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Trends in Mechanical Engineering & Technology

Contents

1. Optimization of EDM Process Parameters with Aluminium-Fly Ash Composite using Taguchi method Pankaj Kr Sharma, Shashi Prakash Dwivedi, Amit Kr Sharma, Vijay Gautam

2. Experimental and Computational Analysis of Parameters in Die-Sinking EDM Machine with AISI 316 Stainless Steel using TOPSIS Madhavi Pathak, Manoj Kumar Gaur, Sharad Agrawal

3. Minimizing the Sand Casting Defects Using Taguchi Method Priyank V. Parekh, J.A. Vadher

4. Hybridizing Principle of TOPSIS with Regression Meta-model Approach for the Optimization of CNC-WEDM Process Parameters Sandeep Tyagi, Manoj Kumar Gaur, Dinesh Kumar Kasdekar

5. Innovaluation: The Skill Set for Make in India Initiative in IOT Era Priyavrat Thareja, Komal Sharma, Samridhi Sharma, Jasleen Kaur, Amanpreet Singh

6. Experimental Investigation on a Diesel Engine Fuelled with Blends of Karanja Biodiesel and Diesel: Combustion and Performance Studies Ajay Partap Singh, Ajay Trehan

7. Comparison of Experimental and Theoretical Results of Tool Wear Rate in Electrical Discharge Machining C.R. Sanghani, G.D. Acharya, K. D. Kothari

Trends in Mechanical Engineering & Technology

ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com

Optimization of EDM Process Parameters with Aluminium-Fly Ash Composite using Taguchi Method 1

Pankaj Kr Sharma1, Shashi Prakash Dwivedi2*, Amit Kr Sharma1, Vijay Gautam3

Department of Mechanical Engineering, Raj Kumar Goel Institute of Technology, Ghaziabad, Uttar Pradesh, India 2 Department of Mechanical Engineering, Noida Institute of Engineering Technology, Greater Noida, Gautam Buddha Nagar, Uttar Pradesh, India 3 Department of Mechanical Engineering, Delhi Technical University, Delhi, India

Abstract

Aluminium based fly ash composites have gained huge popularity over the aluminum and its alloy. These aluminium based composites are being widely used in various applications such as automotive parts, machine cover, frames and ducts, etc. Fly ash addition not only makes aluminium harder, stronger, stiffer and more wear resistant but also saves energy consumption and helps in cutting down greenhouse emissions by utilizing almost freely available fly ash, which is a waste of thermal power plant and problematic to dispose of. Alfly ash composite is electrically conductive and can be processed by Electro Discharge Machining (EDM). Rough cutting operation in EDM is treated as a challenging one because improvement of more than one machining performance measures viz. metal removal rate (MRR), surface finish (SF) and tool wear are sought to obtain a precision work. Using Taguchiâ&#x20AC;&#x2122;s parameter design, significant machining parameters affecting the performance measures are identified as discharge current, pulse duration and dielectric flow. It has been observed that a combination of factors for optimization of each performance measure is different. In this study, the relationships between control factors and responses like MRR and SF have been established. Keywords: EDM, Al-fly ash composite, metal removal rate, surface finish, taguchi method

INTRODUCTION

Electro Discharge Machining (EDM) is the thermal erosion process in which metal is removed by a series of recurring electrical discharges between a cutting tool acting as an electrode and a conductive work piece, in the presence of a dielectric fluid (Figure 1). This discharge occurs in a voltage gap between the electrode and work piece. Heat from the discharge vaporizes minute particles of work piece material, which are then washed from

the gap by the continuously flushing dielectric fluid [1, 2]. EDM is mainly used to machine difficult-to-machine materials and high strength temperature resistant alloys. Work material to be machined by EDM has to be electrically conductive [3]. The most important performance measures in EDM are metal removal rate, surface finish, and tool wear. They depend on machining parameters like discharge current, pulse duration, pulse frequency and dielectric flow rate.

