bluuebunny/crossref_metadata_2025 huggingface dataset:
Effect of Common Cause Failures on Redundancy Optimization
Authors: Hazarika Kalpana , Pahuja G.L.
Published: July 2014

Redundancy allocation (RA) is one of the important approaches to improve system reliability by incorporating generally s-identical and s-independent components. However in the presence of common cause failures (CCF), a rarely studied problem as Redundancy optimization, the optimized system reliability may be adversely affected. In this paper the effect of CCF on Reliability Optimization using Redundancy Allocation has been expedited. The paper is implemented in two steps. Step1 involves obtaining the optimized solution of the problem using existing techniques. In the next step, modifications are done to compute optimized system reliability under CCF. The optimized reliability expression is modified to depict the effect of CCF. The work is extended to complex network analysis & implicit method has been used to do this work. The adverse effect of CCF on system reliability has also been demonstrated quantitatively with the help of example.
Ergonomically Designed Lift - Assist Device in a EOT Crane
Authors: Kumar R.A. Vikranth , Harish Babu M. , Uthayakumar Marimuthu , Murugabhoopathy K.
Published: July 2014

Manual Material Handling (MMH) duringmaintenance activities poses strain to employees and at times it results in injuries. This type of work entails lifting, bending and twisting which can cause great strain to the human body if done improperly. A paradigm shift has taken place in Ergonomics from the narrow to a wide approach dealing with physiological, psychological, technological and organizational aspects of human work environment. This paper analyses the MMH hazards during the replacement of jaw bits in Electrically Operated Tong (EOT) crane in Hot Rolling Mill. Ergonomics risk factors were estimated using Rapid Entire Body Assessment risk assessment (REBA) tool. Based on the analysis, suitable engineering improvement called Lift - Assist Device was developed to reduce extreme range of motion while lifting, moving and inserting and found to be satisfactory.
Hazard Identification in Electrical Discharge Machining (EDM) Process Using What-If Analysis
Authors: Sivapirakasham S.P. , Thiyagarajan S. , Bineesh P. , Mathew Jose , Surianarayanan M.
Published: July 2014

This paper provides guidance to key techniques and methods used in the EDM process industry for identifying and documenting environment, safety, and health (ESH) hazards and theircontrols.This is first time that the brainstorming method “what-if” analysis,one of the well-known process hazard analysis (PHA) techniques, is used to predict hazards in electrical discharge machining (EDM) processes. This technique analyzes potential causes and consequences of fires, explosions, releases of toxic or flammable chemicals and major spills of hazardous chemicals, and focuses on fluid system, machining system, electrical & instrumentation system, utilities, human actions and external factors that might impact the process. This analysis helped to identify conditions that can lead to an accident situation and recommendations are givento overcome the risks of these situations. An exhaustive analysis in the EDM process to identify and analyze hazards is presented in this paper and control recommendations are provided to overcome the risks of these hazards.
Investigation of Environment and Machining Aspects in Electrical Discharge Machining (EDM) Using Different Workpieces and Tool Electrode
Authors: Sivapirakasham S.P. , Thiyagarajan S. , Mathew Jose , Surianarayanan M. , Nathan A.S. Sathya Sai
Published: July 2014

Emission of toxic substances is the major occupational and environmental problem associated with this process. These emissions may cause adverse health effects to the operators and has the direct impact on the environment. The present investigation was conducted to study together the environmental and machining aspects of EDM process. The work aims to investigate the emission and machining parameters in EDM process using different workpiece material viz; like aluminum, mild steel and AISI-D3 tool steel with EDM 30 as a dielectric fluid and brass as a electrode. The results showed that the aluminium workpiece material gave a higher emission rate and MRR compared with mild steel and AISI D3 tool steel due to the low melting and boiling temperature. Among the process parameters, peak current and pulse duration was found to strongly affect the emission and performance aspects.
Parameters Influenced in Car Seat Design from Ergonomic Perspectives - A Review
Authors: Gokila P. , Suresh P.
Published: July 2014

Seats are one of the most important components of vehicles and they are the place where professional driver spend most of their time. Since the beginning of the automotive industry, providing a comfortable, economical and safe ride to the customer, has been the prime objective of all the manufacturers regardless the brand. Present review is done in order to mainly focus on various parameters which lead to seating discomfort in cars. Human experienced seating discomfort has been discussed briefly and ergonomic approach to overcome discomfort has also been analyzed.
Application of Queuing Theory to Address Traffic Problems at a Highway Toll Plaza
Authors: Duhan Dheeraj , Arya Nishant , Dhanda Prateek , Upadhayay Lalit , Mathiyazhagan K.
Published: July 2014

