Manufacturing Technology Today

S. Shivakumar ¹, R. Kumar Swamy ¹

Affiliations
1 Department of Mechanical Engg, Sir MVIT, Bangalore, IN

Abstract

This Paper involves the development of Aluminium T6 6061 alloy using forging process. The Standard Al T6 6061 alloy ingots was melted and super-heated in the electrical resistance furnace for about 8 hours at 750°C. The superheated melt was reinforced with zirconium dioxide in 3% and 6% weight proportions. The molten metal was poured into a cylindrical rod die of dimensions 300mm x 200mm and allowed to solidify at ambient temperature. The cast specimens were later forged for comparison study purposes. The microstructure and mechanical characterization of forged and unforged cast specimens. The microstructural characterization of forged cast sample exhibits fine grain structure with spherical morphology of secondary magnesium and silicon magnesium and silicon phase in the Al matrix whereas the unforged cast sample indicates coarse with dendrite type morphology. The strength results in terms of tensile of forged cast specimen reveals significant improvement in the tensile strength over the unforged cast specimens due to unforged cast specimen due to refined grain structure. The hardness results in terms of brinell hardness of reinforced specimens showed decrement compared to their base alloy.

Keywords

Aluminium T6 6061 Alloy, ZRO₂, Stir Casting, Optical Microscopy, Keller’s Reagent.

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G. N. Lokesh ¹, S. Shivakumar ², K. V. Mahendra ³, S. Karunakara ¹

Affiliations
1 Dept of Mech Engg, Acharya Institute of Technology, Bengaluru, IN
2 Dept of Mech Engg, Sir M. Visvesvaraya Institute of Technology, Bengaluru, IN
3 Amruta Institute of Engg & Management Sciences, Ramanagara, IN

Abstract

In the present work the combined effects of particle size and distribution on the mechanical properties of the fly ash particle reinforced Al–Cu alloy composites is investigated. It has been shown that small ratio between matrix/reinforcement particles sizes resulted in more uniform distribution in the matrix. The particles distributed more uniformly in the matrix with increasing in mixing time. The results also showed that homogenous distribution of the fly ash particles resulted in higher hardness, ultimate tensile strength, yield strength and elongation. Fracture surface observations showed that the dominant fracture mechanism of the composites with small fly ash particle size (27μm) is ductile fracture of the matrix, accompanied by the “pull-out” of the particles from the matrix, while the dominant fracture mechanism of the composites with large fly ash particle size (77μm) is ductile fracture of the matrix, accompanied by the fly ash particle fracture.

Keywords

Powder Metallurgy, Fly Ash, Mechanical Properties, Particle Size.

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S. Shivakumar ¹, G. N. Lokesh ², M. Nataraja ³

Affiliations
1 Mechanical Engg, Sir M Visvesvaraya Institute of Technology, Bangalore, IN
2 School of Engineering, Presidency University, Itgalpura, Rajankunte, Bangalore, IN
3 Mechanical Engg, Sir M Visvesvaraya Institute of Technology, IN

Abstract

 

Solar power energy from the sun is converted into thermal or electrical energy which is the cleanest and most abundant renewable energy source. The U.S.A. has the richest solar sources in the world. Solar energy plays an important role in agricultural operations like drying food products, solar water and air heaters, solar cookers, irrigation, street lights and some home appliances. In Indian farms, the cutting operations are mainly performed by hand. Now a days, the use of mechanized cutting instruments, powered by fossil fuels can also been seen in some places. In hand cutting, the cutting of the crops consumes ample amount of time and labour charges, which is a drawback.

In mechanized cutting methods, the operating & fuel cost of the machine exceeds the budget of a common farmer. To overcome all these drawbacks, we can use renewable, Non-conventional energy source like solar energy as it is easily available in nature. An application of non-conventional, renewable energy source is the alternate solution for current energy demand. In this project solar energy is used which is non-conventional-renewable energy source which is freely available, to reduce the overall cost of the cutting operation. The mechanisms used are also simple. The machine is light weight & Compact. Most importantly, can be easily availed by the farmers.

Keywords

Solar Panel, Battery, DC Motor.

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S. Shivakumar ¹, G. N. Lokesh ², M. Nataraja ¹

Affiliations
1 Mechanical Engg, Sir M Visvesvaraya Institute of Technology, Bangalore, IN
2 School of Engineering, Presidency University, Itgalpura, Rajankunte, Bangalore, IN

Abstract

The global technical market’s demand trend for high strength, high performance, better quality, reduced cost and reduced weight materials has led to an emerging development in research and utilization of composite materials over conventional monolithic materials in various industrial applications. Aluminium –graphite composite has been developed by stir casting technique. Al-Graphite composites having 2%, 4%, 6%, 8% of pure aluminium is prepared. Tensile strength, Hardness test, Impact strength as a function of graphite performs and metal matrices have been determined. The tribological properties were varied significantly with addition of solid lubricant-graphite. The hardness test of composites is carried on Brinell hardness Tester and tensile strength is measured using a Universal testing machine and Charpy and Izod tests are conducted to find the impact energy. Around 15% increase is observed in the hardness of the composite compared to the hardness of pure aluminium and no significant increase is found in the impact energy of the composite, but more than 21% increase is found in the tensile strength of the composite.

