7 Papers_merged

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 In this research, finite element analysis is performed Stress N/mm2 Shear stress & torque diagram for diferent using ANSYS software. To model the composite shaft, orientation for carbon fiber composite the shell 181 element is used and the shaft is subjected to torsion. The shaft is fixed at one end in tangential 100.00 directions and is subjected to torsion at the other end. After performing a static analysis of the shaft, the 50.00 stresses are saved in a file. 0.00 500 1000 1500 2000 fig shows shaft shell model (mid surface model) 0 Torque stress0-90-0-90 stress0-0-0 It is observed that the minimum stress values are obtained in the layer orientation (0-90-0-45) compared to others. fig shows shear strain Shear stress & torque diagram for different fig shows shear stress orientations in E-Glass fiber composite 100.00 90.00 80.00 stress N/mm270.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 2000 0 500 1000 1500 torque N-m stress0-90-0-90 stress0-0-0 stress90-90-90 stress0-90-0-45 It is observed that the minimum stress values are obtained in the layer orientation (0-90-0-45) carbon fiber compared to steel. Results and Conclusion: ISBN: 978-93-5620-351-8 38 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Comparison of shear stress for different Comparison of shear stress between different composite materials same torque composite materials and steel 70.00 100.00 60.00 Stress N/mm2 80.00 Stress N/mm2 50.00 60.00 40.00 40.00 30.00 20.00 20.00 10.00 0.00 500 1000 1500 2000 0 Torque N-m 0.00 500 1000 1500 2000 0 Torque N-M stress0-90-0-45-carbon fiber stress -steel stress0-90-0-45-E-glass fiber stress0-90-0-45-carbon fiber It is observed that the minimum stress values are obtained in carbon fiber compared to carbon fiber. stress0-90-0-45-E-glass fiber It is observed that the minimum stress values are obtained in the layer orientation (0-90-0-45) compared to others. Comparison of shear stress between Angle of twist & torque diagram for different composite materials and steel orientation of carbon fiber composite 100.00 50.00 80.00 Angle ϴ in deg. 40.00 Stress N/mm2 60.00 30.00 40.00 20.00 20.00 10.00 0.00 500 1000 1500 2000 0 Torque N-m 0.00 500 1000 1500 2000 0 Torque N-m stress -steel angle of twist0-90-0-90 stress0-90-0-45-carbon fiber angle of twist0-0-0- It is observed that the minimum stress values are angle of twist90-90-90 obtained in the layer orientation (0-90-0-45) carbon fiber compared to steel. angle of twist0-90-45 The above diagram shows that the layer orientation (0- 90-0-45) has low twist angle with torque compared to other layer orientations ISBN: 978-93-5620-351-8 39 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Angle of twist & torque diagram for The above diagram shows that the layer orientation (0- different orientation for E-Glass epoxy 90-0-45) has low twist angle with torque compared to other layer orientations fiber composite Angle ϴ in deg. 45.00 Angle of twist & torque diagram for Steel 40.00 and carbon fiber composite 35.00 30.00 20.00 25.00 20.00 Angle ϴ in deg. 15.00 15.00 10.00 10.00 5.00 5.00 0.00 500 1000 1500 2000 0.00 500 1000 1500 2000 0 Torque N-m 0 Torque N-m angle of twist0-90-0-90 angle of twist0-0-0-0 angle of twist-steel angle of twist0-90-45-carbon-fiber angle of twist-90-90-90 The above diagram shows that steel has low twist angle of twist 0-90-0- angle with torque compared to other layer orientations 45-90 The above diagram shows that the layer orientation (0- Angle of twist & torque diagram for Steel, 90-0-45) has low twist angle with torque compared to composite of carbon fiber and E-Glass fiber other layer orientations 30.00 Angle ϴ in deg. 25.00 20.00 Angle of twist & torque diagram for E- 15.00 Glass fiber and carbon fiber composite 30.00 10.00 25.00 5.00 Angle ϴ in deg. 20.00 0.00 500 1000 1500 2000 0 Torque N-m 15.00 10.00 5.00 angle of twist-steel angle of twist0-90-45-carbon-fiber 0.00 500 1000 1500 2000 angle of twist 0-90-0-45-90-e-glass fiber 0 Torque N-m The above diagram shows that steel has low twist angle of twist0-90-45-carbon-fiber angle with torque compared to other layer orientations angle of twist 0-90-0-45-90-e-glass 6. Discussion and results fiber ISBN: 978-93-5620-351-8 40 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 The results obtained from analysis show that by using finite element analysis, the strength of a composite drive shaft was simulated. In this the effect of boundary conditions and the stacking sequence of the composite layers on the strength of the drive shaft is studied. It is shown that increasing of the applied torque on the shaft increases the torsional shear strength. The results obtained in this work are summarized in the following: • The boundary conditions of the shaft do not have much effect on the torsional shear. • The fiber orientation of a composite shaft affects the torsional shear. • The stacking sequence of the layers for a composite shaft also affects the twisting angle. • The finite element modeling presented in this analysis is able to predict the torsional shear and angle of twist. 7. REFERENCES [1] Greenhill AG. On the strength of shafting when exposed both to torsion and to end thrust. In: Proc Instn Mech Engrs, London; 1883. p. 182. [2] Schwerin E. Torsional stability of thin-walled tubes. In: Proceedings of the First International Congress for Applied Mechanics, Delf, The Netherlands; 1924. p. 255–65. [3] Sezawa K, Kubo K. The buckling of a cylindrical shell under torsion. Aero Research Inst, Tokyo Imperial University, Report No. 176; 1931. [4] Lundquist E. Strength tests on thin-walled duralumin cylinders in torsion. NACA No. 427; 1932. [5] Donnell LH. Stability of thin-walled tubes under torsion. NACA Report 479; 1934. p. 95–115. [6] Ambartsumyan SA. Theory of anisotropic shells. TT F-118, NASA; 1964. p. 18–60. ISBN: 978-93-5620-351-8 41 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 A Review On Abrasive Water Jet Machining Process And Its Process Parameters On EN-36 1Mr. Lakshimigalla Sunil Kumar, 2Sapavat Sai Kumar, 3Thigulla Srujan Kumar, 4Kalavena Nithin, 5Konda Prasanth, 6Ushagiri Vishal 1Assistant professor, Department of Mechanical, Nalla Narsimha Reddy Education Society’s Group of Instititions, Hyderabad. 2,3,4,5,6 Student, Department of Mechanical, Nalla Narsimha Reddy Education Society’s Group of Institutions, Hyderabad. Abstract— Abrasive water jet machining is a converted into kinetic energy of abrasive water jet in process where the material is removed by the principle nozzle which is made to impinge on the material which of erosion. In this paper, the cutting of EN-36 carbon is to be machined. steel was carried out by AWJM process where the input parameters are water jet pressure, abrasive flow Working principle rate and traverse speed, which are taken into The Abrasive Jet Machining is a non-traditional consideration machining. kerf width and the kerf taper machining process involves the application of a high- angle of EN-36 steel are measured with respect to the speed stream of abrasive particles assisted by the above-mentioned input parameters using Taguchi L9 pressurized air on to the work surface through a nozzle orthogonal array Design of Experiments. In this of small diameter. Material removal takes place by experiment, it has been observed that the main abrading action of abrasive particles. Water jet parameter which affects the experimental values is the machining is an erosion process technique in which abrasive flow rate. water under high pressure and velocity precisely cuts through and grinds away minuscule amounts of Keywords— Kerf Width, Kerf Taper Angle, material. The addition of an abrasive substance greatly Surface Roughness, Taguchi L9 Array increases the ability to cut through harder materials such as steel and titanium. Water jet Machining is a 1. INTRODUCTION cold cutting process that involves the removal of Abrasive water jet machining is a mechanical material without heat. This revolutionary technology machining process where the material is removed by is an addition to non-traditional cutting processes like the principle of erosion. In this process, a high velocity laser and plasma, and is able to cut through virtually stream of water jet mixed with abrasive is made to any material. The water jet process is combined with impinge on the target material that is to be machined. CNC to precisely cut machine parts and etch designs. Upon the impingement of the high velocity water and Abrasive water jet uses the technology of high- abrasive jet the material from the target material is pressure water to create extremely concentrated force removed. In this process the water from the reservoir to cut stuff. A water cutter pressurizes a stream of pure is pumped to the intensifier where its pressure water flow (without abrasive) to cut materials such as increases up to 4 bars. The intensifier increases the foam, rubber, plastic, cloth, carpet and wood. Abrasive pressure of water from 4 bar to about 40000 bars and jet cutters mix abrasive garnet to a pressurized water above as per the requirement. The water from the stream to cut harder materials. Examples are stainless intensifier is sent to the accumulator where the steel, Titanium, glass, ceramic tile, marble and granite. pressure fluctuations due to high pressures are Water jet metal cutting machine yields very little heat eliminated. Then the pressurized water from the and therefore there is no Heat Affected Zone (HAZ). accumulator is sent to the mixing chamber through Water jet machining is also considered as \"cold cut\" control valves. Before entering the nozzle, the water is process and therefore is safe for cutting flammable mixed with abrasives particles in mixing chamber in a materials such as plastic and polymers. With a proportionate ratio. This high pressure of water is reasonable cutting speed setting, the edges resulting ISBN: 978-93-5620-351-8 42 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 are often satisfactory. In Abrasive Water Jet Mrs. Prachi Patel et al; [1] in this research paper author Machining, the abrasive particles are mixed with water worked out Abrasive water jet machining (AWJM) is and forced through the small nozzle at high pressure an emerging machining technology option for hard so that the abrasive slurry impinges on the work material parts that are extremely difficult-to-machine surface at high velocity. Each of the two components by conventional machining processes. Optimization of of the jet, i.e., the water and the abrasive materials the process parameters on abrasive water jet have both separate purpose and a supportive purpose. machining for Inconel 800 H materials by taking The primary purpose of the abrasive material in the jet Material removable rate (MRR) and surface roughness stream is to provide the erosive forces. The water in (SR) as responses. In this traverse speed plays an the jet acts as the coolant and carries both the abrasive important role on influence of material removable rate and eroded material to clear of the work. (MRR). Then the major contribution on MRR is abrasive Flow Rate which is about 30%. We also observed that Standoff distance is sub significant in influencing MRR. Fig no.1 Line Diagram of Abrasive Water jet [2] OPTIMIZATION OF ABRASIVE WATER Machining JET MACHINING PROCESS PARAMETERS USING RESPONSE SURFACE METHOD ON 2. LITERATURE SURVEY INCONEL – 188 Abrasive water jet machining is classified a non- Ajay D. Kumbhar et al; [10] In this research paper conventional machining procedure. Abrasive water jet author investigated that effective technology for machining uses water jet under high pressure as a tool, processing various engineering materials. This paper with added particles of abrasives. The most significant investigated the effects of process parameters on depth characteristic of the abrasive water jet cutting of cut in abrasive water jet cutting of cast iron. Four technology is cold cutting, which does not have a different process parameters were undertaken for this thermic effect on the material. The objective of the study; water pressure, nozzle traverse speed, abrasive experimental investigation is to conduct research of mass flow rate and standoff distance. Experiments the machining parameters' impact on surface were conducted in varying these parameters for cutting roughness of the machined parts, and derive cast iron using abrasive water jet cutting process. The conclusions referring to the manner in which certain influence of these process parameters on depth of cut machining parameters affect kerf width, kerf taper, has been studied based on the experimental results. In metal removal rate, and surface roughness. order to correctly select the process parameters, an Experimental investigation was conducted in the way empirical model for the prediction of depth of cut in that samples of two different materials were cut on the abrasive water jet cutting of cast iron is developed machine using different machining parameters. using regression analysis. This developed model has Measurement of different surface roughness been verified with the experimental results that reveal parameters has been conducted after the cutting. a high applicability of the model within the [1] OPTIMIZATION OF ABRASIVE WATER experimental range used. JET MACHINING PROCESS PARAMETERS USING RESPONCE SURFACE METHOD ON [3] MINIMIZATION OF KERF TAPER ANGLE INCONEL – 800 AND KERF WIDTH USING TAGUCHI’S METHOD IN ABRASIVE WATER JET MACHINING OF MARBLE Vishal Gupta et al; [6] in this paper author worked out on a marble as a work material and for top kerf width, nozzle transverse speed has emerged as most ISBN: 978-93-5620-351-8 43 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 significant parameter with a percent contribution of the most significant factors trailed by the stand-off 84.004% followed by water pressure (13.619%). It distance influencing kerf taper in machined samples. was found that abrasive flow rate failed the test of Kerf taper decreases with decrease in traverse speed significant at 95% confidence level therefore it was and stand-off distance. Also, with the rise in water pooled out. Optimal settings of process parameters for pressure, kerf taper reduces. Further, the predictive minimum top kerf width are water pressure and nozzle model for kerf taper has also been developed and transfer speed at highest levels of 340 M Pa and 100 optimization of significant factors has been performed mm/min respectively. Out of all the selected to minimize kerf taper angle. parameters only nozzle transverse speed was significantly affecting the kerf taper angle with a 3. METHODOLOGY percentage contribution of 92.505%. Water pressure Experimental Setup termed as less significant for kerf taper angle with a Aqua jet abrasive water jet machine G3020 German percent contribution of 3.584 %. Engineering was used for the experiment. the input parameters were taken into consideration with respect [4] ANALYSIS OF SURFACE ROUGHNESS IN to previous papers i.e., water jet pressure, traverse ABRASIVE WATER JET CUTTING OF CAST speed and abrasive flow rate. IRON M.C.P. Selvan et al; [4] As a result of this study, it is Fig :2. Abrasive Water jet Machining setup used for observed that these operational parameters have direct the Experiment of EN-36 effect on surface roughness. It has been found that water pressure has the most effect on the surface Table.1 Machining Range of parameters of Abrasive roughness. An increase in water pressure is associated with a decrease in surface roughness. These findings Water Jet machine indicate that the use of high-water pressure is preferred to obtain good surface finish. Surface roughness Condition Range constantly decreases as mass flow rate increases. It is recommended to use more mass flow rate to decrease Water jet pressure (bar) 4000 surface roughness. Among the process parameters considered in this study water pressure and abrasive Abrasive flow rate 700 mass flow rate have the similar effect on surface roughness. As nozzle traverse speed increase, surface (gm/min) roughness increases. This means that low traverse speed should be used to have more surface smoothness Traverse speed(mm/min) 1200 but is at the cost of sacrificing productivity. This experimental study has resulted surface smoothness Nozzle diameter(mm) 1 increase as standoff distance decreases. Therefore, to achieve an overall cutting performance, low standoff Orifice (mm) 0.35 distance should be selected Water flow rate(lit/min) 4 [5] EXPERIMENTAL INVESTIGATION OF KERF CHARACTERISTICS OF KEVLAR 49 Abrasive particles (mesh 80 EPOXY COMPOSITE MACHINED BY ABRASIVE WATER JET garnet) Puneet Kumar et al; [8] In the paper the author worked on an experimental study of kerf taper of Kevlar 49 Experimental Material epoxy composite machined by AWJM is described. It is found that traverse speed and the water pressure are EN36 (655M13) is a nickel-chromium-molybdenum based case hardening engineering steel which is specifically designed for carburizing. The addition of ISBN: 978-93-5620-351-8 44 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 nickel increases shock resistance and toughness whilst APPLICATIONS the chromium increases the material’s hardenability EN36 (655M13) is a general engineering steel which giving it a uniformed hardness. Once hardened and is ideal for producing lightly stressed parts and carburized. EN36 can achieve core strength of up to components. 