Advances in Computational Methods in Manufacturing (eBook)

Conference Organizing Committee 6
Patron 6
Chairman 6
Executive Chairman 6
Organizing Secretary 6
Joint Organizing Secretary 6
Treasurer 7
Members 7
International Advisory Board 7
Preface 9
Contents 11
About the Editors 20
Material Forming 22
1 Numerical Simulation of Micro Forming of Bio-Absorbable AZ80 Magnesium Alloy 23
Abstract 23
1.1 Introduction 23
1.2 Micro Compression Test and Size Effects 24
1.3 FEM Model 25
1.4 Physical Experiment 26
1.5 Results and Discussion 28
1.6 Conclusions 30
Acknowledgements 31
References 31
2 Investigation on Tensile Testing of Tailor Welded Blanks (TWBs)—A Simulation Study 32
Abstract 32
2.1 Introduction 32
2.2 Numerical Conditions 34
2.2.1 Section-I (Similar Material Dissimilar Gauge TWBs) 34
2.2.2 Section-II (Similar Gauge Dissimilar Material TWBs) 35
2.3 Results and Discussions 38
2.3.1 Section-I (Similar Material Dissimilar Gauge TWBs) 38
2.3.2 Section-II (Dissimilar Material Similar Gauge TWBs) 39
2.4 Conclusions 40
References 41
3 Formability Evaluation of EN-10149-2 (S700mc) Steel Under In-Plane Plane Stretching Condition 43
Abstract 43
3.1 Introduction 44
3.2 Materials and Methodologies 45
3.2.1 Materials 45
3.2.2 Methodologies 45
3.3 Results and Discussion 46
3.3.1 Mechanical Properties of Sheet Metal 46
3.3.2 Microstructure of EN-10149-2 48
3.3.3 Evaluation of Hardness 48
3.3.4 In-Plane Plane Stretching (IPPS) Test 50
3.4 Conclusions 52
References 53
4 Stretch Formability Prediction of AA6023-T6 Alloy Sheet Under Two Different Heating Conditions 54
Abstract 54
4.1 Introduction 55
4.2 Materials and Methodologies 57
4.2.1 Base Material 57
4.2.2 Tensile Test 57
4.2.3 Simulation Details 58
4.3 Results and Discussion 58
4.3.1 Mechanical Properties of Base Material 58
4.3.2 Evaluation of Forming Limit Diagram 60
4.4 Conclusions 64
References 64
5 FE Analysis of Single Point Incremental Forming (SPIF) for Tailor Welded Blanks (TWBs) 66
Abstract 66
5.1 Introduction 67
5.2 Simulation Strategy 68
5.2.1 Challenges in Simulation of TWBs 68
5.2.2 Simulation Methodology 69
5.3 Results and Discussion 73
5.3.1 Formed Component 73
5.3.2 Weld Line Shift 74
5.3.3 Plastic Equivalent Strain (PEEQ) 76
5.3.4 Comparison with the Target Geometry 77
5.4 Conclusions 77
References 79
6 Joining Concentric Tubes by End Forming: A Finite Element Simulation Study 81
Abstract 81
6.1 Introduction 81
6.2 Proposed Joining Method 83
6.3 FE Simulation and Experiment Trial 84
6.4 Material Properties Evaluation 86
6.5 Results and Discussion 87
6.6 Conclusions 89
References 89
7 Optimization of the Forming Parameters in U-Bending for Punch Force and Springback Using Taguchi Method 91
Abstract 91
7.1 Introduction 91
7.2 Materials and Method 93
7.2.1 Tool and Workpiece Material 93
7.2.2 Design of Experiments Using Taguchi Method 93
7.3 Results and Discussion 96
7.3.1 Effect of Forming Parameters on Punch Force 96
7.3.2 Effect of Forming Parameters on Springback 98
7.4 Conclusions 99
References 100
8 Experimental Analysis on Springback of JIS 3302 Grade Steel Sheet Material Under Various Heat-Treated Conditions 101
Abstract 101
8.1 Introduction 102
8.2 Methodology and Materials 102
8.2.1 Materials 102
8.2.2 Experiment: Bending Process 103
8.2.3 Tensile Test Procedure 103
8.3 Results and Discussion 105
8.3.1 Tensile Test Result 105
8.3.2 Springback Results from the Experiments 105
8.4 Conclusions 108
References 108
9 Experimental and Numerical Assessment of Residual Stresses in AA6061 After Surface Treatment by Deep Cold Rolling 110
Abstract 110
9.1 Introduction 111
9.2 Methodology 113
9.2.1 Experimental Work 113
9.2.2 Finite Element Modelling (FEM) 114
9.3 Result and Discussion 117
9.3.1 Tensile Properties 117
9.3.2 Microstructure Characterization 118
9.3.3 Residual Stresses by Experiments and Simulations 118
9.4 Conclusions 122
References 122
10 Analysis of Hot Workability of Inconel Alloys Using Processing Maps 124
Abstract 124
10.1 Introduction 124
10.2 Materials and Experimental Procedures 125
10.3 Processing Map 127
10.4 Conclusions 132
References 132
Welding and Joining Technologies 134
11 Investigation on Metallographic Analysis of Electron Beam Ti6Al4V Alloy Welds 135
Abstract 135
11.1 Introduction 136
11.2 Experimental Investigation 137
11.3 Results and Discussion 139
11.4 Conclusion 145
Acknowledgements 145
References 145
12 Multi-objective Optimization of FSW Process Variables of Aluminium Matrix Composites Using Taguchi-Based Grey Relational Analysis 147
Abstract 147
12.1 Introduction 148
12.2 Experiments 149
12.2.1 Process Variables Selection 149
12.2.2 Evaluation of FSW Performances 150
12.3 Grey Relational Analysis 151
12.3.1 Response Pre-processing 151
12.3.2 Calculating Grey Relational Coefficient (GRC) and Grey Relational Grade (GRG) 153
12.3.3 Validation Test 154
12.4 Result and Discussion 155
12.5 Conclusions 157
References 157