In India, due to the escalating traffic issues, a large number of highways have been built in the recent past, which are maintained by tax collection at toll plazas, by various operating agencies. Due to smooth and hassle free driving on highways, the arrival rate of vehicles at Toll Plazas increases. The arrival rate goes beyond control if the traffic on the highway increases in an uncontrolled manner, with the passage of time. Thus, one of the irrefutable drawbacks of putting up Toll Plazas, is the traffic congestion. The waiting time, in the service lanes, due to such a congestion becomes high and excruciating for the commuters on the route. The objective of this study is to analyze the current situation, of traffic congestion, at a highway toll plaza using queuing theory and suggest possible solutions to encourage greater efficiency, thus reducing waiting time of the customers and money wasted because of that. This study has been carried out in various phases, i.e. problem identification, data collection, data analysis and results at a selected Toll Plaza in North India. The data analysis in the study helps to find out the current operational effectiveness of the Toll Plaza through parameters like, Arrival Rate, Service Rate and Number of toll booths. Finally, possible solutions have been put forward which can be recommended and implemented on various Toll Plazas in the country.
Design and Automation in Back Plug Press Fitting Process of Ball Pen Assembly
Authors: Gajjar Bhavya R. , Sheth Saurin
Published: July 2014

In today’s era automation in the production is a key parameter of interest. Rise in the productivity is the main aim of every industry. To sustain in the global era many companies are switching their assembly line from manual to automatic. Consequently, assembly systems should be more flexible and efficient. Even which process needs the automation should be justified to make it automatic. The amount of automation and payback period plays an important role. On that basis authors identify the back plug process needs to be automate. So an attempt is made to design an Automatic Back Plug Press Fitting Process. The paper describes the design, modeling and manufacturing aspects of this process. In automation decisions, it is necessary to consider human resources, as well as mechanical technology and information flow. The paper also includes rise in the productivity along with payback period.
Effect of Lean Principles on Organizational Efficiency
Authors: Kumar Rajender , Kumar Vikas , Singh Sultan
Published: July 2014

In India, the manufacturing sector is striving hard to generate revenues and this is ongoing for the last one decade. This aspect of generating funds is dependent on two major factors i.e. reduction in product manufacturing cost, and enhancing the product quality to satisfy the customer needs. The production cost can be reduced by improving the design and through incorporating the newest version of materials. The improved version of materials will positively add value to the product quality and thereby attract the customers. On the other hand, the product quality can increased through application of systematic and statistical data analysis tool especially Lean, Six Sigma, SCM, JIT, TPM etc. in the manufacturing sector. This may further results in high labour efficiency. The paper comprises of literature review of published paper in various reputed journals on the concept of Lean manufacturing. "Lean" is a production process which encompasses the expenditure of all the resources to accomplish a goal and creating of value to end customer through eliminate the wastes. The paper reveals that the goal of Lean is creation and maintenance of a production system, which runs repetitively, day after day, week after week in a manner identical to the precious time period. The continuous and smooth flow, earlier delivery, reduced cost and better design are the outcomes of the systems.
Evaluation of Green Supply Chain Factors Using DEMATEL
Authors: Anand K.R. , Ramalingaiah Ramalingaiah , Parthiban P.
Published: July 2014

Green supply chain management (GSCM) is a powerful tool to differentiate one company from the others and it can greatly influence the success of any plan. With increased awareness about corporate responsibility and the necessary to meet the terms of the environmental policy, green supply chain management (GSCM) is becoming increasingly important for Indian manufacturers. This study aims to explore different factors whose consideration in supply chains lead to reduced environmental load. Adoption of those factors reduce environmental footprint and improve green credentials. The questionnaire used to obtain opinion of managers at different level from industries. The best factor for environmental friendly supply chain determined using Decision making trial and evaluation laboratory (DEMATEL) method. DEMATEL is a multi criteria decision making tool which has ability to convert qualitative data into quantitative analysis. DEMATEL method used to study the influence of the most important factor and to find out the ranking of critical factors in supply chain of industry. The result of paper gives best factor and adoption of same influences green performance of supply chain. Key finding from this study tells green manufacturing and green logistics has highest influence in green supply chain practices.
Evaluation of Mechanical Behavior of Multifilament Waste Fish Net/Glass Fiber in Polyester Matrix for the Application of Mechanized Boat Deckhouse in Marine Composites
Authors: Rajf Michael , Nagarajan V.A. , Vinod Kumar K.P.
Published: July 2014

Composite material has long life, higher strength, lower weight and less maintenance cost. These properties have led to marine applications, significantly reduced energy consumption and impact to the environment. Mechanized boat deckhouses are constructed with glass fiber and polyester matrix. But the glass fiber production and utilization is hazardous. The fish net is generally made from nylon fiber and woven in a grid-like structure, which is tough possess high tensile strength, elasticity, resistant to abrasion, impact and chemicals. Fish net gets damaged and large amount of them are wasted every year. The present work focuses on the reuse of this nylon fiber, as reinforcing material, as substitute for glass fiber partially, in polyester matrix. Tensile, impact, flexural and water absorption properties of these specimens are studied according to ASTM standards. The results suggest the possibility of utilizing waste fish net in composite building for boat deckhouse.
Inprocess Quality Control through Propotionate Valve in Electrical Upsetting of Engine Valves
Authors: Elaiyaraja K. , P Periyasamy
Published: July 2014

