International Journal of Machine Design and Manufacturing vol 2 issue 2 by JournalsPub

it le m tic b Su Ar Applied Mechanics r International Journal of Electro Mechanics and u Mechanical Behaviour International Journal of Machine Design and Yo Manufacturing

Mechanical Engineering

¬ International Journal of Thermal Energy and

¬ International Journal of Production Engineering ¬ International Journal of Industrial Engineering

« « «

Applications

International Journal of Mechanical Dynamics and Analysis International Journal of Fracture and damage Mechanics International Journal of Structural Mechanics and Finite Elements

and Design

Technologies « International Journal of Digital Electronics « International Journal of Digital Communication and Analog

Materials Processing ¬ International Journal of Mechanical Handling and

5 more...

Commercialization « International Journal of Environmental Chemistry « International Journal of Agrochemistry « International Journal of Prevention and Control of Industrial

Pollution 1 more...

Civil Engineering

Planning « International Journal of Architecture and Infrastructure

Planning « International Journal of Rural and Regional Planning

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Development

International Journal of Water Resources Engineering International Journal of Concrete Technology International Journal of Structural Engineering and Analysis International Journal of Construction Engineering and Planning

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Computer Science and Engineering International Journal of Wireless Network Security International Journal of Algorithms Design and Analysis International Journal of Mobile Computing Devices International Journal of Software Computing and Testing International Journal of Data Structures and Algorithms 5 more...

International Journal of Analog Integrated Circuits International Journal of Automatic Control System International Journal of Electrical Machines & Drives International Journal of Electrical Communication Engineering « International Journal of Integrated Electronics Systems and 4 more... Circuits

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Material Sciences and Engineering

International Journal of Immunological Nursing International Journal of Cardiovascular Nursing International Journal of Neurological Nursing International Journal of Orthopedic Nursing International Journal of Oncological Nursing

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International Journal of Energetic Materials International Journal of Bionics and Bio-Materials International Journal of Ceramics and Ceramic Technology International Journal of Bio-Materials and Biomedical Engineering 4 more...

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International Journal of Photochemistry International Journal of Analytical and Applied Chemistry International Journal of Green Chemistry International Journal of Chemical and Molecular Engineering 3 more...

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Biotechnology « International Journal of Industrial Biotechnology and « « « «

Jul–Dec 2016

Chemical Engineering « International Journal of Renewable Energy and its

Architecture « International Journal of Housing and Human Settlement

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IJMDM

Automation

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Machine Design & Manufacturing

¬ International Journal of Manufacturing and

Electronics and Telecommunication « International Journal of Radio Frequency Design « International Journal of VLSI Design and Technology « International Journal of Embedded Systems and Emerging

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JournalsPub is a multi-disciplinary international journal boosting innovative & eminence research work by Division of Dhruv Infosystems Pvt. Ltd. Launched in 2014 under the support and guidance by our Honorable Editorial Board Members from renowned institutes.

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International Journal of Machine Design and Manufacturing

International Journal of Machine Design and Manufacturing is a peer-reviewed journal with raison d'être to promote advances in manufacturing and machine design division, manufacturing of machines, machine tools, information in system design, intelligence and precision equipment division. The journal disseminates research that imparts theoretical grounding and practical application of the idea presented in the paper. As a general criterion for the publication of paper in the journal is its emphasis on the practical application and constructive aspect of applied mechanics.

Focus and Scope of the Journal  Design/analysis of all types of gears, gear boxes, gear measurement  Shaft design and bearing selection  Power transmitting shafts  Advanced vibrations  Tribology and bearing design  Bearings, fasteners, springs, brakes and clutches  Computer-aided drafting and electrical drafting  Pipe drafting and solid modeling/design  Microstation, inventor, and GeoSoft montaj drawing  Turbomachines  Intelligent machines

International Journal of Machine Design and Manufacturing is published twice a year (bi-annual) by JournalsPub an imprint of Dhruv Infosystems Pvt. Ltd., India. The outlooks stated in the articles do not essentially reflect of the publisher. The publisher does not endorse the quality or value of the advertised/sponsored products described therein. Please consult full prescribing information before issuing a prescription for any products mentioned in this publication. No part of this publication may be reproduced, stored in retrieval or transmitted in any form without written permission to the publisher. To cite any of the material contained in this journal, in English or translation, please use the full English reference at the beginning of each article. To reuse any of the material, please contact JournalsPub (info@journalspub.com).

