Advanced Manufacturing and Materials Science (eBook)

Contents 6
1 Effect of Magnetic Field to Reduce Emissions and Improve Combustion Performance in a Spark-Ignition Engine 11
1 Introduction 11
2 Methodology 12
3 Experimental Findings 13
4 Results and Discussions 15
5 Conclusion 18
References 19
2 Experimental Investigation on Reverse Engineering Techniques Employing Response Surface Methodology for Freeform Surfaces 21
1 Introduction 21
2 Experimental Methodology 22
2.1 Component Selection 22
2.2 Responses Measurement 22
2.3 Input Factors and Their Levels 22
2.4 Design of Experiments 23
2.5 Results 24
3 Analysis and Discussion 26
4 Conclusions 29
References 30
3 Effect of Process Parameters and Cryotreated Post Tempered Electrodes on the Radial Overcut of AISI 304 During EDM: A Comparative Study 31
1 Introduction 31
2 Experimental Details 32
3 Results and Discussion 34
4 Microstructural Analysis 37
5 Conclusions 38
References 38
4 Shrinkage Porosity Reduction in Aluminium Alloy A356 Using Simulation Tool with Assisted Rapid Prototyping Casting 39
1 Introduction 39
2 Methodology 40
2.1 3D Modelling, Methoding, Simulation 41
2.2 Part and Mold Box 42
2.3 Feeder Design 43
2.4 Solidification Simulation 43
2.5 Shrinkage Porosities 44
2.6 Pattern Printing 46
3 Experimental Validation 46
4 Conclusions 47
Acknowledgements 48
References 48
5 Finite Element Analysis of Rail Vehicle Suspension Spring for Its Fatigue Life Improvement 49
1 Introduction 49
2 Fatigue Analysis 50
3 Finite Element Analysis for Fatigue Life of Suspension Spring 53
4 Modifications Suggested in Suspension System of Rail Vehicle 55
5 Conclusion 62
References 62
6 Analysis of Optimized Roller Burnishing Parameters Using ANSYS 64
1 Introduction 64
2 Development of Compressive Stresses Over the Work Piece Surface 64
3 Finite Element Analysis 65
4 Conclusion 70
References 70
7 Resistance Spot Welding of Cold Rolled Mild Steel with Filler Metal 71
1 Introduction 71
2 Experimental 72
3 Result and Discussion 74
4 Determination of Filler Metal Quantity for Investigation 78
5 Investigation into Effect of Addition of Filler Metal on Mechanical Properties of Resistance Spot Weldments 79
6 Investigation into the Changes in Nugget Diameter with Addition of Filler Metal in Resistance Spot Weldments 80
7 Summary 80
References 81
8 Study on Squeeze Casting of Aluminum Matrix Composites—A Review 82
1 Introduction 82
2 Squeeze Casting Technique 83
3 Single and Multiple-Reinforced AMC 84
4 Mechanical Properties of AMC with Various Reinforcement 85
5 Tribological Behaviour of al MMCs 86
6 Conclusion 88
References 88
9 Development and Investigation of Microstructure and Mechanical Properties of Cast and Hot Forged AL2014-TIB2 In Situ Composite by Stir Casting 91
1 Introduction 91
2 Experimental Details 92
3 Results and Discussions 93
4 Microstructure Studies 93
5 Brinell Hardness Test 94
6 Density 94
7 Impact Strength 95
8 Tensile Strength 96
9 Conclusion 97
References 97
10 Mechanical Characterization and Comparative Evaluation of the Different Combination of Natural and Glass Fiber Reinforced Hybrid Epoxy Composites 98
1 Introduction 98
2 Materials and Methodology 99
3 Mechanical Testing 99
4 Result and Discussion 102
5 Conclusion 105
References 106
11 Use of Polylactic Acid (PLA) Material for Asymmetric Spur Gear Manufactured by 3-D Printing 107
1 Introduction 107
2 Design & Modeling
2.1 Modelling of Gear in CATIA V5 R20 108
2.2 Process of Drawing 109
3 Fea of Asymmetric Spur Gear 110
3.1 Pre-processing 110
3.2 Post Processing 110
4 Manufacturing of Asymmetric Gear by 3D Printing Method 112
4.1 Material Selection 112
