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Dhanalakshmi Srinivasan Institute of Tec-Thirugnana Sambandha T, Arun R
Dhanalakshmi Srinivasan institute of tec-Krishnaraj M
  • Technical Paper
  • 2019-28-2570
To be published on 2019-11-21 by SAE International in United States
Generally brake pads are manufacturing by use of asbestos materials, these materials are chemically harmful and toxic, affects human health. The present investigation fabricates polypropylene composites with mixing constant volume [5 Vol.%] of alumina nano particles and different volume percentages [0%, 5%, 10% & 15%] of basalt fibre by hand layup compression technique. The wear characteristics of polypropylene matrix composites were tested by dry sliding condition using pin on disc apparatus configuration with hardened steel counter-face at elevated temperature. The load was applied 30N to 70N with the interval of 20N and varying of sliding speed 300 rpm to 900rpm with the interval of 300rpm for the time period of 0-180 sec. The wear rate was decreases with addition of alumina nano particle and also increases the frictional force for the effect of basalt fibre content present in the composites. The co-efficient of friction was increases from 0.1 to 0.66 under normal loading condition.

A Mathematical Approach to Determine Die Wear during Forging Process and Validation by Experimental Technique

Dr P K Ajeet Babu-Ajeet Babu P K
  • Technical Paper
  • 2019-28-2563
To be published on 2019-11-21 by SAE International in United States
The automotive industry is constantly trying to develop cost effective, high strength and lightweight components to meet the emission and safety norms while remaining competitive in the market. Forging process plays an important role to produce most of the structural components in a vehicle. Precision forging technology is used to produce components with little or no flash leading to elimination of machining process after forging. The load acting on the dies during net or near net forging is very high and leads to wear in the die. In order to have a good die it is important that die wear which is an inevitable phenomenon in a bulk metal forming processes is predicted mathematically. In this study a review on the vast number of studies done in the area of wear and various predictive models is carried out. The various models available for abrasive wear such as Archard, Felder-Montagut and IFUM model and for adhesive wear such as Holms model has been studied and implemented in commercial FE Code by developing FORTRAN subroutine and wear…

Experimental study on tool wear and cutting temperature during machining of Nimonic C-263 and Waspaloy based on Taguchi Method and Response Surface Methodology

Sri Sairam Engineering College-Vetri Velmurugan Kannan
Vellore Institute of Technology-Venkatesan Kannan, Devendiran Sundararajan
  • Technical Paper
  • 2019-28-0144
To be published on 2019-10-11 by SAE International in United States
Nickel based materials of Nimonic C-263 and Waspaloy are used nowadays for aerospace applications owing to its superior strength properties that are maintained at a higher temperature. Tool wear and cutting temperature in the vicinity of cutting edge are two essential machinability characteristics for any cutting tool. In this regard, this study is pursued to examine the influence of factors on measuring of tool wear (Vba) and cutting temperature (Ts) during dry machining of two alloys are studied experimentally based on Taguchi method and Response surface methodology. Taguchi’s L16 orthogonal array is used to design the experiment and a PVD (TiAlN), CVD (TiN/Al2O3/TiCN) coated carbide inserts are used on turning of two alloys. The factor effect on output responses is studied using analysis of variance, empirical models and responses surface 3D plots. To minimize the response and to convert into one single optimum level, responses surface desirability function approach is applied. The results show that growth of flank wears associated with Waspaloy is faster that of Nimonic C-263 due to rise in the heat for…

Multi Characteristics Optimization of Treated Drill Tool in Drilling Operation Key Process Parameter Using TOPSIS and ANOVA Technique

