Informatics Publishing Limited

Hemanta Singha ¹, V. Jayakumar ¹, G. Ragul ²

Affiliations
1 Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha University, Chennai, IN
2 Department of Mechanical Engineering, Budge Budge Institute of Technology, Kolkata – 700137, West Bengal, IN

Abstract

Background/Objectives: The adoption of cellular manufacturing becomes promising manufacturing philosophy to address the problems of today’s manufacturing plants such as an increasingly turbulent environment and rising customer requirements. Method/Statistical Analysis: Group Technology and Cellular Manufacturing System (CMS) have together paved way for the same through processing of similar parts groups as part families and the formation of a machine cell dedicated for the manufacture of the part family. The traditional CMS design methods do not incorporate many real-life manufacturing parameters such as batch size and machine flexibility, various cost factors at the design stage and also they are not taking the advantage of the machine flexibility in terms of coexistence of alternate process routing. Findings: In this work, a comprehensive mathematical model has been developed capturing these exact production parameters. An optimal solution is obtained using Lingo 8.0 software package and a solution methodology of best possible cell configurations is formed. Applications/Improvements: The effect of considering the alternate process routing in the design stage of CMS is evaluated and it is found that routing flexibility results in better cell configurations.

Keywords

Alternative Routing, Cellular Manufacturing System (CMS), Operation Sequence and Varying Batch Size.

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N. Sivakumar ¹, N. K. Geetha ², J. Venkatamuthukumar ¹, V. Jayakumar ³

Affiliations
1 Department of Physics, School of Engineering, Saveetha University, Thandalam, Chennai - 602105, Tamil Nadu, IN
2 Department of Mathematics, School of Engineering, Saveetha University, Thandalam, Chennai - 602105, Tamil Nadu, IN
3 Department of Mechanical Engineering, School of Engineering, Saveetha University, Thandalm, Chennai - 602 105, Tamil Nadu

Abstract

Background/Objectives: Mechanical properties of the selected materials play an important role in device fabrications. Thus the perfect cleavage (010) plane of doped and un-doped Potassium Hydrogen Phthalate (KHP) crystal is subjected to Vicker’s micro hardness study. Methods/Statistical Analysis: Slow evaporation solution growth method is employed for the growth of Fe³⁺ doped and un-doped Potassium Hydrogen Phthalate (KHP) crystals. Here, 0.1 mol% of FeCl₃ used as dopant. Saturated solution of both doped and un-doped KHP solutions are prepared according to the solubility data (12.5g/100ml at 30°C). Findings: A well developed (010) plane of pure and un-doped crystals have been subjected to hardness studies with various loads. It is found that Vickers Hardness numbers (H_V) for undoped and doped KHP crystals varied for different loads. Meyer’s index or work hardening co-efficient (n) values are found to be greater than 1.6 which reveals that the grown crystals are belongs to soft material’s category. i.e., for pure KHP the value of ‘n’ is 3.68 and for Fe doped KHP, it is 3.46. The minimum load indentation (W) to initiate the plastic deformation on the surface of the crystals are calculated based on Hays and Kendall’s theory. The value of W for KHP and doped KHP are found to be 1.965 and 4.368 respectively. The hardness related constants like materials constant (k₁) and load dependent constant (A₁) for the pure and un-doped KHP crystals have been estimated. The Elastic stiffness constant (C₁₁) are also calculated from Vickers micro hardness values. Applications/Improvements: Potassium Hydrogen Phthalate (KHP) is an efficient crystal analyzer material and is used in X-ray spectrometer. The improvement in hardness by dopant provides the use of materials for efficient optical device applications.

Keywords

Elastic Stiffness Constant, Load Dependent Constant, Material Constant, Meyer’s Index, Minimum Load Indentation, Vickers Hardness Number.