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Trends in Mechanical Engineering & Technology

ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com

Experimental and Computational Analysis of Parameters in Die-Sinking EDM Machine with AISI 316 Stainless Steel using TOPSIS Madhavi Pathak*, Manoj Kumar Gaur, Sharad Agrawal Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior, Madhya Pradesh, India Abstract

This paper proposes an effective solution based on TOPSIS approach to determine the optimal process parameters in die sinking electrical discharge machining. Taguchi L9 orthogonal array is used to gather information regarding the process with less number of experimental runs. Experiments have been conducted using three process parameters such as peak current, gap voltage, pulse on time, with three levels are selected to optimize the multiple objectives. AISI 316 stainless steel as a work-piece material and copper as electrode material used for the experiments are arranged on the electrical discharge machine for the research work in order to develop the optimal condition of the response parameters MRR and TWR. Keywords: Response parameter (MMR, TWR), EDM, AISI 316, TOPSIS, ANOVA

INTRODUCTION

Die sinking Electrical Discharge Machining is one of the earliest nontraditional machining processes. EDM process is based on thermoelectric energy in which electrical energy is used to generate electrical spark and material removal occurs due to thermal energy produced by the spark. A pulse discharge occurs in a small gap between the work-piece and the electrode. Then fresh dielectric fluid rushes in the gap, flushing away the debris and quenching the surface of work-piece. The EDM SPARK EROSION MACHINE TOOLCRAFT A50 spark generator used for the experiments which is having a maximum current capacity of 50A and maximum allowance is 0.2 mm. Today variety of industries require materials that are highly temperature resistant and provide higher strength, toughness, highly resistant to corrosion and other properties therefore, it has become essential to have such process that are safe and conveniently machined the hardened materials with accuracy hence nonconventional machines are preferred. For machining of hardened steel, the preferred metal cutting process is electrical discharge machining. This process is

characterized by good material removal rate, better dimensional accuracy and good surface finish [1]. Basically optimization of every machining process parameter is usually a challenging task, because it requires simultaneously both machining operation experience and knowledge of mathematical algorithms. This study presents a methodology for evaluation and ranking by TOPSIS approach along with Taguchi orthogonal array [2]. The experimental analysis using the proposed approach gave the optimized and profitable result. The overall analysis of the process parameters is done by statistical ANOVA approach in MINITAB 17.0 to have accurate results [3].

LITERATURE REVIEW

Various methodologies have been used by researchers to understand the optimization of a machining process. To establish a relation between input parameters and output parameters various approaches like empirical relation, nonlinear regression, response surface methodology, fuzzy-logic, VIKOR, TOPSIS, etc. Now we have considered here TOPSIS, simple additive weighting. Supported case study shows the effective use of methodology in a (EDM) nontraditional manufacturing

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Trends in Mechanical Engineering & Technology

ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com

Minimizing the Sand Casting Defects Using Taguchi Method 1

Priyank V. Parekh1,*, J.A. Vadher2

Department of Mechanical Engineering, R.K. University, Rajkot, Gujarat, India Department of Mechanical Engineering, Shantilal Shah Government Engineering College, Bhavnagar, Gujarat, India 2 Department of Mechanical Engineering, Government Engineering College, Palanpur, Gujarat, India 1

Abstract

The global market is becoming more and more quality conscious nowadays. This Research work includes minimization of sand casting defects in C.I. based foundry. The survey was carried in small-scale CI based foundry (Surat). Major defects were observed are misrun, coldshut, blowholes, and porosity. Taguchi method is used to optimize the control parameters like moisture, permeability, pouring time, pouring temperature. L18 orthogonal array is used in this research work. Critical parameters are optimized using Signal to noise Ratio (S/N Ratio). Keywords: Casting defects, blow holes, porosity, orthogonal array, S/N ratio

INTRODUCTION

Manufacturing industry tries to maximize the profit in the global market. In sand casting industry the profit can be maximized by minimization of rate of rejection of castings. The defects can be minimized by optimization of critical process parameters. Taguchi method is used in the research work to optimize the critical process parameters [1]. The relevant data are collected from small-scale foundry Surat.

LITERATURE REVIEW

B. Chokkalingam and S.S. Mohammad Nazirudeen have worked on defect analysis from different process like pattern making,

molding, core making and melting, etc. With the use of techniques of root card analysis, the root cause for this major defect was identified through defect diagnostic study approach. Finally, by taking necessary remedial actions the total rejection rate was reduced to 4% from 28%. Conclusion of the work is the root card analysis and systematically approach of the work is effectively possible to eliminate and control the casting defect [2]. Sushil Kumar has carried out an optimization technique for process parameters of green sand casting [3]. Table 1 is indicating the data collection of sand casting for the month of January 2016 to June 2016.

