Manufacturing Technology Today

Mahesh R. Jadhav ¹, Deepak S. Patil ¹, Pramod V. Mulik ¹, Satyashil P. Patil ¹, Pradyumna S. Mane ¹

Affiliations
1 Tatyasaheb Kore Institute of Engineering and Technology, Warananagar, Kolhapur, Maharashtra, IN

Abstract

Al/SiCp is special types of metal matrixes composite which shows excellent mechanical properties and have wide range of application. This paper represents optimum process parameters on Al/SiCp metal matrix composites. For experimental investigation 2024-Al alloy has been used as matrix material and reinforcement as silicon carbide powder (SiCp). A stir casting process was used to developed Al/SiCp metal matrix composite in which 20% weight fraction of SiCp reinforcement has been chosen having 220 mesh size (65μm). The experiment involves turning operation in which cutting tool used as carbide insert having TiN coating. The three process parameter with three levels is considered for experimentation i.e. speed 150 to 250 m/min, feed rate 0.05 to 0.1 mm/rev and DOC 0.5 to 1 mm are under dry state condition. Taguchi L9 orthogonal array methodology was done to decide the optimum process parameter using SN ratio. To identify machinability of Al/SiCp MMC study focused on surface roughness and tool wear response variables. The experimental study showed that the speed is the utmost substantial factor as compared to DOC and feed in case of surface roughness while for tool wear the speed is the most important factor than feed rate and DOC. The signal-to-noise ratio gives optimum conditions as speed of 200 m/min, the feed 0.07 mm/rev, and DOC 0.5 mm for the surface roughness and for tool wear optimum conditions as speed of 150 m/min, the feed 0.07 mm/rev, and DOC 0.75 mm.

Keywords

Al/SiCp MMC, Design of Experiments, Surface Roughness, Tool Wear.

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Pramod V. Mulik ¹, Sourabh S. Jadhav ¹, Prashant J. Patil ¹, Mahesh R. Jadhav ¹

Affiliations
1 Tatyasaheb Kore Institute of Engineering & Technology, Warananagar, Kolhapur, Maharashtra, IN

Abstract

Wheel is important component of any vehicle. Vehicle can run if there is no engine but it cannot run without wheel on road. In power transmission system of vehicle, wheel last element. Wheel is a mechanical device which bear and transfer whole mass of vehicle to road. Wheel is one of the prime components of transporting system hence its analysis is a measure concern. Finding and locating the true compressive stresses is an important and key step in accurate design of the wheel. Because of compressive load Alloy wheel bend and failure usually occurs due to fracture. The present work has been intended for compressive stress analysis at critical section of alloy wheel under static state by different methods. Theoretical analysis has been done using theoretical formulae but it is necessary to carry out experimental analysis of alloy wheel in static condition for better understanding of failure. In order to have a best and reliable design of alloy wheel it is necessary to determine these stresses developed in the alloy wheel. For exact evaluation of failure pattern it is necessary to carry out experimental and finite element analysis of alloy wheel. The paper deals with experimental and finite element analysis of Alloy Wheel. Amount of load coming on wheel is measured and applied on Alloy-wheel by UTM with help of fixture for experimental analysis and by ANSYS for FEA analysis. The wheel is tested for Impact load. The strain gauge along with UTM Machine was used for determining stress at critical section. ANSYS software used for finite element analysis under static state. Accurate Stress coming on front wheel of bike at load and no load condition are calculated. The results obtained from finite element analysis methods were compared with the results of experimental analysis. The results show that the stress calculated by experimental method closer to true value in static state and stress concentration due to load is maximum at intersection area between spoke and rim. It has great scope for further modification in design for stress and failure analysis.

Keywords

Aluminum Alloy Wheel, AL Alloy 201.0-T43, Static Analysis, Impact Load, Strain Gauge, FEA, ANSYS.

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