r D isse r t a t ion . Ea ch t a ble h a s t o be discu sse d t h or ou gh ly a n d in t e r pr e t e d. N e it h e r e x a m in e r / n or a r e vie w e r a r e goin g t o do it . I t is you r w or k a n d you h a ve t o e x pla in in de t a il. M a n y st u de n t s a t t a ch a va st n u m be r of da t a obt a in e d fr om t h e ir com pa n y a n d t h a t w it h ou t a n y r e fe r e n ce t o it in t h e discu ssion in t h e cor r e spon din g ch a pt e r s. Th is m a y a dd im pr e ssive bu lk of t h e D isse r t a t ion bu t of n o va lu e . Ple a se do n ot m isu n de r st a n d t h a t t a ble / da t a a r e u n n e ce ssa r y. Th e y a r e e sse ntial. Provide a basis and means to understand what you are trying to convey through the tables.
7. 8.
T h e f o l l o w i n g p a g e s S1 t o S1 1 c o n t a i n s a m p l e s o f s o m e Di s s e r t a t i o n p a g e s f o r g u i d a n c e a n d f o r i l l u s t r a t i o n o n l y . T h e T i t l e s o f a Di s s e r t a t i o n , n a m e s o f p e r s o n s indic at ed are all fic t it ious and m ay be t hat t he c oinc idenc e of t heir nam es in an o r g a n i za t i o n i s o n l y i n c i d e n t a l a n d i t i s n o t a i m e d a t a n y i n d i v i d u a l /o r g a n i s a t i o n i n making the references.
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QC PROBLEM SOLUTION IN
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ABSTRACT
Dissertation Title : QC PROBLEM SOLUTION IN CLUTCH FACINGS & BRAKELININGS. Supervisor Name of student Semester ID No. : Dr B Ramanathan : V.Sivakumar : Second : 1999 HZ79507
This Dissertation work gives an account of the Quality control aspects of the friction materials that are useful for applications in clutch facing and brake linings Sample analyses, Experiments were done in the moulding department. Defects were analyzed and ranked according to their priorities such as under fill, cracks, warpage, damage and others. Reasons or causes were found out by drawing fish bone diagram. Major steps in the moulding process were verified. Experiments were done to observe the process variables. The process variables having significant changes i.e. temperature of curing and length of curing time Moulding pressure, holding time on the hardness and state of complete cure (measuring unreacted species by acetone extraction test). Improved the conditions of moulding frozen the process parameters such as the Moulding pressure, Temperature, pressure-holding time, number of vents. They have been standardized. This strategy has reduced the defects to an extent of 40 %. Further reduction strategy to reduce the defects has been planned. The Dissertation describes the above work in detail.
Signature of Student
(The abstract should be submitted in triplicate. One should be bound with the Dissertation and the other two should be enclosed with the evaluation report)
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ACKNOWLEDGEMENT
I take this opportunity to express my profound gratitude and deep regards to my guide for his exemplary guidance, monitoring and constant encouragement throughout the course of this Dissertation work. The blessing, help and guidance given by them time to time shall carry me a long way in journey of life on which I am about to embark. Sincere appreciation is extended to Shri I.V.Singh and Shri N.N.Sharma Ford India Ltd for his immense help during the course of this work. In those moment when things used to turn dark his presence had a soothing effect. I am grateful to Shri Durai prabhakaran Lecturer- mechanical Engineering Department, Anna University, for providing me with the timely help in search of the references for this Dissertation. I record with appreciation the help rendered by Shri Tulsiram Sharma, Robotics Lab instructor, for this work. My several well-wishers helped me directly or indirectly; I virtually fall short of words to express my gratefulness to them. Therefore I am leaving this acknowledgement incomplete.in their reminiscence.