Keywords

Pure Aluminium, Graphite, Composites, Stir-Casting, Metal Matrices, Mechanical Properties.

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G. N. Lokesh ¹, S. Shivakumar ², S. Karunakara ³

Affiliations
1 Dept. of Mechanical Engineering, Presidency University, Itgalpura, Rajankunte, Yelahanka, Bengaluru, IN
2 Dept. of Mechanical Engineering, Sir M Visvesvaraya Institute of Technology, International Airport Road, Hunasamaranahalli, Yelahanka, Krishnadeveraya Nagar, Bengaluru, IN
3 Dept. of Mechanical Engineering, City Engineering College, Kanakapura Road, Doddakallasandra, Bikasipura, Bengaluru, IN

Abstract

In the present investigation, the Al-Cu matrix reinforced by B₄C particulate was fabricated using stir casting and squeeze casting technique. The stir cast composites so produced were subjected to hot rolling for 40% reduction and the composites have been evaluated based on the investigation of mechanical properties. The wear tests were carried out using a pin on disc technique. Microstructure of the composites was observed by scanning electron microscope (SEM). The results show that the hardness and tensile strength increases with increase in percentage of B₄C by stir casting squeeze casting and rolled composites. But squeeze casting composites shows higher strength than stir casting and rolled composites show higher mechanical properties than both stir and squeeze cast composites. The test results showed that rolled specimens fabricated by stir casting technique have greater wear resistance than those fabricated by squeeze casting technique. Microstructure shows better bonding between matrix particle interface and no fracture observed in rolled composites.

Keywords

B₄C, Stir Casting, Squeeze Casting, Hot Rolling, Wear.

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S. A. Tejas ¹, P. Dharshak Chandra ¹, P. Dattathreya ¹, N. Vinith Gowda ¹, S. Shivakumar ²

Affiliations
1 Institute of Technology, Bengaluru affiliated to VTU, Belagavi, IN
2 Department of Mechanical Engineering, Sir M. V. I. T, Bengaluru, IN

Abstract

Combustion is one of the most prominent energy conversion processes used in all areas of human life, even though it is being used on a large scale in various fields it has vital drawbacks like emission of greenhouse gases from IC engines majorly affecting the environment on a global level. One of the reasons of this issue being improper or inefficient ignition of the air-fuel mixture. However, this can be reduced to an extent by employing methods like lean combustion and re-circulating the exhaust gases. This is when the need of an alternative ignition system is required, one such concept being LASER IGNITION SYSTEM for internal combustion engines. On comparison laser ignition system provides number of potential benefits over conventional ignition by electric spark plug. Use of laser ignition system comes with advantages like- Reduction of NOx emission by 20% also improved efficiencies are obtained. The thermodynamic requirements of high compression ratios and high power density are fulfilled well by this system.Therefore, laser ignitors could replace conventional spark plugs in automobile industry. This not only provides better performance and fuel economy, but would also create less harmful emissions.

Keywords

Laser Ignitor, Spark Plug, Nox Emissions, Fuel Efficiency, Gas Lasers, Multi Point Ignition.

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S. Shivakumar ¹, G. Balakumar ¹

Affiliations
1 Department of Mechanical Engineering, Sir M Visvesvaraya Institute of Technology, Bangalore, IN

Abstract

This paper involves the Mechanical property Evaluation of Al- Alloy (T6-6061) reinforced with Nano Ceramic Particulates (ZrO²) subjected to forging process. The standard Aluminum alloy ingots/blocks is melted and superheated in the electrical resistance furnace for about 8 hours at 7500 C. The superheated melt was reinforced with zirconium dioxide particulates by varying weight percentages in 3, 6 and 9 percent. The molten metal mixture was poured in a metal die of cylindrical shape having dimensions 300mm X 20mm diameter and allowed to solidify at ambient temperature, the sample were subjected to hand forging process. The microstructural characterization of forged composite specimen exhibits more or less uniform distribution of ZrO² particulates. The grain structure with spherical morphology of secondary magnesium and silicon phase in the Aluminum matrix whereas the unforged composite sample indicates coarse with dendrite type morphology. The strength results in terms of forged composite specimen reveals significant improvement in the tensile strength over the unforged composite specimen due to refined grain structure. The hardness result also reveals significant improvement in the forged and reinforced samples over the matrix alloy.

Keywords

Nanocomposite, Solidification, Critical Particle Size, Strengthening, Grain Refinement.

