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Turning is a widely used manufacturing process in mechanical machining industries, while the cost associated with this process is high due to the cost involved in changing tools or tool regrinding. All the parameters of turning, like feed rate, cutting speed, and depth of cut, substantially impact the tool wear, which subsequently reduces tool life. Cooling methods like flooding, Minimum Quantity Lubrication (MQL), etc., are incorporated to minimise these effects on the tool and workpiece interface. When using these cooling techniques, the process parameters involved play vital roles in increasing the effectiveness. This paper focuses on the effects of machining parameters on the tool and the workpiece quality. Experiments were conducted to study the impact of various input parameters of the turning process on the tool tip temperature, cutting forces, and tool wear, ultimately affecting the tool's life.

The final drivetrain ratio is an essential part of a vehicle. It is responsible for providing the desired torque to overcome obstacles while maintaining the speed and acceleration of a vehicle. A vehicle must have an optimum gear ratio to obtain the desired velocity and acceleration. To achieve this, four different approaches were used considering the input parameters of a BAJA All-Terrain Vehicle (ATV). The traction received from the ground is calculated and plotted against velocity on different terrains. Further, a drivetrain was modeled in Simulink to obtain different parameters like vehicle speed, acceleration, and wheel slip. A range of gear ratios was obtained by following a similar trend of vehicle parameters that were best suited for improving vehicle performance. Graphs were plotted to compare the effect of various vehicle parameters, and an optimum gear ratio was obtained.

Permanent magnet brushed DC (PMBDC) motors are mostly preferred in many automotive applications because of better power density and easier control. Five different automotive applications such as electric parking brake (EPB), power seat, power window, sunroof drive, and tire air pump are chosen and discussed in this paper. A step-by-step electromagnetic analysis is carried out for all the designed models. Low-cost ferrite-based magnets are used for cost reduction keeping the efficiency as high above 77% in all the models. Comparison on performance and cost are discussed in the conclusion section.

Considerable weight of an automobile is constituted by the engine and there is scope for improvement in fuel efficiency and emission control through optimization of weight in the engine. In this work, AlSi10Mg alloy produced by the direct metal laser sintering (DMLS) is suggested for engine application which is a lightweight aluminum alloy. Mechanical properties like tensile strength, compressive strength, and hardness of both cast and DMLS manufactured alloy are compared followed by analysis of SEM images of tensile test fractured surfaces. Reciprocating wear test is carried out for one lakh cycles at 125°C temperature with SAE 40 grade oil as lubricant. Co-efficient of friction (COF), wear rate of the cast and DMLS manufactured samples are compared. Wear patterns are analyzed using SEM images of the wear tracks.

Experimental investigations were carried out on the machinable wax filament using the fused deposition modelling (FDM) rapid prototyping process. The printer used for conducting the experiments was Flash Forge guider 2. The filament material used for this study was machinable wax filament of 1.75 mm diameter. Experimental trials were carried out as per Taguchi L9 orthogonal array to determine the optimum process parameter combination. The dimensional analysis of test samples were carried out in terms of change in volume of samples which is result of combine effect of deviations in all the dimensions of test sample. Four factors each at three levels was used to obtain the optimum printing parameters for better dimensional accuracy and proper printing. The four important printing parameters were taken as factor and set to analyse the significant factor affecting on printing. The complexity in printing of wax filament is taken in to consideration during the experimental study.

In lieu of the drastic growth of the vehicle population, there is a huge consumption of fossil fuels and mineral oils for mobility. This leads to depletion in fossil fuels and mineral oils which are the by-products of petroleum. These fossil fuels can’t sustain for a long period of time because of its toxicity. In order to reduce the usage of existing mineral oil for lubrication, a source of non-edible oil from Jatropha curcus is processed as jatropha methyl ester (JME). It is holding high viscosity, density and easy blend with base oil. In this current work, the wear resistance of the lubricating oil is enhanced by the addition of nano-copper oxide particle blend with the base oil. The emission performance and tribological behavior have been experimentally tested in 98.2CC two-stroke air cooled engine. The 20% of JME blend with CuO nano particle provides better emission performance and wear characteristics than the other combination of blends.