5 Experimental Stress Analysis 115
6 Conclusion 117
References 117
12 Tribological Study of AA2024-B4C Composites Using ANOVA 118
1 Introduction 118
2 Experimental Details 119
2.1 Materials 119
2.2 Sample Preparation 119
2.3 Design of Experiment 119
2.4 Wear Test Procedure 120
2.5 Analysis of Results 121
2.6 Results of Statistical Analysis of Experiments 122
2.7 Analysis of Variance (ANOVA) 123
2.8 Optical and SEM Images of the Wear Tracks 125
3 Conclusions 129
References 130
13 A Review on Effects of Various Parameters in Modulated Tool Path (MTP) Machining 131
1 Introduction 131
2 Parameter Selection Considerations 132
3 Miscellaneous Effects of MTP in Machining 135
4 Limitations to MTP Machining 136
5 Conclusion 138
References 138
14 Machining of Difficult to Cut Materials by Electrochemical Discharge Machining (ECDM) Process: A State of Art Approach 140
1 Introduction 140
2 Various Developments and Statistical Analysis of ECDM Process 142
3 Materials Machined on ECDM Process 145
3.1 Glass 145
3.2 Composites and Ceramics 145
3.3 Steel and Super-Alloys 146
4 Conclusions and Future Scope 147
References 147
15 Development of Super Hydrophobic Surfaces for Oil Spill Separation 151
1 Introduction 151
2 Materials Required 153
3 Experimental Section 154
4 Results and Discussion 155
4.1 Sorption Capacity Studies 155
4.2 Recyclability Studies 156
4.3 Contact Angle Studies 156
4.4 FTIR Analysis 157
4.5 Morphological Studies 160
5 Conclusion 160
References 161
16 FEA Study of the Multiple Structural Orientations on Selective Laser Melted Cobalt Chrome Open-Porous Scaffolds 163
1 Introduction 163
1.1 Design of the Open-Porous Scaffold 165
1.2 Porosity 167
1.3 Finite Element Analysis of Designed Scaffolds 168
1.4 Results and Discussion 168
References 169
17 Effect of Silicon Carbide as Filler Reinforcement on the Mechanical Properties of Glass Fiber Epoxy Composites 171
1 Introduction 171
2 Material Selection and Methodology 172
3 Experimentation 173
4 Results and Discussions 173
4.1 Tensile Properties 173
4.2 Flexural Test 174
5 Conclusions 175
References 176
18 Optimization of Weld Bead Geometry of C263 Nimonic Alloy Electron Beam Weld Joints 177
1 Introduction 177
1.1 Electron Beam Welding 177
1.2 EBW Equipment 177
1.3 Nimonic C263 Alloy 178
2 Literature Survey 179
2.1 Electron Beam Welding 179
2.1.1 Bead Geometry 180
2.1.2 Input and Output Process Variables in EBW 180
2.2 Full Factorial Experiment 180
2.3 Regression Analysis 181
2.4 Genetic Algorithm 181
2.5 Response Surface Methodology 182
3 Experimental Setup 182
3.1 Bead on Plate Welds and Mounting 182
3.2 Regression Analysis 182
3.3 Genetic Algorithm 184
3.4 Response Surface Methodology—Surface Plots 184
4 Results and Discussions 185
4.1 Full Factorial Table for the Experiment 185
4.2 Regression Analysis and RSM Surface Plots 185
4.3 Genetic Algorithm 185
5 Conclusion 189
References 189
19 Development of a System for Simultaneous Rotation of Multiple Stacks of Uranium Dioxide Pellets 191
1 Introduction 191
2 Design Components and Their Specifications 191
3 Live Roller Tray 192
4 Gears 192
5 Worm Gear Design Parameter 192
6 Gear Details 192
7 Gear Specifications/raster= 193
8 Bearings 193
9 Radial Shaft Load Between Bearings 193
9.1 Determination of Basic Load Rating 195
9.2 Bearing Details 195
10 Motor 196
11 Motor Specification 196
11.1 Specification 196
11.2 Motor Gear Head Specification 196
12 Linear Motion Guide 196
12.1 LM Guide Details 196
13 Cantoliver beam 197
14 Pneumatic Cylinders 198
15 Flexible Coupling 198
16 Result and Calculation 198
16.1 Gear Selection Calculation 198
