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Technical Paper

A Comparative Analysis on Corrosion Behavior on Precipitation Hardened Stainless Steel Weldments for Car Parts

2023-11-10
2023-28-0149
Precipitation Hardened Stainless Steel (PHSS) is one of the martensitic steels that possess exceptional strength and corrosion resistance. Because of its characteristics, this PHSS is exclusively adopted in numerous engineering uses such as nuclear, chemical and marine industries. Welding is one of the important methods of joining that helps to make weldments with better performance characteristics. Corrosion behaviour is one of the important characteristics that contribute hugely to marine and other corrosion-related environments and also this is the most common problem for most of the manufacturing industries. The goal of this study was to analyze the PHSS weldments’ corrosive behavior and compare it with that of the two commonly used welding processes, namely MIG and TIG. The corrosive properties of the weldments were evaluated using various mediums, such as nitric acid, ferric chloride, and Oxalic acid.
Technical Paper

Optimizing Concurrent Scheduling of Machines and Tools in a Flexible Manufacturing System with Alternating Machines Using the Flower Pollination Algorithm

2023-11-10
2023-28-0141
This paper examines the concurrent scheduling of machines and tools with machines in a multi-machine flexible manufacturing system (FMS) with the aim of minimizing the makespan in automobile manufacturing industry. Due to the high cost of tools in FMS, each type of tool has only one duplicate in circulation. To reduce the cost of duplicating tools on each machine, a central tool magazine (CTM) is used to store and share tools among several machines. The main challenge in this scenario is to allocate machines from alternate machines and tools to job operations in a way that minimizes the make span. To address this problem, the article proposes a mixed nonlinear integer programming formulation and a Flower Pollination Algorithm (FPA). The results show that the FPA outperforms existing algorithms and using alternate machines for operations can reduce the make span.
Technical Paper

Design Optimization of Solar Energy Harvesting Using Perovskite Solar Cell for Electric Vehicles Using Finite Element Method

2023-11-10
2023-28-0095
Excellent charge-carrier mobilities and life time of perovskite materials enables it with exceptional light absorption capacity. This provides improved device potential and performance with low-cost commercially feasible technology. The challenges towards handling the perovskite cells are its strength and its environmentally compatible property. Resolving these issues leads perovskite-based technology to hold an innovative potential for quick terawatt-scale solar power distribution. In this line, Organic Photovoltaic is a fast developing PV technology with improved the cell efficiency and life time performance. As organic Photovoltaic cell is available in mulit-colours and can be used to build transparent devices, it finds its application in building-integrated Organic Photovoltaic fair. Optimization of device physics, charge-transport methods, charge-separation procedures, and interfacial effects, would enable the development of stable, more effective device architectures.
Technical Paper

Parallel Scheduling of Machines and Tools without Tool Delay Using Symbiotic Organisms Search Algorithm

2023-11-10
2023-28-0142
This work presents a novel approach for parallel scheduling of machines and tools without tool delay in the automobile manufacturing industry using a symbiotic organisms search algorithm (SOSA). This paper proposes nonlinear mixed integer programming (MIP) formulation to model simultaneous scheduling problems. The mutualistic relationship between different species in nature inspires the proposed algorithm. It aims to optimize the scheduling process by minimizing the makespan (MSN) while ensuring no tool delay during the production process. The algorithm is implemented in a parallel computing environment to speed up the search process and handle scheduling problems. Experimental results show that the proposed approach outperforms existing methods in terms of solution quality and computational efficiency. This work offers a promising solution for real-world manufacturing scheduling problems with multiple machines and tools, often characterized by complex constraints and uncertainties.
Technical Paper

Optimization of Spark Erosion Machining of Monel 400 Alloy for Automobile Applications