1230 N/mm². EN36 (655M13) is used specifically in Application examples include: heavy duty and highly stressed applications due to its hardenability, toughness and high core strength. EN36 i. Aircraft and automotive crankshafts also offers excellent fatigue resistance. ii. Ball and roller bearings EN36 Alloy steel which is widely used in disc wheels, iii. Highly stressed gears, collets and gudgeon grooved parts, and gears, heavy duty gears for aircrafts, heavy vehicles and automobile parts. pins Chemical composition was checked. EN36 is a iv. Connecting rods with case hardened ends carburizing steel grade with very high surface strength v. Heavy duty gears, ring gears with a soft but strong core. vi. Heavy duty bushes vii. Couplings and shafts. Fig no.3 G3020 AWJM Design of Experiment Table.2 chemical composition of material Taguchi Method: Mechanical properties of EN-36 material: Modern industrial environment poses experiments of numerous kinds, some have few factors, some have Table.3 mechanical properties of material many, while there are others that demand factors to have mixed levels. A vast majority of experiments, ISBN: 978-93-5620-351-8 however, fall in the category where all factors possess same number of levels. In the conventional varying one factor at a time technique lot of experimental data can be obtained. This way of experimentation not only consumes lot of time but also possess a challenge to the investigator for deriving appropriate conclusion from the huge experimental data. Design of Experiments (DOE) is at our rescue for planning systematic experimentation and arriving at a meaningful conclusion without being inundated in huge set of experimental data. “DOE” is an experimental strategy in which, effects of multiple factors are studied simultaneously by running tests at various levels of factors. There are number of statistical techniques available for engineering and scientific studies. Taguchi prescribed a standard way to utilize DOE technique to enhance the quality of products and process. DOE using Taguchi approach is a handy statistical tool to improve consistency of performance, to build insensitivity towards uncontrollable factors in optimizing 45 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 manufacturing process design, solving manufacturing and is based as a yardstick for comparing different and production problems and in determining the best experimental settings. assembly method etc. It is possible to reduce the time required for experimental investigation and improve Orthogonal array design - Taguchi Method process quality by applying Taguchi technique [19, 14, Taguchi Method is one of the best in the design of the and 16]. Taguchi outlined three step approach for experiment. It is based on a better understanding of assigning nominal values and tolerances to product simple and complex results of different parameters and process design characteristics (i) system design affecting the process with possibly a small number of (ii) parameter design and (iii) tolerance design. System experiments. The aim of the Taguchi method is to design is the basic prototype design to achieve desired determine the optimal combination of parameters that function and parameter design is to specify levels of ensure a high-quality product based on set criteria, control factors that are relatively insensitive to noise while possibly less sensitive to noise variance factors. If parameter design fails to produce parameters. The Taguchi method is used signal-to- adequately low functional variation of product, then noise ratio η (S / N) to determine the current scatter of tolerance design is helpful. In many manufacturing values. Signal (S) is derived from factors are set or processes, one or more control parameters can be used under the control of the user, but the noise (N) to change functional characteristics mean without indicates the factors affecting the signal, but are affecting variability. Such control parameters are beyond your control. The aim of the design is the called signal factors. Signal factors are used to shift choice of experimental parameters (in this case the mean to target by adjusting level of signal factors. process) to maximize the ratio η (S / N). Depending on Parametric design aims at minimizing effect of noise needs, different indicators η (S / N) can be used. The without attempting to eliminate source of noise. most popular is the \"smaller is better\" and \"bigger is Procedure of optimizing of process parameters is better\". briefly mentioned below. Selection of control factors and their levels are made Parameter design experiments can be either physical on the basis of some literature review on the subject. experiments or computer-based simulation trails. Four control factors such as traverse speed, water Experimenter has to identify list of control parameters pressure, abrasive flow rate, stand of distance, etc., and levels of interactions array is selected based on each of the four control factors is treated at three degrees of freedom of all factors and interactions put levels. The choice of three levels has been made together. Orthogonal array was first researched by because the effect of these factors on the performance Dr.C.R. Rao of Indian Statistical Institute. Later characteristic may vary. Taguchi developed readymade orthogonal arrays and linear graphs, so that their use becomes highly Experimental Outcomes simplified. Orthogonal arrays were also known as The outcomes of the experiments are kerf width and square game. Parameters are assigned to columns of kerf taper angle of the material. Kerf width is the width selected array with entries of appropriate level values of the cut made by the abrasive water jet on the target of factors represent experimental design matrix. Each material. it is measured by the formula given below row of array represents an experimental trial combination. This array helps in arriving at number of Where, Top width is the width of the cut on the surface replications of each experimental trial combination. of the material which is facing the abrasive water jet Experimental trial combination is replicated for three Bottom width is the width of the cut at bottom surface times for each process parameter. Kerf taper angle is the angle subtended by the kerf As per experimental plan specified in experimental taper. It is the deviation of the cut from the original design matrix, experiments will be conducted for required number of replications. The observations will be used to compute a criterion called signal to noise ratio. It is the ratio of power of signal to power of noise ISBN: 978-93-5620-351-8 46 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 cut. Kerf taper angle is given by the formula as given consideration with respect to previous papers I.e., below water pressure, traverse speed, and abrasive flow rate. Where, L is the length of the cut made by the abrasive water jet Process parameters: 4. CONCLUSION Parameters Level-1 Level-2 Level-3 Quality of cutting surface in AWJM is depending on so many process parameters. Process parameter which Water 3200 3400 3600 affects less or more on quality of cutting in AWJM are hydraulic pressure, Stand-off distance, types of pressure abrasive, size of abrasives, abrasive flow rate, nozzle diameter, orifice size, and traverse speed. Quality of Abrasive flow 250 350 450 cutting surface is measured by material removal rate, surface roughness, kerf width, kerf taper ratio. From rate the literature review compare to above all mentioned parameter traverse speed is most effective parameter Traverse 154 176 220 for MRR. Abrasive flow rate is also an important parameter for increasing MRR. But beyond some limit speed with increase in abrasive flow rate and traverse speed the surface roughness decreases. Increasing traverse Table.4: the initial input parameters for AWJM of speed also increase the kerf geometry. So, it is required to find optimum condition for process parameter to EN-36 material give better quality of cutting surface. Traverse speed is directly proportional to productivity and should be 6. REFERENCES selected as high as possible without compromising kerf quality and surface roughness. [1] Mrs. Prachi Patel, Optimization of abrasive water 5. FUTURE WORK jet machining process parameters using response Till now in the project stage-1 we have decided the project and researched many literatures based on our surface method on inconel-800, vol-5 issue-6, investigation and just planned our project. now, in project stage-2 what we have planned in IJARIIE, 2019. project stage-1 will be done experimentally in project stage-2. [2] Ajay D Kumbhar, Manvendra Chatterjee, optimization of abrasive water jet machining process parameters using response surface method on Inconel – 188, vol-4 issue-9, IJTRE, may 2017. [3] Vishal Gupta, P.M. Pandey, Mohinder Pal Garg, Rajesh Khanna, N.K. Batra, Minimization of kerf taper angle and kerf width using Taguchi’s method in abrasive water jet machining of marble, ELSEVIER, 2014. [4] M.C. P Selvan, Dr.N.M. Sundara Raju, Analysis of surface roughness in abrasive water jet cutting of cast iron, Vol-1 No.3, IJSE, 2012. [5] Puneet Kumar, Sachin Salunkhe, Ravi Kant, Experimental investigation of kerf characteristics of kevlar 49 epoxy composite machined by abrasive water jet, vol-11, no. 2, IJMMT,2019. Tentative Experimental Procedure: The chemical composition and the mechanical properties of the candidate metal EN36 employed in the AWJM process is represented in Table 2 and 3 the dimensions of the candidate metal employed in this research work have the dimensions of 300x300x10 (all dimensions are in mm). the Aqua jet abrasive water jet machine G3020 germen engineering was used for the experiment. The input parameters were taken into ISBN: 978-93-5620-351-8 47 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 EXPERIMENTAL INVESTIGATION OF EN353 ALLOY STEEL USING SUSTAINABLE MACHINING PROCESS A.VENKATA VISHNU1 1Associate Professor, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India. Abstract— on requirement of parts. While considering all machine Machining operation is one of the most tools lathe or turning machine is considered as Father of all machine tools since by using lathe different essential processes of producing desired products operations can be performed. Normally the customer from raw material, where in machining a lot of heat is satisfied by the supplier through quality, cost and is generated due to the friction between work piece delivery of the part or product. Turning is the and tool. The lubricant/coolant plays an important machining operation that produces cylindrical parts. It role in reducing the friction between work piece and can be defined as machining of an external surface the tool Number of lubricants are introduced in such that, there is a relative movement between work machining out of which, vegetable oils has been a piece and single- point cutting tool. Cutting tool is viable alternative where it reduces the being fed parallel to the axis of the work piece. In the toxics/pollutants released during machining which present work a set of experiments are conducted on the leads to health issues like asthma, throat cancer, lung work piece EN353 with CVD coated carbide cutting cancer, etc., to the operator/ employee. Large tools to evaluate the effect of machining parameters numbers of operators are not familiar with the such as cutting conditions, speed, feed and depth of cut adverse impact of cutting fluids on the health. On the on cutting temperature. Taguchi approach is used to other hand, the cost of lubricant is also playing a vital obtain the optimal settings of these process parameters role which is costing around 16-20% production cost in industries, to overcome with this situation the flow 2. LITERATURE REVIEW of lubricant is to be controlled which is done through A thorough study of literature [1-4] suggests that the a sustainable manufacturing technique known as machining of EN-353 Steel Alloy is very difficult, minimum quantity lubrication. compared to other alloy materials. EN 353 steel has a In this present paper we have studied the effect of carbon content of 0.17% and probably the most usual process parameters using turning of EN 353 alloy form of steel, because of the carbon content the steel under different lubrication conditions with the material becomes tougher and harder. generally help of vegetable-based oils using Taguchi design available in the annealed condition with a maximum methodology. Different models of minimum quantity brinell hardness of 270, characterized by high core lubrication system were available in the market but strength, excellent toughness and fatigue resistance in they are costly, in this project a compact MQL setup relatively large sections with case hardness up to RC64 is been developed for machining under MQL when carburized, hardened and tempered. The [5- condition. 8,10,12] study demonstrates detailed study of the Keywords- EN 353 alloy steel, Taguchi Robust Design proposed optimization technique i.e. Taguchi Robust Methodology, minimum quantity lubrication, design methodology; Hence the literature survey Machining, vegetable based oils,etc. helped in proper selection of controlled parameters. 1. INTRODUCTION 3. EXPERIMENTATION Metal cutting is one of the oldest and continued The aim of the project is to find out the set of optimum values for the selected control factors using Taguchi’s developing processes in industries. The raw material is robust design methodology. The work material converted in to required shape by removing excess selected is E N - 3 5 3 s t e e l a l l o y . The materials through proper machine tool, technicians, dimensions of the EN-353 steel alloy, selected are of cutting and holding tools by applying proper cutting 30mm diameter X 110mm length. The data. For metal cutting different machine tools like experiments are conducted using L9 (34) drilling machines, lathes, milling machines, grinding machines are available with different capacities based ISBN: 978-93-5620-351-8 48 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 orthogonal array. The cutting tool used is gold coated cvd carbide tool with a nose radius of 0.4mm. It consists of This chapter contains the machining aspects 4 tips. It is of very high hardness and good toughness and robust design implementation procedure in and it is principally intended for machining of super Turning of EN-353 steel alloy. The turning operations alloys and steel alloys. are carried out on CNC machine. The work material selected in the present Figure No.3: CVD Coated Carbide Tool Insert work is EN-36 steel alloy. The turning operations (facing) are carried out on CNC machine. The 3.4. Tool Holder: machining tests are conducted under the different The specification of tool holder used for machining is cutting conditions, speed, feed and depth of cut using BT30-ER16, side lock adapter system shown in figure L9 (34) orthogonal array. no.4. . 3.1. Specifications of CNC Turning Machine: The experiments are conducted on CNC Lathe shown in Figure No.1. Figure No. 1: CNC Turning Machine Figure No. 4: Tool Holder 3.2. Work piece Material: EN 353 steel has a carbon content of 0.17% and 3.5. Cutting Fluid: probably the most usual form of steel, because of the The cutting fluid used in this experimentation is the carbon content the material becomes tougher and combination of vegetable oil(sunflower oil) and water harder. generally available in the annealed condition in the ratio 1:20 i.e., for example when the oil is taken with a maximum brinell hardness of 270, characterized for 1 liter then the quantity of water will be 2 liters by high core strength, excellent toughness and fatigue Sunflower oil is the non-volatile oil pressed from the resistance in relatively large sections with case seeds of sunflower. Sunflower oil is commonly used in hardness upto RC64 when carburized, hardened and food as a frying oil, and in cosmetic formulations as an tempered emollient. Sunflower oil is primarily composed of linoleic acid, a polyunsaturated fat, and oleic acid, a Figure No. 2: EN353 Steel Alloy Specimens mono unsaturated fat. Through selective breeding and manufacturing processes, oils of differing proportions of the fatty acids are produced. 3.3. Cutting Insert: 49 ISBN: 978-93-5620-351-8 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Figure No. 7: Block diagram of MQL Figure No. 5: Cutting Fluid 3.6. Cutting Temperature Tester Temperature measurement is measured using a portable IR THERMOMETER MT-4, the device ability to measure temperature from a distance. By knowing the amount of infrared energy emitted by the object and its emissivity, the object’s temperature can often be determined within a certain range of its actual temperature. The measurement results are displayed on the screen. Figure No. 6: Cutting Temperature Tester Figure No. 8: Compact MQL setup 3.7. Minimum Quantity Lubrication setup: 4. DESIGN OF EXPERIMENT: Minimum quantity lubrication eliminates large Total of four process parameters with three levels are chosen as the control factors such that the levels are number of water and oil based coolants and replaces sufficiently far apart so that they cover wide range. The process parameter and their ranges are finalized using them with a small quantity of lubricant mixed with air. literature, books and machine operator’s experience. The four control factors selected are cutting condition The air-oil stream is precisely metered and delivered (A), spindle speed (B), feed rate (C) and depth of cut(D). EN-353 STEEL alloy work pieces are used in to the cutting tool’s edge. The philosophy behind mql experimentation. The machining is performed individually. is based on simple principle-more is not always better; use only what’s needed for the application, because enough is as good as a feast. This MQL also goes with many names. It has been referred as “Minimum Quantity Lubrication”, “Near-Dry Machining” or “NDM”, “Micro-Lubrication” or “Microlubrification”, “Micro-Dosing” and sometimes as “Mist coolant”. ISBN: 978-93-5620-351-8 50 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Table No. 1: Control Factors and Levels 5. RESULTS AND DISCUSSIONS Then cutting temperature is measured precisely with the help of a portable IR THERMOMETER MT-4 and the results are tabulated in table no 3. For each experiment the corresponding S/N values are also tabulated. Optimization of cutting temperature is carried out using Taguchi method. Confirmatory test have also been conducted to validate optimal results. Table No 3: Experimental Data Related To Cutting Temperature ` EXP Cutting Temperature NO. S/N RATIO MEAN 1 38.2 -31.64 2 35.1 -30.90 Accordingly, the present study has been done through 3 43.8 -32.82 4 31.3 -29.91 the following plan of experiment. 