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Hatia, India

Tiwari A.,BIT | Mandal A.,NIFFT | Kumar K.,BIT
Materials Today: Proceedings | Year: 2015

Objective: of thework is to achieve best optimal combination of various input parameter for radial over-cut (ROC) in electrochemical machining for EN 19 tool steel with copper electrodeapplyingtaguchitechnique. The electrolytic concentration, voltage, feed rate and inter electrode gap are considered as input process parameters for electro-chemical machining. Optimal combination of selected input parameters utilized in order to achieve the minimum overcut effects for better accuracy of shape features. The experiments were undertaken as per taguchiL27 orthogonal array (OA) with three levels for each machining parameter. The Design of Experiments of L27 orthogonal array was tabulated with the aid of Minitab software version 16. The impact of each machining process parameterswere predicted by performing ANOVA at 95% level of significance. This paper also stress on the development of mathematical model by using regression analysis, second order response equation obtained between the controllable variables and parametric interactions for overcut as response. From the obtained results, it wasobserved thatvoltage and concentrationwere the most dominating criteria for minimization of overcut. © 2015. Source

Sahoo S.,Indian Institute of Technology Kharagpur | Kumar A.,NIFFT | Dhindaw B.K.,Universiti Sains Malaysia | Ghosh S.,Indian Institute of Technology Kharagpur
Materials and Manufacturing Processes | Year: 2013

Mathematical modeling of the solidification behavior of Al-33 wt% Cu strips in a twin roll caster at speeds varying between 0.079 m/s to 3.98 m/s predicted that at high casting speed strips will have layered structure with distinct morphology. The model was validated by production of Al-33 wt% copper strips in a laboratory twin roll caster. As per the prediction from the model the high speed cast strips had layered structure with zones near the roll surface showing higher hardness as compared to the interior. Copyright © 2013 Taylor and Francis Group, LLC. Source

Tiwari A.,BIT Mesra | Mandal A.,NIFFT | Kumar K.,BIT Mesra
Materials Today: Proceedings | Year: 2015

Quality of machined surface strongly depend on the selection of optimal parameter settings and type of machining process. Electro-chemical machining (ECM) offers several unique feature, like higher machining rate, better surface finish, and it is suitable for machining a wide range of materials. In this regard, an attempt has been made to develop a mathematical model for responses i.e. metal removal rate (MRR) and surface roughness (SR) through regression analysis for electro-chemical machining on EN 19. And analysis of variance (ANOVA) test is perform to check the aptness of the developed mathematical models. The performance for ECM process is optimized through Non-dominated Sorting Genetic Algorithm-II (NSGA-II) for maximizing the metal removal rate and minimizing the surface roughness. Through this non-dominated optimum parameter settings has been obtained and reported. © 2015 Elsevier Ltd. Source

Pathak A.K.,NIFFT
Advanced Materials Research | Year: 2012

Lean manufacturing production system considers the expenditure for any goals other than the creation of value for the end customer to be wasteful. Only operation adds value to the product and other functions such as inspection, transportation, and delays of a permanent or temporary nature are waste and should be eliminated. The beginning of lean manufacturing can be seen in Just In Time (JIT). It was first implemented in Ford automobile in the form of line assembly. Lean manufacturing is based on pull system. In the pull system parts are produced when they are pulled by the process before that. Lean manufacturing defines the value of a product or a service with the customer point of view not on the basis of type of technology and amount of labour. In the lean manufacturing the organization is treated as a single unit. Team work is more important than individual effort. The implementation of lean manufacturing reduces lead time, reduces work in progress (WIP), saves floor space, increases productivity, improves quality and reduces overall cost. In this paper various aspects of lean manufacturing have been examined and discussed. © (2012) Trans Tech Publications. Source

Das R.,KIIT University | Sarmah A.,KIIT University | Sood A.,NIFFT
Procedia Engineering | Year: 2014

Extrusion process has proved its potential in bulk metal forming process since the industrial development. The better product quality, mechanical property and the strength of the extruded products are the advantages in extrusion process. Multi-hole extrusion is used where pressure required for extrusion is in excess of press capacity. It is used for the production of small and precise products such as parts used in automobiles, health-care and aviation industries. The different process parameters affect the extrusion process and quality of the extruded products. In the present investigation, finite element analysis is carried out to study the effect of loaction of holes on the die, die pockets and the extrusion speed on the extrusion load, efective strain and the extruded product length. Extrusion load is found to increase with increase in extrusion speed. The die pockets help in reducing the extrusion load. The effective strain, which provides the information about the work hardening of the material during the extrusion process is dependent of the above said process parameters. The extruded product lengths become more uniform when die pockets are made. The selection of process parameter is based upon the required quality of the product. © 2014 The Authors. Source

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