V.Sivakumar
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:
n:
: : :
n(x): n: w(x): d:
cross sectional area of beam width of beam damping coefficient electric displacement depth of beam piezoelectric moduli modulus of elasticity force modulus of rigidity heaviside step function half of depth moment of inertia stiffness matrix length of beam one element length moment unit vector time dependence of the load resistance thickness of PZT displacement or deflection in beam voltage applied on PZT coefficient of model series derivative for step function strain strain in PZT actuator piezoelectric strain slope eigenvalue damping ratio density tensile strength modes natural frequency transverse displacement damping frenquency
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TABLE OF CONTENTS
Ch No.
i) ii) iii) iv) v) vi)
Title
Certificate Abstract Acknowledgements List of symbols List of Figures List of Tables
Page No
i ii iii iv v vi 1 1 4 7 9 12 14 22 22 23 25 27 38 42 45 46 - 76 77
1. Introduction 1.1. The problems encountered in FORD India 1.2. Introduction Brakes & Clutches 1.3. Introduction to Friction (LINING) materials 1.4. Strategies for QC 2. Background to the problem 3. Classification of defects in clutches and brake-linings and their influence on performance 4. Understanding the defects, Cause and effect diagram 4.1 various defects 4.2 trends in the monthly production statistics 4.3 Ranking of defects 4.4 Inspection strategy 4.5 Process parameters 5 Experimental Work, Data collection and analysis 6 Discussion 7 Conclusion 8 Appendices 9 References
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CHAPTER 1 Introduction
In all the transportation (or automobile) vehicles, the clutch and brake systems are very important and critical components. The results can be disastrous if the clutch or brake systems fail. A brake system consists of a braking mechanism, and its actuating system connected to foot/ brake pedal (through a slack adjuster) near the drivers seat. The braking mechanism consists of a brake drum, brake pads / brake shoes, a Scam , and an air brake chamber to actuate the Scam. The S cam pushes the brake pads such that the brake shoes press against the drum to bring the vehicle to the state of rest. The clutch is a form of mechanical coupling which enables the transmission of power between the driver and driven shafts aligned along the same axis while former shaft is continuously rotating and the other is in a state of rest or rotating at a lower speeds. Usually clutch is actuated to bring about a change of the speed in the driven shaft. The Brake pads / clutch facings have one thing in common. That is the friction material which provides frictional surface to provide enough frictional force required to transmit the power either to brake the vehicle (former )or to accelerate the vehicle as clutch. The brake pads /Clutch facings are made of friction material to provide a positive power transmission and the material should withstand sufficient wear and tear due to forces of friction. The Brake pads or clutch are moulded using a specially formulated phenolic moulding compound to provide a very high coefficient of friction. Usually these materials are used in the light duty vehicles while woven materials are used in moulding heavy-duty facings or pads. Woven materials provide high strength and stiffness which are present in heavy duty vehicles. Phenolic resin is appropriately selected depending upon the requirements of moulding conditions and product demands. Phenolic resins are very versatile thermosetting resin systems for high temperature service conditions such as braking systems or clutch systems. Since the resin is a thermosetting one, its cure (further information provided in Appendix I) has to be accomplished only at elevated temperature and pressure conditions. This requires a curing pressure and temperature cycle that is possible in Hydraulic presses which can provide pressures in the range of 50 t0 100 Kg / cm2 and a temperature range of operation around 1500 2500 C. S8
CHAPTER 7 Conclusions
In this Dissertation an effort is made to understand the functions of frictionmaterials and to minimize the manufacturing defects. Experimental work indicates that the manufacturing defects account about 40% of the defective parts produced. (From table - 5.1) (almost to an extent of 1/2 ). Planned experiments point out that optimizing the Compression moulding process - and its variables can prevent the defects. Studies conducted reveal that moulding pressure, its holding time, and moulding temperature have the significant effect to produce defect-free samples. Production has been optimized to implement the best combination of the process variables to give defect-free or aiming at 0% defect rates during moulding. Optimization of other non-process parameters also has to be taken up for producing ZERO defect products so that rejection can be totally minimized.