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Trends in Mechanical Engineering & Technology

ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com

Hybridizing Principle of TOPSIS with Regression Metamodel Approach for the Optimization of CNC-WEDM Process Parameters Sandeep Tyagi1,*, Manoj Kumar Gaur2, Dinesh Kumar Kasdekar3

Department of Mechanical Engineering, Madhav Institute of Technology and Science, Gwalior, Madhya Pradesh, India

Abstract

Experiment is conducted on a Computer Numerical Control wire electric discharge machine under different conditions of process parameters. The experiment is carried out by using Aluminum Alloy AA6061 as a work material and a Brass wire as a cutting tool in CNCWEDM. This paper aims to develop a combination of DOE and Entropy based TOPSIS to solve multi response parameter optimization problems. An experimental investigation was carried out based on DOE to analyses, the sensitivity of CNC-WEDM attributes to the variations in process parameters such as Servo-voltage (SV), Wire-feed (WF), pulse on time(POT), pulse off time (POF). The most desirable factor level combinations were selected using DOE. The model developed in this study can be used as a systematic framework for process parameter optimization in conscious manufacturing process. Keywords: CNC-WEDM, TOPSIS, DOE

INTRODUCTION

Computer Numerically Controlled Wire Electrical Discharge Machining (CNCWEDM) is one of the most popular comes under the category of non-traditional manufacturing process suitable for machining very grade hard and brittle materials. The machining processes are non-conventional in this sense that they do not employ such traditional tools for metal removal but they directly use other forms of energy. The problems of high complexity in size, shape and higher demand for product accuracy and surface finish can be solved through nontraditional methods. Recent advances in the CNC-WEDM technology made it a valuable and viable process in the manufacturing of critical parts such as medical, sports and surgical, optical, instruments, aerospace and aeronautical components including automotive, turbine blades, Research and development areas. WEDM has been established to be applicable to machine electrically conductive materials such as stainless steels, tool steel, carbides, super alloys, ceramic etc. in spite of their other physical and metallurgical properties [1]. The

quality of the machined parts in WEDM is significantly affected by control parameters [2]. Optimal machining conditions are accomplished by executing a detailed analysis of all the factors affecting the process and also the interactions between them. The major factors influencing WEDM process are Pulse on time, Pulse off time, Spark gap, Gap current, etc. and physical properties of electrode, work piece and dielectric fluid [3]. As a well-known classical MADM/MCDM method, MCDM method has been used quite effectively in industrial applications to optimize and solve real-world decision problems [4, 5] (Hwang and Yoon, 2013; Fendel and Spronk, 1983). Methods such as the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS), Entropy, DOE are widely used methods. However, these methods have their own advantages and disadvantages [4]. In previous MADM methods presented by researchers, a limited number of studies have been conducted in terms of graphical method, and no method has been presented based on the proposed algorithm. Among the many MADM methods available, in our research, we have

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Trends in Mechanical Engineering & Technology

ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com

Innovaluation: The Skill Set for Make in India Initiative in IOT Era Priyavrat Thareja*, Komal Sharma, Samridhi Sharma, Jasleen Kaur, Amanpreet Singh Faculty of Engineering and Technology, GNA University, Phagwara, Punjab, India

Abstract

This work attempts to analyze the role of new manufacturing scenario, in the IOT (Internet of things) era, which has facilitated manufacturing automation, while simultaneously witnessing unprecedented competitiveness. Manufacturing has been threatened in most of the world except in China and USA, and awaits an action for a speedy recovery. One of the modes to revival is projected through all round cost cutting. To affect cost cutting, it is envisaged that the element of value addition be invigorated, using innovation as input and IIOT (industrial IOT) as the tool. The latter allows manufacturers to assign each of their physical assets a digital identity to maneuver the exact location and condition of those assets in real-time ubiquitously throughout. The trio of Value addition, innovation, and IIOT has been paradigm as an extension of the Joiner’s trilogy model. This set of imperatives of innovation, valuation and IIOT, which serve for cost cutting individually and collectively, may be holistically applied. In that holistic form these have been collated as a tool termed as Innovaluation. By providing for the most ‘valuable’ domains fitting into Joiner’s model—grounded over competence—Innovaluation assures achieving the most of profitability in manufacturing. This is in line with the coveted ‘Make in India’ initiative proposed by our worthy Prime Minister, Shri. Narendra Modi. Keywords: Innovation, value engineering, values, manufacturing, capatence (capacity + competence), IIOT (industrial internet of things)

