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The lattice structure design enables topology optimization of a robotic arm
Kinematic Mounting Scheme of Miniature Precision Elements for Mission Survivability against Externally Imposed Environmental Conditions
1. Kinematic Mounting Scheme of Miniature
Precision Elements for Mission Survivability
against Externally Imposed Environmental
Conditions
PREPARED BY :
ANKITKUMAR P. SARVAIYA
M.TECH (CAD/CAM)
09CAD14
GANPAT UNIVERSITY
GUIDED BY:
PROF. D. M. PATEL
MECHANICAL ENGG. DEPT.,
U.V.PATEL COLEEGE OF ENGG.,
GANPAT UNIVERSITY,
KHERVA
GUIDED BY:
MR. J. T. DESAI
SCI /ENGG, HEAD, LPMD
OPMG,MESA,SAC
ISRO
AHMEDABAD
2. Presentation Outline
1. Introduction
2. Literature Review
3. Design of Kinematic Mount
4. Actual Testing and Realization
5. Conclusion
6. Future Work
7. References
3. 1. Introduction
Space craft
• A spacecraft is designed to leave Earth's atmosphere and operate
beyond the surface of the Earth in outer space. Spacecrafts are
designed for a variety of missions which may include
communications, earth observations, navigation, planetary
explorations, scientific research, and so on.
• Spacecraft – Typical Subsystems like Attitude control, Payloads,
Launch vehicle etc.
Payload
• The payload is dependent upon the mission of the spacecraft,
Typical payloads could include scientific instruments (cameras,
telescopes, or particle detectors, etc.).
4. Remote sensing payload
• The remote sensing component of the programme, in particular, has
successfully achieved global acceptance. Operational satellites have
been indigenously built and launched, which cater to land and
ocean applications.
• There are numbers of elements for imaging, sensing etc. in remote
sensing payload.
Telescope
• A telescope is an instrument designed for the observation of remote
objects.
6. Filters:
• To have single collecting optics for all 4 bands and use appropriate
spectral separation system for band selection.
• To use separate collecting optics for each band
Types of Filters
• Low Pass Filter- Passes low-frequency signals but attenuates signals.
• High Pass Filter- Passes high frequencies well but attenuates frequencies
lower than the filter's cutoff frequency.
• Band Pass Filter- Band pass filter are uses to pass these 4 bands, every
band has a specific spectrum.
7. Kinematic mount
• Kinematic Mount are widely used to minimize the deformation of
optical elements caused by Kinematic mount induced stresses.
Kinematic mount uses the principle of kinematic theory.
Theory of Kinematics
• A rigid body in space has 6-DOF, three translations and three
rotations. Kinematic theory assumes that perfectly rigid bodies
contact only at infinitesimal points.
• The application of kinematic theory consists of selecting no more
than six contact points to provide the type of support or motion
required.
8. Flexure:
Definition of Flexure:
“Flexure is usually considered to be a mechanism of a series of rigid
bodies conducted by compliant elements that is designed to produced
a geometrical well defined motion upon application of force”
Or
“Flexure is an elastic element which provides controlled motion”
2. Literature Review
9. Advantages:
• It must exert low force on the optical element to minimize optical
surface distortion.
• The mount must be such that a thermal changes in temperature must
not degrade the optical surface or change the position of the optical
element.
• It must maintain the position of the optical element throughout its
assigned life time.
• Mounting fabrication and material cost should be as low as possible.
10. Flexure Elements:
• Flexure device consist of compliant elements that connect ‘rigid’
bodies to from a mechanism.
Types of Flexure Elements
Types of
Notch Joints
Compliant Joint
Compliant Notch
Universal Joint
Cruciform Joint
11. Material Selection:
• Compliance of an individual flexure depends of the shape and
flexure material.
• Stability of flexure material with respect to time so its important for
maintaining alignment of optical element.
• Dimensional stability of flexure is controlled by choice of material.
• Another consideration, thermal properties of flexure material- good
matching between CTE of flexure and optical element.
Test on Vibration Shaker:
12. Sinusoidal Vibration Test
• Sine vibration testing is used to find out natural frequencies, peak
value of acceleration.
Random Vibration Test
• Many vibration environment are not related to a specific deriving
frequency and may have input from multiple sources which may not be
harmonically related.
