International Journal of Innovation in Mechanical Engineering and Advanced Materials
Not a member yet
93 research outputs found
Sort by
Enhancing Kiln Reliability in Cement Industry Using RCM II and FMEA
Get PDFThis study applies to the Reliability-Centered Maintenance (RCM) II methodology to improve the reliability and cost efficiency of a kiln system in a cement manufacturing plant. Kiln failures are critical because they cause unplanned downtime, reduced productivity, and financial losses. Traditional corrective or time-based maintenance strategies often fail to address the stochastic nature of failures in such high-temperature rotary systems. To overcome this gap, the research integrates Failure Mode and Effect Analysis (FMEA) with RCM II decision logic to identify and prioritize maintenance actions. The analysis focused on five critical kiln components—crusher cooler, firebrick lining, thrust roller, grate cooler, and main drive—using 12 months of operational data supported by expert interviews and technical manuals. Reliability indicators, including Mean Time to Failure (MTTF), Mean Time to Repair (MTTR), and Mean Time Between Failures (MTBF), were calculated, while Risk Priority Numbers (RPN) were assigned to rank failure modes. Results showed that the crusher cooler had the highest risk, whereas the main drive required the longest repair duration. Implementation of RCM II recommendations increased MTBF by 29–38% across components and reduced maintenance costs by more than 50%. These findings confirm that RCM II provides a practical, data-driven framework for enhancing system availability. The study contributes to maintenance engineering by demonstrating a structured approach that supports risk-informed and condition-based maintenance strategies in continuous-process industries
Viability of R-290 Refrigerant as Residential AC Retrofit: Effect of Charge Mass Variations
Get PDFThe growing concerns over ozone depletion and global warming caused by refrigerants have led to the search for environmentally friendly alternatives. This study evaluates the impact of varying R-290 refrigerant charge masses on the performance of a wall-mounted residential air conditioner using the drop-in substitute method. A ¾ HP residential AC unit originally charged with 550 grams of R-22 refrigerant was retrofitted with R-290 and tested at charge masses of 140 grams, 165 grams, and 190 grams—approximately 25%, 30%, and 35% of the original R-22 charge, in accordance with the commonly applied “one-third rule.” The results showed that retrofitting with R-290 increased the Refrigeration Effect (RE) by up to 75%, Compression Work (Wc) by 68%, and Coefficient of Performance (COP) by up to 18%. The system with a 25% refrigerant charge was unable to reach the set temperature due to a 23% reduction in cooling capacity, while the 30% charge showed a 10% reduction. The 35% refrigerant mass retrofit proved the most suitable, achieving adequate cooling capacity, an 18% increase in COP, and a 14% reduction in power consumption. Additionally, the retrofit resulted in an indirect CO₂ emission reduction of 1.15 metric tons annually, highlighting the environmental and energy-saving advantages of using R-290. These findings provide empirical validation of the one-third rule for refrigerant mass variation in R-290 retrofits and offer valuable insights into optimizing performance and efficiency in residential AC units, with significant energy and environmental benefits
Fuel Efficiency Evaluation of Automatic Motorcycles in Indonesia Using MATLAB-Based Clustering
Get PDFThe continuous rise in fuel prices in Indonesia has made fuel efficiency a crucial factor for consumers when selecting vehicles, particularly motorcycles. Automatic scooters with engine capacities below 160 cc have become increasingly popular in urban areas due to their fuel-saving benefits. This study aims to analyze the influence of engine capacity, vehicle weight, and engine torque on the fuel consumption of automatic scooters with engine capacities ranging from 109 cc to 156.9 cc. The study also considers additional performance parameters, including average fuel consumption, power output, and Power-to-Weight Ratio (PWR). Using statistical analysis and MATLAB-based modeling, the data were classified into three distinct clusters. Cluster 1 comprises scooters with engine capacities between 109 and 125 cc; Cluster 2 includes those with capacities between 150 and 160 cc; and Cluster 3 represents scooters with unique component specifications. The results show that Cluster 2 records the highest average maximum power output at 11.47 kW and torque at 14.25 Nm, while Cluster 1 has the lowest at 6.1 kW and 9.64 Nm, respectively. In terms of weight, Cluster 3 is the heaviest, averaging 129.33 kg, while Cluster 1 is the lightest at 96.14 kg. Fuel efficiency is highest in Cluster 1 at 55.3 km/l and lowest in Cluster 3 at 38.67 km/l. Comparative analysis using MATLAB confirms that scooters with lower engine capacities and weights tend to be more fuel-efficient, whereas higher engine capacities lead to increased torque, power, weight, and fuel consumption. These findings can guide consumers in selecting motorcycles that align with their usage needs and assist manufacturers in developing more efficient and high-performing scooters tailored to diverse market segments
