Experimental Study of Electrical Discharge Machining of PS-M A-463 Plastic Material

Vol.1  No.3

Year : 2013

Issue : Oct-Dec

Title : Experimental Study of Electrical Discharge Machining of PS-M A-463 Plastic Material

Author Name : Sameh Habib

Synopsis :

Plastic materials have become the optimum choice for numerous industrial applications where the performance rather than cost is the prime consideration. The demand for the machining processes of plastics has recently increased. This work investigates the Electrical Discharge Machining (EDM) of PS-M A-463 plastic material with polystyrene base. The characteristics of PS-M A-463 plastic machined by EDM are studied in terms of machining parameters. Machining of plastics can be realized in EDM by assisting electrode method. In this method, the EDM workpiece surface is covered with an electrical conductive layer during discharge. The layer holds the electrical conductivity during discharging process. The workpiece surfaces were examined by Scanning Electron Microscopy (SEM). Moreover, surface roughness was determined with a Surface Profilometer. Experimental results indicate that the extent of delamination and surface roughness are proportional to the machining parameters. The EDM process effectively produces excellent surface characteristics and high quality holes in PS-M A-463 plastic material under low discharge energy conditions.

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Experimental measures of surface roughness by investigate the effect of Process Parameters in Abrasive Flow Machining Process

Vol.1  No.3

Year : 2013

Issue : Oct-Dec

Title : Experimental measures of surface roughness by investigate the effect of Process Parameters in Abrasive Flow Machining Process

Author Name : ravi gupta, Mohit Sharma, Rahul O Vaishya

Synopsis :

In the present era, modern manufacturing processes are hybridized with conventional and non-conventional processes to obtain better results. AFM is a widely used non conventional machining process for smoothening of rough edge inside the work piece by flow of an abrasive medium. The abrasive particles in abrasive media remove the excess material from surface and produce finished surface. Centrifugal force assisted abrasive flow machining process is a new hybrid non-traditional machining process that is developed as a technique for better finishing of surface as compared to simple AFM. In this study, an attempt was made to depict the effect of different process parameters on percentage change in roughness value. The parameters are type of material, abrasive particle size, rotational speed of rod inside the workpiece and axial pressure, to see their effect on percentage change in surface roughness. Taguchi technique was considered for experimental design without taking any interaction. The unit has been designed to satisfy the basic requirement of hybrid AFM i.e. by attaching a rod inside fixture by gear arrangement having rotational mechanism in set-up. For experimental design and analysis of different parameters, L orthogonal array based upon taguchi method 9 was used.

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Root Cause Analysis for the Thickness Measurement of Corrode Metal Sheet by Ultrasonic Thickness Gauge

Vol.1 No.2

Year : 2013

Issue : Jul-Sep

Title : Root Cause Analysis for the Thickness Measurement of Corrode Metal Sheet by Ultrasonic Thickness Gauge

Author Name : Sheetal Dewangan, K.Ganpati Shrinivas

Synopsis :

This paper summarizes some of the major aspects of precision ultrasonic thickness gauging. Ultrasonic NonDestructive Testing (NDT) characterizing material thickness, integrity, or other physical properties by means of high-frequency sound waves has become a widely used technique for quality control. In thickness gauging, ultrasonic techniques permit quick and reliable measurement of thickness without requiring access to both sides of a part. During the thickness measurement of any corroded plate, the reading of ultrasonic equipment gives many different readings for each time of inspection at same position due to their non uniform surfaces. Due to corrosion of metal piece, a material whose thickness is lower than the low limit of the probe causes measurement errors. Sometimes the displayed reading is twice as big as the actual thickness. To prevent these errors, the critical thin materials should be measured repeatedly for verification. This paper looks at the review causes of poor performance with ultrasonic techniques and suggests some methods to improve the situation.

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Parametric Optimization of Friction Stir Welded AA5083 Using Response Surface Methodology

Vol.1 No.2

Year : 2013

Issue : Jul-Sep

Title : Parametric Optimization of Friction Stir Welded AA5083 Using Response Surface Methodology

Author Name : Neeraj Sharma, Rajat Gupta, Sumit Jain

Synopsis :

Response surface methodology is used to model Friction Stir Welding (FSW) for the prediction of % elongation of AA 5083.The applications of friction stir welding are in aerospace, railways and space craft. The control factors of the process are tool rotational speed, welding speed, shoulder diameter and tool pin profile. Planning of experiments was carried using central composite design. The Analysis Of Variance (ANOVA) is used for the prediction of significant control factors along with their percentage contribution. The predicted optimized (minimum % elongation) setting of FSW control factors are tool rotational speed of 3966.23 rpm, a welding speed of 34.91 mm/min, and 19.89 mm shoulder diameter with trapezoidal pin profile. From this research it is found that the trapezoidal pin profile tool has the best effect on percentage elongation as compared to other pin profiles.