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Application Heat Resistance Brake Lining Compounding of Nitrile Rubber Brake Lining Rice Rollers
Feature Cream Powder form, Melting Point=75 - 85 Light Brown Powder form, Melting Point=75 - 85 Light Brown Powder form, Melting Point=75 - 85 Light Brown Powder form, Melting Point=75 - 85
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References
1. A.V.SRINIVASAN, D.MICHAEL MCFARLAND, 2001, Smart structures: Analysis and design, Cambridge University press. 2. B.L.WANG, N.NODA, 2001, Design of a smart functionally graded thermopiezoelectric composite structure, Smart materials and structures, Institute of physics publishing, Bristol, UK, 10, pp 189-193. 3. BRUANT.I, COFFIGN P.L, G.LENE, F. and VERGE.M.A 2001 Active control of beam4. structure with piezoelectric actuators and sensors: modeling and simulation. Smart materials and structures, Institute of physics publishing, Bristol, UK, 10, pp. 404-408. 4. .C.S. KRISHNAMURTHY, 1994, Finite element analysis :Theory and programming Tata McGraw-Hill publication company limited, New Delhi, second edition, 5. COFFIGNAL G., 1996, DYNADID2D Code de calcul en Elements finis de Poutres Paris: ENSAM. 6. G. VENKATESWARA RAO, GAJBIR SINGH, 2001,A smart structures concept for the buckling load enhancement of columns., Smart materials and structures, Institute of physics publishing, Bristol, UK, 10, pp. 843-845. 7. GERE & TIMOSHENKO, 1986,Mechanics of materials, C.B.S. Publishers & Distributors, Delhi, Second Edition. 8. I.J.NAGRATH,1996 , Electronics :Analog and Digital , Prentice Hall of India, New Delhi
9. JAFFE,B .COOK,W.R. & JAFFEH.,1971,Piezoelectric ceramics, Academic press, London 10. KALYANARAMAN V., 1999, Smart control of instability of struts Smart Material, Structures, and Systems ed. P.D.Mangalgiri et al, (Bangalore, India: Allied Publishers) pp. 343-348. 11. LEONARD MEIROVICH (2nd edition) 1986 :Element of vibration analysis, McGraw-Hill International Edition Singapore . 12. MERESSI T., PADAN B., 1993. Buckling control of a flexible beam using pieozoelectric actuators, J.Guidance(AIAA), 16, pp. 977-980.
13. N.K.MEHTA, 1996 Machine tool design and numerical control, Second
14. R.D.COOK, D.MALKUS, M.E.PLESHA, 1989 Concept and application of finite element analysis, John Wiley & sons, London, Third edition.
15. RONALD
L. HUSTON, CHRIS E. PASSERELLO., 1984 finite element methods and introduction , Marcel dekker. Inc Newyork,
16. RUDRA PRATAP, 1999. Getting started with matlab5-A Quick introduction for scientists and engineers, Oxford university press, Delhi, 17. S.TIMOSHENKO, D.H.YOUNG, W.WEAVER, JR.,1974,Vibration problems in engineering ,John Wiley & Sons, New York, fourth edition. 18. SADHU SINGH, 1998, Strength of materials , Khanna Publishers, Delhi, Sixth Edition.
19. SCILAB Software INRIA Unite de Recherche de Rocquencourt-project Meta-
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MATH WORKS, MATLAB. 1993 High performance computation and visualization software, The math works inc,
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21. TSE. MORSE, HINKLE, 1968, Mechanical vibration, Prentice-Hall of India private
22. U. O.AKPAN, T. S. KOKO, I.R. ORISAMOLU, B.K. GALLANT, 2001,Fuzzy
finite element analysis of smart structures. Smart materials and structures, Institute of physics publishing, Bristol, UK, 10, pp.273-284. 23. V.P.SINGH, 1999Mechanical vibration. Dhanpat Rai & Co.(p) LTD. New Delhi.
24. YUKIO KAGAWA, TAKAO TSUCHIYA, NAOTO WAKATSUKI, 2001
Equivalent circuit representation of a vibrating structure with piezoelectric transducers and the stability consideration in the active damping control. Smart materials and structures, Institute of physics publishing, Bristol, UK, 10, pp. 389-394. 25. www.spie.org/web/oer/february/feb98/smartmat.html 26. www.darpa.mil/dso/thrust/md/smart_2.htm 27. www.intellimat.com/materials/
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