• Unlike Sine vibration, acceleration, velocity & displacement are not
directly related by any specific frequency.
• Primary concern in Random testing is the complete spectral content of the
vibration being measured.
13. 3. Design of Kinematic Mount
Introduction
Design Steps
CAD models
Structural Analysis of Assembly
14. Introduction
• Kinematic mount is monolithic part. The mount needs to be
designed to perform satisfactorily without losing its alignment.
• The mount itself has to avoid deformation of the mounted optics.
Kinematic mount is to be made by incorporating different types of
flexures in this design.
• Kinematic mount following the cantilever principle, a large mount
allows finer control than a smaller one.
16. 1) Identification of Need
• Filters need to be housed in mechanical assembly to give them
support as well as to maintain separation between different optical
elements under the application of loads. Need arises to design to this
mechanical element.
2) Definition of Problem
“To design mechanical support for supporting optical elements like
band pass filter in such a way that it will sustain different loads and
the optical elements will perform satisfactorily under this load.”
Goals:
1) Supporting optical element and maintaining its position relative to other
optical elements in an optical system.
2) Design has to be such a way that to sustain gravity loads and changing
temperature conditions in space, sine and random vibrations.
17. Loads and boundary conditions :
1. Loads
• Inertial load: 100g, 200g (gravity load) individually in all axes as per
requirement.
• Temperature: 40°c excursion load.
• Sine loads, Random loads as per below table
Qualification Levels
(ii) Sine Vibration loads (iii) Random Vibration loads
Direction In Plane Out of Plane Direction In Plane Out of Plane
Frequency
(Hz)
Amplitude at
Qualification
Level
Amplitude at
Qualification
Level
Frequency
(Hz)
Qualification
Level
Qualification
Level
5 – 16 4.85 mm 9.7 mm 20 – 100 +3 dB/Oct +3 dB/Oct
16 – 50 5 g 10 g 100 - 700 0.1g2 / Hz 0.2 g2 / Hz
50 – 80 3 g 6 g 700 – 2000 - 3 dB/ Oct - 6 dB/ Oct
80 - 100 3g 3 g Overall ‘g’
rms
11.89 rms 14.8 rms
Rate &
Duration
2 Oct/min 2 Oct/min Duration 2 minutes 2 minutes
18. 2. Boundary conditions:
• Mount should have 2 fixing holes at the end.
Specifications:
1) Mount design to hold optical elements having sizes: 85x10x2,
30x20x1and 30x20x3 mm3.
2) Filter material: NBK-7, fused silica (glass material).
3) Mount should be made with optimum size (approaching close to filter
size) and minimum mass as possible.
19. 3) Synthesis
• This is the most important step in the designing.
• Here are various schemes for designing of kinematic mount. Kinematic
mount is made by using different types of thin sections. These thin sections
are called flexures.
Cross strip,
Notch joints (Square, Circular, Elliptical),
Cruciform flexure etc.
20. Material selection for mount:
1) Sufficient flexibility of mount should be made up from material which has
low stiffness.
2) Difference between CTE (co-efficient of thermal expansion) of filter
material and mount material should be as minimum as possible.
3) Mount material should have sufficient strength so that it should not fail
under the action of different loads.
4) The mount material should be dimensionally stable over a period of time.
5) Flexures will be having complicated geometry and the material should
have good machinability.
21. 4) Analysis and Optimization
• Analysis of the mount gives the results in frequencies, stress, acceleration
and displacement.
• Here , Two types of analysis
1) Static Analysis
2) Dynamic Analysis
Natural
Frequency
Analysis
Frequency
Response
Analysis
Random
Response
Analysis
Dynamic Analysis
Static Analysis
Inertial load Temperature load
22. 6) Presentation
• Evaluation is the final proof of a successful design and usually involves
the testing of a prototype.
5) Evaluation
• A brief summary is presented which involves different steps in the process
as well as final results obtained from the analysis and testing.
33. Structural Analysis of Assembly
• Analysis means examination of the different components or
elements that make up an assembly, to discover their
interrelationships and relative importance in the realization of its
goals or purpose.
