Manufacturing Technology Today

B. Satheesh Kumar ¹, G. Padmanabhan ², P. Vamsi Krishna ³

Affiliations
1 Department of Mechanical Engineering, N.B.K.R. Institute of Science & Technology, Vidyanagar, IN
2 Department of Mechanical Engineering, S. V. University College of Engineering, Tirupati, IN
3 Department of Mechanical Engineering, National Institute of Technology, Warangal, IN

Abstract

This study focuses on evaluating the influence of different proportions (5%, 10% and 15%) of extreme pressure (EP) additive in vegetable oil based cutting fluids (canola, coconut and sesame oils) during turning of AISI 1040 steel. The process parameters considered in this work are type of cutting fluid, proportion of EP additive, cutting speed and feed rate. The influence of these process parameters on performance characteristics viz. cutting force (F_c), cutting tool temperature (T), tool flank wear (V_b) and surface roughness (R_a) is investigated by signal-to-noise ratio (S/N) and analysis of variance (ANOVA) from the experimental data developed by using L₂₇ orthogonal array. The results indicated that cutting fluid has significant influence on tool flank wear and surface roughness whereas, cutting speed has significant influence on cutting force and cutting tool temperature.

Keywords

Turning, Vegetable Oils, Extreme Pressure Additive, Taguchi Method, Regression Analysis.

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A. L. S. Brahma Reddy ¹, B. Satheesh Kumar ², G. Padmanabhan ¹

Affiliations
1 Dept of Mech Engg, S. V. University College of Engineering, SV University, Tirupati, IN
2 Dept of Mech Engg, N.B.K.R. Institute of Science & Technology, Vidya Nagar, SPSR Nellore Dt., IN

Abstract

Coolants are used during machining for variety of reasons such as improving tool life, reducing workpiece thermal deformation and surface roughness. Conventional cutting fluids are non-biodegradable which results in environmental pollution and danger to human health, hence there is a growing demand for biodegradable material thus opening an avenue for vegetable oils as an alternative to conventional cutting fluids. In this context, the present work focuses on environmental friendly cutting fluids such as vegetable oil based cutting fluids (VBCFs). The objective of present work is to determine the influence of canola based cutting fluid with Sulphur based extreme pressure (EP) additive on machining performance. Forces, cutting tool temperature and surface roughness are measured during turning of AISI 1040 steel with CNMG120408 NC3220 coated carbide tool. Machining performance of canola based cutting fluid with different proportions of EP additive in its mixture is analysed.

Keywords

Turning, AISI 1040, EP Additive, Canola Based Cutting Fluid.

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K. Nageswara Reddy ¹, G. Padmanabhan ²

Affiliations
1 Dept. of Mechanical Engineering, Sri Venkateswara University, Tirupati, Andhra Pradesh, IN
2 Dept. of Mechanical Engineering, Sri Venkateswara University, Tirupati, Andhra Pradesh

Abstract

In present days, Job Shop Scheduling Problem (JSSP) is one of the most important areas of research. JSSP is a Non - Deterministic Polynomial hard combinatorial optimization problem. In JSSP, there are 'n' jobs and 'm' machines and each job has its own predefined Operation Sequence and processed in that order. Many Metaheuristics such as Genetic Algorithm (GA), Simulated Annealing (SA), Artificial Immune System (AIS), Artificial Bee Colony (ABC) and Differential Evolution (DE) had been applied for a few years in the past to find an Optimal Operation Scheduling with minimum Makespan. TLBO is a recently developed random population optimization technique for solving scheduling problems. It has two phases namely, Teacher Phase and Learner Phase. Teacher phase indicates learning something from a teacher and Learner phase indicates learning by self study. TLBO performance can be assessed by solving 10 Taillard benchmark problems at different number of iterations and population size, and comparing the results with AIS and DE. The results show that TLBO is an effective evolutionary algorithm to develop an Optimal Operations Scheduling.

Keywords

Job Shop Scheduling, Makespan, Taillard’s Benchmarks, TLBO, Artificial Immune System, Differential Evolution.

