Archive

Abstract:

The woven E-glass/epoxy composite with circular artificial defect located at center position between first and second plies was manufactured using hand lay-up method. The composite consisted of twelve layers of glass cloth. Experiments were conducted in tension and flexure with four-point loading to determine the behavior of laminate. The results were compared with those of laminates without artificial defect. A knee was observed on the load displacement curve for the laminate without defect loaded in tension. Results show that the defect does not affect considerably the tensile strength of the composite and the existence of defect influences highly the flexural properties.

Keywords:

Tension, Flexure,Artificial defect, Knee,Four-point loading,Delamination ,

Refference:

I. ASTM D6272 -17, Standard test method for flexible properties of unreinforced and reinforced plastics and electrical insulating materials by four point bending, Annual Book of ASTM Standards 2006; American Society for Testing and Materials, Philadelphia: 1-9
II. D. Pradeep, N.J. Reddy, C.R. Kumar, L. Srikanth, R.M.V.G.K. Rao. “Studies on mechanical behavior of glass epoxy composites with induced defects and correlations with NDT characterization parameters”, Journal of Reinforced Plastics and Composites, 26(15), 1539-1556, 2007
III. M. Ashir, A. Nocke, C. Cherif. “Effect of the position of defined local defect on the mechanical performance of carbon-fiber-reinforced plastics”, Autex Research Journal, DOI: 10.1515/aut-2018-0034
IV. P.B. Rao, A.R. Krishna, K. Ramji, A.S. Devi. “Fatigue life and damage evolution of glass fiber/epoxy laminates containing interacting circular holes”, Journal of Materials: Design and Applications, 231(4), 394-402, 2017
V. P.N.B. Reis, J.A.M. Ferreira, F.V. Antunes, M.O.W. Richardson. “Effect of interlayer delamination on mechanical behavior of carbon/epoxy laminates”, Journal of Composite Materials, 43(22), 2609-2621, 2009
VI. P.N.B. Reis, J.A.M. Ferreira, J.D.M. Costa, M.O.W. Richardson. “Fatigue life evaluation for carbon/epoxy laminate composites under constant and variable block loading”, Composite Science and Technology, 69, 154-160, 2009
VII. T. Yokozeki, T. Ogasawara, T. Ishikawa. “Effects of the fiber nonlinear properties on the compressive strength prediction of unidirectional carbon-fiber composites”, Composite Science and Technology, 65, 2140-2147, 2005
VIII. T.K. O’Brien, M. Rigamonti, C. Zanotti. “Tension fatigue analysis and life prediction for composite laminates”, International Journal of Fatigue, 11(6), 379-393, 1989
IX. W. Gong, J. Chen, E.A. Patterson. “An experimental study of the behavior of delaminations in composite panels subjected to bending”, Composite Structures, 123, 9-18, 2015
X. Z. Liu, P. Li, N. Srikanth. “Effect of delamination on the flexural response of [+45/–45/0]2S carbon fiber reinforced polymer laminates”, Composite Structures, 209, 93-102, 2018

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Abstract:

This paper mainly focuses on the Nano clay effect in mechanical properties of sisal/banana hybrid FRP composites. The composites with and without the addition of Nano clay have been made by fusing sisal/banana fiber up to maximum volume of 30% as support in polymer matrix and mechanical properties are Investigated. The composite material prepared was tested for tensile, flexural, impact strength with aid of respective apparatus. Fiber length and % of weight were calculated initially for preparation of specimens. Banana fiber was hybridized with sisal fiber to examine the changes in mechanical properties of the samples. Mechanical properties (Tensile strength, Flexural strength along with their modulus) of the composites with nano clay   are found to be 0.8, 1, 1.5 and 2.3 times greater than that of composites without nano clay. 50% better results in the impact test were achieved. SEM analysis was carried out on the samples after conducting the test to find out the fracture pattern and the fiber pull out.  The experimental outcomes illustrate that under testing the mechanical properties shows an increase with adding up of Nano clay at higher volume fraction. Tensile & flexural properties show an affirmative hybrid effect.

Keywords:

Polymer- Matrix composites,Mechanical properties,scanning Electron Microscope analysis,Hybridization of sisal/banana,

Refference:

I M., R. Sanjay, G.R. Arpitha, and B. Yogesha. Study on Mechanical Properties of Natural – Glass Fibre Reinforced Polymer Hybrid Composites: A Review. Materials Today: Proceedings, 2015; 2 (4–5): 2959–2967.

II Pothan LA, Thomas S, Neelakantan NR. J ReinfPlast Comp 1997; 16:744.

III Joseph K, Varghese S, Kalaprasad G, Thomas S, Prasannakumari L, Koshy P, et al. EurPolym J 1996;3210:1243.

IV Venkateshwaran. N, Elaya Perumal, A., Alavudeen, A. and Thriuchitrambalam, M., “Mechanical and Water Absorption Behaviour of Banana/Sisal Reinforced Hybrid Composites”, Mater res, published by evisa. Vol. 32, pp. 4017-4021 (2011).