SRM Institute of Science and Technology-Sundar Singh Sivam Sundarlingam Paramasivam, Aishik Banerjee, Avanti Kulkarni
  • Technical Paper
  • 2019-28-0055
To be published on 2019-10-11 by SAE International in United States
To survive in the present global competitive world, the manufacturing sectors have been making use of various tools to achieve the high quality products at a comparatively cheaper price. Appropriate cutting set up must be used to further better the machinability of a work piece material. A longer life of the tools and equipments are important factors in any industry. Since the inception of the machine tool industry, cutting tool life and tool wear remain a subject of deep interest to study its failure and improvement. The present study finds out the optimum cutting results in drilling of AM60 magnesium alloy using different cryogenically treated cutting inserts. The Utility concept coupled with Taguchi with Multi response approach (TOPSIS) was employed. According to Analysis of variance (ANOVA) results, the feed was the major dominating factor followed by the cutting speed. This work deals with optimization approaches for the determination of the optimum process parameters by cryogenically treated drill HSS tools which minimizes surface roughness, torque, tool life, entry burr and tool cost, and maximizes material removal…

Investigation of Dry sliding Wear behavior of AA8011 reinforced with Zirconium Oxide and Aluminium Oxide Hybrid Composites processed through Multi direction forging

Sri Krishna College of Engg. and Tech.-Sathishkumar Kuppuraj, Soundararajan Ranganathan, Sathishkumar Aruchamy, Shanthosh Gopal
  • Technical Paper
  • 2019-28-0057
To be published on 2019-10-11 by SAE International in United States
The present work focused on fabricating hybrid composites of AA8011 with reinforcement particles of Zr2O3 and Al2O3 was taken equal (5wt%) weight percentage respectively. The hybrid composites were casted in square shape (50x50x50 mm size) under the optimal stir casted process parametric condition, further it was taken for forging process. The prepared three samples were induced for uni-direction (x), bi- direction (x and y) and multi direction (x,y and z) forging route and the response of micro hardness of 68,81 and 96 VHN were obtained due to microstructural phase changes with uniform distribution of particles in the matrix. Further the forged hybrid composites were investigated for tribological tests under dry sliding condition in a Pin-on-Disc tribometer apparatus by varying the load of 5,10,15,20 N and by adjusting the sliding speed as 200, 450 and 800 rpm respectively. The outcomes uncovered all the samples that the wear rate increments with increase in load and coefficient of friction shows decrement at most extreme load conditions. Wear rate increases with increase in sliding speed and coefficient of friction…

Critical wear assessment of AA8011/Hybrid metal matrix composites with surface amendment using Friction Stir process

Sri Krishna College of Engg. and Tech.-Soundararajan Ranganathan, Shri Vignesh Ramachandran, Ramprakash Palanivelu, Saravanakumar Ramasamy
  • Technical Paper
  • 2019-28-0096
To be published on 2019-10-11 by SAE International in United States
Friction Stir Process (FSP) was used for surface modification of steel, titanium, aluminum and magnesium based alloy has been considerably reviewed during the last decade. FSP can improve surface properties such as abrasion resistance, hardness, strength, ductility, corrosion resistance, fatigue life and formability without affecting the bulk properties of the material. The aluminum alloy having low ductility and softness characteristics are restricted because of their poor tribological properties. Preliminary studies reveal that, an ideal circumstance is to improve the aluminum alloy material life cycles by the way of strengthening the surface layer which can be modified through reinforcing nano particles through FSP. By the way, this experiment was carried out to obtain three set of samples like virgin AA8011, AA8011 with shape memory alloy and AA8011 along with shape memory alloy and silicon nitride during FSP under optimal process parametric condition. The improved distributions of nanoparticles were obtained after each FSP pass and progress in mechanical properties was observed. On the other hand to assess the tribological performance of prepared hard surface, three samples were…

Stress and Model Analysis of Upper and Lower Bolster Components of Molten Steel Transfer Vehicle

Vellore Institute of Technology-Darla Siva Prasad, Chooriyaparambil Damodaran Naiju, Posam Naveen Kumar
  • Technical Paper
  • 2019-28-0119
To be published on 2019-10-11 by SAE International in United States
The transportation of hot metal from blast furnaces to melting shops is carried out by molten steel transfer vehicle such as Torpedo ladle car in the steel plants. In need to design Torpedo ladle car within size limitation, capacity requirement and withstanding the impact, static, thermal shock and abrasion conditions, structural analysis is essential for validation. In this paper, stress and model analysis for upper and lower bolsters of Torpedo Ladle Car is carried out. The components are modelled in CAD and analysed using finite element method using software with the required boundary conditions. The results of structural analysis of bolster components are presented and discussed.