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P. Vaidehi ¹, G. Padmanabhan ¹

Affiliations
1 Department of Mechanical Engineering, S V University College of Engineering, Tirupati, IN

Abstract

In manufacturing environment, unpredictable market changes results in modifications of part design and engineering specifications trigger frequent and costly fluctuations in process plans, setups, and machinery. Traditionally, process planning and scheduling were carried out in a sequential way. These approaches have become the obstacles to improve the productivity and responsiveness of the manufacturing system. Therefore, the integrated process planning and scheduling was introduced for significant improvements in manufacturing efficiency through eliminating or reducing scheduling conflicts. This paper presents Cuckoo Search (CS) based integrated process planning and scheduling which according to prescribed multi objectives such as minimizing process time, process cost, make span time and tardiness, could swiftly search for the optimal process plan and scheduling. The proposed methodology demonstrated with case study to validate its effectiveness and feasibility. It has proved from comparative study that the present method is flexible and robust.

Keywords

Integrated Process Planning and Scheduling, Precedence Relationship, Cuckoo Search, Makespan, Tardiness.

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P. Ravi Kumar ¹, G. Padmanabhan ¹

Affiliations
1 Department of Mechanical Engineering, Sri Venkateswara University, Tirupati, Andhra Pradesh, IN

Abstract

In this paper single point cutting tool is modeled using PTC parametric Creo 3.0 and exported to HyperMesh software (OptiStruct) for the analysis of deflection and stress for different tool angles at constant loading and best tool angles are identified from the analysis. Afterwards a model of single point cutting tool is developed for best angles. For verification of results, physical models of initial geometry and final geometry are prepared by grinding angles on HSS tool bits and several cutting experiments are performed at different cutting conditions. Results show that the final geometry has shown less deflection than initial geometry. Hence, it is considered as optimal geometry. This geometry is further modelled and its volume is minimized within the allowable deflection limit using topology optimization method in HyperMesh OptiStruct software.

Keywords

Single Point Cutting Tool, Topology Optimization, HyperMesh, OptiStruct & HyperView.

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B. Swaranalatha ¹, G. Padmanabhan ², S. B. V. S. P. Sastry ³

Affiliations
1 S V University College of Engineering, Tirupati, IN
2 Department of Mechanical Engineering, S V University College of Engineering, Tirupati, IN
3 Vizag Steel Plant, IN

Abstract

Scheduling of Steel Melt Shop is a Non-deterministic Polynomial optimization problem, which is one of the most substantial areas of research survey in Integrated Steel Industry. In SMSSP there are n No. of jobs and m No. of machines where each job is processed on every machine in predefined operation sequence. Many traditional and Non - traditional methods such as First cum First Serve, Shortest Job First, Earliest Deadline First, Mixed Integer Linear Programming Model, Integrated Production Process, Ant Colony Optimization, Non Linear Optimization, Linear Programming Model, Lagrangian Relaxation Methods had been applied for some years in the past to find an accurate optimal operation scheduling with minimum Operation Time. The major contribution of this work has been the implementation of an effective scheduling method based on Teaching Learning process for solving SMSSP. TLBO is a recently developed optimization technique based on random population for solving any type of scheduling problem. It consists of two phases namely, Teacher Phase and Learner Phase. Teacher phase signify learning something from a teacher and Learner phase tells about learning by self study. TLBO performance can be attained by solving Scheduling of Steel Melt Shop by minimizing Operation time, Reduction of Tardiness and maximization of number of charges at each stage of SMS at population size of 20,39,1132 charges. The present work is a realistic case study and has proved by the results thus obtained show that TLBO is an active evolutionary algorithm to prosper a best operations scheduling.

Keywords

TLBO, Steel Melt Shop Scheduling Problem (SMSSP), PBX and VNS.

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B. Narayana Reddy ¹, P. Hema ¹, G. Padmanabhan ¹

Affiliations
1 Department of Mechanical Engineering, Sri Venkateswara University, Tirupati, IN

Abstract

Laser Beam Welding technique is applied to conduct experiments on joining of dissimilar metals, AISI 4130 and AISI 310 steels so as to study the influence of process parameters on mechanical properties of joints. Taguchi L₂₅ Orthogonal Array is selected to join 2mm thick dissimilar steels by varying Laser Power, Welding Speed, Beam Incident Angle, Focal Point Position and Focal Length. Output results of Ultimate Tensile Strength (UTS) and Impact Strength (IS) are measured. ANOVA is carried out to obtain the levels of influence of process parameters and statistical evolution of the results. TOPSIS optimization is applied to transmogrify a multi-criteria optimization problem into a single-criterion problem, so as to obtain optimal combination of process parameters of Laser Beam Welding. Then UTS and IS are maximised. Results have revealed that the proposed method is appropriate for solving multi-criteria optimization of process parameters.

Keywords

Laser Beam Welding, Ultimate Tensile Strength, Impact Strength, Analysis of Variance, TOPSIS.

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