iosr-JMCE   National Conference on Contemporary Approaches in Mechanical, Automobile and Building sciences-2014

Abstract: Human activities since preindustrial time have resulted in large increase in air pollution. Air pollutants are substances which when present in the atmosphere adversely affect the human health, animals, plants, or microbial life; damage materials, or interfere with the normal activitiesof life. In this paper, the air quality index in four places of Chennai such as Anna Nagar, Adyar, T.Nagar, Kilpauk was calculated. The pilot surveywas conducted based on the questionnaires from various categories of people such as vendors, auto drivers and passers by. The impact on human health is then presented in this paper.
Key words: Air quality Index, Ambient air Quality, RSPM, and SPM.

[1] AlliraniThiyagarajan (2003) Air Pollution and Respiratory Illness. Proceedings of the Third International Conference on Environment and Health, Chennai, India, 15-17 December 2003, pp 588- 596
[2] Chelani, A.B., Chalapati, Rao C.V., Phadke, K.M., Hasan, M.Z.,( 2002). Formation of an airquality index for India. International Journal of Environmental Studies 59, 331-342.
[3] Indian Air Quality Index, 2005, http://home.iitk.ac.in/~mukesh/ .
[4] John A. Maga& John R. Goldsmith M.D. (1960) Standards for Air Quality in California , Journal of the Air Pollution Control Association, 10:6, 453-467
[5] Nagendra, S., Venugopal, K. and Jones, S. (2007) "Assessment of air quality near traffic intersections in Bangalore city.", Journal of Transportation Research Part D, vol 12, 167-176.

Abstract: Tool wear is common problem in machining, where in tool wear is compensated by Wear offset in CNC machine. By measuring the dimension we give compensation in wear offset column. The CNC m/c operators enter the wear offset, mostly the error occurred during input the offset as direction is important, Due to this error we face more Rejection and assembly problem as dimension is important in fitment of assembly. And this error occurred due to the operator skill and fully depends upon the man. To eliminate the error we plan to give Automatic tool wear offset by simple automation. In this experimental work, simple online monitoring system adapted by studying various Adaptive control technology. The Air gauges are used for measuring Hard turned jobs with dim tolerance of 0.025mm and to know the ovality in the Hard turned jobs,, the operator adjust the tool wear by adjusting wear offset in CNC machine. He adjusts when the dimension reaches maximum which is indicated by RED light in Air gauge with alarm and also gives alarm when it reaches minimum. so we plan to trigger wear offset in CNC when it reaches maximum and minimum, so that dimension will be maintained middle in control chart. Further, tool wears offset automats updated by eliminating manual offset error and following poko yoke method. The SPC study and MSA study done to know the process is stable or not the studies are done before and After the implementation of tool wear offset online adaptive control, and the result achieved is satisfactory.
Keywords: CNC Machine, Tool Wear, Adaptive Control.

[1] S.C.Lin Online tool life monitoring, RWTH Aachen 1996.
[2] MrC.Scheffer and H.Kratz Tool wear offset for Hard turning,volume43,issue 10Augest 2003,pages 973-985.
[3] G.F Micheleti.W.koeng,In process tool wear sensor for cutting operation,CIRP,vol-25/02/1976.
[4] Katsushi Furukani,Nguyen Trm Hieu Automatic tool compensation for Grinding.
[5] M.Shiraishi Scope of inprocess measuring and monitoring and control technique in Machining process-1989

Abstract:Sound joining of aluminum alloys is a fundamental prerequisite for their successful integration into high temperature aerospace applications. It has been well demonstrated that diffusion bonding, a commonly used joining technology in conventional aluminum alloys, can successfully be used in joining similar and dissimilar Al alloys both in thermo mechanically treated conditions. In this study, diffusion bendability of AA5083 alloy using bonding parameters such as bonding temperature, bonding pressure and bonding time using a specially designed experimental die setup will be studied.
The bonding parameters (i.e., temperature, pressure and time) will be systematically changed to determine the optimum parameters for achieving sound bonds. Short-term tensile test at elevated temperatures will be performed for the DB sheets to determine the material characteristic 'm' and k (material constant) with constant. Hot tensile test will be carried to elevated temperature (up to 550ºC) to obtain the insight of mechanical behavior (uni-axial stress-strain) of AA5083. The basic method and specimen are studied from the literature survey. The whole tensile experimental setup will be designed and fabricated. The flow stress of the material under super plastic condition and room temperature will be determined from the true stress-strain and strain rate sensitivity (m), material constant (k) and strain hardeningexponent.