5 35 -30.88 6 32.1 -30.13 1. Cutting steel bars by electric saw and 7 29.5 -29.39 performing initial turning operation in CNC 8 34.1 -30.65 machine to get desired dimension of the work 9 31.1 -29.85 piece. Table No 4: Summary of S/N Ratios 2. Checking and preparing the CNC machine ready for performing the machining Factor Level 1 Level 2 Level 3 operation. Cutting -31.78 -30.30 -29.96 3. A detailed study has been carried out for the condition(A) selection of the cutting parameters i.e. -30.93 Cutting conditions, speed, feed and depth of Speed(B) -30.31 -30.81 -31.03 -31.12 cut are taken according to the machine Feed(C) -30.80 -30.22 standards. Depth of Cut(D) -30.79 -30.14 4. Selection of appropriate tool depending upon the cutting parameters i.e., speed, feed, depth of cut are changed depending upon the experimental design. 5. Performing operations on specimens in various cutting environments involving various combinations of process control parameters like: cutting conditions, speed, feed and depth of cut. 6. Measuring cutting temperature of workpiece material with the help of a portable IR THERMOMETER MT-4 for temperature measurement. ISBN: 978-93-5620-351-8 51 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 5.1 Selection of Optimum Set of Conditions for Table No 6: Conformation Test Results Cutting Temperature: CT S/N Ratio The best condition for Cutting condition is level 3 31.68 23.82 (MQL), for Speed is level 1 (900rpm), for Feed Rate is level 2 (0.5mm/min), for Depth of Cut is level 2 (1.5mm). Thus, the optimum conditions chosen were: A3-B1-C2-D2. Table No 5: Optimum Set Of Control Factors Table No. 7: Comparison Of S/N Ratios Factors/ Cutting Speed(A) Feed(B)( Depth of η predicted 22.401 Levels condition (rpm) mm/min Cut(C)( ) mm) η conformation 23.82 Optimu MQL 900 0.5 1.5 m Value 5.2. Prediction of Process Average for Optimum 5.4. Effect of Cutting Parameters on Cutting Condition for Cutting Temperature: temperature: From table 5, the following calculations are done, for From Figure No 9, it is observed that the cutting all the cases the predicted value is calculated in the temperature is low at the cutting condition MQL when same procedure. A3-B1-C2-D2. compared with the other cutting conditions i.e., at the flooded and compressed air conditions. Where in this ƞpredicted= Y+ (A3-Y) + (B1-Y) + (C2-Y) + (D2-Y) graph 1=Compressed Air, 2=Flooded, 3=MQL conditions on X-axis. Figure No 10, it is observed that, = A3+B1+C2+D2-3Y the cutting temperature is low at low cutting speed and it is increasing at moderate cutting speed conditions, = [(-29.96) + (-30.31) + (-30.22) + (-30.14)] – [3X again from moderate to high cutting speeds, the (34.46)] Cutting Temperature increases. Figure No 11, it is observed that, the cutting temperature is low at low ƞpredicted= 22.401 feed rate and certainly increasing from low feed rate to moderate feed conditions, but again from moderate to Therefore, the predicted average for optimum high feed rate, the cutting temperature increases. From condition of Cutting temperatures is 22.401. the figure 12, it is observed that, the cutting temperature is low at low depth of cut and certainly 5.3. Performing Verification Test for Cutting increasing from low depth of cut to moderate depth of Temperature: cut conditions, but again from moderate to high depth of cut, the cutting temperature decreases. A confirmation test is performed with the obtained optimum cutting parameters (cutting conditions MQL, speed 900rpm, feed rate 0.5 mm/min and depth of cut 1.5mm). The cutting temperature values are taken and the S/N ratio is calculated for this condition. These values are shown in Table no 6 & 7. ISBN: 978-93-5620-351-8 52 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Figure No. 9. Tc V/S Cutting Conditions Figure No. 10. Tc V/S Cutting Speed Figure No. 11. Tc V/S Feed rate Figure No. 12. Tc V/s Depth of cut 6. CONCLUSION • The S/N ratio of predicted value and The objective of the project work is to find out the set verification test values are valid when of optimum values for the selected control factors in compared with the optimum values. It is order to reduce cutting temperature, using Taguchi’s found that S/N ratio value of verification test robust design methodology considering the control is within the limits of the predicted value and factors and steel alloy EN-353 work piece. the objective is full filled for cutting temperature. Based on the results of the present experimental investigations the following conclusions can be drawn: • Taguchi method has been successfully applied in optimizing cutting temperature for • The cutting conditions used for this Turning operation. experimentation are compressed air, flooded, MQL, in this MQL is the optimum 7. REFERENCES environment of cutting condition [1] Nirav M. Kamdar, Prof. Vipul K. Patel, “Experimental Investigation of Machining Parameters • The cutting speed used for the of EN36 Steel”, International Journal of Engineering experimentation 900rpm, 1200rpm, Research and Applications (IJERA) ISSN: 2248-9622. 1500rpm, in this 900 rpm is the optimum Vol. 2, Issue 3, May-Jun 2012, pp.1833-1838. speed for obtaining the optimum value of cutting temperature. [2] Kaushal Pratap Singh and Girish Dutt Gautam:“Selection of Optimum Machining • For obtaining the optimum value of cutting Parameters for EN36 Alloy Steel in CNC Turning temperature., the optimum feed is 0.5 Using Taguchi Method” International Journal of mm/min among used feeds 0.2 mm/min, 0.5 Scientific & Engineering Research, Volume 5, Issue 3, mm/min, 0.8 mm/min. ISSN 2229-5518 – March 2004. • Depth of cut 1.5mm is the optimum depth of cut for obtaining optimum cutting temperature in the values 0.5mm, 1.5mm, 2.5mm ISBN: 978-93-5620-351-8 53 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 [3] Manan Kulshreshtha: “Analysis of the Effect of [11]HMT \"Production Technology\", Tata McGraw Machining Parameters on Surface Roughness of EN Hill, 2004. 36 Nickel Steel”, International Journal of Advanced [12] Phillip j. Ross \"Taguchi Techniques for Quality Information Science and Technology (IJAIST) ISSN: Engineering\", Tata McGraw Hill, Second Edition, 2319:2682 Vol.16, No.16, August 2013. 2005. [4] A .Venkata Vishnu, G. Guruvaiah Naidu, K B G Tilak, J.Ramakrishna, “Application of Taguchi Method in the Optimization of Turning Parameters for Material Removal Rate of En-36 Material”, International Journal of Advance Engineering and Research Development E-ISSN (O): 2348-4470 P- ISSN (P): 2348-6406, Volume 2, Issue 8, August- 2015. [5] Ballal, Inamdar and Patil P.V. “Application Of Taguchi Method For Design Of Experiments In Turning Gray Cast Iron ” International Journal of Engineering Research and Applications (IJERA) Vol. 2, Issue 3, May-Jun 2012, pp.1391-1397. [6] G. Guruvaiah Naidu, A.Venkata Vishnu, G.Janardhana Raju “Optimization of Process Parameters for Surface Roughness in Milling of EN- 31 Steel Material Using Taguchi Robust Design Methodology”, International Journal of Mechanical And Production Engineering ISSN: 2320-2092, Vol.2 Issue 9, September-2014. [7]Mahendra Korat, Neeraj Agarwal, “Optimization of Different Machining Parameters of En24 Alloy Steel In CNC Turning by Use of Taguchi Method”, International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.160-164. [8] A.Venkata Vishnu, K B G Tilak, G. Guruvaiah Naidu, Dr.G.Janardhana Raju “Optimization of Different Process Parameters of Aluminium Alloy 6351 in CNC Milling Using Taguchi Method”, International Journal of Engineering Research and General Science, ISSN: 2091-2730,Nepal, Vol.3 Issue 2, March-April-2015. [9]M.A. Lajis and T.L. Ginta,”Hot machining of Hardened Steels with Coated Carbide Inserts,” American Journal of Engineering and Applied Sciences 2 pp. 421-427 (2009). [10] K. Adarsh Kumar, Ch.Ratnam, Bsn Murthy, B.Satish Ben, K. Raghu Ram Mohan Reddy, “Optimization Of Surface Roughness In Face Turning Operation In Machining Of En-8” [IJESAT] International Journal Of Engineering Science & Advanced Technology ISSN: 2250–3676, Jul-Aug 2012, Volume-2, Issue-4, pp.807 – 812. ISBN: 978-93-5620-351-8 54 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 SOFT TOOL DESIGN USING FUSED DEPOSITION MODELLING Mr P.Srinivas1 1Associate Professor, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India. Abstract: Hard tools are tools made of metals. This Aim of this work is to manufacture a typically means steel and nickel alloys capable component using silicon mould. The pattern of withstanding thousands of production for silicon mould is manufactured by using cycles. 3D printing technology (FDM). Silicon mould is also called as soft tool and it has FUSED DEPOSITION MODELLING many industrial and domestic applications. (FDM) FDM was introduced by Stratasys, 1. INTRODUCTION: Minnesota, USA. A filament of material is ADDITIVE MANUFACTURING: extruded out ofa fine nozzle in a semi liquid A Process of joining materials to make state and deposited onto a platform. The objects from 3D model data, usually layer nozzle moves in the XY plane so that the upon layer, as opposed to subtractive filament is laid down to form a thin cross- manufacturing methodologies. Commonly sectional slice of the part. As each layer is known as “3D printing “Manufacturing extruded, it bonds to the previous layer and components with virtually no geometric solidify. The platform is then lowered relative limitations or tools.AM uses additive process to the nozzle and the next slice of the part is Design for manufacturing to manufacturing deposited on top of the previous slice. A for design Distinguished second nozzle is used to extrude a different material in order to build-up support structures for the part where needed. Once the part is completed, the support structures are broken away from the part. from traditional subtractive machining 2. LITERATURE REVIEW: techniques.There are three types of additive The literature reveals that many of the manufacturing technology: researchers have mainly concentrated on machining parameters optimization by using Softooling: Taguchi and evolutionary heuristics for Soft tools are made of composite materials. This typically means carbon fiber or fiberglass. Because the materials are softer than metals, they are not capable of withstanding as many production cycles. Hard tooling: ISBN: 978-93-5620-351-8 55 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 minimizing the rejection rate. The detailed cavity for mould should be prepared by using literature review reveals that, the wood or aluminum sheet or galvanized iron optimization of sand-casting process has not sheet with the required dimensions. Mould been attempted by the researchers. In general, material for the mould should be selected. the die casting process, gear blank casting and Gating systemi.e., runner, sprue and gate is sand-casting mould related parameters were designed with required dimensions. optimized using robust design technique of Procedure: - Taguchi and evolutionary heuristics like GA Core is taken, and it is filled with clay up to and SA. But the sand casting processes 10mm. Check there is no leakages. Now, fit particularly green sand and CO2 casting the pattern in the clay, such that the bottom process were not at all addressed for part of the pattern should be within the clay. optimization by any researcher work as Now, arrange the gating system of the mould selection of optimal parametric combination and use non sticking spray. After arranging for minimizing the percentage rejection for the gating system, now pour the “silicon green sand casting and CO2 casting process resin” in the core. Before pouring the Si- by using Taguchi and evolutionary heuristics resin, add adhesives to the Si-resin About 6 to like GA, SA and ACO. 8 hours the resin will solidifies and mould is An online case study for investigating the prepared. The mould for another side of the parameters that are affecting the final quality pattern is prepared by following the same of the products in green sand casting and co2 procedure. After pouring the moulds the casting processes. The case study was pattern and gating systems should be conducted at one sand casting industry for the removed carefully After removal of pattern manufacture of SG iron and alloy steel the core and cavity of the moulds are arranged components using green sand casting and co2 one on other and resin material is poured for casting processes, located near Madurai in the preparation of component. After resin south part of Tamilnadu. Already the industry solidifies, the component is removed from the had their own operating standards but, they mould. still did not select the optimal process parameters. Thus, they got a little higher 4.CONCLUSION: - defect percentage than the acceptable level, In this project work a pattern for the and the profit gets reduced thereby increasing preparation of mould has been manufactured the manufacturing cost of the product. This using fused deposition modelling (FDM), research work aims to reduce the percentage which is one of the methods of 3D printing of rejection rate by selection of optimal input technology (also known as additive process parameters. A detailed study was manufacturing technology, AMT). carried out on the types of defects occurring Later mould material is decided which is in the end products and their causes. silicon and components of mould such as According to the present study, a number of runner, sprue, gate etc are designed. Finally, parameters are associated with the quality of a mould is prepared using clay, mould products. Among them, the most important material and pattern. After preparation of and controllable parameters are selected by mould we prepare the component. In future conducting brain storming sessions, we can use this mould to manufacture questionnaire technique and cause and effect different components as per the requirement analysis. with preparation of different moulds. Also, after the completion of the project we gained 3.METHODOLOGY: knowledge of 3D printing technology and Process of mould making soft tool designing. By this project we can Following steps are to be followed for conclude that small batch productions can preparing the mould. They are, Core and ISBN: 978-93-5620-351-8 56 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 done with less cost and this process takes Tooling Research, Great Missenden, place without material removal process, this England, November 6-7, 1995, pp. 237-247. require less space area(we can produce Acknowledgements component in small area also). The authors wish to thank Rod Haskell For this process no machine and no power is ofFinecast (Maidenhead) Ltd for his required except for the pattern preparation continual help and support during this project. 5.REFERENCES: - [1]Dickens, P.M.; Stangroom, R; Greul, M.; Holmer, B.; Hon, KK.B.; Hovtun, R; Neumann, R; Noeken, S.; Wimpenny, D.; 'Conversion of RP models to investment castings' Rapid Prototyping Journal, Vol 1, No.4, 1995, pp. 4-11. [2] Hague, R; Dickens, P.M. 'Stresses created in ceramic shells using QuickCast models' Proceedings of the First National Conference on Rapid Prototyping and Tooling Research, Great Missenden, England, November 6-7, 1995, pp. 89-100. [3] Jacobs,P.F. 'QuickCast™ and Rapid Tooling',Proceedings ofthe Fourth European Conference on Rapid Prototyping and Manufacturing, Belgirate, Italy, June 13-15, 1995, pp. 1-25. Klocke, F.; Celiker, T.; Song, Y.-A.. 'Rapid metal tooling' Rapid Prototyping Journal, Vol 1, No.3, 1995, pp. 32-42. [4] Luck, T.; Baumann, F.; Baraldi, U. 'Comparison of Downstream Techniques for fimctional and technical prototypes - fast tooling with RP', Proceedings of the Fourth European Conference on Rapid Prototyping and Manufacturing, Belgirate, Italy, June 13- 15, 1995, pp. 247-260. Mueller, T. 'Investment casting notes', Rapid prototyping report, Vol. 5, No 8, 1995. [5] Sachs, E.; Cima M.; Allen, S.; Wylonis, E.; Michaels, S.; Sun, E.; Tang, H.; Guo, H. 'Injection molding tooling by three- dimensional printing' Proceedings of the Fourth European Conference on Rapid Prototyping and Manufacturing, Belgirate, Italy, June 13-15, 1995, pp. 285-296. [6] Tsang, H.; Bennett, G. 'Rapid tooling - direct use of SLA moulds for investment casting', Proceedings of the First National Conference on Rapid Prototyping and ISBN: 978-93-5620-351-8 57 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 A STUDY ON FRICTIONSTIR WELDING BY USING SIMILAR ALUMINIUM ALLOY MATERIALS 6061 A. Venkata Vishnu1, B. S V S Sai Ganesh2, Mohd.Omer2, S.Lalithya2, M.Vamshi Krishna2, B.Daya Sagar2 1Assosiate Professor, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. 