Manufacturing Engineering (eBook)

Dr. Vishal Sharma is a Professor at the Department of Industrial and Production Engineering at Dr. B. R. Ambedkar National Institute of Technology, Jalandhar. He obtained his bachelor’s degree (Production Engineering) from Shivaji University, Kolhapur; masters in Mechanical (Production) Engineering from Punjab University Chandigarh; and his Ph.D. in Mechanical Engineering from Kurukshetra University. He also received a postdoctoral fellowship from ENSAM Cluny, France. He has published more than 70 scientific papers in international journals and conferences, and edited more than 15 books and proceedings. His current research interests include additive manufacturing and 3D printing, machining, condition monitoring, industrial IOT/Industry 4.0. Dr. Uday Shanker Dixit is a Professor at the Department of Mechanical Engineering at IIT Guwahati. He received his bachelor’s degree (Mechanical Engineering) from IIT Roorkee in 1987; and his masters and Ph.D. (Mechanical Engineering) from IIT Kanpur in 1993 and 1998, respectively. He has published over 200 scientific papers in international journals and conferences, and edited more than 12 books and proceedings. He has also undertaken 19 research and consultancy projects. In addition to developing course material on mechatronics for IGNOU, and on engineering mechanics for NPTEL, he has produced QIP course material in the area of “Finite Element Method in Engineering and its applications in manufacturing”, and “Introduction to Micro-manufacturing Technologies”. His research interests include plasticity, metal forming, laser-based manufacturing, finite element modeling, and optimization. He has authored/edited more than 15 books and proceedings.Dr. Noe Alba-Baena is a Professor at the Department of Industrial and Manufacturing Engineering, UACJ, Mexico. He received his bachelor’s degree in Industrial and Systems Engineering from the University of Juarez City, Mexico in 1999 and his masters (Industrial Engineering) and Ph.D. (Material Science & Engineering), both from University of Texas at El Paso in 2002 and 2006, respectively. He was awarded an M.Ed. (Educational Administration) degree by the same university in 2009. He has published more than 50 scientific papers in international journals and conferences. He also holds two patents: “Methods for industrial-scale production of metal matrix nanocomposites” and “Apparatus and methods for industrial-scale production of metal matrix nanocomposites”. His current research interests include aluminum alloys, nanocomposites, ultrasonic treatment, product design, and manufacturing processes.

Preface 6
Contents 7
About the Editors 9
1 A Variable Viscosity Technique for the Analysis of Static and Dynamic Performance Parameters of Three-Lobe Fluid Film Bearing Operating with TiO2-Based Nanolubricant 11
1.1 Introduction 13
1.2 Theory 13
1.3 Results and Discussion 18
1.3.1 Validation 18
1.3.2 Three-Lobe Fluid Film Bearing 18
1.4 Conclusions 25
References 26
2 Friction Stir Welding of Shipbuilding Grade DH36 Steel 27
2.1 Introduction 28
2.2 Experimental Procedures 31
2.3 Results and Discussion 34
2.3.1 Visual Inspection 34
2.3.2 Weld Thermal History 35
2.3.3 Macrostructure Evaluation 35
2.3.4 Microstructure Characterization 36
2.3.5 Microhardness 38
2.3.6 Tensile Properties 40
2.3.7 Tool Performance Evaluation 41
2.4 Conclusions 43
References 43
3 Experimental Investigation on the Effect of Cryogenic CO2 Cooling in End Milling of Aluminium Alloy 45
3.1 Introduction 46
3.2 Materials and Methods 47
3.3 Results and Discussions 48
3.3.1 Effect of Cryogenic CO2 Coolant on Cutting Temperature 49
3.3.2 Effect of Cryogenic CO2 Coolant on Cutting Forces 50
3.3.3 Effect of Cryogenic CO2 Coolant on Surface Roughness 51
3.3.4 Effect of Cryogenic CO2 Coolant on Surface Morphology 52
3.3.5 Effect of Cryogenic CO2 Coolant on Chip Morphology 52
3.4 Conclusions 55
References 55
4 Transient Thermal Analysis of CO2 Laser Welding of AISI 304 Stainless Steel Thin Plates 58
4.1 Introduction 59
4.2 Experimental Details 61
4.3 Finite Element Modeling 61
4.3.1 Thermal Analysis 63
4.3.2 Modeling Details 64
4.3.3 Volumetric Heat Source 64
4.4 Material Properties 65
4.5 Results and Discussion 66
4.6 Validation of Thermal Model 71
4.7 Conclusions 72
References 74
5 Transient Thermal Analysis on Friction Stir Welding of AA6061 75
