Informatics Publishing Limited

P. Srinivasa Pai ¹, B. R. Shrinivasa Rao ¹, Niranjan N. Chiplunkar ¹, K. Subrahmanya Bhat ¹

Affiliations
1 Dept. of Mechanical Engg., NMAM Institute of Technology, Nitte - 574 110, Karnataka, IN

Abstract

Undergraduate students are the important element of any University/Institution involved in higher education and research. They influence the education system and their involvement, experience and satisfaction determines the success or failure of any Institution. Research is an integral component of the teaching-learning process and it has been found that academic excellence depends on research excellence. In this context, there is a need to involve undergraduate students in the research activities in different disciplines, in order to train them to understand the nuances of research. In fact the involvement of undergraduate students in faculty research activities is very minimal and they are denied the benefits of a research-based learning experience. This paper tries to present the current status of involvement of undergraduate students in research activities in two departments in an autonomous Institution. It discusses the students' awareness, experiences and perceptions and suggests measures that can be taken to increase their involvement in research.

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P. Srinivasa Pai ¹, Niranjan N. Chiplinkar ², B. R. Shrinivasa Rao ³, K. Subrahmanya Bhat ¹

Affiliations
1 Dept. of Mechanical Engineering, NMAM Institute of Technology, Nitte - 574110, Karnataka State, IN
2 NMAM Institute of Technology, Nitte, IN
3 NMAM Institute of Technology, Nitte - 574110, Karnataka State, IN

Abstract

Teaching-learning process is the important component of any education system. In the context of outcome based education (OBE), its outcomes have assumed significance. There has been a paradigm shift from a teacher-centered education system to a learner-centered system, where students play a major role. The explosion in information and communication technology has impacted education in a big way. There has been a sustained interest and use of information and communication technology (ICT) in higher education. This paper tries to provide some perspective on use of ICT for enhancing the teaching learning outcomes. Video is one technology which is being widely used both in normal mode and distance mode for delivery of education. Some thoughts on use of video has been discussed based on the literature and a plan of action for implementing video in teaching one course in the author's institution has been presented. A survey instrument regarding use of ICT by teachers has been administered and the results of the same have been presented to establish the need for use of ICT in teaching learning process.

Keywords

Outcome Based Education, Information and Communication Technology, Video.

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P. Srinivasa Pai ¹, Rashmi P. Shetty ¹

Affiliations
1 Department of Mechanical Engineering, NMAM Institute of Technology, Nitte, Karnataka, IN

Abstract

Tool condition Monitoring is an important aspect to maintain quality of machined products. A tool is considered as failed, when it is no longer able to produce parts within the required specifications. Tool Condition Monitoring Systems (TCMS) are an integral part of machine condition monitoring systems, which continuously monitor the condition of the tool either using 'direct' or 'indirect' methods. In this paper, acoustic emission signals, which are widely used in TCMS are used along with surface roughness measurements to monitor the condition of an insert in face milling operations on grey cast iron. Artificial Neural Networks (ANN), a widely used artificial intelligence technique in machining applications have been used to model tool flank wear using acoustic emission signal parameters, surface roughness parameters and cutting conditions. Three ANN techniques have been investigated and compared namely Multi-layer Perceptron Neural Network (MLPNN), Radial basis function Neural Network (RBFNN) and Summation Wavelet - Extreme Learning Machine (SW-ELM). The results indicate that SW-ELM performs better than other two techniques in tool wear modeling and achieves a prediction accuracy of more than 85 % on test data.

Keywords

Tool Condition Monitoring, Acoustic Emission, Surface Roughness, Multi-Layer Perceptron, Radial Basis Function, Summation Wavelet-Extreme Learning Machine.

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N. P. Puneet ¹, P. Srinivasa Pai ¹, Grynal D’Mello ¹

Affiliations
1 Dept. of Mech. Engg., NMAM Institute of Technology, Nitte, IN

Abstract

This paper reviews the literature on use of optimization techniques in machining operations, particularly turning. Optimization techniques have undergone lot of changes and developments and include conventional methods like Weighted sum method, Ellipsoid algorithm etc. and advanced techniques like Genetic Algorithm (GA), Particle Swarm Optimization (PSO) etc. The review has been carried out considering different objectives like cost, cutting forces, production time and surface roughness. The review considers application of single method and combination of methods and its use in conventional and non-conventional material machining. Finally a case study which involves application of GA and PSO for optimizing surface roughness in high speed turning of mild steel is presented.