Natural Inhibitors for Corrosion Protection of 6061 Aluminum Alloy: A Review
Get PDF6061 aluminum alloys are widely used in automotive, marine, and aerospace industries, yet their high susceptibility to corrosion in acidic and chloride environments remains a challenge. Bio-based inhibitors from natural sources have emerged as sustainable alternatives to toxic synthetic chemicals. This review synthesizes findings from published studies on AA6061 alloys and composites, integrating evidence from Potentiodynamic Polarization (PDP), Electrochemical Impedance Spectroscopy (EIS), and Scanning Electron Microscopy (SEM). Cross-study evaluations show that inhibition efficiency depends on inhibitor type and mechanism. Reports indicate that Boswellia serrata provides only moderate protection (~70%) due to weak physiosorbed films that are unstable under flow, whereas Alocasia odora achieves higher efficiency (~94% in HCl) through chemisorption with cathodic inhibition. Aerva lanata demonstrates ~88% efficiency in chloride-based fiber-metal laminates via polyphenolic adsorption, while glutathione provides ~80% protection at 0.75 mM through multisite coordination. Pectin consistently achieves the highest efficiency (~95% in mild acidic media) by forming compact polymeric films that increase charge-transfer resistance and reduce double-layer capacitance. This synthesis indicates that chemisorption-based inhibitors (e.g., pectin, Alocasia) generally outperform physisorption-based systems (e.g., Boswellia) because they form stronger and more stable films. Reported studies highlight both advantages and limitations: natural inhibitors are effective and eco-friendly, but most evaluations remain short-term and laboratory-based. Key gaps include durability testing, advanced characterization (XPS, ToF-SIMS, Raman, AFM), galvanic effects in composites, and poor hydrodynamic stability of physisorption systems. Future work should explore hybrid strategies, synergistic multi-inhibitor approaches, and validation under real-sea conditions to enable scalable and industrially viable corrosion protection
Correlation Analysis of Battery Capacity, Range, and Charging Time in Electric Vehicles Using Pearson Correlation and MATLAB Regression
Get PDFThe increasing adoption of electric vehicles (EVs) reflects growing global awareness of climate change and air pollution challenges. As a sustainable alternative to conventional internal combustion vehicles, EVs produce zero tailpipe emissions and can significantly reduce carbon emissions—particularly when powered by renewable energy sources. However, one of the primary barriers to widespread EV adoption remains the high cost of battery components, which are essential to vehicle performance and energy storage. In Indonesia, two dominant battery types used in EVs are Lithium Ferro Phosphate (LFP) and Nickel Manganese Cobalt (NMC), each offering distinct advantages. LFP batteries are recognized for their thermal stability and longer life cycles, making them suitable for everyday use, while NMC batteries offer higher energy density and are preferred for performance-focused and long-distance applications. This study aims to evaluate the correlation between battery capacity, driving range, and charging time for LFP and NMC batteries using Pearson correlation and regression analysis through MATLAB simulation. The results indicate a strong and statistically significant correlation among the key parameters, with a Pearson coefficient of 0.576 for battery capacity and range, and an R-square value of 0.99 for the regression model, demonstrating high predictive accuracy. Furthermore, the analysis reveals that LFP batteries have a higher average energy efficiency of 7.53 km/kWh compared to 6.84 km/kWh for NMC batteries, indicating more consistent performance in energy usage. These findings offer valuable insights for optimizing battery selection in EV applications and contribute to strategic planning for the development of more efficient electric vehicle systems. The combination of statistical and simulation-based analysis provides a robust foundation for future research and policy-making in the field of electric mobility
