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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.

The economic growth of the company depends on the quality and delivery time of the components. The pursuit of new techniques is mandatory to maintain quick delivery time without compromising quality. Ergonomics is one such technique that helps to improve workstation productivity by reorganizing the workspace, changing the sequence in operations, up-gradation of machine tools, reducing operator fatigue, etc. The ergonomic study was performed in a tractor steering gearbox manufacturing unit. In the present work, an ergonomic assessment of the workstation is done. Ergonomics assessment includes RULA assessment and Work-place assessment helped to find out the factors influencing the work station to be in the alert zone. During the observation of base milling operation, the operator needs to clamp and de-clamp the steering box manually by using mechanical tools. Due to which operator feel more fatigue in the wrist and lower-arm position which reduces productivity.

The research aims to optimize the surface roughness, material removal rate (MRR), tool wear, and spark gap for input machining parameters such as Pulse on-off time and wire feed rate. The experiment results of WEDM of Duplex stainless steel are optimized by ANOVA and Response surface methodology (RSM) approach. Taguchi’s orthogonal array L9 (3*3) was used to design the test condition for the experiment. After the model validation, ANOVA was used to identify the most significant input factor on the output. Response surface methodology was used to find the ideal cutting conditions which produce the best-desired output in terms of less tool wear, lower surface roughness, lower spark gap, and higher material removal rate. The optimal MRR, Spark Gap, surface roughness, and tool wear parameters for Duplex Stainless Steel are obtained at Pulse on 110.23, Pulse off time of 56.0, and a wire feed rate of 1.0.

In the last decade, there was growing interest in the use of green composites because of their environment-friendly nature, improvement in mechanical & chemical properties, better processability, and low cost. In this work, short sisal fiber was reinforced in a polycaprolactone (PCL) matrix and four different degradable green composites were developed with different weight fractions. Experimental studies were conducted as per standard to find the mechanical properties of PCL based composites. The data obtained shows that there is a 22% increase in tensile strength, 18% increase in hardness and 100% increase in impact strength for the specimen with 10% sisal fiber compared to neat PCL specimen. The mechanical property reduces when the fiber content is increased to 15%. These PCL based composites shall find applications in the packaging industry and consumer goods that have less service temperature.

The surface properties have a vital role in the overall performance of the parts like brake shoe pad and other frame system. The mechanical and residual stress measurements of aluminium alloy 5083 were investigated on friction stir processed plates using the reinforcements of chromium oxide (Cr2O3) and titanium dioxide (TiO2) separately as well as combination of these powders. A comparative study was made to analyze the effects of reinforcements, tool type (cylindrical and threaded), parameters and the volume fraction of the reinforcements. The mechanical properties such as surface hardness and residual stress of the friction stir processed specimens were investigated. The experimental results shows that there was a significant increase in surface hardness (118 HRC) as well as a decrease in residual stress compare to the base metal. This study also reveals that the threaded tool with a reinforcement of Cr2O3 and TiO2 reflected better mechanical properties than the cylindrical tool.