Manufacturing Technology Today

S. John Alexis ¹, M. Dinesh ²

Affiliations
1 Department of Mechanical Engineering, Sri Krishna College of Engineering and Technology, Kuniamuthur, Coimbatore-641 008, IN
2 Department of Mechatronics Engineering, Sri Krishna College of Engineering and Technology, Kuniamuthur, Coimbatore-641 008, IN

Abstract

ECM is a very potential non-traditional machining process that is being widely accepted to machine conductive material of any hardness. The manufacturers are exploiting this process for the past one-decade. This paper mainly deals with combined ECM processes, which utilize the benefit of two, or more non-traditional machining process combined with ECM process. The process parameters involved in the combined process are dealt briefly.

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S. John Alexis ¹, G. Chandramohon ²

Affiliations
1 Department of Mechanical Engineering, Sri Krishna College of Engineering and Technology, Coimbatore-641008, IN
2 Department of Production Engineering, PSG College of Technology, Coimbatore-641004, IN

Abstract

One of the aims of the sheet metal processing industry is the minimization of the costs and the optimization of its product concerning weight, strength characteristics and rigidity. In conventional deep drawing process, the mechanical force of the punch imparts non-uniform strain distribution and the cost of tooling, (i.e., the cost involved in the die and punch) is also too high while drawing complex shapes. Another drawback of the conventional process is that, it cannot be used for forming of tubes. Internal high pressure stretching, otherwise called as hydro forming uses directly the hydrostatic pressure of the fluid media to form the sheet metal. The detailed studies on the existing development have shown that this technique can be used for forming complex parts with increased strength-to-weight ratio due to work hardening and help reducing the cost involved by part consolidation and no punch is required. In this paper an attempt has been made to find the pressure required for drawing sheet metal to the required shape, size and depth by stretching it using high pressure oil and consolidates the parameters available. It is found that internal high pressure forming of sheet results in a much larger draw depth compared to forming using mechanical punch obtained through empirical relation.

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S. John Alexis ¹, Karayil Srikanth Rajan ²

Affiliations
1 Department of Mechanical Engg., Sri Krishna College of Engg. and Technology, Coimbatore-641008, IN
2 Department of Mechatronics Engg., Sri Krishna College of Engg. and Technology, Coimbatore-641008, IN

Abstract

Rapid prototyping techniques are time compression tools finding very wide applications in product development and rapid manufacturing . The time and the cost spent for building actual prototypes demands for high tooling cost and longer product development time. The past two decades have witnessed a substantial growth of newer techniques, which would reduce the above-mentioned factors. In this paper an attempt has been made to enhance the process capabilities of one of the RP techniques, the Laminated Object Manufacturing by incorporating the Resistance Welding Technique to produce actual metal prototypes, using which the real time parameters can be checked and verified. So far only a very few metal RP techniques are available which are very costly for Indian manufacturers to afford. This Resistance Foil Fusion Technology (here after referred to as RFFT) is a combination of Laminated Object Manufacturing and Resistance Welding Technique. A detailed description of the technique and its working is dealt in this paper.

Keywords

Laminated Object Manufacturing, Resistance Welding, Part Building, Layer Thickness, Sliced Data.

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Karayil Srikanth Rajan ¹, S. John Alexis ², G. Venkatesh ¹

Affiliations
1 Department of Mechatronics Engineering, Sri Krishna College of Engineering and Technology, Sugunapuram, Kuniamuthur Post, Coimbatore-641 008, IN
2 Department of Mechanical Engineering, Sri Krishna College of Engineering and Technology, Sugunapuram, Kuniamuthur Post, Coimbatore-641 008,, IN

Abstract

Rapid prototyping techniques are time compression tools finding very wide applications in visualization, functionality and testing of part prototypes. The time and the cost spent for building actual prototypes demands for high tooling cost and longer product development time. The past two decades have witnessed a substantial growth of newer techniques, which would reduce the above-mentioned factors.

In this paper an attempt has been made to enhance the process capabilities of one of the RP techniques, the Laminated Object Manufacturing [LOM] by replacing the standard constant power, profile cutting laser with that of a more powerful profile cutting/welding laser with varying power output. The dual advantage of using a variable power laser is that it can be used for both profile cutting and bonding of layers, which in turn provides the option of producing both metal and non-metal prototypes. The use of a variable power output laser would provide strong and reliable bonding between layers as compared to the weak bonding provided by the use of heat sensitive adhesive roller in conventional LOM machines. Only a very few metal RP techniques are available for Indian manufacturers which are very costly. A detailed description of the dual application laser technique and its working are dealt in this paper.

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P. Chandramohan ¹, S. John Alexis ², R. Srivatsavan ³

Affiliations
1 Dept. of Mechatronics Engg., Sri Krishna College of Engineering and Technology, Kuniamuthur, Coimbatore-641008, IN
2 Dept. of Mechanical Engg., Sri Krishna College of Engineering and Technology, Kuniamuthur, Coimbatore-641008, IN
3 Mechanical Sciences, Sri Krishna College of Engineering and Technology, Kuniamuthur, Coimbatore-641008, IN

Abstract

This paper discusses the various fabrication techniques and their automation being used in composite material fabrication. Research and development efforts have made some of the structures amenable to computer aided design and numerical control fabrication. About 70% of total cost of Boron and graphite preliminary composites is spent on fabricating into end shapes. Automation could reduce this cost by 50%. Automated processing of tapes has been widely investigated to reduce lay-up costs. One such approach is using automated facilities at the material supplier's plant to handle alternative materials, thus reducing handling in the processor's facility. These concepts include wide tapes [up to 1.2m], uniweave fabric, and fabrics of conventional construction which are unrolled, automatically cut into full or partial plies, sorted into kits, and then laid up onto a tool.
The next step in composite material fabrication is the paperless factory, where automation is being developed and applied in handling, storage and retrieval of frozen materials through automated cutting, kitting and lay up. Assembled parts would be carried automatically to autoclaves for cutting on an overhead monorail or other conveyor.

Keywords

SMC, PMC, LCM, Prepreg, Autoclave.

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P. Chandramohan ¹, S. John Alexis ², R. Srivatsavan ³

Affiliations
1 Dept of Production Engg, Sri Krishna College of Engineering and Technology, Kuniamuthur, Coimbatore-641 008, IN
2 Dept of Mechanical Engg, Sri Krishna College of Engineering and Technology, Kuniamuthur, Coimbatore-641 008, IN
3 Mechanical Sciences, Sri Krishna College of Engineering and Technology, Kuniamuthur, Coimbatore-641 008, IN

Abstract

The increased use of the sheet metal in industries, because of its increased strength to weight ratio demands quick and efficient manufacturing methods. Conventional sheet metal forming processes result in the increase of tool and die making and material cost This has made the researchers to think in a different direction, which ended up in sheet metal forming by using flexible media. In this paper, a detailed study has been done on the analysis of sheet metal forming using liquid media alone. The results of the analysis are given by means of graphs.

Keywords

Liquid Media, Stretching, Punch, Die, Pressure.

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