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Rajmohan T.,Sri Chandrasekharendra Saraswathi Viswa Mahavidyalaya | Palanikumar K.,Sri Sai Ram Institute of Technology | Prakash S.,Sathyabama University
Composites Part B: Engineering | Year: 2013

Metal matrix composites (MMCs) are difficult to machine due to their abrasive properties. With the projected widespread application of MMCs, it is necessary to develop an appropriate technology for their effective machining. The present investigation focuses on finding the optimal machining parameters setting in drilling of hybrid aluminium metal matrix composites using the grey-fuzzy algorithm. This proposed algorithm, coupling the grey relational analysis with the fuzzy logic, obtains a grey-fuzzy reasoning grade to evaluate the multiple performance characteristics according to the grey relational coefficient of each performance characteristics. The Taguchi method of experimental design is a widely accepted technique used for producing high quality products at low cost, therefore a L27 3-level orthogonal array is used for the experiments. The optimisation of multiple responses in complex processes is common; therefore, to reduce the degree of uncertainty during the decision making, fuzzy rule-based reasoning is integrated with the Taguchi's method. The response table, response graph and analysis of variance (ANOVA) are used to find the optimal setting and the influence of machining parameters on the multiple performance characteristics. Experimental results have shown that the required performance characteristics in the drilling process are improved by using this approach. © 2013 Elsevier Ltd. All rights reserved.


Ramesh M.,Jawaharlal Nehru Technological University Anantapur | Palanikumar K.,Sri Sai Ram Institute of Technology | Reddy K.H.,Jawaharlal Nehru Technological University Anantapur
Composites Part B: Engineering | Year: 2013

The composite materials are replacing the traditional materials, because of its superior properties such as high tensile strength, low thermal expansion, high strength to weight ratio. The developments of new materials are on the anvil and are growing day by day. Natural fiber composites such as sisal and jute polymer composites became more attractive due to their high specific strength, lightweight and biodegradability. Mixing of natural fiber with Glass-Fiber Reinforced Polymers (GFRPs) are finding increased applications. In this study, sisal-jute-glass fiber reinforced polyester composites is developed and their mechanical properties such as tensile strength, flexural strength and impact strength are evaluated. The interfacial properties, internal cracks and internal structure of the fractured surfaces are evaluated by using Scanning Electron Microscope (SEM). The results indicated that the incorporation of sisal-jute fiber with GFRP can improve the properties and used as a alternate material for glass fiber reinforced polymer composites. © 2013 Elsevier Ltd. All rights reserved.


Rajamurugan T.V.,Annamalai University | Shanmugam K.,Annamalai University | Palanikumar K.,Sri Sai Ram Institute of Technology
Materials and Design | Year: 2013

Glass fiber reinforced plastic (GFRP) composite materials are finding increased application in aeronautical, automobile and structural applications. Drilling is a complex process, owing to their tendency to delaminate is used to join composite structures. In the present work, an attempt has been made to develop empirical relationships between the drilling parameters such as fiber orientation angle, tool feed rate, rotational speed and tool diameter with respect to delamination in drilling of GFR-polyester composites. The empirical relationship has been developed by using response surface methodology. The developed model can be effectively used to predict the delamination in drilling of GFRP composites within the factors and their limits are studied. The result indicated that the increase in feed rate and drill diameter increases the delamination size whereas there is no clear effect is observed for fiber orientation angle. The spindle speed shows only little effect on delamination in drilling of GFR-Polyester composites. © 2012 Elsevier Ltd.


Prakash S.,Sathyabama University | Palanikumar K.,Sri Sai Ram Institute of Technology
Journal of Composite Materials | Year: 2011

Medium density fiberboard (MDF) panels are an industrial wood product which belongs to wood-based composite. MDF panels are made with wood fibers clued together with resin by heat and pressure. Nowadays the MDF products are preferred over solid wood in many applications due to certain comparative advantage and mainly used in furniture industry. This article discusses the use of Taguchi and response surface methodologies for predicting the surface roughness in drilling MDF material by a physical vapor deposition TiN coated carbide step drill bits. The experiments are conducted based on Taguchi's experimental design technique. The drilling parameters used are spindle speed, feed rate, and drill diameter. The effect of drilling parameters on the surface roughness is evaluated and discussed in detail. The second order model has been established between the drilling parameters and the surface roughness using response surface methodology. The experimental result reveals that the most significant drilling parameter for the surface roughness is feed rate followed by the cutting speed. The predicted values and measured values are fairly close which indicates that the developed model can be effectively used to predict the surface roughness in the drilling of MDF panels. The predicted results are validated by using validation experiments. © The Author(s) 2010.


Rajmohan T.,Sri Chandrasekharendra Saraswathi Viswa Mahavidyalaya | Palanikumar K.,Sri Sai Ram Institute of Technology
Measurement: Journal of the International Measurement Confederation | Year: 2013

In this study, the application of response surface methodology (RSM) and central composite design (CCD) for modeling, optimization, and an analysis of the influences of dominant machining parameters on thrust force, surface roughness and burr height in the drilling of hybrid metal matrix composites produced through stir casting route. Experiments are carried out using Al 356-aluminum alloy reinforced with silicon carbide of size 25 μm and Mica of size 45 μm. Drilling test is carried out using carbide drill of 6 mm diameter. The design of experiment concept has been used to optimize the experimental conditions. The experimental data are collected based on a three-factor-three-level full central composite design. The multiple regression analysis using RSM is used to establish the input-output relationships of the process. The mathematical models are developed and tested for adequacy using analysis of variance and other adequacy measures using the developed models. The main and interaction effect of the input variables on the predicted responses are investigated. The predicted values and measured values are fairly close, which indicate that the developed models can be effectively used to predict the responses in the drilling of hybrid metal matrix composites. The optimized drilling process parameters have been obtained by numerical optimization using RSM by ensuring the minimum thrust force of 84 N, surface roughness of 1.67 μm, and the burr height of 0.16 mm. After the drilling experiments, a scanning electron microscope (SEM) is used to investigate the machined surface and tool wear.


