Table of Contents
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FOREWORD
PREFACE
List of Contributors
Optimization of Machining Process Parameters to Calculate Surface Finish, Metal Removal Rate, and Cutting Force on AA6061-T6 Alloy
Abstract
INTRODUCTION
MATERIALS AND METHODS
Steps Involved in TOPSIS Method
Results and Discussion
CONCLUDING REMARKS
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Machinability Analysis and Optimization by the Taguchi-gra-pca Approach of PMEDM Process Parameters of Monel K 500
Abstract
INTRODUCTION
Materials and Methods
Results and Discussions
Material Removal Rate
Tool Wear Rate
Surface Roughness
Grey Relational Analysis
Principal Component Analysis
Confirmatory Experiment
Analysis of Variance
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Analyzing the Influence of RSW Process Parameters on the Cross Tension Failure Load of Dissimilar functionally graded AISI 304/316L Stainless Steel Sheets
Abstract
INTRODUCTION
Experimental studies
Specimen Preparation and Welding
Testing of Specimens
Mathematical Modelling
RSM Modelling
Artificial Neural Network Modelling
Results and Discussions
ANOVA for Determining the Influence of Process Parameters
Effect of Process Parameters
Confirmatory Experiments at Optimum Process Levels
Artificial Neural Network Analysis of Cross Tension Load
SEM Analysis for Analyzing the Weld Nugget
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
A Review on Manufacturing of Aluminium Alloy Based Metal Matrix Composites through Stir Casting Route
Abstract
INTRODUCTION
Methods of preparing Composites
Stir Casting Process
Fabrication of Stir Casting Setup
Effect of Reinforcements in Composites
Manufacturing of Aluminium Based Metal Matrix Composites
Review on Mechanical and Wear Properties of Composites Based on Matrix
Aluminium Alloy
Al6061 Alloy
Al7075 Alloy
A356 Alloy
A413 Alloy
LM13 Alloy
LM26 Alloy
Applications
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Experimental Analysis of Different Machining Parameters on Epoxy Granite Composite
Abstract
INTRODUCTION
MATERIALS AND METHODS
Process of End Milling
Measurement of Ra
Optimization Techniques
RESULT AND DISCUSSION
Results of Thrust Force
Results of SR
Ideal Cutting Constraints
RESULTS OF ANOVA
Investigation of S/N Ratio
Investigation of Thrust Force
SR Investigation
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Analysis on Synthesized Carbon Aerogels Doped with Resorcinol Formaldehyde by XPS and Fesem Techniques
Abstract
INTRODUCTION
MATERIALS AND METHODS
RESEARCH METHODOLOGY
RESULT AND DISCUSSION
Determination of Density
FESEM Study
XPS Study
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Tribological Behaviour of Hybrid Natural Fiber Polymer Composites with Novel Fillers
Abstract
INTRODUCTION
LITERATURE REVIEW
MATERIALS AND METHODS
Materials Used
Methodology Used
Grey Relational Analysis (G.R.A.)
Data Pre-processing
Calculation of Grey Relational Co-efficient
Calculation of Grey Relational Grade
Analysis of Variance (ANOVA)
EXPERIMENTAL WORK
Fabrication Process
Wear Test
Scanning Electron Microscope Test
RESULT AND DISCUSSION
Wear Test
Surface Morphology
Determination of Influencing Factor
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Application of Natural Fiber-reinforced Composites in Additive Manufacturing
Abstract
INTRODUCTION
Natural Fibers
Additive Manufacturing
ADDITIVE MANUFACTURING OF NFRPC
FUTURE SCOPE
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Investigation of Ionic Transport in Ionic Liquid BMIMBF4 Incorporated in ZnBDC-Metal-Organic Framework Based PVdF-HFP Composite Membranes
Abstract
INTRODUCTION
MATERIALS AND METHODS
RESULTS AND DISCUSSION
X-ray Diffraction Analysis
X-ray Photoelectron Spectroscopy (XPS) Analysis
Scanning EXAFS and XANES Analysis
Thermogravimetric Analysis
Ionic Conductivity Analysis
Electrochemical Stability Analysis
CONCLUDING REMARKS
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Manufacturing Techniques and Applications of Multifunctional Metal Matrix Composites
Abstract
INTRODUCTION
PROCESSING OF METAL MATRIX COMPOSITES
Manufacturing Methods of Composite Materials - Pultrusion Process
Compression Moulding Process
Vacuum Bagging
Liquid State Composite Manufacturing Processes
Stir Casting
Squeeze Casting
APPLICATIONS OF METAL MATRIX COMPOSITES
SUMMARY
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Machining Studies of Basalt Fiber Reinforced Aluminium Metal Matrix Composites Using Abrasive Jet Machining
Abstract
INTRODUCTION
EXPERIMENTAL WORK
Material Used
Specimen Geometry
Preparation of Specimen by Stir Casting Method
Abrasive Water Jet Machining
RESULT AND DISCUSSION
Kerf Angle
Surface Roughness
Taguchi’s Main effect plot for Kerf Angle and Surface Roughness
Density Test
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
REFERENCES
Multi-objective Optimization on Processing Parameters for Micro ECM of Inconel Alloy Using Taguchi Based Grey Relation Analysis
Abstract
INTRODUCTION
MATERIAL AND METHODS
Working Principle of Micro ECM
Selection of Material
Response Variables
Design of Experiment and Grey Relation Technique
RESULTS AND DISCUSSION
Experimental Results
Influencing of μ-ECM Input Process Variables on MRR and SR
Regression Analysis
Multi-objective Optimization
Confirmation Test
Application
CONCLUSION
CONSENT FOR PUBLICATION
CONFLICT OF INTEREST
ACKNOWLEDGEMENTS
References
Functional Composite Materials: Manufacturing Technology and Experimental Application
Edited by
C. Samson Jerold Samuel
Department of Mechanical Engineering,
Sri Krishna College of Engineering and Technology,
Kuniamuthur, Coimbatore
India
M. Suresh
Department of Robotics and Automation Engineering,
PSG College of Technology,
Peelamedu, Coimbatore
India
&
S. Gnanasekaran
Department of Mechanical Engineering,
Sri Shakthi Institute of Engineering and Technology,
Coimbatore,
India
BENTHAM SCIENCE PUBLISHERS LTD.