V Al-Qureshi, H. A. (1999).”The Use of Banana Fiber Reinforced Composites for the Development of a Truck Body”, In: 2nd International Wood and Natural Fiber Composite Symposium, June 2829, kassel, Germany

VI Mohan T., Kanny K. “Nanoclay infused banana fiber and its effects on mechanical and thermal properties of composites”. Journal of Composite Materials.

VII Kulkarni AG, Satyanarayana KG, Rohatgi PK, Vijayan K. “Mechanical properties of banana fiber”. J Mater Sci 1983; 18:2292–6.

VIII Mukherjee KG, Satyanarayana KG. Structure and properties of some vegetable fibers. J Mater Sci 1984; 19:3925–34.

IX AV Ratna Prasad, K Mohana Rao, G. Nagasrinivasulu. “Mechanical properties of banana empty fruit bunch fibre reinforced polyester composites”, published by CSIR IJFTR Vol.34 (2) pp.162-167 [June 2009].

X A.V. Ratna Prasad, KB Rao, KM Rao and SP Kumar Gudapati. “Influence of Nano clay on mechanical performance of wild cane glass fiber reinforced polyester composites” materials letters 2012 Elsevier.

XI A. Yasmin, J.L Abort & I. M Daniel (2006) “Mechanical and thermal behavior of clay/Epoxy Nano composites”. Composites science and technology,66,2415-2422

XII Alawar Ahmad, Hamed Ahmad M, Al-Kaabi Khalifa. Characterization of treated date palm tree fiber as composite reinforcement. Compos Part B 2009; 40:601–6.

XIII Rout j, Misra M, Tripathy SS, Nayak SK, Mohanty AK. The influence of fibre treatment on the performance of coir- polyester composites. Compos sci tech nol 2001; 61:1303-10.

XIV ASTM D638-89. Standard test method for testing tensile properties of plastics

XV ASTM D79M-86. Standard tests method for testing flexural properties of unreinforced, reinforced plastics and electrical insulating material.

XVI ASTM D256-097. Standard test method for determining izod pendulum impact resistance of plastics.

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Abstract:

Abrasive water jet had proven to be a suitable unconventional machine technique for cut-through operation. Using abrasive water jet turning only limited studies are available. Apart from usual machining practice in Abrasive Water Jet Machine (AWJM), the installation of the chuck with motor assembly as a unit similar set up like conventional lathe machine will enhance the machinability of AWJM. From the earlier studies, it is understood that the author has performed the machinability studies using this experimental set up in AWJM. But no standard procedure is described as the installation procedure of chuck and motor assembly in AWJM. Considering this, a review is conducted on the design and implementation of turning setup in an abrasive water jet machine. Based on the acquired knowledge through a literature survey and also, considering vibration, assembly, and safety factors, a new design is proposed. The author ensures that implementing this setup in an abrasive water jet machine will enhance the research work to a higher level of significance.

Keywords:

AWJM,Turning,Chuck and motor assembly,Worktable design,

Refference:

I. R. Rakshit, A.K. Das, “A review on cutting of industrial ceramic materials” Precision Engineering, Vol:59, Pages : 90-09, 2019
II. P. Ranjan, S.S. Hiremath,”Role of textured tool in improving machining performance: a review”, Journal of Manufacturing Processes, Vol:43,Pages : 47-73, 2019
III. A.I. Ansari, M. Hashish, M.M. Ohadi, “Flow visualization study of the macromechanics of abrasive-waterjet turning”, Experimental Mechanics, Vol:32, Pages : 358-364, 1992
IV. I Zohourkari, M. Zohoo, M. Annoni,“Investigation of the effects of machining parameters on material removal rate in abrasive waterjet turning”, Advances in Mechanical Engineering, Vol:6, 624203,2014
V. A.I. Ansari, M. Hashish,“Effect of abrasive waterjet parameters on volume removal trends in turning”, Journal of engineering for industry, Vol: 117, Pages : 475-484, 1995
VI. F. Kartal , H. Gökkaya, Z.yerlikaya ,”Development of a new method in order to do silent abrasive water jet turning process apparatus”, WJTA-IMCA Conference and Expo, 2015
VII. K. Flogel, F. Faltin, “Waterjet Turning of Titanium Alloys” In Advanced Materials Research, Trans Tech Publications ,Vol: 769, Pages :77-84., 2013
VIII. M. Gupta,S.K. Gill,“Prediction of cutting force in turning of UD-GFRP using mathematical model and simulated annealing” Frontiers of Mechanical Engineering, Vol: 7, Pages : 417-426 ,2012
IX. P Hlaváček, J Cárach,, S Hloch,, K Vasilko, D, Klichová, J. Klich, D. Lehocká,“Sandstone turning by abrasive waterjet”, Rock Mechanics and Rock Engineering, Vol: 48, Pages : 2489-2493, 2015
X. Z. Hutyrová, J. Ščučka, S. Hloch,P. Hlaváček,M. Zeleňák,“Turning of wood plastic composites by water jet and abrasive water jet”, The International Journal of Advanced Manufacturing Technology, Vol: 84,Pages : 1615-1623, (2016)
XI. G. Ramu, B. Bapiraju, M.L. Kumari,“Theoretical and graphical analysis of abrasive water jet turning”, International Journal of Modern Engineering Research, Vol: 3, Pages: 3207-3215, 2013.
XII. F. Kartal, H. Gökkaya, M. Nalbant,“Turning of (Cu-Cr-Zr) alloy with abrasive water jet”, In 21st International Conference on Water Jetting, Ottawa, Canada, (2012, September)
XIII. F. Kartal, M.H. Çetin, H. Gökkaya Z. Yerlikaya,“Optimization of abrasive water jet turning parameters for machining of low density polyethylene material based on experimental design method”, International Polymer Processing, Vol: 29, 535-544, (2014)
XIV. Q.W. Xu, C.H. Qiang, C.W. Guo,“Experimental Study on the Surface Roughness of 1060 Aluminum Alloy Cut by Abrasive Water Jet”, Materials Science Forum, Trans Tech Publications, Vol: 950, Pages: 32-37, 2019
XV. K. Balamurugan,M. Uthayakumar,S. Sankar, U.S Hareesh, K.G.K. Warrier, “Modeling and surface texturing on surface roughness in machining LaPO4–Y2O3 composite”, Materials and Manufacturing Processes, Vol: 33, Pages : 405-413, 2018
XVI. K. Balamurugan, M. Uthayakumar, S.Gowthaman,R. Pandurangan, “A study on the compressive residual stress due to waterjet cavitation peening”, Engineering Failure Analysis, Vol; 92, Pages : 268-277, 2018
XVII. A.C. Bhasha, K.Balamurugan,“Fabrication and property evaluation of Al 6061+ x%(RHA+ TiC) hybrid metal matrix composite”, SN Applied Sciences, Vol: 1(9), Pages : 977, 2019
XVIII. K. Arunkarthikeyan, K. Balamurugan,“Experimental Studies on Deep Cryo Treated plus Tempered Tungsten Carbide Inserts in Turning Operation”, ICAIASM conference proceedings, Santhiram Engineering college, Kurnool, India, 2019

