Browse Topic: Manufacturing processes

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A Comparative Study on fault diagnosis of Electrical vehicle motor testing machine Gear Components Using machine Learning algorithms2025-28-0177To be published on 02/07/2025
Electric vehicles (EVs) are the way of the future for the automobile industry. The drive motor is a vital part of modern EVs. A motor testing machine is used to verify the critical parameters of the electrical motor, which is seen to be of the utmost importance. Electric motor characteristic curve points and their electromagnetic behaviour under different conditions are regularly found using the motor testing machine. But it has been noted that a flaw in the testing machine's helical gear arrangement causes frequent malfunctions and less-than-ideal performance, which impacts the assembly line's effectiveness in producing electric cars. The research project is to enhance the motor test bench apparatus by modifying crucial design parameters using machine learning and vibration signal analysis methods. Vibration signals are recorded at various gear settings before statistical features are extracted. Following that, these signals are classified using classifiers such Quadratic SVM and
S, Ravikumar, Syed, Shaul, V, Muralidharan, D, Pradeep Kumar
Technical Paper
A hybrid algorithm for optimizing machining and spraying parameters in MQL-turning of Inconel 800H2025-28-0042To be published on 02/07/2025
Inconel 800H superalloy is a difficult-to-turn material. This study aims to achieve optimal machining results, including reduced cutting force, improved surface roughness, and minimized residual stress, by optimizing input machining parameters like cutting speed, feed rate, spraying angle, and nozzle distance on Inconel 800H. The Taguchi L27 method is utilized for experimentation, while the Harris hawks optimizer (HHO) is applied in a multi-objective optimization model. Additionally, the Technique for Order of Preference by Similarity to the Ideal Solution (TOPSIS) is used to identify the optimal input parameters. Five distinct weight schemes were employed, including the Analytic Hierarchy Process (AHP), the Entropy weight method, Criteria Importance through Inter-Criteria Correlation (CRITIC), Grey relational analysis (GRA), and Principal Component Analysis (PCA) to determine response weights. The analysis revealed that the primary factor affecting all measured weights is the feed
Kannan, Venkatesan, Mokshajna, Kotha
Technical Paper
Finite Element Fatigue Life Prediction and Test Correlation for Seam Welded Joints in Sheet-Metal Assemblies2025-28-0054To be published on 02/07/2025
Tractors, agricultural machines comprising diverse interconnected assemblies, collaboratively perform specific functions to attain desired outputs. Among these assemblies, the footstep assembly—an affixed structure or platform facilitating convenient access for the operator to the tractor cabin or platform. The components of the footstep assembly are fabricated from sheet metal and are connected using various joining technologies, such as bolts, welds, and others. During field operations, several failures have been noted in the footstep component, specifically at the weld connections. This paper delineates a methodology for simulating and predicting the occurrences of weld joint failures in the sheet-metal components. The inherent characteristics of the welding process lead to welded joints generally exhibiting a fatigue strength lower than that of the individual parts being joined. Additionally, welds are frequently applied at geometric features or points of section changes within a
Kumar, Arun, Pandey, Manoj Kumar, Thirugnanam, Vivekanndan, Mani, Suresh, Redkar, Dinesh
Technical Paper
Optimization of Vibrational characteristics Using Taguchi Method for CNT Reinforced Composite Plates2025-28-0174To be published on 02/07/2025
The integration of carbon nanotubes (CNT) into composite materials has revolutionized various high-performance industries, including aerospace, marine, and defence, due to their exceptional mechanical, thermal, and electrical properties. The critical nature of these applications demands precise control over the manufacturing process to ensure the optimal performance of the CNT-reinforced composites. This study employs the Taguchi approach to systematically investigate and determine the optimal proportion of CNT volume fraction, fiber volume fraction, and stacking sequence in composite materials to achieve the optimal fundamental frequency. The Taguchi method, known for its efficiency in optimizing design parameters with a minimal number of experiments, enables the identification of the most influential factors and their optimal levels for enhancing material properties. Our findings demonstrate that the proper arrangement and proportioning of these components significantly improve the
B, Srivatsan, Balakrishna Sriganth, Pranav, Bhaskara Rao, Lokavarapu, Biswas, Sayan
Technical Paper
Development of AI Prediction Tool for Fused Deposition Modeling of ABS Material for automobile applications2025-28-0127To be published on 02/07/2025
Additive Manufacturing (AM), notably Fusion Deposition Modeling (FDM), has grown in popularity owing to its ability to create complicated forms from a variety of materials. This research aims to increase the efficiency and accuracy of the FDM process for Acrylonitrile Butadiene Styrene (ABS) material. ABS plastic material is an important material in automotive manufacturing due to its strength, durability, and versatility. It is used extensively for a wide range of components, including dashboard components, bumpers, fenders, exterior trim, and interior trim. The objective will be accomplished by the development of a prediction model using an Adaptive Neuro-Fuzzy Inference System (ANFIS). The research investigates the influence of FDM parameters, including layer height, nozzle temperature, and printing speed, on significant printing characteristics such as dimensional accuracy, surface quality, printing speed, and dimensional deviation. The essential data is derived from empirical
Natarajan, Manikandan, Pasupuleti, Thejasree, Kumar, V, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R
Technical Paper
Experimental Characterization of Fabricated (310) and (210) Symmetrical Tilt High-Angle Grain Boundaries in Bicrystalline Copper Thin Films Using NaCl Substrates2025-28-0034To be published on 02/07/2025