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FOREWORD
N.L. Parthasarathi
Scientific Officer
MFTS/MDTD/MEG/MMG
IGCAR
Kalpakkam, India
The book Functional Composite Materials: Manufacturing Technology and Experimental Applications presents research work on polymer matrix composites, metal matrix composites, metal and composite machinability studies, and resistance spot welding of the sheets.
This volume contains significant original and theoretical experimental results that make use of problem-solving technologies that are often unfamiliar to the general reader. This book's review and research papers present novel applications of experimental techniques and analyses of functional composite materials, indicating the need for novel analytical techniques.
N.L.Parthasarathi
Scientific Officer
MFTS/MDTD/MEG/MMG
IGCAR Kalpakkam,
PREFACE
The main attentions in this collection of scientific book chapters is focused on recent theoretical and practical advancements in functional composite materials related to mechanical and wear properties, microstructural characterization, and advanced manufacturing techniques used in aerospace, automobile, marine and defense industries.
This book highlights the advancements in the functional composites, metal matrix composites, polymer matrix composites, machinability studies of metals and composites using CNC turning process, electrical discharge machining, end milling, abrasive jet machining, electro chemical machining, additive manufacturing of products, joining of metals using resistance spot welding and carbon aerogels doped with resorcinol formaldehyde. We anticipate that this book will be of significant interest to the industrialists working on the basic issues surrounding the functional composites and manufacturing technology, as well as those who work in the industry in applied problems such as processing and applications. Because of multidisciplinary nature of the research, this book will attract a broad audience, including materials scientists, chemists, physicists, manufacturing and chemical engineers and processing specialists who are involved and interested in the future frontiers of blends.
The editors are grateful to their management, institution, family members and effort of the authors who have contributed the book chapters. Additionally, without the tireless effort of the publication staff of Bentham Science Publishers, this book would have not been possible.
C. Samson Jerold Samuel
Department of Mechanical Engineering,
Sri Krishna College of Engineering and Technology,
Kuniamuthur, Coimbatore
IndiaM. Suresh
Department of Robotics and Automation Engineering,
PSG College of Technology,
Peelamedu, Coimbatore
IndiaS. Gnanasekaran
List of Contributors
Ajith Arul DanielVels Institute of Science, Technology & Advanced Studies, Chennai 600117, Tamil Nadu, IndiaAmuthakkannan P.PSR Engineering College, Sivakasi, Tamillnadu, India – 626140Arumugaprabu V.Kalasalingam Academy of Research and Education, Krishnankoil, Tamillnadu, India – 626126Arunprasath K.PSN College of Engineering and Technology, Tirunelveli-627152, Tamilnadu, IndiaAshok KumarTezpur University, Tezpur, Napaam-784028, Assam, IndiaAshokaVarthanan P.Sri Krishna College of Engineering and Technology, Coimbatore, Tamilnadu, India - 641008Deepak Joel Johnson R.Saveetha Institute of Medical and Technical Sciences, Chennai, Tamillnadu, India– 600077Ganesh N.K Ramakrishnan College of Engineering, Samayapuram, Trichy, Tamilnadu621112, IndiaGaneshkumar S.Sri Eshwar College of Engineering, Coimbatore, Tamil Nadu, IndiaGnanasekaran S.Sri Sakthi Institute of Engineering and Technology, Coimbatore, TamilNadu, IndiaJafrey Daniel James D.K. Ramakrishnancollege of Engineering, Trichy, Tamil Nadu, IndiaJeyakumar R.Sri Krishna College of Engineering and Technology, Coimbatore, Tamilnadu, India - 641008KarthikPandiyan G.Sri Vidya College of Engineering and Technology, Virudhunagar, Tamil Nadu, IndiaKalirasu S.Sethu Institute of Technology, Pulloor, Kariapatti - 626115, Virudhunagar