PUBLICATION MANAGEMENT TEAM

Chairman Mr. Puneet Mehrotra Managing Director, JournalsPub, New Delhi

INTERNAL MEMBERS

Associate Manager Hidam Renubala

Commissioning Editors Ankita Singh

Dr. Chhavi Goel

Deepika Bhadauria

Manisha Dhoble Rekha Rani

EDITORIAL BOARD MEMBERS Dr. Basel Alsayyed Department of Mechanical Engineering, UAE University, United Arab Emirates

Dr. R S Jadoun G. B. Pant University of Agriculture & Technology, Pantnagar, India

Dr. N. Bose Department of Mechanical Engineering, Mepco Schlenk Engineering College, Virudhunagar, India

Dr. Vasudev Malhotra Y.M.C.A University of Science and Technology (State Govt. University), Faridabad (Haryana), India

Dr. Muthuramalingam Thangaraj SRM University, Chennai, India

Dr P. M. M. Subrahmanya Sarma VIZAG Institute of Technology, Dakamarri, Bheemunipatnam Mandal, Visakhapatnam, India

Dr. V Sugumaran Associate Professor, School of Mechanical Engineering and Building Sciences, VIT University, India

Dr. Sam Paul Associate Professor, Department of Mechanical Engineering, Karunya University, Coimbatore, India

Bo-Wun Huang China

Dr. Siva Prasad Kondapalli Associate Professor, Anil Neerukonda Institute of Technology & Sciences,Visakhapatnam, India

Prof. D.S. Robinson Smart Department of Mechanical Engineering, Karunya University, Coimbatore, India

From the Editor's Desk Dear Readers, We would like to present, with great pleasure, the inaugural volume of a new scholarly journal, International Journal of Machine Design and Manufacturing. This journal is part of the Engineering Sciences, and is devoted to the scope of present Machine Design issues, from theoretical aspects to application-dependent studies and the validation of emerging technologies. This new journal was planned and established to represent the growing needs of Machine Design and Manufacturing as an emerging and increasingly vital field, now widely recognized as an integral part of scientific and technical investigations. Its mission is to become a voice of the Engineering Science community, addressing researchers and practitioners in this area. The core vision of International Journal of Machine Design and Manufacturing in JournalsPub is to propagate novel awareness and know-how for the profit of mankind ranging from the academic and professional research societies to industry practitioners in a range of topics in Machine Design in general. JournalsPub acts as a pathfinder for the scientific community to published their papers at excellently, welltime & successfully. International Journal of Machine Design and Manufacturing focuses on original high-quality research in the realm of Turbomachines, Intelligent machines, Shaft design and bearing selection, Power transmitting shafts, Advanced vibrations, Tribology and bearing design, etc. The Journal is intended as a forum for practitioners and researchers to share the techniques of Machine Design and Manufacturing and solutions in the area. Many scientists and researchers have contributed to the creation and the success of the Mechanical Engineering community. We are very thankful to everybody within that community who supported the idea of creating an innovative platform. We are certain that this issue will be followed by many others, reporting new developments in the field of Machine Design and Manufacturing. This issue would not have been possible without the great support of the Editorial Board members, and we would like to express our sincere thanks to all of them. We would also like to express our gratitude to the editorial staff of JournalsPub, who supported us at every stage of the project. It is our hope that this fine collection of articles will be a valuable resource for engineering readers and will stimulate further research into the vibrant area of Machine Design and Manufacturing. Puneet Mehrotra Managing Director

Contents 1. Speculative Study of Ball Bearings and Its Related Parts C. Chinglenthoiba, V. Balaji, B. Abbas, A. Madhan Kumar