[1]. AlHazaa A., Khan T.I., Haq I., "TRANSIENT LIQUID PHASE (TLP) BONDING OF AL7075 TO TI–6AL–4V ALLOY" materials characterization 61 ( 2 0 1 0 ) 312 – 317.
[2]. Anton Smolej, Brana, MatevzFazarinc, "Determination of strain-rate sensitivity and the activation energy of deformation in the superplastic deformation alloy AL-Mg-Mn-Sc" (2009), RMZ-Material and Geo environment, Vol.56,No.4.
[3]. Abu-Farha, M.K.Khraisheh, "Post-Superplastic forming analysis under different loading paths. Part one: Uniaxial loading case" ASM International (2008) Vol.17:153-162.
[4]. Bulent Kurt, NuriOrhan, ErtanEvin, Adnan Çalik "DIFFUSION BONDING BETWEEN TI–6AL–4V ALLOY AND FERRITIC STAINLESS STEEL", Materials Letters 61 (2007) 1747–1750.
[5]. G.C.Wang, M.W.Fu,C.X.Cao, H.B.Dong, "Study on the maximum superplastic deformation of TI-6.5Al-3.5Mo-1.5Zr-0.3Si alloy", Material science and enginerring (2009) A513-514,32-41.

Abstract: An auto electrical parts manufacturing company located in Padi, Chennai, is manufacturing sealed version gear reduction starters to various customers for their trucks & buses applications. The demand requirements for these starters are slowly growing up. The reason is they are low in weight, when compared to a direct drive starter with same output performance. The starter will be placed very close to the engine so that it can trigger the engine through it's flywheel upon switching on the ignition key. But the starter mounting position will get varied from customer to customer as per their mounting requirement. Hence the splashing of water from the road to the starter motor is inevitable. Now the firm is facing water ingress issue on these sealed version starters as field failures (warranty issue) leading to loss in business. This paper focuses on elimination of water ingress failure on sealed version gear reduction starters. An analysis has been made in order to find the root cause for the failure & to eliminate it. The methodology adopted for the analysis includes the Root cause analysis using Cause and effect diagram and through the Process Failure Mode Effect Analysis. Application of these tools helped in improving the knowledge base of the assembly process and also helped narrowing down to the root cause or a number of root causes in quick span of time.
Keywords: Gear Reduction Starter, Cause & Effect analysis, Process Failure Mode Effect Analysis, Air Leak testing, Error proofing and Rapid detection

[1]. Automotive Industry Action Group (AIAG) – Potential Failure Mode Effects Analysis (2008), Reference manual Fourth edition, ISBN: 978-1-60534-136-1, June 2008, pp. 67 – 139.
[2]. Awadhesh Kumar, Poonia M.P., UpenderPandel and Jethoo A.S. (2011)FMEA: Methodology, Design and Implementation in a Foundry. International Journal of Engineering Science and Technology, Vol. 3 No. 6 June 2011, ISSN: 0975-5462.
[3]. Christine Connolly (2007) Sensor trends in processing and packaging of foods and pharmaceuticals, Sensor Review, Vol. 27 February 2007, ISSN 0260-2288, pp. 103 – 108.
[4]. Mhetre R.S. and Dhake R.J. (2012)Using Failure Mode Effect Analysis in a Precision Sheet Metal Parts Manufacturing Company. Int. Journal of Applied Sciences and Engineering Research, Vol. 1, No. 2, 2012, ISSN 2277 – 9442.
[5]. Rajiv Kumar Sharma, Dinesh Kumar and Pradeep Kumar (2007) FM – a pragmatic tool to model, analyze and predict complex behavior of industrial systems, International Journal for Computer-Aided Engineering and Software Vol. 24 No. 4, 2007, pp. 319-346