A novel sintering method of bridging the two mechanically polished and oriented single-crystals together face-to-face in a non-environmental controlled atmosphere to fabricate the bicrystal substrate of NaCl of macroscopic thickness, with a common zone axis and having planarity over large areas, has been developed. Epitaxial [001] bicrystalline thin face-centered cubic (fcc) metal film of surface-reactive metal-containing tilt grain boundary across the interface is first grown in high vacuum directly by flash deposition on initially fabricated [001] oriented bicrystalline substrate of NaCl. The [001] tilt boundary, thus produced, is examined by electron microscopy to characterize grain boundary morphology and structure. The findings of some preliminary investigations are then presented. A distinct atomic structure is observed for {310} and {210} inclination. Both HAADF-STEM and Diffraction images reveal that such fabricated high-angle grain boundary accommodates minor deviations from
Dish, Nilabh, Gautam, Abhay, Behera, Rakesh, Banka, Hemasunder, Chavan, Pradeep
Technical Paper
A Machine learning Approach for the prediction of Surface Roughness Using The Tool Vibration Data In Turning Operation2025-28-0152To be published on 02/07/2025
Surface roughness is a key factor in different machining processes and plays an important role in ergonomics, assembly, wear and fatigue life of components. Functionality, performance and durability of parts are also affected by surface roughness. Although maintaining an optimum surface roughness is a major challenge in many manufacturing industries. Surface roughness during machining depends upon machining parameters such as cutting speed, feed rate and depth of cut. Also, tool vibrations during machining have significant influence in surface roughness. In this work an attempt is made to predict the surface roughness of machined components during the turning process by using machine learning techniques with vibration signals. By varying different machining parameters and keeping other tooling and material properties same, a range of surface roughness values can be obtained. For each condition, corresponding tool vibration signals were recorded. Our experimental setup involves
S S, Safeer, Sadique, Anwar, D, Navaneeth
Technical Paper
Optimization of Fused Deposition Modeling Using Taguchi-Based Grey Relational Analysis for TPU used in Auto parts2025-28-0158To be published on 02/07/2025
Fused Deposition Modeling (FDM) is a highly adaptable additive manufacturing method that is extensively employed for creating intricate structures using a range of materials. Thermoplastic Polyurethane (TPU) is a highly versatile material known for its flexibility and durability, making it well-suited for use in industries such as footwear, automotive, and consumer goods. Hoses, gaskets, seals, external trim, and interior components are just a few of the many uses for thermoplastic polyurethanes (TPU) in the automobile industry. The objective of this study is to enhance the performance of Fused Deposition Modeling (FDM) by optimizing the parameters specifically for Thermoplastic Polyurethane (TPU) material. This will be achieved by employing a Taguchi-based Grey Relational Analysis (GRA) method. The researchers conducted experimental trials to examine the impact of key FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical responses
Pasupuleti, Thejasree, Natarajan, Manikandan, Ramesh Naik, Mude, Silambarasan, R, D, Palanisamy
Technical Paper
Vibration-based cutting tool condition monitoring in face milling process using wavelet features and machine learning algorithms – A comparative study2025-28-0151To be published on 02/07/2025
In automotive applications, most of the engineering components come across the material removal process in manufacturing. Face milling is one of the prominent material removal processes wherein a multi-point cutter is used to machine the flat workpiece to bring it to its required dimension. In the material removal process, the cost of the cutting tool occupies the major part of the total manufacturing cost of a product. Also, the continuous usage of the cutting tool results in tool wear. The usage of the cutting tool after the threshold value of the tool wear deteriorates the surface finish of the workpiece which leads to product rejection. Hence, optimal tool usage is inevitable. The continuous monitoring of the cutting tool condition will ensure optimal tool usage. In the present work, four real-time tool conditions are considered, namely, fresh tool (G), tool flank wear (FW), tool flaking on rake surface (FL) and tool with broken tip (B). Vibration signals are acquired while milling
D, Pradeep Kumar, Syed, Shaul, V, Muralidharan, S, Ravikumar
Technical Paper
Design and Finite Element Analysis of Pneumatically Actuated Soft Gripper under Combined Positive and Negative Pressure2025-28-0044To be published on 02/07/2025
Soft-bending actuators have garnered significant interest in the field of robotics and biomedical engineering due to their ability to mimic the bending motions of natural organisms. In this study, we propose a novel soft bending actuator that utilizes combined positive and negative pressures to achieve enhanced performance and control. The actuator consists of a flexible elastomeric chamber divided into two compartments: a positive pressure chamber and a negative pressure chamber. By selectively applying positive and negative pressures to the respective chambers, controlled bending motion can be achieved. The combined positive and negative pressure approach allowed for faster response times and increased flexibility compared to traditional soft actuators. Additionally, the actuator exhibited a high level of controllability, enabling precise manipulation of the bending motion. Its flexibility, controllability, and enhanced performance make it suitable for a wide range of tasks requiring
Lalson, Abirami, Sadique, Anwar
Technical Paper
Optimization and Regression Modeling of Fused Deposition Modeling for TPU Material used in automotive instrument panels2025-28-0142To be published on 02/07/2025
Fused Deposition Modeling (FDM) is a widely recognized additive manufacturing method that is highly regarded for its ability to create complex structures using thermoplastic materials. Thermoplastic Polyurethane (TPU) is a highly versatile material known for its flexibility and durability. TPU has several applications, including automobile instrument panels, caster wheels, power tools, sports goods, medical equipment, drive belts, footwear, inflatable rafts, fire hoses, buffer weight tips, and a wide range of extruded film, sheet, and profile applications.. The primary objective of this study is to enhance the FDM parameters for TPU material and construct regression models that can accurately forecast printing performance. The study involved conducting experimental trials to examine the impact of key FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical responses, including dimensional accuracy, surface quality, and mechanical
Pasupuleti, Thejasree, Natarajan, Manikandan, Sagaya Raj, Gnana, Silambarasan, R, Kiruthika, Jothi
Technical Paper
Novel Test Method for Accelerated Fatigue Testing of Engine Camshaft2025-28-0055To be published on 02/07/2025