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P. Srinivasa Pai ¹

Affiliations
1 Dept. of Mechanical Engg. NMAM Institute of Technology, Nitte-574 110, Karnataka, IN

Abstract

There has been an increasing need for improving research potential at Universities and Institutions, to supplement the work done by the leading research Institutions in the country like the IITs. Faculty at engineering educational Institutions need to upgrade their skills both related to teaching and research. It so happens that most of the time, research stops after the acquisition of the Ph.D degree by the faculty and hence nothing much happens either in the Institutions or at the personal level by the faculty. Thus there is a need to rejuvenate and revitalize the research or teaching skills of the faculty, sometime after getting the Ph.D degree. This helps not only in improving the research or teaching skills of the faculty, but also helps in obtaining a new perspective about research, learn or improve upon existing skills, establish contacts and build networks for furthering research both at the personal or professional level. It helps the faculty in Learning the art of writing proposals, write technical papers of the highest quality, understand the nuances of independent research and contribute to the development of new research programs, improve existing programs and write proposals and get more funds to further research in a particular field. This paper provides an overview about the author's recent experience in completing an international post doctoral fellowship in an American University. This paper basically tries to put together the planning and efforts needed to take up such fellowships. The author hopes that the paper may provide some kind of guidance to new and young faculty to take up these opportunities in bettering their personal and professional lives and Leverage the most from these.

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P. Srinivasa Pai ¹, T. N. Nagabhushana ²

Affiliations
1 Dept. of Mech. Engg., NMAM Institute of Technology, Nitte, IN
2 Dept. of Information Science & Engg., S. J. College of Engg., Mysore, IN

Abstract

Tool Condition Monitoring (TCM) is a very important aspect to maintain quality of products manufactured in any machining process. Tool wear is a complex phenomenon occurring in different and varied ways in metal cutting processes. There is a need to identify the tool condition well in advance and take necessary action like replacement, to prevent damaged tools from negatively affecting production in terms of excessive power takeoff, inaccurate tolerances and uneven workpiece surface finish and some times damage to the machine tools and also injury to the operator. There is a need to reliably detect the condition of the tool and take necessary steps. Artificial Neural Networks (ANN) has been widely used for sensor fusion in TCM. This paper presents a brief overview of ANN and followed by it presents an overview of the application of ANN for tool condition monitoring and briefly to other manufacturing processes. Conclusions at the end of the paper contain a brief summary of some of the observations relevant to the application of ANN to TCM.

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P. Srinivasa Pai ¹, Bhaskara P. Achar ¹

Affiliations
1 Dept. of Mechanical Engineering, NMAM Institute of Technology, Nitte, IN

Abstract

Magnesium and its alloys are widely used in a number of applications including automotive and aerospace. Because of its biocompatibility, it is also being used in many medical applications including orthopedics. Machining is a commonly used manufacturing process to produce components. Magnesium because of its characteristics like light weight and other mechanical properties is the easiest to machine. But there are several issues related to its machining. There has been considerable research work going on outside India regarding machinability studies of magnesium alloys, but there have been very minimal efforts going on in India. In order to understand the various issues related to machining of magnesium alloys, this review is an honest effort to review the literature available regarding the same and classify them based on areas of relevance in machining and then draw some major conclusions from the review. The authors feel this review will help prospective researchers to get necessary information about machining of magnesium alloys.

Keywords

Magnesium Machining, Cryogenic Machining, Surface Integrity, Optimization, Cutting Temperature.

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P. Srinivasa Pai ¹, T. N. Nagabhushana ²

Affiliations
1 Dept. of Mechanical Engg., NMAM Institute of Technology, Nitte-574110, IN
2 Dept. of Information Science & Engg., S.J. College of Engineering, Mysore-570006, IN

Abstract

This paper attempts to monitor the surface roughness caused by the increase of tool wear (flank wear), through the variations of acoustic emission in face milling operations under different cutting conditions and for one workpiece material. The analysis revealed that there is a good correlation between two important parameters of the acoustic emission signal namely ring down count and RMS voltage with the surface roughness parameter namely R_a. The results show that acoustic emission can be used as an effective signal for monitoring surface roughness in face milling and thereby can be useful for establishing the end of tool life in face milling operations. Artificial Neural Network (ANN) is a powerful tool that can be applied to many scientific and engineering problems. In this paper a simple feed forward ANN has been applied to predict surface roughness using acoustic emission parameters, flank wear and cutting conditions.

