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Ramesha N.,Government Tool Room and Training Center | Akhtar S.,Sant Longowal Institute of Engineering And Technology
Polymer Composites | Year: 2016

Banyan tree saw dust powder (BSD) filled Polypropylene (PP) green composites have been fabricated with varying amounts viz., 0%, 20%, and 40% of BSD particulate filler by using a co-rotating twin screw extruder followed by injection molding. The mechanical properties such as surface hardness, tensile behavior, and impact strength of the fabricated PP/BSD green composites have been studied in order to standardize the composites. Abrasive water jet (AWJ) machining has been reported mainly for ceramics, concrete, and glass but not much literature is available on AWJ machining of polymer composites. This research is aimed at examining the AWJ machining of green polymer composites. The effect of BSD loading on the AWJ machining behavior of the PP/BSD green composites has been investigated. Furthermore, the effect of addition of 4% maleic anhydride grafted PP (coupling agent) and 4% talc (mineral filler) on the machining behavior of PP/BSD composites has also been evaluated. Surface roughness and optical micrographs of the AWJ cut composite specimens were examined to assess the effect of BSD content, AWJ traverse speed and pressure on the machining behavior of the composites. In order to probe the mechanism of AWJ machining behavior of PP/BSD composites, the kerf width and taper have been measured and results are correlated. © 2014 Society of Plastics Engineers. Source


Sridharakeshava K.B.,Government Tool Room and Training Center | Ramesh Babu K.,Government Tool Room and Training Center
IET Conference Publications | Year: 2013

Fixtures are special production tools which make the standard machine tool, more versatile to work as specialized machine tools. Fixture planning is a complex activity restricted by the complexity of work pieces size, shapes and including machine tools, assembly tools, and cutting tools. This paper reviews methods and techniques for the geometry analysis of fixture feasibility in product development. Fixture synthesis methods including geometrical analysis and fixture assembly planning are surveyed. The implementation of CAD-based fixture planning system is discussed in respect to their reasoning methods, functionality, limits and potentials. Source


Anil Kumara H.T.,Government Tool Room and Training Center | Ramesh Babu K.,Government Tool Room and Training Center
IET Conference Publications | Year: 2013

Due to heavy demand in plastic products, plastic industries are growing in a fastest rate. Plastic injection moulding begins with mould making and in manufacturing of critical shapes. The optimum gate location is one of the most important criterions in mould design. Mould Flow analysis is a powerful simulation tool to optimize the best gate location and to predict the production time required at the lowest possible cost. Verification using simulation requires much less time to achieve a quality result, and with no material costs, as compared with the conventional trialand- error methods on the production floor. In this paper, an attempt has been made in analysis by taking four gate locations for a rectangular - shaped plastic component. Mould Flow Plastic simulation software is used for the analysis and the optimum gate location is found with least defects. The placement of a gate in an injection mould is one of the most important variables of the total mould design. The tool is of single cavity mould. The component has got 12 circular holes, rectangular slots, flat openings which requires two side cores and two core inserts. This asks for a finger cam in tool construction. Analysis for filling, flow, best gate location and cooling is carried out using mould flow software.The quality of the moulded part is greatly affected by the gate location, because it influences the manner in which the plastic flows into the mould cavity. The mould flow analysis helps in reducing costs and time and also prevents other defects occurring in the process. Source


Santhosh V.,Government Tool Room and Training Center | Ramesh Babu K.,Government Tool Room and Training Center
IET Conference Publications | Year: 2013

This paper presents the design of a plastic injection mould for producing ejector component and performing wrapage analysis for the moulded component. The technique, theory, methods as well as consideration needed in designing of plastic injection mould are presented. Design of mould was carried out using design software and wrapage analysis is done in simulation software. The results show that shrinkage is likely to occur in the region near the cooling channels as compared to other regions. This uneven cooling effect at different regions of mould contributed to warpage. During cooling, location near the cooling channel experiences more cooling than location far away from the cooling channel. This different temperature causes the material to experience differential shrinkage causing thermal stresses. Significant thermal stress can cause warpage problem. Therefore, it is important to simulate the wrapage analysis of the injectionmolded part during the cooling stage. By understanding the characteristics of wrapage, deformation caused can be predicted. Source


Yogeshkumar K.S.,Government Tool Room and Training Center | Ramesh Babu K.,Government Tool Room and Training Center
IET Conference Publications | Year: 2013

Jigs and fixtures are special production tools which make the standard machine tool, more versatile to work as specialized machine tools. Fixture planning is a complex activity restricted by the complexity of work pieces size, shapes and including machine tools, assembly tools, and cutting tools. This paper reviews methods and techniques for the geometry analysis of fixture feasibility in product development. Fixture synthesis methods including geometrical analysis and fixture assembly planning are surveyed. The implementation of CAD-based fixture planning system is discussed in respect to their reasoning methods, functionality, limits and potentials. Source

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