In some IC engines, fuel injection pump is driven by camshaft; thus, these camshafts are designed for bending and torsional loads. Conventionally, camshafts are built-to-specification. Typically, durability assessment of camshafts happens at engine level, this calls for proto or calibration engine to be made and available for testing. As there are limited number of engine level proto testing, the overall scatter in camshafts due to manufacturing/process variations is not possible to be covered. This poses a risk of camshaft failures in the final stages of product development. To mitigate this risk, a component level standard test method is needed for quickly validating design and manufacturing process of camshafts for second source suppliers. The current paper discusses the process followed for arriving at a standard test setup and the challenges in terms of capturing the appropriate physics. Camshaft rear end experiences bending load due to FIP operation, and this bending load is
Chakraborty, Abhirup, S, Aravamuthan, K, Karthikeyan
Technical Paper
Microstructural and Mechanical characterization of Overhanging AA 4043 structures fabricated by CMT Pulse based WAAM for Automotive applications2025-28-0140To be published on 02/07/2025
This study investigates the fabrication and characterization of overhanging structures using the Cold Metal Transfer (CMT) pulse based Wire Arc Additive Manufacturing (WAAM) technique, specifically targeting automotive applications on commercial aluminum components. Focusing on optimal welding strategies for overhanging structures, components are fabricated by providing offsets during consecutive deposition of layers, thus producing parts with angles of 45, 60 and 90 degree inclinations from the substrate. Three specimens undergo twenty-three layers of deposition, resulting in structurally sound joints within this specified angle range. AA 4043 electrode is utilized, and welding parameters are optimized through trials by verifying with bead on plate deposition. Successful outcomes are achieved within the specified angle range, though challenges arise beyond 60 degrees, complicating the maintenance of desired weld quality. The study further evaluates the microstructure, microhardness
A, Aravind, S, Jerome, A, Rahavendran
Technical Paper
Optimization and Regression Modeling of Fused Deposition Modeling for PLA Material for Vehicle interior applications2025-28-0159To be published on 02/07/2025
Fused Deposition Modeling (FDM) is a prominent method of additive manufacturing known for its capacity to create intricate structures using thermoplastic materials. Automobile components consisting of PLA are easily recovered from end-of-life vehicles (ELV) at a cheap cost, potentially yielding better purity recycled lactic acid monomers. PLA is used by automobile manufacturers (including Ford and Mazda) to make floor mats, tires, and consoles. Polylactic Acid (PLA) is a commonly utilized biodegradable thermoplastic recognized for its environmentally friendly nature, cost-effectiveness, and straightforward processing. This study aims to optimize the FDM parameters for PLA material and construct regression models to accurately predict printing performance. The study involved conducting experimental trials to investigate the impact of important FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including dimensional
Natarajan, Manikandan, Pasupuleti, Thejasree, C, Navya, Kiruthika, Jothi, Silambarasan, R
Technical Paper
Qualification of Shorter Cure Cycle for fabrication of Carbon/Epoxy towpreg Pressure Vessel2025-28-0033To be published on 02/07/2025
A workable shorter curing cycle is required for the manufacturing of carbon/epoxy towpreg and is crucial for attaining defect-free component consolidation. A rational "processing methodology" based approach is established in this paper, and a cure cycle design protocol is proposed. For thick component, autoclave processing with conventional and shorter curing cycles was used. This has been validated through experimental studies. For thick composites, an uncontrolled exotherm could lead to a cure of the component from the inside out, with high process-postulated residual stresses. To determine and regulate the exotherm cross-linking reaction's maximal heat generation, thermal tests were conducted. These tests revealed isothermal holds and ramp rates were most effective in lowering the exothermic peak. Based on these findings, a shortened cure cycle was developed and applied to the material system. During the curing process, embedded thermocouples were utilized to track heat production
K, Tejasvi, Singh, P. Sundar
Technical Paper
Challenges in Cost Reduction for Automotive Parts: A Comprehensive Analysis2024-36-017412/20/2024
The automotive industry is facing unprecedented pressure to reduce costs without compromising on quality and performance, particularly in the design and manufacturing. This paper provides a technical review of the multifaceted challenges involved in achieving cost efficiency while maintaining financial viability, functional integrity, and market competitiveness. Financial viability stands as a primary obstacle in cost reduction projects. The demand for innovative products needs to be balanced with the need for affordable materials while maintaining structural integrity. Suppliers’ cost structures, raw material fluctuations, and production volumes must be considered on the way to obtain optimal costs. Functional aspects lead to another layer of complexity, once changes in design or materials should not compromise safety, durability, or performance. Rigorous testing and simulation tools are indispensable to validate changes in the manufacturing process. Marketing considerations are also
Oliveira Neto, Raimundo Arrais, Souza, Camila Gomes Peçanha, Brito, Luis Roberto Bonfim, Guimarães, Georges Louis Nogueira
Technical Paper
Experimental Determination of the Residual Torque Range in a Plastic Connector of the Fuel Pump Module at End of Life2024-36-012912/20/2024
The study of residual torque is necessary in various fields to ensure the safety and reliability of bolted joints. The present study aims to determine, experimentally, the decrease in torque applied to a nut used in the assembly of two polymeric components (POM - Polyoxymethylene). These components are part of the fuel supply module, responsible for supplying fuel from the tank to the engine. This reduction in torque initially applied is mapped to the end-of-life of the components and is used as an approval criteria in the audit procedures of the Robert Bosch company. The first component features an overmolded metallic screw, injected into POM. The mating part is also injection molded from POM and is assembled onto the first part, secured by tightening a metal nut. Due to the plastic-to-metal interface, it’s expected that there will be a reduction in the initially applied torque required to fasten the pieces together. The study was based on 5 steps: 1 Theoretical study on residual
Spitaletti, Laís Scotelari, da Fonseca, Márcio Ghiraldelli
Technical Paper