In regular electrical upsetting process, the process parameters were determined by the experience. During working, these parameters were constant and could not be controlled online. In this paper a new proportionate valve and various velocity top anvils, electrical upsetting system is introduced. Based on the bulb temperature measured at the time of operation proportionate valve will vary the upset pressure to obtain the bulb without crack or fold. The control strategy includes two key parts: sensing the temperature and controlling it by varying the power intensity in the circuit through controlling the upset pressure. And the different anvil position and anvil velocity will be used to change the bulb shape based on the valve profile. This control strategy also includes two key parts: Velocity of anvil is directly proportional to height of bulb, in various positions various velocity will be used to form a different shape of bulb without defects.
Lead Time Reduction through Lean Technique in an Monoblock (SWJ1HP) Pump Industry
Authors: Ganesan K. , Prasad Mohan M. , Suresh R.K.
Published: July 2014

Value Stream Mapping has the reputation of uncovering waste in manufacturing, production and business processes by identifying and removing or streamlining value-added steps and eliminating non-value-added steps. The various process times for manufacturing a mono block pump were obtained from a pump manufacturing industry. The flow diagram showing the process is drawn to reflect the current state of the operation. The non-value actions are identified in each step and between each step by their waste of time and resources. The process is analyzed for opportunity to drastically reduce and simplify it to the fewest actions necessary. By reducing waste the proportion of value adding time in the whole process rises and the process throughput speed is increased. This makes the redesigned process more effective (the right things are being done) and more efficient (needing fewer resources). The reengineered process is flow charted in its future state with process steps and information flows redesigned, simplified and made less expensive. This paper addresses the application of lean manufacturing concepts to the pump manufacturing industry.
Network Design for Reverse Logistics – A Case of Recycling Used Truck Tires
Authors: Kumar B Manoj , Saravanan R.
Published: July 2014

Managing the products at the end of its intended use and recovery of such used products from the market is gaining significant importance these days due to global environmental concerns, resource reduction, government regulations and economic factors. Reverse logistics networks serve the same. The handling of products, components and materials during the recovery process can be called reverse logistics. Due to the increasing number of heavy vehicles in the country like India, large quantities of used tires are generated every year, and proper disposal of these used tires creates problem in the day-to-day life. Hence recover the value from these used tires in the form of material recovery is gaining importance. The implementation of such recycling system usually requires an appropriate reverse logistics network for choosing the physical locations, facilities, and transportation links to convey the used products from the end customers to the recycling facility. A case study was conducted and traditional reverse logistics networks involved in the used tires focusing quality characteristics has been analyzed in the paper and a new network has been suggested focusing the quality characteristics of material recovered out of used tires through laboratory work and at the same time without compromising the cost factor involved in it. Finally a mathematical model has been developed and optimization of cost subjected to quantity, and time has been done and validated for the decision makers involved in the reverse logistics activities of used tires recycling.
Role of Kaizens to Improve Productivity: A Case Study
Authors: Jadhav Ganesh S. , Jamadar Vahid M. , Gunavant Pradeep S. , Gajghate Sameer Sheshrao
Published: July 2014

Continuous improvement is a vital component of an effective performance management system. Simply measuring performance will not result in system improvements. Getting improvement in any service requires an educational strategy for linking performance measurement to the implementation of the specific system improvements. The aim of the paper is to identify the effectiveness and implementation of the kaizen programme in an electronics manufacturing company. Customers focus on product quality, delivery time and cost. Because of this a company should introduce a quality system to improve and increase both quality and productivity continuously. Kaizen is a methodology that aims to increase the availability of the existing equipment hence reducing the need for further capital investment. This paper identifies role of maintenance in reducing production cost and increasing plant profit with the implementation of kaizen. Use of the Timed-PDCA concept makes it possible to pursue productivity improvement in the current works including nurturing motivations to workers concurrently by arranging kaizen theme.
Supply Chain Performance Evaluation Using Spreadsheet Simulation
Authors: George Joby , Pillai V. Madhusudanan
Published: July 2014

The objective of this paper is to develop a spreadsheet-based simulation methodology to evaluate the performance of a serial supply chain under different inventory position based ((r, Q) and (r, S)) and non-inventory position based (Fixed Order Quantity (FOQ) and Demand Flow Strategy (DFS)) periodic review inventory policies. The performance measures comprises of Fill Rate, Risk of Shortage, Bullwhip Effect and Total Cost of Supply Chain. An experimental study with four scenarios are carried out for two customer demand distributions under information sharing and no information sharing scenarios to determine performance measures in lost sales environment. The best performing inventory control policy for each scenario is found by conducting Grey Relational Analysis and the analysis show that one of non-inventory position based policy, FOQ is the better policy compared to other three policies.
The Effect of Rescheduling on Operating Performance of the Supply Chain under Disruption - A Literature Review
Authors: Rao Konteti V.N.V.N. , Ranga Janardhana Ginka
Published: July 2014