13 Tool Durability and Weldability in Hybrid Friction Stir Welding of High-Strength Materials 159
Abstract 159
13.1 Introduction 159
13.2 Finite Element Method 160
13.3 Results and Discussion 162
13.4 Conclusion 165
References 165
14 Swarm-Intelligence-Based Computation for Parametric Optimization of Electron Beam Fabrication 167
Abstract 167
14.1 Introduction 168
14.2 Experimentation and Data Collection 169
14.3 Method of Analysis: Proposed Approaches 170
14.3.1 Regression Analysis 170
14.3.2 Problem Formulation 171
14.3.3 Genetic Algorithm (GA) 172
14.3.4 Bonobo Optimizer (BO) 172
14.3.5 Cricket Algorithm (CA) 173
14.4 Results and Discussion 174
14.5 Conclusion 176
References 177
15 Effect of Pulsation on Temperature Distribution of Laser-Welded Dissimilar Joint of Thin Sheet 178
Abstract 178
15.1 Introduction 179
15.2 Experimental Investigation 180
15.3 Theoretical Background 181
15.3.1 Thermal Analysis 181
15.4 Result and Discussions 183
15.4.1 EDS Analysis 183
15.4.2 Numerical Result 185
15.4.3 Cooling Rate Estimation 187
15.5 Conclusion 189
Acknowledgements 190
References 190
16 Activated TIG Welding of AISI 321 Austenitic Stainless Steel for Predicting Parametric Influences on Weld Strength of Tensile Test—Experimental and Finite Element Method Approach 192
Abstract 192
16.1 Introduction 193
16.2 Experimentation Procedure 193
16.3 Results and Discussion 195
16.3.1 Experimental and FE Simulation of the Tensile Test 195
16.3.2 Fractography Examination 201
16.4 Conclusions 202
References 205
17 Design Optimization of Welding Parameters for Multi-response Optimization in TIG Welding Using RSM-Based Grey Relational Analysis 206
Abstract 206
17.1 Introduction 207
17.1.1 Literature Survey 208
17.2 Response Surface Methodology (RSM) and Grey Relational Analysis (GRA) 209
17.3 Experimental Procedure 211
17.4 Converting Multi-response into Single-Response Problem 212
17.5 Results and Analysis 213
17.5.1 Mathematical Modeling and Contour Plots 213
17.6 Conclusions 215
References 215
18 Subjective Factors Consideration in the Selection of Welding Technique for Welded Tube Manufacturing 217
Abstract 217
18.1 Introduction 217
18.2 Methodology and Implementation 219
18.2.1 AHP Model 219
18.2.2 Implementation of Decision-Making Model 220
18.3 Results and Discussion 222
18.3.1 Discussion 222
18.4 Conclusions and Future Scope 224
References 224
19 GMAW Investigation of AISI 201 Stainless Steel and Industry Need Optimization Using Genetic Algorithm 226
Abstract 226
19.1 Introduction 226
19.2 GMAW Experimentation Procedure 228
19.2.1 Effect of Welding Parameters On the Performance Measures 229
19.3 Development of RSM Modelling 230
19.4 Parametric Analysis 232
19.4.1 Contour Figures for Penetration (P) 232
19.4.2 Contour Figures for Bead Width (W) 232
19.4.3 Contour Figures for Bead Height (H) 233
19.5 Optimization of GMAW Welding 234
19.5.1 Single-Objective Optimization Using GA 234
19.5.2 Simultaneous Optimization 236
19.6 Industrial Application Optimization 237
19.7 Conclusion 239
Acknowledgements 239
References 239
20 Finite Element Modelling and Experimental Verification of Dissimilar Joining Between Inconel 718 and SS 316L by Micro-plasma Arc Welding 241
Abstract 241
20.1 Introduction 242
20.2 Experimental Procedure 244
20.3 Numerical Model 245
20.4 Results and Discussion 247
20.4.1 Temperature Field Characteristics 247
20.4.2 Effect of Cooling Rate on Weld Micro-structure and Mechanical Properties 249
20.5 Conclusion 251
Acknowledgements 251
References 252
21 Numerical Simulation and Experimental Validation of A-TIG Welding of 2.25Cr–1Mo Steel 254
Abstract 254
21.1 Introduction 255
21.2 Finite Element Modeling 256
21.2.1 Material Properties 257
21.2.2 Governing Equations 257
21.2.3 Boundary Condition 259
21.3 Experimental 259
21.4 Results and Discussion 260
21.4.1 Thermal Analysis 260
21.4.2 Mechanical Analysis 262
21.5 Conclusions 264
References 265
22 Finite Element Modeling of Hybrid Laser-TIG Welding of Type 316L(N) Stainless Steel 267
Abstract 267
22.1 Introduction 268
22.2 Experimental 268
22.3 Numerical Modeling 270
22.3.1 Governing Equations 271
22.3.2 Boundary Condition 271
22.3.3 Finite Element Modeling 271
22.4 Results and Discussion 272
22.4.1 Temperature Distribution and Weld Bead Comparison 272
22.4.2 Residual Stress Analysis 273
22.4.3 Distortion Analysis 275
22.4.4 Microstructure 275
22.5 Conclusions 276
References 276
23 Numerical Study on Electromagnetic Crimping of Aluminum Tube and Steel Profiled Rod 278
Abstract 278
23.1 Introduction 278
23.2 Governing Equations of EMF Process 280
23.3 Geometrical Dimensions of Workpiece and Material Properties 281
23.4 3D Finite Element Modeling 281
23.5 Results and Discussion 282
23.5.1 Effect of Voltage on Effective Plastic Strain 283
23.5.2 Effect of Voltage on Resultant Displacement and Velocity 283
23.5.3 Effect of Voltage on Temperature and Current 284
23.5.4 Effect of Capacitance on Process Parameters (V and ?) 285
