International Journal of Machine Design and Manufacturing vol 2 issue 1 by JournalsPub

Office No-4, 1 Floor, CSC, Pocket-E, 6 Mayur Vihar, Phase-2, New Delhi-110091, India 1 t E-mail: info@journalspub.com 0 i e l 2 m ic b rt u S A Mechanical Engineering Applied Mechanics r International Journal of Electro Mechanics and International Journal of Thermal Energy and u Mechanical Behaviour Applications International Journal of Machine Design and International Journal of Production Engineering Yo «

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¬ ¬ International Journal of Industrial Engineering

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

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

Materials Processing ¬ International Journal of Mechanical Handling and

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

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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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Machine Design & Manufacturing

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

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International Journal of Machine Design and Manufacturing International Journals Publisher

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'ĂŞtre 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

Priyanka Garg

Akanksha Marwah

Chhavi Goel

Deepika Bhadauria

Shrawani Verma

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. An Experimental Investigation of Optimum Flank Wear of Carbide Inserts for Dry Turning of EN19 Tool Steel Saurav Nandi, Nirmal Kumar Mandal

2. Total Productive Maintenance (Tpm) Implementation Process in Machining Line V. Nithiyanandhan, K.M. Senthil Kumar

3. Optimization of Weld Bead Geometry in Gas Metal Arc Welding of High Strength Low Alloy Steel Using Response Surface Methodology S. Veera Jeyendra Prakash, V. Manivel Muralidaran

4. Predictive Modelling and Optimization of Cutting Tool Life and Machine Vibration for Making a Poppet Valve Someswar Dey, Nirmal K. Mandal

5. A Brief Note on Rover Design Priyanka Garg

International Journal of Machine Design and Manufacturing Vol. 1: Issue 2

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An Experimental Investigation of Optimum Flank Wear of Carbide Inserts for Dry Turning of EN19 Tool Steel Saurav Nandi*, Nirmal Kumar Mandal Department of Mechanical Engineering, National Institute of Technical Teachers’ Training and Research, Kolkata, India

Abstract Flank wear of cutting tools is often selected as the tool life criterion because it determines the diametric accuracy of machining, its stability and reliability. In this work the effect of cutting parameters like RPM, feed rate and depth of cut is studied on dry turning of EN19 tool steel and input parameters are optimized for minimum tool wear. RSM technique is employed to achieve the minimum tool wear. Combined effects of the cutting parameters on tool wear (VB) are investigated. Keywords: dry turning, feed rate and depth of cut, RPM, RSM, tool wear

INTRODUCTION The turning of EN19 tool steel material, which have high tensile strength yields desirable results only when optimum process parameters are selected. This tool steel has a very high usage in automobile industry. Turning operation is used and flank wear as well as optimum condition are studied. Tool wear in machining is defined as the amount of volume loss of tool material on the contact surface due to the interactions between the tool and work piece. Specifically, tool wear is described by wear rate (volume loss per unit area per unit time) and is strongly determined by temperature, stresses, and relative sliding velocity generated at the contact interface. Tool wear have significant influences on the accuracy of the finished product. [1–3] Response surface method (RSM) is very useful for modelling and analysis of a process. It adopts both mathematical and statistical techniques in which a response

of interest is influenced by several variables. Tool Wear High contact stress between the tool rakeface and the chip causes severe friction at the rake face. This results into a variety of wear patterns and scars which can be observed at the rake face and the flank face. Flank Wear (Clearance Surface) Flank wear creates inaccuracy of the product size and results in the formation of a wear land. It is observed that wear and formation of wear is not always uniform throughout the wear land. In fact, flank wear can be monitored in production by examining the tool or by tracking the change in size of the tool or machined part. Flank wear is generally measured by using the land size VB and VBmax (Figures 1, 2). [4, 5]

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International Journal of Machine Design and Manufacturing Vol. 1: Issue 2

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Total Productive Maintenance (Tpm) Implementation Process in Machining Line V. Nithiyanandhan*, K.M. Senthil Kumar Department of Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India

