Informatics Publishing Limited

N. Sivanandham ¹, A. Rajadurai ², S. M. Shariff ³, J. Senthilselvan ⁴, A. Mahalingam ¹

Affiliations
1 Department of Physics, Anna University, Chennai-600 025, IN
2 Department of Production Technology, MIT Campus, Anna University, Chennai-600 044, IN
3 International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI), Centre for Laser Processing, Hyderabad, IN
4 Department of Nuclear Physics, University of Madras, Guindy Campus, Chennai-600 025, IN

Abstract

This research work deals with studies on the laser surface melting (LSM) of SUS 420F plastic mould steel and EN32B plain low carbon steel by a high power diode laser (HPDL). The laser treated samples were investigated by scanning electron microscopy (SEM) for microstructure and corrosion resistance was carried out using electrochemical method. In plastic mould steel, the microstructure is columnar dendrite and fine martensite microstructures with residual austenite phases are formed. The microstructures were transformed from columnar dendrite to randomly oriented ones, as the laser power was increased from 2 to 3 kW. On the other hand, the low carbon steel laser surface melted by the HPDL has created lath martensite microstructure. The potentiodynamic electrochemical corrosion method reveals improved corrosion resistance in the laser treated layers.

Keywords

HPDL Treatment, Martensite, Lath Martensite, Corrosion Resistance.

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N. Srirangarajalu ¹, G. Madhusudhan Reddy ², S. R. Koteswara Rao ³, A. Rajadurai ¹

Affiliations
1 Madras Institute of Technology, Anna University, Chennai - 600 044, IN
2 DMRL, Hyderabad - 500 058, IN
3 Tagore Engineering College, Chennai - 600 048, IN

Abstract

Friction Stir Welding (FSW) is relatively new joining process that is presently attracting considerable interest. The process is solid-state in nature. Copper and Brass are widely used engineering materials in electrical and chemical industry because of their high electrical and thermal conductivity, high corrosion resistance and high strength. The main objective of this work is to investigate the feasibility of Friction Stir Welding (FSW) of copper and brass. FSW trials were carried out on 6 mm thick commercially pure copper and brass plates with travel speeds ranging from 30 to 75 mm/min and tool rotational speeds ranging from 1300 to 1600 rpm. The FSW tool pin was made of high speed steel (M2) hardened and tempered to 55 HRC. Friction stir tool is the key art of friction stir welding processes. The tool pin profile used in this study are straight cylindrical, taper cylindrical, threaded cylindrical and tapered threaded cylindrical with a pin lengths of 5.0 mm to 5.4 mm. Defect free welds were obtained using several sets of parameters. Vickers micro hardness testing and tensile tests were carried out to evaluate the mechanical properties of sound welds. Use of tapered threaded tool and tool rotational speed of 1300 to 1600 rpm resulted in high quality welds with good mechanical properties. Different microstructure zones were revealed by optical microscopy (OM). The Weld Zone (WZ) and Thermo Mechanically Affected Zone (TMAZ). The WZ fine equiaxed grains were observed and TMAZ fine elongated grains were observed.

Keywords

Friction Stir Welding (FSW), Dissimilar Welding, Welding of Copper with Brass.

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A. Rajadurai ¹, J. Ilanchezhian ¹, V. Varadharassu ¹, A. Ranjeeth ¹

Affiliations
1 Sri Manakula Vinayagar Engineering College, Puducherry, IN

Abstract

Cloud computing is Internet-based computing, whereby shared resources, software and information, are provided to computers and devices on-demand, like the electricity grid. Though the concept of “clouds” is not new, it is undisputable that they have proven a major commercial success over recent years and will play a large part in the ICT domain over the next 10 years or more, as future systems will exploit the capabilities of managed services and resource provisioning further. In this paper we discuss a brief survey on cloud computing concepts and its future research opportunities.