INTRODUCTION The Manufacturing Competitiveness The world is today hot in terms of the manufacturing competition in a scenario where financial affluence determines not only the political supremacy of nations but rather their overall empowerment. Needless to say that all weaponry, transport and energy, etc. are aftermath of manufacturing that empowers the nations. In spite of such affluence, there is still a lull in manufacturing, when over the next decade, nearly 3.5 million manufacturing jobs will likely be needed [1] out of which 80% manufacturers report a shortage of qualified applicants for skilled and highly skilled production positions. Thus, 2 million positions are expected to remain unfilled due to the skills gap. National Association of Manufacturers reports that manufacturing has the highest multiplier effect of any economic sector through for every $1.00 spent in manufacturing; another $1.40 is added to the economy. Since Manufacturing makes a large

contribution in China’s GDP, the latter has large techno-commercial supremacy vis-à-vis the rest of world. Such success undoubtedly rides on the back of China’s manufacturing competency. Rightly so, this industrial tiger [2] is being dreaded by the word in cognizance to their nursed icon—the Dragon—which China fondly uses to show an iconic supremacy. Factually, China is the only country in the world, which differs in terms of the manufacturing contribution at say over 30 % of the GDP (c/f India at 13 %) vis-à-vis the next higher country. This is in a scenario when globally the overall manufacturing GDP percentage was 23.7% of GDP in 1980 and dropped to 17% in 2008. More so, the only other country whose manufacturing contribution was marginally trying to catch up includes USA as evidenced in Figure 1, which shows manufacturing production by country [3] as a percent of GDP. Recently, however China tended to outrun the competitive race, leaving others behind at half the pace.

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Trends in Mechanical Engineering & Technology

ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com

Experimental Investigation on a Diesel Engine Fuelled with Blends of Karanja Biodiesel and Diesel: Combustion and Performance Studies Ajay Partap Singh1,*, Ajay Trehan2

Department of Mechanical Engineering, IIMT Group of Colleges, Meerut, Uttar Pradesh, India Department of Mechanical Engineering, Dr. B.R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India

Abstract

With the stock of fossil fuels diminishing throughout the world and demand for energy based comforts and mobility ever increasing, time is ripe that we strike a balance between energy security and energy usage. Moreover having uplifted to such a sphere of engineering excellence, reverting back to the ages of the bull carts will prove next to impossible thereby compelling us to search for a basket of alternative fuels to derive energy to cater to our needs. Several sources of energy, especially for driving the automotives are being developed and tested. Biodiesel, which is a derivative of vegetable oils, is catching the attention of various nations through its much similar properties to conventional diesel. An experimental investigation was carried out on a small direct injection (DI) diesel engine, fuelling the engine with 20% (B20), 50% (B20), and 100% (B100) blending of rapseed oil methyl ester with diesel. The performance and combustion characteristics of the engine at various loads are compared and analyzed. The results showed higher brake specific fuel consumption (BSFC) and lower brake thermal efficiency (BTE) for the rapeseed blends. The engine indicated power (IP) was more for the blends B20, but found to be reduced for the blend B100 when compared to that of diesel. The engine combustion parameters such as pressure crank angle diagram, peak pressure, time of occurrence of peak pressure, net heat-release rate, cumulative heat release, ignition delay and combustion duration were computed. The rapeseed blends exhibited similar combustion trend with diesel. However, the blends showed an early start of combustion with shorter ignition delay period. The study reveals the suitability of rapeseed blends up to B20 as fuel for a diesel engine mainly used in generating sets and the agricultural applications in India without any significant drop in engine performance. Keywords: Karanja oil, biodiesel, diesel, single cylinder four stroke DI engine