Abstract The core of this paper is doing a study on CNC machining line of automobile components production industry and coming up with suggestions to implement total productive maintenance on the Machining line. Companies around the world spend a lot of money on buying new equipments to increase production but a little is done to get hundred percent output from the machine for which it is designed for. Small losses in time or small deviations from designed capability are taken as normal machine behaviour. But now because of increased competency levels and demand of quality products at lower costs, buying latest equipment is not a solution unless it is fully utilized. Total Productive Maintenance (TPM) is a plan which concentrates on total involvement of everyone from top management to all employees to implement a comprehensive maintenance program for all equipment throughout its life. This plan results in maximum effectiveness of equipment, tidier, neat and clean work place and morally boosted employees. In this report over all equipment effectiveness OEE is measured before implementing TPM and after implementing TPM. At the end of the report over all equipment effectiveness OEE is compared with previous results. Keywords: autonomous maintenance, preventive effectiveness, total productive maintenance, 5S

INTRODUCTION In order to be successful in today’s worldclass manufacturing environment companies have to fulfil several requirements. Maintaining a reliable manufacturing process is a key success factor to satisfy these requirements which can be achieved through implementing a proper maintenance strategy. Any operation or process done on machine or its parts to enhance the efficiency of machine before or after the breakdown is called maintenance. In the recently released European Standards regarding maintenance, maintenance is defined as “the combination of all technical, administrative and managerial actions during the life cycle of an item intended to retain it in, or restore it to, a state in which

maintenance,

overall

equipment

it can perform the required function”. A manufacturing business is said to be prosperous over the years, when it runs non-interrupted and always maintains a stable and high productive production flow. Plant can achieve productivity up to a satisfactory level by proper maintenance work. An efficient maintenance strategy not only reduces the probability of breakage of machine elements or shutdown of machines which hinders the production’s schedule, but also such a strategy enhances the efficiency and lifespan of machines, process quality and labour force productivity. Total Productive Maintenance (TPM) has widely been accepted as an effective strategy for

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International Journal of Machine Design and Manufacturing Vol. 1: Issue 2

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Optimization of Weld Bead Geometry in Gas Metal Arc Welding of High Strength Low Alloy Steel Using Response Surface Methodology S. Veera Jeyendra Prakash1*, V. Manivel Muralidaran2 1

Industrial Engineering, Kumaraguru College of Technology, Coimbatore, India Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India

Abstract The input parameters of welding play a very important role in determining the quality of a weld joint. The weld joint quality can be defined in terms of weld-bead geometry, mechanical properties, and distortion. Generally, all type of welding processes is used with the aim of obtaining a welded joint with the desired weld-bead parameters, excellent mechanical properties with minimum distortion. Response surface methodology is used to develop a mathematical relationship between the welding process input parameters and the output variables of the weld joint in order to determine the welding input parameters that lead to the desired weld quality. Keywords: gas metal arc welding, regression equation, response surface methodology

INTRODUCTION The gas metal arc (GMA) welding process is a welding process that yields coalescence of metals by heating with a welding arc between continuous filler metal (consumable) electrode and the work piece. Molten weld pool and electrode wire are protected from contaminants in the atmosphere by a shielding gas obtained from various combinations. [1–8] The quality, efficiency and overall operating acceptance of the welding operation are strongly dependent on the shielding gas, since it dominates the mode of metal transfer.

The shielding gas not only affects the properties of the weld but also determines the shape and penetration pattern as well. Various techniques such as gas, slag, gas and slag, vacuum and self-protection can be used to protect the weld pool during the fusion welding. Obviously, different

protection techniques provide different degrees of weld pool protection (Kacar et al., 2005) Since empirical optimization of welding parameters is both time-consuming and costly, the application of statistical methods such as design of experiments (DOE) is preferred. Response surface methodology (RSM) which is one of the main applications of DOE can be used to estimate unknown mechanisms through the use of an empirical model. [9–12] Using RSM, it is possible to evaluate effects of many parameters on weld mechanical properties and to optimize them to achieve suitable results. [13] The use of a statistic approach (response surface methodology) to correlate welding parameters to weld joint properties is considered by researchers. Correia et al. [13] presented comparison between genetic algorithms and response surface methodology in

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International Journal of Machine Design and Manufacturing Vol. 2: Issue 1

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Predictive Modelling and Optimization of Cutting Tool Life and Machine Vibration for Making a Poppet Valve Someswar Dey*, Nirmal K. Mandal Department of Mechanical Engineering, NITTTR, Kolkata (WB), India