The transportation of hot metal from blast furnaces to melting shops is carried out by molten steel transfer vehicle such as Torpedo ladle car in the steel plants. In need to design Torpedo ladle car within size limitation, capacity requirement and withstanding the impact, static, thermal shock and abrasion conditions, structural analysis is essential for validation. In this paper, stress and model analysis for upper and lower bolsters of Torpedo Ladle Car is carried out. The components are modelled in CAD and analysed using finite element method using software with the required boundary conditions. The results of structural analysis of bolster components are presented and discussed. The results shows that the deflection at the centre of upper and lower bolster was due to bending and applied load. The modal analysis predicted the natural frequencies by using block lanczos method.

Inconel 600 is a face-centered cubic structure and nickel-chromium alloy. Alloy 600 has good resistance to oxidation, corrosion-resistant, excellent mechanical properties, and good creep rupture strength at a higher temperature. Alloy 600 is used in heat treating, phenol condensers, chemical and food processing, soap manufacture, vegetable, and fatty acid vessels. In this context, the present paper investigates the machinability characteristics of Alloy 600 under dry environment. Also, the parametric effect of cutting speed, feed rate, and cutting depth on the force, surface roughness, and tool wear is carried out using 3-Dimensional surface and 1-Dimensional plots. The optimal parameters are determined systematically based on Taguchi-desirability analysis with turned with TiAlN coated carbide insert. From the graphical analysis of collected data, the low rate of feed and moderate cutting for roughness and cutting force and average feed rate for tool wear with low cutting depth.

Inconel 718 has excellent material properties, corrosion, and oxidation property among the nickel based superalloy. This property makes it suitable for producing components operating under extreme environments subjected to pressure and heat. The present study aims to examine the machinability comparison under dry and MQL turning of Inconel 718. The secondary aim is to report the sustainable machining on Inconel 718. Dry and MQL (Minimum Quantity Lubrication) experiments are carried out on Inconel 718 alloy based on Taguchi’s designed L16 orthogonal array. The cutting tools are an advanced coated cutting tool and uncoated tool. The levels of turning parameters are varied at 70, 120, 170 and 220 m/min of turning speed, 0.1, 0.15, 0.2 and 0.25 mm/rev of feed rate and 0.3, 0.4, 0.5 and 0.6 mm of cutting depth. The cutting forces, surface roughness, flank wear, and chip morphology are taken for the current investigation. The factor effect on output responses is studied using 2D plots.

Inconel 825 is nickel (Ni)-iron (Fe)-chromium (Cr) alloy with additions of copper (Cu), molybdenum (Mo), and titanium (Ti). The alloy has excellent resistance to corrosion and is often the most cost-effective alloy in sulphuric acid piping vessels and chemical process equipment. No attempt of applying MQL with three nanofluids was reported conferring to the works accessed. The present study is focused on evaluating the effect of the addition of three nanoparticles (CuO, Al2O3, and CNT) in vegetable oil applied by MQL mode during turning of Inconel 825 with coated carbide tool. Cutting force, surface roughness, and tool wear are evaluated. The results showed that the addition of nCNT substantially improved the machining performance and smaller flank the tool edge, while the adhesion and abrasion are observed as wear mechanism and better results are obtained at 0.5% of nCNT+ vegetable oil to produce the lowest values.