23.5.5 Effect of Capacitance on Resultant Displacement and Temperature 286
23.5.6 Effect of Capacitance on Magnetic Field 286
23.5.7 Failure Prediction 287
23.5.8 Experimental Work 287
23.6 Conclusions 288
References 289
24 Temperature Prediction During Self-pierce Riveting of Sheets by FEA-ANN Hybrid Model 290
Abstract 290
24.1 Introduction 291
24.2 FE Simulation of SPR 293
24.3 SPR Parameters 295
24.4 ANN Model 295
24.5 ANN Prediction 299
24.6 Conclusions 300
References 301
Subtractive Manufacturing 302
25 Determination of Optimal Cutting and Tool Geometry Parameters for Better Surface Integrity of Hard Turned AISI 52100 Steel-Hybrid GRA-PCA 303
Abstract 303
25.1 Introduction 304
25.2 Experimental Work 305
25.3 Methodology Adopted 307
25.4 Results and Discussion 307
25.5 Conclusions 313
References 313
26 Study of Cutting Edge Radius Effect on the Cutting Forces and Temperature During Machining of Ti6Al4V 315
Abstract 315
26.1 Introduction 315
26.2 Numerical Modeling 316
26.3 Results and Discussion 318
26.3.1 Forces Evaluation 318
26.3.2 Maximum Temperature in the Tool 320
26.4 Conclusions 321
References 322
27 Comparative Study on Effect of Inclusions and Machinability Aspects of Alloy Steels 323
Abstract 323
27.1 Introduction 323
27.2 Experimental Details 325
27.2.1 Chemical Composition 325
27.2.2 Hardness and Microstructure 325
27.2.3 Inclusions 326
27.2.4 Experimentation 328
27.3 Result and Discussion 329
27.3.1 Chip Morphology 330
27.3.2 Discussion 332
27.4 Conclusion 332
Acknowledgements 332
References 333
28 Process Parameters Optimization of Electrical Discharge Machining of Al7075/SiC/WS2 by Using MCDM 334
Abstract 334
28.1 Introduction 334
28.2 Literature Review 335
28.3 Description of the Experiments 336
28.4 Analysis Method 337
28.5 Results and Discussion 339
28.6 Conclusion 340
References 340
29 CNC Turning and Simulation of Residual Stress Measurement on H13 Tool Steel 342
Abstract 342
29.1 Introduction 343
29.2 Experimental Method 344
29.2.1 Selection of Tool Materials 344
29.2.2 Machining Methodology 345
29.2.3 Measurement Condition of H13 Tool Steel 345
29.2.3.1 Sample Information 346
29.2.3.2 Measurement of Residual Stresses 346
29.3 Modeling of Cylindrical and Taper Cylindrical Tool 346
29.4 Results and Discussion 349
29.5 Conclusions 353
References 353
30 Small-Scale Machining Simulations 354
Abstract 354
30.1 Introduction 354
30.2 Simulation Techniques 356
30.2.1 Molecular Dynamics Simulation 356
30.2.2 Crystal Plasticity Finite-Element Simulation 357
30.3 Case Studies 359
30.3.1 MD: Influence of Microstructure on Cutting Behaviour of Silicon [19] 359
30.4 Crystal Plasticity Simulation of Micromachining of Single-Crystal Metal: Methodology and Analysis [14] 362
30.5 Comparison of the Two Methods 364
30.6 Conclusion 365
References 366
31 Process Parameters Optimization of Cylindrical Grinding Machining Using Taguchi Method 368
Abstract 368
31.1 Introduction 368
31.2 Experimentation 369
31.2.1 Grinding Machine Specifications 369
31.2.2 En Alloy Steels 369
31.2.3 Input Process Parameters and Output Variables 370
31.2.3.1 Process Parameters 370
31.2.3.2 Output Parameters 370
31.2.4 Experimental Setup 371
31.3 Results and Discussions 373
31.3.1 Discussions 373
31.4 Conclusions 374
References 374
32 Effect of Sequential Drilling Process on In-situ Bone Temperature 375
Abstract 375
32.1 Introduction 375
32.2 Materials and Methods 376
32.3 Results and Discussion 378
32.4 Conclusion 380
Ethical Approval 381
References 381
Additive Manufacturing and Casting 382
33 FE-Based Heat Transfer Analysis of Laser Additive Manufacturing on Ti–6Al–4V Alloy 383
Abstract 383
33.1 Introduction 384
33.2 Theoretical Background 386
33.3 Results and Discussions 388
33.4 Conclusion 392
Acknowledgements 393
References 393
34 Material Perspective and Deformation Pattern of Micro-Sized Metallic Particle Using Cold Gas Dynamic Spray 395
Abstract 395
34.1 Introduction 395
34.2 Numerical Methodology 397
34.3 Results and Discussion 399
34.3.1 Deformation Behaviour of Soft Particle on Hard Substrate 400
34.4 Conclusion 402
References 403
35 Towards an Improved Understanding of Stereolithography Process—A Computational Study 404
Abstract 404
35.1 Introduction 405
35.2 Process Modelling 407
35.2.1 Assumptions 407
35.2.2 Governing Equations 408
35.2.3 Beer–Lambert’s Law 408
35.2.4 Domain and Boundary Conditions 408
35.2.5 Meshing 409
35.3 Results and Discussion 410
35.4 Conclusions 413
References 414
36 Experimental Investigations for Effects of Raster Orientation and Infill Design on Mechanical Properties in Additive Manufacturing by Fused Deposition Modelling 415
Abstract 415
36.1 Introduction 416
36.2 Fused Deposition Modelling Process 417
36.3 Experimental Details 418
36.4 Results and Discussion 420
36.5 Fractography 421
36.6 Conclusion 423
Acknowledgements 424
References 424
37 Development of Methods for Machine Intelligence Quotient Measurement for Piston Casting by Die Casting Machines: A Study 425