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Abstract:

The pressurized high-speed water flows together with the Al₂O₃ particles forms slurry used in abrasive water jet machining (AWJM) to slice specimens. This approach is particularly appropriate for fragile, soft and strident materials. D3 tool steel used as a sample size of 200 x 200 x 23 mm has excellent strength and is also suitable for high-temperature machining operations. In the present work, the 8 mm diameter hole was created using AWJM. The L27 orthogonal array experiments were conducted with crossover speeds (Ts) 80, 100 and 120 mm / min, abrasive mass flow rate (A_f) 250, 325 and 400 (g / min) and a standoff distance (Sod) of 1,1.5 and 2 mm as processing parameters. Optimum parameters have been set from ANOVA to achieve high metal extraction. Optimum Sod, T_s, and A_f are 400 g / min, 1.5 mm and 120 mm / min. Experiment number 26 and the 27 processing parameters are the best for the D3 tool steel unit to achieve higher metal extraction.

Keywords:

AWJM, D3 Tool Steel, ANOVA, cutting speed ,standoff distance,Traverse speed,

Refference:

I Geethapriyan T., Manoj Samson R., Arun Raj A.C., Senkathi S., Gunasekar C. (2019) Parametric Optimization of Abrasive Water jet Machining Process on Inconel 600 Using Two Different Abrasive Grain Sizes. In: Vijay Sekar K., Gupta M., Arockiarajan A. (eds) Advances in Manufacturing Processes. Lecture Notes in Mechanical Engineering. Springer, Singapore.
II K.Balamurugan, M.Uthayakumar, S.Gowthamam, R.Pandurangan, “A study on the compressive residual stress due to water jet cavitation peening”, Engineering Failure Analysis, (2018).
III Rishi Pahuja, M. Ramulu, Mohamed Hashish,” Surface quality and kerf width prediction in abrasive water jet machining of metal-composite stacks” Composites Part B 175(2019).
IV Ketan Verma, Anandakrishnan V., Sathish S. “Modelling and analysis of abrasive water jet machining of AA2014 alloy with Al2O3abrasive using fuzzy logic” Material Today: Proceedings (2019).
V M Douiri, M Boujelbene, E Bayrakta, “A Study of the Surface Integrity of Titanium Alloy Ti-6Al-4V in the Abrasive Water Jet Machining Process” Mechanics of Composite (2019) Springer.
VI Deepak Doreswamy, Akash V, NattWinitthumkul, AnjaiahDevineni“ Machining of D2 heat treated steel using Abrasive water jet: The effect of standoff distance and feed rate on kerf width and surface roughness” International Journal of Research in Engineering and Technology (2014).
VII D.Sidda Reddy, A.Seshu Kumar, M.Sreenivasa Rao, “ Parametric optimization of Abrasive water jet machining of Inconel 800H using Taguchi Methodology” Universal Journal of Mechanical Engineering (2014) 158-162.
VIII P. Shanmughasundaram,” Influence of abrasive water jet machining parameters on the surface roughness of eutectic Al-Si alloy- graphite composites” Journal of materials physics and mechanics19 (2014) 1-8.
IX DerzijaBegicHajdarevic, Ahmet Cekic, MuhamedMehmedovic, Almina Djelmic,”Experimental study on surface roughness in abrasive water jet cutting” Proceding Engineering (2015) 394-399.
X MS Rao, S Ravinder, AS Kumar, “Parametric optimization of abrasive water jet machining for Mild Steel: Taguchi Approach” International Journal of Current Engineering and Technology,“(2014) P-ISSN 2347-5161.
XI E Azarsa, L Cinco, M Papini, “Fabricated of high aspect ratio free-standing structures using abrasive water jet micro-machining” Journal of material processing Technology (2019) Volume 275.
XII K Balamurugan, M.UthayaKumar,S.Sankar,U.S.Hareesh& G.K.Warrier,”Modeling and Surface Texturing on surface roughness in machining LaPO4-Y2O3 Composite” Materials and Manufacturing Processes, (2017).
XIII L Nagdeve, V Chaturvedi, J Vimal, “Implementation of Taguchi approach for optimization of abrasive water jet machining process parameters” International Journal of Instrumentation control and Automation, (2012) ISSN:2231-1890.
XIV T.P.Latchoumi, K.Balamurugan,,K.Dinesh, T.P.Ezhilarasi,”Particle Swarm Optimization approach for water jet cavitation peeing” Measurement, (2019),184-189.
XV K.Balamurugan,M.Uthayakumar,S.Sankar,U.S.Hareesh,K.G.K.Warrier,” Predicting correlations in abrasive water jet cutting parameters of Lanthanum Phosphate/ Yttria composite by response surface methodology”, Measurement (2019), 309-318.
XVI SenerKarabulut, “Optimization of surface roughness and cutting force during AA7039/Al2O3 metal matrix composites milling using neural networks and Taguchi method”, Measurement (2015), 139-149.
XVII Pandu R.Vundavilli, M.B.Parappagoudar,S.P.Kodali,Surekha Benguluri,”Fuzzy logic-based expert system for prediction of depth of cut in abrasive water jet machining process”, Knowledge-Based Systems (2012), 456-464.
XVIII KSK Sasikumar,KP Arulshri, K Ponappa,“ A study on kerf characteristics of hybrid aluminum 7075 metal matrix composites machined using abrasive water jet machining technology”, Journal of Engineering Manufacture, (2016).
XIX S.Vigneshwaran, M.UthayaKumar, V Arumugaprabu, “Abrasive water jet machining of fiber-reinforced composite materials”, Journal of Reinforced plastics and composites, (2017).
XX John Kechagias, George Petropoulos, Nikolaos Vaxevanidis, ”Application of Taguchi design for quality characterization of abrasive water jet machining of TRIP sheet steels.” The international Journal of advanced manufacturing technology, (2012).
XXI K Balamurugan , A.chinnamahammad bhasha, Fabrication and property evaluation of Al 6061 + x% (RHA + TiC) hybrid metal matrix composite”, Sn applied science,(2019),1:997.

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Abstract:

Surface quality is a vital aspect  to assess the eminence of products that chooses wear and also stimuli quality of assemblies. The research journal article is focused to estimate the surface quality during helical milling with ultrasonic vibration assistance to workpiece. This study presents an investigation of surface eminence on ultrasonic machining (UM) of difficult to cut material of D2 steel, an effort was  made for modeling response i.e. surface roughness(Ra) in UM technique by means of DESIGN EXPERT software. Three operational factors i.e. spindle speed(N), axial depth(ap)  each at two levels and orbital speed(nc) of four levels were  varied to investigate surface quality variations with respect to levels of operational factors. The ANOVA was performed to ascertain importance of model established. The testings outcomes confirms validity and competence of model developed.

Keywords:

Surface quality ,ultrasonic vibration,ANOVA,Helical milling,

Refference:

Bhuvnesh Bhardwaj, Rajesh Kumar, Pradeep K. Singh, et al., “Surface roughness prediction model for turning of AISI 1019 steel using response surface methodology and Box-Cox transformation”, Proc. Inst. Mech. E Part B: J. Eng. Manuf. 228 (2) (2014) 223–232.
II. C. Sanjay, C. Jyothi, “A study of surface roughness in drilling using mathematical analysis and neural networks”, International Journal of Advanced Manufacturing Technology, vol.29, pp. 846–852, 2006.
III. D. Dinakaran, S. Sampathkumar, K. Madhivanan, “An experimental investigation of surface roughness monitoring in surface grinding through ultrasonic technique”, Mechatronics and Intelligent Manufacturing, vol.1, pp.107-118, 2012.
IV. M. Subramanian, M. Sakthivel, K. Sooryaprakash, R. Sudhakaran, “Optimization of end mill tool geometry parameters for Al7075-T6 machining operations based on vibration amplitude by response surface methodology”, Measurement 46 (2013) 4005–4022.
V. Nitesh Dhar Badgayan, Ankan Mishra, Sameer Panda, “Prediction of Surface Roughness on Ultrasonic Machining Of Titanium Using Response Surface Methodology”, Proceedings of the ICIET’14, Volume 3, Special Issue 3, March 2014, Tamilnadu, India, pp. 1234-1236.
VI. Q. Zhao, X. Qin, C. Ji, Y. Li, D. Sun, Y. Jin, “Tool life and hole surface integrity studies for hole-making of Ti6Al4V alloy”, Int. J. Adv. Manuf. Technol. 79 (5–8) (2015) 1017–1026.
VII. R. Iyer, P. Koshy, E. Ng, “Helical milling: an enabling technology for hard machining precision holes in AISI D2 tool steel”, Int. J. Mach. Tool Manufact. 47 (2) (2007) 205–210.
VIII. R.B.D. Pereira, L.C. Brandão, A.P. de Paiva, J.R. Ferreira, J.P. Davim, “A review of helical milling process”, Int. J. Mach. Tool Manufact. 120 (2017) 27–48.
IX. Sanjay, Prithvi, “Hybrid intelligence systems and artificial neural network (ANN) approach for modeling of surface roughness in drilling”, Cogent Engineering, vol.1 (1), 2014.
X. Vishy Karri, Tossapol Kiatcharoenpol, “Prediction of internal surface roughness in drilling using three feed forward neural networks – a comparsion”, Proceedings of the 9th International Conference on Neural Information Processing (ICONIP’OZ) , vol. 4,2003.
XI. X. Qin, L. Gui, H. Li, B. Rong, D. Wang, H. Zhang, G. Zuo, “Feasibility study on the minimum quantity lubrication in high-speed helical milling of Ti-6Al-4V”, J. Adv. Mech. Design, Systems Manufacturing 6 (7) (2012) 1222–1233.

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Abstract:

AA2014 has been extensively used in manufacture of light weight fabricated components similar to commercial automobile components, which requires high strength with minimal weight and along with decent corrosion effect. The traditional welding of thisAluminium alloyed materials generally encounter solidification problems like hot cracking. Friction Stir Welding (FSW) is an ecofriendly joining process where in the actual melting of material and recasting will not happen. Many of the researchers carried out sufficient experiments for optimizing process parameters and to establish empirical relationships in order to predict better mechanical properties. In the present investigation, a comparative study of FSW between experimentation and optimization of process parameters such as tool rotation speed and weld speed, to attain maximum mechanical properties using Genetic Algorithm (GA) and Teaching Learning Based Optimization (TLBO) algorithm. From the results it shows that the TLBO gives the better combinations of process parameters which give superior mechanical properties compared to experimental results as well as other optimization techniques.

