Band 14, Heft 1

AISI 304L is an austenitic Chromium-Nickel stainless steel offering the optimum combination of corrosion resistance, strength, and ductility. These attributes make it a favorite for many mechanical switch components. The low carbon content reduces susceptibility to carbide precipitation during welding. In the present paper a thorough review on welding of AISI 304L austenitic Stainless Steel by various welding processes was made. From the review it is understood that AISI 304L austenitic Stainless Steel is the best material where there is a problem of intergranular corrosion. Also it is one of the best materials frequently used in manufacturing non heat treatable components.

The present investigation proposes the optimization of the wire electrical discharge machining process for machining ZC63/SiC P metal matrix composite. SiC particulate size and its percentage with the matrix are considered as the process variables along with the most significant WEDM variables such as pulse-on time, pulse-off time and wire tension. In view of quality cut, surface roughness, metal removal rate and kerf are considered as the process responses. Since, these responses are correlated with each other and they need to be optimized simultaneously. Therefore, the problem is treated as multi-response optimization problem. Principal component analysis (PCA) has been implemented to convert the multi-objective optimization problem in to single objective optimization problem by converting the multiple correlated responses in to the total quality index. Taguchi's robust optimization technique has been adopted to derive the set optimal process parameters which maximize the total quality index. The derived optimal process responses are confirmed with the experimental validation tests. ANOVA is conducted find the importance of the chosen process variables on the overall quality of the machined component. The practical possibility of the obtained optimal process performance is observed using SEM studies.

The cutting parameters such as the cutting speed, the feed rate, the depth of cut, etc. are expected to affect the two constituents of surface integrity ( SI ), i.e., surface roughness and micro-hardness. An attempt has been made in this paper to investigate the effect of the CNC hard turning parameters on the surface roughness average ( R a ) and the micro-hardness ( μ h ) of AISI 52100 hard steel under dry cutting conditions. Nine experimental runs based on an orthogonal array of the Taguchi method were performed and grey relational analysis method was subsequently applied to determine an optimal cutting parameter setting. The feed rate was found to be the most influential factor for both the R a and the μ h . Further, the results of the analysis of variance (ANOVA) revealed that the cutting speed is the most significant controlled factor for affecting the SI in the turning operation according to the weighted sum grade of the surface roughness average and micro-hardness.

The aim and objective of the project work is the modeling of control surface which has complex three dimensional aerodynamic profiles using solid works software, performing analysis of the model with the imposed loads and boundary conditions using ANSYS to estimate the maximum stress and deflection. The material used for this component is titanium alloy (Ti-6Al-4V) which has good properties like resistance to corrosion, high strength to weight ratio, which are mostly needed for aerospace vehicles. The actual dimensions of control surface are 350×225×20. The model of the control surface is scaled to 1:2 for manufacturing using Proe/Manufacturing module, the part programmes are generated and are transferred to the specific machine through DNC system. Control surface is probably the most commonly used form of missile control, particularly for long range airto-air missiles and surface-to-air missiles. The primary reason for this application is because tail provides excellent maneuverability at high angles of attack. Deckel E3LV CNC milling machine has been used for manufacturing the control surface. Development of 3D model using solid works then it is transferred to PROE software for generating error-free tool path and checking the tool path using simulation. Post processing of CL (cutter location) Data file to generate CNC part program, transferring the same to the respective machine tool via DNC system from CAM workstation and manufacturing of the control surface. Co-ordinate measuring machine (CMM) is used for the inspection of features, as the control surface is having complex three-dimensional aerodynamic profile. On this machine, every dimension of the control surface has been inspected and found that the dimensions are within the design considerations of the given design.

In the modern industrial world, speed, agility, accuracy and less time are the key factors to attain a position in the market. Various forms of the products manufactured which could either be symmetric or asymmetric. The stacking of the asymmetric parts are either done manually which is a time-consuming job or by installing robots which are costly. To overcome this problem, part feeders are introduced to stack the parts in a specific orientation. In the automotive industry the brake pads are the components manufactured in a large scale. The manufacture of components and stacking them is an intensive task which necessitates agile manufacturing. So a linear part feeding system is designed along with the trap and conveyor system to reorient the asymmetric part to its most favorable orientation for stacking. The major problem arrives in part feeding system is to send parts one by one to trap. The main objective of this work is to design and develop the singularizing unit for sending the parts one by one. The system is designed to separate the brake pads from clusters and singularize them. The singularizing unit is designed by using Markov model and the unit is fabricated. Experiments were conducted for selecting the suitable parameters by making the unit at various levels of inclinations by using base plates of various thicknesses. The parameters which are concentrated while orienting the parts are frequency of vibration, time to travel the part on the singularizing unit and acceleration of the part for effective part motion in a singularizing unit.

In this paper, there is an attempt to derive an observation and study of specific machining parameters after turning process of a DIN 34CrNiMo6 nickel-chromium stainless steel in a conventional center (lathe). The machining parameters concerned are the temperatures developed on cutting tools and the workpiece, the surface roughness of the workpiece after process, the level of vibrations of cutting tool, the noise levels of the process, and the current of the lathe motor. Four different experimental scenarios completed namely wet, dry and air-cooled process. An optimally designed sensor network installed to monitor and record the measurements of the examined machining parameters. The experimental data considered for examination with statistical analysis of developed charts which presented interesting research findings. In dry cutting, the machining temperatures and the amount of removed material, observed with the highest values among other experimental scenarios. The surface roughness found its smallest value after the end of the lubricated cutting and the machining process with minimum vibrations observed during the operation of the Airgun. However, the study also brought out an interesting and useful observation for future consideration in the area of a Life Cycle Assessment. The chips taken at the end of experimental scenarios will be used for an LCA analysis in relation to the initial material and machining process. This will give an opportunity of an interesting approach that can be applied to assess the environmental impacts throughout a product's life cycle.