Manufacturing Technology Today

Snehashis Sarkar ¹, Krishnendu Mondal ¹, Santanu Das ¹, Probal Kr. Das ²

Affiliations
1 Dept. of Mech Engg., Kalyani Government Engineering College, Kalyani, West Bengal, IN
2 Non-Oxide Ceramics and Composites Division, CSIR-Central Glass Ceramic Research Institute, Kolkata, IN

Abstract

The aim of this work is to evaluate the performance of a newly developed multi-walled carbon nanotube (MWCNT) reinforced alumina inserts. Machining of 'difficult to machine' materials requires harder cutting tool. So, for machining hardened materials, reinforced ceramic inserts with enhanced mechanical properties like fracture toughness and hardness are used. In this research work, multi-walled carbon nanotube reinforced alumina nanocomposite is used as a cutting tool that has Vicker's hardness value of 20GPa and fracture toughness of 6.43 MPa m^1/2. Machining of AISI 4340 steel rod is done under dry environment. Progress of tool wear at two cutting conditions is evaluated. Tool life of the newly developed insert may be improved by employing suitable machining environment, proper tool geometry and parameters during production of the MWCNT reinforced alumina insert.

Keywords

Turning, Alumina, Carbon Nanotube, Cutting Tool, Tool Wear, Machinability.

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Krishnendu Mondal ¹, Santanu Das ²

Affiliations
1 Dept. of Mechanical Engg., Bankura Unnayani Institute of Engineering, Bankura, IN
2 Dept. of Mechanical Engg., Kalyani Government Engineering College, Kalyani, IN

Abstract

This paper concerns with machinability studies in finish turning of AISI 52100 steel using various tool inserts. This steel is applied in different structural and other industrial applications. Turning tests are performed under different cutting velocity and feed with plain, narrow groove and wide groove coated carbide tool inserts. Using these diverse conditions, types of chips formed, cutting force, etc., were noted, and machinability of the tool-work combine under different conditions is explored, so that some conditions can be found out at which good machinability can be achieved. Although narrow or wide groove chip breakers are used, chip breaking is not much observed in general. Fair machinability is observed while turning using all the three types of inserts. However, fairly good tool performance is obtained when plain carbide insert is employed at higher cutting velocities of 174 and 274 m/min at the chosen feed even in dry condition.

Keywords

Machining, Turning, Forces, Insert, Tool, Chip.

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Manab Das ¹, Bijoy Mandal ¹, Santanu Das ¹

Affiliations
1 Department of Mechanical Engineering, Kalyani Govt. Engineering College, Kalyani-741235, West Bengal, IN

Abstract

Grinding of titanium alloy is difficult due to its high hot strength, poor thermal conductivity and high work hardenability. At the time of grinding operation, large amount of heat is generated. To control resulting temperature rise at the grinding zone, suitable coolant and/or lubricant is to be used along with selection of appropriate process parameters and grinding wheel. However, supplying grinding fluid inside the grinding zone is difficult, and it needs suitable method of application to control temperature to obtain quality ground specimen. In the present work, a comparative study has been done through experimental investigation between dry grinding, wet grinding using flood cooling, and grinding with grease. Workpiece quality, force needed, grinding-ratio, and chips formed have been observed and results are discussed. Better grindability has been found with the use of grease at 30 μm in feed than the other two conditions tested.

Keywords

Grinding, Grinding Fluid, Grease, Flood Cooling, Grindability, Grinding Force.

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S. K. Ghosh ¹, N. P. Mukherjee ², A. B. Chattopadhyay ³, Santanu Das ⁴

Affiliations
1 Dept of Mechanical Engg, IIT, Kharagpur, IN
2 Bengal College of Engg and Technology for Women, Durgapur, IN
3 Dept of Mechanical Engg, Birbhum Institute of Engg and Technology, Suri, IN
4 Dept of Mechanical Engg, Kalyani Government Engg College, Kalyani, IN

Abstract

Recently, austempered ductile iron (ADI) is finding many applications in different areas due to its high strength-to-weight ratio. However, it is a difficult-to- machine material. In this work, experimental investigations have been done to observe machining performance during turning ADI rods using two tool inserts. Cutting force components, chip forms, etc. have been observed during straight turning of ADI rods with TiAlN-coated carbide and cBN tool inserts. Observations have been made by varying cutting velocities under dry condition. Machining tests indicate that coated carbide inserts require less cutting forces and it can machine even after 1 minute of machining, while the cBN inserts show deterioration of the cutting edge just at the end of 20 seconds of machining under a typical machining condition. It is seen that at certain experimental conditions, coated carbide inserts and cBN inserts show fairly good machinability for machining ADI in dry condition.