Laser Welding Applied to Complex Phase Steel2024-36-015912/20/2024
The development of advanced high-strength steels has become essential in the production of lightweight, safe, and more economical vehicles within the context of the automotive industry. Among the advanced high-strength steels, complex phase steels stand out, characterized by their high formability and high energy absorption and deformation capacity. Laser welding is a technique that applies laser using high energy density as a heat source. It has the advantages that the high welding speed and low heat input compared to other welding methods cause a decrease in deformation, and the narrow width of the weld bead and heat-affected zone allows for the welding of complex parts that would be difficult for other welding methods. Based on a study of a complex phase steel, an analysis was made of the microstructures observed by optical microscopy, the grain boundaries and certain phases contained in this microstructure, as well as the microstructures of each area in the laser welding region
Dias, Erica Ximenes, Reis de Faria Neto, Antonio, Castro, Thais Santos, Martins, Marcelo Sampaio, Santos Pereira, Marcelo
Technical Paper
Preliminary Indication Approach of Jute Fiber Fabric with Polyester for Bumpers of Passenger Cars2024-36-014912/20/2024
Polypropylene has been the plastic traditionally used in the manufacture of bumpers. Composite materials have been presented as an alternative due to lightness and sustainability. This article presents a composite of polyester resin and jute fiber fabric as an innovative alternative to be studied for the manufacture of automotive bumpers. Composite material was manufactured for characterization. It was used as matrix the terephthalic polyester resin, unsaturated and pre-accelerated, and the catalyst MEK V388 for curing the composite. The chosen reinforcement was the jute fiber fabric. Silicone molds with dimensions according to ASTM 3039 were used to manufacture specimens, and subsequent tensile strength test to determine properties and compare with literature data. The composite with jute fiber reinforcement with alignment 0°/0°/0° was evaluated as viable for the application in car bumpers, having its value of tensile strength surpassed that of the composite reinforced by jute fiber
Dias, Roberto Yuri Costa, Soares, Rafael Vilhena, de Mendonca Maia, Pedro Victor, dos Santos, Jose Emilio Medeiros, Miranda, Igor Ramon Sinimbú, Junior, Waldomiro Gomes Paschoal, Fujiyama, Roberto Tetsuo
Technical Paper
Steel, Bars, and Forgings, Aircraft Quality, 0.50Cr - 0.55Ni - 0.25Mo (0.38 - 0.43C) (SAE 8740), Heat Treated, 105 ksi (724 MPa) Tensile StrengthAMS6325M (Current)12/18/2024
This specification covers an aircraft-quality, low-alloy steel in the form of heat-treated bars and forgings
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Steel Bars, Forgings, Tubing, and Forging Stock, 1.0Cr - 3.25Ni - 0.40Mo (0.17 - 0.22C), Electroslag Remelted or Consumable Electrode Vacuum Remelted, Premium Aircraft QualityAMS6493C (Current)12/18/2024
This specification covers a premium aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Coating, Plasma Spray DepositionAMS2437E (Historical)12/18/2024
This specification covers the engineering requirements for applying coatings to parts by the plasma spray process and the properties of such coatings
AMS B Finishes Processes and Fluids Committee
Material Specification
Low-Cost Fusion Odometry Algorithm Based on 4D Radar and Pseudo-LiDAR: Bridging the Gap between 4D Radar and Images in 3D Space2024-01-703112/13/2024
Recently, four-dimensional (4D) radar has shown unique advantages in the field of odometry estimation due to its low cost, all-weather use, and dynamic and static recognition. These features complement the performance of monocular cameras, which provide rich information but are easily affected by lighting. However, the construction of deep radar visual odometry faces the following challenges: (1) the 4D radar point cloud is very sparse; (2) due to the penetration ability of 4D radar, it will produce mismatches with pixels when projected onto the image plane. In order to enrich the point cloud information and improve the accuracy of modal correspondence, this paper proposes a low-cost fusion odometry method based on 4D radar and pseudo-LiDAR, 4DRPLO-Net. This method proposes a new framework that uses 4D radar points and pseudo-LiDAR points generated by images to construct odometry, bridging the gap between 4D radar and images in three-dimensional (3D) space. Specifically, the pseudo
Huang, Minqing, Lu, Shouyi, Zhuo, Guirong
Technical Paper
Titanium Alloy, Bars, Wire, Forgings, Rings, and Drawn Shapes, 4Al - 2.5V -1.5 Fe, Annealed, Heat TreatableAMS6947C (Current)12/10/2024
This specification covers a titanium alloy in the form of bars, wire, forgings, flash-welded rings, and drawn shapes 4.000 inches (101.60 mm) and under and stock for forging, heading, or flash-welded rings of any size (see 8.6
AMS G Titanium and Refractory Metals Committee
Material Specification
Aluminum Alloy, Extrusions, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T73, 7075-T73511, 7075-T73510), Solution Heat Treated, Stress Relieved by Stretching when required, and OveragedAMS4617B (Current)12/10/2024
This specification covers an aluminum alloy in the form of extruded bars, rods, wire, shapes, and tubing 0.040 to 4.499 inches (1.01 to 114.27 mm), inclusive, in nominal diameter or least thickness and with areas up to 32 square inches (206 cm2), inclusive (see 8.6
AMS D Nonferrous Alloys Committee
Material Specification
Titanium Alloy Bars, Wire, Forgings, Rings, and Drawn Shapes, 4Al - 2.5V -1.5 Fe, AnnealedAMS6948C (Current)12/10/2024
This specification covers a titanium alloy in the form of bars, wire, forgings, flash-welded rings, drawn shapes 5.000 inches (127.00 mm) and under, and stock for forging or flash-welded rings of any size (see 8.6
AMS G Titanium and Refractory Metals Committee
Material Specification
Automatic Hose Cutting Machine for Small Scale Industries2024-01-521712/10/2024
The goal of this work is to increase the accuracy and efficiency of hose cutting operations in small scale industries is by designing and building an automatic hose-cutting equipment. The device uses a computer-controlled system to autonomously cut pipes of various sizes and lengths. By means of a stepper motor-driven, rapidly spinning blade, the cutting process is accomplished. Additionally, the machine has sensors that measure the hose's length and modify the cutting position as necessary. Premium components and materials are used in the machine's construction; these are chosen for their performance and longevity. The device is able to boost cut precision and raise industry production all around from 100% to 190% efficient system thereby decreasing labor and time needed for hose cutting operations
Feroz Ali, L., Manikandan, R., Madhankumar, S., Sri Hari, P., Suriya Prakash, T., Vishnu Doss, G.