For many years,companies have focussed on quality and productivity of their products. Globalization, competition and information technology development have forced the industries to manufacture the products with low cost, good quality, availability in the market. Integration of all business entities will promote the value of above said criteria. Supply chain management is an integrated activity, which can meet this critical challenge. Supplier, customer and manufacturer are the entities of the supply chain, which are associated with more uncertainty. Therefore, the supply chain requires an effective rescheduling strategy to manage the disruption and uncertainty by updating and revising the existing schedule. However, the literature survey on rescheduling activity is very limited. The present literature review attempts to analyze the rescheduling activity due to the disruption from the supplier, manufacturer and customer. Literatures on the rescheduling environment, rescheduling factors, and rescheduling algorithm are reviewed to get over all focus. Finally, the review suggests that, to meet the delivery schedule with least makespan and without any disruptions the following factors viz (i) delivery capability (ii) machine utilization rate and (iii) stock level are to be considered. Keywords: Rescheduling, supply chain, disruption, uncertainty, performance measure
Deformation of Potato during Convective Drying
Authors: Chandramohan V.P. , Talukdar Prabal
Published: July 2014

Deformation of potato is estimated by experimentally during convective drying. Size of the potato slice is 4cm x 2cm x 2cm. The percentage changes in length, breadth and width of potato are estimated during drying. Shrinkage of the object during drying is estimated. Air velocity chosen for this present analysis is 2 m/s and the range of air temperature is selected as 40 to 70 °C. The product experiences the maximum dimension changes upto 30% in length and 47.5 % in both breadth and width wise. The parameters are non dimensionalised to get generic solution.
Aerostatic Spherical Bearing Manufacturing Methods and Criticalities - An Approach
Authors: Arun Kumar S. , Sekar A. , Govinda K.V.
Published: July 2014

In general, aerostatic bearings are flat bearings and the stringent manufacturing tolerances in geometric dimensions and profile will make the bearing ideal for obtaining high stiffness during measurement. Aerostatic Spherical Bearing (ASB) on the contrary is a special bearing which provides a frictionless pivot and allows three degrees of rotational freedom. Methods involved in manufacturing and realizing a highly stiff ASB is discussed in this paper. ASB components viz. Stator and Rotor of hemi-spherical in geometry are the critical components to be machined, which are used in Mass properties and Dynamic Balancing Measurement machine (MaPDBM). MaPDBM is used to measure mass, center of gravity, moments of inertia and static & dynamic unbalance of spacecraft. An air film of 25-50 μm thickness separates the stator and rotor during measurement, thus forming an aerostatic bearing. Precise Machining, Thermal treatments to ensure crash-proof design, Special processes like lapping for profile correction, Geometrical and profile measurements during different stages in the sequence for controlling the bearing parameters using Coordinate Measurement Machine (CMM) are the challenges involved in the machining and realization of the ASB components and the same is discussed in this paper.
Evaluation of Quality Diffusion Bonding in Similar Material (Cu/Cu) Using Ultrasonic ‘C’ Scan Testing Method
Authors: Kumar S. Suresh , Ravisankar Balasubramanian
Published: July 2014

In the present study, diffusion bonding of Cu/Cu was carried out at 750 °C for 60min under uniaxial pressureof 5-15MPa in vacuum. The joints were evaluated by Microtensile testing and Ultrasonic testing. The bond qualities were assessed by destructive testing (strength ratio) and nondestructive ultrasonic C–scan testing method.The bond quality obtained by both the methods is correlated in a view to use the C scan for regular testing. The optimum condition for obtaining the best bonding characteristics is reported. The joint obtained by diffusion bonding at 750 °C and a applied pressure of 15MPa for 60min gives the best bonding characteristics.Keywords: diffusion bonding/welding, Interface, Ultrasonic nondestructive testing.
Experimental Investigation on the Impact of the Tool Material & Geometry in Joining of Al 63400 Alloy Using Friction Stir Welding Process
Authors: Sevvel P. , Jaiganesh V.
Published: July 2014

In this paper, a detailed experimental investigation was carried on the impact of the effects of tool pin and shoulder diameter in joining the Al 63400 aluminium alloy using FSW process. Flat plates of 6 mm thickness have been selected as the base material for obtaining single butt welded joints. The tool materials used for joining these base material plates are High Speed Steel (HSS) and High Chromium High Carbon Steel (HCHCr). This paper experimentally investigates and suggests the appropriate, suitable tool material & tool geometry for producing good quality welds in joining of Al 63400 alloy using FSW process.
Experimental Investigations on Wire EDM of Al7075-TiB2 In Situ Metal Matrix Composite
Authors: Dalve Varun R. , Keshavamurthy R. , Ugrasen G. , Prakash C.P.S.
Published: July 2014

This paper focuses on optimization of process parameters for wire electric discharge machining (WEDM) of In-situ Al7075-TiB2 metal matrix composites processed by stir casting technique using Taguchi method of experimental design. The effect of pulse-on, pulse-off, current, and bed speed on dimensional accuracy, surface roughness and volumetric material removal rate (VMRR) have been investigated keeping voltage and flush rate constant. L27 orthogonal array of Taguchi technique was used for experimental trials. The optimum process parameters have been identified. Significant process parameters were identified from the analysis of variance (ANOVA). Further, verification experiment has been carried out to confirm the performance of optimum process parameters.
Fatigue Performance in Abrasive Flow Machining
Authors: Cherian Jose , Issac Jeoju M.
Published: July 2014

