Journal of Advancement in Machines

Numerical Simulation of Closely Spaced Nozzle Openings for Fixed Tube sheet Heat Exchanger

Dinesh H. Burande — 2026-03-30

The location of nozzle openings is an important structural determinant in heat exchangers (of shell and tube type), for fixed tubesheet separation. When a nozzle is situated too near the tubesheet to shell connection, the local area will be vulnerable to large stress concentrations because of these loads conveyed by external piping systems. Such stresses may undermine the solidity and trustworthiness of the junction and the tubesheet. The study is intended to measure how the nozzle diameter size and its distance to the tubesheet junction affect the stresses that it produces to establish the nearest safe position to make the nozzles conform to the requirements of the ASME Section VIII design criteria Division 2. Finite Element Analysis (FEA) numerical simulations of different geometric models of a heat exchanger shell with a fixed tubesheet, and with nozzles of different diameters and movement off the junction were made. Depending on the scenario of the worst loading of the nozzle surface, the analyses were conducted to determine the resulting stresses within the shell and tubesheet area. Some important parameters, like the equivalent stress, deformation, and stress intensification adjacent to the junction, were also examined. The aim of this is to provide a rule of thumb for the minimum acceptable distance between the nozzle and the tubesheet junction to prevent loss of the structure at the design loads. The findings suggest that there is a critical response between the size and location of nozzles, offering information on the best design habits. This research is useful for enhancing the reliability and safety of heat exchangers, especially in those designs where the nozzle openings cannot be far apart because of space limitations.

Evolution of Latch Systems: From Mechanical Devices to AI-Integrated Smart Security Solutions

Amol More — 2026-04-09

Latches are crucial mechanical components used in the commercial, industrial, and residential sectors to secure doors, windows, and enclosures. The construction, operation, and applications of latch systems are all thoroughly examined in this study. The components of conventional latch mechanisms, including the latch bolt, spring, handle, and strike plate, are analysed. Additionally, it covers how door latches operate when they are opened and closed. Conventional latch systems are changing into intelligent systems that incorporate artificial intelligence (AI) and the Internet of Things (IoT) due to the quick advances in technology. This study investigates contemporary implementations like intrusion detection, real-time monitoring, and OTP-based access control. In order to assess practical performance, a case study on the deployment of smart latches in rental systems is included. The results of the experiment show increased intrusion detection (~95% reliability), decreased response time (<1.5 s), and improved authentication accuracy (~98%). The results show that smart latch systems greatly increase operational effectiveness, security, and accessibility.

Process Parameters and Machining Performance in Wire Electric Discharge Machining: A Review

Yash Unune — 2026-03-27

Wire Electrical Discharge Machining (WEDM) is widely regarded as a sophisticated non-traditional machining technique utilised for processing difficult-to-machine materials such as titanium alloys and high-strength engineering alloys. Due to its ability to produce intricate geometries with high-dimensional accuracy and excellent surface quality, WEDM has attracted significant interest in contemporary manufacturing sectors. This study provides a comprehensive review of the existing literature, with a particular focus on the optimisation of WEDM process parameters and their impact on machining performance. The key response variables examined in prior research include material removal rate (MRR), surface roughness (SR), dimensional accuracy, and kerf width. Critical process parameters such as pulse-on time, pulse-off time, peak current, wire feed rate, and servo voltage have been identified as major factors influencing machining efficiency and output quality. To achieve optimal performance, various optimisation methodologies, including the Taguchi method, Response Surface Methodology (RSM), Grey Relational Analysis (GRA), fuzzy logic-based techniques, and machine learning approaches, have been extensively applied to determine the most suitable machining conditions. Furthermore, the selection of electrode material and coating has been shown to influence machining stability and surface integrity, with zinc-coated brass wire electrodes demonstrating improved flushing efficiency and enhanced performance. Recent advancements in hybrid optimisation strategies and artificial intelligence-based models have further enhanced prediction accuracy and facilitated effective multi-objective optimisation. Overall, the review highlights that systematic optimisation of process parameters, combined with advanced modelling and intelligent optimisation techniques, is essential for improving machining efficiency, surface quality, and dimensional accuracy in WEDM, particularly when machining difficult materials such as titanium alloys.