Technical Paper
Machining Studies on AISI 4140 Steel as Automotive Axle and Drive Shafts in Automobile via Numerical Simulation2024-01-523212/10/2024
This study focuses on machining automobile parts such as drive shafts and axles made of low alloy steel AISI 4140. The influence of cutting inserts geometrical parameters, viz., relief angle (RIA), rake angle (RAA), and nose radius (NA) are studied by designing experiments using Taguchi’s methodology. Numerical simulation is conducted using DEFORM-2D; a suitable L9 orthogonal array (OA) is considered for this work for varying combinations of inputs, and the resultant cutting force, maximum principal stress, and tool life are determined. Adopting a signal-to-noise (S/N) ratio minimizes the outputs for better machining conditions and achieves high-quality components with precision, tolerance, and accuracy. The ideal conditions obtained from the S/N ratio are RAA of 6°, RIA of 3°, and NR of 0.6 mm. Analysis of variance presents that the NR influences the resultant cutting force, wear depth, and work piece damage 73.51%, RAA following by 23.99%, and RIA by 2.03% achieved with a R2 value of
Senthilkumar, N.
Technical Paper
Empirical Modelling of Machinability during Drilling of Aluminium Oxide/Glass Fiber Reinforced Resin/Epoxy Composites2024-01-521912/10/2024
This study describes the Taguchi optimization process applied to optimize drilling parameters for glass fiber reinforced composite (GFRC) material. The machining process is analyzed in relation to process parameters using analysis of variance (ANOVA). The characteristics assessed for both the drilling and the specimen include speed, feed rate, drill size, and specimen thickness. The commercial software program MINITAB14 was used to collect and analyze the measured results. Cutting force and torque during drilling are examined in relation to these parameters using an orthogonal array and a signal-to-noise ratio. The primary goal is to identify the critical elements and combinations of elements that impact the machining process to achieve minimal cutting thrust and torque, based on the evaluation of the Taguchi technique
Raja, Rosari, Jannet, Sabitha, Kandavalli, Sumanth Ratna
Technical Paper
Establishing an Empirical Relationship to Predict the Tensile Strength of a FSSW-AA7075 Aluminum Alloy with Mild Steel2024-01-522412/10/2024
In this study, an investigation was conducted on friction stir spot-welded AA7075 aluminum alloy with mild steel. Fusion welding of these two materials presents challenges because of differences in melting points and metallurgical incompatibility. To overcome these challenges, friction stir spot welding was employed for joining these materials. Trial runs were conducted based on a central composite rotatable design matrix, which encompassed four factors at five levels: tool rotational speed, plunge rate, dwell time, and tool diameter ratio. Shear tests were conducted to evaluate the joint strength, and subsequently, an empirical equation was developed via analysis of variance. Notably, a joint fabricated under specific conditions demonstrated exceptional strength, with the highest fracture load of 9.56 kN. These optimal parameters included the tool rotational speed, plunge ratio, dwell time and diameter ratio of 1000 rpm, 4 mm/min, 5 sec and 3.0. This achievement underscores the
Salman, Riyam Abd Alrazaq, Mohammed, Khidhair Jasim, Rajan, Rajthilak Krishnan, Smaisim, Ghassan Fadhil, Siva Subramanian, R.
Technical Paper
Effect of Silicon Carbide Addition and Jute Fiber Surface Treatment on Functional Qualities of Low-Density Polyethylene Composites2024-01-523812/10/2024
In the modern era, advanced hybrid polymer-based composites have the potential to replace conventional polymers and exhibit unique behaviour. This study focuses on low-density polyethylene (LDPE) hybrid composite made with jute fiber and enhanced with nano silicon carbide particles through the injection moulding process. The natural jute fiber undergoes chemical surface treatment to improve its adhesive behaviour. The study evaluates the effects of 10wt% chemically treated jute fiber and 1, 3, and 5wt% of SiC on the structural, impact, tensile, and flexural strength of the synthesized composites according to ASTM D7565, D3039, and D790 standards. The structural behaviour of LDPE composites is assessed through X-ray diffraction analysis, revealing improved crystalline structure and interaction. Among the five prepared composite samples, the composite containing 10wt% treated jute fiber and 5wt% SiC demonstrated enhanced impact, tensile, and flexural strength of 5.7 J/mm2, 43 MPa, and 56
Venkatesh, R., Kaliyaperumal, Gopal, Manivannan, S., Karthikeyan, S., Aravindan, N., Mohanavel, Vinayagam, Soudagar, Manzoore Elahi Mohammad, Karthikeyan, N.
