International Journal of Manufacturing and Materials Processing 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

and Design ¬ International Journal of Manufacturing and

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

Chemical Engineering « International Journal of Renewable Energy and its

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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International Journal of Manufacturing and Material Processing

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International Journal of Manufacturing and Material Processing

International Journal of Manufacturing and Material Processing is a peer-reviewed journal that provides students, researchers and leading industries with high quality of scientific data. Journal focuses on traditional and non-traditional manufacturing processes, as well as new advances in designing methodology, making the theoretical aspect of the research as important as the practicality of the work done. The prominence of the journal lies in the industrial application and novelty of the research work.

Focus and Scope of the Journal !

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Computer-Aided Manufacturing Medical Device Design And Manufacturing. Traditional And Non-Traditional Manufacturing Processes, Manufacturing Processes In Dental And Medical Practices, Multibody System Dynamics, Control Systems, Kinematics, Compliant Mechanisms, Electro-Mechanical Systems, Computer-Aided Design, Mechatronics, Design For Manufacturing, Dynamics And Vibrations Of Mechanical And Continuous Systems, Finite Element Modeling, Modal Testing, Model Updating, Structural Damage Detection And System Identification

International Journal of Manufacturing and Material Processing 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. D.S. Robinson Smart Karunya University, Coimbatore, (Tamil Nadu), India

Dr. P. Narendra Mohan University College of Engineering and Technology, Acharya Nagarjuna University, Nagarjuna Nagar Guntur, (Andhra Pradesh), India

Dr. Muthuramalingam Thangaraj SRM University, Chennai, (Tamil Nadu), India

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

Dr. S. John Alexis Kumaraguru College of Technology, Coimbatore, (Tamil Nadu), India

Dr. Sarang Pande Faculty of PG and Research, Marwadi Education Foundation, Rajkot, India

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

Dr. K R Sivadas Sree Narayana Gurukulam College of Engineering, Kadayiruppu, India

Dr. Nataraj J.R R.V. College of Engineering, Mysore Road, Bangalore, (Karnataka), India

Dr. D. Siva Prasad GITAM Institute of Technology, Visakhapatnam, India

Dr. Sam Paul Karunya University Coimbatore, (Tamil Nadu), India

Bo-Wun Huang China

Dr. Siva Prasad Kondapalli Anil Neerukonda Institute of Technology & Sciences, Visakhapatnam, (Andhra Pradesh), India

Mr. Harish Kumar Noida International University, Yamuna Expressway, Greater Noida, (Uttar Pradesh), 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 Manufacturing and Material Processing. This journal is part of the Engineering Sciences, and is devoted to the scope of present Manufacturing and Material Processing 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 Manufacturing and Material Processing 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 Manufacturing and Material Processing 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 Manufacturing and Material Processing in general. JournalsPub acts as a pathfinder for the scientific community to published their papers at excellently, well-time & successfully. International Journal of Manufacturing and Material Processing focuses on original high-quality research in the realm of Computer-aided manufacturing, Medical device design and manufacturing, manufacturing processes in dental and medical practices, Multi body system dynamics, Control systems, kinematics, and compliant mechanisms, Electro-mechanical systems, Computer-aided design. The Journal is intended as a forum for practitioners and researchers to share the techniques of Manufacturing and Material Processing 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 Manufacturing and Material Processing. 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 Manufacturing and Material Processing readers and will stimulate further research into the vibrant area of Manufacturing and Material Processing. Puneet Mehrotra Managing Director

Contents 1. A Comprehensive Study on Optimization of Neural Networks and Global Minimization M. Aravindh, C. Velmurugan

2. Productivity Improvement in a Four Wheeler Seat Manufacturing Industry Using Lean Techniques B. Senthilnathan, M. Gomathi Prabha

3. Review of Optimization Process Parameters in Welding System N.H. Khan, R.P. Kori

4. Effect of Cutting Parameters in Hard Turning on Chip Formation and Machined Surface S. Choubisa, B.P. Nandawana, M.A. Saloda, M.S. Khidiya