Keywords:

FSW,Process Parameters, Mechanical Properties,Genetic Algorithm,TLBO,

Refference:

I. W,M,Thomas, E,D,Nicholas, J,C,Needham, M,G, Murch, P,Temple Smith, and C,J,Dawas, Int.Patent Appl.No.PCT/GB92/02203 and GB patent Appl:No 9125978.8, Dec1991, U.S.Patent Appl.No.5460317, Oct 1995.
II. R,Nandan, T,DebRoy, and H,K,D,H,Bhadeshia, “Recent Advances in Friction-Stir Welding:process, weldment structure and properties”, Prog.Mater.Sci., vol.53, pp.980-1023, 2008
III. R, S, Mishra and Z, Y,Ma, “Friction Stir Welding and Processing”, Mater. Sci. Eng. R, vol.50, pp.1-78, 2005.
IV. Anton Savio Lewise, K and Edwin Raja Dhas,J, “A Review of Friction Stir Welding of Aluminium alloys”, International journal of Advanced Chemical Science and applications, vol.5, no.3, pp.28-32, 2017.
V. Thirupathireddy, G, Syed Rabbani Bash, “Effect of weld speed on tool pin profile using friction stir welding”, IJSRM, vol.3, no.1, pp.1892-1896, 2015.
VI. Indira Rani, M, Marpu, RN and Kumar, ACS, “A study of process parameters of friction stir welded AA6061 aluminum alloy in O and T6 conditions”, ARPN J EngAppl Sci, vol.6, pp.2006–2011, 2011.
VII. Khalid Hussain, A and Pasha Quadri, S, “A evaluations of parameters of friction stir welding for aluminum AA6351 alloy”, Int J Eng Sci Technol, vol.2, pp.5977–5984, 2010.
VIII. MortezaGhaffarpour, Ahmad Aziz and Taha-Hossein Hejazi, “Optimization of friction stir welding parameters using multiple response surface methodology”, Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, vol.231, no.7, pp.571–583, 2017.
IX. Ghaffarpour, M, MollaeiDariani, B and Kokabi, AH et al, “Friction stir welding parameters optimization of heterogeneous tailored welded blank sheets of aluminium alloys 6061 and 5083 using response surface methodology”,J EngManuf, vol.44 no.A, pp.2013–2022, 2012.
X. Yousif, YK, Daws, KM and Kazem, BI, “Prediction of friction stir welding characteristic using neural network”, Jordan J Mech Ind Eng, vol.2, pp.151–155, 2008.
XI. Vidal, C, Infante, V, and Pec¸as P, et al, “Assessment of improvement techniques effect on fatigue behavior of friction stir welded aerospace aluminium alloys” Procedia Eng, vol.2, pp.1605–1616, 2010.
XII. Shahrabi, J and Hejazi, TH, “A new mathematical program based on principal component analysis for multiple response optimization”, IEEE International Conference on Quality and Reliability, vol.42, pp. 445–450, 2011.
XIII. Venkata Rao, R, Kalyankar, VD, multi-pass turning process parameter optimization using teaching-learned-based optimization algorithm, Scientia Iranica E, vol.20, no.3, pp. 967-974,2013.
XIV. Venkata Rao,K, Murthy PBGSN and Vidhu KP, “Assignment of weightage to machining characteristics to improve overall performance of machining using GTMA and utility concept”. CIRP, journal Manufacturing Science and Technology, vol. 18, pp.152–158,2017.
XV. Cheema, MS, Dvivedi, A, and Sharma, AK, “A Hybrid approach to multicriteria optimization based on user’s preference rating”. Proceesings of I Mech E Part B: Journal of Engineering Manufacture, vol.227, no.11, pp.1733-1742, 2013.
XVI. Kadaganchi,R, Gankidi,M.R and Gokhale,H, “Optimization of process parameters of aluminum alloy AA 2014-T6 friction stir welds by response surface methodology”. Def. Technol, vol.11, pp.209–219, 2015.
XVII. Kumar, A and Suvarna Raju, L, “Influence of Tool Pin Profiles on Friction Stir Welding of Copper”. Materials and Manufacturing Processes, vol.27, no.12, pp.1414-1418, 2012.