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P. Srinivasa Pai ¹

Affiliations
1 Dept. of Industrial & Production/Mech. Engg., NMAM Institute of Technology, Nitte-574110, Karnataka, IN

Abstract

This paper discusses about the need to have Tool Condition Monitoring (TCM) Systems for achieving automation in manufacturing processes. Based on the literature available, some of the important techniques of tool condition monitoring are discussed. The complexity of the metal cutting processes with different variables coming to play during the process, makes it impossible for use of a single technique for TCM. In order to improve the reliability of TCM systems for better monitoring of metal cutting processes, the need for 'Sensor Integration’ is emphasized. Artificial Neural Networks are one of the most widely used method for sensor integration. A brief overview of the same is presented next.

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P. Srinivasa Pai ¹, Niranjan N. Chiplunkar ², B. R. Shrinivasa Rao ¹

Affiliations
1 Department of Mechanical Engg., NMAM Institute of Technology, Nitte – 574 110, Udupi District, Karnataka State, IN
2 NMAM Institute of Technology, Nitte – 574 110, Udupi District, Karnataka State, IN

Abstract

Project based learning (PBL) is increasingly being used in technical education as a learningmethodology to enhance student learning and make them useful to the society and employable. There is a need to integrate it into the existing curriculum to make it current and relevant to the society. Projects have been an integral part of technical education, ever since it started. But these have not been managed properly to make students realize the use of this for their learning. The needs of the industries keep changing and the developments in science and technology is so fast that existing technologies become outdated in no time. In this changing scenario, there is a need to implement PBL in the teaching-learning process to effectively attain the 'outcomes' of a course, as there is a transformation to 'Outcome-based Education' (OBE), and the accreditation is also OBE based. Among the various aspects, the role of faculty in effective implementation of PBL is very important. In this context, this paper will analyze the various issues faced by the faculty and then take one of the departments of the authors' institution for obtaining feedback based on a survey instrument. The preliminary findings are presenteda long with the general guidelines to be followed to overcome difficulties and to facilitate effective implementation of PBL.

Keywords

Project Based Learning, Faculty, Implementation, Questionnaire, Feedback.

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P. Srinivasa Pai ¹, K. Subrahmanya Bhat ¹, B. R. Shrinivasa Rao ¹, Niranjan N. Chiplunkar ¹

Affiliations
1 Dept. of Mechanical Engineering, NMAM Institute of Technology, Nitte – 574110. Karnataka, IN

Abstract

Engineering education has seen lot of changes in the last fifty years. There has been a drastic change in the way engineering education is delivered today than it was before. In today's world, the emphasis is on 'outcomes', and we are supposed to follow the 'outcomes based education' (OBE). The accreditation methodology adopted by the National Board of Accreditation (NBA) is outcomes based, where the focus in on the student (learner), rather than the teacher. In this scenario, the approach to teach engineering also should undergo a change and accordingly, this paper provides some thoughts on the need to follow a structured approach to teach engineering. The formal training of teachers is very much essential, as teachers lack awareness about the need to follow a proper methodology when they teach their students. A two day workshop carried out at the authors' institution has provided some valuable feedback regarding the need for such a structured approach to teach engineering. Such kind of programs / courses will go a long way in improving the quality of teaching and make the teachers more oriented towards OBE.

Keywords

Teaching Engineering, Outcome Based Education.

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P. Srinivasa Pai ¹, Niranjan N. Chiplunkar ¹

Affiliations
1 Department of Mechanical Engineering, NMAM Institute of Technology, Nitte – 574 110, Karnataka, IN

Abstract

Technical education system in India has undergone a transformation in the last several years. The focus is more on students to make them readily employable and face the competition. Research and teaching are the two important aspects of any higher education system, which complement each other and improve the quality of education. Research is an important component of the teachinglearning process, as its helps in disseminating current knowledge to the students and keeps them updated in their discipline. Thus teaching-research nexus has assumed lot of importance. Involvement of undergraduate students (UG) in research in technical Institutions is a recent phenomenon. It has been a regular feature in Institutions of National importance namely the IITs and NITs, but in private Institutions and Universities it is not happening regularly. There is a need to involve UG students in research, in order to stimulate them towards innovation. A country like India with a huge student population can really make wonders by making this happen and the students can be easily motivated and trained. This requires a ‘research-based curriculum’. In this regard, this paper tries to present a perspective on teaching-research nexus and evolve a broad framework for a research-based curriculum, with regard to authors’ Institution, which is an autonomous Institution, with lot of flexibility with regard to curriculum. This curriculum can help UG students to get a feel of research, when they are young and motivate them to take up research as a future career and also help them in their placements.