Abstract 425
37.1 Introduction 426
37.2 Machine Intelligent Quotient and Its Sub-systems 426
37.3 Die Casting Machines for Piston Manufacturing 428
37.4 Methods for MIQ Measurement for Die Casting Machines 430
37.4.1 Method for MIQ Measurement for Die Casting Machines by Human–Machine Cooperative System 430
37.4.2 Estimation of MIQ by Geometric Polytope Method 432
37.4.3 Estimation of MIQ by Multiple Perspective Analysis 433
37.5 Computation of MIQ by Machine–Human Cooperative System for Die Casting Machines 433
37.6 Conclusions 436
Acknowledgements 436
References 436
38 Optimization of Porosity in Cast Aluminium Foams 438
Abstract 438
38.1 Introduction 439
38.2 Materials and Methods 440
38.3 Results and Discussion 441
38.4 Conclusion 443
References 443
39 To Predict Surface Roughness and Linear Shrinkage of Die Casting Process by Using of Fuzzy Algorithm Model 445
Abstract 445
39.1 Introduction 445
39.1.1 Fuzzy Logic Overview 447
39.2 Experimental Work 447
39.2.1 Fuzzy Logic Modelling 448
39.3 Discussion 453
39.4 Conclusion 455
References 455
40 Prediction of Hot Spot and Hot Tear of the Al–Cu Cast Alloy by Casting Simulation Software 457
Abstract 457
40.1 Introduction 457
40.2 Methodology 459
40.2.1 Problem Definition 459
40.2.2 Process Design 459
40.2.3 Numerical Simulation 460
40.3 Results and Discussion 462
40.4 Conclusion 464
Acknowledgements 464
References 465
41 Influence of Pouring Temperature on Fluidity of Al–Cu Cast Alloy: Analyses Using Casting Simulation Software 466
Abstract 466
41.1 Introduction 466
41.2 Methodology 468
41.2.1 Problem Definition 468
41.2.2 Process Design 468
41.2.3 Numerical Simulation Using AutoCAST Software 471
41.3 Results and Discussion 476
41.4 Conclusion 478
Acknowledgements 478
References 478
Modelling and Analysis 480
42 Analysis and Optimization of Tool Wear Rate in Magnetic Field-Assisted Powder-Mixed Electrical Discharge Machining of Al6061 Alloy Using TLBO 481
Abstract 481
42.1 Introduction 481
42.2 Experimental Setup and Methods 483
42.3 Optimization Using TLBO 484
42.4 Results and Discussion 485
42.4.1 Analysis of Tool Wear Rate 486
42.4.2 Response Surface Modeling 487
42.4.3 Optimization Using TLBO 489
42.4.4 Confirmation Test 490
42.5 Conclusions 490
References 490
43 ANFIS-Based Subtractive Clustering Algorithm for Prediction of Response Parameters in WEDM of EN-31 492
Abstract 492
43.1 Introduction 493
43.2 Experimental Work 495
43.3 Modeling Approach 496
43.4 Results and Discussion 498
43.5 Model Verification 499
43.5.1 Analysis of Machining Variables 501
43.6 Conclusion 502
References 502
44 On Estimation of Scallop Height from CNC Part Programs 504
Abstract 504
44.1 Introduction 504
44.2 Modular Diagram of the System 505
44.2.1 Slicing of CAD Model 506
44.2.2 Curve Fitting and Residual Calculation 507
44.2.3 Segmentation and Scallop Height Calculation 508
44.3 Results and Discussions 509
44.3.1 Case Study 1 509
44.3.2 Case Study 2 511
44.4 Conclusions 512
References 512
45 Influence of Guides on Critical Speeds of Circular Saws 514
Abstract 514
45.1 Introduction 515
45.2 Mathematical Model for the Critical Speed of Circular Saws 516
45.3 Numerical Verification of Critical Speed Model 519
45.4 Results and Discussion 521
45.4.1 Convergence Analysis of Discrete Multiple Spring Elements to Model the Guide Pad 521
45.4.2 Influence of Damping on the Critical Speed 522
45.4.3 Influence of Circumferential and Radial Distribution of Spring Elements on the Critical Speed 523
45.5 Conclusion 524
Acknowledgements 525
References 525
46 Investigations on the Influence of Radial Run-Out on Cutting Forces for Serrated Cutters 526
Abstract 526
46.1 Introduction 526
46.2 Geometric Model of Serrated Cutter with Run-Out 528
46.2.1 Modelling of Serration Profile 528
46.2.2 Local Chip Thickness 531
46.3 Effect of Run-Out for Serrated Cutter at Different Operating Conditions 532
46.3.1 Influence of Run-Out at Low Feed (0.02 mm/tooth) Rates 533
46.3.2 Influence of Run-Out at High Feed (0.25 mm/tooth) Rates 534
46.3.3 Influence of Run-Out at High Feed (0.25 mm/tooth) Rates for Regular End Mills 535
46.4 Conclusions 536
References 537
47 Modeling and Optimization of WEDM Parameters Using Design of Experiments 538
Abstract 538
47.1 Introduction 538
47.1.1 Materials and Processes 540
47.1.2 Design of Experiments 541
47.2 Examination of Data and  Analysis of  the Outcome 542
47.2.1 Cutting Speed (CS) 544
47.2.2 Wire Wear Ratio (WWR) 544
47.2.3 Development of Mathematical Models 544
47.2.3.1 Optimum Values of Speed of Cut 545
47.3 Conclusions 549
References 550
48 Analysis on Thermal Characteristics of Micro-Drilled Glass Using Microwave Energy at 2.45 GHz 551
Abstract 551
48.1 Introduction 552
48.2 Modeling and Simulation 553
48.2.1 Model Development 554
48.2.2 Meshing 555
48.2.3 Assumptions 555
48.2.4 Governing Equations 556
48.2.5 Validation 557