Technical Paper
Effect of Nano Silica on the Mechanical Behaviour of High Impact Polypropylene/Nano Clay Composites2024-01-521112/10/2024
This study investigated the effect of nano silica on the mechanical behaviour of blends containing high impact polypropylene (hiPP) and nano clay. This study used nano silica from rice husk ash with an average particle size of 26 nm. The hiPP composites were mixed with 3 wt. % nano clay and different weight percentages (1%, 2%, and 3%) of nano silica were also added. The blending process used twin-screw extrusion, and composite samples were subsequently produced by injection moulding. Various parameters including tensile, compressive, and impact strengths were analyzed. In particular, the hiPP composite containing 3 wt. % nano clay and 2 wt. % nano silica had significantly improved mechanical properties, showing a 37.5% increase in tensile strength, a 56.8% increase in flexural strength, and a 51.4% increase in impact strength. It exhibited the highest tensile (53.51 MPa), flexural (67.19 MPa), and impact strength (5.17 KJ/m2) among all tested composites, demonstrating superior
Thangavel, Anand, Ragupathy, K., Manivannan, S., Murali, M.
Technical Paper
Impact of Tool Rotational Speed and Welding Speed on Tensile Strength of Friction Stir Welded AA5083 Aluminum Alloy Joints2024-01-520512/10/2024
One of the most common materials in the fabrication sectors, especially in the auto sector, is Aluminum alloy. Owing to its low strength to weight ratio, it could be a good fit for a number of applications. The cold working procedure may strengthen the 5XXX series Aluminum alloy, which is not heat treatable and it is also challenging to fuse these alloys together using fusion welding processes. In Recent days, a solid-state welding procedure, Friction Stir Welding (FSW) is used to join this alloy. The impact of FSW process parameters on tensile strength of the joint is examined in this study. Based on the outcomes of the experiment, the highest tensile strength is observed at 900 RPM tool rotation, 100 mm/min welding speed, 1.5-degree tilt angle, and 3.0 tool diameter ratio. Superior strength (246 MPa) of this parameter over its competitors can be attributed to the balanced material flow and the formation of finer grains in the weld region
Maram, Sreenivasulu Reddy, Kumar, M. Vinoth, Hariram, V.
Technical Paper
Investigation on Mechanical and Metallurgical Characterization of Micro-Alloyed Steel Produced by Friction Stir Welding (FSW2024-01-520312/10/2024
This research investigates the impact of friction stir welding (FSW) used to join micro-alloyed steel, on the material and its mechanical characteristics. FSW increases the metallurgical and mechanical qualities of joints made from micro-alloyed steel. However, Friction Stir Welding has produced only modest improvements in connecting steels. Automobile chassis, offshore platforms, oil and gas pipelines, mining, shipbuilding and railroad carriages, pressure vessels, bridges, and storage tanks are just some of the many places and find micro-alloyed steels employed. Frictional heat and tool movement over the joint cause micro defects occurred. Tungsten carbide tools are used in this investigation. Welding shares the same process characteristics, such as the tool's rotating speed (900 rpm) and axial force (10 kN). The table's traverse speed options are available, including 50 mm/min, 60 mm/min, and 70 mm/min. Vickers microhardness testing machines and tensile testing machines are used to
Rajan, C. Sakthi, Kumar, N. Mathan, Kumar, K. Vetrivel, Kannan, S., Soundararajan, S.
Technical Paper
Tensile Strength Analysis of Electron Beam Welded AA2024 Aluminum Alloy Joints2024-01-522012/10/2024
The AA2024 aluminum alloy is a precipitate-hardening material renowned for its exceptional strength and corrosion resistance, making it a preferred choice for various applications in industries such as aircraft and automobile manufacturing. However, it is challenging to weld using fusion welding processes due to differences in melting points between the aluminum base material and its oxide layer. Consequently, this often results in issues such as partially melted zones, alloy segregation, and hot cracking. In this investigation, electron beam welding was employed to minimize heat input and prevent the formation of coarse grains in the heat-affected zone. Observations revealed that the joint achieved a maximum strength of 285 MPa, representing 62% of the base material's strength. This improvement in strength can be ascribed to the establishment of fine and recrystallized grains at the weld interface, along with the presence of copper aluminide strengthening precipitates
Rajesh, A., Karthick, S., Mallieswaran, K., Shanmugam, Rajasekaran
Technical Paper
Fabrication and Functional Behavior Studies of Polypropylene Composite Containing Hybrid Reinforcements05-18-02-001512/06/2024
Hybrid reinforcement-made polypropylene (PP) composites are beneficial over monolithic PP and utilized for various engineering and non-engineering applications. The present investigation of PP hybrid composites is developed with 10 percentages of weight (wt%) of E-glass fiber embedded with 0–6 wt% of silicon carbide via compression technique associated with hot press. E-glass fiber and SiC influencing wear rate, tensile strength, and microhardness behavior of PP and its composites are experimentally investigated. The peak loading of SiC as 6 wt% into PP/10 wt% E-glass fiber is recorded as better wear resistance (0.021 mm3/m), maximum tensile strength value (54.9 MPa), and highest hardness (68 HV). Moreover, the investigation results of hybrid PP composite are better resistance to wear and hiked tensile and hardness behavior compared to monolithic PP. This PP/10 wt% E-glass fiber/6 wt% of SiC hybrid composite is adopted for high-strength to lightweight sports goods applications
Venkatesh, R.