• Basically in analysis three steps are involved
1) Pre Processing
2) Processing
3) Post Processing
34. Pre-Processing:
1) Meshing:
• Meshing is performed to discretize the geometry created into small
pieces called elements.
FE model of Mount:
Option -2
36. Loads and Boundary Condition:
• Loads:
Inertial, temperature, sine & random vibration loads
• Boundary conditions:
Fixing point
37. Processing:
• Import the model for processing which is exported from Pre-
processor.
Two types of analysis has been carried out
1) Static analysis
2) Dynamic analysis
38. Post- Processing:
• After completion of analysis solver generates result files.
Viewing and Interpretation of Results:
• Before looking the results the terms Von-Mises and Max. Principal
are as follows.
Von-Mises Stress:
• Ductile material fails at a plane inclined 45° to axis of loading.
Normal stress not act on this plane so this theory is best for ductile
material.
Max.Principal:
• Failure of brittle material subjected to uniaxial test is along a plane
to perpendicular to axis of loading. So this theory is best for brittle
material.
39. Case-1 : Inertial Load of 100g & 200g
Inertial loading analysis is done to analyses strength of the structure
during its flight.
Stresses due to Inertial Load
Option-2
Band Pass Filter assembly
Component Stress (MPa) value at 200 g Inertial load
Filter ( Max Principal) 9.2 2.29 3.23
Mount (Von Mises) 39.6 13.0 50.9
Adhesive 14.7 3.09 11.5
40. Stress on filter ( Max. Principal)
Stress on Mount ( Von Mises)
Stress Counters
This results shown only Yaw axis
results because yaw axis is critical
axis for analysis
41. Option-4
Band Pass Filter assembly
Component Stress (MPa) value at 100 g Inertial load
Filter ( Max Principal) 2.88 1.44 0.84
Mount (Von Mises) 8.64 8.16 2.96
Adhesive 2.48 1.59 0.76
42. Stress Counters Stress on filter ( Max. Principal)
Stress on Mount ( Von Mises)
This results shown only Yaw axis
results because yaw axis is critical
axis for analysis
43. Case-2 : Temperature Load (ΔT= 40°c)
• Temperature loading analysis is done to measure the strength of
structure under temperature difference. During in-orbit operation of
payload, some faces see the sun side and experiences radiation
from the sun.
Stresses due to Temperature Load
Option-2
Band Pass Filter assembly
Component Stress (MPa) on Temperature change
ΔT=40°C
Filter ( Max Principal) 4.35
Mount (Von Mises) 51.3
Adhesive 5.75
45. Option-4
Band Pass Filter assembly
Component Stress (MPa) on Temperature change
ΔT=40°C
Filter ( Max Principal) 13.2
Mount (Von Mises) 36
Adhesive 12.4
47. Case-3 : Normal Mode Analysis
• Normal mode analysis is done for finding out normal mode shapes
and frequencies for final configured models to be tested on
vibration shaker.
• It determines the natural (resonant) frequency and mode shapes of
the structure.
Results of Normal Modes:
• Only flexure modes are important because its shows the behavior of
mount and shows the acceleration of filter also.
48. Normal Mode Analysis
Option-2
First mode: 885.1 Hz
• Filter has translation in out of plane.
• Flexure worked as a cantilever beam.
Frequency (Hz)
Mode Nastran ( Theoretical )
First mode 885.1
Second mode 1597.2
Flexure in plane mode 2141
49. Second mode: 1597.2 Hz
• Flexure will flex in plane direction
Third mode: 2141 Hz
50. Option-4
First mode: 885.1 Hz
• Filter has translation in out of plane.
• Flexure worked as a cantilever beam.
Frequency (Hz)
Mode Nastran ( Theoretical )
First mode 985.27
Local mode of mount 1519.5
Second mode 2030
Flexure in plane mode 2036
51. Local mode of mount: 1519.5 Hz
Second mode: 2030 Hz
Flexure in plane mode: 2036Hz
52. Case-4: Frequency Response
• Frequency response analysis is done to simulate the response at
different locations of the job for given acceleration
• Critical damping factor is most unpredicted term of the frequency
response analysis.
• Critical damping factor is most unpredicted term. It depends on
many parameters like material, shape, no. of joints in the structure
etc). It is difficult to evaluate damping factor theoretically.