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Abstract:

Metal cutting or machining is a backbone of manufacturing industries. In machining process, heat is generated and it must be removed with the help of cutting fluid. Generally, hydrocarbon oil based cutting fluid is used, but it leads to environmental pollution and as well as operator’s ill health. Solid lubrication is a good alternative to hydro carbon oil based cutting fluid.In this work, turning process is carried out on Inconel 718 with perpendicular direction textured cutting insert filled with different solid lubricants.Solid lubricants as lubricant materials, which are basically solid but becomesoft due to frictional heat at the point of contact. In this work, Molybdenum disulfide (MoS₂) and Graphite solid lubricants are used.Experiments are performed as per L₉ orthogonal array and theeffect of each process parameter is determined through the Analysis of Variance (ANOVA). The result revealed that solid lubricant with textured tool produces a continuous lubricating layer on the surface of the tool due to the thermal expansion of heat produced during machining. This thin layer may reduce friction in the machining zone. Perpendicular direction textured cutting inserts are used to reduce friction and good surface finish is obtained.Compared with MoS_2, graphite has shown better results in terms of surface finishdue to its low shear strength properties.

Keywords:

Turning,Solid Lubrication, Surface finish,Taguchi,

Refference:

I. Debnath, S., Reddy, M.M. and Yi, Q.S., 2014. Environmental friendly cutting fluids and cooling techniques in machining: a review. Journal of cleaner production, 83, pp.33-47.

II. Lawal, S.A., Choudhury, I.A. and Nukman, Y., 2012. Application of vegetable oil-based metalworking fluids in machining ferrous metals—a review. International Journal of Machine Tools and Manufacture, 52(1), pp.1-12.

III. Ghosh, S. and Rao, P.V., 2015. Application of sustainable techniques in metal cutting for enhanced machinability: a review. Journal of Cleaner Production, 100, pp.17-34.

IV. Sharma, V. and Pandey, P.M., 2016c. Recent advances in turning with textured cutting tools: A review. Journal of Cleaner Production, 137, pp.701-715.

V. Krishna, P.V. and Rao, D.N., 2008. Performance evaluation of solid lubricants in terms of machining parameters in turning. International Journal of Machine Tools and Manufacture, 48(10), pp.1131-1137.

VI. Song, W., Wang, Z., Wang, S., Zhou, K. and Guo, Z., 2017. Experimental study on the cutting temperature of textured carbide tool embedded with graphite. The International Journal of Advanced Manufacturing Technology, 93(9-12), pp.3419-3427.

VII. Song, W., Wang, S., Lu, Y. and Xia, Z., 2018. Tribological performance of microhole-textured carbide tool filled with CaF2. Materials, 11(9), p.1643.

VIII. Lei, S., Devarajan, S. and Chang, Z., 2009. A comparative study on the machining performance of textured cutting tools with lubrication. International Journal of Mechatronics and Manufacturing Systems, 2(4), pp.401-413.

IX. Arulkirubakaran, D., Senthilkumar, V. and Kumawat, V., 2016. Effect of micro-textured tools on machining of Ti–6Al–4V alloy: an experimental and numerical approach. International Journal of Refractory Metals and Hard Materials, 54, pp.165-177.

X. Sharma, V. and Pandey, P.M., 2016. Comparative study of turning of 4340 hardened steel with hybrid textured self-lubricating cutting inserts. Materials and Manufacturing Processes, 31(14), pp.1904-1916.

XI. Padmini, R., Krishna, P.V. and Mohana Rao, G.K., 2015. Performance assessment of micro and nano solid lubricant suspensions in vegetable oils during machining. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 229(12), pp.2196-2204.

XII. Yılmaz, B., Karabulut, Ş. and Güllü, A., 2018. Performance analysis of new external chip breaker for efficient machining of Inconel 718 and optimization of the cutting parameters. Journal of Manufacturing Processes, 32, pp.553-563.