5.1 Introduction 76
5.2 Background and Literature Review 77
5.3 Mathematical Model 78
5.3.1 Friction at the Surface of the Tool Due to Rotation 78
5.3.2 Plastic Deformation of the Metal Due to the Visco-Plastic Mass Flow 78
5.4 Boundary Conditions 82
5.5 Material Properties 84
5.6 Results and Discussion 85
5.7 Experimental Setup 87
5.8 Conclusions 88
References 89
6 Recycling of H30 Aluminium Alloy Swarfs Through Gravity Die Casting Process 91
6.1 Introduction 92
6.2 Materials 93
6.3 Experimental Procedure 94
6.4 Results and Discussion 98
6.4.1 Melt Loss 98
6.4.2 Evaluation of Chemical Composition 98
6.4.3 Porosity Inspection 99
6.4.4 Evaluation of Mechanical Properties 100
6.4.5 Effect of Alloying Elements 102
6.5 Conclusion 102
References 103
7 Effect on Mechanical and Metallurgical Properties of Cryogenically Treated Material SS316 105
7.1 Introduction 105
7.2 Experimental Procedure 106
7.2.1 Material Selection and Specimen Preparation 106
7.2.2 Cryogenic Treatment 107
7.2.3 Tensile Test 108
7.2.4 Hardness Test 108
7.2.5 Impact Toughness Test 108
7.2.6 Optical Microstructure Test 109
7.3 Results and Discussion 110
7.3.1 Hardness Test Result 110
7.3.2 Tensile Test Result 111
7.3.3 Charpy Impact Toughness Test Results 112
7.3.4 Microstructural Analysis 113
7.4 Conclusions 113
References 115
8 Microstructure and Mechanical Properties of Lamellar Ti–6Al–4V ELI Alloy 116
8.1 Introduction 117
8.2 Experimentation 117
8.2.1 Material 117
8.2.2 Specimen Preparation 118
8.2.3 Heat Treatment 118
8.2.4 Tensile Properties 118
8.2.5 Charpy Impact Strength and Microhardness 118
8.2.6 Optical Microscopy 120
8.3 Results and Discussions 120
8.3.1 Tensile Properties 120
8.3.2 Hardness and Charpy Strength 121
8.3.3 Optical Micrographs 121
8.4 Conclusions 122
References 123
9 Influence of Process Parameters on Surface Roughness Hole Diameter Error and Burr Height in Drilling of 304L Stainless Steel 124
9.1 Introduction 125
9.2 Background and Review 125
9.3 Experimental Setup 127
9.3.1 Cryogenic Treatment 128
9.4 Methodology 129
9.5 Experimental Results and Analysis 130
9.6 Tool Life 136
9.7 Microstructure 137
9.8 Chip Study 139
9.9 Conclusions 139
References 141
10 Investigation of Impression Creep Deformation Behavior of Boron-Modified P91 Steel By High-End Characterization Techniques 143
10.1 Introduction 144
10.2 Experimentation 145
10.2.1 Material 145
10.2.2 Specimen Preparation and Microscopic Characterization Techniques 146
10.2.3 Impression Creep Testing 146
10.3 Results and Discussions 148
10.3.1 Characterization of as Received Steels 148
10.3.2 Impression Creep Tests 151
10.3.3 Characterization of Crept Specimens 152
10.4 Conclusions 154
References 155
11 Tribological and Machining Performance of Graphite-, CaF2- and MoS2-Coated Mechanical Micro-textured Self-lubricating Cutting Tool 157
11.1 Introduction 158
11.2 Materials and Method 159
11.2.1 Mechanical Micro-textured Pins and Solid Lubricants Coating 160
11.2.2 Friction and Wear During Dry Sliding Test 162
11.2.3 Machining Test 163
11.3 Results and Discussion 163
11.3.1 Dry Sliding Coefficient of Friction 163
11.3.2 Dry Sliding Wear, Weight Loss and Wear Coefficient of Pins 165
11.3.3 Machining Performance 166
11.4 Conclusion 168
References 170
12 Chemical Assisted USM of Acrylic Heat Resistant Glass 172
12.1 Introduction 173
12.2 Material and Mechanism 174
12.3 Experimentation 177
12.3.1 CUSM Machine Tool Design 177
12.3.2 Machining Parameters 177
12.3.3 Tool Materials Properties 179
12.3.4 CUSM Experimental Setup 179
12.3.5 Experiment Data 182
12.4 Grey Relational Analysis 182
12.4.1 Analysis of Variance (ANOVA) 182
12.5 Surface Topography 184
12.5.1 SEM Image of A1B1C1D1E3F3 Sample 184
12.5.2 SEM Image of A3B3C2D2E3F3 Sample 185
12.6 Validation of Experimentation 186
12.7 Conclusions 186
Reference 187
13 Study of Temperature Distribution During FSW of Aviation Grade AA6082 189
13.1 Introduction 189
13.2 Literature Review 191
13.3 Experimental Procedure 193
13.3.1 Machine Setup, Workpiece and FSW Tool 193
13.3.2 Temperature Measurement 196
13.3.3 Tensile Testing 197
13.3.4 Microhardness Testing 197
13.4 Results and Discussion 197
13.4.1 Temperature Distribution 197
13.4.2 Statistical Analysis of Temperature Distribution 198
13.4.3 Thermal Mapping 200
13.4.4 Tensile Strength 202
13.4.5 Microhardness Distribution 203
13.5 Conclusions and Future Scope 204
References 205