Abstract: Chloride ion diffusion is one of the main factors affecting the durability of reinforced concrete structures. The purpose of the present study is to evaluate the chloride migration coefficient under accelerated test conditions. Accelerated test methods permit migration rates to be evaluated for a specific mix design in a relatively short time. Ordinary Portland Cement concretes of three different water-cement ratios 0.55, 0.45, 0.35 are used in this study. Two accelerated non-steady state test methods (i) Rapid chloride migration test (RCMT) (NT BUILD 492) and (ii) Accelerated chloride migration test (ACMT) with 24V are used. Chloride penetration depth is obtained by Colourimetric method (0.1N AgNO3) and comparison is made with two accelerated test methods. It has been observed that in RCMT, the chloride migration coefficient increases with increase in water-cement ratio and is about 2.5 times less for w/c ratio 0.35 when compared to that of w/c ratio 0.55 and in ACMT, the chloride migration coefficient is 1.7 times less. The rate of penetration between two accelerated test methods showed good correlation.
Keywords- Concrete; Chlorides; Durability; Migration Coefficient; OPC Concrete

[1] Chiang, C. T, Yang, C.C, ̏Relation between the diffusion characteristic of concrete from salt ponding test and accelerated chloride migration test˝, Mater.Chem.Phys.106 (2007) 240-246.
[2] D. Whiting, ̏Rapid determination of the chloride ion permeability of concrete˝, Final Report No. FHWA/RD-81/119, Federal Highway administration, 1981.
[3] Stanish, k., Hooton, R.D., Thomas, M.D. ̏Prediction of chloride penetration in concrete˝, Dept. of Transportation, Federal Highway Administration, 2001.
[4] Luping.T, Nilsson S, ̏Rapid determination of the chloride diffusivity in concrete by applying an electrical field˝, ACI Mater.89 (1992).
[5] ̏Chloride migration coefficient from non-steady-state migration experiments˝, NT BUILD 492, NORDTEST (1999).

Abstract: In this project work an investigation into Minimum Quantity Lubricant (MQL) and wet machining in milling processes of AISI 6060 Aluminum work material has been carried out with the main objective is to determine the effect of lubrication conditions on the surface roughness. Three other parameters were also consider in this study; feed rate (FR), depth of cut (DOC) and cutting speed(CS).The levels each parameter had been selected is four levels. The ranges of feed rate 0.05mm/min,0.15mm/min,0.20mm/min and 0.25mm/min depth of cut used were 0.2mm, 0.4mm,0.6mm and 0.8mm whereby the cutting speed values were 600mm/min,800mm/min,100mm/min and 1200mm/min.

[1]. E-G Ng ', D. Szablewski ', M. Dumitrescu ', M.A. Elbestawi'(1) and J.H. Sokolowski ―High Speed Face Milling of aAluminium Silicon Alloy Casting‖
[2]. F. Itoigawa a,∗, T.H.C. Childs b, T. Nakamuraa, W. Belluco c ―Effects and mechanisms in minimal quantity lubrication machining of an aluminum alloy‖
[3]. Z.T. Tanga,b,∗, Z.Q. Liub, Y.Z. Panb, Y. Wanb, X. Aib ―The influence of tool flank wear on residual stresses induced by milling aluminum alloy‖
[4]. BalkrishnaRao, Yung C. Shin ―Analysis on high-speed face-milling of 7075-T6 aluminum using carbide and diamond cutters‖
[5]. Gwo-LianqChern ―Experimental observation and analysis of burr formation mechanismsin face milling of aluminum alloys‖

