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Dhanbād, India

Kannan S.,IIT ISM | Senthil Kumaran S.,RVS Educational Trusts Group of Institutions | Kumaraswamidhas L.A.,Indian School of Mines
Journal of Alloys and Compounds | Year: 2016

In this present study, Tungsten inert gas (TIG) welding was applied to weld the dissimilar materials and authenticate the mechanical and metallurgical properties of tube to tube plate made up of commercial aluminium and Al 2025 respectively using an Zirconiated tungsten electrode along with filler material aluminium ER 2219. In total, twenty five pieces has been subjected to compression strength and hardness value to evaluate the optimal joint strength. The three optimization technique has been used in this experiment. Taguchi L25 orthogonal array is used to identify the most influencing process parameter which affects the joint strength. ANOVA method is measured for both compression strength and hardness to calculate the percentage of contribution for each process parameter. Genetic algorithm is used to validate the results obtained from the both experimental value and optimization value. The micro structural study is depicted the welding joints characterization in between tube to tube plate joints. The radiograph test is conducted to prove the welds are non-defective and no flaws are found during the welding process. The mechanical property of compression strength and hardness has been measured to obtain the optimal joint strength of the welded sample was about 174.846 MPa and 131.364 Hv respectively. © 2016 Elsevier B.V. All rights reserved. Source


Pandia Rajan S.,IIT ISM | Senthil Kumaran S.,RVS Educational Trusts Group of Institutions | Kumaraswamidhas L.A.,IIT ISM
Alexandria Engineering Journal | Year: 2016

Friction welding is widely used as a large scale production method for fabrication in various industries such as automotive, aeronautic and other industries. Friction welding of tube to tube plate using an external tool (FWTPET) is an innovative friction welding process which is accomplished of manufacturing leak proof high quality weld joints with good mechanical properties. In this study, the friction welding is carried out to weld two dissimilar materials of SA 213 tube to SA 387 tube plate with three different filler materials as brass sheet, filler plate and steel ball using an external tungsten carbide tool to enhance and validate the flow of metal pattern toward the center of tool axis. The micro structural studies are made to reveal about the welding configuration locate and discover the flow of metal path toward the center of the workpiece, then it is followed by the hardness test which ensures a high hardness value at welded zone determines the flow of metal toward the center of the hole has strong bonding structure. Finally, the workpiece with filler material and steel ball is used by the radiography test and the analysis is done by using ANSYS software. © 2016 Faculty of Engineering, Alexandria University. Source


Mathan Kumar N.,IIT ISM | Senthil Kumaran S.,RVS Educational Trusts Group of Institutions | Kumaraswamidhas L.A.,IIT ISM
Alexandria Engineering Journal | Year: 2016

Al 2618 matrix material was mixed with the Silicon Nitride (Si3N4), Aluminium Nitride (AlN) and Zirconium Boride (ZrB2) reinforced particles. AMC was synthesized successfully by the stir casting method with the various X-wt.% of reinforcements (X =0,2,4,6,8). Tribological behaviour was studied in this composite with various temperature conditions. The working conditions were Temperature (°C), Load (N), Velocity (m/s) and Sliding Distances (m). Before wear testing the mechanical behaviour has been analysed. EDAX was confirmed by the matrix material composition. The Al 2618 alloy and the reinforcement mixers were confirmed by the X-ray Diffraction analysis. Wear rate (mm3/m), Wear resistance (m/mm3), Specific Wear rate (m/Nm) and Co-efficient of friction (μ) were analysed with various conditions. The worn surfaces were analysed before and after wear testing by Scanning Electron Microscope (SEM). Influence of process parameters and Percentage of contribution were analysed by Taguchi and Analysis of Variance (ANOVA) methods. Genetic Algorithm (GA) was adopted for optimizing the best and mean of the wear rate and to identify the exact influence of input parameters. © 2016 Faculty of Engineering, Alexandria University. Source


Kumar N.M.,IIT ISM | Senthil Kumaran S.,RVS Educational Trusts Group of Institutions | Kumaraswamidhas L.A.,IIT ISM
Journal of Alloys and Compounds | Year: 2016

In this investigation, Aluminium Matrix Composite (AMC) has implicated in this paper. The Aluminium 2618 alloy is taken as the Matrix material along with Reinforcement particles such as Silicon Nitride (Si3N4), Aluminium Nitride (ALN) and Zirconium Boride (Zrb2). It is well mixed with Al 2618 alloy in various weight percentages (Wt. % = 0,2,4,6,8) by stir casting method. The Mechanical properties like hardness, tensile strength, compressive Strength for Al 2618 composites were increased along with increasing Wt. % of reinforcement. A new attempt has been tried to optimize the parameters to obtain minimum value in Material Removal Rate (MRR), Tool Wear Rate (TWR) and Depth (mm) through Electrical Discharge machining process (EDM) at elevated temperatures. The input process parameters are taken for the machining is Temperature (°C), Pulse ON (μS), Pulse OFF (μS) and Current (Amps). Taguchi L25orthogonal array was used to identify the optimize parameter is MRR, TWR and Depth. Each parameters contribution in percentage was calculated by the Analysis of Variance (ANOVA). The exact input and output parameters were examined with help of Genetic Algorithm (GA). © 2015 Elsevier B.V. Source


Kumar N.M.,IIT ISM | Kumaran S.S.,RVS Educational Trusts Group of Institutions | Kumaraswamidhas L.A.,IIT ISM
Journal of Alloys and Compounds | Year: 2015

Abstract It is submitted that new approach is tried to find out what would be the outcome if Aluminum 2618 reinforced by AlN (Aluminum Nitride), Si3N4 (Silicon Nitride) & ZrB2(Zirconium Boride) particles were fabricated in Wt % (x = 0,2,4,6,8) by stir casting method. If the wt% is increased, the mechanical properties of the composite will proportionally increase. There will be no other promising technique than Electrical Discharge Machining (EDM) for machining metal matrix composites when they were conducted on the Aluminum 2618 composite work piece using a copper electrode in an EDM machining. It becomes very vital in the field machines and mechanism to find out Current(I), Pulse on time(TON), Pulse off time (TOFF) on Metal Removal Rate (MRR),Tool Wear Rate(TWR) on the machining of hybrid Al2618 metal matrix composites. Taghuchi's design of experiment was used to analyse the machining characteristics of hybrid composites. To effect the parameters like current (I), Pulse on time(TON), Pulse off time (TOFF) has been chosen as the input parameters of this work. Machining results go to show that Al2618 composites have improved mechanical properties and as a result of Material Removal Rate (MRR) and Tool Wear Rate (TWR) are reduced. Hence ANOVA (Analysis of Variance) and signal to Noise ratio are used to determine the influence of input parameters on the Material Removal Rate and Tool Wear Rate (TWR). © 2015 Elsevier B.V. Source

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