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Characterization of NiCrAIY Coatings on Ni- And Fe-Based Superalloys by the Cold Spray Process

Vol.1 No.2

Year : 2013

Issue : Jul-Sep

Title : Characterization of NiCrAIY Coatings on Ni- And Fe-Based Superalloys by the Cold Spray Process

Author Name : Sukhminderbir Singh Kalsi, T.S. Sidhu , Harminder Singh

Synopsis :

Coatings are always considered to improve the thermal, chemical and mechanical properties of the materials. Cold spray is one of the upcoming technologies for coatings. In this study NiCrAlY coatings were successfully deposited on Superni 76, Superni 600 and Superfer 800H superalloys (Midhani grade) for hot corrosion protection. The characterization of the cold sprayed coatings have been studied using the combined techniques of, optical microscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDAX). The deposited coatings found were dense with a porosity less than 1% and micro hardness of the order of 582- 670 Hv. XRD and EDAX analysis show Ni as the major phase in as-sprayed coating. Coating was found free from oxides.

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Hot Corrosion in Bio Medical Waste Incinerator and Cold Spray Coatings - A Review

Vol.1 No.2

Year : 2013

Issue : Jul-Sep

Title : Hot Corrosion in Bio Medical Waste Incinerator and Cold Spray Coatings - A Review

Author Name : Sukhminderbir Singh Kalsi, T.S. Sidhu , Harminder Singh

Synopsis :

Fireside corrosion of boiler tubes in bio medical waste incinerator plants has been of great concern for plant operators, boiler designers, and boiler tube manufacturers since quite a few number of boiler tubes in these plants suffered from wall thinning due to hot corrosion. The corrosion problem at high temperature is more serious due to the highly aggressive environment in bio medical waste incinerator plants such as Cl , HCl, alkali metals and heavy metals. 2 Corrosion resistant coatings are the key technologies to reduce the maintenance in bio medical incinerator plants by reducing the hot corrosion problem. Different corrosion resistant coatings processes have been developed such as thermal spray, HVOF, HVSFS, PVD and cold spray. Employing the corrosion resistant coatings ensure the high corrosion and wear resistant of the boiler tubes. This paper highlights the hot corrosion in bio medical incinerator plants, its effects and its protection with corrosion resistant coatings. Cold spray coatings have been reviewed with the aim of summarizing their high temperature corrosion resistance properties.

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Experimental Investigations on Natural Frequencies of a Mono Composite and Steel Leaf Springs using Fast Fourier Transforms

Vol.1 No.2

Year : 2013

Issue : Jul-Sep

Title : Experimental Investigations on Natural Frequencies of a Mono Composite and Steel Leaf Springs using Fast Fourier Transforms

Author Name : Kandasamy J, Ravikumar , M. Madhavi

Synopsis :

The riding comfort of an automobile is greatly affected by the suspension system. Springs are crucial suspension elements, necessary to minimize the vertical vibrations, impacts and pumps due to road irregularities, vertical vibrations and impacts are buffered by variations is the spring deflection so that the potential energy is stored in spring as strain energy and then released slowly. Composite leaf spring made of Eglass/Epoxy is the best alternate to steel spring for having excellent higher strength-to-weight ratio, high energy spring capacity, excellent corrosion resistance and higher natural frequency.In the present paper, shape optimization of mono composite leaf spring was carried out with design constraints as stress and displacements. Through finite element technique, structural parameters are computed for both steel and optimized composite leaf springs. Experimental validations were done on steel and composite leaf spring for both static and dynamic conditions. The dynamic analysis is computed through Fast Fourier Transform (FFT) and MATLAB code is developed to determine the natural frequencies of the leaf springs. Composite leaf spring is found to have low deflections, less stress, weight, high natural frequency and high damping property compared to steel leaf springs. This results in fuel savings and better riding comfort in automobiles.

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