48.3 Results and Discussion 558
48.4 Conclusion 561
References 561
49 A Study on the Effect of Polarity Change on Various Parameters on Ti6Al4V in Powder-Mixed Micro-EDM Using Multi-objective Grey Fuzzy Optimization 563
Abstract 563
49.1 Introduction 564
49.2 Methodology 565
49.2.1 Grey Relational Generation 565
49.2.2 Fuzzy Logic 566
49.3 The Experimental Set-Up and Procedure 568
49.4 Results and Discussion 570
49.4.1 The Grey Reasoning Coefficient 570
49.4.2 The Grey Fuzzy Reasoning Analysis 572
49.4.3 Analysis of Variance 573
49.4.4 Theoretical Prediction and Confirmation of Experiments 576
49.5 Conclusions 577
References 578
50 Multi-output Response Optimization for Overall Enhancement of Mechanical Characteristics Using Utility Approach for AISI 316L Austenitic Stainless Steel Using Microplasma Arc Welding 580
Abstract 580
50.1 Introduction 581
50.2 Experimental Work 582
50.2.1 Weld Direction Determination for Rolled Sheet 582
50.3 Result and Discussion 585
50.3.1 Optimization Using Utility Approach 585
50.3.2 Utility Concept Approach 586
50.3.3 Determination of Utility Value 587
50.3.3.1 Steps in Calculation of Utility 587
50.3.4 Confirmation Experiment 591
50.4 Conclusion 593
References 593
51 Characterization of Geometrical Features of Ultra-Short Pulse Laser-drilled Microholes Using Computed Tomography 595
Abstract 595
51.1 Introduction 595
51.2 Microhole Drilling 596
51.3 Characterization of Microholes 597
51.3.1 Computed Tomography 597
51.4 Computational Methods 600
51.5 Results and Discussion 602
51.5.1 Comparison of Results with Least Squares Limacon Technique 602
51.6 Conclusion 605
Acknowledgements 606
References 606
52 Investigation on Rotary Electrical Discharge Machining (EDM) of EN-25 Material Using Copper Electrode for Improving Geometrical Errors 607
Abstract 607
52.1 Introduction 608
52.2 Literature Review 608
52.3 Research Plan 609
52.4 Experimental Methodology 609
52.4.1 MRR and TWR Formula 612
52.5 Results and Discussion 613
52.6 Conclusions 617
References 619
53 Computation of End-Cutting-Edge Wear of Single-Point Cutting Tool Using Image Processing 620
Abstract 620
53.1 Introduction 620
53.2 Methodology 622
53.2.1 Image Acquisition 622
53.2.2 Preprocessing 623
53.2.3 Wear Computation 625
53.3 Experimental Setup 627
53.4 Results and Discussion 628
53.4.1 Image processing 628
53.4.2 Speed Test Results 630
53.5 Conclusion 630
References 631
54 Modelling and Analysis of Multi-agent Approach for an IoT-Enabled Autonomous Manufacturing System 633
Abstract 633
54.1 Introduction 633
54.2 Core Technologies 635
54.2.1 Swarm Intelligence 635
54.2.2 Control Architecture 636
54.3 Performance Metrics 636
54.3.1 Workflow Modelling 637
54.3.2 Performance Analytics 640
54.4 Conclusion 642
Acknowledgements 642
References 642
Material Fabrication 644
55 Estimation of Distortion for CFRP Antenna Reflector During Autoclave Processing 645
Abstract 645
55.1 Introduction 646
55.2 Experimental Approach 647
55.2.1 Material Selection 647
55.2.2 Fabrication of Antenna Reflectors 647
55.3 Numerical Approach 648
55.3.1 Simulation Procedure 649
55.4 Results and Discussion 651
55.4.1 Distortion Measurement in Experimental Approach 651
55.4.2 Distortion Measurement in Numerical Approach 651
55.4.3 Comparison of Experimental and Numerical Results 652
55.5 Conclusions 654
Acknowledgements 654
References 654
56 Comparative Study of Hydroxyapatite Nanocomposites Reinforced with Zirconia and Titania Produced by Using HEBM 656
Abstract 656
56.1 Introduction 657
56.2 Materials and Methods 658
56.2.1 Sample Preparation 658
56.2.2 Experimental Procedure 658
56.3 Results and Discussion 660
56.3.1 Microscopic Analysis 660
56.3.2 Mechanical Properties 666
56.4 Conclusions 669
References 670
57 Parametric Optimization of Corrosion Resistance of Electroless Ni–Co–P Coating 672
Abstract 672
57.1 Introduction 672
57.2 Experimental Methods 673
57.3 Results 675
57.4 Conclusion 679
Acknowledgements 679
References 679
58 Investigation on Dimensional Accuracy for CFRP Antenna Reflectors Using Autoclave and VARTM Processes 680
Abstract 680
58.1 Introduction 681
58.2 Experimental Preparation 682
58.2.1 Reflectors Manufacturing Using Autoclave Process 682
58.2.2 Reflectors Manufacturing Using VARTM Process 684
58.2.3 Curing of CFRP Reflectors 684
58.3 Dimensional Measurement Using 3D Scanning 687
58.4 Conclusions 688
References 689
59 On Finite Element Analysis of Melting of Metallic Powders Using Microwave Energy at 2.45 GHz 690
Abstract 690
59.1 Introduction 691
59.2 Modeling and Simulation 693
59.2.1 Model Development 693
59.2.2 Assumptions 693
59.2.3 Governing Equations 695
59.2.4 Boundary Conditions 697
59.2.5 Meshed Model 698
59.3 Results and Discussion 699
59.3.1 Electric Field Distribution and Temperature Distribution 699
59.3.2 Effect of Input Power 700
59.3.3 Effect of Size of Powder Particles 702
59.4 Conclusion 702
Acknowledgements 703
References 703