District, Tamilnadu, IndiaMadhankumar S.Sri Krishna College of Engineering and Technology, Coimbatore, India-641008Manikandan A.Lord Jegannath College of Engineering and Technology, Nagercoil, IndiaMuthiah A.P.S.R. Engineering College, Sivskasi, IndiaMuthukumaran RamasamyCMR Institute of Technology, Hyderabad, Telangana 501401, IndiaNallusamy S.Jadavpur University, Kolkata-700032, IndiaNithya M.CMR Institute of Technology, Hyderabad, Telangana 501401, IndiaPaulraj G.SRM TRP Engineering College, Trichy, Tamilnadu, India 621105Pitchipoo P.P.S.R. Engineering College, Sivskasi, IndiaPrabaharan T.Mepcoschlenk Engineering college, Sivakasi, Tamil Nadu, IndiaPrabu SubramanianSRM TRP Engineering College, Trichy, Tamilnadu, India 621105Prakash P.Karpagam Institute of Technology, Coimbatore, TamilNadu, IndiaRaja S.Sri Krishna College of Engineering and Technology, Coimbatore, Tamilnadu, India - 641008Rajakarunakaran S.Ramco Institute of Technology, Rajapalayam, IndiaRamesh Babu R.Karpagam Institute of Technology, Coimbatore, TamilNadu, IndiaRituraj DuttaTezpur University, Tezpur, Napaam-784028, Assam, IndiaSaiyath Ibrahim A.Karpagam Institute of Technology, Coimbatore, Tamil Nadu, IndiaSamson Jerold Samuel ChelladuraiSri Krishna College of Engineering and Technology, Coimbatore, Tamil Nadu, IndiaSelvan T. A.Sri Krishna College of Engineering and Technology, Coimbatore, India-641008Senthil Kumar K. M.Kumaraguru College of Technology, Coimbatore, India-641049Senthil Kumar S.SRM TRP Engineering College, Trichy, Tamil nadu, India 621105Sujatha K.Dr. M.G.R. Educational and Research Institute, Chennai-600095, Tamilnadu, IndiaS. SundarDepartment of Adult, Continuing Education and Extension, Jadavpur University, Kolkata-700032, India
Department of Mechanical Engineering, Dr. M.G.R. Educational and Research Institute, Chennai-600095, Tamilnadu, IndiaThilak M.SRM TRP Engineering College, Trichy, Tamilnadu, India 621105Venkatesh S.Sri Eshwar College of Engineering, Coimbatore, IndiaVigneshkumar M.Sri Krishna College of Engineering and Technology, Coimbatore, Tamilnadu, India - 641008Vijayan S. N.Karpagam Institute of Technology, Coimbatore, Tamil Nadu, IndiaViswanathan A.SNS College of Technology, Coimbatore, India – 641035
Optimization of Machining Process Parameters to Calculate Surface Finish, Metal Removal Rate, and Cutting Force on AA6061-T6 Alloy
Karthik Pandiyan G.1,*,T. Prabaharan2,Jafrey Daniel James D.3
1 Department of Mechanical Engineering, Sri Vidya College of Engineering and Technology, Virudhunagar, Tamil Nadu, India
2 Department of Mechanical Engineering, Mepco Schlenk Engineering College, Sivakasi, Tamil Nadu, India
3 Department of Mechanical Engineering, K.Ramakrishnan College of Engineering, Trichy, Tamil Nadu, India
Abstract
In this study, CNC turning process parameters are optimized while machining AA6061 – T6 alloy. The process variables, namely, cutting spindle speed or spindle velocity (Cs), rate of feed (Fr), rate of the depth of cut (Dc), and nose radius (Nr), were optimized with output responses such as surface roughness (Ra), feed power (Fx), thrust power (Fy), cutting power (Fz), and removal rate of material (MRR). The optimized results showed higher MRR, Fy, and Fz and lower Fx and Ra were obtained at a cutting spindle speed or spindle velocity (Cs) of 100 rev/min, rate of feed (Fr) of 0.2 mm/min, depth of cut (Dc) of 1.5 mm/min, and nose radius (Nr) of 0.8 mm. TOPSIS and ANOVA were used to assess the experimental results to determine the most favourable factors that were superior and suitable for selecting the optimal variable condition.
Keywords: AA6061-T6 alloy, ANOVA, CNC Turning, Cutting power, Depth of the cut, Feed power, Material removal rate, Multiresponse Optimization, Nose radius, Rate of feed, Spindle Speed, Surface roughness, Thrust power, TOPSIS.
*Corresponding author Karthik Pandiyan G.: Department of Mechanical Engineering, Sri Vidya College of Engineering and Technology, Virudhunagar, Tamil Nadu, India; E-mail:
[email protected]