Journal Article
Steel Bars, Forgings, Mechanical Tubing and Forging Stock, 1.0Cr - 3.25Ni - 0.40Mo (0.17 - 0.22C), Aircraft QualityAMS6492C (Current)12/05/2024
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock
AMS E Carbon and Low Alloy Steels Committee
Material Specification
Aluminum Alloy, Flash-Welded Rings, 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T73), Solution and Precipitation Heat TreatedAMS4174F (Current)12/05/2024
This specification covers an aluminum alloy in the form of flash-welded rings 0.062 to 4.499 inches (1.57 to 114.27 mm), inclusive, in radial thickness with cross-sectional areas up to 32 square inches (206 cm2) (see 8.6
AMS D Nonferrous Alloys Committee
Material Specification
Nickel Alloy, Corrosion- and Heat-Resistant, Bars, Forgings, Rings and Forging Stock 72Ni - 15.5Cr - 0.95Cb - 2.5Ti - 0.70Al - 7.0Fe Consumable Electrode or Vacuum Induction Melted, 1800 °F (982 °C) Solution Heat Treated, Precipitation Hardenable (X750AMS5671J (Current)12/05/2024
This specification covers a corrosion- and heat-resistant nickel alloy in the form of bars, forgings, and flash-welded rings up to 4.00 inches (101.6 mm), exclusive, in least distance between parallel sides (thickness) or diameter, and stock of any size for forging or flash-welded rings
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Nickel Alloy, Corrosion- and Heat-Resistant, Welded Tubing, 57Ni - 19.5Cr - 13.5Co - 4.2Mo - 2.9Ti - 1.4Al - 0.006B - 0.08Zr (Waspaloy), Consumable Electrode Remelted or Vacuum Induction Melted, AnnealedAMS5586J (Current)12/05/2024
This specification covers a corrosion- and heat-resistant nickel alloy in the form of welded and drawn tubing 0.125 inch (3.18 mm) and over in nominal OD and 0.015 inch (0.38 mm) and over in nominal wall thickness
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Nickel - Copper Alloy, Corrosion-Resistant, Bars, Forgings and Forging Stock, 67Ni - 30Cu - 0.04S, Free MachiningAMS4674J (Current)12/05/2024
This specification covers a corrosion-resistant nickel-copper alloy in the form of bars up to 3.00 inches (76.2 mm), inclusive, in thickness and forgings and forging stock of any size
AMS F Corrosion and Heat Resistant Alloys Committee
Material Specification
Cold Spray Additive Manufacturing (CSAM) ProcessAMS7057 (Current)12/05/2024
This specification establishes process controls for the repeatable implementation of the CSAM process for the manufacturing of metallic and metal-nonmetal blend components
AMS AM Additive Manufacturing Metals
Material Specification
Aerospace & Defense Technology: December 202424AERP1212/05/2024
Making a Material Difference in Aerospace & Defense Electronics Acquiring and Telemetering Test Data from Hypersonic Platforms Analog Transformation Complements Open System Designs to Optimize Modern Defense Systems These Speedy Cold Spray Machines Can 3D Print Vehicle Parts in War Zones Researchers Use Ancient Japanese Art Method to Create Tunable Antennas What is Drone Jamming and How Can it Be Countered? AI-Trained Vehicles Can Adjust to Extreme Turbulence on the Fly Researchers at Caltech took an important step toward using reinforcement learning to adaptively learn how turbulent wind can change over time, and then uses that knowledge to control a UAV based on what it is experiencing in real time. 'First of Its Kind' Composite Material to Help Space Vessels Travel Longer Distances A Coventry University design and materials engineer is leading an international team of researchers in the creation of a new material for liquid hydrogen storage tanks that are used to propel rockets into
Magazine Issue
Development of New Generation Battery Cooling Hoses with TPV Material2024-28-016112/05/2024
The market for battery-fitted electric cars continues to experience robust growth globally as well as in Indian market. During the charging process heat generation happen because of internal resistance of the battery cells and electrical connectors. Making an efficient battery cooling system is vital for all electric vehicles. One common cause of battery overheating is due to low cooling efficiency. So this research highlights the importance of scientifically designing coolant circuits and selecting appropriate coolant hose materials. Currently, EPDM (ethylene propylene diene monomer) material is widely used for battery cooling hoses due to its design Flexibility, Compatibility with a 50:50 glycol-water mixture and Resistance to thermal and ozone cracking [1]. This study benchmarks EPDM hose technical properties with leading EV battery cooling plastic hose materials, such as mono layer polyamide, mono layer TPVs (thermoplastic vulcanizates) and PA PP two layer hose. Comparative
Murugesan, Annarajan
Technical Paper
Efficient Robot Roller Hemming Process Using Turntable over Linear Setup2024-28-016412/05/2024
Hemming is an incremental joining technique used in the automotive industry, it involves bending the flange of an outer panel over an inner panel to join two sheet metal panels. Different hemming methods are available such as Press die hemming, Table-top hemming and Robot roller hemming. Robot roller hemming is superior to press hemming and tabletop hemming because of its ability to hem complex-shaped parts and is typically used in low-volume automotive production lines. For higher production volumes, such as 120 Jobs per Hour (JPH), press hem or tabletop hem is generally preferred. However, to achieve high-volume production from roller hemming method multi station setup is used. This static multi station setup can be configured into a Turntable setup. This new method eliminates the robot load and unload time at each station in the existing setup, resulting in a 40% increase in hemming robot utilization. Therefore, this process reduces the number of robots and the required floor space
Raju, Gokul, Roy, Amlan, Sahu, Shishir, Palavelathan, Gowtham Raj, Jagadeesh, Nagireddi, Chava, Seshadri
Technical Paper
Optimizing the Capacity of Dozer Blade with Hydraulic Foldable Wings to Enhance Productivity2024-28-026812/05/2024