2. Nontraditional Material Removal Processes for a Variety of Machining Materials Priyanka Garg

3. MEMS and Failures Caused by Tribological Issues in Them S. Sharmila

4. Review on Methodologies Used For Compliant Mechanism Deepika Bhadauria

5. Development of an Effective Uncemented Femoral Stem Implant With CNC Ball End Milling Sadananda Chakraborty, Bidhan Chandra Biswas, Nirmal Kumar Mandal

International Journal of Machine Design and Manufacturing

Vol. 2: Issue 2

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Speculative Study of Ball Bearings and Its Related Parts C. Chinglenthoiba*, V. Balaji, B. Abbas, A. Madhan Kumar

Department of Mechanical Engineering, Mahendra Engineering College, Affiliated to Anna University, Namakkal, Chennai, India

ABSTRACT A bearing is a mechanical device used to enable rotational or linear movement, while reducing friction and handling stress. A bearing is easier to move both in rotary and linear, and it has a simple structure with internal and external smooth metal surfaces. Keywords: angular contact, ball bearing, cap

INTRODUCTION Although the concept of the ball bearing dates back at least to Leonardo da Vinci, their design and manufacture has become remarkably sophisticated. This technology was brought to its present state of perfection only after a long period of research and development. The benefits of such specialized research can be obtained when it is possible to use a standardized bearing of the proper size and type. However, such bearings cannot be used indiscriminately without a careful study of the loads and operating conditions.[1–10] BEARING WITH BEARING CAP The bearings are pressed smoothly to fit into the shafts because if hammered the bearing may develop cracks. Bearing is made upon steel material and bearing cap is mild steel. Ball and roller bearings are used widely in instruments and machines in order to minimize friction and power loss. In addition, the bearing must be provided with adequate mounting, lubrication and sealing.[11–17] Design engineers have usually two possible sources for obtaining information which they can use to select a bearing for their particular application: a) Textbooks b) Manufacturers

Catalogs textbooks are excellent sources; however, they tend to be overly detailed and aimed at the student of the subject matter rather than the practicing designer. They, in most cases, contain information on how to design rather than how to select a bearing for a particular application. Manufacturers’ catalogs, in turn, are also excellent and contain a wealth of information which relates to the products of the particular manufacturer. These catalogs, however, fail to provide alternatives – which may divert the designer’s interest to products not manufactured by them. Our Company, however, provides the broadest selection of many types of bearings made by different manufacturers. For this reason, we are interested in providing a condensed overview of the subject matter in an objective manner, using data obtained from different texts, handbooks and manufacturers’ literature. This information will enable the reader to select the proper bearing in an expeditious manner. If the designer’s interest exceeds the scope of the presented material, a list

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International Journal of Machine Design and Manufacturing

Vol. 2: Issue 2

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Nontraditional Material Removal Processes for a Variety of Machining Materials Priyanka Garg*

University of Madras, Tamil Nadu, India

ABSTRACT Some non-conventional machining methods which are widely accepted in material processing are ultrasonic machining and laser-beam machining. Since these technologies are implemented for machining of variety of materials, they are extensively used to meet extra required machining conditions. When these processes are employed properly, they offer many advantages over non-traditional machining processes. The present paper gives a precise description about the two machining technologies and their uses. Keywords: composite material, microstructures, milling, laser-beam machining, nontraditional machining process

INTRODUCTION USM is mechanical material removal process or an abrasive process used to erode holes or cavities on hard or brittle workpiece by using shaped tools, high frequency mechanical motion and an abrasive slurry. USM offers a solution to the expanding need for machining brittle materials such as single crystals, glasses and polycrystalline ceramics, and increasing complex operations to provide intricate shapes and workpiece profiles. It

is therefore used extensively in machining hard and brittle materials that are difficult to machine by traditional manufacturing processes. The hard particles in slurry are accelerated toward the surface of the workpiece by a tool oscillating at a frequency up to 100 KHz – through repeated abrasions, the tool machines a cavity of a cross section identical to its own. A schematic representation of USM is shown in Figure 1.[1–4]

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International Journal of Machine Design and Manufacturing

Vol. 2: Issue 2

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MEMS and Failures Caused by Tribological Issues in Them S. Sharmila*

