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Effect of Cryogenic Treatment of Copper Electrode on Electro-Discharge Machining

B S Abdur Rahman University-Pervaz Ahmed Mouda, H Siddhi Jailani
Published 2017-07-10 by SAE International in United States
Cryogenic treatment is an ultra low temperature treatment technique. Effect of cryogenic treatment on properties of ferrous materials and alloys is well understood. Due to which, cryogenic treated materials are being used in various applications. One among them is Electro-Discharge Machining (EDM). In EDM, the replica of electrode is obtained on the work piece, during the process tool also worn out to certain extent. In order to reduce the tool wear rate cryogenic treatment can be applied to the tool material. In this paper, the effect of cryogenic treatment on electrode wear rate of electro-discharge machining for varied pulse ON time (EDM) was studied. The cryogenic treatment was applied to the copper electrode and the microstructure analysis was carried out using optical microscope. EDM experiment was conducted using untreated and cryogenic treated copper as electrode and High Speed Steel (HSS) as work piece. Electrical resistivity was also measured. From the microstructure analysis it was inferred that the grains of cryogenic treated electrode are smaller than that of the untreated sample. Electrode Wear Rate (EWR) was…
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Implementation of Lean Approaches in Proto Body Build to Improve Productivity and Flexibility

B S Abdur Rahman University-Prince Arockia Doss Sebastian
Mahindra Research Valley-Ganesan Selvam, Surya Prakash Vaidhyanathan, Mohamed Zaheer Abdulla, Vedantham Baskaran
Published 2017-07-10 by SAE International in United States
Lean approaches are being implemented in various manufacturing facilities across the globe. The application of lean approaches are extended to Body proto build shop to maximize the efficiency of the shop with lesser floor space and optimized equipment. Weld fixture, Weld equipment and assembly tools are the major tools required essentially for proto BIW assembly. This paper explains how the Weld equipment planning was carried out with lean approaches and implemented effectively in proto body assembly shop. The implemented lean concepts are compared with Italy and Japanese proto body build makers to validate the frugal planning of the facility for the said intent. The implemented facility is capable of producing more than a model at a time. Weld parameter selection for weld gun, gun movement to the fixture with minimized change over time and movable weld gun gantry are the lean approaches implemented.
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Cryogenic Treatment of SG Iron for Disc Brake Application

B S Abdur Rahman University-R. Rajendran, G. Ramanjaneyulu, T R Tamilarasan
Ufa State Aviation Technical University-Vladimir I. Semenov
Published 2015-04-14 by SAE International in United States
Cryogenic treatment has a good potential to significantly increase the service life of automotive components, where friction and wear are the major factors in their operation leading to failure. Cryogenic treatment changes the surface as well as the core properties of the component in comparison with other treatments. It has significant improvement in wear and toughness. Numerous studies have been conducted on cryogenic treatment of steels and tool steels showing significant improvements in wear resistance, only minimal work has been done in cast irons. In this study, the effect of cryogenic treatment on the wear resistance, hardness, tensile strength, toughness and microstructure of spheroidal graphite iron was assessed. The deep cryogenic treatment was carried out at 87K for 12h and annealed in the chamber itself. The samples were tempered at 473K for 1 h. The hardness, toughness and tensile strength of base material, cryotreated and cryotreated tempered samples were measured using Rockwell hardness, Impact testing machine and Universal testing machine respectively. Wear studies were performed using pin-on-disc wear testing machine with EN 31 steel as…
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Effect of Coating Time on the Performance of Electroless Nickel Coated Steel

B S Abdur Rahman University-Raj Rajendran, Tharanipathy Venkatesan
Pondicherry Engineering College-Rasu Elansezhian
Published 2011-04-12 by SAE International in United States
Electroless Nickel (EN) coatings are used in automotive application due to its high hardness, uniform thickness and wear resistance. The study deals with the improvement of surface properties of mild steel by the deposition of Ni-P alloy. The steel specimens were EN coated for various time duration ranging from 0.5 to 3 h. The effect of coating time on thickness, structure, hardness and wear of EN coated steel are investigated. It has been found that the coating thickness is uniform and it increases as the coating time increases. There is no significant change in hardness and wear with increase in coating time. The structure of EN coated steel comprises a surface layer of Ni-P alloy deposit which is instrumental in increase in the hardness. Microhardness of EN coated steel is in the range of 500-540 Hv0.025. The wear rate and coefficient of friction of EN coated steel is found to be low compared to the base metal. EN coated steel could be of use for improving the performance and life of various automotive components.
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