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A. Rajadurai ¹, J. Ilanchezhian ¹, V. Varadharassu ¹, A. Ranjeeth ¹

Affiliations
1 Sri Manakula Vinayagar Engineering College, Puducherry, IN

Abstract

Cloud computing is Internet-based computing, whereby shared resources, software and information, are provided to computers and devices on-demand, like the electricity grid. Though the concept of “clouds” is not new, it is undisputable that they have proven a major commercial success over recent years and will play a large part in the ICT domain over the next 10 years or more, as future systems will exploit the capabilities of managed services and resource provisioning further. In this paper we discuss a brief survey on cloud computing concepts and its future research opportunities.

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D. Kumaran ¹, A. Rajadurai ², K. Padmanabhan ³

Affiliations
1 Department of Mechanical Engineering, SRM University, Chennai - 603203, Tamil Nadu, IN
2 Department of Production Technology, Madras Institute of Technology, Chennai - 600044, Tamil Nadu, IN
3 School of Mechanical and Building Sciences, VIT-University, Vellore - 632014, Tamil Nadu, IN

Abstract

Objectives: The present work reports the possible solution of using the high thermal stability polymer fibres with superior mechanical properties as that of, or, even better than metals for light weight applications like aerospace and automobile. Methods/Statistical Analysis: The PBO filament fibre was used as reinforcement. The PBO fibres were electroless copper coated to protect the polymer fibre from oxidation during processing and to improve the interfacial properties between the reinforcing polymer and the metal matrix. LM6 aluminium cast alloy was used as a matrix metal. The electroless copper coated PBO fibres preform were unidirectional placed inside a mould and infiltrated by molten liquid metal. Findings: After casting, it was found that the liquid melt could infiltrate only partially through the first layer of the fibre preform, and could not infiltrate further, which was evident from the infiltrated metal front. This was mainly because of the forced convective heat transfer made by the argon cover gas, which cools the molten metal front and thereby increases the surface tension of the advancing front. It was further noticed that some charring of the polymer fibres after two hours of casting, which reflects that, there was oxidation of polymer fibres after prolonged heating by the hot infiltrating metal front in absence of argon cover gas after first one hour of its use after casting. Application: The new material proposed for development could find applications in light weight high performance vehicles like aerospace and automobiles..

Keywords

Composites, High-Modulus, High-Strength, Metal-Matrix, Polymer, Reinforced

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G. Murali ¹, M. Gopal ², A. Rajadurai ³

Affiliations
1 School of Mechanical Engg., S R M University, Chennai, IN
2 D.M. I. College of Engg., Chennai, IN
3 Dept. of Prod. Technology, MIT, Anna University, Chennai, IN

Abstract

Drawbeads are often applied in the deep drawing process to improve control of the material flow during the forming operation. Drawbeads restrain the sheet from flowing freely into die cavity. This paper deals with analysis of effect of draw bead geometry in sheet metal drawing process. Finite element analysis of drawing of circular blanks into axi-symmetric hemispherical cup is done. Circular and rectangular drawbeads are introduced into the finite element models and their influence in distribution of strain and thickness are investigated. DYNAFORM and LS-DYNA, a commercially available explicit FEA code were used to model and analyze the forming process respectively. These outcomes are compared with experimental results. The results show good agreement between numerical method and experiment. On comparison, rectangular drawbeads restrain the material more than circular drawbead due to their geometry.

Keywords

Sheet Metal Forming, Drawbead, LS-DYNA, Plastic Strain.

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M. Pradeep Kumar ¹, K. S. Vijay Sekar ¹, A. Rajadurai ²

Affiliations
1 Dept. of Mech. Engg., CEG, IN
2 Dept. of Production Engg, MIT, Anna University, Chennai, IN

Abstract

This paper presents a comparative study of the effect of two different flow stress models on the orthogonal metal cutting process using the FEM. The flow stress models used were the Oxley's model and the modified Johnson and Cook model. The orthogonal cutting experiments were conducted with AISI 1045 steel work material and tungsten carbide cutting tool. The FEA results with modified Johnson's model for the cutting force, feed force, chip thickness, shear angle and shear strain compared well with the experimental values with only a marginal deviation of 10-20% for feed rates of 0.16mm/rev and above while the deviation for Oxley's model was higher across most feed rates. The Oxley model gave better results for the FE predictions of contact temperature. This study suggested that the modified Johnson and Cook model was an efficient alternative tool for FE simulation of the orthogonal metal cutting process.