2 Student,Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. Abstract— The joining of similar 6061 -to- 6061 by the mechanical pressure, which is applied by the tool, much aluminum plates of 4mm thickness was carried out by like joining clay, or dough. It is primarily used on wrought or friction stir welding (FSW) technique. FSW process, a extruded aluminum and particularly for structures which need so-called welding-head pin rotating at speeds usually in very high weld strength. FSW is capable of joining aluminum excess of a few hundred rpm, travels down the length of alloys, copper alloys, titanium alloys, mild steel, stainless steel contacting metal plates, creating a highly plastically and magnesium alloys. More recently, it was successfully used deformed zone through the associated force and in welding of polymers. In addition, joining of dissimilar frictional heating. FSW of Aluminum to Aluminum has metals, such as aluminum to magnesium alloys, has been captured important attention from manufacturing recently achieved by FSW. The systematic development of industries, such as Shipbuilding, Automotive, Railway Friction stir welding (FSW) has led to a number of variants of and Aircraft production. Variable Process Parameters the technology. The following describes preliminary studies have been employed to analyze the influence of being carried out on Twin-stir, bobbin stir welding, friction stir Microstructural and Tensile Properties. Effect of welding of steel and friction stir welding of titanium. Currently welding speed on microstructures, hardness distribution FSW is used particularly for joining aluminum alloys in and tensile properties of the welded joints were shipbuilding and marine industries, aerospace, automotive and investigated. By varying the process parameters, defect the rail industry. free and high efficiency welded joints were produced. Automotive suppliers are already using the technique for wheel rims and suspension arms. Fuel tanks joined by FSW have been 1. INTRODUCTION: launched in spacecraft, and many other space advances are 1.1. INTRODUCTION OF FRICTION WELDING: under development; commercial jets welded by FSW have Friction welding (FRW) is a solid- state welding process that successfully completed flying trials, with high volume generates heat through mechanical friction between work pieces commercial production forthcoming. Aluminum panels for in relative motion to one another, with the addition of a lateral high-speed ferries and panels for rail vehicles are also produced. force called \"upset\" to plastically displace and fuse the Moreover, the friction stir welding of 50mm thick copper materials. Because no melting occurs, friction welding is not a material has provided a potential solution for nuclear fusion welding process, but a solid-state welding technique encapsulation of radioactive waste. more like forge welding. Friction welding is used with metals and thermoplastics in a wide variety of aviation and automotive applications. 1.2. FRICTION STIR WELDING: Fig 1.1- Friction stir welding process Friction stir welding (FSW) is a solid-state joining process that 2. Literature survey: uses a non-consumable tool to join two facing work pieces without melting the work piece material. Heat is generated by friction between the rotating tool and the work piece material, which leads to a softened region near the FSW tool. While the tool is traversed along the joint line, it mechanically intermixes the two pieces of metal, and forges the hot and softened metal ISBN: 978-93-5620-351-8 58 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 In the literature survey we have observed that researchers From the two cases it has been observed that the maximum have made extensive study in evaluating the effect of process tensile strength obtained is 182 Mpa from case II. control parameters on features of bead geometry, which We know that tensile strength of base material is 320Mpa; it indirectly influence the mechanical strength of the weldment. means the joint efficiency is 60%. Usually, desired welding parameterd based on experience or handbook. [3]friction stir weld and tensile properties in AA5083 and [1]In this study, a combination of Taguchi based Grey AA6061 aluminium alloy. From this investigation, the relational analysis method was implemented to come up following: with the optimal process parameters for FSW. 1.Friction stir welding is performed to join 5mm thick plates of Aluminium alloys with varied parameters like tool rotation Analysing the effect of combined factors on the mechanical speed (rpm), welding speed (mm/min) and downward strengths, the following conclusions are drawn. pressure (MPa). i. From the experimental outcome and analyses of variance, 2.Quality welds are produced with the tool rotation speed of one can conclude that the rotational 500-1000 RPM at weld speed 25mm/min and down- load speed and traverse speeds are significant parameters: pressure 5MPa. a. Significance shows a small change caused by the 3.Joints fabricated at rotational speed of 500 rpm and weld amount of this parameter will result in a diminished speed of 25 mm/min at Square tool profile exhibited superior mechanical property of targeted quality criteria. tensile strength properties. b. Altering the value of significant controllable factors will 4.At high rotational speed cracks were observed by visual influence the formation of defects. inspection. ii. The highest hardness of 71.6 HR and tensile strength of 5.In FSW it is understood that increasing the welding speeds, 283 MPa was achieved at a parameter setting of the rotational decreasing the tool rotation speed and reduction in thickness speed of 1400 rpm, traverse speed of 37.5 mm/min, and tool which in turn increases the tensile properties. shape of taper threaded pin. Similarly, the lowest hardness From the results, the square tool is better than cylindrical tool and tensile strength of 54.23 HR and 217 MPa respectively, for aluminium alloy were observed at a rotational speed of 900 rpm, traverse speed of 47.5 mm/min, and tri-flute threaded tools and, flash defect 3. Methodology is found at the stir zone. Taguchi Method: The rotational speed and traverse speed are sources of welding Modern industrial environment poses experiments of temperature. If the rotational speed increased, the welding numerous kinds, some have few factors, some have many, temperature also increased and gets a maximum hardness and while there are others that demand factors to have mixed tensile strength. Traverse speed is indirectly proportional to levels. A vast majority of experiments, however, fall in the the rotational speed, and welding temperature. In addition, the category where all factors possess same number of levels. In maximum temperature was obtained at a tapered tool pin the conventional varying one factor at a time technique lot profile of 416 ◦C, which is (36.19%) less than the temperature of experimental data can be obtained. This way of of (652 ◦C) of the liquid of the base material. The advancing experimentation not only consumes lot of time but also side gave higher temperatures than the retreating side, with the possess a challenge to the investigator for deriving increment of rotational speed, and the temperature difference appropriate conclusion from the huge experimental data. between the advancing and retreating side at the weld centre Design of Experiments (DOE) is at our rescue for planning varied from 11 ◦C to 23 ◦C. Based on the analysis of variance systematic experimentation and arriving at a meaningful results, rpm has a greater effect, with an 80.33% contribution conclusion without being inundated in huge set of and the traverse speed effect has an 18.042% contribution. experimental data. \"DOE\" is an experimental strategy in iii. For this material, a combination parameter of the tapered which, effects of multiple factors are studied simultaneously threaded tool with a rotation speed by running tests at various levels of factors. There are of 1400 rpm and a traverse speed of 37.5 mm/min imparts a sound weld. number of statistical techniques available for engineering [2]Case I: Tool rotation speed 1120 rpm, Welding speed 20 and scientific studies. Taguchi prescribed a standard way to mm/min and Pin length of the tool 5.2mm.Tensile strength utilize DOE technique to enhance the quality of products obtained is 142Mpa. and process. DOE using Taguchi approach is a handy Case II: Tool rotation speed 1400 rpm, Welding speed 25 statistical tool to improve consistency of performance, to mm/min and Pin length of the tool 5.7mm. Tensile strength build insensitivity towards uncontrollable factors in obtained is 182Mpa. optimizing manufacturing process design, solving ISBN: 978-93-5620-351-8 59 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 manufacturing and production problems and in determining engineering and materials science test whereby controlled the best assembly method etc. It is possible to reduce the tension is applied to a sample until it fully fails. This is one of time required for experimental investigation and improve the most common mechanical testing techniques. It is used to process quality by applying Taguchi technique [19, 14, and find out how strong a material is and also how much it can be 16]. Taguchi outlined three step approach for assigning stretched before it breaks. This test method is used to determine nominal values and tolerances to product and process design yield strength, ultimate tensile strength, and ductility, strain characteristics. hardening characteristics, Young's modulus and Poisson's ratio. (i) SystemDesign Test Properties (ii)Parameter Design (iii)ToleranceDesign. • Yield strength • Ultimate Tensile Strength (UTS) Ductility System design is the basic prototype design to achieve • Strain Hardening Strain Hardening desired function and parameter design is to specify levels of control factors that are relatively insensitive to noise factors. Hardness Test If parameter design fails to produce adequately low A hardness test is a method employed to measure the hardness functional variation of product, then tolerance design is of a material. Hardness refers to a material’s resistance to helpful. permanent indentation. There are numerous techniques to In many manufacturing processes, one or more control measure hardness and each of these tests can identify varying parameters can be used to change functional characteristics hardness values for a single material under testing. Hence, mean without affecting variability. Such control parameters hardness test as a method can be dependent and each test's are called signal factors. outcome needs to be labeled to determine the kind of hardness Signal factors are used to shift mean to target by adjusting test used. level of signal factor. Parametric design aims at minimizing Hardness tests are beneficial because: effect of noise without attempting to eliminate source of noise. Procedure of optimizing of process parameters is • The hardness test is easy to conduct. Results can be briefly mentioned below. obtained within 30 seconds. Tests are relatively cost Parameter design experiments can be either physical effective. experiments or computer-based simulation trails. Experimenter has to identify list of control parameters and • Finished components can be subjected to testing levels of interactions array is selected based on degrees of without being damaged. freedom of all factors and interactions put together Orthogonal array was first researched by Dr.C.R. Rao of Any shape and surface size can be subjected to testing. The five Indian Statistical Institute. Later Taguchi developed most common hardness scales are: readymade orthogonal arrays and linear graphs, so that their use becomes highly simplified. Orthogonal arrays were also • Knoop known as square game. Parameters are assigned to columns • Vickers of selected array with entries of appropriate level values of • Rockwell factors represent experimental design matrix. As per • Brinell experimental plan specified in experimental design matrix, • Shore experiments will be conducted for required number of replications. The observations will be used to compute a 5. Future Scope of Work criterion called signal to noise ratio. It is the ratio of power of Bringing FSW to the Production Floor signal to power of noise and is based as a yardstick for FSW equipment comes in varying configurations, from simple comparing different experimental settings. CNC production machines the size of a dining room table to the largest spacecraft welding tool built, which stands 170 feet tall, 4. Experimentation is 78 ft. in diameter, and weighs more than 3 million pounds. The 9- different specimens can be tested mechanically. It For general production of simple butt/lap joint welds, a modular includes: system offers flexibility and economy and brings the technology Tensile test Hardness test to a broader base of users. These systems are designed for Tensile Test welding depths from 0.02 to 2.56 in. (0.5 to 65 mm) and for Tensile Testing is a form of tension testing and is a destructive production of small to medium-sized components and small batches in varied sizes, such as electronic enclosures, flat panels, and heat exchangers. The welding head travels on heavy-duty linear bearings and is driven by a rack-and-pinion drive system. Modular systems are built for easy integration with larger fixtures, rotary units, and exchangeable clamping ISBN: 978-93-5620-351-8 60 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 systems. Welding', International Patent Application WO 95\\26254, 28th Welding Speed The welding speed of the system depends on the welding tool, March 1994. (Assigned to TWI). joint type, alloy, material thickness, and stability of the welding machine and fixture station. 5. Thomas W M et al : 'Friction stir welding', Metalworking Welding Force FSW equipment must be designed for high welding forces. In Technology Europe, 1994, Sterline Publications, pp 143-145. FSW, a cylindrical shouldered tool with a profiled pin is rotated and plunged into the joining area between two pieces of sheet 6. Midling O T. : 'Material flow behaviour and microstructural or plate material. Parts must be securely clamped in a way that prevents the joint faces from being forced apart. A 0.20-in .- (5- integrity of friction stir butt weldments', Proc. of the 4th mm-) thick 6082 T6 butt joint can be welded at low speed with a specific downforce, but the same welding at 20 FPM (6 International Conference on Aluminium Alloys, Atlanta, GA, m/min.) requires a downforce that is eight to 10 times higher. Surface Contact USA, 11-16 September 1994 Good surface contact with the workpiece must be maintained constantly. Otherwise, friction will decrease, and the quality of 7. Dawes C J : 'An introduction to friction stir welding and its the weld will suffer. The best welding result comes from equipment having force control. With force control, the system development', Welding and Metal fabrication, January 1995. monitors downforce to maintain force accuracy throughout the welding process. This ensures full contact with the material at 8. 'Seam Welding Aluminium Sheet and Plate, using the all times. Tool Design Friction Stir Welding Process', Proc. of the 6th Int. Symp. JWS Welding tool design is critical in FSW. Optimizing tool geometry to produce more heat or achieve more efficient (1996), Nagoya.Innovative tool improves friction stir welds', “stirring” offers two main benefits: improved breaking and mixing of the oxide layer and more efficient heat generation, Welding & Metal Fabrication Journal, June 1995, pp. 214 yielding higher welding speeds and better quality. Tool materials should have relatively high hardness at elevated 9. haagensen P J, Midling O T and Ranes M : 'Fatigue temperatures and retain this hardness for an extended period. The combination of tool material and base material is critical to performance of friction stir butt welds in 6000 series aluminium the tool’s operational lifetime. alloy', Proc. Conf. Computer Methods & Experimental Measurements for Surface Treatment Effects, pp. 225-237, 11 Milan 7-9 June 1995. 6. Conclusion Friction Stir Welding provides a novel, relatively hazard free, solid phase joining process, which produces sound longitudinal joints, especially butt, in a range of materials and thicknesses. The FSW process is already in commercial use and has been found to be a robust, parameter tolerant, technique that has much to offer in the welding aluminum alloys. 7. References 1. Thomas W M et al.: 'Friction stir butt welding', International Patent Application No PCT/GB92 Patent Application No.9125978.8, 6th December 1991. 2. North T H. : 'Friction Joining of Particles - Reinforced Composites', Proc of the 6th International Symposium, JWS (1996), Nagoya. 3. Thomas W M, Nicholas E D and Murch M G.: Friction stir welding?' TWI, Connect, March 1993. 4. Midling D T, Morley G J, and Sandvick A. : 'Friction Stir ISBN: 978-93-5620-351-8 61 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 MECHANICAL CHARACTERIZATION OF BANANA AND COCONUT FIBRE RCC MATERIAL Mr. G.GOPI1 , S. SHIVA KUMAR2, P. PRUTHVI REDDY2 , A. RAJAVARDHAN2, K. LIKITH2, P. VIKRAM2 1Assistant Professor, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. 