XIII. Singaravel, B. and Selvaraj, T., 2016. Application of desirability function analysis and utility concept for selection of optimum cutting parameters in turning operation. Journal of Advanced Manufacturing Systems, 15(01), pp.1-11.

XIV. Wenlong, S., Jianxin, D., Hui, Z. and Pei, Y., 2010. Study on cutting forces and experiment of MoS 2/Zr-coated cemented carbide tool. The International Journal of Advanced Manufacturing Technology, 49(9-12), pp.903-909.

XV. Singaravel, B. and Selvaraj, T., 2016. Application of Taguchi method for optimization of parameters in turning operation. Journal for Manufacturing Science and Production, 16(3), pp.183-187.

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Abstract:

Pure copper is reinforced with 20µm ceramic particles like SiCp and TiB₂ using FSP to fabiricate surface composites at constant rotational speed of 1120 revaluations per minutes and speed of the weld at 40mm/min. Cylindrical tapper threaded profile pin made of high carbon high chromium was used to prepare the copper surface composites. Experiments were conducted on a vertical milling machine to prepare Surface composites by varying volume percentage of reinforcements (vol.%2, vol.%4,vol.%6). six combinations of surface composites Cu/2vol.%SiC, Cu/4vol.%Sic, Cu/6vol.%Sic; Cu/2vol.%TiB_2, Cu/4vol.%TiB₂ and Cu/6vol.%TiB₂ were fabricated. The processed composites were examined by using and optical microscope to reveal the microstructure. At 4 vol. % sic particles and 4vol.% of TiB₂ particles the microstructure reveals fine grains (equiaxed) at the processed region as compared with 2&6 vol.% of reinforcements. Mechanical tests were conducted to determine ultimate tensile strength, yield strength. Hardness survey was made on the processed sample and base metal. From the results, it is found that at 4 vol. % of SiC and 4 vol.% of TiB₂  superior properties were obtained as that of vol.% 2 and vol.% 6 of reinforcements. This is attributed to the fine grains formed in the copper surface composites. Cu surface composite reinforced with 6 vol. % of TiB₂ resulted in higher hardness. As the vol. % of SiC and TiB₂ increased the resistance to wear is also increased.

Keywords:

Volume percentage (vol.%),SiCp (Silicon Carbide particles),TiB2p (Titanium diboride particles), Cu/SiC (Copper surface composite),

Refference:

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Abstract:

Wire Arc Additive Manufacturing an arc based metal additive manufacturing creates 3D components with layer by layer weld depositions has a lot of advantages over powder based techniques and has the capability of fabricating medium to large components . The present work focussed on the study of the microstructure and hardness for wall structure fabricated by weld depositions based on Wire Arc Additive Manufacturing technique with different wire feed rates utilized from bottom to top in the build direction. Component fabricated is with 3 slabs with different wire feed rate in each slab and these slabs are deposited with multiple beads and multiple layers by using ABB 6 – AXIS Industrial Robot 1520ID. It is observed that internal matrix irrespective of slabs has insignificant variations in the hardness of the material in the build direction. The microstructure characterization exposes typically a homogenous polygonal ferrite with perlite. In general the overall process looks to be stable with negligible hardness variation. The core idea of this paper is to understand the microstructure and hardness of as-built WAAM components with varying feed rates.

Keywords:

Hardness, Microstructure,Wire Arc Additive Manufacturing,

Refference:

I Apparao and M. V. J. Raju, International Conference on Emerging Trends in Engineering (ICETE), vol. 2, no. i. Springer International Publishing, 2020.

II Cong, Z. Qi, B. Qi, H. Sun, G. Zhao, and J. Ding, “A comparative study of additively manufactured thin wall and block structure with Al-6.3%Cu alloy using cold metal transfer process,” Appl. Sci., vol. 7, no. 3, 2017.

III J. Ding et al., “Thermo-mechanical analysis of Wire and Arc Additive Layer Manufacturing process on large multi-layer parts,” Comput. Mater. Sci., vol. 50, no. 12, pp. 3315–3322, 2011.

IV L. Quintino, O. Liskevich, L. Vilarinho, and A. Scotti, “Heat input in full penetration welds in gas metal arc welding (GMAW),” Int. J. Adv. Manuf. Technol., vol. 68, no. 9–12, pp. 2833–2840, 2013.

V P. M. Sequeira Almeida and S. Williams, “Innovative process model of Ti-6Al-4V additive layer manufacturing using cold metal transfer (CMT),” 21st Annu. Int. Solid Free. Fabr. Symp. – An Addit. Manuf. Conf. SFF 2010, pp. 25–36, 2010.

VI S. Suryakumar and M. A. Somashekara, Manufacturing of functionally gradient materials by using weld-deposition. Woodhead Publishing Limited, 2013.

VII S. Suryakumar, K. P. Karunakaran, U. Chandrasekhar, and M. A. Somashekara, “A study of the mechanical properties of objects built through weld-deposition,” Proc. Inst. Mech. Eng. Part B J. Eng. Manuf., vol. 227, no. 8, pp. 1138–1147, 2013.

