Manufacturing Technology Today

Deepjyoti Baruah ¹, M. Chandrasekaran ²

Affiliations
1 North Eastern Regional Institute of Science and Technology (NERIST) (DU) Nirjuli, Arunachal Pradesh, IN
2 Mechanical Egineering. Dept., North Eastern Regional Institute of Science and Technology (NERIST) (DU) Nirjuli, Arunachal Pradesh, IN

Abstract

Optimization of machining process is one of the most widely investigated areas of research due to its importance for the need of economic production of components for global competiveness. In recent time it has been brought to a new dimension with the application of computer and internet technology by connecting different manufacturer and customers globally on wire. Recently, cloud computing has evolved from the web based technologies find application in every field. In this work, an attempt is made for developing cloud based machining optimization system (CBMOS) for sharing machining information among different cloud users. The system facilitates to retrieve the optimum process parameters from the cloud data base (created with virtual machine and MySQL) and display it on users' browser. The cloud user may implement it in their system and may give their feedback. The system can be easily accessed with the help of web browsers such as Internet Explorer, Google Chrome, Mozilla Firefox, etc.

Keywords

Machining, Optimization, Cloud Data Base, Internet.

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Shiv Sharma ¹, M. Chandrasekaran ¹, R. Thirumalai ²

Affiliations
1 Mechanical Engineering Department, NERIST, Nirjuli, Arunachal Pradesh, IN
2 Mechanical Engineering Department, SNS College of Technology, Coimbatore, IN

Abstract

In this work a new approach of multi response optimization for turning process in Inconel 718 using Taguchi based desirability function analysis (TDFA) is presented. Experiments based on Taguchi L₉ orthogonal array (OA) was considered in this study. Three machining parameters viz., cutting speed (v), feed rate (f) and depth of cut (d) are optimized by multi response considerations namely surface roughness (R_a), tool wear (VB), tool life (TL), cutting force (F), cutting power (P) and material removal rate (MRR). The approach obtains composite desirability value for the multiple response using individual desirability values evaluated. The optimum parameters are obtained based on composite desirability value. It is observed that the combination of turning parameters as v = 35 m/min, f = 0.1 mm/rev and d = 1.25 mm (i.e., v₂-f₁-d₂) are obtained as optimal parameters producing R_a, VB, TL, F, P, and MRR respectively as 0.46128 μm, 0.1140 mm, 21.8296 min, 770.135 N, 4.89497 kW, 4375 mm³/min. Confirmation test of the predicted result shows the maximum % error is 6.67.

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Santosh Tamang ¹, M. Chandrasekaran ¹

Affiliations
1 Dept. of Mech. Engg, North Eastern Regional Institute of Science and Technology (NERIST), Nirjuli, Arunachal Pradesh, IN

Abstract

Metal matrix composites (MMCs) having aluminum (Al) in the matrix phase and particulates/particles of silicon carbide (SiCp) in reinforcement phase have been found in common use for making components in manufacturing industries with various operations viz., turning, milling, grinding, and drilling as well as number of non conventional machining processes. Recently the machinability study of composite machining has attracted researchers. Surface roughness (R_a) and tool flank wear (VB) are two important parameters are studied. Researchers’ employed numbers of conventional and soft computing based computational techniques for modelling and optimization machining process with are single/multiple optimization objective. In the present work, an attempt has been made to obtain optimum process parameters in turning Al/SiCp using carbide tool using Taguchi grey relational analysis. Cutting speed (v), feed rate (f) and depth of cut (d) are three machining parameters on which R_a and VB depends. In the present investigation Taguchi L₉ orthogonal array of experimental design were considered and grey relational analysis is used for obtaining optimal parameters of the multi response problem. The predicted result shows that the surface roughness and tool wear at optimum cutting conditions found as 4.08 μm and 0.72mm respectively, resulting the percentage of error as 1.03% for R_a and 5.5% for VB. The method does not require mathematical computation and can be applied easily for multi response problems.

Keywords

Multi Response Optimization, Surface Roughness, Tool Wear, Turning, Taguchi Grey Relational Analysis, MMCs.