2 Student,Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. Abstract— This paper describes experimental and hemp. It has been found that the nature composite studies on the use of coconut fibre and banana fibre of these fibers has good electrical resistance, good to enhance the strength and applications of concrete. thermal and acoustic insulating properties and higher These natural fibres have excellent physical and resistance to fracture. The main idea of composites mechanical properties and can be utilized more reinforced with natural fibers. Is to increase the effectively. They are economical (zero cost), with no mechanical properties of the polymer, such as the chemicals. The addition of coconut-fibres and tensile strength, impact strength and bending strength. banana fibres significantly improved many of the From the research of many researchers found that the engineering properties of the concrete notably mechanical properties of composites reinforced with compressive strength, tensile strength and flexural natural fibers have high value depend on the adhesion strength. The ability to resist cracking and spalling between fibers and the polymer matrix. Natural fiber were also enhanced. we are comparatively studied on is composed of cellulose, hemicellulose and lignin and banana, coconut fibers with different orientations. rich in pectin. This resulted in the important problem we have undergone mechanical test on 6- specimens. of compatibility between fiber and matrix due to weakness in the adhesion between the surface fibers Keywords—Fibre Reinforced Concrete, Coconut and the polymer matrix, so changing the fiber surface Fibre, Banana Fibre, Material Properties, Hardened by treatment. It is the best method that researchers use Properties, multi-orientation in direction. to improve the strength and the compatibility between the interfacial bond strength. The surface treated bio 1.INTRODUCTION: fibers showed better efficiency than the untreated. This In recent years, the using a biodegradable material alkaline treatment removes wax, hemicellulose and based on natural resources of from natural fibers which lignin hiding the surface of the fiber. It is accepted that containing cellulose and starch, called \"green the alkaline treatment result from increases surface composite\" and developed the high strength, stiffness, roughness which create better mechanical interlocking low weight and low density, high specific strength, less between hydrophilic fibers and hydrophobic matrices. damage during production, improved the surface Banana fiber is a best of natural fiber which can molded, good mechanical properties and develop the interesting products from the waste environmental friendliness. However, there are some products from the farming bananas. It is a disadvantages such as the surface is poor, more absorb lingocellulosic fiber which can be extracted from the the moisture, poor quality of the adhesion between stem of the banana plant and the good mechanical fibers and the matrix, which require the use of physical properties. Short banana fiber content has a greatly and chemical treatment appropriate. The composite effect on mechanical properties of the fiber reinforced fiber reinforced nature of these is often used with the polyester composites. It is found that the mechanical automobile industry, packaging industry for the properties such as flexural strength, impact strength of furniture, aviation construction and so on. The natural the composites which provides superior hybrid fiber that has received attention from scientists and composites. Cost effective and environmentally technologists apply to consumer goods, housing prices friendly composite material with sufficient stiffness low and other structure parts. For the example of and damping behavior can be prepared by means of natural fiber like banana, coconut, cotton, sisal, jute hybrid of banana fiber and coconut fiber. Coconut ISBN: 978-93-5620-351-8 62 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 fiber is nowadays widely used in many industrial temperature. The composites were prepared with applications. Coconut fiber possesses elongation at various fiber content (3, 5, 10, 15, 20 and 30% by break highest among typical bio fibers. Besides, it is weight) of banana and coconut fibers in epoxy high failure strain, which provides a better contact polymer matrix. The mechanical properties between the fiber and matrix in reinforced composites. (tensile and impact strength) tests were carried The high lignin content in coconut fiber is responsible out using composites specimen. And examine the for other beneficial properties such as weather microstructure of the composites by scanning resistance. The lignin content in coconut fiber is quite electron microscope (SEM). The results from the high, so the fiber becomes stiffer and tougher. In this tensile tests of banana and coconut fiber study, to evaluate the mechanical properties of banana- reinforced epoxy composites are that the 15 wt.% coconut fiber reinforced composite materials. banana fiber showed the highest value is 73.23 Preparation of by lay-up process that is used in the MPa for maximum tensile strength. The impact invention of banana and coconut fiber reinforced strength highest values for 10 wt.% of coconut composite materials. Mechanical properties study and fiber reinforced epoxy composites are 363.66 explain in detail such as tensile and impact strength. kJ/m2 which more than banana fiber reinforced The results showed that adding fiber banana and epoxy composites. This is consistent with the coconut fiber in the composite material can improve results for determining the microstructure of the mechanical properties. composite materials with the higher fiber content tended to have void inside. 2. LITERATURE SURVEY: [3] properties and behavior of banana fiber and [1] Experimental Studies on Coconut Fibre and coconut coir (baconet) geotextile Banana Fibre Reinforced Concrete. This paper presents the properties and field The addition of coconut-fibres and banana fibres performance of the developed geotextile from significantly improved many of the engineering banana fiber and coconut coir named \"Baconet\". properties of the concrete notably compressive A ratio of 50:50 by weight of banana fiber and strength, tensile strength and flexural strength. coconut coir was adopted for the geotextile. The ability to resist cracking and spalling were Laboratory tests were conducted to determine the also enhanced. Thus, it acts as a natural admixture suitability of the fibers as raw materials for giving additional properties to the ordinary erosion control blanket. Field tests were likewise cement concrete. In this context six different carried out to evaluate the performance of percentages of coconut fibres and banana fibres Baconet after weather exposure in terms of runoff (5%, 10%, 15%, 20%, 25% and 30%) having and soil loss, degradation through tensile 40mm length were used. M20 concrete and strength, and growth of vegetation. Baconet was Ordinary Portland cement of grade 43 was used. laid out on a 45° slope and in 4 meters x 5 meters The coconut fibre and banana fibre reinforced plot in Mogpog, Marinduque. Results were concrete are tested for compressive strength, compared with a control plot. Laboratory test splitting tensile strength, flexural strength at results showed an average tensile strength of different ages. virgin Baconet of 7.9 and 6.2 KN/m in the machine direction and cross machine direction, [2] Mechanical Properties of Banana and Coconut respectively. Field test results showed that Fibers Reinforced Epoxy Polymer Matrix Baconet is likewise effective in increasing the Composites. amount of runoff and in reducing soil loss. This researches the mechanical properties. Of Moreover, the growth of vegetation is denser in epoxy resin by using random orientation Baconet covered slope compared to the control discontinuous banana fiber and coconut fiber as plot. reinforcement were studied. The both fibers are successively treated by alkaline treatment in sodium hydroxide solution (NaOH) at room ISBN: 978-93-5620-351-8 63 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 [4] Experimental Investigation on Banana Fibre biodegradable fiber with relatively good mechanical Reinforced Concrete with Conventional properties. Concrete. The fiber is extracted from banana in many ways like In this paper, examines the strength behaviour of in mechanical and chemical process. concrete reinforced with banana fibres. Banana plant (Scientific name: Musa acuminate) not only Fig 3.1.1 banana fiber produces the delicious fruit but it also provides Coconut fiber: the textile fibre. This paper mainly focuses the coconut fibre is a natural fibre extracted from the banana fibre-based composites which have wide outer husk of coconut and used in products such as applications in construction. These banana fibres floor mats, doormats, brushes and mattresses. Coir is have good physical and mechanical properties the fibrous material found between the hard, internal and can be employed more productively. shell and the outer coat of a coconut. Other uses Banana fibres are economical, ecological and of brown coir (made from ripe coconut) are in perishable. upholstery padding, sacking and horticulture. White Emphasis is placed on the influence of fibre coir, harvested from unripe coconuts, is used for content on the key micromechanics properties making finer brushes, string, rope and fishing nets. It relevant to composite ductility. In this has the advantage of not sinking, so can be used in long investigation, six different percentages of banana lengths in deep water without the added weight fibres 1%, 2%, 3%, 4%, 5% and 6%) having dragging down boats and buoys. 40mm length was used. Ordinary Portland cement of grade 53 and M30 grade concrete were used. At various periodical ages, the banana fibre reinforced concrete is tested for compressive strength and split tensile strength. [5] Experimental Study on Coir Fibre Mixed Concrete This paper presents the versatility of coconut fibre is one of the natural fibers abundantly available in tropical regions, and is extracted from the husk of coconut fruit the properties of composites of concrete in which coconut fibers are used as reinforcement, are discussed. The research carried out and the conclusions drawn by different researchers in last few decades are also briefly presented. Coconut fibers reinforced composites have been used as cheap and durable non-structural elements. 3.Methodology Fig 3.1.2 coconut fiber 3.1 specimen preparation Epoxy resins: The material used for the preparation are Epoxy resins are reactive intermediates that, before they can be useful products, must be “cured” or cross- • Banana fiber linked by polymerization into a three-dimensional • Coconut fiber infusible network with co-reactants (curing agents). • Epoxy resin Cross-linking of the resin can occur through the • Hardener epoxide or hydroxyl groups and proceeds basically by • Wax only two types of curing mechanisms: direct coupling Banana fibre of the resin molecules by a catalytic Banana fiber, known as Musa fiber, is one of the photopolymerization, or coupling through a reactive world's strongest natural fibers. It is also a bast ISBN: 978-93-5620-351-8 64 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 intermediate. Reactions used to cure low molecular by plants and animals and occur in petroleum. weight epoxy resins occur with the epoxide ring Fig 3.1.3 epoxy resin Fig 3.1.5 wax Hardener: In the preparation we Maintain constant volumetric A hardener is a component of certain types of fraction of fiber and epoxy resin and changing the mixtures. In some mixtures a hardener is used simply orientation of fiber. to increase the resilience of the mixture once it sets. In other mixtures a hardener is used as a curing In the specimen preparation the wax is applied at first component. A hardener can be either a reactant or a on the board then the fiber is placed on the wax. The catalyst in the chemical reaction that occurs during the resin applied on the fiber then again, the fiber places mixing process. on the resin up to 3 layers. BANANA FIBER 60% of banana fiber and 40% of resin in uni- directional. 60% of banana fiber and 40% of resin in bi-axial direction. 60% of banana fiber and 40% of resin in zig- zag(random). Fig 3.1.4 Hardener Fig 3.1.6 banana fiber in uni-directional Wax: Waxes are a diverse class of organic compounds that are lipophilic, malleable solids near ambient temperatures. They include higher alkanes and lipids, typically with melting points above about 40 °C (104 °F), melting to give low viscosity liquids. Waxes are insoluble in water but soluble in organic, nonpolar solvents. Natural waxes of different types are produced ISBN: 978-93-5620-351-8 Fig 3.1.7 banana fiber in bi-directional 65 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 • Microscopic test Fig 3.1.8 banana fiber in random(zig-zag) Tensile Test Tensile Testing is a form of tension testing and is a COCONUT FIBER destructive engineering and materials science test 60% of coconut fiber and 40% of resin in uni- whereby controlled tension is applied to a sample until directional. it fully fails. This is one of the most common 60% of coconut fiber and 40% of resin in bi-axial mechanical testing techniques. It is used to find out direction. how strong a material is and also how much it can be 60% of coconut fiber and 40% of resin in zig-zag. stretched before it breaks. This test method is used to (random) determine yield strength, ultimate tensile strength, ductility, strain hardening characteristics, Young's modulus and Poisson's ratio. Test Properties • Yield strength • Ultimate Tensile Strength (UTS) • Ductility • Strain Hardening • Strain Hardening Fig 3.1.9 coconut fiber in uni-directional Hardness Test A hardness test is a method employed to measure the Fig 3.2.0 coconut fiber in bi-directional hardness of a material. Hardness refers to a material’s resistance to permanent indentation. Fig 3.2.1 coconut fiber in random(zig-zag) There are numerous techniques to measure hardness 4.Experimentation and each of these tests can identify varying hardness The 9- different specimens can be tested values for a single material under testing. Hence, mechanically. hardness test as a method can be dependent and each It includes: test's outcome needs to be labeled to determine the kind of hardness test used. • Tensile test Hardness tests are beneficial because: • Hardness test • Impact load test • The hardness test is easy to conduct. • Results can be obtained within 30 seconds. • Tests are relatively cost effective. • Finished components can be subjected to testing without being damaged. • Any shape and surface size can be subjected to testing. The five most common hardness scales are: • Knoop • Vickers • Rockwell • Brinell • Shore Impact Load Test Impact tests are used in studying the toughness of material. A material's toughness is a factor of its ability to absorb energy during plastic deformation. Brittle materials have low toughness as a result of the small ISBN: 978-93-5620-351-8 66 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 amount of plastic deformation that they can endure. The impact value of a material can also changes with temperature. Impact testing most commonly consists of Charpy and IZOD Specimen configurations. Microscopic Test It is an examination of microstructure of the specimen done by microscope. 5.Future Scope of Work We have spent a lot of time to get full clarity on our project by referring journal papers. The specimens have been prepared by ourself with the all the equipment in required orientation and one step delay to test and get the results. 6. Conclusion The findings of experimental investigations on the strength characteristics of coconut fibres and banana from the literature are derived. These natural fibres have excellent physical and mechanical properties and can be utilized more effectively. 7. References [1] Ramakrishna, G., and Sundara, T., (2005). Study into the durability of natural Cement and concrete composite fibres and the effect of corroded fibres on the strength of mortar, 27, (5), 2005, pp. 575-582. [2] Wambua P, Ivens J, Verpoest I, Natural fibres: can they replace glass in fibre reinforced plastics? Compos Sci Technol 2003;63(9):1259-64. [3]. Shinji O. Mechanical properties of kenaf fibers and kenaf/PLA composites. Mech Mater 2008;40(4- 5):446-25. [4]. Alawar A, Hamed AM, Al-Kaabi K. Characterization of treated date palm tree fiber as composite reinforcement. Compos B Eng 2009;40(7):601-6. [5] Prasannan. D, Nivin. S, Raj Kumar. R, Giridharan.S, Elavivekan. M, “Comparative Study of Banana and Sisal Fibre Reinforced Concrete with Conventional Concrete” in International Journal of Pure and Applied Mathematics, Volume 118 No. 20, 2018, 1757-1765, ISSN: 1311-8080. ISBN: 978-93-5620-351-8 67 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 OPTIMIZATION OF INPUT PARAMETERS IN TURNING OF EN-353 A.VENKATA VISHNU1 B.NAVEEN2 1Associate Professor, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Instititions, Hyderabad, Telangana State, India. 