VIII S. W. Williams, F. Martina, A. C. Addison, J. Ding, G. Pardal, and P. Colegrove, “Wire + Arc additive manufacturing,” Mater. Sci. Technol. (United Kingdom), vol. 32, no. 7, pp. 641–647, 2016.

IX Sola and A. Nouri, “Microstructural porosity in additive manufacturing: The formation and detection of pores in metal parts fabricated by powder bed fusion,” J. Adv. Manuf. Process., vol. 1, no. 3, pp. 1–21, 2019.

X Wu et al., “A review of the wire arc additive manufacturing of metals: properties, defects and quality improvement,” J. Manuf. Process., vol. 35, no. February, pp. 127–139, 2018.

XI Y. Koket al., “Anisotropy and heterogeneity of microstructure and mechanical properties in metal additive manufacturing: A critical review,” Mater. Des., vol. 139, pp. 565–586, 2018.

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Abstract:

The present work is aimed to investigate the influence of process parameters namely cutting speed, feed and uncut chip thickness ontool life in micro milling of Ti-6Al-4V alloy. Twenty Seven experiments have been planned as per full factorial design with three levels of each parameter using carbide end mill cutters. Surface roughnessand vibration amplitude are considered as responses to evaluate the tool life and to identify significance of input process parameters. In this study, a non-contact sensor, Laser Doppler Vibrometer (LDV) was used to measure the vibration of tool in terms of AcoustoOptic Emission (AOE) signals. A high-speed Fast Fourier Transform (FFT) analyser was used to transform the acousto optic emission signals in to useful signals like vibration amplitude. In the analysis of surface roughness and amplitude of vibration, optimum cutting parameters were found as 5000 r.p.m. of spindle speed, 40 mm/min of feed rate and 25.6 µm of uncut chip thickness.

Keywords:

Surface Roughness,Micro Milling,Tool wear,Taguchi,LDV,Multi Response Optimization,

Refference:

I. Bhuvnesh Bhardwaj, Rajesh Kumar, Pradeep K Singh, “Surface roughness predction model for turning of AISI 1019 steel using response surface methodology and Box–Cox transformation”, Proc I Mech E Part B: Journal of Engineering Manufacture,Volume: 228, Issue:2, pp: 223–232, 2014.
II. EmelKuram and Babur Ozcelik, “Effects of tool paths and machining parameters on the performance in micro-milling of Ti-6Al-4V titanium with high-speed spindle attachment”, International Journal of Advanced Manufacturing Technology, Volume: 84. Pp.691–703, 2016.
III. Fabio de Oliveira Campos, Adriane Lopes Mougo and Anna Carla Araujo, “Study of thecutting forces on micromilling of an aluminum alloy”, Journal of Brazilian Society of Mechanical Science and Engineering, Volume: 39, pp:1289–1296, 2017.
IV. Hongqiu Liu, Yongjun He , Xinyong Mao , Bin Li and Xing Liu, “Effects of cutting conditions on excitation and dynamic stiffness in milling”, International Journal of Advanced Manufacturing Technology, Volume: 91, pp.813–822, 2017.
V. James M. Griffin, Fernanda Diaz, Edgar Geerling, Matias Clasing, Vicente Ponce, Chris Taylor, Sam Turner, Ernest A. Michael, F. Patricio Mena and Leonardo Bronfman, “Control of deviations and prediction of surface roughness from micro machining of THz waveguides using acoustic emission signals”, Mechanical Systems and Signal Processing, Volume: 85, pp:1020–1034, 2017.
VI. Rajesh kumar Bhushan, “Multiresponse Optimization of Al Alloy-SiC Composite Machining Parameters for Minimum Tool Wear and Maximum Metal Removal Rate”, ASME, Journal of Manufacturing Science and Engineering, Volume:135, pp:210-219, 2013.
VII. Rosemar B. da Silva Álisson R. Machado, Emmanuel O. Ezugwu, John Bonney, Wisley F. Sales, “Tool life and wear mechanisms in high speed machining of Ti–6Al–4V alloy with PCD tools under various coolant pressures”, Journal of Materials Processing Technology, Volume: 213, pp: 1459– 1464, 2013.
VIII. Samad NadimiBavilOliaei and YiğitKarpat, “Influence of tool wear on machining forces and tool deflections during micro milling”, International Journal of Advanced Manufacturing Technology,, Volume: 84, pp:1963–1980, 2016.
IX. Subramanian M., Sakthivel M., Sooryaprakash K., Sudhakaran R.,” Optimization of end mill tool geometry parameters for Al7075-T6 machining operations based on vibration amplitude by response surface methodology”, Measurement, Volume:46, pp: 4005–4022, 2013.
X. Wanqun Chen, Xiangyu Teng, DehongHuo and Quanlong Wang, “An improved cutting force model for micro milling considering machining dynamics”, International Journal of Advanced Manufacturing Technology,Volume:93, pp.3005–3016, 2017.
XI. W Rmili, A Ouahabi, R Serra, R Leroy, “An automatic system based on vibratory analysis for cutting tool wear monitoring”, Measurement, Volume: 77, pp: 117-123, 2016.

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