Surface finish and Manufacturing process has a prominent role in the fatigue life of a machine component. Fatigue strength of a material generally increases with the surface finish. But the super finishing process like electro polishing reduces the fatigue strength of the material. In Abrasive flow machining it is found that surface finish and fatigue strength always increasing. In Abrasive flow machining the fatigue strength is mainly governed by the process variables extrusion pressure, abrasive concentration and mesh size. This research studies the influence of the process variables on the fatigue strength of the material. In this study an approximate surface finish of 4μm is obtained after AFM. The effect of three process variables on the response function selected, fatigue strength, were studied. A statistical 23 full factorial experimental technique is used to find out the main effect, interaction effect and contribution of each variable on fatigue strength. The instron machine is used to find out the number of cycles to failure of the material. The fatigue strength is obtained with S-N curve analysis.
Formation and Structural Characterization of Electroless Ni-B-P Ternary Alloy Coatings
Authors: Venkatakrishnan P.G. , Nazirudeen S.S. Mohamed , Narayanan T.S.N. Sankara
Published: July 2014

The aim of the present investigation is to study the formation of electroless Ni-B-P alloy coatings and structural and morphological characterization of various coatings with different boron and phosphorous content. An alkaline plating bath with nickel chloride hexahydrate as the source of nickel ions and sodium borohydride and sodium hypophosphite as reducing agents were used for the formation of electroless Ni-B-P alloy coatings. The influence of changes in the concentrations of the reducing agents in the electroless plating bath on the chemical composition, structural and morphological characteristics of the coatings were studied. Scanning electron microscopic studies revealed that the surface morphology of Ni-B-P alloy coatings changed from corn cob-like structure to cauliflower-like structure with increasing borohydride concentration in electroless plating bath, whereas increase in hypophosphite concentration favoured sideway growth, thereby decreased the surface roughness of the Ni-B-P alloy coatings. The peak broadening in the X-Ray Diffraction profiles indicates the large reduction in the crystallite size of the electroless Ni-B-P alloy coatings with increasing boron content in the coating (i.e. for higher borohydride concentration in the plating bath).
Investigation of Tensile Property and Pore Closure Behavior and the Influence of Processing Route during Equal Channel Angular Pressing of Pure Aluminum Powder Compacts
Authors: Venkatraman R. , Raghuraman S. , Balaji R. , Ajay Kumar K.S. , Viswanath M.
Published: July 2014

This paper revolves around the idea of finding the strength enhancement of pure ‘Al’ compacts processed through Equal-Channel Angular Pressing (ECAP) process which ultimately results in fine grain structure of the material processed. The material initially prepared through conventional powder metallurgical route is processed in an ECAP die with a channel angle of 1100. The tensile test and micro-structural evaluation is done following the ECAP process and it is found that there was a substantial enhancement in the tensile properties and Ultrafine Grain (UFG) structure is obtained due to the Severe Plastic Deformation (SPD) phenomenon taking place during the process. The pore closure behavior is also analyzed using the TEM micrographs after each pass in ECAP die and promising results are obtained when the material is processed through different routes. The dislocation cell structure is also found to get refined after each pass through the die. The pore closure behavior is also confirmed using the DEFORM 3D software when the aluminum is simulated under similar conditions.
Investigation on Interlaminar Shear Stresses in Laminated Composite Plates under Thermal and Mechanical Loading
Authors: Murugesan Nagaraj , Vasudevan R.
Published: July 2014

In this study the combined effect of thermal environment and mechanical loadings on the interlaminar shear stresses of both moderately thin and thick composite laminated plates are numerically analyzed. The finite element modeling of laminated composite plates and analysis of interlaminar stresses are performed using the commercially available software package MSC NASTRAN/PATRAN. The validity of the present finite element analysis is demonstrated by comparing the interlaminar stresses developed due to mechanical loadings derived using the present FEM with those of available literature. Various parametric studies are also performed to investigate the effect of thermal environment on interlaminar stresses generated in asymmetric cross-ply composite laminated plates of different length to thickness ratios (L/H) and boundary conditions with identical mechanical loadings. It is observed that the elevated thermal environment under identical mechanical loading lead to higher interlaminar shear stresses varying with length to depth ratio and boundary conditions in asymmetric cross-ply laminated composite plates.
Investigation on the Effect of Multi Wall Carbon Nano Tubes in Wire Electrical Discharge Machining of Hybrid Metal Matrix Composites
Authors: Ramesh S. , Natarajan N. , Krishnaraj Vijayan , Kumar K. Sathish
Published: July 2014