16.2 Motor Power Calculation 199
16.3 ROD 199
16.4 Motor for LM Guide 200
16.5 Calculation for Linear Motion Guide 200
16.6 Imposed Load on Nut Block 200
16.7 Combined Radial and Thrust Loads 201
16.8 Rated Life of Ball Bearing 201
16.9 Bearing Calculation 201
17 Conclusion 202
References 202
20 Investigation on the Influence of Nano Structured Zirconia Coating on the Corrosion Inhibition of SS 304 Stainless Steel 203
1 Introduction 203
2 Materials and Methods 204
2.1 Experimental Design 204
2.2 Nano ZrO2 Coating 205
2.3 Coating Surface Characterization 205
2.4 Evaluation of Corrosion Resistance 207
2.5 Statistical Analysis 207
3 Results and Discussion 207
3.1 Structural Analysis of the Coating 207
3.2 Electrochemical Measurements 208
3.3 Statistical Analysis 210
4 Conclusions 211
References 211
21 Size Effect in Mechanical Behavior of Nb Microwires 213
1 Introduction 213
2 Background 214
2.1 Size Effect in Polycrystals 214
2.2 Cu–Nb Composite 214
3 Experimental Materials and Procedure 215
3.1 Materials 215
3.2 X-Ray Diffraction 216
3.3 Tensile Testing 216
4 Results and Discussions 217
4.1 XRD 217
4.2 Tensile Test 218
4.3 Fracture Surface Analysis 218
5 Conclusions 220
References 220
22 Modeling and Predicting the Mechanical Properties of Nano Clay Dispersed Natural Fiber Hybrid Intra-ply Woven Fabric Composite by Using Response Surface Methodology 221
1 Introduction 221
1.1 Experiment Details 222
1.1.1 Materials and Methods 222
1.1.2 Preparation of Composite Specimens 222
1.1.3 Testing of Composite Specimens 222
1.2 BB Parameters and Levels 223
1.3 Design of Experiments 223
2 Results and Discussion 223
2.1 Statistical Analysis 223
2.2 Mathematical Model for Tensile, Flexural and Impact Strength 226
2.3 BB Parameters and Their Influence 226
3 Optimization and Validation 228
4 Conclusion 231
References 233
23 Design and Evaluation of Al Hybrid Composite for Connecting Rod 234
1 Introduction 234
2 Design of Connecting Rod 235
2.1 Dimension of I Division 235
2.2 Dimension of Crank Pin and Piston Pin 236
3 Experimental Details 236
4 Real Time Analysis and Its Influence on the System 238
5 Result and Discussions 238
5.1 Evaluation of Mechanical Properties 238
5.1.1 Tensile Strength 238
5.1.2 Impact Strength 239
5.1.3 Hardness Test 239
5.1.4 Density Test 239
5.2 Metallographic Analysis 240
5.2.1 SEM Analysis 240
5.2.2 Micro Examination 240
5.3 Dynamic Analysis Results 241
6 Conclusion 241
References 241
24 Literature Review of Hard Turning and It’s Thermal Aspects 243
1 Introduction 243
2 What Is Hard Turning? 243
3 Cutting Tool Materials 244
4 Importance of Temperature Study 244
5 White Layer 244
6 Temperature Measurement 245
7 Heat Sources in Machining 247
8 Effect of Different Cutting Parameters 247
9 Insert Coating Effects 248
10 Conclusion 251
References 251
25 Photocatalytic Degradation of Rhodamine-B by Advance Oxidative Process Using Electrochemically Synthesized ZnO–V2O5 Nanostructures 253
1 Introduction 253
2 Materials and Methods 255
3 Characterization 255
4 Results and Discussion 256
5 Photocatalytic Procedure 257
6 Summary 259
Acknowledgements 260
References 260
26 Facile Synthesis and Characterisation of Nanocomposite Doped Chitosan—Polystyrene Polymer Blends 262
1 Introduction 262
2 Materials and Methods 264
2.1 Preparation of Polymer Bends 264
2.2 Synthesis of ZTiO Nanoparticles 265
3 Result and Discussion 266
3.1 FT-IR Analysis 266
3.2 Powder Diffraction Study 267
3.3 Surface Morphology Studies 268
4 Thermal Analysis 269
5 Conclusion 269
Acknowledgements 269
References 270
27 Influence of EDM Control Factors for Aluminium Hybrid Composites 271