5. Risk Assessment and Analysis in a Chemical Industry M. Ananthu, A.P. Arun

International Journal of Manufacturing and Material Processing Vol. 2: Issue 1

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A Comprehensive Study on Optimization of Neural Networks and Global Minimization M. Aravindh*, C. Velmurugan Department of Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India

Abstract The neural network toolbox is one of the commonly used, commercially available and powerful software tool for constructing new networks and it forms a inter linkage between functionalities and their respective objective function. The software is user-friendly, permits flexibility and convenience in interfacing with other toolboxes in the same environment to develop a full application and has a wide range of scope in making models with linear and non-linear functions, without any assumptions and applied in almost every field of science and engineering. In addition, it underlies in one directional linear function with and without hard limit, and possesses the responsibility of radial and triangular biasing and suitable for competitive soft max functions. A wide variety of training and learning algorithms are supported through neural networks. The functions used in the neural networks are as same as model of brain and nervous system which are highly parallel and possess high speed information resemble the brain and a super computer. The functionalities in neural networks have very simple principles and possess very complex behaviors. In this paper, an attempt is made to enhance effortless operation of neural networks in a systematic procedure through MATLAB for optimizing and global minimizing. Keywords: global minimization, MATLAB, neural networks, optimization, training

INTRODUCTION An optimization function is defined as the system which possesses a function for getting objective values with a valid constraint equation set and variables that defines a function. The objective of any optimization is that find the variables that lead to an optimal value to find (either minimum or maximum), while satisfying all the constraints. [1–3] Learning of problem domains for neural network is considered by the factor when a Input is highly-dimensional discrete or real-valued (e.g. raw sensor input) and output in the form of discrete or real valued which has a vector of values and

considered as a target function, Humans need not to interpret during the results.[4] Neural networks can be trained using local, gradient-based procedures. Such methods frequently find suboptimal solutions as local minima. Optimization of neural network structures and global minimization methods is applicable for cost functions have strong influence on all aspects of network performance. [5] The structure of neurons is considered with the input layers, output layers and hidden layer. Neuron acts as an input signal when it exceeds a certain amount in a short time period. Synapses or connection may vary in strength that

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International Journal of Manufacturing and Material Processing Vol. 2: Issue 1

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Productivity Improvement in a Four Wheeler Seat Manufacturing Industry Using Lean Techniques B. Senthilnathan*, M. Gomathi Prabha Department of Mechanical Engineering, PSG College of Technology, Coimbatore, Tamil Nadu, India

Abstract The industries along with the development of technology became competitive in nature. Moreover globalization made this scenario even worst. The productivity becomes vital element with product variety. The four wheeler seat manufacturing industries are badly affected by productivity issues due to high cycle time, unbalanced workload and improper layout. Our ultimate aim of this paper is to use lean methodology to improve productivity without affecting current working pressure in industry. The problems in the current layout are identified and analyzed through value stream mapping. Then the layout is modified in sub-assembly and workload is balanced in conveyor line. The results are compared with the current layout. The results revealed an improvement of 14% in productivity. Keywords: line balancing and layout optimization, value stream mapping

INTRODUCTION One of the most important characteristics of manufacturing is cycle time. The customers expect their manufacturers to be responsive in delivering products on time. So, they are constantly leaning towards cycle time reduction of all the processes. Cycle time is an interval of time, during which a set of consecutive actions takes place repeatedly which in turn is defined as the time of longest operation in a sub-assembly and assembly line. If the line is balanced properly and sub-assembly layout is optimized it will reduce the cycle time. Value stream mapping is used to identify the NVA activities.

eliminating NVA activities and reducing production time.

The four wheeler manufacturing industry finds problem in assembly section as cycle time taken by process is irregular and unbalanced. The scope of this paper is to use different lean tools such as line balancing, VSM, layout optimization and kaizen for improving the productivity by

Johan [3] identified that there is a less accuracy of standard time and a poor work arrangement. In order to overcome root causes, line balancing is suitable method.

