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Nickel based superalloys have a wide range of applications due to high mechanical strength at high temperatures, fracture toughness and resistance to corrosion. However, because of their outstanding properties, it is considered as the difficult to machine materials. Inconel alloy X-750 is used extensively in rocket-engine thrust chambers. Airframe applications include thrust reversers and hot-air ducting systems along with large pressure vessels are formed from Inconel alloy X-750. Moreover, the comparative analysis of machinability aspect using coated carbide inserts is reported few. The current study explains the machinability investigation on Inconel alloy X-750 superalloys using coated carbides. To collect the experimental data, the L16 experimental design plan is used to experiment with a machining length of 40 mm.

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.

In the fabrication of parts in auto and aero segments, the use of ceramic (SiCp, Al2O3p) reinforces aluminum alloy found to be increased than that of steel and cast iron. This matrix-reinforced alloy has a high strength to weight ratio along with higher modulus and hardness, the lower thermal coefficient of expansion, and improved tribological properties. To this extent, this paper investigates the turning characteristics and optimization study of newly developed metal matrix composites by the addition of both hard ceramic SiCp and soft stable lubricant molybdenum disulfide (MoS2p). The samples such as Sample 1: AlSi10Mg/3SiCp, Sample 2: AlSi10Mg/2MoS2p and Sample 3: AlSi10Mg/3SiCp /2MoS2p are prepared using the automated stir-casting machine. The particles are observed to be uniformly distributed in the composite. After density and hardness measurement, the samples are subjected to machining, and the responses are optimized by using response surface method.

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.

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.

Suspension system of a vehicle plays an important role to carefully control motion of the wheel throughout the travel. The vertical and the lateral dynamics (ride and handling) is affected by the unsprung-to-sprung mass ratio. Lower value of this mass ratio leads to enhanced performance of the car. To optimize the unsprung mass of the car, design of control arm plate is optimized with Aluminum material and Carbon fibre reinforced composite control arms framework are used to achieve high stiffness to weight ratio. These leads to increase in overall power to weight ratio of the car which helps to deliver maximum performance to the wheels. Through analysis of real-life working conditions of the entire steering knuckle assembly in ACP pre- post ANSYS 18.1 with the defined boundary conditions, equivalent stress and total deformations are obtained. Based on the results, geometrical topology of the control arms plates is further optimized.

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.

The main purpose of this study is to investigate additive manufactured Inconel super alloy subjected to cryogenic treatment (CT). Cryogenic treatment is mainly used in aerospace, defense and automobile application. Direct metal laser sintering is an additive manufacturing technique used for manufacturing of complex and complicated functional components. Inconel is an austenitic chromium nickel based super alloy often used in the applications which require high strength & temperature resistant. In this work, a study is carried out on microstructure and mechanical properties of additive manufactured Inconel 718 when subjected to cryogenic treatment at three different time intervals. The micro-structural evolution of IN718 super-alloy before and after CT was investigated by both optic microscope and scanning electron microscope. Surface roughness and hardness at different CT time intervals has also analyzed. Additionally, XRD technique was used to analyze the surface residual stress.

This paper describes the modelling and electromagnetic analysis of Permanent Magnet Brushed Direct Current (PMBDC) motor using Finite Element Analysis (FEA) software packages. The designed motors referred in this analysis are fit for use in applications of the electronic throttle control and exhaust gas recirculation in automobiles. Performances of the designed PMBDC models are compared with the traditionally used machines. Three PMBDC models with different operating characteristics are proposed for the two applications. Each model is suitable for use in both applications. Cost analysis of the motors is also carried out, and comparison with the traditionally used machines is done.

In the present paper, to predict the process relation between laser-assisted machining parameters and machinability characteristics, statistical models are formulated by employing surface response methodology along with artificial neural network. Machining parameters such as speed of cut; the rate of feed; along with the power of laser are taken as model input variables. For developing confidence limit in collected raw experimental data, the full factorial experimental design was applied to cutting force; surface roughness; along with flank wear. Response surface method (RSM) with the least square method is used to develop the theoretical equation. Furthermore, artificial neural network method has been done to model the laser-assisted machining process. Then, both the models (RSM and ANN) are compared for accuracy regarding root mean square error (RMSE); model predicted error (MPE) along with the coefficient of determination (R2).

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 experimental investigation aims to improve natural composite materials aligned with feasible development principles. These composites can be exploited across several industries, including the automobile and biomedical sectors. This research employs date seed powder and neem gum powder as reinforcing agents, along with polyester resin as the base material. The fabrication route comprises compression moulding, causing the production of the natural composite material. This study focuses extensively on mechanical characteristics such as tensile strength, flexural strength, hardness, and impact resistance to undergo comprehensive testing. Furthermore, the chemical properties of the composites are examined using the FTIR test to gain understanding by integrating different proportions of date seed powder (5%, 10%, 15%, and 20%) and neem gum powder (0%, 3%, 6%, and 9%) in the matrix phase.

The present study discusses the effects of engine combustion, performance and emission features of methanol-gasoline blend fired lean burn Spark Ignition (SI) engine. Performance features such as Brake Power (BP), Brake Specific Fuel Consumption (BSFC), Brake Thermal Efficiency (BTE), tail pipe emissions namely Hydrocarbon (HC), Carbon Monoxide (CO), Nitrogen Oxide (NO), Carbon di Oxide (CO2) and combustion characteristics viz. in-cylinder pressure, Heat Release Rate (HRR), Cumulative Heat Release (CHR) and variation of mean effective pressure were measured and compared with that of neat gasoline. Experiments were conducted on a modified sole cylinder four-stroke compression engine (Kirloskar TAF1) to operate as SI engine with a compression ratio of 10.5:1. A new manifold injection system and ignition system were developed by replacing the fuel injection pump and injector.

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.

Today manufacturing industries have become more competitive and to survive, industries should be capable of accommodating the sudden market change. The conventional manufacturing systems like Dedicated Manufacturing Lines (DMLs) can produce high volume of product but difficult to cater to varying product types. On the other hand, Flexible Manufacturing System (FMS) is capable of handling product variety but not suited for mass production, The Reconfigurable Manufacturing System (RMS) gives the advantage of both the system, as it has the capability to adjust to both high volume requirement and product variety, and it able to upgrade to new process technology with minimal effort. In this work the reconfiguration is carried out in machine and system level. At machine level, a new inspection machine is proposed which can be used for multiple products with minimal adjustments and a special drilling and bore tool is suggested to reduce the cycle time and ramp up time when product changes.

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.

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.

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 research work describes the effect of microsegregation, microstructure and tensile strength of the Hastelloy X weldment produced by keyhole plasma arc welding (K-PAW). Weld joint was obtained in a single pass without the addition of filler wire. The significant results obtained in this research work are (i) fine equiaxed dendrite was detected in the weld centre due to lesser heat input (HI) along with the faster solidification attained in K-PAW (ii) The existence of secondary precipitates in the interdendritic boundary was identified by the scanning electron microscope (SEM) analysis (iii) Energy dispersive X-ray spectroscope (EDS) revealed the Cr and Mo microsegregation in interdendritic boundary of the weld zone (iv) X-ray diffraction (XRD) analysis confirmed the Mo-rich P phase and Cr-rich M23C6 phase. The observed tensile strength of weldment is 6.14 % inferior to base metal.