60 Tribological Behaviour of Nylon 6 Composites and Optimization of Process Parameters Using Hybrid Taguchi-GRA and CSA 705
Abstract 705
60.1 Introduction 706
60.2 Materials and Methods 706
60.3 Results and Discussion 708
60.3.1 Effect of GF Content, Load and Sliding Distance on COF 709
60.3.2 Effect of GF Content, Load and Sliding Distance on SWR 711
60.3.3 Grey Relational Analysis and Implementation of Cuckoo Search Algorithm 711
60.3.4 Confirmation Tests for CSA 713
60.3.5 Worn Surface Morphology 714
60.4 Conclusions 716
References 717
61 Fabrication of Hexagonal Bar from Aluminum Alloy AA6063 Scrap by Frictional Stir Back Extrusion on Milling Machine 718
Abstract 718
61.1 Introduction 719
61.2 Materials and Methodologies 720
61.2.1 Design and Fabrication of Die and Chamber 722
61.2.2 Process Parameters of Milling Machine to Fabricate Hexagonal-Shaped Bar 722
61.2.3 Consolidation and Extrusion Period of Time 723
61.2.4 Fabrication of Hexagonal Bar 724
61.3 Results and Discussion 725
61.3.1 The Fabricated Die and Chamber 725
61.3.2 Extruded Samples at Different Speeds and Discussion 725
61.4 Conclusions 727
References 727
62 Fabrication, Characterization and Evaluation of Mechanical Properties of Aluminium Hybrid Matrix Composite (Al6063/SiC-Bagasse Fly-Ash) 728
Abstract 728
62.1 Introduction 729
62.2 Experimental Methodology 730
62.2.1 Matrix and Reinforcement Materials 730
62.2.2 Methods 731
62.2.3 Sampling and Sample Method 732
62.2.4 Equipment Used for This Work 732
62.2.5 Mould Preparation and Fabrication 733
62.2.6 Tensile Test Specimen 733
62.3 Results and Discussion 733
62.3.1 Fabrication of Al/SiC/Bagasse Ash Composite 733
62.3.2 Mechanical Tests of the Al/SiC-Bagasse Ash Composite 734
62.4 Conclusions 737
References 737
63 Fuzzy-EDAS (Evaluation Based on Distance from Average Solution) for Material Selection Problems 739
Abstract 739
63.1 Introduction 739
63.2 Fuzzy Theory and Some Definitions 741
63.2.1 Definition Number 1 741
63.2.2 Definition Number 2 741
63.2.3 Definition Number 3 741
63.2.4 Definition Number 4 742
63.2.5 Definition Number 5 742
63.2.6 Definition Number 6 742
63.3 The Conceptual Framework of Fuzzy-EDAS Methodology 742
63.3.1 Step 1 743
63.3.2 Step 3 743
63.3.3 Step 4 744
63.3.4 Step 5 745
63.3.5 Step 6 745
63.3.6 Step 7 745
63.3.7 Step 8 746
63.4 Illustrative Example 746
63.5 Result and Discussion 748
Acknowledgements 754
References 754
64 Tensile and Flexural Property Analyses of Glass/Carbon Embedded Hybrid Natural Fibre Composites 756
Abstract 756
64.1 Introduction 756
64.2 Experimental Methodology 757
64.2.1 Materials 757
64.2.2 Composite Preparation 758
64.2.3 Mechanical Property Testing 759
64.3 Results and Discussion 760
64.3.1 Tensile Properties 760
64.3.2 Flexural Properties 761
64.4 Conclusions 763
Acknowledgements 764
References 764
65 Mechanical Characterization of Hybrid Carbon–Glass-Reinforced Polypropylene Composites 766
Abstract 766
65.1 Introduction 766
65.2 Experimental Details 768
65.3 Results and Discussion 771
65.3.1 Tensile Test 771
65.3.2 Impact Test 772
65.4 Conclusion 774
References 774
66 Effect of Temperature on the Fracture Strength of Perfect and Defective MonoLayered Graphene 776
Abstract 776
66.1 Introduction 776
66.2 Molecular Dynamics Simulation 778
66.2.1 Molecular Dynamics 778
66.2.2 Modelling and Simulation 779
66.2.3 Potential Field 780
66.2.4 Calculation of Stress 781
66.2.5 Constant Strain Method 782
66.3 Effect of Temperature Variation 782
66.4 Conclusion 785
Acknowledgements 786
References 786
67 Effect of Process Parameters of Plasma Arc Preheating on Low Carbon Steel 788
Abstract 788
67.1 Introduction 788
67.2 Experimental Details 789
67.3 Finite Element Analysis and Model Details 790
67.3.1 Heat Source Model 791
67.4 Material Properties 793
67.5 Results and Discussion 793
67.5.1 Transient Temperature Profiles of Plasma 794
67.5.2 Peak Temperature–Distance Profiles on Top Surface 795
67.5.3 Effect of Variation in Traverse Speed on Transient Temperature Profile at Different Power Supply 797
67.6 Conclusion 797
References 798
Process Simulation and Optimization 799
68 Reduced-Order Finite Element Analysis of Rough Surface Contact Using Reduced Integration Elements 800
Abstract 800
68.1 Introduction 800
68.2 Description of the Rough surface Geometry 802
68.3 Mesh Generation 804
68.4 Boundary Conditions 805
68.5 Results and Discussion 807
68.6 Conclusion 808
Acknowledgements 808
References 808
69 FEM-Based Modeling of Drilling-Induced Delamination in Laminated FRP Composites 809
Abstract 809
69.1 Introduction 810
69.2 Modeling Approach 811
69.2.1 Fiber-Reinforced Plastics (FRP) 811
69.2.2 Cohesive Zone Method (CZM) 811
69.3 Finite Element Modeling 812
69.3.1 Double Cantilever Beam (DCB) Test 812
69.3.2 Drilling of FRP Laminate 813
69.4 Results and Discussion 814
69.4.1 Double Cantilever Beam (DCB) Test 814
69.4.2 Drilling of FRP Laminate 815
69.5 Conclusions 817