Abstract The present work has been done to investigate experimentally the relationship between Machine Vibration and Tool Life in turning of EN 31 steel for making a Poppet Valve using Response Surface Methodology (RSM) & Fuzzy Logic. Response Surface Methodology (RSM) is a method of obtaining the best suited result from minimal number of experiments and Fuzzy logic is used for optimization. Thus the work process becomes less tedious, i.e., with minimal effort one can come to an almost precise outcome. In this case, RSM has been used to predict the Machine Vibration and Tool Life under various machining conditions. Machine Vibration and Tool Life are the main parameters that have been dealt with in this work. The proposed work is mainly based on finding a relationship about how machine vibration can affect the tool life of the cutting tool. The proposed method is easy to carry out in the workshop area, easy to maintain and easy to understand because assessing the images of cutting tool is easy. Also, this method is flexible to use for different machining process using this Carbide Insert (CNMG 120408 EA TT5080). After the experiments has been done the following results has been found: the levels of process cutting parameters in the study are limited to the following data Speed (900, 1400, 1900 rpm), Feed rate (0.07, 0.12, 0.17 mm/rev.), Depth of Cut (0.08, 0.18, 0.28 mm). Keywords: Machine Vibration, Tool Life, Response Surface Methodology (RSM), Fuzzy Logic, EN 31, Carbide Insert.

INTRODUCTION Increase of efficiency and decrease of production costs are the two primary goals of mechanical machining. Cutting tools and the whole system of machine-toolwork piece are constantly improving to reach this aim. Surface finish and Quality of machined part are depended on parameters such as cutting forces, temperature in contact surfaces, and wear of cutting tool, friction between tool and chip etc. These parameters give the measure of performance of machining. During the search for more effective cutting methods it was found that cutting quality can also be improved. It is seen that if vibration cutting method is used, the

cutting force magnitude can be reduced significantly. [21] Hence, it is important not only to increase efficiency, but also to meet ecological requirements. During vibration-assisted cutting temperature in work piece & contact tool is decreasing together with decreasing friction forces. This results in lower consumption of cutting oil, which in turn reduces costs for oil removal, storage and utilization. Vibration is a frequent problem in the turning operation, which influenced the

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International Journal of Machine Design and Manufacturing Vol. 2: Issue 1

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A Brief Note on Rover Design Priyanka Garg University of Madras, Tamil Nadu, India

INTRODUCTION Traditionally, the space exploration is accustomed to the use of orbiting spacecraft for the fact that, it is efficient in taking humans with the much needed amenities in bulk to other space environs. However, their design prospects limit the capability to do more exhaustive tasks on erratic planetary surfaces along with making insightful and distinctive observations. An urge to optimize accountability on planetary research was realized and a novel design of space exploration vehicle known as surface rover spacecraft was proposed which not only maneuver across the wide surface area of a planet as well as other celestial bodies but persuade many important tasks that seemed to be as forlorn as might expected to be. A rover is a well-equipped vehicle having wheels with some kind of lateral propulsion i.e. powered wheels. The wheels help the rover to move across the unusual terrestrial surface except on the surface of sun or gas planets, in spite of the difficulty to operate in extremely low gravity surface such as of moon and other planetary bodies. Rover spacecraft composes of a Solarpowered electrical system in the form of solar panels, an autonomous command module and wheelers. Figure 1 shows Mars Pathfinder spacecraft that includes rover as a small mobile instrument to be deployed on Mars.[1–3]

Fig. 1. Mars Pathfinder Spacecraft. Source: http://pics-aboutspace.com/pathfinder-marsprobe?p=4#img12328159915946181149.

Although, rovers used for Mars Exploration usually invoke same principle as that of landed spacecraft, for landing and taking off, they possess high mobility and are capable to make detailed observation to wider planetary surface area, to take samples for laboratory examination such as dust, rocks and other substances as well as to even take pictures. Figure 2 illustrates well-labelled Mars Pathfinder Rover with all its structural and operational components. In the present paper, we are leaving the technical aspect of the rover operation and concentrating on its physical design.

Page 38

« « « «

¬ ¬ International Journal of Industrial Engineering

Manufacturing 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 « « « «

Jan – Jun 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

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