2023-11-10
2023-28-0140
Monel 400, a type of nickel alloy which is adopted in numerous engineering fields, such as high-temperature devices. Owing to its better strength and thermal diffusion, it can be difficult to machine with conventional methods. In order to avoid the disadvantages of conventional methods, various advanced material removal techniques have been developed. One of these is Wire Electro Discharge Machining (WEDM). This process is an evolution of the electrical discharge method. In the process of WEDM, difficult materials with intricate forms are usually machined. In this study, the performance of this method on Monel 400 has been analyzed. The three independent variables that are considered when it comes to analyzing the performance of this process are the pulse on, the applied current, and the pulse off. The experiments were performed using the design approach of Taguchi, which involves using an L27 orthogonal array.
Technical Paper

Application of Taguchi Approach on Wire Electrical Discharge Machining of SS304 for Automotive Applications

2023-11-10
2023-28-0151
SS304 is a type of stainless steel that is well-known for its high ductility and resistance to corrosion; as a result, it is typically utilized in a variety of applications, such as the exhaust systems of automobiles and the springs that are used in seatbelts. Because of its qualities, it will eventually be employed in a variety of body parts, including fuel tanks and chassis, among other things. Due to its properties, SS304 is known to be incredibly difficult to machine using conventional methods. Through a wire electrical discharge machining process, it is easier to cut complex materials with high surface finishes. In this study, a study was conducted on the WEDM process parameters of SS304 to optimize its machining process. The study was carried out using the DoE approach, which involved planning the various experiments. The parameters of the process, such as the pulse on time, peak current, and off time, were analyzed to determine their performance.
Technical Paper

Investigations on Wire Electrical Discharge Machining of Magnesium Alloy for Automobile Parts

2023-11-10
2023-28-0155
Magnesium alloy, known for its high strength and lightweight properties, finds widespread utilization in various technical applications. Aerospace applications, such as fuselages and steering columns, are well-suited for their utilization. These materials are frequently employed in automotive components, such as steering wheels and fuel tank lids, due to their notable corrosion resistance. The performance of magnesium alloy components remains unimproved by normal manufacturing methods due to the inherent characteristics of the material. This work introduces a contemporary approach to fabricating complex geometries through the utilization of Wire-Electro Discharge Machining (WEDM). The material utilized in this study was magnesium alloy. The investigation also considered the input parameters associated with the Wire Electrical Discharge Machining (WEDM) process, specifically the pulse duration and peak current.
Technical Paper

Evolution of Regression and Neural Network Models on Wire Electrical Discharge Machining of Nickel Based Superalloy

2023-11-10
2023-28-0078
In addition to traditional methods, there are also non-traditional techniques that can be used to overcome the challenges of conventional metal working. One such technique is wire electrical discharge (WEDM). This type of advanced manufacturing process involves making complex shapes using materials. Utilizing intelligent tools can help a company meet its goals. Nickel is a hard metal to machine for various applications such as nuclear, automobile and aerospace. Due its high thermal conductivity and strength, traditional methods are not ideal when it comes to producing components using this material. This paper aims to provide a comprehensive analysis of the various steps in the development of a neural network model for the manufacturing of Inconel 625 alloy which is used for specific applications such as exhaust couplings in sports motor vehicle engines. The study was conducted using a combination of computational and experimental methods.
Technical Paper

Taguchi’s Approach to Wire Electrical Discharge Machining of Magnesium Alloy AZ31B

2023-11-10
2023-28-0136
One of the most common types of lightweight materials used in aerospace is magnesium alloy. It has a high strength-to-weight ratio and is ideal for various applications. Due to its corrosion resistance, it is commonly used to manufacture of fuselages. Unfortunately, the conventional methods of metal cutting fail to improve the performance of magnesium alloy. One amongst the most common methods used for making intricate shapes in harder materials is through Wire-Electro-Discharge (WEDM). In this study, we have used magnesium alloy as the work material. The independent factors were selected as pulse duration and peak current. The output parameters of the process are the Surface Roughness (SR) and the Material Removal Rate (MRR). Through a single aspect optimization technique, Taguchi was able to identify the optimal combination that would improve the effectiveness of the WEDM process.
Technical Paper