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G. Ragul ¹, G. Kalivarathan ², V. Jayakumar ³, Praveen Maruthur ², Into Jacob ², S. Naveen Kumar ⁴

Affiliations
1 Department of Mechanical Engineering, Budge Budge Institute of Technology, Kolkata – 700137, West Bengal, IN
2 Department of Mechanical Engineering, Nehru College of Engineering and Research Centre, Thrissur – 680597, Kerala, IN
3 Department of Mechanical Engineering, Saveetha University, Chennai – 602105, Tamil Nadu, IN
4 Department of Mechanical Engineering, St. Josephs Collegeof Engineering, Chennai – 600119, Tamil Nadu, IN

Abstract

Objectives: This paper reports an investigation that was carried out for modelling and structural analysis of cam shaft. Methods/Statistical Analysis: The modelling of cam shaft is carried out using the software solid works and the structural analysis of the model is carried out by using Ansys software. Initially, the model is designed with Solid works software and then it is converted into Initial Graphics Exchange Specification (IGES) file. Then it is systematically analyzed using the IGES model of cam shaft. Experimental results under static load containing the stresses and deflection are predicted cast iron material. Findings: Testing was carried out for unidirectional different materials like ductile cast iron, nodular iron and carbon epoxy. By considering these materials, it is noted that the ductile cast iron is a good material compared to the nodular iron because the breakage of nodular cast iron is higher than the ductile cast iron. Application\ Improvements: Ductile cast iron is considered for making the cam shaft in vehicles because the cost of material slightly higher than nodular iron. In the development of modelling and also analyse by software helps to better result in design.

Keywords

Cam shafts, Gray cast iron, Spheroidal cast iron, Carbon Epoxy, Solid works and Ansys.

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G. Ragul ¹, Arun Thampi ², Tedy Thomas ², C. P. Praveen ², Into Jacob ², V. Jayakumar ³, S. Naveen Kumar ⁴

Affiliations
1 Department of Mechanical Engineering, Budge Budge Institute of Technology, Kolkata – 700137, West Bengal, IN
2 Department of Mechanical Engineering, Nehru College of Engineering and Research Centre, Thrissur – 680597, Kerala, IN
3 Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha University, Chennai – 602105, IN
4 Department of Mechanical Engineering, St. Josephs College of Engineering, Chennai - 600119, Tamil Nadu, IN

Abstract

Objectives: This paper aims at studying force distribution characteristics and load with standing capability of a remodelled IC engine piston connecting rod arrangement where the conventional single piston single connecting rod arrangement is replaced by linking two pistons with a single connecting rod. Methods\Statistical Analysis: 3D Modelling of the arrangement is carried out using Solid works while force analysis of the model is done using ANSYS workbench. Parallel twin cylinder 4 stroke petrol engine is utilized as reference for creating the model and analysis purpose. Findings: The results gives the theoretical evidence that there can be a considerable reduction in engine weight and complexity with this new arrangement with stress, deformation and strain values lying within the boundary. Applications\Improvements: This arrangement gives extra room for lubricants thereby indeed indirectly increasing performance characteristics.

Keywords

Aluminium Alloy, Brake Power, Connecting Rod, Piston, Internal Combustion Engine, Solid Works and Ansys.

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G. Ragul ¹, S. Naveen Kumar ², G. Kalivarathan ³, V. Jayakumar ⁴, C. P. Praveen ³, Into Jacob ³

Affiliations
1 Department of Mechanical Engineering, Budge Budge Institute of Technology, Kolkata, IN
2 Department of Mechanical Engineering, St. Josephs College of Engineering, Chennai, IN
3 Department of Mechanical Engineering, Nehru College of Engineering and Research Centre, IN
4 Department of Mechanical Engineering, Saveetha University, Chennai, IN

Abstract

Objectives: To compare the process parameters such as tool performance, surface roughness in turning process under, dry and near-dry conditions. Methods\Statistical Analysis: This study deals with the comparative performance of carbide coated tools in conventional dry turning with minimal lubricant application method by varying depth of cut keeping feed and speed as constant. The performance of the tool and the roughness of the work material under different conditions are analyzed. Findings: It is found that according to the selected cutting conditions in the model-based comparisons, the predicted tool wear under near dry lubrication are reduced as high as about 30% compared with those in dry cutting while the predicted tool wear land lengths are reduced by 60% compared with those in dry cutting. After the physical behaviors in near dry turning are understood, it is possible to calculate the tool life with given material properties and cutting conditions. Applications\ Improvements: This study gives sufficient information about performance of carbide tool with minimum amount of lubrication.

Keywords

Carbide Coated Tools, Dry Turning, Eco Friendly Environment, Minimum Quantity Lubrication (MQL), Surface Roughness.