Wire Electrical Discharge Machining (WEDM) is an very accurate non-traditional machining process for producing parts with accurate dimensions and complex shapes. The performance of WEDM is measured by evaluating the parameters like Material Removal Rate (MRR), Surface Roughness (Ra), cracks, voids, pores and recast layer. In this paper, an attempt is made to improve the machining performance by adding multi wall carbon nanotube (MWCNT) with dielectric fluid. The MRR, Ra and surface characteristics are compared with surface that is machined using dielectric fluid with and without MWCNT. The results show that addition of MWCNT improves the MRR and surface finish.
Investigations on Machinability and Machining Characteristics of Hybrid Polymer
Authors: Revanthkumar J. , Babu Rama Kishore G. , Thirupathi Reddy M. , Venkatachalam G. , Jeevanantham A.K.
Published: July 2014

One of the interests in machining is to attain better surface roughness with dimensional accuracy. Polymer composites has been continuously dispatching the conventional materials. Polymer based composites have superior mechanical strength and stiffness such as strength-to-weight ratio, high stiffness-to-weight ratio. Polymer composites are the one which are produced closer to the required shape and further machining is often necessary to achieve the expected surface characteristics. This study targets the machining of hybrid polymer, made in the form of round rod, using general purpose resin and cashew nut shell liquid with varying proportions of CSNL by volume fraction up to 30%. Machining is carried out and the study includes the influence of the various process parameters such as cutting speed and feed with depth of cut kept constant and their importance in deciding the surface roughness. Surface roughness was measured after machining under specified measuring conditions using Talysurf.
Magnetic Field Assisted Electrical Discharge Machining of AISI 4140
Authors: Walkar Hemant , Jatti Vijaykumar S. , Singh T.P.
Published: July 2014

Electric discharge machining (EDM) is a non-conventional machining process in which material removal take place by a series of electric spark generated between the small gap of both electrode and both immersed in dielectric medium. The gap conditions of EDM significntly affect the stability of machining process. Thus, the machining performance would be improved by removing the debris from the machining gap fastly. In view of this, the objective of present work was to investigate the effect of magnetic field on the material removal rate (MRR) and surface roughness (SR), in conjunction with the variation of electrical parameters like pulse on-off times and gap current, while keeping other electrical parameters and work piece/ tool material constant. Experimental results showed that the magnetic field assisted EDM improves the process stability. Moreover, the EDM process with high efficiency and quality of machined parts could fulfill the requirements of modern manufacturing industries.
Metallurgical and Mechanical Characterization of Al 6082-B4C/Si3N4 Hybrid Composite Manufactured by Combined Ball Milling and Stir Casting
Authors: Sharma Pardeep , Khanduja Dinesh , Sharma Satpal
Published: July 2014

Aluminium matrix composites (AMCs) having more than one reinforcement (hybrid AMCs) found enlarged use due to better strength, high thermal stability and wear resistance properties and can be a substitute for single reinforced AMCs .The effect of varying ball milled (BM) B4C/Si3N4 particles on the microstructure of as cast AA6082 and mechanical properties of AA6082 alloy hybrid composites produced by combined ball milling and conventional stir casting method have been reported. The combined reinforcement of BM B4C/Si3N4 particles were varied from 0-9 % in a step of 3. The wettability of B4C/Si3N4 into the aluminium melt has been increased by ball milling the boron carbide with silicon nitride powder, so that combined reinforcement of B4C/Si3N4 neither float nor sink in the aluminium melt. The investigated result showed that addition of combined reinforcement of BM B4C/Si3N4 increased Hardness and Ultimate tensile strength at the cost of reduction in percentage elongation.
Microstructure and Mechanical Properties of Friction Stir Welded Pure Copper
Authors: Raju Lam Suvarna , Kumar A. , Prasad S. Rajendra
Published: July 2014

Abstract. Conventional welding of copper and its alloys tends to degrade the mechanical strength at the welded area due to high thermal diffusivity and melting point. Friction stir welding (FSW) is an excellent alternative for joining of these materials against fusion joining. FSW is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a non-consumable tool to generate frictional heat in the abutting surfaces. The main objective of this investigation is to use FSW for joining of 3 mm thick copper sheet using taper cylindrical tool pin profile. The defect free welds were obtained at a tool rotational speed of 900rpm and 1120 rpm and traverse speeds of 25, 31.5, 40 and 50 mm/min respectively. Mechanical and microstructure analysis has been performed to evaluate the characteristics of friction stir welded copper. From the investigation it is found that the joints fabricated at a tool rotation speed of 900 rpm and traverse speed of 40mm/min resulted in better mechanical properties compared to other tool rotation and traverse speeds. The tensile properties of all the weld joints showed a relative correspondence to the variation of the hardness in the weld zone. The observed results were correlated with the microstructure and fracture features.
Modelling and Analysis of Electrical Discharge Alloying through Taguchi Technique
Authors: Arun Ilangovan , Durai Selvam Muthukannan , Senthilkumar V.
Published: July 2014