2Assistant Professor, Department of Mechanical Engineering Vijaya Engineering College, Khammam, Telangana, India. Abstract— cutting speed, feed rate, depth of cut and type of tool There is a development of new materials every day at three different levels. and for each new material, we need economical and efficient machining. Taguchi is one of the good 2. LITERATURE REVIEW method for optimization of various machining Thorough literature survey has been carried out, the parameters that reduces number of experiments. The literature survey helped in proper selection of input objective of this paper is to develop the Taguchi parameters, issues related to Taguchi method and optimization method using Lubricant for high Selection of Lubricant for machining. material removal rate in terms of process parameters, in turning of EN-353 steel, considering 3. EXPERIMENTATION DETAILS the process parameters as cutting speed, feed rate, The turning operations (facing) are carried out on CNC depth of cut, type of tool. A series of turning Lathe machine shown in fig no.1. The machining tests experiments were performed to measure material are conducted under the different conditions of Cutting removal rate. Taguchi orthogonal arrays, signal-to- speed, Feed rate, Depth of cut and different types of noise(S/N) ratio are used to find the optimal levels tool using L9 (34) orthogonal array. . and the effect of the process parameters on material removal rate. Keywords- S/N Ratio, Taguchi Method, EN-353 alloy Steel, Lubricant, Orthogonal Array etc., 1. INTRODUCTION Figure No. 1: CNC Turning Machine Lubrication is the process or technique employed to Table No. 1: Composition of EN-353 Steel Alloy reduce friction between, and wear of one or both, surfaces in proximity and moving relative to each other, by interposing a substance called a lubricant in between them. A proper combination of Lubricant is extremely important because this determines surface quality of manufactured parts. The cutting fluids/ Lubricants serve many useful functions including, cooling of the cutting tool at higher speeds, lubricating at low speeds and high loads, increasing tool life, improving the surface finish, reducing the distortion due to temperature rise in the work piece, facilitating chip handling and disposal, providing a protective layer on the machined surface from oxidation and protecting the machine tool components from rust. But the application of conventional cutting fluids creates some environmental problems like environmental pollution, water pollution, and biological problems to operators [1]. The objective of the present work is to find out the set of optimum condition for the selected process parameters in order to improve material removal rate using Lubricant. Taguchi method is used to determine the optimum process parameters viz. ISBN: 978-93-5620-351-8 68 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 The work material selected in the present work is main engineering material in various industries such as EN-353 steel alloy. EN 353 is nickel- chromium high Rollers, Supporting shafts, and Structural column etc. hardenability, case hardening (carburizing) steel. The These materials are considered as easy to machining composition of EN 353 Alloy is tabulated in the Table and possess superior mach inability. Taguchi’s no 1 and the corresponding alloy round bars of 30mm orthogonal arrays are highly fractional designs, used to diameter and 150mm length shown in figure no.2. estimate main effects using only few experimental runs. These designs are not only applicable to two level Figure No. 2: EN353 Steel Alloy factorial experiments, but also can investigate main The cutting tool inserts used are CNMG carbide effects when factors have more than two levels. The tools of KORLEY Company, which are experiments designed using Taguchi Robust Design • UNCOATED (shown in Fig. 3 ) Methodology with four control factors i.e. cutting • PVD coated (shown in Fig. 4) speed (A), feed rate (B), depth of cut(C) and types of • CVD coated (shown in Fig. 5) tool (D) selected with three levels and the corresponding orthogonal array are chosen with respect to its degrees of freedom [2,5]. Lubrication is the process, or technique employed to reduce wear of one or both surfaces in close proximity, and moving relative to each other, by interposing a substance called lubricant. Here the lubricant used is mixture of SAE 40+ water(H2O), at a ratio of 1:20. Figure No.3: Uncoated Carbide Tool Insert Figure No. 6: Lubrication SAE 40 . Figure No.4: PVD Coated Carbide Tool Insert 4. DESIGN OF EXPERIMENTS: Steel bars of 30mm diaX150mm length are prepared for conducting the experiment. Using different levels of the process parameters the specimens have been machined in CNC Lathe Machine accordingly, as per the experimental design shown in table no.3. Then the MRR is calculated [6], the results of the experiments have been shown in table no 4. Table No. 2: Control Factors and Levels Figure No.5: CVD Coated Carbide Tool Insert The Investigation presents the use of Taguchi method for optimizing the material removal rate in turning medium EN353 which is extensively used as a ISBN: 978-93-5620-351-8 69 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Table No. 3: Experimental Design Table No 5: Summary of S/N Ratios 5.1 Selection of Optimum Set of Conditions for Material removal rate: The best condition for Spindle Speed factor is level 3 (1910rpm), for Feed Rate is level 3 (0.2mm/rev), for Depth of Cut is level 3 (0.5 mm) and Type of Tool is level 2 (CVD). Thus, the optimum conditions chosen were: A3-B3-C3-D2. Table No 6: Optimum Set Of Control Factors Figure No. 7: Machining of Work Piece EN 353 5.2. Prediction of Process Average for Optimum Alloy Condition for material removal rate: From table no. 6 the following calculations are done, RESULTS AND DISCUSSIONS for all the cases the predicted value is calculated in the The MRR is measured precisely and the results are same procedure. tabulated in table no 4. For each experiment the ηpredicted=[ A2+B3+C2+D2]-3Y corresponding S/N values are also tabulated. = [70.896+66.495+67.559+65.836] – [3X (63.480)] Optimization of MRR is carried out using Taguchi ηpredicted= 80.346 method. Confirmatory test have also been Therefore, the predicted average for optimum conducted to validate optimal results. condition of material removal rate is 80.346. Table No 4: Experimental Data for Material 5.3. Performing Verification Test for MRR: Removal Rate A confirmation test is performed with the obtained optimum cutting parameters. The material removal rate values are taken and the S/N ratio is calculated for this condition. The conformation test and the predicted values are tabulated in the table no 7 & 8. ISBN: 978-93-5620-351-8 70 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 5.4. Effect of Cutting Parameters on material removal rate: From Figure No 8, it is observed that, the material removal rate is low at low cutting speed conditions and increasing from low cutting speed to moderate speed conditions, and from moderate to high cutting speeds, the material removal rate is increasing. From Figure No 9, it is observed that, the material removal rate is high at low Feed Rate conditions and certainly decreasing from low feed rate to moderate and from moderate to high feed rate, the material removal rate increases. From Figure No 11, it is observed that, the material removal rate is low at small depth of cut and certainly increasing from small depth of cut to moderate depth of cut conditions, and from moderate to high depth of cut, the material removal rate increases. From Figure No 12, it is observed that, the material removal rate is low for PVD tool and the material removal rate is slightly increasing when UNCOATED tool, compared to PVD and UNCOATED tool CVD coated tool has high material removal rate. ISBN: 978-93-5620-351-8 6. CONCLUSION The theme of the paper is to find out the set of optimum conditions in order to improve hardness, using Taguchi’s techniques with the help of SAE 40 Lubricant and considering the selected parameters for the EN 353 Steel Alloy material. Based on the results of the present experimentation the following conclusions are drawn: • In the present experimentation the optimum speed obtained using Tauguchi Robust Design Methodology is 1910rpm. Similarly the results obtained for feed and depth of cut are 0.2mm/min and 0.5mm respectively. • The corresponding Type of tool is CVD coated. 7. REFERENCES [1] Byrne, G; Scholta, E. (1993). Environmental clean machining processes a strategic approach, Annals of the CIRP, Vol.42, 471- 474 [2] A .Venkata Vishnu, K B G Tilak, Manik Reddy, “Optimization of Process Parameters for Surface Roughness in CNC Turning of EN-36 Material Using Taguchi Robust Design Methodology”, International Journal of Core Engineering & Management (IJCEM), ICCEMT-2015, ISSN: 2348-9510, Special issue, December-2015. pp: 89-104 71 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 [3]Nirav M. Kamdar, Prof. Vipul K. Patel, [12] Phillip j. Ross \"Taguchi Techniques for Quality “Experimental Investigation of Machining Parameters Engineering\", Tata McGraw Hill, Second Edition, of EN36 Steel”, International Journal of Engineering 2005. Research and Applications (IJERA) ISSN: 2248-9622. Vol. 2, Issue 3, May-Jun 2012, pp.1833-1838. [4] Kaushal Pratap Singh and Girish Dutt Gautam:“Selection of Optimum Machining Parameters for EN36 Alloy Steel in CNC Turning Using Taguchi Method” International Journal of Scientific & Engineering Research, Volume 5, Issue 3, ISSN 2229-5518 – March 2004. [5] Manan Kulshreshtha: “Analysis of the Effect of Machining Parameters on Surface Roughness of EN 36 Nickel Steel”, International Journal of Advanced Information Science and Technology (IJAIST) ISSN: 2319:2682 Vol.16, No.16, August 2013. [6] A .Venkata Vishnu, G. Guruvaiah Naidu, K B G Tilak, J.Ramakrishna, “Application of Taguchi Method in the Optimization of Turning Parameters for Material Removal Rate of En-36 Material”, International Journal of Advance Engineering and Research Development E-ISSN (O): 2348-4470 P- ISSN (P): 2348-6406, Volume 2, Issue 8, August- 2015. [7] G. Guruvaiah Naidu, A.Venkata Vishnu, G.Janardhana Raju “Optimization of Process Parameters for Surface Roughness in Milling of EN- 31 Steel Material Using Taguchi Robust Design Methodology”, International Journal of Mechanical And Production Engineering ISSN: 2320-2092, Vol.2 Issue 9, September-2014. [8]Mahendra Korat, Neeraj Agarwal, “Optimization of Different Machining Parameters of En24 Alloy Steel In CNC Turning by Use of Taguchi Method”, International Journal of Engineering Research and Applications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 2, Issue 5, September- October 2012, pp.160-164. [9] A.Venkata Vishnu, K B G Tilak, G. Guruvaiah Naidu, Dr.G.Janardhana Raju “Optimization of Different Process Parameters of Aluminium Alloy 6351 in CNC Milling Using Taguchi Method”, International Journal of Engineering Research and General Science, ISSN: 2091-2730,Nepal, Vol.3 Issue 2, March-April-2015. [10]M.A. Lajis and T.L. Ginta,”Hot machining of Hardened Steels with Coated Carbide Inserts,” American Journal of Engineering and Applied Sciences 2 pp. 421-427 (2009). [11]HMT \"Production Technology\", Tata McGraw Hill, 2004. ISBN: 978-93-5620-351-8 72 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 FABRICATION OF 3D PRINTER 1Mr. Penta Srinivas , 2Ajmeera Ashok, 2Guduri Pranay Kumar, 2Gantaji Vignesh, 2Dudala Akhil Goud, 2Banda Prashanth 1Assistant Professor, Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. 2 Student,Department of Mechanical Engineering, Nalla Narasimha Reddy Education Society’s Group of Institutions, Hyderabad, Telangana India. ABSTRACT: The 3D Printer is an additive Modeling (FDM) machines can take hours, or days to manufacturing technology which is developing now- complete a large load-bearing part, just because the a-days as it has the potential to change the part requires a sizeable amount of plastic to complete manufacturing industry. It takes few hours to develop a higher percentage infill component with additional a new product with this technology which was perimeters. completed in day, months, and years with traditional Some solutions have been faster machines, that can technology. 3D printing also known as Additive extrude material quicker at the cost of print quality, manufacturing, is a method of creating a 3- multi-extruder systems that have multiple extruders Dimensional object layer-by-layer using a computer that all work on the same part in unison, or larger created design technique in which 3D objects are diameter nozzles that cause a loss of print quality and printed with the help of CAD (computer-aided dimensional accuracy due to a reduction in the number design) software. 3D printing is an additive process of layers, or perimeters used in a print. whereby layers of material are built up to create a 3D A 3d printer is an additive manufacturing technique part. Different processes are available in 3D printing where 3D objects and parts are made by the addition technology such as FDM (fused deposition method), of multiple layers of material. It can also be called as SLS (selective laser sintering) EBM (electron beam rapid prototyping. It is a mechanized method where 3D machining, LOM (laminated object manufacturing), objects are quickly made as per the required size DLP (digital light processing), etc. The process machine connected to a computer containing adopted by us is fused deposition modelling (FDM) blueprints of any object. The additive method may technology, in which Poly Lactic Acid (PLA) is used differ with the subtractive process, where the material as printing material. FDM technology works with is removed from a block by sculpting or drilling. The specialized 3D printers and product-grade main reason to use 3d printer is for 90% of material thermoplastics to build strong, durable and utilization, increase product life, lighter and stronger. dimensionally stable parts with the best accuracy and 3D printing is efficiently utilized in various fields such repeatability of any 3D printing technology. By as aerospace, automobile, medical, construction and in heating the PLA or filament material to its melting manufacturing of many household products. point and it is deposited layer by layer. Combination of many layers of such type will give us a final 3D model. KEYWORDS: Low-cost 3D printer, FDM Technique, Poly Lactic Acid (PLA) material, Types of processes. 1. INTRODUCTION: Additive Manufacturing is constantly expanding as a manufacturing technique for parts that serve a function, rather than just rapid prototyping and modeling. There are many different methods to use to additively manufacture a part. One of the holdbacks of additive manufacturing processes is that they can be time-consuming. Particularly, Fused Deposition ISBN: 978-93-5620-351-8 73 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 2. LITERATURE SURVEY: stagnant for a large period of time. Also, our method [1] REVIEW ON THE FUSED DEPOSITION of construction has an impact on the environment. The MODELING (FDM) 3D PRINTING FILAMENT paper discusses about an alternative method of PROCESSING, MATERIALS, AND PRINTING construction, using technology called as 3D printing. PARAMETERS The paper discusses about the technology, various Ruben bayu kristiawan et al; This study aims to review methods of using the technique, its method of research the progress on factors that affect the 3D application and the advantages it offers. Further it printing results of the fused deposition modeling gives a brief idea about the technology and explains (FDM) process. The review is carried out by mapping the need for including 3D printing as part of our critical parameters and characteristics determining construction methods in comparison to the traditional FDM parameters, the effects of each parameter, and method of construction. their interaction with other parameters. The study started from the filament manufacturing process, [4] THE IMPACT OF USING 3D PRINTING ON filament material types, and printing parameters of MODEL MAKING QUALITY AND COST IN THE FDM techniques. The difference in each section has ARCHITECTURAL DESIGN PROJECTS determined different parameters, and the respective Dina R. Howeidy et al; The expert educators use relationships between parameters and other different techniques in the educational process determinants during printing have a significant effect targeting the teaching effectiveness considering the on printing results. This study also identifies several disciplinary of the learners. They also encourage their vital areas of previous and future research to optimize sense of creativity by adding the technology to the and characterize the critical parameters of the FDM educational process, in the field of architecture as an printing process and FDM filament manufacturing. art and science, the use of new technologies is an important reflection of the design concept. Moreover, [2] ANALYZING THE COMPOSITE 3-D PRINTER architects use some technological programs presenting FRAME FOR RIGIDITY their ideas such as 2and 3 dimensional drawings, V Mr. Jonathan Mark Holman et al Additive Ray, 3D Max, Primavera etc. The new technique “3- Manufacturing offers a wide variety of options when it Dimensional Printing” means using the architectural comes to the construction of a part. Different infill new modeling technique to show the feasibility and patterns, infill densities, varying shell thickness, and effectiveness of using the new technique in this different materials all have different effects on the final discipline as a presentation tool for the learners’ strength of a functional 3D printed part. This paper projects in the design process. studies the benefits of using a fused deposition modeling (FDM) process to print a part completely [5] DEVELOPING LOW-COST 3D PRINTER hollow and fill the completed hollow shell with epoxy Lalit kumar et al; The 3D Printer is an additive resin to create a solid component. FDM is also known manufacturing technology which is developing now a as fused filament fabrication (FFF). Often times, large day as it has the potential to change the manufacturing functional FDM parts can take quite a long time to industry. It takes few hours to develop a new product complete printing due to high strength setting with this technology which was completed in day, requirements. Hollow parts can print much faster than months, and years with traditional technology. This is parts with infill, then be filled with an epoxy