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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

Application of Grey Taguchi Method for Optimization of EDM Process Parameters on Stir Casted Aluminium Hybrid Metal Matrix Composites

2023-11-10
2023-28-0152
Composites made of aluminium and other materials are now essential materials for a variety of engineering tasks, including those in the automotive industry. The present work reports on the machinability studies of Al 6061 hybrid metal matrix composites (HMMC). For the investigation, Al6061 alloy is reinforced with Boron carbide and Graphene nanoparticles (GNp) and the hybrid composite was prepared by stir casting under suitable conditions. The Electrical discharge machining (EDM), advanced machining process, was chosen to machine HMMC as it is difficult to machine by conventional machining. EDM machinablity studies were done on stir casted Al-B4C-GNP composites. The optimization of EDM process parameters were carried out using L27 orthogonal approach with input parameters such as pulse on time, pulse off time and peak current for the response of material removal rate (MRR) and surface roughness.
Technical Paper

Application of Optimization Technique on Spark Erosion Machining of AA 2014 Alloy for Aircraft Components

2023-11-10
2023-28-0146
Due to their various features, aluminum alloy can be used in various applications. These include aerospace, automotive, and electrical and thermal applications. Compared to structural steels, aluminum offers superior corrosion resistance and specific strength. Aluminum alloy known as AA 2014 exhibits various mechanical properties. These include its improved strength and weight ratio. It can also be used in military and aircraft applications. Aluminum alloy is commonly used in various engineering applications, such as the manufacturing of structures and aircraft components. Due to its corrosion resistance, it can be utilized in severe environmental environments. Different methods are used in unconventional ways to generate complicated forms of electrical components. One of these is wire electro-discharge machine (WEDM). This process involves making intricate shapes out of conductive materials.
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

Design and Investigation of Automatic Trash Collecting Machine for Industry

2023-11-10
2023-28-0179
Scrap collection from any location is handled with mortal interference in several places and companies which may be extremely harmful or even dangerous to humanity. The demand for robotization has risen rapidly in recent years, owing to cutting-edge technologies that minimize manpower and threat-taking training directly or indirectly. The main objective of the paper is to study, analyze, investigate the main contribution of waste collecting by workers while cleaning in the Mechanical Industry. In order to ensure the safety of the workers during cleaning we had implemented the Automatic Trash Collecting Machine in the industry. For Fabricating the Trash collecting Machine first we had analyzed the problem in the industry and then we had started the free hand sketch of Trash Collecting Machine. Then the design work of Automatic Trash Collecting Machine is done in the modeling software Catia V5. Then the material selection for our model has been done.
Technical Paper

Investigational Analysis on Wire Electrical Discharge Machining of Aluminium Based Composites by Taguchi’s Method

2023-11-10
2023-28-0075
A wide range of engineering domains, such as aeronautical, automobiles, and marine, rely on the use of Metal Matrix Composites (MMC). Due to the excellent properties, such as hardness and strength, Aluminum base MMC are generally adopted in various uses. Due to the increasing number of reinforcement materials being added to the MMC, its properties are expected to improve. In this exploratory analysis, an effort was given to develop a new aluminium-based MMC. The analysis of the machinability of the composite was also performed. The process of creating a new MMC using a stir casting technique was carried out. It resulted in a better and more reinforced composite than its base materials. The reinforcement materials were fabricated using different weight combinations and process parameters, such as the temperature and duration required to stir. Due to the improved properties of the composite, the traditional machining method is not feasible for machining of these materials.
Technical Paper

Investigations on the Effects of Chemical Treatment on Mechanical Properties of Thespesia Lampas Fiber Reinforced Composites for Automobile Applications

2023-11-10
2023-28-0121
In today's world, there is an increasing emphasis on the responsible use of fiber reinforced materials in the automobile applications, construction of buildings, machinery, and appliances as these materials are effectively reused, recycled, or disposed with minimum impact on the environment. As such, it has become mandatory to incorporate sustainable, environmental friendly and green concepts in the development of new materials and processes. The primary objective of this study is to manufacture composites using fibers obtained from Thespesia Lampas plants, which are known for their soft, long fibers that are commonly used in various domestic products. The composites are made by combining these fibers with a general purpose polyisocyanurate resin, and their potential applications in both domestic and commercial products are explored. To evaluate the properties of these composites, tests are conducted for tensile strength, flexure, and water absorption.
Technical Paper

Machinability Analysis of PH Stainless Steel with Uncoated and Textured Tool Inserts with Minimum Quantity Lubricants

2022-12-23
2022-28-0543
The alloy investigated in this research is Precipitation Hardened Stainless Steel (PHSS) 15-5, which provides good corrosion, high strength and hardness. 15-5 Stainless Steel is extensively employed in a variety of applications, including aero plane components, high-pressure corrosive environments that include valves, fasteners, shafts, fittings and gears. In this current exploration, an analysis of the machinability of PHSS is analyzed with textured inserts and the outcomes as compared to conventional inserts. To increase the machinability conditions, two distinct types of textures were produced on the rake face of the tool inserts and employed for this machining procedure utilizing a Wire Electric Discharge Machine (WEDM).The dimensions of the textures were cut on the trial-and-error method. Three different machining parameters with three different levels were chosen. Cutting Speed, feed rate and depth of cut were chosen as the input parameters.
Technical Paper

Multiple Regression Analysis for Ti-6Al-4V Wire Electrical Discharge Machining (Grade 5) for Light Weight Automobile Applications

2023-11-10
2023-28-0163
Wire Electrical Discharge Machining (WEDM) is a variant of the electrical discharge machining (EDM) process, which represents an innovative method for the removal of material from a workpiece. The aforementioned process is frequently employed for the machining of harder materials that possess intricate geometries. Titanium alloys are a class of lightweight materials that find extensive utilization in many technical applications. Titanium Grade-5 is a titanium-based alloy that exhibits enhanced mechanical strength and improved resistance to corrosion. The objective of this exploratory analysis is to establish empirical correlations between the selected input variables, namely ‘Pulse on,’ ‘Pulse off,’ and peak current, and the desired output measures, which are material removal rate and surface roughness. The experimental design employed the Taguchi method to effectively organize the combination of tests by considering input factors.
Journal Article

Role of Thermo-Mechanical Treatment on Creep Deformation Behaviour of Reduced Activation Ferritic Martensitic Steel

2022-10-05
2022-28-0064
To enhance the microstructural and mechanical properties of Reduced Activation and Ferritic-Martensitic (RAFM) steel thermo mechanical treatment (TMT) was performed on as received Normalised and Tempered steel (N+T). The RAFM with 9Cr-1W-0.06Ta major alloying elements steel was used in the study in N+T and TMT conditions. The refinement in microstructure and precipitates was observed in TMT steel in comparison to N+T steel. There is a drastic improvement in mechanical properties such as hardness, tensile properties are observed without losing the ductility. The creep deformation behaviour of thermo-mechanical treated steel and N+T steel were studied at different stress levels at 823 K. The comparative creep rupture and strain properties were studied, and various creep deformation regimes were also analysed for both the conditions of steel.
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.
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