1 Introduction 271
2 Methodology 272
2.1 Manufacture of Hybrid Composite 272
2.2 Control Factors and Machining Characteristics 273
2.3 Conduction of Experiments 273
3 Result and Discussion 275
3.1 SN Ratio for Machining Characteristics 275
3.2 Effect of Control Factors on Machining Characteristics 276
4 Conclusions 279
Acknowledgements 279
References 279
28 Thermal Conductivity of Silicon Nitride Reinforced Al6061 Based Composites 281
1 Introduction 281
2 Experimental Details 283
2.1 Synthesis of Composite and Forging 283
2.2 Thermal Conductivity Test 283
3 Results and Discussions 284
3.1 Microstructure 284
3.2 Thermal Conductivity 284
4 Conclusion 286
References 287
29 Grinding of Inconel 718 Using Soap Water Jet and Liquid Carbon Dioxide 288
1 Introduction 288
2 Experimental Procedure 290
3 Results and Discussions 291
4 Conclusion 294
References 294
30 Mechanical Properties of Al7075-SiC-TiO2 Hybrid Metal Matrix Composite 296
1 Introduction 296
2 Experimental Procedure 297
3 Results and Discussions 299
4 Hardness 299
5 Tensile Test 300
6 Conclusions 301
References 301
31 Study on Machinability of Aluminum Alumina Metal Matrix Composites 303
1 Introduction 303
2 Experimental Setup 304
3 Result and Discussion 307
3.1 Cutting Forces 307
3.2 Chip Formation 307
4 Conclusions 309
References 309
32 Performance Evaluation of Cutting Parameters for Surface Roughness & Power Consumption in Turning of 904L Stainless Steel Using Vegetable Oil Based Cutting Fluids
1 Introduction 310
1.1 Cutting Fluids 310
2 Experimentation Details 311
2.1 Selection of Workpiece Material & Tool
2.2 Vegetable-Based Cutting Fluids 312
3 Analysis of Variance (ANOVA) 314
3.1 ANOVA for Surface Roughness 315
3.2 ANOVA for Power Consumption 315
4 Result & Discussion
4.1 Surface Roughness 316
4.2 Power Consumption 317
5 Conclusion 317
References 317
33 Experimental Study on the Effects of Bio Ethanol Petrol Blends in a Spark Ignition Engine: Performance Analysis 319
1 Introduction 319
2 Materials and Methods (Preparation of Bio Ethanol from Rice Water Waste) 321
2.1 Preparation of Rice Water Starch 321
2.2 Distallation of Rice Water Starch 321
3 Experimental Procedure and Data Acquisition 322
3.1 Test on Engine Without Inlet Air Heating 323
3.2 Test on Engine with Inlet Air Heating 323
4 Results & Discussion
5 Conclusion 328
References 328
34 An Experimental and Theoretical Study on the Effect of Microstructure on the Tensile Behavior of Polylactide Nano Composites 329
1 Introduction 329
2 Characterization Techniques 330
3 Materials 331
4 Nanocomposite Preparation 331
5 Morphology 332
6 Density 334
7 Mechanical Properties 335
8 Electrical Simulation 339
9 Conclusions 339
Acknowledgements 340
References 340
35 Oxidation and Hot Corrosion Performance of Al2O3-40%TiO2 Coating on Nickel Based Superalloys at 800 °C 341
1 Introduction 341
2 Experimental Procedure 342
2.1 Development Coatings 342
2.1.1 Substrate Material, Coating Powders 342
2.1.2 Detonation-Gun Technique 343
2.2 Oxidation Test 343
2.3 Hot Corrosion Test 344
3 Result 344
3.1 Visual Observations for Oxidation 344
3.2 Cyclic Oxidation in Air 345
3.3 Visual Observations for Hot Corrosion 346
3.4 Cyclic Hot Corrosion in Molten Salt 346
3.5 SEM Analysis 348
4 Conclusions 349
References 349
36 Numerical Simulation of Crack Propagation in Double Torsion Test 351
1 Introduction 351
2 Analytical Approaches 352
3 Extended Finite Element Modelling 353
4 Results and Discussion 354
5 Summary 358
Acknowledgements 358
References 358
37 Structural and Dielectric Properties of Polycrystalline Calcium Copper Titanate (CCTO) 360
1 Introduction 360