Electrical discharge alloying was performed on AISI D2 tool steel with addition of nickel powder. Taguchi method has been used to plan and analysis the experiment.The major parameters like Peak current, pulse on time, and pulse off are taken for this study for formation of alloyed layer. The influences of these process parameters have been identified by Signal to noise ratio (S/N) and analysis of variance (ANOVA) and their results are within the limits of predicted and experimental values. The experiments were conducted on a specially designed apparatus in laboratory itself. The layer thickness varies from 70 to 140 μm and the highest hardness value of 1788 HV0.3 with a lower specific wear rate.
Multi Response Optimization of Drilling Parameters during Drilling of Particle Board Using Grey Relational Analysis
Authors: Mercy J. Lilly , Prakash S. , Vijayalakshmi P. , Siva Teja Putti Venkata
Published: July 2014

Particle board serves numerous functions such as cabinetry, tabletops, shelving, wall & floor panels, etc. Though Particle boards are much cheaper compared to solid wood, machining the material by optimizing the process parameters is a big challenge. Drilling is the major operation during final assembly of particle board, where fasteners are used to join together to bring final shape to the product. In this paper, the operation parameters such as speed, feed, drill diameter has been considered during drilling operation performed on Particle board and the output responses-surface roughness of the drilled hole and the Thrust force acting on the board during drilling are measured. Good surface finish of the hole ensures reduction of localised stresses around the hole due to fastening. Reduced Thrust force contributes to lesser delamination in particle board. Hence minimisation of both surface roughness and delamination is desired and hence optimisation of both responses is done simultaneously using grey relational analysis.
Multi-Objective Optimization in Wire-Cut Electric Discharge Machining of Al 6063/Al2O3 Metal Matrix Composite through Response Surface Methodology
Authors: Hemalatha K. , Venkatachalapathy V.S.K. , Alagumurthi N.
Published: July 2014

This paper proposed a response surface methodology technique to optimize the multi-response of wire-cut electric discharge machining process. The machining was done on Al 6063 plate is casted with varying mass of Al2O3 (3%, 6%, 9%). Stir casting process is adopted for casting the composite plate. Design Expert is used to identify the effect of key operating factors on output measures such as surface finish and kerf by using Pulse on-time, pulse off-time, servo feed and varying mass of Al2O3 (3%, 6%, 9%). Also the distribution of Alumina and Aluminium is examined by microstructure analysis, and the material is tested for its mechanical Properties such as tensile strength and Hardness. We found that with respect to increase in pulse on-time and weight percentage of alumina the Surface roughness and kerf decreased leaving a better finish. Also a comparison has been done between the result obtained through response surface methodology and experimental values which indicates that the experimental values are very much close to the predicted values.
Multi-Objective Optimization of EDM Parameters Using Grey Relational Analysis for Titanium Alloy (Ti–6Al–4V)
Authors: Palanisamy A. , Rekha R. , S Sivasankaran , Sathiya Narayanan C.
Published: July 2014

In this paper optimization of the electrical discharge machining (EDM) process with multiple performance characteristics based on the orthogonal array with the grey relational analysis was studied and investigated. A grey relational grade obtained from the grey relational analysis is used to solve the EDM process. Optimal machining parameters are determined by considering the grey relational grade as the performance index. The input independent parameters of peak current, pulse on time and pulse off time were examined and optimized on multiple response characters (material removal rate, electrode wear ratio and surface roughness). Experimental results have shown that machining performance in the EDM process can be improved effectively through this approach.
Multi-Objective Optimization of Surface Roughness and Tool Wear in Turning Inconel 718: A Desirability Analysis, Genetic Algorithm and Firefly Algorithm
Authors: Sharma Shiv Kumar , Chandrasekaran Muthumari , Thirumalai Ramanathan
Published: July 2014

In this work, a parameter optimization in turning Inconel 718 for multiple performance characteristics has been attempted. The process parameters viz., cutting speed (v), feed (f) and depth of cut (d) is optimized that minimizes surface roughness (Ra) and tool wear (VB). Response surface methodology (RSM) employing CCD experimental design was used to develop predictive model for Ra and VB. The predictive capability of the model provides the average percentage error as 3.87 % and 5.10% for Ra and VB respectively with maximum percentage error limited to 14.67 %. The data are analysed to study the main effect and interaction effects of machining parameters through surface plot. Feed remains dominating factor. Process parameters are optimized for single and multiple objectives using three different techniques viz., statistical and mathematical approach based desirability analysis (DA) and soft computing based genetic algorithm (GA) and firefly algorithm (FA). The results are compared.
Multi-Objective Optimization on Electric Discharge Machining Using by Grey Relational Analysis
Authors: Selvarajan L. , Sathiya Narayanan C. , Jeyapaul R.
Published: July 2014

The present study ,Sparking parameters namely current (I), pulse on time (ton), pulse off time (toff), spark gap and dielectric flushing pressure (P) are optimized with the considerations of multi responses such as Material Removal Rate (MRR), Electrode wear Rate (EWR), of the MoSi2-SiC intermetallic/ceramic composite are investigated by use of the Taguchi L18 orthogonal array (OA) with grey relational grade analysis was reported.
An Investigation on the Effect of Process Parameters on Microstructure, Hardness and Wear Properties of Surface Modified Cu-Sn Bronze Alloy
Authors: Cherian Paul , Sellamuthu R.
Published: July 2014