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R. Ramadoss ¹, A. Rajadurai ¹, S. Venugopal ², S. Satishkumar ³

Affiliations
1 Department of Production Technology, Madras Institute of Technology, Chrompet, Anna University, Chennai-600044, IN
2 Metal Forming and Tribology Section, Indira Gandhi Center for Atomic Research, Kalpakkam, IN
3 Department of Mechanical Engineering, St. Joseph’s College of Engineering, Chennai-600119, IN

Abstract

Austenitic stainless steels are special grades of steels with improved corrosion resistance and oxidation resistance. In this work forming limit diagrams (FLDs) for Austenitic stainless steels of grades AISI 316 and 316L of thickness 1.25mm have been studied and their suitability for forming applications have been examined. FLDs were experimentally found using the hemispherical punch forming test. The micro structural aspects, tensile properties, formability parameters of the above mentioned steels were studied and compared. The fracture surfaces of the formed samples were viewed using the scanning electron microscope (SEM) and the SEM images were correlated with the fracture behavior and formability of the sheet metal. It was found that the formability of AISI 316L posses good drawability and stretchability.

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R. Ramadoss ¹, A. Rajadurai ²

Affiliations
1 Department of Mechanical Engg., St.Joseph’s College of Engg., Chennai, IN
2 Dept. of Production Technology, Madras Institute of Technology Chrompet, Anna University, Chennai, IN

Abstract

Many of the stainless steel components ore manufactured through forming. Therefore on understanding of formability sheet metal is essential for successful prediction of quality stomping. In the present work, the forming limit of AISI 316LN stainless steel has been evaluated using the hemispherical punch forming test. The experimental forming limit diagram is compared with theoretical models of Swift, Hill and Sing Roo for validation. Sheet metal forming simulation was performed using the finite element software. The solution methodology was based on explicit time integration. A failure criterion has been introduced based on localized necking for the prediction of forming limit. The finite element predictions seem to be in good correlation with experimental results of AISI 316LN stainless steel. An error analysis on the FE-predictions was performed and the percentage deviation was found to vary between 0.28 and 12.24%. Theoretical models ore not predicting well with the experimental forming limit diagram.

Keywords

Hemispherical Punch Forming, Finite Element Simulation, Theoretical Model, Stainless Steel, Forming Limit Diagram.

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R. Rajendran ¹, S. Venkataswamy ¹, U. Jaikrishna ², N. Gowrishankar ², A. Rajadurai ³

Affiliations
1 Department of Mechanical Engineering, B.S.A. Crescent Engineering College, Chennai-600048, IN
2 IP Rings Ltd, D 11/12, Industrial Estate, Maraimalainagar-603209, IN
3 Department of Production Technology, Anna University, MIT Campus, Chennai-600044, IN

Abstract

Duplex coating is used in surface engineering to provide improved wear and corrosion resistance. The present study aims at hot dip aluminizing of a steel base followed by diffusion and nitriding treatments. The base material chosen for study is BS970 grade EN 8 steel (or 080M40). The specimens were dipped in molten aluminium-silicon alloy bath (11-13% Si) for various dip times (5-23 minutes) at 988K and diffused at 1173K for 8 hours. The diffused specimens were gas nitrided for 10 hours 50 minutes. The effect of dip time on coating thickness, diffusion layer thickness, microhardness and microstructure of aluminized, diffused and nitrided steel specimens were studied. The aluminium coating thickness does not significantly increase with the dip time beyond certain duration. The experimental studies indicate that the diffused layer thickness varies from 54-69 μm. The prolonged dipping time does not provide any significant advantage in increasing the diffused layer thickness. The surface hardness of EN 8 steel could he increased to about 800 HV when aluminized diffused and to about 1200 HV on subsequent nitriding. The increase in the hardness is attributed to the formation of hard nitride layer (Al-N). This methodology could be adopted for automotive and other engineering applications.