resin to how it changing the world and so new and better create a solid part in much less time. When cured, the machines are needed to cope up with the rapidly resin filled components will produce a stronger and changing industry. This research highlights a low-cost more rigid finished product than a printing the part 3D printer’s manufacturing and its working. The with comparable print settings. To illustrate this, a 3D whole printer along with the software was developed printer frame was designed, analyzed with an FEM to reduce the cost of printers as compared to one simulation and fabricated. already present in the market. The results show that low-cost printer with good accuracy can be [3] 3D PRINTING IN ARCHITECTURE manufactured. Rajshree Mathur Technology is evolving at a fast pace and so is technology of construction. The technologies and processes to produce buildings have remained ISBN: 978-93-5620-351-8 74 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 3. METHODOLOGY The methodology we have adopted is Fused Deposition Modelling (FDM). The following flow chart shows the methodology used by us in construction of 3D printer. The first step is to select one of the additive manufacturing processes among many processes. Then an appropriate mechanism is selected for X, Y and Z axis movements, considering various factors such as cost of fabrication, simplicity of design, synchronization, accuracy etc. Once the mechanism is selected the next step is integration of electronics and software then the machine is designed and fabricated. The last step is, synchronization of mechanical, electrical and software elements of the machine. FDM starts with a product procedure which forms an 4. CONCLUSION STL file (stereolithography file format), scientifically The outcome of this project was to build a portable 3D cutting and situating the model for the building Printer which has been successfully completed. The procedure. In the event that required, support design of the frame is made robust and compact using structures might be created. The machine may aluminum sections. The material selection of the apportion numerous materials to accomplish diverse various elements is economical. Using a single motor objectives. The model or part is created by extruding little amount of thermoplastic material to the desired for vertical movement along with a proximity sensor shape layers as the material solidifies promptly after makes bed leveling easy and the bed movement is expulsion from the nozzle. A plastic filament or metal wire is loosened up from a loop and supplies material monitored with resolution in microns. The drawback to an extrusion nozzle which can turn the flow on and off. There is commonly a worm drive that pushes the in few of the 3D Printer which uses bed movement in filament into the nozzle at a controlled rate. The nozzle is warmed to soften the material. The thermoplastics Y axis has distortion of the printed layer at high rates are warmed past their glass change temperature and are then saved by an expulsion head. of printing. To overcome this drawback, a new The nozzle can be moved in both even and vertical mechanism has been developed which uses bed bearings by a numerically controlled component. The nozzle takes an instrument way controlled by a PC movement in Z. The control of the mechanism helped producing (CAM) programming bundle, and becomes easy because of less number of motors and the part is developed from the last, one layer at any good synchronization can be achieved using this new given moment. Stepper engines or servo engines are 3D printer technique. commonly utilized to move the expulsion head. The system utilized is frequently an X-Y-Z rectilinear Specifications outline, albeit other mechanical plans have been utilized. In spite of the fact that as a printing innovation Method Fused FDM is exceptionally adaptable, and it is fit for Deposition managing little shades by the help of bringing down layers. Modeling Number of One Extruders Machine 400mm(L) x Size 350mm(W) x 500mm(H) Power DC 12V, Supply 5amp Power 250v, 50- Consumption 60Hz, 5amp, 600W Connectivity USB, SD Nozzle 0.3mm Diameter ISBN: 978-93-5620-351-8 75 Department of Mechanical Engineering, NNRG.

Filament Proceedings of RTIME-2K22 Material 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Print File PLA Type Gcode, STL MACHINE SPECIFICATIONS Now we have to assemble all these clamps and This machine is intended for accuracy. Utilizing a components using M5 sliding nuts and bolts and give solitary motor for vertical development makes Bed all the electrical and electronic connections. leveling simple and the bed development can be observed with determination in microns. In some REFERENCES machines, the extruder nozzle is made to move in Z – axis direction and bed is made to move in Y – axis • Beck, J.E.; Fritz, B.; Siewiorek, Daniel; direction, these mechanisms face problem of Weiss, Lee (1992). \"Manufacturing mutilation of printed parts while printing at high rates Mechatronics Using Thermal Spray Shape because of fast development of bed in Y – hub Deposition\" (PDF). Proceedings of the 1992 bearing. The outcome of this paper was to build a Solid Freeform Fabrication Symposium. portable 3D Printer which has been successfully completed. The design of the frame is made robust and • Amon, C. H.; Beuth, J. L.; Weiss, L. E.; compact using aluminum sections. The material Merz, R.; Prinz, F. B. (1998). 1. Lalit kumar, selection of the various elements is economical. Using Mohd Qamar Tanveer, Mohd Javid, a single motor for vertical movement along with a Developing low-cost 3D printer Int.Journal proximity sensor makes bed leveling easy and the bed movement is monitored with resolution in microns. The drawback in few of the 3D Printer which uses bed movement in Y axis has distortion of the printed layer at high rates of printing. To overcome this drawback, a new mechanism has been developed which uses bed movement in Z. The control of the mechanism becomes easy because of less number of motors and good synchronization can be achieved using this new 3D printer technique. • A consumer-based product was developed in accordance with the product design and prototyping process. The product being rapid prototyping machine which is helpful in small level applications like educational, household, research purposes. • The different concepts generated to address the problem statement were found to be fruitful. For some problems, combinations of the concepts were used. • The project work has helped to understand integration of electronic and mechanical system. • Product development from concept to testing has resulted in implementing design for manufacturing and assembly. FUTURE WORK: Till now, we have completed literature survey, and we decided to adopt FDM (fused deposition modelling. We have completed frame assembly, and we have printed clamps and other parts using 3D printer. ISBN: 978-93-5620-351-8 76 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 of Applied Sciences and Engineering Research, Vol. 5, No. 6, 2016 • Mr. Jonathan Mark Holman, Dr. Tumkor Sardar, Analyzing the Composite 3-D Printer Frame for Rigidity, making sense of 3-D printing: Creating a map of additive manufacturing products and services. Additive Manufacturing, 1, pp.64-76. • Mary B. Halli, Narayan Swamy R, Design and Implementation Of Arduino Based 3d Printing Using FDM Technique, ISSN: 2321- 0869, Volume-3, Issue-2, February 2015 • Samson Wilson, Rahul Thomas, Nimmi Mary, Eric Tom Bosco, Ajith Gopinath, Development and fabrication of fused deposition modelling 3D printer, International Conference on Innovations in Mechanical Sciences (ICIMS 21). ISBN: 978-93-5620-351-8 77 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 A REVIEW ON ABRASIVE WATER JET CUTTING Lakshmigalla Sunil kumar1, Telkar Mahesh2 1 Assistant Professor, Mechanical Engineering, NNRG, Telangana, India. 2 Assistant Professor, Mechanical Engineering, NNRG, Telangana, India. ABSTRACT: The development of high- they are a) Initial damage region (IDR), b) performance material such as composites and Smooth cutting region (SCR) and c) Rough advanced ceramics has a variety of manufacturing cutting region (RCR). challenges. It is known that many of these materials During 60s the study of application of pure water cannot be effectively machined by conventional for cutting was conducted by O. Imanaka, machining methods. Apart from economics, the University of Tokyo, and by late 60's R. Franz of process selection is based on the machined surface University of Michigan, analyze the cutting of integrity. The high-pressure water jet with abrasive wood using high velocity water jets. Main additives known as abrasive water jet (AWJ) is one applications of pure waterjet machining include viable alternative to conventional processing and cutting paper products, wood, cloths, plastics etc. has been suggested for use in post mold shaping of By the end of 1970’s composites materials was composites and other hard to cut material. The introduced and its advantages such as high research works on water jet cutting is discussed in strength, low weight, resistant to heat, hard etc this paper. Omni directional cutting potential as increase its use and applications, but there was no well as minimal thermal and mechanical loading suitable method to machine such materials are few advantages. There are several parameters economically machine hard to machine materials. influencing the performance of abrasive water jet The abrasive water jet machine became machining. Important process parameters which commercially available by the end of 1983 and mainly affect the quality of cutting are traverse the various types of abrasives are garnet, silicon speed, hydraulic pressure, abrasive flow rate, carbide, aluminum oxide, glass pieces etc. The standoff distance, and abrasive type, work material. added abrasives in the water jet increase the range Material removal rate (MRR) and surface of cutting materials, which can be cut with a roughness (Ra), taper of cut, width of cut are Water jet drastically. important quality parameters of AWJM. Abrasive water jet machining is very much KEYWORDS: Composites, Water jet, Omni- suitable for cutting soft, brittle and fibrous directional, Abrasives, Mechanical loading & materials. AWJM is a unconventional machining Parameter process without much heat generation and the machined surface is virtually without any heat 1. INTRODUCTION affected zone. The other advantages of abrasive Abrasive waterjet machining is a mechanical, water jet machining over other unconventional non-conventional machining method in which machining are: abrasive particles such as Silica sand, Garnet, i) Rapid setup of the abrasive water jet cutting, ii) Aluminum oxide, Silicon carbide etc are High accuracy of the components and features entrained in high speed waterjet to erode generated, extreme versatility of the system, iii) materials from the surface of material. About No heat generated during the process and above 90% of machining is done by using garnet as all, minimal kerf is obtained. Therefore, in this abrasive particle. In AWJM material removaltake paper, a review of the contributions by important place by erosion induced by the impact of solid researchers on water jet machining using particles. Material removal occurs by cutting abrasives (AWJM) is presented. The idea of wear and deformation wear, cutting wear defines development of a abrasive water jet machining erosion at smaller impact angle. Deformation system is followed by identification of relevant wear occur by repeated bombardment of abrasive processing parameters. The processing at larger impact angle. Abrasive waterjet parameters, their importance and influence on the machined surface are grouped into three sections abrasive water jet machining system are finally ISBN: 978-93-5620-351-8 78 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 compared and critically summarized to in pressure the cutting energy of jet increases. The understand the process outputs as a function of depth of penetration of jet increases with increases in input conditions. hardness of abrasives. M.A. Azmir, A.K. Ahsan [6] conducted a practical study for analyzing the surface 2. LITERATURE SURVEY: roughness and kerf taper ratio of glass/epoxy composite laminate machined using abrasive water jet JayprakashUmap, Shantanu Shelke, Satyam machine. The various process parameters considered are abrasive types (2-level), hydraulic pressure (3- Tripathi, Omkar Karande, Abhimanyu level), standoff distance (3-level), abrasive flow rate (3-level), traverse rate (3-level), cutting orientation (3- Chandgude [1] Manufacturing and Optimization of level). The optimization of AWJM was done with the use of Taguchi method and ANOVA (analysis of Process Parameters by using Abrasive Water Jet varience). The ratio of top kerf width to bottom kerf width is called Kerf taper ratio. Types of abrasives and Machining Carbon Fibre Reinforced Polymer traverse speed are insignificant parameter for surface roughness while hydraulic pressure is most significant Composites SOD=0.5mm,AMFR=200g/min, factor that influences surface roughness in AWJM. Standoff distance (SOD), cutting orientation and TS=30mm/min, Pressure=400MPa one of the basic abrasive mass flow rate are equally significant factors that influence surface roughness, but the kerf taper techniques used for optimization and comparing the ratios are influenced by hydraulic pressure, abrasive mass flow rate and cutting orientation. Abrasives type, results of different experiments using MINITAB standoff distance and traverse speed are most significant factors that had significant influences on software which gave optimized results. kerf taper ratio. The quality of cutting in AWJM can be increased by increasing the kinetic energy of the Prachi Patel [2] Optimization Of Abrasive Water Jet water jet. Ahmet Hascalilk, Ulas Aydas, Hakan Gurun [7] has Machining Process Parameters Inconel -800pressure carried out the study of effect of traverse speed on AWJM of Titanium alloy. The width of cutting, of 290MPa, traverse speed is varied from 80 to 100 changes with changes in traverse speed. The study also reveals that the kerf taper ratio and surface roughness mm/min, abrasive flow rates of 200 and 300 g/min, increases with increases in traverse speed. The increase in traverse speed reduces the interaction of SOD=2mm The effects of five process parameters ie, abrasives particles and the work piece thus narrow kerf widths with a greater kerf taper ratio can be cut with Abrasive flow rate, Traverse speed and standoff J. John Rozario Jegaraj, N. Ramesh Babu [8] worked on 6063-T6 aluminum alloy to find efficient distance and their effects on material removal rate and strategy and quality cutting of materials with abrasive water jets considering the variation in orifice and surface roughness is analyzed and studied using the focusing nozzle diameter in cutting. The study found that the effect of orifice size and focusing nozzle experimental values. diameter on depth of cut, material removal rate, cutting efficiency, kerf geometry and surface roughness. The Selvakumar guruswamy,Lenin Nagarajan, Ram study suggested that a ratio of 3:1 between focusing nozzle diameter to orifice size was best suited Prakash [3] Experimental study on abrasive water jet combination to achieve the maximum depth of cut out of several combinations of focusing nozzle to orifice machining of AA5083 in a range of thickness size. They suggest that the ratio of 5:1 and beyond cause ineffective entrainment of abrasives in cutting AA5083Jet Dia= 0.76-1.2 mm, SOD=0.5-0.9 mm, head. The investigation also analyze that the increase thickness=15-55 mm, abrasive flow rate= 270-320 g/min the influence of the process parameters on MRR, Ra and taper error. M.El-Hofy,M.O.Helmy,G.Escobar-Palafox and K.Kerrigan, R.Scaife, H.El-Hofy[4] AWJM of multidirectional CFRP(carbon fibre reinforced plastic) laminates CFRP technique pressure= 100MPa, feed rate= 50mm/min, SoD= 2 mm, CFRP material type= Lay-up 1for better surface quality, high operating pressure, low feed rate and small SOD are recommended. Lay-up type 1 gives better surface quality than layup 2 CFRP material A.A. Khan and M.M. Hague [5] analyses the performance of different abrasive particles in abrasive water jet machining of glass. They compare the effect of different abrasives on taper of cut by varying the stand-off distance, work feed rate, pressure. Garnet abrasive produce the largest taper of cut, followed by aluminum oxide, and silicon carbide. The study also describe that the taper of cut increases with increase in the standoff distances because water jet get widen with increase in standoff distance. The taper of cut decreases with increase in jet pressure, with increase ISBN: 978-93-5620-351-8 79 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 in hydraulic pressure for different combinations of achieved for certain thickness. A sufficient supply of orifice and focusing nozzle size the depth of cut hydraulic energy, fine mesh abrasives at moderate increases. The material removal rate also increases speed gives smooth kerf surface. By experiment with an increase in the size of focusing nozzle up to investigation they found that the kerf width increases 1.2 mm diameter and further increase tends to decrease with increasing these factors such as pressure, traverse the material removal rate. The abrasive flow rate has speed, abrasive flow rate and abrasive size. They also less significant on kerf width. This study suggests that found that the taper ratio increases increase in traverse taper of kerf can be minimized