Keywords

Turning, Machinability, Austempered Ductile Iron, ADI, Ceramic Inserts, Coated Tools.

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Anirban Bhattacharya ¹, Santanu Das ², Ajay Batish ¹

Affiliations
1 Mech. Engg. Dept., Thapar University, Patiala, IN
2 Mech. Engg. Dept., Kalyani Govt. Engg. College, Kalyani, IN

Abstract

An investigation has been made to study the effect of various machining parameters during high speed machining on the workpiece surface roughness. The experiments were carried out taking AISI 1045 steel as the workpiece material and coated carbide tool Five levels of cutting speeds and feed rates were selected. The Taguchi's orthogonal arrays and analysis of variance (ANOVA) were employed to design the experiments, study the performance characteristics and to find the significance and contribution of cutting parameters on surface roughness in high speed turning. It was observed from these experiments that at the higher cutting speeds (240m/min) the best surface roughness results were observed. Cutting speed was found to be most significant factor for surface roughness and contributes up to 76%. The feed rate and interactions between cutting speed and feed rate were observed to have no significant impact. Thereafter optimum parametric combinations were also found.

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Niramay Ghosh ¹, Santanu Das ²

Affiliations
1 Mechanical Engineering Department, Asansol Engineering College, Asansol, IN
2 Department of Mechanical Engineering, Kalyani Govt. Engineering College, Kalyani, IN

Abstract

Aluminium and aluminium alloys have large uses in different industries due to its higher strength to weight ratio. Due to controllable heat input and filler consumption Tungsten Inert Gas Welding (TIG) is widely used in aluminium welding. In this work, bead geometry of Al 6060 alloy have been studied in different AC TIG welding parameters, like welding current, welding speed etc. Butt joint was performed. From the observation, it is found out that at a current 177, 190 and 200 A with a welding speed of 110, 130 and 150 mm/min respectively, good depth of penetration can be achieved, and hence, this condition can be used for joining aluminium alloy satisfactorily.

Keywords

Aluminium, TIG Welding, Visual Bead Inspection, Penetration, Bead Width, Bending Test, Micro Hardness Test.

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Kapil Roy ¹, Partha Pratim Saha ¹, Santanu Das ¹

Affiliations
1 Mechanical Engineering Department, Kalyani Govt. Engineering College, Kalyani, West Bengal, IN

Abstract

In drilling, burr formation is mostly observed at the exit edge of a workpiece. A burr can cause premature failure of cutting tools, dimensional errors in manufactured components and serious problems in assembly. Deburring operation is usually employed for removal of burr. For reduction of deburring cost and time, burr reduction is essentially needed. The present investigation on drilling burr formation demonstrates an approach for burr reduction at the exit edge of the workpiece. A number of experiments has been carried out on low carbon steel flats under water soluble oil cooled environment to explore the influence of different exit edge bevel angles on burr formation under different machining conditions. At 20^o exit edge bevel angle, negligible burr is found at 0.2 mm/rev feed at all the cutting velocities considered and this condition may be adopted. However, with 25^o exit edge bevel angle, sizeable burr is obtained making it unsuitable.

Keywords

Drilling, Exit Edge Beveling, Wet Environment, Machining, Burr, Backup Support.

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Jaydeep Mondal ¹, Manas Kumar Saha ¹, Santanu Das ¹

Affiliations
1 Kalyani Government Engineering College, Kalyani, West Bengal, IN

Abstract

Surfaces of structural members usually degrade under corrosion causing reduction in service life. This results in increased cost involving preventive methods or/and rework. Cladding is one such method for preventing this problem to some extent. Desired weld quality for gas metal arc welding process, a well-accepted method for developing clad layer and overlays, can be achieved by selecting appropriate process parameters. In the present investigation, gas metal arc welding is applied to develop 316 γ stainless steel clad layer on E350 constructional steel base plate with varying welding current and torch travel speed. Results indicate lowering of corrosion rate with increasing welding current and arc travel speed at a constant travel speed and constant current respectively. No clear trend of change in corrosion rate with the variation of heat input is seen. However, austenitic stainless steel cladding is found to improve corrosion resistance remarkably to apply to industry effectively.