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P. Hariharan ¹, R. P. Chandrasekar ¹, A. Suresh Babu ¹, A. Rajadurai ², D. Mohanlal ³, S. Renganarayanan ³

Affiliations
1 Department of Manufacturing Engg., Anna University, Chennai-25, IN
2 Department of Production Technoiogy, MIT Campus, Anna University, Chennai-44, IN
3 Department of Mechanical Engineering, Anna University, Chennai-25, IN

Abstract

Bearing components should have high hardness accompanied by good wear resistance and load bearing strength. The most commonly used material for the manufacture of bearing components is steel. To achieve high hardness accompanied by good wear resistance, cryogenic treatment is considered as a supplementary process to conventional heat treatment. Increasing the wear resistance and the impact strength of the bearing components plays an important role in improving manufacturing standards. Since simultaneous enhancement of both these opposing properties is difficult in the heat treatment processes, a method of optimizing these properties together can increase the life o f the bearing components. The factors identified as affecting impact strength and wear resistance are the austenitising temperature, the austenitising time, the tempering temperature, the tempering time, the cryogenic treatment, the quenching media and the type of tempering. In this paper, an attempt is made to find out the optimum combination of heat treatment factors to optimize wear resistance and impact strength of the SAE 51100 bearing steel by using Taguchi’s techniques.

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V. Venkatesan ¹, A. Manickavasagam ¹, A. Rajadurai ²

Affiliations
1 Technical Training Centre, Integral Coach Factory, Chennai, IN
2 Madras Institute of Technology, Anna University, IN

Abstract

Modelling is a technique widely used to represent the effect of multiple and interacting parameters on responses of many process. Welding is one such process where various parameters independently and interactively determine properties. The aim of this study is to reestablish the relationship between welding process parameters and tensile strength, slag inclusion count and penetration on the basis of statistical modelling. AISI 301 grade Stainless Steel Plates were welded with different CO₂ flow rates such as 10, 15 and 20L/min.

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M. V. Venkatesan ¹, A. Manickavasagam ¹, A. Rajadurai ²

Affiliations
1 Technical Training Centre, Integral Coach Factory, Chennai, IN
2 Madras Institute of Technology, Anna University, Chennai, IN

Abstract

Integral Coach Factory is the Premier Coach (ICF) building Industry in Indian Railways. This factory has so far produced more than 30000 coaches in about 170 designs. It was the first among the Indian Railway production units to get ISO 9001 certification. Quality of the coach is being ensured from the raw material to end product. In ICF. fabrication of coaches are being carried out by welding process. Though welding is a reliable metal joining process, the soundness of the weldment largely depends on Men, Machine, Material and Method. The quality of the weldment is ensured by implementation of various quality tools. Even then it is quite difficult to achieve 100% defect free product in manufacturing. Even if 100% inspection is resorted to at every stage of manufacturing defects are inevitable since the inspection is being carried out by human and human errors are inadvertent and inevitable. Poka-Yoke is a tool which achieves 100% defect free product at low cost with the aid of low cost equipments. These low cost equipments aids the employee to manufacture defect free product. The aim of this study is to develop Poka-Yoke methods in a welding application. Few parameters which affect the quality of the weld are identified, and various methods are developed to control these parameters and eliminate defects. The parameters identified are shielding gas flow rate, pre and post heat temperature, welding sequence and electricity. These parameters are recorded in a standard format. Poka-Yoke Techniques were applied to control the above said parameters and ensure error free welding in ICF.

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