INTRODUCTION

Energy is primary requirement in present day world due to increasing industrialization and motorization. Abundant and economical energy is life blood of modern civilization. Energy is one of the most important building blocks in human development, and, as such, acts as a key factor in determining the economical development of all countries. Reheman et al. [1] investigated the fuel properties of Karanja methyl ester and its blends with diesel from 20% to 80% by volume. In the investigation, performance and emission of Karanja methyl ester and its blends (B20, B40, B60 and B80) were used to test a single cylinder, 4-stroke, DI, water

cooled diesel engine having a rated output of 7.5 KW at 3000 rpm and CR 16:1. B. Baiju et al. [2] investigated the scope of utilization of biodiesel developed from through the methyl as well as ethyl alcohol route from Karanja oil as an alternative diesel fuel. The major problem of using neat Karanja oil as a CI engine arises due to its very high viscosity. Viscosity can be reduced by transesterification process with alcohol and other properties have been evaluated to be compared with those of diesel fuel. R. A. Bakar and Semin et al. [3] investigated the effects of fuel injection pressure on DI diesel engine performance. Experiments were performed on a diesel engine with four-cylinder, two-stroke,

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Trends in Mechanical Engineering & Technology ISSN: 2231-1793(online), ISSN: 2347-9965(print) Volume 6, Issue 3 www.stmjournals.com

Comparison of Experimental and Theoretical Results of Tool Wear Rate in Electrical Discharge Machining C.R. Sanghani1,*, G.D. Acharya2, K.D. Kothari3

1,3

Department of Mechanical Engineering, School of Engineering, R.K. University, Rajkot, Gujarat, India 2 Department of Mechanical Engineering, Atmiya Institute of Technology and Science, Rajkot, Gujarat, India

Abstract

Though electrical discharge machining (EDM) process is capable for complex and precise machining of materials irrespective of their hardness, it has certain limitations like low material removal rate (MRR), high tool wear rate (TWR), etc. which restrict its application areas. In EDM, material removal from workpiece and tool takes place by means of sparking between them which is a quite complex process. So, it is difficult to predict material removal rate and tool wear rate for various process parameters. In this paper, the experimental data available in existing literature are used to derive empirical formulas for heat distribution factor, crater radius and depth. The tool wear rate is calculated based on these formulas and validated with experimental results. For the selection of optimum process parameters, the proposed theoretical model can be used in EDM process. Keywords: EDM, TWR, experiment, empirical formula

INTRODUCTION

At the present time, electrical discharge machining (EDM) is the widespread technique used in industry for high-precision machining of electrically conductive materials irrespective of the hardness and it is widely used for the manufacture of mould, die, automotive, aerospace and surgical components [1]. In this process, material removal takes place as a result of the generation of extremely high temperatures due to the high-intensity discharges between tool and workpiece that melt and evaporate the material. In EDM, the tool wear is a critical problem as the change in tool shape directly affects the final shape of the product. The contribution of the tool cost is more than 70% to the total operation cost in most of EDM operations. So, during planning and designing of EDM operations, the tool wear should be carefully taken into consideration [2]. The amount of electrode wear depends on various parameters like tool-workpiece material, dielectric fluid, flushing method, electrical parameters (pulse on time, pulse off time, frequency of spark)

etc. [3]. Abdulkareem showed that electrode wear can be reduced up to 27% by cooling of electrode using liquid nitrogen [4]. Khan found that wear along the cross-section of the tool electrode is more compared to the same along its length due to easier heat transfer along the length [5]. Over last four decades, researchers are trying to develop different models for MRR and TWR using various techniques. Due to the uncertainty and complexity of EDM process in nature, so far, the material removal process in EDM machining is still not very clear, and hence, nobody has established a complete mathematical model to expose the laws governing tool wear in EDM machining. Marafona and Chousal developed a thermalelectrical model for sparks generated by electrical discharge based on the Joule heating effect [6]. Using electro-thermal concept, Yeo et al. developed the theoretical models for the anode and cathode in micro-EDM process [7]. Thermal analysis of workpiece was carried out by Saedodin et al. using hyperbolic heat conduction model [8]. Kalajahi et al.

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