• Hence, to determine damping factor, low level Sine test of Band
Pass filter assembly was carried out. Damping factor is calculated
by half power bandwidth method
54. • Derived dynamic magnification factor (Q) for BP filter mount
assembly are shown in following.
Option-2
Option-4
Yaw axis
Frequency (Hz) Q
929 18
Yaw axis
Frequency (Hz) Q
1010 19.6
1570 116
55. Results of Frequency Response Analysis
Option-2
Input level of 1mm/s2 for 10Hz-2000Hz
Theoretical Experimental
Frequency (Hz) 885 929
Response (g/g) 30.46 27.11
Sine Response at middle of the filter
57. Theoretical value of stress
At 1st freq stress is 0.00127 x 10-5 MPa for input of 1 mm/s2
Calculation: 0.00127 x 10-5 *9810*0.5= 0.622 MPa
Experimental value of stress
Strain is 15.4 x 10-6
Stress σ = E*ε
= (0.82x105) x (8.35 x 10-6)
= 0.684 MPa
Theoretical Experimental
Frequency (Hz) 885 929
Stress (MPa) 0.622 0.684
Stress middle of filter
59. Option-4
Input level of 1mm/s2 for 10Hz-2000Hz
Theoretical Experimental
Frequency (Hz) 985 1010
Response (g/g) 24.1 20.55
Sine Response at middle of the filter
61. Theoretical value of stress
At 1st freq stress is 9.3 x 10-5 MPa for input of 1 mm/s2
Calculation: 9.3 x 10-5 *9810*0.5= 0.456 MPa
Experimental value of stress
Strain is 6.78 x 10-6
Stress σ = E*ε
= (0.73x105) x (6.78 x 10-6)
= 0.495 MPa
Theoretical Experimental
Frequency (Hz) 985 1010
Stress (MPa) 0.456 0.495
Stress middle of filter
62. Case-5: Random Response
• Random response analysis is the same analysis that performed as the
random vibration test on vibration shaker. This is the most effective
step towards the measurement of vibration characteristics.
• This analysis takes input from the result of frequency response
analysis. So it's a dependable analysis. Along with above input, this
analysis requires power spectral density (PSD) level for the
frequency range to be tested.
63. Results of Random Response Analysis
Option-2
Theoretical Experimental
Input level(gRMS) at mounting I/P 14.8 14.8
Response at middle of filter
(gRMS)
96.31 64.83
Random Response at middle of Filter due to Random Qualification load
72. Stress counter for stress
(rms) due to Random
Qualification load
Stress on filter 2.93 MPa
Stress on Mount 2.56 MPa
73. 4. Actual Testing and Realization
• Actual test is performed by vibration testing of band pass filter
assembly on vibration shaker.
Purpose of Testing
• This test has basic purpose of evaluating the behavior of filter assembly to
the actual launch environment that is simulated during testing.
The set up consists of
1. Shaker
2. Fixture
3. BP filter assembly
4. Spacer
5. Accelerometers
6. Strain gauges
74. Test Configuration
Requirements to measure Acceleration and Strain
Accelerometer
• It is a piezoelectric transducer used to convert the kinetic energy into an
electrical signal. One accelerometer is used in the test. Its mass was 1
gram.
Strain Gauge
• A strain gauge is used to measure the strain of an object. The gauge is
attached to the object by a suitable adhesive.
• Strain gauge measure the strain of filter in terms of mst (micro strain).
One strain gauge is used in the test.
75. Location of Accelerometer and Strain gauge
Location of Accelerometer (Tri axial)
Location of strain gauge
Actual locations of Accelerometer and Strain gauge for testing (option-4)
76. Test Sequence
1. Low Level Sine test (LLS)
2. Sine qualification test (SQ)
3. Post SQ LLS
4. Low Level Random (LLR)
5. Random Qualification test (RQ)
6. Post RQ LLS
77. Test Results ( option-4)
1) Yaw axis
Yaw axis Test Set up
83. Comparison of Theoretical and Experimental data
of Band Pass Filter Assembly
• In actual test, accelerometer & strain gauge are present; hence
their masses are considered. So in theoretical analysis, I have
to add those masses and so my analysis is done with
consideration of these masses. In theoretical analysis,
accelerometer has been simulated as a lumped mass.