References 817
70 Fuzzy Inference System-Based Neuro-Fuzzy Modeling of Electron-Beam Welding 819
Abstract 819
70.1 Introduction 820
70.2 Experimentation and Data Collection 821
70.3 Adaptive Neuro-Fuzzy Inference System (ANFIS)—Based Modeling 821
70.3.1 Grid Partition-Based Fuzzy Inference System (G-ANFIS) 822
70.3.2 Subtractive Clustering-Based Fuzzy Inference System (S-ANFIS) 823
70.3.3 ANFIS Models for Prediction of Depth of Penetration 823
70.4 Results and Discussion 825
70.4.1 Grid Partition-Based Fuzzy Inference System (G-ANFIS) 825
70.4.2 Subtractive Clustering-Based Fuzzy Inference System (S-ANFIS) 826
70.4.3 Nonlinear Regression 826
70.4.4 Discussion 827
70.5 Conclusion 829
References 830
71 Numerical Analysis of Erosion of Rough Surface 831
Abstract 831
71.1 Introduction 831
71.2 Model Description 834
71.3 Results and Discussion 836
71.4 Conclusion 839
Acknowledgements 839
References 839
72 Numerical Simulation and Experimental Validation of Nanoindentation of Silicon Using Finite Element Method 841
Abstract 841
72.1 Introduction 842
72.2 Theoretical Background 842
72.3 FEM Modeling and Simulation of Nanoindentation of Silicon 843
72.3.1 Assumptions 844
72.3.2 Geometric Modeling 844
72.3.3 Material Model 844
72.3.4 Element and Meshing 846
72.3.5 Modeling of Surface Contact 847
72.3.6 Boundary Conditions 848
72.3.7 Solution Methodology 848
72.4 Results and Discussion 849
72.4.1 Measurement of Young’s Modulus 849
72.4.2 Measurement of Hardness 851
72.5 Experimental Validation of Nanoindentation Simulation 851
72.6 Conclusions 854
References 855
73 Effect of Microchannel Pattern on Fluid Flow and Heat Transfer Characteristics 856
Abstract 856
73.1 Introduction 856
73.2 Geometric Models of Microchannels 858
73.3 Numerical Study 859
73.3.1 Boundary Conditions 859
73.3.2 Grid Independence Test 860
73.3.3 Model Validation 860
73.4 Results and Discussion 861
73.4.1 Pressure Drop 861
73.4.2 Temperature 862
73.4.3 Velocity Profile 864
73.4.4 Heat Transfer Coefficient 865
73.5 Conclusions 866
References 866
74 Comparative Analysis of GPU-Based Solver Libraries for a Sparse Linear System of Equations 868
Abstract 868
74.1 Introduction 869
74.1.1 Parallel Computing 869
74.2 Sparse Matrix Solver Libraries 871
74.2.1 CUSP 871
74.2.2 cuSolver 871
74.2.3 SuiteSparse 872
74.2.4 PETSc 872
74.2.5 MAGMA 872
74.3 Results and Discussion 872
74.4 Conclusion 875
References 875
75 Hybridizing Evolutionary Multi-objective Algorithm Using Random Mutations and Local Searches 877
Abstract 877
75.1 Introduction 878
75.2 Framework for Hybrid MOEA (HMOEA) 879
75.3 Results and Discussions 881
75.3.1 Effect of Random Mutations 881
75.3.2 Pareto-Optimal Solutions 882
75.3.3 Convergence Plots 883
75.4 Conclusions 885
References 885
76 Local Search Heuristics-Based Genetic Algorithm for Capacitated Vehicle Routing Problem 887
Abstract 887
76.1 Introduction 888
76.2 Problem Formulation for Capacitated VRP 889
76.3 Local Search Heuristics for Genetic Algorithm 890
76.4 Results and Discussion 894
76.4.1 Obtained Solutions and Computational Time 895
76.4.2 Convergence Plots 895
76.5 Conclusions 896
References 896
Design 898
77 Performance Evaluation of Adhesive Spur Gear with the Influence of Properties of Adhesive 899
Abstract 899
77.1 Introduction 900
77.2 Methodology 902
77.2.1 Materials Used and Mechanical Properties 902
77.3 Results and Discussion 904
77.3.1 Effect of Hardener to Resin Ratio of Adhesive on Failure Pattern of Gears 904
77.3.2 Effect of Hardener to Resin Ratio of Adhesive on Gear Performance 905
77.4 Conclusions 906
References 907
78 Design Analysis and Modification of Sugarcane Fibrizer Hammer at Wonji Shoa Sugar Factory (WSSF) Ethiopia 908
Abstract 908
78.1 Introduction 909
78.2 Experimental Methodology 910
78.2.1 Experimental Analysis 911
78.2.1.1 Visual Examination 911
78.2.1.2 Stress Concentration Factor Analysis 911
78.2.1.3 Load Analysis of Current Fibrizer Hammer 912
78.2.1.4 Hardness Measurement 913
78.2.1.5 Design Modification of Fibrizer Hammer 914
78.2.1.6 Harmonic Analysis Using Finite Element Simulation 915
78.3 Results and Discussion 916
78.3.1 Stress Concentration Factor Analysis Result of the Existing and Proposed Fibrizer Hammer 916
78.3.2 Load Analysis Result 916
78.3.3 Vickers Hardness Results 917
78.3.4 Cost Comparison Between Existing and Modified Fibrizer 917
78.3.5 Harmonic Analysis Results of Existing and Modified Fibrizer Hammers 917
78.4 Conclusions 920
References 921
79 FEA Validation of Experimental Results of First Ply Failure of Composite Structure 922
Abstract 922
79.1 Introduction 922
79.2 Finite Element Method 924
79.2.1 Finite Element Modeling 924
79.2.2 Results and Discussion 925
79.3 Theoretical Approach 925
79.4 Conclusions 928
Acknowledgements 929
References 929
80 Triply Periodic Minimal Surface-Based Porous Scaffold Design and Analysis Subjected to Hard Tissue Reconstruction 930
Abstract 930
80.1 Introduction 931