Use of Hibiscus rosa-sinensis as a Green Corrosion Inhibitor for Valve Materials in RO Water
Get PDFValves are mechanical devices that regulate the flow of oil and gas fluids and are typically constructed from materials that are heat-resistant, corrosion-resistant, and capable of withstanding high pressure. However, observations from valve manufacturing companies in the Banten area have shown that valve components made from medium carbon steel ASTM A105N are susceptible to corrosion during hydrotesting, particularly when using reverse osmosis (RO) water as the testing medium. This corrosion can degrade product quality before delivery to customers. To address this issue, this study investigates the use of Hibiscus rosa-sinensis as a green corrosion inhibitor. The objective of this research is to evaluate the corrosion rate, inhibitor efficiency, and surface morphology of ASTM A105N valve materials using Hibiscus rosa-sinensis in RO water media, with varying inhibitor concentrations and immersion durations. The electrochemical methods used include Potentiodynamic Polarization, Electrochemical Impedance Spectroscopy (EIS), Chronoamperometry, and Scanning Electron Microscopy (SEM). Results from the corrosion rate tests indicated that the highest inhibitor efficiency—59.04%—was achieved at 24 hours of immersion with a 2 g inhibitor concentration. This condition also yielded the lowest corrosion rate of 1.2231 × 10⁻² mm/year and the lowest corrosion current (Icorr) of 3.2601 × 10⁻⁶ A/cm². Chronoamperometry testing confirmed these findings with the lowest electric charge value of 0.0125 C. SEM analysis further revealed a more uniform and homogeneous protective coating on the metal surface under these conditions. Based on these results, Hibiscus rosa-sinensis demonstrates promising performance as a green corrosion inhibitor and is recommended as an additive in RO water for valve hydrotesting. This study highlights the potential of environmentally friendly and cost-effective inhibitors in reducing corrosion risk in valve materials
Performance Analysis of Centrifugal Pumps Before and After Wear Ring Restoration
Get PDFA pump is a mechanical device used to move fluids from a lower elevation to a higher one. In general, pumps are classified into two types: positive displacement pumps and non-positive displacement pumps. Centrifugal pumps fall into the latter category and operate by converting mechanical energy into kinetic energy to transport fluids. A centrifugal pump consists of several key components, including the casing, shaft, bearing, coupling, and impeller. In the case of closed impeller-type centrifugal pumps, wear rings (wearing components) are installed to provide a clearance between the impeller and the casing, preventing physical contact during operation. The size of this clearance significantly affects pump performance. Wear ring damage can result from mechanical wear, corrosion, cavitation, and fatigue, leading to performance losses such as reduced flow rate, lower pressure, and decreased efficiency. This research aims to analyze the effect of wear ring damage on the performance of a centrifugal pump by comparing operational data before and after repair of the wearing components. The performance parameters evaluated include pump head, pressure, hydraulic power, motor power, and overall efficiency. Data were collected through a structured procedure consisting of preparation, testing, measurement, and analysis. Prior to repair, the pump operated with a wear ring clearance of 1.2 mm, resulting in an average efficiency of 8.5% and a flow rate of 0.000646 m³/s. After the clearance was restored to 0.43 mm, the average efficiency increased to 15.5%, with a corresponding flow rate of 0.000932 m³/s. These results demonstrate that maintaining wear ring clearance within recommended standards significantly improves pump performance, highlighting the importance of regular maintenance and timely component repair
Enhancing The Formability of SS304 in ISF via Pre-Heating Treatment Strategies
Get PDFThe increasing demand for lightweight yet high-strength components in the automotive and aerospace industries has accelerated interest in Incremental Sheet Forming (ISF) as a flexible, dieless, and cost-effective manufacturing process, particularly for low-volume and customized production. Unlike conventional forming processes that rely on expensive dies, ISF offers greater geometric flexibility and rapid prototyping capabilities. However, its broader industrial adoption remains limited due to persistent challenges such as poor surface finish, springback, and restricted formability, especially when forming hard-to-deform materials like Stainless Steel Grade 304 (SS304). This study investigates the influence of customized heat treatment on the formability and