84. Low level Sine Response
1) Comparison of Frequency Response during LLS
0.01
0.1
1
10
100
10 100 1000
Acceleration(g/g)
Frequency (Hz)
Low Level Sine Response
THEORITICAL_985Hz/24.1g/g EXPERIMENTAL_1010Hz/20.55g/g
85. Sine Response at middle of Filter
Theoretical Experimental
Frequency (Hz) 985 1010
Response (g/g) 24.1 20.55
86. 2) Comparison of Stress during Low Level Sine Test
1.00E-04
1.00E-03
1.00E-02
1.00E-01
1.00E+00
10 100 1000
STRESS(mPa)
Frequency (Hz)
Stress for Low Level Sine test
THEORITICAL_985Hz/0.45mPa EXPERIMENTAL_1010Hz/0.49mPa
87. Stress at middle of Filter
Theoretical Experimental
Frequency (Hz) 985 1010
Stress (MPa) 0.456 0.495
88. Low Level Random Response
1) Comparison of Random Vibration Qualification Response
0.00001
0.0001
0.001
0.01
0.1
1
10
100
20 200 2000
g2/Hz
Frequency ( Hz)
Random Vibration Response for Qualification
theoritical_gRMS_71.8g experimental_gRMS_64g
89. Random Response at middle of Filter due to Random Qualification
Load
Theoretical Experimental
Input level (gRMS) at
mounting I/P
14.8 14.8
Response at middle of
filter (gRMS)
71.8 63.93
90. 2) Comparison of Stress during Random Vibration Qualification
1.00E-08
1.00E-07
1.00E-06
1.00E-05
1.00E-04
1.00E-03
1.00E-02
1.00E-01
1.00E+00
10 100 1000
Stress(MPa)2/Hz
Frequency (Hz)
Stress due to Random Qualification level
THEORITICAL_Stress_RMS_2.93mPa EXPERIMENTAL_Stress_RMS_3.29mPa
91. Stress (rms) at middle of filter due to Random Qualification Load
Component Theoretical Experimental
Filter (Max. prin.) MPa 2.93 3.29
93. Yaw axis test data
Band pass filter
assembly
Pre SQ LLS
(I/P= 0.5g)
Freq (Hz) 929
g/g 27
Micro strain 8.35
Post SQ LLS
(I/P = 0.5 g)
Freq (Hz) 929
g/g 26.1
Micro strain 8.04
LLR
I/P=1.48g
gRMS 929
Micro Strain RMS 4.347
RA
I/P= 10.52g
gRMS 932
Micro Strain RMS 28.45
RQ
(Qualification)
I/P=14.8 g
gRMS 932
Micro Strain RMS 39.86
Post RQ LLR
(I/P= 0.5g )
g/g 28.3
Micro strain 8.84
Freq (Hz) 929
94. Comparison of Theoretical and Experimental data
of Band Pass Filter Assembly
Low level Sine Response
Theoretical Experimental
Frequency (Hz) 885 929
Response (g/g) 30.46 27.11
Sine response at the middle of the Filter
95. 1) Comparison of Frequency Response during LLS
0.1
1
10
100
20 200 2000
Acceleration(g/g)
Frequency (Hz)
Low Level Sine Response
theoritical_885_30.46g/g experimental_929_27.11g/g
96. 2) Comparison of Stress during Low Level Sine Test
0.001
0.01
0.1
1
20 200 2000
Stress(MPa)
Frequency (Hz)
Stress at Low Level Sine test
theoritical_stress_0.67MPa experimental_stress_0.68MPa
97. Stress at middle of Filter
Theoretical Experimental
Frequency (Hz) 885 929
Stress (MPa)* 0.622 0.684
98. Low Level Random Response
1) Comparison of Random Vibration Qualification Response
0.00001
0.0001
0.001
0.01
0.1
1
10
100
1000
20 200 2000
g2/Hz
Frequency (Hz)
Random Vibration Response for Qualification
theoritical_gRMS_96.31g experimental_gRMS_64.83g
99. Random Response at middle of Filter due to Random Qualification
Load
Theoretical Experimental
Input level (gRMS) at
mounting I/F
14.8 14.8
Response at middle of
filter (gRMS)
96.31 64.83
100. 2) Comparison of Stress during Random Vibration Qualification
1.00E-07
1.00E-06
1.00E-05
1.00E-04
1.00E-03
1.00E-02
1.00E-01
1.00E+00
20 200 2000
stress(MPa)2/Hz
Frequency (Hz)
Stress due to Random Qualification level
theoritical_2.94MPa experimental_3.28MPa
101. Stress (rms) at middle of filter due to Random Qualification Load
Component Theoretical Experimental
Filter (Max. Prin.) MPa 2.94 3.28
102. 5. Conclusion
The dissertation establishes a need to develop an accurate mechanical
structure that corrects the deficiencies of the alignment problem during
launching and it's throughout operational life in orbit. Different types of
flexure geometries are evaluated for making a kinematic mount.