An investigation was carried out to understand the effect of process variables on the microstructure, hardness and wear properties of surface modified Cu-10Sn bronze alloy. The surface modification was carried out using Gas Tungsten Arc (GTA) as the heat source. Hardness and wear rate of the modified layer were measured using a microhardness tester and a Pin-On-Disc wear tester, respectively. A uniformly distributed fine grained microstructure was observed in the modified layer. The hardness and wear resistance of the modified layer were improved when compared with that of as cast sample. The coefficient of friction is found to be a constant and is not a function of hardness. The results of this study are comparable to those of previous works.
Optimisation of Machining Parameters for High Feed End Milling on Inconel 718 Super Alloy
Authors: Varghese Vinay , Annamalai K. , Kumar K. Santhosh
Published: July 2014

This study investigates about machining practices used worldwide for machining of Inconel 718 super alloy. The effect of machining parameters like cutting speed, feed and depth of cut on machining responses like surface roughness and material removal rate when end milling Inconel 718 is studied using nine trials carried out based on L9 orthogonal array. A Taguchi based grey relational analysis was used for optimisation of machining parameters for high feed end milling operation on Inconel 718. An analysis of variance (ANOVA) was used to find the most significant factor. Validation of results through confirmation tests was performed and experimental results show that surface quality and productivity can be improved efficiently with this approach.
Optimization of Machining Characteristics in EDM of Si3N4-TiN Composites by Taguchi Grey Relational Analysis
Authors: Selvarajan L. , Sathiya Narayanan C. , Jeyapaul R.
Published: July 2014

In this study, Sparking parameters specifically Current (I), pulse on time (ton), pulse off time (toff), spark gap and dielectric flushing pressure (P) are optimized with the consideration of multi responses such as Material Removal Rate (MRR) and Electrode wear Rate (EWR). The characteristic features of the Spark EDM process are explored through Taguchi L18 orthogonal array design of experimental studies with various process parametric combinations. To optimize the above machining parameter, grey relation techniques are used. Based on the grey relation grade, optimum levels of parameters have been identified and major contribution of parameters is determined by ANOVA. Verification test is conducted to validate the test result.
Optimization of Multiple Responses in Dry Turning Process Using Taguchi-Grey Relational Analysis
Authors: Verma Sumit , Singh Hari
Published: July 2014

The present study investigates the optimization of multiple responses in turning of EN-8 steel by the Taguchi and grey relational analysis. The performance characteristics considered are tangential force, feed force and radial force. Grey relational theory is adopted to determine the best process parameters that give lower magnitude of tangential, feed, radial forces and optimal cutting parameters. An orthogonal array L18 is used for the experimental design. The setting of process parameters— nose radius, 0.8mm; cutting speed, 60.65 m/min; feed rate, 0.04 mm/rev; and depth of cut, 0.60 mm— has highest grey relational grade and therefore produces best turning performance in terms of cutting forces.
Optimization of Tensile Strength during Ultrasonic Lap Welding of Dissimilar Metals Using Taguchi’s Philosophy
Authors: Satpathy Mantra Prasad , Sahoo Susant Kumar , Datta Saurav
Published: July 2014

Ultrasonic welding (USW) is a solid-state joining process in which the joint is created between the workpieces by the application of high frequency ultrasonic waves under pressure. Poor weld strength is one of the major problem experienced in the application of such weldments. It is mainly due to improper selection of process parameters. In order to achieve satisfactory weld strength optimization of welding process parameters is indeed essential. In this present context, the USW has been carried out to join dissimilar materials like A1100 aluminum alloy and CuZn37 brass plates of thickness 0.1 mm using Taguchi’s L16 orthogonal array design of experiments. The process parameters like amplitude, weld pressure and weld time have been taken into consideration. Taguchi’s S/N ratio concept has been employed to study the effect of different process parameters on the response like tensile strength; and finally, the optimum setting of process parameters has been decided in view of maximizing tensile strength. The predicted result of the optimized tensile strength has been validated by conducting a confirmatory test. This analysis shows that the high quality and efficient joints can be generated by exploring optimized setting of process parameters which is fruitful in mass production as well as off-line quality control of such a welding practice.
Optimization of WEDM Process Parameters of Hybrid Composites (A413 / B4C / Fly Ash) Using Grey Relational Analysis
Authors: Peter J. Milton , Udaya Prakash J. , Moorthy T.V.
Published: July 2014

This paper presents an optimum method to find the significant parameters affecting Wire Electrical Discharge machining (WEDM) performance using Grey relational analysis. A413 Aluminium Alloy reinforced with 20 microns of Boron Carbide and 75 microns of Fly Ash, hybrid composites was fabricated using stir casting technique. Experiments have been conducted with the process parameters like pulse on time, pulse off time, wire feed, gap voltage and weight percentage reinforcement with three different levels. The influence of each parameter on the responses material removal rate and surface roughness is established using analysis of variances (ANOVA). The optimal machining-parameters setting for minimum surface roughness and maximum material removal rate was obtained by applying Grey relational analysis.