Machinability Investigations on Wire Electrical Discharge Machining of Inconel 625 by Taguchi Based Grey Approach

2023-11-10
2023-28-0124
Among the challenging materials used in high-temperature applications is Inconel 625. Due to its low thermal coefficient and greater strength, traditional methods tend to produce poor results when it comes to turning Inconel 625. In order to overcome these issues, a new approach has been proposed that utilizes unconventional techniques. WEDM is a variant of the electrical discharge manufacturing process that is commonly used in the production of complex components. It is mainly utilized for the hard to machine parts. A study on the process parameters of WEDM for the machining of Inconel 625 was performed by utilizing the analysis of Taguchi. The study focused on the various parameters of the process, such as peak current, pulse on time, and off time. The performance measures that were considered in this study included surface roughness and material removal rate. The results of the analysis revealed that the various process variables affected the performance indicators.
Technical Paper

Thermomechanical Study on Induction Preheating in Friction Stir Welding of Structural Steel Using COMSOL Software for Automotive Applications

2023-09-14
2023-28-0034
In this investigation, friction stir welding (FSW) was employed for joining HSLA steel plates (5 mm thick) of grade DMR249A in the development of light weight ship structures. This investigation aims to study the effect pre-heating temperature (PHT) on microstructure and mechanical properties of FSWed DMR249A steel-joints. The PHT of W99 tool was varied from 100 to 250°C. The optical microscopy (OM), scanning electron microscopy (SEM), and an elemental analysis of stir zone (SZ) of DMR249A steel-joint was carried out. The tensile properties, hardness and impact toughness of DMR249A steel-joints were evaluated and compared to BM and joints without PHT. Results disclosed that the DMR249A steel-joints made at PHT 100°C exhibited superior tensile properties and impact toughness compared to other joints. It is attributed to the evolution of finer acicular ferritic and upper bainitic microstructure with no debris of tool in SZ.
Technical Paper

Modeling and Verification of 1D Array Methyl Ammonium Lead Halide Perovskite Solar Cells for Electric Vehicles

2023-09-14
2023-28-0026
Low-dimensional materials are essential in optoelectronic, electrical, and contemporary photonics areas because of their specific properties with decreased dimensions. Low-dimensional materials are those with dimensions in the nanoscale range that are between 1 and 100 nm. Halide perovskites of low dimension can be produced inexpensively using solution-processable procedures, unlike usual semiconductor nanomaterials. Since halide perovskite in thin layers may be produced utilizing a variety of solution-based techniques like simple spin coating. It is possible to produce it with a variety of compositions using low-cost, simple, and large-scale procedures. Quantum dots, perovskite nanoplatelets, nanosheets, perovskite nanorods or nanowires, and other low-dimensional perovskites are all examples of such small-dimensional devices that have been created in a range of morphologies (two-dimensional).
Technical Paper

Finite Element Analysis of Graphene Based Solar Photonic Battery for Electric Vehicle

2023-09-14
2023-28-0021
The sun has tremendous potential to address the world’s increasing energy needs, but the increased cost of employing lunar power is a considerable hurdle when equated to more conventional energy sources. The low energy density and low conversion efficiency of solar radiation, expensive raw materials, and labor-intensive manufacturing process all contribute to the high cost of a photovoltaic system. In the last ten years, advances in nano science and nanotechnology have opened up new possibilities for the creation of effective solar cells. Designing semiconductor, metal, and polymer nanostructure designs for solar cells has become possible. Understanding the methods involved in the photovoltaic energy conversion like optical and electrical process, has also benefited from theoretical and modelling studies. The high price and insufficient efficiency of current solar cells prevent the widespread usage of solar energy.
Technical Paper

Neural Network Model for Machinability Investigations on CNC Turning of AA5052 for Marine Applications with MQL