deformation quality of SS304 sheets formed via ISF. Sheets were subjected to preheating at controlled temperatures ranging from room temperature to 700°C, followed by dieless forming using a CNC machining center equipped with a hemispherical tungsten carbide tool. Key process parameters, including a step size of 0.3 mm, a feed rate of 180 mm/min, and a tool speed of 500 mm/min, were maintained throughout forming. Comprehensive mechanical and microstructural analyses, including tensile testing, surface roughness evaluation, and optical metallography, were performed. Results revealed significant improvements in formability: ductility increased from 24.28% to 65%, and surface roughness (Ra) decreased from 9.7993 µm to 5.4809 µm after annealing at 700°C and tempering at 500°C. Microstructural analysis confirmed grain refinement and carbide dissolution, contributing to improved plastic flow and reduced surface defects. Integrating controlled heat treatment with ISF significantly enhances forming capabilities, surface quality, and geometric precision of SS304, making it a viable solution for manufacturing complex, high-performance components. These findings provide valuable insights for developing more efficient, defect-minimized, and adaptable forming strategies suitable for advanced manufacturing industries
Review: Optimizing Plastic Injection Processes for Enhanced Quality and Sustainable Manufacturing
Get PDFIn the automotive world, plastic products are components that cannot be separated. Almost all automotive products use plastic because it is easy to produce, and the price is relatively cheap compared to other materials. For applications such as covers, the demand on plastic surface quality are higher than for different uses. Therefore, a lot of costs are incurred to achieve this quality. However, ongoing efforts have decreased the time and expense of developing plastic molds. Many researchers have conducted studies to improve the quality of these products. This review consolidates several research articles on optimizing plastic injection processes to reduce defects and improve product quality. Techniques such as Taguchi Method, Response Surface Methodology (RSM), Artificial Neural Networks (ANN), and Finite Element Method (FEM) were evaluated in this research. This review highlights the importance of process parameters such as melt temperature, injection pressure, and cooling time, as well as the role of digital simulation in designing efficient and sustainable molds. The results of the study show that in several studies, defects often occur in the product without carrying out the optimization process. Still, the Taguchi and ANOVA methods can reduce the weld line and sink after optimizing the process parameters, such as melting temperature, injection pressure, cooling time, and injection speed. Mark up to 30%. These findings highlight the potential of these techniques to significantly improve product quality and support more sustainable manufacturing practices in the plastic injection molding industry
Mechanical Properties Analysis of Stainless Steel 304 Linear Guide Rail Using Autodesk Inventor and MATLAB
Get PDFThis study investigates the mechanical properties of a stainless steel 304 linear guide rail using a combination of Autodesk Inventor and MATLAB. The primary objective is to analyze the von Mises stress distribution, displacement, and safety factor of the linear guide rail under varying load conditions, as well as to develop a model representing the relationship between stress and strain. A detailed 3D model of the guide rail was created using Autodesk Inventor, followed by finite element analysis (FEA) to evaluate stress and strain distribution across different sections of the rail. The simulation was conducted to assess the structural response under multiple loading scenarios, ensuring its reliability for real-world applications. Furthermore, a linear regression analysis was performed using MATLAB to establish a predictive model correlating stress and strain, enabling more accurate forecasting of the material's mechanical behavior. The results revealed that the maximum von Mises stress obtained from the simulation was 23.595 MPa, with a corresponding maximum displacement of 0.397 mm. The safety factor analysis confirmed the rail's structural integrity, with a minimum safety factor of 10.595, well above the failure threshold. These findings indicate that the linear guide rail meets the necessary mechanical performance requirements for its intended application
Access Repository Dashboard
Do you manage International Journal of Innovation in Mechanical Engineering and Advanced Materials? Access insider analytics, issue reports and manage access to outputs from your repository in the CORE Repository Dashboard!