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Saravanan R.,Bannari Amman Institute of Technology
International Journal of Advanced Manufacturing Technology | Year: 2010

With the advent use of sophisticated and high-cost machines coupled with higher labor costs, concurrent optimization of machining process parameters and tolerance allocation plays a vital role in producing the parts economically. In this paper, an effort is made to concurrently optimize the manufacturing cost of piston and cylinder components by optimizing the operating parameters of the machining processes. Design of experiments (DoE) is adopted to investigate systematically the machining process parameters that influence product quality. In addition, tolerance plays a vital role in assembly of parts in manufacturing industries. For the selected piston and cylinder component, improvements efforts are made to reduce the total manufacturing cost of the components. By making use of central composite rotatable design method, a module of DoE, a mathematical model is developed for predicting the standard deviation of the tolerance achieved by grinding process. This mathematical model, which gives 93.3% accuracy, is used to calculate the quality loss cost. The intent of concurrent optimization problem is to minimize total manufacturing cost and quality loss function. Genetic algorithm is followed for optimizing the parameters. The results prove that there is a considerable reduction in manufacturing cost without violating the required tolerance, cutting force, and power. © 2010 Springer-Verlag London Limited. Source

Perumalraj R.,Bannari Amman Institute of Technology
Journal of Industrial Textiles | Year: 2013

A study of single-stage antimicrobial and crease proof finishing of cotton materials has been reported. The bleached and reactive dyed cotton woven fabrics have been selected for this finishing process. The various concentrations of DMDHEU and triclosan and temperature have been selected to analyze the crease recovery and antimicrobial properties of fabric using Box-Behnken design. It was observed that increasing the concentration of DMDHEU and triclosan increases the crease recovery angle. It is also observed that the breaking strength retention properties have been reduced when increasing the concentration of DMDHEU and triclosan and temperature. It is also found that the antimicrobial effect was increased when the concentration of DMDHEU and triclosan increased. © The Author(s) 2012 Reprints and permissions: sagepub.co.uk/journalsPermissions.nav. Source

Anandha Moorthy A.,Bannari Amman Institute of Technology
International Review of Mechanical Engineering | Year: 2013

AA2218 based self-lubricating metal matrix composite was prepared with 5, 10 & 15 weight percent of fly ash and 4 weight percentage of MoS2. Dry sliding wear behavior of self lubricating composite was tested at room temperature by pin on disc wear testing apparatus. Wear rate, Coefficient of friction and volume loss of self lubricating composite has been tested as the result of applied load, sliding velocity and weight percent of fly ash particles. From this investigation it was observed that the wear rate increases with the increasing load, at the same time wear rate and coefficient of friction get reduced to increase in wt. % of fly ash particles. Another dominant factor is the formation of the tribochemical layer at the interface, which was formed by MoS2. Formation of tribochemical layer was clearly observed from SEM micrographs. This study reveals that wear resistance of the self-lubricating composites containing 15 wt. % fly ash and 4 wt. % MoS2 has been superior to that of the other compositions. © 2013 Praise Worthy Prize S.r.l. - All rights reserved. Source

Ayyappan S.,Government of Tamilnadu | Sivakumar K.,Bannari Amman Institute of Technology
International Journal of Advanced Manufacturing Technology | Year: 2014

This paper investigates the performance enhancement of electrochemical machining (ECM) process by oxygenated aqueous sodium chloride (NaCl) electrolyte. It is experimentally found that the performance parameters such as material removal rate (MRR) and surface roughness (Ra) are greatly improved with this new mix of electrolyte. The oxygen gas is suitable to electrochemically react with aqueous NaCl solution to enhance the oxidation of metal oxides on the machined surface to increase the MRR. In this work, experimental investigations are conducted with both aqueous NaCl electrolyte and oxygenated aqueous NaCl electrolyte on the alloy steel specimen (20MnCr5). Largest MRR of 7.33 g/min with Ra of 1.90 μm is obtained in oxygenated NaCl environment compared to MRR of 1.98 g/min and Ra of 3.13 μm in aqueous NaCl environment with machining conditions of voltage (V) of 17 V, tool feed rate (F) of 0.5 mm/min, and electrolyte concentration (EC) of 142.5 g/l of water. Microstructure of surface of the specimen machined with oxygenated aqueous NaCl electrolyte is more homogeneous and promises a good surface quality. © 2014, Springer-Verlag London. Source

Boopathi S.,Bannari Amman Institute of Technology | Sivakumar K.,Bannari Amman Institute of Technology
International Journal of Advanced Manufacturing Technology | Year: 2013

The near-dry wire-cut electrical discharge machining (WEDM) process is an environment-friendly manufacturing process, in which there is no harmful effect to the operators. The authors focus on the non-polluting ways to cut the materials and to meet the technical requirements like high material removal rate (MRR) and low surface roughness (Ra). In the near-dry WEDM, the finite discrete periodic series sparks between the wire electrode and conducting work material separated by minimum quantity of deionized water mixed with compressed air (air-mist) as a dielectric medium. In the present research, parametric analysis of the process has been performed with the molybdenum wire tool and high speed steel (HSS-M2) work piece. Experiments have been performed using air-mist as the dielectric medium to study the impact of gap voltage, pulse-on time, pulse-off time, airmist pressure and discharge current on the MRR and Ra using the mixed orthogonal (L18) array-Taguchi method. Taguchi based analysis of variance test was performed to identify the significant parameters. The gap voltage, pulse-on time, discharge current and air-mist pressure were found to have momentous effects on MRR and Ra. The best regression models for MRR and Ra have been developed by regression analysis. The optimal rough and finish cutting parameters have been predicted by Pareto-front using the multi-objective evolutionary algorithm (MOEA). © Springer-Verlag London 2012. Source

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