80.2 Materials and Method 932
80.2.1 TPMS-Based Porous Scaffold-Primitive (P) and Gyroid (G) Surface Modeling 932
80.2.2 Design and Formulation of Finite Element Model for FEA 934
80.3 Porosity 936
80.4 Results 936
80.5 Discussion 938
References 940
81 Design of Medical Device Product Using Multiphysics Simulations 942
Abstract 942
81.1 Introduction 942
81.1.1 Blood Warmer 943
81.2 Multiphysics Simulation Procedure and Results 944
81.2.1 Simulation Procedure 944
81.2.2 Simulation Results 944
81.3 Conclusion 947
References 947
82 Finite Element Analysis of a Disc Brake Mounted on the Axle of a Train 948
Abstract 948
82.1 Introduction 948
82.2 Literature Review 949
82.3 Problem Definition 949
82.3.1 Aim of the Project 949
82.3.2 2D Drawings of Models 950
82.3.3 Software Used 950
82.4 Research Methodology 952
82.4.1 Theoretical Background 952
82.4.2 Solution Methodology 952
82.5 Results and Discussions 953
82.5.1 Static Structural Analysis 953
82.5.2 Coupled Analysis 954
82.6 Future Scope 956
Appendix 957
References 959
83 Modelling and Analysis of Composite Conical Space Adapter 960
Abstract 960
83.1 History of Lattice Structures 961
83.2 Introduction 961
83.3 Configuration 962
83.4 Input Generation 963
83.5 Modelling 964
83.6 Boundary Conditions and Load Cases 964
83.7 Results and Discussions 966
83.8 Conclusion 970
Acknowledgements 970
References 970
84 Parametric Study of Axisymmetric Circular Disk Subjected to Rotational Autofrettage 972
Abstract 972
84.1 Introduction 972
84.2 Plane Stress Model of Rotational Autofrettage Proposed by Kamal [18] 974
84.3 Parametric Study 976
84.3.1 Influence of the Wall Thickness Ratio (b/a) 976
84.3.2 Influence of Autofrettage Rotational Speed 980
84.3.3 Influence of Material Properties 981
84.4 Conclusions 983
References 984
85 Influence of Varying Fully Constrained Circular Boundary Condition Area on Damage Mechanism of GFRP Laminate Under Low Velocity Impact Loading 985
Abstract 985
85.1 Introduction 986
85.2 Numerical Simulation 988
85.2.1 Materials Used 988
85.2.2 Numerical Modeling 988
85.3 Results and Discussion 988
85.4 Conclusion 994
References 994
86 Process Capability Index for Geometrically Distributed Quality Characteristics 996
Abstract 996
86.1 Introduction 997
86.2 Process Capability Index for Geometric Distribution 999
86.2.1 Process Capability Index (Ig) 999
86.2.2 Estimation of Îg 1000
86.2.3 Sampling Properties of Îg 1000
86.3 Optimum Choice of ? 1001
86.4 Typical Applications 1002
86.5 Conclusion 1002
Acknowledgements 1002
References 1002
87 Thermomechanical Analyses of Single Sided Single Pass Submerged Arc Welding of AISI 304 Austenitic Stainless Steel 1004
Abstract 1004
87.1 Introduction 1005
87.2 Experimental Details 1006
87.3 Thermomechanical Analysis 1007
87.3.1 Assumptions for Thermo-Mechanical Analysis [7] 1007
87.3.2 3D Finite Element Model 1007
87.4 Modelling Details 1008
87.4.1 Modelling the Moving Heat Source 1010
87.5 Results and Discussions 1010
87.5.1 Moving Heat Source and Thermo-Mechanical Analysis 1011
87.5.2 Effect of Welding Speed 1012
87.5.3 Analysis of Residual Stress on Top Surface of Plate 1014
87.5.4 Analysis of Residual Stress on Bottom Surface of Plate 1014
87.6 Validation of the Model 1015
87.7 Conclusions 1016
References 1016
88 Stochastic Longitudinal Vibration of Single Walled Carbon Nanorods—A Non Local Elasticity Approach 1018
Abstract 1018
88.1 Introduction 1018
88.2 Nonlocal Parameter and Nonlocal Elastic Model 1020
88.3 Materials 1021
88.4 Methodology 1021
88.4.1 Governing Equation of Motion of Rotating Nanocantilever 1021
88.4.2 Characteristics Equations of Nanorod 1023
88.5 Result and Discussion 1026
88.6 Conclusion 1029
References 1030
89 Finite Element Analysis and Three-Point Bend Testing of Indian Rice Grains with Fissure Effects 1032
Abstract 1032
89.1 Introduction 1033
89.2 Materials and Methods 1034
89.2.1 Detection of Fissures in Rice Grains 1034
89.2.2 Types of Fissures Observed in Rice Grains 1036
89.2.3 Physical Characteristics of Rice Grains 1037
89.2.4 Three-Point Breaking Test 1038
89.3 Results 1039
89.3.1 Finite Element Analysis of Rice Grain (Three-point Breaking Test) 1039
89.3.2 A Typical Graph of Load (N) Versus Deformation (mm) Obtained After Three-point Breaking Test of Rice Grains 1040
89.3.3 Modified Graph of Load (N) Versus Deformation (mm) Obtained After Three-Point Breaking Test of Rice Grains 1043
89.3.4 Graph of Breaking Force Versus no of Fissures for Five Varieties of Rice Grains 1043
89.3.5 Different Breaking Patterns of Rice Grains While Three-Point Breaking Test 1044
89.4 Conclusions 1044
Acknowledgements 1045
References 1045
90 Finite Element Analysis of Potential Liner Failures During Operation in Spherical Pressure Vessel 1046
Abstract 1046
90.1 Introduction 1047
90.2 Materials and Design 1048
90.3 Finite Element Modelling 1049
90.4 Results and Discussion 1053
90.5 Conclusions 1059
References 1060
Index 1061