LITERATURE SURVEY Line Balancing Assembly line balancing is the process of dividing the workloads between stations. So that workstations have equal time allotted and less time is wasted. Santhosh [1] gave an idea about line balancing in truck assembly line, which helps to reduce cycle time of the process. Shamuvel [2] found that with help of line balancing it is possible to improve productivity and better utilization of resources.

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International Journal of Manufacturing and Material Processing Vol. 2: Issue 1

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Review of Optimization Process Parameters in Welding System N.H. Khan*, R.P. Kori Department of Mechanical Engineering MITS, Gwalior, MP, India

Abstract This study was based on design of experiment (DOE) using Taguchi method with four welding parameters namely welding current, welding speed, root gap and electrode angle considered for experimentation. An orthogonal array of L9 experimental design was adopted and ultimate tensile strength was investigated for each experimental run. The tensile test was carried out on extracted welded and unwelded specimens using universal testing machine (UTM). Microstructures of the welded specimens were carried out and analyzed. Statistical analysis (ANOVA) and signal to noise ratio were used to study the significant effect of input parameters on ultimate tensile strength and optimized conditions for the process performance respectively. The results showed that experiment number 7 has the highest ultimate tensile strength (UTS) of 487MPa and S/N ratio of 53.74 dB. The S/N ratio of higher value indicates better characteristic of optimum MMAW process performance. The study shows that the optimum condition is A3B1C3D2 at welding current 100A, electrode angle of 700, root gap of 3.3 mm and a welding speed of 3.6 mm/s. Keywords: optimized conditions, welding parameters, welding processes, work piece

INTRODUCTION Welding process is very critical to the development of a nation because it is the hub on which modern industries revolve. Gasser et al. [1] stated that no secondary process has been and continues to be more important to the survival, comfort and advancement of mankind than welding. According to him, welding has made it possible to build our world. It is in view of this that many researchers have employed various optimization techniques to improve different welding process parameters on both semi and full automated welding processes. Although, the semi and full automatic welding processes are more productive, experience has shown that due to complexity and economic cost of the equipment and their operations, the choice of manual metal arc welding (MMAW) process is very popular

in developing countries. This is so because of its several advantages such as low cost and simple operation. The MMAW process is portable and it can easily be used in places where other welding methods are not possible. Manual metal arc welding is also known as shielded metal arc welding (SMAW), or stick welding process. It is one of the oldest and most widely used arc welding processes. The process involves the use of arc current to strike an arc between the base material and a consumable electrode rod. The electrode rod is made of a metal that is compatible with the base material being welded and it is covered with a flux. The heat generated melts a portion of the tip of the electrode, its coating and the base metal just below the arc. As the coating on the electrode melts, the flux gives off vapors that serve as a shielding gas and

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International Journal of Manufacturing and Material Processing Vol. 2: Issue 1

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Effect of Cutting Parameters in Hard Turning on Chip Formation and Machined Surface S. Choubisa*, B.P. Nandawana, M.A. Saloda, M.S. Khidiya Department of Mechanical Engineering, College of Technology and Engineering, Udaipur, Rajasthan, India

Abstract Cost effectiveness, increasing demand, high production rates and reliability of the product have increased the potential of industrial application of hard turning technology during the past few years. Grinding operation for hard steel component reduces the machining sequence, the machining time and the specific cutting energy. Hard turning also shows effects like generation of high temperature, the formation of saw toothed chips. In this thesis, experimental investigation is conducted in order to study the chip transition using Scanning Electron Microscopy and chip micro-hardness were conducted to correlate the chip morphology, cutting forces using micro-hardness tester. The surface integrity of machines part is also investigated. This study focuses on surface and sub-surface defects and white layer formation. The machined surfaces are examined using SEM to study effect of different process parameters on the quality of the machined surface. Cutting forces were measured by lathe tool dynamometer and ANOVA test were performed to observe the effect of cutting parameters on cutting forces. Keywords: AISI D2 steel, chip formation, cutting forces, hard turning, microstructure of machined surface ANOVA

