Manufacturing Technology Today

S. P. Leo Kumar ¹, J. Jerald ¹, S. Kumanan ¹, R. Nargundkar Aniket ¹

Affiliations
1 Department of Production Engineering, National institute of Technology, Tiruchirappalli, IN

Abstract

This paper presents an experimental study on effect of micro end milling process parameters on surface roughness with PMMA (Poly methyl methacrylate) as work piece material. It has wide applications in micro features and micro parts fabrication for automobile, aerospace, biomedical industries. Effect on surface finish during micro end milling on PMMA with 0.7mm carbide end mill tool was analyzed in this work. Response Surface Methodology (RSM) technique used for design of experiments for the factors feed rate and spindle speed. Experiments were carried out using multipurpose micro machine tool. Analysis was carried out with surface roughness value measured using surface roughness tester and inferences were made.

Keywords

Micro End Milling, PMMA, Response Surface Methodology, Surface Roughness.

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S. P. Leo Kumar ¹, J. Jerald ¹, S. Kumanan ¹, Shashank Pansari ¹

Affiliations
1 Dept of Production Engg, National Institute of Technology, Tiruchirappalli, IN

Abstract

This paper presents an experimental study on effect of micro drilling parameters on burr formation in C360 brass. Burr formation during machining is unacceptable in nature. Hence its dominant parameters are studied in this work. Micro drilling with 0.8mm HSS drill on C360 brass was performed. Response Surface Methodology (RSM) is used for design of experiments for the factors such as feed rate and spindle speed and experiments were carried out using multipurpose micro machine tool. Burr formation analysis was carried out using Scanning Electron Microscope (SEM) and inferences were made.

Keywords

Micro Drilling, Burr Formation, Response Surface Methodology, Scanning Electron Microscope.

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R. Ravi Kumar ¹, P. Asokan ¹, J. Jerald ¹, M. Shanthi ¹

Affiliations
1 Dept. of Production Engg., National Institute of Technology, Tiruchirappalli, IN

Abstract

Electro Chemical Machining (ECM) is a Non-traditional machining technique that has been used in the production of dies and it is originally as signed for manufacturing complex shaped components in defense and aerospace applications. The most important performance measures in ECM are material removal rate (MRR) and surface roughness (R_a). In this work, experiments were performed to determine parameters affecting material removal rate and surface roughness. The data obtained for performance measures have been analyzed using the design of experiments method. A considerably profound equation is obtained for the MRR and R_a using current, gap voltage, flow rate and gap setting parameters. SPSS software and C programming have been used to optimize the machining parameters of ECM.

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J. Jerald ¹, P. Asokan ², R. Saravanan ³, A. Delphin Carolina Rani ⁴

Affiliations
1 School of Mechanical Engg., SASTRA (Deemed University), Thanjavur-613 402, IN
2 Dept. of Production Engg., National Institute of Technology, Trichy-625 015, IN
3 Dept. of Mechanical Engg., Kumaraguru College of Engg., Coimbatore-641 006, IN
4 Dept. of Computer Science and Engg., PR Engg. College, Thanjavur-613 403, IN

Abstract

Flexible Manufacturing System (FMS) is a highly automated system consisting of computer controlled machines and peripherals combined with intensive material and dataflow. Extensive research has been conducted to design and solve the operational problems of FMS, but many of the problems still remain unsolved. In particular, the scheduling task, the control problem during the operation, is of importance owing to the dynamic nature of the FMS such as flexible parts, tools and Automated Guided Vehicle (AGV) routings. Owing to its highly automated nature, a typical FMS has a high investment cost. Hence, it becomes necessary to identify the most efficient scheduling rules at the operating stage. Automated Guided Vehicles (AGVs) are among various advanced material handling techniques that are finding increasing applications today. They can be interfaced to various other production and storage equipment and controlled through an intelligent computer control system. Simultaneous scheduling can be defined as the scheduling of machines and a number of identical AGVs in a FMS. In this paper, simultaneous scheduling of parts and AGVs is done for a particular type of FMS environment by using a nontraditional optimization technique called Genetic Algorithm (GA). The problem considered is a large variety problem and objective is combined objective (minimizing penalty cost and minimizing machine idle time). The results are found and conclusions are presented.

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K. Thangadurai ¹, J. Jerald ¹, P. Satheesh ¹, R. Saravanan ²

Affiliations
1 School of Mechanical Engineering, Shanmugha Arts, Science, Technology & Research Academy, Thanjavur - 613 402, IN
2 Department of Mechanical Engineering, J.J. College of Engineering, Tiruchirappalli-620 009, IN

Abstract

Wire Electric Discharge Machining process is one of the important nontraditional machining process which is used to machine hard materials, complex shapes and contours which are difficult by conventional methods. In this paper Particle Swarm Optimization (PSO) and Memetic Algorithm (MA) based optimization procedures have been developed to optimize machining parameters viz machining speed, pulse on time, pulse off time, and peak current by using two response equations for material removal rate and surface roughness. The objective function considered for optimization is maximization of material removal rate and minimization of surface roughness. Here objective function is solved by taking combined objective function (weightage given 50% to material removal rate and 50% to surface roughness) i.e. minimization of material removal rate and surface roughness. The output results o f these two algorithms are compared.

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