Abstract: Fixture is a precision device for restraining the work piece during manufacturing, inspection, assembly and transportation. Fixtures are used in many manufacturing processes to hold work piece and to reduce the set up time. The position of fixture elements is called as fixture layout. Placing the clamps and locators in wrong positions may disturb the equilibrium of the work piece, resulting in excessive deformation of the work piece. Hence optimization of fixture layout to minimize the work piece deformation is one of the critical aspects in the fixture design process. In this paper discussed about to find the optimum location of the clamps.
Key words: Fixture Layout, Optimization

[1]. S. Vallapuzha, E.C. De Meter, S. Choudhuri and R.P. Khetan, "An investigation into the use of spatial coordinates for the genetic algorithm based solution of the fixture layout optimization problem", International Journal of Machine Tools and Manufacture 42 (2002) 265–275.
[2]. K. Krishnakumar and S.N. Melkote, "Machining fixture layout optimization", International Journal of Machine Tools and Manufacture 40 (2000) 579– 598.
[3]. Wang MY, "A full-kinematic model of fixtures for precision locating applications" in IEEE/RSJ international conference on intelligent robots and systems, Maui (HI USA); 2001. p. 1135–40.
[4]. B. Li and B.W. Shiu, "Principle and simulation of fixture configuration design for sheet metal assembly with laser welding. Part 2. Optimal configuration design with the genetic algorithm", International Journal of Advanced Manufacturing Technology 18 (2001) 276–284.
[5]. Y.G. Liao, "A genetic algorithm-based fixture locating positions and clamping schemes optimization", Proceedings of the Institute of Mechanical Engineers. Part B, Journal of Engineering Manufacture 217 (2003) 1075–1083.

Abstract: Metal matrix composites (MMCs) possess significantly improved properties including high specific strength, specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. MMCs could be produced by variety of methods such as Stir cast, Liquid Infiltration, Osprey and Powder metallurgy.Among this Powder Metallurgy processing is one of the effective methods to manufacture MMCs with high volume of reinforcement with fairly uniform distribution. The present investigation deals with the production of SiC particle reinforced Aluminium powder and Aluminium-flyash composite through powder metallurgy route with conventional sintering as well as microwave sintering.An attempt was made to optimize process parameter such as sintering time, sintering temperature and compacting load. The Aluminium powders (44 micron) and SiC particle (37 micron) and Flyashpowder(20 micron) at a volume fraction of 5-20% of SiC and 20% of SiC-10%Flyash was processed. Compacting load was varied between 4000kg to 8000kg.Sintering was performed in Microwave furnace .2At a load of 8000kg in Al-(20%)SiC-(10%)Flyash a maximum densification of (96%) was achieved.Hardness test was conducted in Rockwell testing Machine. In Al-20%SiC-10%Flyash composition corresponding to the 8000 kg load, the Hardness 81HRB(Rockwell B-scale) was obtained.

[1]. Anklekar.R.M, Agrawal.D. K, and Roy.R, "Microwave Sintering and Mechanical Properties of P/M Copper Steel", Powder Metallurgy, Vol. 44, pp.355-362, (2001).
[2]. Bescher.P, Urmimalasarkar and John D. Mackenzie, "Microwave Processing of Aluminum-Silicon Carbide Cermets", Department of Materials Science and Engineering, University of California Los Angeles, CA 90024, Mat.Res. Soc. Symp. Proc. Vol. 269, pp. 371-378, (1992).
[3]. Charles, Arunachalam , "Property analysis and mathematical properties of aluminium alloy hybrid (Al-alloy/SiC/flyash) composites produced by liquid metallurgy and powder metallurgy techniques", Indian Journal of Engineering and Materials Sciences, Vol.11, pp.473-480, (2004).
[4]. Guo R.Q, Rohatgi.P.K , "Preparation of Aluminium–Fly Ash Particulate Composite by Powder Metallurgy Technique", Journal of materials science, Vol.32, pp.3971–3974, (1997)
[5]. Gokce.A, Findik.F , "Mechanical and physical properties of sintered aluminum powders", Journal of Achievements in Materials and Manufacturing Engineering, volume 3, pp. 157-164, (2008).