Inconel 625, nickel based alloy, is found in gas turbine blades, seals, rings, shafts, and turbine disks. On the other hand, the manufacturing of this alloy is challenging, mainly when machining processes are used due to excellent mechanical properties. Application of nanofluids in minimum quantity lubrication (MQL) shows gaining importance in the machining process, which is economical and eco-friendly. The principal objective of this investigational work is to study the influence of three types of nanofluids in the MQL turning of Inconel 625 nickel based alloys. The used nanofluids are multi-walled carbon nanotubes (CNT), alumina (Al2O3) and copper oxide (CUO) dispersed in vegetable oil. Taguchi-based L27 orthogonal array is used for the experimental design. The parameter optimization of design variables over response is carried out by the use of Taguchi-based derringer's desirability function.

Nimonic 90A alloy is a nickel-chromium-cobalt alloy and found as a potential material for turbine blades, discs, forgings, a ring section, and hot-working tools. This paper presents the effect of concentration along with cutting speed and feed rate on Fz: cutting force, Ra: surface roughness and Vba: tool wear with the application of two different nanofluids (NFS) on turning of Nimonic 90A by TiAlN PVD carbide cutting inserts. The nanoparticles suspended in oil taken for present investigation are nAl2O3, nCNT, and groundnut oil. The Taguchi L9 orthogonal array and derringer’s desirability response surface has been employed for parameter design and optimal search. 3D surface plots, factor effect plots, Taguchi S/N, and variance tests are used to study the effect of concentration on the machining performance of Nimonic 90A. The statistical analysis revealed % concentration for nCNT and cutting speed for nAl2O3 are found as an influenced parameter on performance characteristics.

This paper describes the design of a novel pneumatic gear shifting system to replace the existing gear stick manual shifting system for ease of the driver while shifting gears. The aim of this work is to have a semi-automatic shifting (pneumatic shifting) removing the need for the driver clutch operation. The system consists of a solenoid valve, CO2 gas-pressurized cylinder, double-acting cylinder, and single-acting cylinder. On basis of the signal received the gear needs to be changed, the shifter opens or closes a magnetic valve assembly. The solenoid valve allows the compressed air into the piston that comes from a pressurized cylinder, in order to create the effect of shifting gears. The pedal shifter and buttons are used to shift the gears. The pedal shifter was designed by using a 3-D printing technique using PLA material. The microcontroller used is ATMEGA-328 in this system. There are three switches, one for upshift, downshift, and clutch respectively.

In recent years, aluminum metal matrix composites (Al-MMC) are found as a potential material for numerous applications owing to its excellent tribological and mechanical properties. In this work, the machining characteristics of aluminum alloy (Al7075) reinforced with TiC/MoS2 having nanoparticle has been studied. The samples of aluminum metal matrix composites by varying TiC in 0, 2 and 4 and MoS2 in 0 and 2 of the percentage weight of aluminum alloy (Composite 1(Al7075), Composite 2 (Al7075/2TiC/2MoS2) and composite 3 (Al7075/4TiC/2MoS2), respectively) are fabricated by the stir-casing method. The turning characteristics of the developed metal matrix composites are studied at various parameters such as cutting velocity (30 m/min, 60 m/min and 90 m/min), cutting depth (0.5 mm, 1.0 mm and 1.5 mm) and composites (1, 2 and 3) using TiN coated cutting tool by dry turning at 0.05 mm/rev feed rate.

The present work compares the tribological properties of ZnO (Zinc Oxide) nanoparticle based lubricant with ZDDP (zinc dialkyl dithiophosphate) based lubricant. The nanolubricant was prepared by mixing the nanoparticles in base oil followed by ultrasonification and ZDDP based lubricant was prepared by mixing ZDDP and stirring with base oil. Base oil used was mineral base oil. Both the lubricants were tested at three different temperatures, loads and roughness values. The test was carried out on AISI 52100 steel samples prepared by wire cutting and were grinded to three different levels of surface roughness. Friction and wear tests were performed using a reciprocating sliding tribo-tester at three different loads and temperatures. Taguchi orthogonal array was used to reduce the number of experiments. SEM, EDS and AFM analysis were carried out to study the surface wear phenomenon.

