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Technical Paper

Prediction of Material Removal Rate in Wire Electrical Discharge Machining of Aluminum Composites for Automotive Components

2020-09-25
2020-28-0399
Wire Electrical Discharge Machining (WEDM) is a contemporary approach of material removal which is conceived from the concept of Electrical Discharge Machining process. Wire Spark Erosion Machining which is known as WEDM, predominantly employed for removing material from hard materials and also especially used for making intricate shapes on any electrically conductive work material with irrespective of the hardness. Composite materials offers improved mechanical properties depends upon the constituents to be added. Graphene is identified as outstanding reinforcing element which provide support to enhance the desired properties of aluminium metal matrix composites in a considerable manner. In this present exploration an analysis has been performed on WEDM of Al-GNP composites. Pulse on time (μs), pulse off time (μs) and servo voltage (V) are deemed as input process parameters in this present exploration.
Technical Paper

Mechanical and Microstructures Investigation of Stir Casted Aluminium Alloy 8011-Graphene Composites

2020-09-25
2020-28-0427
This study investigated experimentally the microstructural and mechanical properties of Aluminium Alloy 8011 (AA8011)/Graphene nano-platelets composites. AA8011/Graphene composites with nano-platelets content ranges from 0.5 to 2 weight (wt.) % were manufactured by stir casting process. The test results revealed that compared to pure AA8011 matrix, AA8011/0.5 wt. % Graphene composite had better mechanical properties such as tensile strength and hardness. Micrographic/Fractography analysis by Scanning Electron Microscopy (SEM) and X-ray Diffraction (XRD) analysis confirm that uniform distribution of Graphene in AA8011 matrix and low porosity in the microstructure lead a substantial improvement in mechanical properties such as tensile strength and micro hardness of AA8011/0.5 wt. % Graphene composite compared to other AA8011/Graphene composites prepared with different weight percentages.
Technical Paper

Mechanical Property Optimization of Tamarind Fruit Fiber for Lightweight Structural Composites Applications

2021-10-01
2021-28-0270
Natural fibers are dominating many composite industries due to their unique properties such as reusability, biodegradability, and environmental safety. Tamarind fruit fiber (TFF) stands out among the various fruit fibers and has been discovered in large quantities being discarded from the food processing industries. However, many natural fibers are extracted from their sources, which results in deforestation and environmental degradation. As a result, in today's world, recycling waste into new useful products is the primary concern in any field of engineering. In light of this, the current study used TFF obtained from agro industries and processed into fibers, which were then mixed with an unsaturated polyester matrix to create a natural composite material. Furthermore, by considering process parameters and their levels for conducting experiments, an orthogonal array has been achieved using Taguchi's design approach.
Technical Paper

Machinability Studies on Wire Electrical Discharge Machining of Aluminium Based Metal Matrix Composite for Automotive Applications

2022-10-05
2022-28-0353
The advanced lifestyle demands materials that are light and robust, and aluminum and its alloys are commonly used in various engineering components due to their exceptional properties such as light weight, enhanced strength, and being economically affordable. Due to their superior mechanical properties, such as strength and flexibility, are commonly used in various industrial applications. Metal Matrix Composites (MMCs) are very essential materials used in several applications as they are more robust and harder than any conventional material. In this study, a metal matrix composite made of aluminum and Boron Nitride (BN) is investigated to analyze its various properties. The study is performed by using Wire Electrical Discharge Machining (WEDM). The three independent parameters of the composite are its pulse on time, peak current, and pulse off time. The study aims to analyze the effects of various process variables on the desired performance of the metal matrix composite.
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.
Technical Paper

Influence of Titanium Oxide Nanoparticle on Solar Desalination with Phase Change Material

2020-09-25
2020-28-0464
The present study is focused on the significance of solar desalination heat storage method. The Solar energy is a prime source of energy existing directly or indirectly from the nature. The primary drawback of solar energy, which is existing in hours only. Thermal storage devices can overcome this problem as they can store the energy in daylight that can be utilized in off sunshine hours. The purpose of this work is to evaluate the increase in productivity of the solar desalination by using phase change material and combination of PCM with TiO2 (Nano particles). The present work is focused on performance of solar water desalination using Phase Change Materials along with TiO2 Nanoparticles. The Titanium Oxide Nanoparticles were synthesized by Sol-Gel method. The Titanium oxide Nano particles were characterized by XRD, SEM, EDS, and FTIR etc. In this experiment paraffin 34-carbons is used as phase change materials and Titanium Oxide Nanoparticles used for energy storage materials.
Technical Paper

Experimental Analysis on Wire Electrical Discharge Machining of Nickel Alloy Using Taguchi Based Grey Relational Analysis

2021-10-01
2021-28-0273
Stellite is a nickel based superalloy and expansively adopted in higher temperature engineering applications. This alloy possesses better mechanical properties such as strength and hardness. Due to its lesser thermal conductivity, it is difficult to machine by conventional methods of machining. For avoiding such kind of demerits, advanced methods of machining have been introduced. Wire Electrical Discharge Machining (WEDM) is one of category of thermal energy based machining methods which is developed from the concept of Electrical Discharge Machining. This kind of machining method is preliminarily engaged for making complex shaped components especially in harder and electrically conductive materials. In this present experimental study, an endeavour has been taken to analyse the optimized process parameters for achieving better machining performance during WEDM of Stellite using Taguchi-Grey approach.
Technical Paper