2 Experimental and Characterization Details 361
3 Result and Discussion 362
3.1 XRD Analysis 362
3.2 HRSEM and EDX Analysis 363
3.3 Dielectric Constant 363
3.4 Dielectric Loss 365
3.5 Impedance Analysis 366
3.6 Ac Conductivity 367
4 Conclusion 368
References 368
38 Investigation on Mechanical and Wear Properties of Aluminium Based Metal Matrix Composite Reinforced with B4C, Gr and Fly Ash 370
1 Introduction 370
2 Materials and Methodology 371
3 Results and Discussion 372
4 Conclusion 376
References 376
39 Aluminium Carbon Nanotube Composites—A Review on Latest Approaches 377
1 Introduction 377
2 Literature Review 378
3 Conclusion 381
References 382
40 Effect of Mechanical and Metallurgical Analysis of Magnesium and Aluminium Alloys Using Diffusion Bonding 384
1 Introduction 384
2 Experimentation 385
3 Results and Discussion 387
3.1 Mechanical Testing 387
3.2 Metallurgical Testing 388
4 Conclusion 389
Acknowledgements 389
References 389
41 Operation Sequence Dependent Part Family Formation for Reconfigurable Manufacturing System (RMS) 391
1 Introduction 391
2 Literature Review 392
3 Part Family Formation for RMS 393
3.1 Operation Sequence 393
3.2 Calculation of BMIM 394
4 Conclusion 397
References 398
42 Modeling and Analysis of Tool Wear Based on Cutting Force and Chip-Tool Interface Temperatures in Turning 399
1 Introduction 399
2 Experimental Procedure 401
3 Experimental Results and Mathematical Modeling 402
3.1 Relationship Between Cutting Forces and Tool Wear Rate 402
3.2 Relationship Between Chip-Tool Interface Temperature and Tool Wear Rate 402
3.2.1 Polynomial Models 405
3.2.2 Maximum Machining Ratio 406
4 Conclusions 407
References 407
43 On the Mechanical and Microstructural Properties of Novel A356/Kevlar Surface Composite Fabricated via Friction Stir Processing 409
1 Introduction 409
2 Experimental Procedure 410
3 Results and Discussion 412
3.1 Microstructure 412
3.2 Tensile Strength 413
3.3 Microhardness 415
4 Conclusions 416
References 416
44 Production of Biodiesel from High FFA Non-edible Nahar Oil and Optimization of Yield 418
1 Introduction 418
2 Materials and Methods 419
3 Characterization of Nahar Seed Oil 419
4 Results and Discussion 420
4.1 Biodiesel Production 420
4.2 First Stage Acid Esterification 421
4.3 Second Stage Alkali Catalyzed Transesterification 422
5 Evaluation of Fuel Properties 423
6 Conclusion 425
Acknowledgements 425
References 426
45 Microstructural Evaluation, Tribological Behavior and Mechanical Properties of Cu–Ni Alloy After Addition of Chromium Under Spinodal Conditions 427
1 Introduction 427
2 Experimental Procedure 428
3 Results and Discussion 429
3.1 Microstructural Evolution 429
3.2 Coarsening Behavior 430
3.3 Hardening Behavior 430
3.4 Tribological Behavior with Cr Content 431
4 Conclusions 432
Acknowledgements 432
References 433
46 Development of Fire Resistant Polymeric Nano Composites Using Plasma Modified Calcium Silicate 434
1 Introduction 434
2 Experimental 435
2.1 Materials 435
2.2 Plasma Modification 435
2.3 Preparation of PP/(Unmodified/Modified) Nano Calcium Silicate Composites 435
3 Characterization 436
3.1 FTIR Spectroscopy 436
3.2 Tensile Test 436
3.3 Scanning Electron Microscopy 436
3.4 Limiting Oxygen Index 436
3.5 Horizontal Flammability 436
4 Results and Discussion 437
4.1 FTIR Spectroscopy 437
4.2 Tensile Tests 438
4.3 SEM 438
4.4 LOI 438
4.5 Horizontal Flammability 439
5 Conclusion 440
References 441
47 Welding Metallurgy of Corrosion Resistant 21st Century Ni-Based Superalloy 686 442
1 Introduction 442
2 Problem Statement and Critical Review of the Work Done 444
3 Conclusions 447
References 447