2022-12-23
2022-28-0515
Aluminium alloys are attracting importance in various engineering industries because of their exceptional characteristics such as strength, resistance to oxidation etc., AA5052 is an alloy that categorized under Al-Mg series, commonly adopted in anti-rust applications, especially for desalination applications because of its good corrosion resistance in seawater at temperatures up to 125°C, low cost, good thermal conductivity, and non-toxicity of its corrosion products. Minimum Quantity Lubrication (MQL) is one of the approaches that are economically affordable and also eco-friendly used in various machining operations. This present exploration details the investigation CNC turning of AA5052 alloy with conventional Tungsten Carbide (WC) tool inserts under MQL conditions. There are two different natural cutting fluids were engaged such as live oil and coconut oil.
Technical Paper

Development of Adaptive Neuro Fuzzy Inference System Model for CNC Milling of AA5052 Alloy with Minimum Quantity Lubrication by Natural Cutting Fluid

2022-12-23
2022-28-0511
In view of the improvements in manufacturing sectors, which are an important component of any economy’s growth, there is a significant need for new and advanced materials, particularly alloy materials need to be analysed and investigated so that new technologies may be effectively utilized. Materials with low weight and high strength, such as aluminium alloys, are recommended for a variety of applications that require both strength and corrosion resistance, such as marine applications and high-temperature applications. Aluminium alloy Al 5052, a nonferrous material with outstanding properties is an Al-Mg alloy with high thermal conductivity and corrosion products that are non-toxic. Minimum Quantity Lubrication (MQL) is a cost-effective and environmentally friendly method of lubrication employed in a variety of machining processes. The investigation of CNC milling of AA5052 alloy with standard Tungsten Carbide (WC) tool inserts with MQL settings are detailed in this paper.
Journal Article

Microstructure and Mechanical Behaviour of Dissimilar Laser Welded Joints for Automobile Applications

2022-12-23
2022-28-0548
Over the last decade the utilization of laser sources has seen a marked increase with its reducing expenses and increasing productivity. Enabling technologies such as better process knowledge, better laser sources and systems, and on-going advances in Laser Beam Welding (LBW) processing technologies have all contributed to these accomplishments which include both macro and micro component fabrication through LBW. There are various existing applications that benefit from using challenging materials together, hence integrating dissimilar metals allows us to gain their benefits at a higher level and can be applied extensively for multiple applications. Metals with different mechanical and microstructural qualities and features such as high corrosion resistance and low specific weight are commonly chosen to fabricate dissimilar joints.
Technical Paper

Investigation on Formability of Tailored AA7075 Thin Sheets by Friction Stir Processes

2022-10-05
2022-28-0349
TWBs (tailored welded blanks) technology can open new avenues for obtaining components in the automotive, aerospace and electronics industries. Friction stir process (FSP) can control the properties by deep localized plastic deformation using the non-consumable tool. In this study, the primary objective is to investigate the effects of Graphene nanoparticles (GNPs) in AA7075 material and the effect of FSP graphene NPs on the forming limit curve of the TWBs through experiments. The micrographs of the weldment are obtained by metallography practices. Tensile specimens are separated for evaluating FSP weld zones. Obtained results exhibits the formability limit of AA7075 thin sheets and decrease FSP thin sheets formability as compared with the formability of base metals
Technical Paper

Investigations on advanced Joining Method for Inconel 718 and SS304 Dissimilar Joints

2022-10-05
2022-28-0345
Modern automobile applications such as petrol, diesel, and gaseous fuel injection system use dissimilar Inconel 718 (IN718) and Stainless Steel 304 (SS 304) joints. IN 718 is a precipitation-hardened austenitic nickel-based superalloy with exceptional qualities such as high strength, resistance to corrosion, greater toughness, as well as resistance to thermal induced fatigue at elevated temperatures (between 150 and 1500oC), while SS 304 is a T 300 Series austenitic stainless steel alloy that can be used successfully in wide range of applications due to greater resistance to corrosion, good high and low temperature strength and ductility with excellent weld ability and formability. To get a better understanding of the mechanical characteristics of these heterogeneous weldments, these alloy joints were created using laser beam welding, one of the most modern joining techniques for high-strength materials.
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