Effect of Weld Speed on Joint Quality of Nd: YAG Laser Welded Inconel 718 Alloy Weldments

2021-10-01
2021-28-0263
Inconel 718, a nickel based superalloy is used in all kinds of applications where outstanding strength and corrosion resistance are essential. The Inconel 718 alloys joints from sheets of 1mm thickness are fabricated using a 4 kW Nd: YAG laser welding equipment. The influence of welding speed on the weld bead ripples, weld morphology, defects and the mechanical properties are investigated. Microstructure of the weld fusion zone, Heat Affected Zone (HAZ) and the weld ripple structure were analyzed using optical microscope and the scanning electron microscope. The weldments obtained were with nominal cracks, porosity and shape imperfections that signifying Nd: YAG laser welding as an effective method for fabricating joints of Inconel 718 of thickness 1mm. The weld fusion zone consists of fine dendritic structure and HAZ is found with columnar grain structure.
Technical Paper

Development of Regression Models for Laser Beam Welding of Inconel 718 Alloy Thin Sheets

2022-10-05
2022-28-0340
Inconel 718 is a superalloy made from nickel that has exceptional mechanical properties. It has been widely used in the manufacturing of various components such as nuclear and aerospace aircraft. Due to its exceptional corrosion resistance, this material can be utilized in various environments. Due to the increasing number of challenges that come with conventional methods of welding, the use of advanced techniques has been developed to produce better and sound quality joints. One of these is Laser Beam Welding (LBW) technique. This method utilizes a high-intensity beam to create a better and more quality weld joints with improved mechanical properties. This study aims to develop multiple regression models that can be used to analyze the performance of laser beam welding on Inconel 718 alloy joints.
Technical Paper

Development of Prediction Models for Spark Erosion Machining of SS304 Using Regression Analysis

2022-10-05
2022-28-0339
Stainless Steel 304 (SS304) is a nickel–chromium–based alloy that is regularly used in valves, refrigeration components, evaporators, and cryogenic containers due to its greater corrosion resistance, high ductility, and non-magnetic properties, as well as good weldability and formability. Multiple regression analysis was used to establish empirical relationships between process variables. Additionally, the established regression equations are employed to predict and compare experimental data. Due to the increasing demands for high-quality surface finishes and complex geometries, traditional methods are being replaced by non-conventional techniques such as wire EDM. This process, which emerged from the electrical discharge machining concept, mainly involves creating intricate components. WEDM results in a high degree of precision and excellent surface quality. Due to the complexity of WEDM, the processing parameters cannot be selected by using the trial-and-error method.
Technical Paper

Characterization and Optimization of Mechanical Properties of Sustainable Moringa Oleifera Fruit Husk Fiber for Polymer Composite Applications

2018-07-09
2018-28-0045
Natural fiber reinforced composites are playing a vital role in the polymer industry due to its low cost, light weight, renewable, biodegradable and eco-friendly properties. However, conventional E-glass fibers are hazardous for human health and causes cancer. Hence, currently the research on exploring the promising and novel sustainable natural fibers as a bio-reinforcement in polymer composites for different applications are of great demand. Huge amount of Moringa Oleifera fruit husk (MOFH), which is rich in fiber are being wasted from commercial industries after yielding its economic value. In the present work, MOFH fiber is tested comprehensively for ensuring its potentiality as a reinforcement in polymer matrix and to optimize the mechanical properties. The optimum fiber content is found to be 20 wt.%, whereas beyond that the fiber pull out and debonding occurred due to poor compatibility between the fiber and the matrix.
Technical Paper

Application of Taguchi Approach on Wire Electrical Discharge Machining of SS304

2021-10-01
2021-28-0271
SS304 (Stainless Steel 304) is a nickel- chromium based alloy, that is extensively used for the applications like cryogenic vessels, valves, refrigerator equipment and evaporators because of its high corrosion resistance, ductility and ability to remain as solid up to a temperature of 14000 C. SS304 is one of the tough to machine materials by conventional methods of machining. Wire Electrical Discharge Machining (WEDM) facilitates the ease of machining complicated cuts with hard to machine, conductive materials where high surface finish is required. In this investigation, a study has been done on WEDM of SS304 and mainly to optimize the process parameters during the machining of SS304 by using Taguchi’s analysis. Taguchi’s DoE approach is used to plan the experimental runs and by considering the process parameters such as pulse on time, pulse off time and peak current at three different levels the experiments were conducted.
Technical Paper

A Comparative Study on Microstructures and Mechanical Properties of Al-GNPs Composites Fabricated by Casting Method

2019-10-11
2019-28-0139
This paper describes an investigation on microstructures as well as mechanical properties of pure aluminium graphene nano platelets (GNPs) metal matrix composites prepared via novel based stir casting technique combined with ultrasonic treatment. The proportion of graphene changes from 0.5 to 2.0 wt. % in aluminium with 99% purity. The investigations on composites revealed that Al with combination of 1.0 % graphene composite showcased enhanced mechanical properties with 48.49 % (~49%) increase in tensile strength and 34.53 % (~35%) increase in micro hardness compared to test results of composites produced by traditional stir casting technique. FESEM analysis was done to examine the surface morphology of produced composite and fracture surface of tested composites where as XRD analysis was to inspect the phase analysis of produced composites.
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