Crawler Dozers play a critical role in global construction, mining and industrial sectors, performing essential tasks like pushing the material, grading, leveling and scraping. In the highly competitive dozer market, meeting the growing demand for increased productivity requires strategies to enhance blade capacity and width. Dozer operations involve pushing the material and dozing, where blade capacity significantly influences performance. Factors such as mold board profile, blade height, and width impact the blade capacity which are crucial for productivity in light weight applications such as snow removal and dirt pushing. Blade width is also pivotal for grading and leveling tasks. Traditional blade designs, like straight or fixed U-type blades, constrain operator flexibility, limiting overall productivity. The integration of hydraulic-operated foldable wings on both sides of the blade offers the adaptability to adjust blade capacity which also helps to reduce material spillage
Sahoo, Jyoti Prakash, Sarma, Neelam Kumar
Technical Paper
Optimization of Wire Electrical Discharge Machining Parameters for SAE 1010 Material Using Taguchi-Based Grey Relational Approach2024-28-023112/05/2024
Wire Electrical Discharge Machining (WEDM) has attracted considerable attention in contemporary manufacturing because of its capacity to accurately form conductive materials. This study aims to optimize the parameters of Wire Electrical Discharge Machining (WEDM) for SAE 1010 material, which is a commonly used low-carbon steel. The Taguchi-based Grey Relational Approach (GRA) is employed for this purpose. The goal is to optimize machining efficiency and quality while minimizing production costs. The research methodology combines the Taguchi method for experimental design with the GRA for multi-response optimization. The Taguchi L27 orthogonal array is utilized to carry out experiments, taking into account three controllable factors: pulse-on time, pulse-off time, and discharge current. In addition, the performance characteristics to be optimized include surface roughness (Ra) and material removal rate (MRR). The experimental results are analyzed using the GRA (Grey Relational Analysis
Natarajan, Manikandan, Pasupuleti, Thejasree, Kiruthika, Jothi, Krishnamachary, PC, Silambarasan, R
Technical Paper
Development of ANFIS Predictive Model for Wire Electrical Discharge Machining of Cupronickel Material2024-28-023912/05/2024
Wire Electrical Discharge Machining (WEDM) is an essential manufacturing process used to shape complex geometries in conductive materials such as cupronickel, which is valued for its corrosion resistance and electrical conductivity. The aim of this explorative study is to enhance the efficiency and precision of machining by creating a specialized predictive model using an Adaptive Neuro-Fuzzy Inference System (ANFIS) for cupronickel material. The study examines the intricate correlation between process variables of the WEDM (Wire Electrical Discharge Machining) technique, such as pulse-on time (Ton), pulse-off time (Toff), and discharge current, and crucial machining responses, including surface roughness, material removal rate. Data is collected through systematic experimentation in order to train and validate the ANFIS predictive model. The ANFIS model utilizes the collective learning capabilities of neural networks and fuzzy logic systems to precisely forecast machining responses by
Pasupuleti, Thejasree, Natarajan, Manikandan, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R.
Technical Paper
Optimization and ANFIS Predictive Modeling of Additive Manufacturing (Fused Deposition Modeling) for PLA Material2024-28-024012/05/2024
Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has become a revolutionary technology for creating intricate shapes using different materials. Polylactic Acid (PLA) is a biodegradable thermoplastic that is commonly used in additive manufacturing (AM) because of its environmentally friendly properties, affordability, and ease of use. The objective of this study is to optimize the FDM parameters for PLA material and create predictive models using the Adaptive Neuro-Fuzzy Inference System (ANFIS) to forecast printing performance. An investigation was carried out through experimental trials to examine the impact of important FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes such as dimensional accuracy, surface finish, and mechanical properties. The utilization of design of experiments (DOE) methodology enabled a methodical exploration of parameters. A predictive model using ANFIS was created to
Pasupuleti, Thejasree, Natarajan, Manikandan, Kiruthika, Jothi, Ramesh Naik, Mude, Silambarasan, R
Technical Paper
Optimization and Regression Modeling of Additive Manufacturing (Fused Deposition Modeling) of PETG Material for Automobile Applications2024-28-023412/05/2024
Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has become a highly promising method for creating intricate shapes using different materials. Polyethylene Terephthalate Glycol (PETG) is a highly utilized thermoplastic that is recognized for its exceptional strength, resistance to chemicals, and effortless processing. This study aims to optimize the process parameters of the FDM technique for PETG material using Taguchi Grey Relational Analysis (GRA). An empirical study was carried out to examine the impact of various FDM process parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on important outcome variables like dimensional accuracy, surface quality, and mechanical properties. The Taguchi method was used to systematically design a series of experiments, while GRA was used to optimize the process parameters and performance characteristics. The results unveiled the most effective parameter combinations for attaining
Natarajan, Manikandan, Pasupuleti, Thejasree, Kiruthika, Jothi, D, Palanisamy, Silambarasan, R
Technical Paper
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