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M. Chandrasekaran ¹, Amresh Kumar ², Rajeev Kumar Gupta ², Gauri Shankar ², O. P. Roy ², Narendra Kumar Rana ¹

Affiliations
1 Dept. of Mechanical Engg., North Eastern Regional Institute of Science and Technology (NERIST), Nirjuli, Arunachal Pradesh, IN
2 Dept. of Electrical Engg., North Eastern Regional Institute of Science and Technology (NERIST), Nirjuli, Arunachal Pradesh, IN

Abstract

Pneumatic system and its control are commonly used in industrial automation and rationalisation. The automation, integrated control system and mechanism are becoming popular in every field and packaging industries are no exception. Micro computer based control mechanism, control sensor, measurement and mechanical drives, and pneumatic/hydraulic actuation system together forms highly flexible form of automated control in the field of mechatronics. In this work, the feasibility design of a Programmable Logic Controller (PLC) based box segregation system is aimed to segregate boxes of different sizes/heights moving on a flat bed conveyor. Proximity sensor is used to distinguish box sizes and sends signal to the PLC controller which in turn energizes solenoid controlled DC value to actuate pneumatic actuator system to segregate the boxes. The system developed is much of industrial importance and can be modified for different other applications too.

Keywords

Pneumatic System, PLC, Sensors, Box Segregation.

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S. Kannan ¹, S. Sendhil Kumar ¹, M. Chandrasekaran ¹

Affiliations
1 Department of Mechanical Engg., Rajalakshmi Engg. College, Chennai, IN

Abstract

Automobile body is collective assembly of several assembly parts. Function of assemblies is related to one another assembly parts. Assemblies and its actions are derived from the basic mechanical chain mechanisms. These relative motions are most important term to achieve the required function. Precision and accuracy is the sound term of assembly parts for automobile body. Over all efficiency of automobile body function may contributed by even a small element of the assembly parts. Failure of small element in a part may affect function of the body system. Every part of the assembly should meet the basic requirement like strength. There should not be any failure of the product during its entire life time, what reliability engineering talks about. Consideration must be tune to the over all life time function not only at the period of launching. Achieving those strategies can be possible in many ways. Factors to be consider for choosing the right way to meet the requirement which may balance functional constrain and operational conditions. Optimization is term which establishing the balancing of functional constrain and operational condition. This paper deals about the optimization of automobile body part which fails during its function. CAD system made this project simpler to achieve optimized solution for the problem.

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M. Chandrasekaran ¹, S. Kannan ¹, P. Pandiaraj ¹

Affiliations
1 Dept. of Mechanical Engg., Rajalakshmi Engg. College, Chennai, IN

Abstract

The 'part mismatch problem' is one of the general quality, problems in automobile assembly production line. Part mismatch affects the production by quality rejection, rework, down time etc. Most of the time part mismatches leads to major functional problem at the assembly section. Kaizen is a method which can control and eliminate such part mismatch problems in automobile assembly production. In this paper, the applicability of kaizen for quality improvement in the production of automobile assemblies with a case study is illustrated. By using kaizen, automobile assembly production line quality problem is solved. Case study about the bracket mismatch leads to brake hose mounting nut offset. This was the major problem of the under body assembly. Step by step kaizen procedure followed to solve the problem by data collection, ischolar_main cause analysis, selection of best solution method, corrective action, documentation and continuing improvement. Kaizen implementation for solving the problem also reflects in the improvement of quality, cost reduction, delivery to customer, morale of the employees and safety. Kaizen was found to be an effective process for improving the quality and productivity. Practical implications of Kaizen can improve the productivity by downtime reduction and quality improvement.

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Dipankar Bose ¹, M. Chandrasekaran ¹, Santanu Paul ¹, Proshenjeet Baruah ¹

Affiliations
1 Department of Mechanical Engineering, North Eastern Regional Institute of Science and Technology (NERIST), Nirjuli-791 109, IN

Abstract

Pneumatic circuits are designed by various methods. Earlier circuits were designed based on intuitive method which mostly fulfil only the operational requirements. Control aspects and systematic design are evolved by using analytical techniques like Cascade, Karnaugh - Veitch (K-V) diagram, etc., and being used nowadays. In the present investigation, three above methods are analyzed for the component assembly problem. Different features like cost, control aspects, fault diagnosis, etc., are compared and K-V diagram methodology is found more appropriate in many respects, selected for circuit design.

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M. Chandrasekaran ¹, C. Murali Krishna ¹, Menguzelie Suhu ¹, Arenbo Peter ¹

Affiliations
1 Department of Mechanical Engineering, North Eastern Regional Institute of Science and Technology, Nirjuli 791 109, IN

Abstract

The present paper describes the intra cell layout design of cellular manufacturing system with an objective of makespan minimization through reduction in total transportation distance (TTD). For the present investigation, a hypothetical problem of 15 machines and 15 parts are formed into three machine cells and three corresponding part families. Three types of layout viz. In-line, Square and U-shape are considered for layout design. Variation in part mix in terms of volume of production is analyzed to identify most probable part mix to be considered for layout design. An algorithm/Source code is developed in C++ to evaluate the layout arrangement of the system. Results are shown that using less number of machines in in-line layout is more advantageous followed by square and U-shape.

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