Abstract: Due to the stringent legislation on emissions from diesel engines and also increasing demand on fuel consumption, the importance of detailed 3D simulation of fuel injection, mixing and combustion has been increased in the recent years. The Common-rail injection system has allowed achieving a more flexible fuel injection Control in DI-diesel engines by permitting a free mapping of the start of injection, Injection pressure, rate of injection. All these benefits have to be gain by installing this device in combustion chambers born to work with the conventional distributor and in-line-pump injection systems. Their design was aimed to improve air-fuel mixing and therefore they were characterized by the adoption re-entrant bowls. All the other relevant parameters namely compression ratio, maximum diameter of the bowl, squish clearance and injection rate were kept constant. A commercial CFD code STAR-CD was used to model the in-cylinder flows and combustion process, and experimental results of the baseline bowl have been used to validate the numerical models. The simulation results show that, bowl 3 enhance the turbulence and hence results in better air-fuel mixing among all three bowls in a DI diesel engine. As a result, the ISFC and soot emission reduced, although the NOX emission is increased owing to better mixing and a faster combustion process.
Key word - Combustion chamber, CFD analysis, Fuel consumption.

[1]. Arturo de Risi, Teresa Donateo, Domenico Laforgia,"Optimization of the Combustion Chamber of Direct Injection Diesel Engines", SAE 2003-01-1064.
[2]. Bianchi, G.M., Pelloni, P., Corcine, F.E. Mattarelli, E.Luppino, Bertoni. F, "Numerical Study of the Combustion Chamber Shape for Common Rail H.S.D.I Diesel Engines", SAE 2000-01-1179.
[3]. Corcione. F. E, Annunziata Fusca, and Gerardo Valentino, "Numerical and Experimental Analysis of Diesel Air Fuel Mixing", SAE 931948.
[4]. Herbert Schapertons, Fred Thiele," Three Dimensional Computations for Flow Fields in D I Piston Bowls", SAE 860463.
[5]. Ikegami. M, Fukuda. M, Yoshihara. Y and Kaneko. J, "Combustion Chamber Shape and Pressurized Injection in High- Speed Direct –Injection Diesel Engines", SAE 900440.

Abstract: This paper presents an effective approach to study process parameters in electrical discharge machining. Electrical Discharge Machining (EDM) is frequently used in machining of precision and intricate parts and in machining of hard materials and micro-machined features. Due to the nature of the process, parameters influence the final quality characteristics. This study presents the influence of the main EDM process parameters pulsed current, pulsed time and pulsed pause time are carried out in Aluminum Silicon Carbide (AlSiC) alloy using different tool geometrical shapes of copper electrodes. In addition to this, Material Removal Rate (MRR), Tool Wear Rate (TWR) and different dimensional and geometrical micro-accuracies are analyzed through statistical methods. Since the process has multiple performance characteristics, the grey relational analysis is used. A grey relational grade obtained from the grey relational analysis is used to optimize the process parameters.
Keywords—orthogonalarray,Greyrelationalanalysis, optimisit

[1] Krar and Gill, The erosive effect of electrical discharges, pp 6.2.1.
[2] Lazarenko, B.R., To invert the effect of wear on electric power contact, Dissertation of the All-Union Institute for Electro Technique in Moscow/CCCP, Russian.
[3] Frans Van Dijck, Physico-mathematical analysis of the electro dicharge machining process, PhD Thesis Katholieke Universiteit te Leuven, 1973.
[4] Singh, A. & Ghosh A., A Thermo-Electric Model of Material Removal during Electric Discharge Machining. International Journal of Machine Tools Manufacture 39, pp 669-682 (1999).
[5] N. Mohri; M. Suzuki; M. Furuya & N. Saito (1995). Electrode wear process in electrical discharge machining, Ann. CIRP 44 (1), pp165-168.