Keywords

Welding, GMAW, Cladding, Austenitic Stainless Steel, Heat Input, Corrosion Resistance.

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Krishnendu Mondal ¹, Santanu Das ², Bijoy Mandal ²

Affiliations
1 Bankura Unnayani Institute of Engineering, Bankura, West Bengal, IN
2 Kalyani Government Engineering College, Kalyani, Nadia, West Bengal, IN

Abstract

Cutting fluids play a significant part of metal working industries. They are broadly utilized due to their capacity to diminish tool wearing, cutting force, temperature, etc. to improve workpiece surface quality. The present work focuses on the machinability study of hard AISI 4340 steel using eco-friendly cutting fluids. Turning experiments are carried out using coated carbide inserts through Small Quantity Lubrication (SQL) under different cutting velocities and feed. Dry, rice bran oil-based solution and alkaline solution are chosen to be the environmental conditions. Under different machining conditions, types of chips, cutting force, surface roughness, etc. are noted. Full factorial type response surface methodology is used to decide on experimental runs. Tool wear tests are also performed under wet conditions. Cutting force is observed to be significantly reduced in a chosen wet environment under some cutting conditions. Rice bran oil-based emulsifier is found to perform better than alkaline solution to increase tool life.

Keywords

Machining, Machinability, Turning, Cutting Fluid, Hard mMaterials, Eco-Friendly Fluid.

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Ankur Das ¹, Santanu Das ²

Affiliations
1 Global Institute of Management & Technology, Krishnanagar, Nadia, West Bengal, IN
2 Kalyani Government Engineering College, Kalyani, Nadia, West Bengal, IN

Abstract

In today’s highly competitive environment, several inventory control strategies are introduced in different manufacturing organizations or supply chain perspective. Multiple criteria based inventory control technique is required to achieve efficient inventory management system which contemplate the different aspects of inventory as well as supply chain management system. In this context, monthly demand, inventory consumption value and lead time are considered as the inventory performance measuring criteria. Here, different multiple criteria based ‘ABC’ inventory control methods have been utilized to categorize the stock items properly. In addition, the overall inventory service costs and average fill rate are computed for different MCIC techniques. These inventory control approaches have been applied to raw material inventories of a pump manufacturing company. Ng-model performs better than ZF and H-models where the overall fill rate of stock items has been considered. ZF-model and H-model ensure better results from Ng-model regarding total safety stock inventory cost.

Keywords

Inventory Control, ABC Analysis, Inventory Consumption Value, MCIC, Pump Manufacturing.

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Deb Kumar Adak ¹, Prosenjit Dutta ², Barun Haldar ³, Santanu Das ², Naser Abdulrahman Alsaleh ³, Sibsankar Dasmahapatra ²

Affiliations
1 College of Engineering and Management, Kolaghat, Purba Medinipur, West Bengal Kalyani Government Engineering College, Kalyani, West Bengal, IN
2 Kalyani Government Engineering College, Kalyani, West Bengal, IN
3 College of Engineering, Imam Mohammad Ibn Saud Islamic University (IMSIU), Riyadh, SA

Abstract

Abrasive jet machining (AJM) is often applied in drilling of hard and brittle ceramic materials, and is also used for other processes like surface preparation, deburring, shot-peening, polishing, etc. AJM process parameters need be appropriately selected to have optimized responses like MRR, nozzle wear, etc. Experimental investigation is performed in this work by precisely controlling abrasive flow rate. Along with system pressure, abrasive flow rate, stand-off distance (SOD) and grain size are considered during performing AJM with silicon carbide abrasive on commercially pure 4 mm thick alumina tiles using response surface methodology (RSM). Analysis of variance is done to detect the relative significance of each of the variables. Artificial neural network (ANN) is constructed to estimate the response in AJM based on input parameters. Estimation of machining performance is effectively carried out by ANN based on the training data with less than 8% estimation error, particularly for MRR and NWR.

Keywords

Abrasive Jet Machining (AJM), Alumina, Drilling, ANN, Estimation

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