Keywords

Curriculum, Research, Undergraduate.

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Bhaskara P. Achar ¹, P. Srinivasa Pai ¹, G. Benaka ¹, Grynal D’mello ¹

Affiliations
1 Dept. of Mechanical Engineering, NMAM Institute of Technology, Nitte, IN

Abstract

Need for an efficient cutting tool and machining techniques are the prime requirements of modern machining industries. Certain domains such as defense, aerospace and automobile use the typical ‘difficult to cut materials’, which has specific applications. Materials’ machinability, tool life, surface finish achieved by the machining process, factors affecting surface quality and tool life are the key areas of investigations that researchers are focusing on. In this paper two difficult to machine materials namely Inconel 718 and Stellite 6 have been experimentally investigated for their machining characteristics. The effect of Flood and Jet cooling techniques on the machinability of these materials have been compared with dry machining, having a focus on tool wear, surface roughness, cutting temperature and cutting vibrations.

Keywords

Inconel 718, Stellite 6, Jet Cooling, Surface Finish, Cutting Temperature.

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Ganesha Prasad ¹, P. Srinivasa Pai ²

Affiliations
1 Department of Mechanical Engineering, Shri Devi Institute of Technology, Kenjar, Mangalore, Karnataka, IN
2 Department of Mechanical Engineering, NMAM Institute of Technology, Nitte, Karnataka, IN

Abstract

Machining processes have undergone lot of changes over the last several years to improve the quality and productivity. There are several important problems, faced by machinists when machining so called ‘difficult-to-machine’ materials, which includes metals, alloys, composites, rubber, refractory materials etc. These include excessive tool wear, temperature, severe work hardening, chip formation and breakage, bad surface finish and surface integrity. Cryogenic cooling is a relatively new cooling technique explored by researchers and industries all over the world to machine these materials and reduce the associated problems. There has been lot of research articles available in this domain. In this regard, this paper reviews research articles published during 2000 to 2018, with focus on introduction of cryogenics to machining, some details of difficult to machine materials, effect of cryogenics on surface finish, tool wear, chip formation and breakage, microstructure and hardness. About 108 articles have been reviewed and salient conclusions are drawn at the end of the paper, which establishes the fact that cryogenic machining is going to be an important machining technique, which will be adopted by industries to produce better quality products from machining of these materials and promote ‘sustainability in machining’.

Keywords

Cryogenic Machining, Difficult to Machine Materials, Tool Wear, Surface Roughness.

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P. Vasudeva Bhat ¹, P. Srinivasa Pai ¹

Affiliations
1 NMAM Institute of Technology, Nitte, Karnataka, IN

Abstract

There are lots of research happening in high speed machining especially for hard materials which find its applications in vast areas like aerospace, marine, automobiles etc. The main parameters which need to be taken care of while doing high speed machining are surface roughness and tool wear. To achieve high degree of surface finish and close tolerance in the work piece materials, care should be taken to select the right type of tool and lubrication. The conventional type flood lubrication system is found to be having more cost involved and also more time and work is involved in cleaning and disposal of used lubricants, which is also an ecological hazard. For high speed machining, reducing the temperature generated is the main concern by using suitable cooling system. In this regard Minimum Quantity Lubrication (MQL) has been found to be more effective compared to other lubrication systems. This paper presents a review of research work with regard to MQL and its systems with suitable additions for machining difficult to machine materials. An overview about different lubrication system types is presented, followed by some of the commonly used MQL systems. Further the different aspects related to use of MQL in different applications is presented, followed by the use of additives in MQL like use of nano particles is reviewed, to understand its effect on the performance of MQL. MQL with nano particles is more effective in reducing tool wear and surface roughness for all types of machining processes.

Keywords

Minimum Quantity Lubrication, Surface Roughness, Tool Wear, Difficult-To-Machine Materials, Nanoparticles.

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