University of Madras, Chennai, India

ABSTRACT Because of large surface-to-volume ratios and low restoring forces, unwanted adhesion and friction can dominate the performance of microelectromechanical systems (MEMS) devices. To guarantee the function and reliability of MEMS devices, tribologists must understand the origins of adhesion, friction, and wear over a broad range of length scales from the macroscopic to the molecular. In this article, we present an overview of challenges, successes, and initial steps toward a fundamental understanding of MEMS microelectromechanical systems. Keywords: adhesion, device fabrication, microelectromechanical systems, macroscale, tribological issues

INTRODUCTION The manufacture of many types of extremely small devices and structures, such as microelectromechanical systems (MEMS) is possible due to recent developments in micro-fabrication technology. A development of microtribology is presented by investigating surface and interfacial forces. Adhesion and friction will be discussed with not only an emphasis on theory, but also a look at experimental tools used to measure these properties in the laboratory, and an explanation of wear in MEMS actuators will follow. Because these devices must react to mechanical signals, many of these use construction topologies that require physical motion. For example, an accelerometer-type device translates the motion of a suspended proof mass into

capacitance which is later converted to a voltage output.[1] Similarly, micromechanical mirrors must be able to deflect a light beam in a particular direction. Suspended micromachined structures such as plates and beams are commonly used in the manufacturing of pressure and acceleration sensors. These structures are typically made by forming a layer of the plate or beam material on top of a sacrificial layer of another material and etching the sacrificial layer. These microstructures have relatively large areas, but a very small stiffness. At the same time these elements are fabricated a few microns from their supporting substrate. The combination of these three characteristics makes MEMS devices highly susceptible to surface forces which can cause the suspended members to deflect toward the substrate. Under certain conditions, the elastic member can collapse and permanently

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International Journal of Machine Design and Manufacturing

Vol. 2: Issue 2

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Review on Methodologies Used For Compliant Mechanism Deepika Bhadauria*

I.P.University, New Delhi, India

ABSTRACT This paper gives a brief overview and comparison of the methods applied in the design of compliant mechanisms. Since the first research works on the subject appeared in the 1980s, several methods have being conceived to analyze and design these mechanisms that gain part of their motion from the deflection of flexible members rather than from movable joints only. The scope and limitations of the most widely used design tools in the field are also presented in the article. Keywords: compliant mechanism, flexible structure, structural optimization, joints INTRODUCTION A mechanism is a mechanical device used to transfer or transform motion, force, or energy. Traditional rigid-body mechanisms consist of rigid links connected at movable joints. The linear input is transformed to an output rotation, and the input force is transformed to an output torque. This mechanism transfers energy from the input to the output (neglecting friction losses) due to which, the output force may be much larger than the input force, but the output displacement is much smaller than the input displacement. Structures may also consist of rigid links connected at joints, but relative motion is not allowed between the links. Since a structure does not have mobility, it does not perform work (Figures 1, 2).[1] Mechanisms in nature customize their shape, their mechanical geometry, to maintain optimal performance under changing conditions in a dynamic environment. This is possible since natural bodies are essentially single-piece compliant mechanisms in that their various components grow out of one another or are bonded with self-renewing transitional

surfaces. Such compliant designs are inherently robust since fatigue stresses are distributed throughout the entire form and thus strains are disbursed or absorbed during normal operation.

Fig. 1. The portion of a reciprocating engine. Source: https://compliantmechanisms.byu.edu/cont ent/intro-compliant-mechanisms.

Fig. 2. Vice grips. Source: https://compliantmechanisms.byu.edu/cont ent/intro-compliant-mechanisms.