• After considering four options, it is realized that option 2 and option
4 are practically suitable as per the requirements cited.
• Further, option 4 is better in comparison to option 2 since it has
satisfies all the design requirements and it has a very good match of
analytical results with its experimental results.
• Hence, option 4 can be used for future space projects which are
having similar design criterion.
103. 6. Future Work
• Present work has excluded Opto-mechanical analysis like finding surface
deformations due to different mechanical loading conditions. This sort of
work can be undertaken in future during integrated payload development.
• This design philosophy of the filter mount assembly can also be applied to
other mechanical components holding different optical elements.
• Though the design is made for different mounts having different materials,
actual testing is done only for mounts made from Aluminum and Invar due
to scarcity of time. Mounts from other materials like titanium, composite
materials can be made and can be tested to know their behavior.
• Experimentation of the filter mount assembly can be done by putting them
in thermo-vacuum chamber and subjecting it to designed temperature
excursion loads to know their practical suitability.
104. 7. References
• Dr. Jinjun Shan, Assistant Professor of Space Engineering, ENG 4360 - Payload
Design, 1.2 Introduction to Space Missions.
• Dr. Jinjun Shan, Assistant Professor of Space Engineering, ENG 4360 - Payload
Design, 2.1 Payload Design and Sizing.
• Dr. Jinjun Shan, Assistant Professor of Space Engineering, ENG 4360 - Payload
Design, 4.2 Space Craft Sensors- Introduction to Sensors.
• George Joseph and P.D. Bhavsar, Activities at Indian Space Research Organization
(ISRO) on development of space borne remote sensing sensors.
• Daniel Vukobratovich and Ralph M. Richard, Flexure Mount for High Resolution
Element, Proc. of SPIE Vol. 0959, Opto-mechanical and Electro-Optical Design of
Industrial Systems, ed. R J Bieringer, K G Harding (Jan 1988) Copyright SPIE.
• Daniel Vukobratovich, Opto-Mechanical Design Principal, 1999 CRC Press,
http://www.engnetbase.com
• Stuart T. Smith. Flexure: Elements of Elastic Mechanisms. New York, (2000).
• Brian Trease, Flexures: lecture summary. Compliant System Design Laboratory
The University of Michigan, April 30 (2004).
• Chirag Kalariya, M Tech. thesis, Design, Development and Analysis of Payload
Fixation Device for Space Optical Payload. Department of Mechanical
Engineering, Nirma University, Ahmedabad, May 2010.
105. • http://enpub.fulton.asu.edu/imtl/HTML/Manuals/MC105_Cantilever_Flexure.htm,
accessed on 21st May 2011.
• Rechard G. Budynas and J. Keith Nisbett, Shigley’s Mechanical Engineering
Design, Eighth Edition (2008).
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Compliant Mechanism Design based on Dimensionless Graph Analysis,
Science Direct, Precision engineering 34(2010)92-100.
• 3M Scotch Weld Epoxy Adhesive 2216B/A, Technical Data, December 2009.
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h06.pdf, chapter – 6 FEM Modeling: Introduction.
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Practical Finite Element Analysis, First Edition.
• Naimesh Patel, J.B.Rami, A.P.Vora, C.P.Dewan, D.Subrahmanayam, Derived
vibration spectrum based qualification of opto-mechanical subassembly, SSME
(Space Society of Mechanical engineers) Journal of Mechanical Engineering ,Vol.8
No.1 ,June, 2010, Page 43-47.