INTRODUCTION For aerospace industries high precision hardened steel is required therefore hard turning technology has been increased and now a dayshard turning has been replaced the grinding processes of hardened steel components in practice. Improved ceramic tool and CBN tool have been emerged as very important cutting for machining of hardened steel without any coolant. If we talk economically then it also provides less â&#x20AC;&#x201C;effective time, less cost and most importantly high precision parts. When compared to grinding process the machining time is comparatively 50% lesser. If the right combination of nose radii, feed rate, cutting speed, depth of cut is used then a better surface finish can be obtained as compare to grinding operations. Here, it is confirmed that these

tool offers less machining time, higher surface finish during hard turning but its mechanism is need to be studied.[1] During hard turning the designing of cutting tool is to be considered and these can be studied by observance of cutting force at various cutting conditions. In the current environment, the performance variables are determined experimentally using a trial and error method. To obtain this design plan, it is necessary to estimate the cutting forces from a basic approach so that the performance of the cutting tools and machine tools can be calculated. An analytical model can also be obtained to the predicted values. In the process of hardened machining such as hard turning

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International Journal of Manufacturing and Material Processing Vol. 2: Issue 1

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Risk Assessment and Analysis in a Chemical Industry M. Ananthu1*, A.P. Arun2 1

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

Abstract Chemical manufacturing sector in India is well established and has recorded a steady growth in the overall industrial scenario. The chemical and the allied industries are among the faster growing segments of Indian industry. The risks associated with the chemical industry are commensurate with their growth. Apart from their utility, chemicals have their own inherent properties and hazards like flammable, explosive, toxic or corrosive etc. Several major accidents had occurred in India and around the world killing many lives of people. Thus safety in a chemical industry is of prime concern and this project deals with safety in a chemical company (TCC LTD).There are several methods to improve the safety and minimize the risks like risk assessment, safety models, safety management systems. Several methods are implemented in the industries with safety standards like OSHA, HSE, etc. Even though many industries are implementing safety systems with these standards still injuries and accidents tend to happen due to many reasons. In this project these reasons are searched and necessary actions are taken by implementing a loss prevention programme so that the potential risks are detected and eliminated. The objective is to improve safety and working conditions by carrying out risk assessment in the chemical industry which is TRAVANCORE COCHIN CHEMICALS Ltd, ERNAKULAM. Keywords: failure, loss management, occurrence, risk assessment, safety, severity

INTRODUCTION Organizations often adopt safety management system or behavior based system approaches to manage their safety functions in an attempt to achieve performance excellence. Safety is a critical issue in the chemical industry because chemical plants store and use large volumes of hazardous materials that can cause major incidents such as fires, explosions, and the release of toxic chemicals. An effective safety management system is vital to improve the overall safety of the industry. In this project a chemical industry is selected and a loss management program is implementing to improve the safety in the firm.

In the past several accidents have taken place in the plant and generally in all the chemical industries there is always a risk of major hazard due to various reasons.[1,2] A loss management program integrates the concepts of safety as well as identification, assessment and control of both hazards and risks for the express purpose of reducing harmful risks to people, environment, assets and production. In this project one of the elements in loss management has been taken and applied in the industry which is hazard identification and risk assessment

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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

and Design ¬ International Journal of Manufacturing and

Materials Processing ¬ International Journal of Mechanical Handling and

Automation 5 more...

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

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

Chemical Engineering « International Journal of Renewable Energy and its

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

Pollution

5 more...

Signals

1 more...

Civil Engineering

Architecture « International Journal of Housing and Human Settlement

« « « «

2 more...

Electrical Engineering

Computer Science and Engineering « « « « «

Nursing « « « « «

Jan – June 2016

IJMMP

Material Sciences and Engineering

« « « «

5 more...

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

International Journal of Manufacturing and Material Processing

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