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International Journal of Machine Design and Manufacturing

Vol. 2: Issue 2

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Development of an Effective Uncemented Femoral Stem Implant With CNC Ball End Milling Sadananda Chakraborty*, Bidhan Chandra Biswas, Nirmal Kumar Mandal

Mechanical Engineering Department, National Institute of Technical Teachers’ Training and Research, Salt Lake City, Kolkata, India

ABSTRACT Now a days uncemented total hip replacement (THR) is mostly used in surgery of hip joint. Quality and reliability of an uncemented femoral stem depends on many factors. The effect of roughness of the implant on the stress distribution, Von Mises Stress of the implanted femur with varying frictional co-efficient ranges from 0.2 to 0.4 have been studied through finite element analysis using commercial finite element analysis package ANSYS. Machining of the implant is very important because there are so many factors likes, quality of the product, combination of tool-work piece material, machinability of the work material, productivity etc that depends on performance. The aim of the present study is to find out the optimum significant parameters of the machining operation of femoral stem implant for optimum surface roughness. SS316L has been taken as the work material as it is widely used as hip implant. Ball end milling cutter of coated carbide has been chosen as the cutting tool as it is used in the finish cut of complex shapes. Speed, feed rate and Step over are taken as the cutting parameters. MINITAB 16 commercial software package is used to determine the number of experiment through Design of Experiment (DOE). Total 20 no. of experiments are conducted and the collected data are analyzed to predict the surface roughness through regression analysis. Significance of input process parameters are tested by Analysis of Variance (ANOVA). A model equation is formed using coefficients obtained from Analysis of Variance (ANOVA) and this equation is used to find out optimum process parameters using Genetic Algorithms. Keywords: CATIA model, CNC ball end milling, femoral stem implant, GA, secondary fixation

INTRODUCTION In hip replacement surgery it has been found that mainly some bone marrow top section and head of femur can be replaced. The total arrangement of these sections must be secured and comfortable John Charnley has introduced the use of polymetacrylate bone cement to secure the components to original living bone and high-density polyethylene is used as a bearing material in THA. This concept of cemented THA shows very good results even today. In the first generation of cemented hips early failure has been

reported mostly of the cemented stem. These failures has been associated with localized areas of osteolysis mostly in the femur caused by the systemic inflammatory response believed to be a process by cement particles, a phenomenon called “cement disease”. Several investigators therefore proposed that the future of THA should be the development of prostheses that are implanted avoiding the use of cement. This triggered the development of uncemented

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it le m tic b Su Ar Applied Mechanics r International Journal of Electro Mechanics and u Mechanical Behaviour International Journal of Machine Design and Yo Manufacturing

Mechanical Engineering

¬ International Journal of Thermal Energy and

¬ International Journal of Production Engineering ¬ International Journal of Industrial Engineering

« « «

Applications

International Journal of Mechanical Dynamics and Analysis International Journal of Fracture and damage Mechanics International Journal of Structural Mechanics and Finite Elements

and Design

Technologies « International Journal of Digital Electronics « International Journal of Digital Communication and Analog

Materials Processing ¬ International Journal of Mechanical Handling and

5 more...

Commercialization « International Journal of Environmental Chemistry « International Journal of Agrochemistry « International Journal of Prevention and Control of Industrial

Pollution 1 more...

Civil Engineering

Planning « International Journal of Architecture and Infrastructure

Planning « International Journal of Rural and Regional Planning

« « « «

Development

« International Journal of Town Planning and Management

2 more...

Electrical Engineering

« « « «

Nursing

Material Sciences and Engineering

« « « «

5 more...

Biotechnology « International Journal of Industrial Biotechnology and « « « «

Jul–Dec 2016

Chemical Engineering « International Journal of Renewable Energy and its

Architecture « International Journal of Housing and Human Settlement

« « « « «

IJMDM

Automation

5 more...

Signals

Machine Design & Manufacturing

¬ International Journal of Manufacturing and

Electronics and Telecommunication « International Journal of Radio Frequency Design « International Journal of VLSI Design and Technology « International Journal of Embedded Systems and Emerging

« « « « «

International Journal of

Office No-4, 1 Floor, CSC, Pocket-E, Mayur Vihar, Phase-2, New Delhi-110091, India E-mail: info@journalspub.com

Nanotechnology « International Journal of Applied Nanotechnology « International Journal of Nanomaterials and Nanostructures « International Journals of Nanobiotechnology

Chemistry

Physics « International Journal of Solid State Materials « International Journal of Optical Sciences