Nickel based materials of Nimonic C-263 and Waspaloy are used nowadays for aerospace applications owing to its superior strength properties that are maintained at a higher temperature. Tool wear and cutting temperature in the vicinity of cutting edge are two essential machinability characteristics for any cutting tool. In this regard, this study is pursued to examine the influence of factors on measuring of tool wear (Vba) and cutting temperature (Ts) during dry machining of two alloys studied experimentally based on Taguchi method and response surface methodology. Taguchi’s L16 orthogonal array is used to design the experiment and a PVD (TiAlN), CVD (TiN/Al2O3/TiCN) coated carbide inserts are used on turning of two alloys. The factor effect on output responses are studied using analysis of variance, empirical models, and responses surface 3D plots. To minimize the response and to convert into one single optimum level, responses surface desirability function approach is applied.

Composites materials are substituting constituents for traditional materials due to their remarkable properties, and the addition of nanoparticles gives a new development in the material domain. The nanoparticles influence on fabrication and machinability investigation study is essential as the composites to be used in applications like automotive and aerospace. The current study investigates the machinability characteristics of Al2219 based metal composites reinforced with nanoparticles of SiN/MoS2. Al2219- reinforcements (SiN and MoS2) composites are fabricated by the method of stir casting. Four different compositions (Al2219/SiN (2 wt% and 4 wt%), , Al2219/2 wt.% SiN/ 2 wt.% MoS2, Al2219/2 wt.% MoS2) are fabricated by varying the different weight percentages of nanoparticles reinforcements. An attempt is made to study the investigation analysis of force, surface roughness, and tool wear using CNC machine lathe to consider the effect of cutting speed, cutting depth, and samples.

A Formula Student race car is a car designed and manufactured for speed, performance, and competition. For a car to have high speed and performance, their parts also need to be lighter with being able to sustain the dynamically occurring stresses. Effective braking is a crucial factor which determines the performance of the car. This paper focuses on designing a brake caliper on the basis of calculations done with respect to a Formula Student race car, selecting a material which is of low density but with higher strength which can be easily manufactured with low cost and analyzing the design. Further, the manufactured part is also tested statically to ensure proper working before being tested on an actual formula student race car. The caliper is again tested dynamically, where the caliper is mounted on rear wheels of the car. To ensure proper working, brake pressure sensors are being mounted which also helps to validate the calculations.

Friction Stir Welding (FSW) is a widely used solid state welding process in which its heats metal to the below recrystallization temperature due to frictional force. FSW mostly avoids welding defects like hot cracking and porosity which are mainly occur in conventional welding techniques. In this process the combination of frictional force and the mechanical work provide heating the base metal to get defect free weld joints. Aluminium Alloys 2014 and 6061 are generally used in a wide range of automobile applications like Engine valves and tie rod, shipbuilding, and aerospace due to their high corrosion resistance, lightweight, and good mechanical properties. In the present work, aluminium alloys of AA6061 and AA2014 were effectively welded by friction stir welding technique. The tool rotational speed, travel speed, and tool profile are the important parameters in FSW process. High Speed Steel (HSS) tool with Hexagonal profile is used for this joining.

This paper presents the parametric study, process benefits, optimization and chip appearance of machining parameters on turning of the Inconel 718 using Nd: YAG laser source. To analyze the mentioned above effect on alloy 718, the cutting inserts of chemical vapor disposition coated (CVD) TiN/TICN/Al2O3 are used to turn at the time of machining. To evaluate the linear (mean effect plots) and interaction effect (3D surface plots) of laser parameters on the force, roughness and tool wear to keep the minimal, experiments of the L27 orthogonal array are done by selecting the controllable parameters viz speed, the rate of feed along with laser power. From the parametric study, increase in speed and laser power along with decrement in the rate of feed resulted in lower cutting force. But surface finish and tool wear reduced with a decline in speed and scale of feed and increased with increment in laser power.