Assessment of tribo meter study of 20MnCr5 alloy steel under case hardened and shot peened condition

Shanthi Gears Limited-Vignesh Nataraj
Sri Krishna College of Engg. and Tech.-Soundararajan Ranganathan, Janarthanan Prakash, Dinu Mathew
  • Technical Paper
  • 2019-28-0098
To be published on 2019-10-11 by SAE International in United States
This research is constrained to study the strength and wear resistance of 20MnCr5 (SAE 5120) alloy steel under monolithic, case hardened and case hardened with shot peening processing condition. Improve the hardness of the material by enhancing the core and surface strength of case hardened with shot peened sample. The principle goal of this proposed work is to conduct the tribo meter test for the three test samples by differing the load of 5, 10, 15 and 20N and sliding speed of 290,580,870 rpm respectively. The impact on tribo meter process parameters on wear rate and co-efficient of friction be calculated and recorded for this study. Less wear rate and nominal co-efficient of friction was observed for case hardened with shot peened sample. Load and sliding distance increases wear rate decreases and co-efficient of friction increases for all the tested samples due to oxide layer formation. After reaching certain load and sliding speed the curve goes linear because of more contact between pin and disc, so that mechanical amalgamation layer will be framed. On the…

Development of Methodology to Determine Toe Geometry of any Vehicle at its Early Design Stage for Optimum Tyre Life

Mahindra & Mahindra, Ltd.-Nitin Kumar Khanna, Karthik Senthi, Vignesh Natarajan
  • Technical Paper
  • 2019-28-0105
To be published on 2019-10-11 by SAE International in United States
Toe setting, or the Vehicle geometry is one of the major wheel alignment parameters which directly effects handling of a vehicle. Correct toe setting ensures desired dynamic behavior of an automobile like straight line stability, cornering behavior, handling and tire durability. Incorrect setting of toe during design stage significantly deteriorates tire durability and leads to uneven tire wear. Within the current scenario in the Automotive Industry, the toe setting is majorly an iterative or a trial and error process which is both time consuming and involves higher development cost as there may be instances where 2 to 3 sets of iterations are needed before specification is finalized for production. Therefore, determining optimum toe setting at an early stage of a product development will not only save significant development time but it will also benefit in reducing product validation time and cost. Through this paper, an attempt has been made to develop a methodology for deciding toe setting for any vehicle as a First Time Right (FTR) approach to cut down on conventional, expensive & time-consuming…

Tensile and Fatigue behavior of shallow cryogenically treated En19 alloy steel

BSACIST-Loganathan Sekar, Tamil Arasan
SRM Institute of Science and Technology-Rajendran Raj
  • Technical Paper
  • 2019-28-0100
To be published on 2019-10-11 by SAE International in United States
Wear, tensile and axial fatigue tests were conducted on shallow cryogenically treated En19 medium carbon alloy steel to investigate its mechanical behavior. The test samples are conventionally heat treated then oil quenched at 34 ˚C. Followed by the samples were kept under shallow cryogenic treatment to -80˚C for 12 hours using liquid nitrogen. Then the samples were tempered in a muffle furnace to relieve the induced residual stresses. Wear, Tensile and axial fatigue test was carried out on both treated and non-treated samples to measure its wear resistance, tensile strength and fatigue behavior respectively. Microscopic examination also done using scanning electron microscope to compare the effect of shallow cryogenic treatment on its microstructure. The results exposed that there is a reduction in the tensile strength and fatigue life of shallow cryogenically treated samples over base metal and improved wear resistance.