Valarmathi T.N.,Sathyabama University | Palanikumar K.,Sri Sai Ram Institute of Technology | Latha B.,Sri Sairam Engineering College
Measurement: Journal of the International Measurement Confederation | Year: 2013

Particleboard is a wood based composite extensively used in wood working. Drilling is the most commonly used machining process in furniture industries. The surface characteristics and the damage free drilling are significantly influenced by the machining parameters. The thrust force developed during drilling play a major role in gaining the surface quality and minimizing the delamination tendency. The objective of this study is to measure and analyze the cutting conditions which influences the thrust force in drilling of particle board panels. The parameters considered are spindle speed, feed rate and point angle. The drilling experiments are performed based on Taguchi's design of experiments and a response surface methodology (RSM) based mathematical model is developed to predict the influence of cutting parameters on thrust force. The results showed that high spindle speed with low feed rate combination minimizes the thrust force in drilling of pre-laminated particle board (PB) panels. © 2012 Elsevier Ltd. All rights reserved.


Ramesh S.,Salem College | Karunamoorthy L.,Anna University | Palanikumar K.,Sri Sai Ram Institute of Technology
Measurement: Journal of the International Measurement Confederation | Year: 2012

Titanium alloys are extensively used in aerospace, biomedical applications and they are used in corrosive environments. In this study, the effect of cutting parameters on the surface roughness in turning of titanium alloy has been investigated using response surface methodology. The experimental studies were conducted under varying cutting speeds, feed and depths of cut. The chip formation and SEM analysis are discussed to enhance the supportive surface quality achieved in turning. The work material used for the present investigation is commercial aerospace titanium alloy (gr5) and the tool used is RCMT 10T300 - MT TT3500 round insert. The equation developed using response surface methodology is used for predicting the surface roughness in machining of titanium alloy. The results revealed that the feed was the most influential factor which affect the surface roughness. © 2012 Elsevier Ltd. All rights reserved.


Rajmohan T.,Sri Chandrasekharendra Saraswathi Viswa Mahavidyalaya | Palanikumar K.,Sri Sai Ram Institute of Technology | Arumugam S.,Sri Chandrasekharendra Saraswathi Viswa Mahavidyalaya
Composites Part B: Engineering | Year: 2014

The application of nano-sized particles is increasing because it strengthens the Metal Matrix composites (MMCs) and maintains the ductility of the matrix alloy. The present investigation deals with the synthesis and characterization of hybrid aluminium matrix reinforced with micro SiC particles, and nanocopper oxide (CuO) particles prepared by sintering process. First the powder mixtures containing fixed weight (wt)% of SiC and different wt% of nanocopper oxide as reinforcement constituents that are uniaxially cold pressed. Afterwards the green compacts are sintered in an electric muffle furnace. Microstructure and mechanical properties such as tensile strength, microhardness and density of the composites are examined. Microstructure of the samples has been investigated by using scanning electron microscope (SEM), X-ray diffraction (XRD) and Atomic Force Microscope (AFM). The results indicated that the increase in weight% of nano Cuo particles improves the mechanical properties. © 2013 Elsevier Ltd.


Rajmohan T.,Sri Chandrasekharendra Saraswathi Viswa Mahavidyalaya | Palanikumar K.,Sri Sai Ram Institute of Technology | Ranganathan S.,Saveetha University
Transactions of Nonferrous Metals Society of China (English Edition) | Year: 2013

Hybrid metal matrix composites are important class of engineering materials used in automotive, aerospace and other applications because of their lower density, higher specific strength, and better physical and mechanical properties compared to pure aluminium. The mechanical and wear properties of hybrid aluminium metal matrix composites were investigated. Mica and SiC ceramic particles were incorporated into Al 356 alloy by stir-casting route. Microstructures of the samples were studied using scanning electron microscope (SEM). The chemical composition was investigated through energy dispersive X-ray (EDX) detector. The results indicate that the better strength and hardness are achieved with Al/10SiC-3mica composites. The increase in mass fraction of mica improves the wear loss of the composites.


Palanikumar K.,Sri Sai Ram Institute of Technology | Muniaraj A.,Sathyabama University
Measurement: Journal of the International Measurement Confederation | Year: 2014

Composite materials are used in different engineering applications and are continuously displacing conventional materials due to their excellent properties. This paper discusses the influence of drilling parameter on thrust force in drilling Al 6061/15%SiC 4%Gr metal matrix composites. The composite materials are fabricated by stir casting method. The experiments are conducted on computer numeric control vertical machining centre using titanium nitride coated solid carbide twist drills of 4 mm, 8 mm and 12 mm diameter under dry conditions. A response surface analysis is carried out. The effect of drilling parameters on thrust force is studied and presented. The results indicated that feed rate is the main parameter which influences the thrust force in drilling of hybrid metal matrix composites. © 2014 Elsevier Ltd. All rights reserved.

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