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R. Suthan ¹, V. Jayakumar ², S. Madhu ³

Affiliations
1 Dept. of Mech. Engg., Panimalar Engg. College, Chennai, Tamil Nadu, IN
2 Dept. of Mech. Engg., Saveetha School of Engg., Saveetha Institute of Medical and Technical Scis., Tamil Nadu, IR
3 Dept. of Auto. Engg., Saveetha School of Engg., Saveetha University, Chennai, IN

Abstract

Kevlar fiber reinforced polymer composites are rapidly growing in manufacturing applications such bicycle tires and racing sails to body armor, bullet proof vests, military helmets, walking boots etc. Kevlar epoxy composite material using the Kevlar fiber and epoxy resin LY-556 was fabricated with manual hand layup procedure. The mechanical characteristics like tensile, impact strength and flexural rigidity were evaluated. With the results obtained it is found that kevlar epoxy composite provides better mechanical characteristics than aluminum. In this work, the possibility of replacing aluminum with Kevlar reinforced epoxy composite material is investigated for various applications viz. manufacturing of bus body frame, bullet proof vests, automobile body, sports applications, fire proof clothing, military helmets etc. Also, the FE analysis is carried out with MIDAS NFX software to correlate the test results with FEA.

Keywords

Composite Material, Kevlar, Mechanical Tests, Finite Element Analysis.

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D. Santhoshkumar ¹, V. Jayakumar ², M. Ravi Teja Reddy ¹, A. Muniappan ¹

Affiliations
1 Dept. of Mech. Engg., Saveetha School of Engg., Saveetha Institute of Medical and Technical Sci., Chennai, IN
2 Dept. of Mech. Engg., Saveetha School of Engg., Saveetha Institute of Medical and Technical Scis., Tamil Nadu, IN

Abstract

Vibrations are caused in an engine due to the continuous motion of reciprocating and rotating parts. Engine mounts are used as the vibration isolators from the engine to frame. The absorbing capacity of the mounts should be large enough to withstand the vibrational force for longer periods. Engine mount’s strength depends upon the material and the type of the design. The modelling and assembly of the engine mount is done using solidworks and the analysis of the mount is done using Ansys software. Modal analysis is done on the engine mount at working frequency. With the results obtained, factor of safety is calculated and it is compared with the existing mount. The proposed engine mount model results in encouraging factor of safety value.

Keywords

Vibrations, Engine Mount, Modal Analysis, Finite Element Analysis.

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M. Ravi Teja Reddy ¹, V. Jayakumar ², D. Santhoshkumar ¹, A. Muniappan ¹

Affiliations
1 Dept. of Mech. Engg., Saveetha School of Engg., Saveetha Institute of Medical and Technical Sci., Chennai, IN
2 Dept. of Mech. Engg., Saveetha School of Engg., Saveetha Institute of Medical and Technical Scis., Tamil Nadu, IN

Abstract

In order to isolate the vibrations in rotating machineries, engine mounts are used. In this paper, a novel engine mount that is specially designed using fluorocarbon material is experimentally assessed for an improved performance with an existing rubber based engine mount. The changes are made in the dimensions of the existing engine mount for better vibration absorption. Experimental results have shown a considerable benefit in vibration suppression by the engine mount using fluorocarbon more than the ones using rubber.

Keywords

Vibrations, Engine Mount, Fluorocarbon, Tractor Engine, Experimental Mechanics.

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Abdul Hafeez Asif ¹, V. Jayakumar ², Chintala Sai Virinchy ¹, K. Shanmuganandam ¹

Affiliations
1 Dept. of Mech. Engg., Saveetha School of Engg., Saveetha Institute of Medical and Technical Sci., Chennai, IN
2 Dept. of Mech. Engg., Saveetha School of Engg., Saveetha Institute of Medical and Technical Scis., Tamil Nadu, IN

Abstract

For the past few decades the wheels of an automobile are usually made out of alloy materials. Due to the increased demand for peculiarity and enhanced outlook, metal matrix composites can be used for the alloy wheels. They enhance the performance of the vehicle by reducing its weight and thereby increasing its fuel efficiency. Many literature works are initiated and progressed on design and development of automotive alloy wheels. There is a scope for enhancing their properties with reinforcements. This study focuses on manufacturing a novel metal matrix composite material comprising aluminium as metal matrix and magnesium, silicon carbide and fly ash as reinforcements. The newly fabricated composition is tested. The alloy wheel is further analysed using ANSYS. The analysis results are compared with that of the existing aluminium alloy. The obtained results confirm that the proposed metal matrix composite is a reliable replacement for the aluminium alloy.

Keywords

Alloy Wheels, Aluminium Metal Matrix Composite, Finite Element Analysis, Mechanical Testing.

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