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G. N. Lokesh ¹, S. Shivakumar ², S. Karunakara ³

Affiliations
1 Department of Mechanical Engineering, Presidency University, Rajanukunte, Yelahanka, Bangalore, Karnataka, IN
2 Department of Mechanical Engineering, Sir M Visvesvaraya Institute of Technology, Yelahanka, Bangalore, Karnataka, IN
3 Department of Mechanical Engineering, City Engineering College, Kanakpura road, Bangalore, Karnataka, IN

Abstract

The processing of metal matrix composites (MMCs) by casting process is a very promising way of manufacturing near net shape composites at relatively low cost. The liquid metallurgy stir, squeeze casting technique has the characteristics such as fine microstructure as a result of rapid cooling, low porosity and good bonding between the particles and base alloy. Hematite is a common iron oxide with a formula called Fe₂O₃ and has been widespread in rocks and soils. Hematite forms in the shape of crystals through the rhombohedral lattice system, and it has the same crystal structure as lmenite and corundum. The paper presents the results of experimental investigation on mechanical properties of Fe₂O₃ particle reinforced aluminium metal matrix composite. The influence of 3, 6, 9 and 12wt% Fe2O3-p reinforced on mechanical properties was examined and the outcome of the tests revealed that hematite particles can be successfully used as a reinforcement material and it does not deteriorate the properties. The increase in hematite particle percentage and high squeeze pressure resulted in high density of the compact, thereby increasing compression strength, tensile strength and hardness of the composite. The results also showed that for the same base alloy the squeeze cast shows higher hardness, tensile and compression strength compared to the gravity cast base alloy. Squeeze cast composites exhibit higher hardness tensile and compression properties by increasing weight percentage of reinforcements. The microphotographs of squeeze cast samples shows uniform dispersion of the reinforcements in MMCs with good bonding between the matrix and reinforcement.

Keywords

MMCs, Hematite, Stir and Squeeze Casting.

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K. S. Nagaprasad ¹, S. Shivakumar ², D. Madhu ³

Affiliations
1 K. S. Institute of Technology, Bangalore, IN
2 Sir M. Visvesvaraya Institute of Technology, Bangalore, IN
3 Government Engineering College, Ramanagara, IN

Abstract

The experimental investigations on existing diesel engine adopted with two after treatment devices viz; Diesel particulate filters, Diesel oxidation catalyst with injection of fluids at the exhaust pipe were carried out. In the first part of the experimentation, only DPF and DOC were fixed; performance and emissions were measured at all the loads. Injecting fluid viz; urea solution, sodium chloride and distilled water separately at the exhaust pipe was second part of the experimentation keeping same DPF and DOC. From all the emission values, the optimum condition leading to least emission value is engine having both DPF and DOC and injecting urea solution at the exhaust pipe. Running the existing diesel engine with this suggested optimum condition would lead decremental of 79.3% in smoke, 41.1% in CO and 30.3% in NO_x emissions.

Keywords

Diesel Engine, Urea Solution, Sodium Chloride, Diesel Particulate Filters, Diesel Oxidation Catalyst

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G. N. Lokesh ¹, S. Shivakumar ², B. G. Rohit ³, T. R. Preetham ³

Affiliations
1 Presidency University, Itgalpura, Rajanukunte, Bengaluru, IN
2 Sir M.V. Institute of Technology, Bengaluru, IN
3 Desmaco Engineering Services Pvt. Ltd, Bengaluru, IN

Abstract

Nowadays the production of light weight, low cost and high performance aluminium based composites has undergone significant evolution. In this work, Boron Carbide (B4C) were introduced into Al-2024 alloy produced by stir casting method. The B4C particles is coated with TiB2 via sol-gel process and reinforced in Al-2024 alloy by stir casting process to produce composite. Stir casting technique is gaining importance due to its easy setup, low cost, uniform dispersion of reinforcement compare to other techniques. Metal Matrix Composite is stir casted by incorporation of B4C reinforcements by varying 2%, 4%,6%, 8% and 10 wt% to investigate mechanical properties. Hardness, porosity and tensile behavior of alloy and composites were evaluated and found that both hardness and tensile strength increases with increases in percentage of reinforcement. On the other hand a slight increasing amount of porosity is observed with increasing the B4C particles of the composites. Microstructure of tensile fractured surface of Al-2024/B4Cp composites indicates that the presence of intact reinforcement B4C particles on the fracture surface and bonding between boron carbide and aluminum was superior indicating that deformation caused due to ductile behavior.

Keywords

Al-2024, Hardness, Porosity, Tensile, Tensile Fracture.

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Suraj Khadri ¹, B. V. Venkatadri ¹, N. Vinith Gowda ¹, S. Shivakumar ¹

Affiliations
1 Sir M Visvesvaraya Institute of Technology, Bangalore, IN

Abstract

The industrial cleaning today is complex undertaking. Each cleaning problem is unique from others because of many variables in manufacturing process integrating the cleaning process with production & plant requirement through a proper equipment sizing & selection is very important. The Project presented mainly focuses on an effective solution for conventional processing systems carried out in industries to reduce the manual efforts. The simplest version for automation in the field of demagnetizing, cleaning & counting is the result of our research & project. The main idea of our Project is to fabricate a simple conveyor belt system and automate the processing of Machined Components. By developing such system the production rate of the manufacturing industry will be increased since these systems replaced the human resources. Also, the accidents in manufacturing industry can be prevented because the uses of operator in manufacturing floor had been reduced.

Keywords

Industrial Washing, Demagnetizer, Automation.

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