by maintaining the speed and decreases with increase pressure and orifice size and focusing nozzle size within certain abrasive size. Abrasive flow rate has no influence over limits raging from 0.25–0.3 mm and 1.2 mm, taper ratio. respectively. The surface quality does not depend on Mahabalesh Palleda [12] investigated the influence the increase in the size of orifice and focusing nozzle of the different chemical such as acetone, phosphoric but larger size of orifice, produce a better surface finish acid and polymer (polyacrylamide) in the ratio of 30% on cut surface. chemicals with 70% of water. He also analyzes the J. Wang, W.C.K. Wong [9] conducted a statistically effect of standoff distance on the taper angles and designed experiment to study the effect of abrasive material removal rates (MRR) of drilled holes in the water jet cutting of metallic coated sheet steels. The abrasive water jet machining process. It found that the relationship between kerf characteristics and process Material removal increases with slurry added with parameters are also investigated in this experiment. An polymers compare to the other three slurries. The study empirical model was developed for kerf geometry and also reveals that the MRR increase with increase of quality of cut for the prediction and optimization of standoff distance, because momentum of impacting AWJ cutting performance. A three-level four-factor abrasive particles on the work surface creating craters full factorial designed experiment performed for of more depth. As the standoff distance increase the analyzing the AWJM process. The various process taper holes of drilled holes decreases. The use of parameters used are water jet pressure, traverse speed, phosphoric acid combination and the slurry with abrasive flow rate and standoff distance (SOD). The acetone combination with slurry observes less taper in study found that the top and bottom kerf widths drilled holes than with the plain water slurry. Taper in increase with increase in hydraulic pressure, standoff drilled holes are almost nill by using polymer distance but the rate of increase for the bottom kerf additives. The study also found that the material width is smaller. The traverse speed produces a inverse removal rate increases with increase in chemical effect on the top kerf width and bottom kerf widths but concentration of acetone and phosphoric acid in the at same time the kerf taper increase as the traverse slurry up to a certain limit and then decreases. In case speed increase. The surface roughness of the cut of polymer with the slurry the material removal is surface decreases with an increase in the abrasive flow found to increases continuously. rate. P K Ray and Dr A K Paul [13] had investigated the Mohemed Hashish [10] observed that as the pressure effect of air pressure, grain size and nozzle diameter increases the power required for cutting get reduced on material removal rate. MRR is found to increases drastically. This suggests that cutting at higher increases with increase in standoff distance (SOD) at a pressure is more efficient than at low pressure for the particular pressure. Their investigation found that the same power consumption. Plain waterjets are capable MRR increases and then it is almost constant for small of cutting thn sheet metals at pressure of 600 Mpa. range and after that MRR decreased as SOD increases. Elevated pressure promise cost reduction due to They also introduced a material removal factor (MRF), reduction in abrasive usage or increased cutting speed. MRF is a non-dimensional parameter and it gives the The study shows that the depth of cut increases with weight of material removed per gram of abrasive increases in water pressure. particles. MRF is found to decrease with increase in H. Hocheng and K.R. Chang [11] conducted pressure that means the quantity of material removed experimental evaluation on the kerf formation over per gram of abrasives at a lower pressure is higher than ceramic plate cut with an abrasive water jet. It found the quantity of material removed per gram of abrasives that a critical combination of hydraulic pressure, at a higher pressure. This is happened because at abrasive flow rate and traverse speed are required for higher air pressure more number of abrasive particles through- out cut of ceramics, below which it cannot be are carried through the nozzle so more numbers of ISBN: 978-93-5620-351-8 80 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 inter particle collisions and hence more loss of energy. cutting width varies with depth, depending on the Alberdi, A. Suarez, T. Artaza, G.A. Escobar- cutting speed. The kerf width increases with low Palafox, K. Ridgway, [14] studied the behavior of a cutting speed and narrows down at high cutting speeds. machinability model in composite materials. The M. Chithirai Pon Selvan, Dr. N. Mohana Sundara machinability index of different composite materials is Raju, Dr. R. Rajavel [16] had investigated the effects very different, so they have to be studied separately. of process parameters on the depth of cut in abrasive The machinability index may be related to the tensile waterjet machining of cast iron. They investigated that modulus and/or to the fibre content of the composite the depth of cut increases with increases in water materials, but still now there is no solid evidence to pressure, when mass flow rate, standoff distance, relate mahinability index with the material property traverse speed were kept constant. Increases in and researches are required to relate the machinability abrasive flow rate also increase the depth of cut index with the material properties. The separation keeping other parameters constant. The depth of cut is speed has to be re-defined for this kind of material as found to decrease with increase in traverse speed the traverse rate at which the material can be cut because the contact of abrasive particle over the work without delamination. piece is for shorter duration. It is also found that the C. Ma, R. T. Deam [15] studied the kerf geometry of depth of cut decreases with increase in the standoff cut in abrasive waterjet machining using an optical distance between nozzle and work piece keeping other microscope. The kerf width developed on the work has operational parameters constant. shown that there are two regions, called the developing stage and the fully developed stage. The first region is 3. SUMMARY: the developing stage, and it ends after about 2 mm of The investigation on various process parameters of the cutting depth. The developing stage is due to the AWJM shows that MRR increases with increase in velocity profile of the jet changing from a uniform water pressure, but the major drawback is that the profile to a fully developed flow in a groove. The surface roughness and sub-surface damage increases velocity profile developed is similar to the velocity with increase in pressure. Types of abrasives and profile developed when flow enters a pipe from a large traverse speed also effects the various quality tank. In the second section, the fully developed stage parameters of work part. See Table 1 for a comparative which starts from 2 mm to the cutting depth and the analysis and a summary of results. Table 1. Effect of processing parameters on process outputs in AWJM Quality parameters→ Surface MRR Kerf Top Bottom Taper Wid Process parameters↓ of cut th of roughn widt width width of cut ess h of cut cut ↑ PRESSURE Increases ↑ ↑ ↑ ↑ ↑ to a ↓ small ↑ extent ↓ TRAVERS Decreases ↑ ↑ ↑ to a ↑ E SPEED Increases small Decreases ↑ to extent STANDOF F Increases some DISTANCE extent ABRASIVE Decreases ↓ FLOW RATE Increases Decrease ↑ WORK FEED s RATE Increases Decreases ISBN: 978-93-5620-351-8 81 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 4. CONCLUSIONS: glass/epoxy composite laminate “Journal of Quality of cutting surface in AWJM is depending on so many process parameters. Process Materials Processing Technology 209 (2009) parameter which affect less or more on quality of cutting in AWJM are hydraulic pressure, Standoff 6168–6173 distance, types of abrasive, size of abrasives, abrasive flow rate, nozzle diameter, orifice size, • Ahmet Hascalik, Ulas C aydas, Hakan Guru and traverse speed. Quality of cutting surface is measured by material removal rate, surface “Effect of traverse speed on abrasive water jet roughness, kerf width, kerf taper ratio. From the literature review compare to above all mentioned machining of Ti–6Al–4V alloy, ” Materials Parameter traverse speed is most effective parameter for MRR. Abrasive flow rate is also an and Design 28 (2007) 1953–1957 important parameter for increasing MRR. But beyond some limit with increase in abrasive flow • J. John Rozario Jegaraj, N. Ramesh Babu “A rate and traverse speed the surface roughness decreases. Increasing traverse speed also increase strategy for efficient and quality cutting of the kerf geometry. So it is required to find optimum condition for process parameter to give materials with abrasive waterjets considering better quality of cutting surface. Traverse speed is directly proportional to productivity and should the variation in orifice and focusing nozzle be selected as high as possible without compromising kerf quality and surface diameter” roughness. • International Journal of Machine Tools & Manufacture 45 (2005) 1443–1450 • J. Wang, W.C.K. Wong, “A study of abrasive water jet cutting of metallic coated sheet steels” • International Journal of Machine Tools & Manufacture 39 (1999) 855–870 • Mohemed Hashish, “Observations on cutting with 600-MPa waterjets” Journel of pressure vessel technology, May 2002, Vol. 124. • Hocheng and K.R. Chang, “Material removal analysis in abrasive water jet cutting of REFERENCES ceramic plates “Journal of Materials • Jayprakash Umap, Shantanu Shelke, Satyam Processing Technology, 40(1994) 287-304 Tripathi, Omkar Karande, Abhimanyu • Mahabalesh Palleda, “A study of taper angles • Chandgude Manufacturing and Optimization and material removal rates of drilled holes in of Process Parameters by using Abrasive the abrasive water jet machining process Water Jet Machining 2020. “Journal of Materials Processing Technology • Prachi Patel Optimization Of Abrasive Water 18 (2007) 292– 295 Jet Machining Process Parameters Inconel - • Studies on Abrasive Jet Machining by P K 800 International Journal of Advance Ray, Member A K Paul, Fellow Department Research and Innovative Ideas in Education of Mechanical Engineering Regional 2019 Engineering College Rourkela UDC 621.921 • G Selvakumar, SSR Prakash, N Lenin page no 27 to 29. Experimental study on abrasive water jet • Alberdi, A. Suárez, T. Artaza, G. A. Escobar- machining of AA5083 International Journal Palafox, K. Ridgway,” Composite Cutting of Abrasive Technology 8 (3), 218-231 with Abrasive Water Jet,” The Manufacturing • M.El-Hofy,M.O.Helmy,G.Escobar-Palafox Engineering Society International and K.Kerrigan, R.Scaife, H.El-Hofy AWJM Conference, MESIC 2013, Procedia of multidirectional CFRP(carbon fibre Engineering 63 ( 2013 ) 421 – 429 reinforced plastic) laminates 2018 • Ma, R.T. Deam, “A correlation for predicting • A.A. Khan, M.M. Hague,” Performance of the kerf profile from abrasive water jet different abrasive material during abrasive cutting,” Experimental Thermal and Fluid water jet machining of glass” Journal of Science 30 (2006) 337–343 Materials Processing Technology 191 (2007) 404–407 • M.A. Azmir , A.K. Ahsan, “A study of abrasive water jet machining process on ISBN: 978-93-5620-351-8 82 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 FABRICATION OF WOOD CUTTING POWERED HACK SAW USING RENEWABLE (SOLAR) ENERGY, RECHARGEABLE BATTERY, D.C. MOTOR AND SLIDER CRANK MECHANISM Mr.G.Kiran Kumar Assistant Professor, Department of Mechanical Engineering, NNRESGI. Abstract— The project aims at designing a system kept in the bench vice and the hacksaw blades is set to be facing forwards. In some frame saws, like Piercing which makes the Hacksaw Blade cutter-based Saws the blades are set to be facing the handle because they are used to cut in the pulled down direction motor running through solar energy. Power plays a against the horizontal surface. In multi-operation great role wherever man lives and works. The living machine at research areas, there are motivated by standard and prosperity of a nation vary directly with many question related production. The hacksaw the increase in the use of power. The electricity machine completely changed the cutting operation of requirement of the world is increasing at an alarming hand saw hacksaw. The direction of cutting plays the rate due to industrial growth, increased and extensive major role for quick cutting. The perfect cutting use of electrical gadgets. According to world energy dimension is achieved by the machining operation. report, we get around 80% of our energy from Consider a large work piece is to cut with less power conventional fossil fuels like oil (36%), natural gas than we go for solar hacksaw machine. The main solar (21%) and coal (23%). It is well known that the time renewable energy is converted in to electrical energy is not so far when all these sources will be completely and then to mechanical energy is utilized for cutting exhausted. So, alternative sources should be used to operation. avoid energy crisis in the nearby future. The best This machine is not only use at the hill stations where alternative source is solar energy. A solar panel is a the regular power supply is not available since this large flat rectangle, typically somewhere between the machine is compact in structure and easy movable size of a radiator and the size of a door, made up of from place to place. The solar hacksaw machine solves many individual solar energy collectors called solar many of the limitations in regular cutting machines. cells covered with a protective sheet of glass. The The system depending on the charging circuit the cells, each of which is about the size of an adult's motor can be controlled using relay switch. The solar palm, are usually octagonal and colored bluish black. power stores the energy to a battery and then runs the Just like the cells in a battery, the cells in a solar motor. panel are designed to generate electricity; but where Features: a battery's cells make electricity from chemicals, a 1. Utilization of free available source of energy from solar panel's cells generate power by capturing sun sunlight instead. They are sometimes called 2. Storage of energy into rechargeable battery. photovoltaic cells because they use sunlight (\"photo\" 3. Stored energy is used for running wood cutter comes from the Greek word for light) to make motor. electricity (the word \"voltaic\" is a reference to 4. Charging circuit electricity pioneer Alessandro Volta). 5. Low Power consumption Keywords- Hacksaw cutter, solar panel, 2. LITERATURE REVIEW Rechargeable battery, DC motor, Slider crank After the study of many literatures about design, construction and working of solar power hacksaw mechanism ,etc. machine, some of them describe the methodology of solar power hacksaw. Lots of factor have been 1. INTRODUCTION consider for the design, construction and working of solar power hacksaw machine such as cutting speed, A hacksaw consists of toothed blade for cutting cutting material, cutting time ,power ,efficiency etc. various metals and wood. By There are two types So, lots of literatures have been found which gives the hacksaws will be there one will be handsaw and other relevance information and methodology of will power hack saw. Generally hacksaws will have a constructing an solar power hacksaw machine. The C-shaped frame which holds a blade rigidly. problem of cutting-off material to size is common to According to the blade sizes the frame can be adjusted. practically every industry. Often, sawing is the first A screw mechanism will be used to hold the blade operation carried out on bar stock. Therefore, it is firmly and rigidly. Now Power tools like jigsaws, and surprising that so little work has been done to angle grinder used cutting long sheet metals. In understand the problems of this common operation. hacksaws mostly frame saw, the blade is mounted with the teeth facing outwards the handle. The cutting action is done in both the push and pull stroke. While cutting vertically downwards direction the work is ISBN: 978-93-5620-351-8 83 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 Many reasons have been consider better methods. Solar Power Hacksaws are used to cut large sections Often the foreman will assign a new trainee to a sawing of wood. Cutting of wood of diameters more than task, on the principle that it is easy to learn and difficult twenty millimeters is a very hard work with a normal to foul up. Furthermore cut-off machines are hand held hacksaw. Therefore solar power hacksaw frequently housed in stores away from the main machine is used to carry out the difficult and time production areas and the operation of the sewing consuming work. This power hacksaw machine is machines appears to be simple. The fact remains that considered as an energy saving machine because the cutting-off operations can account for a significant part operator need not be there to provide the reciprocating of the cost per piece (Remmerswaa and Mathysen, motion and downward force on the work-piece in 1961). order to cut it. Once the operator has fed the work- piece till the required length in to the machine and 3. EXPERIMENTATION starts the machine, then the machine will cut until the The simple back-and-forth motion of the blade made work-piece has been completely cut into two pieces. the hacksaw one of the first types of sawing machines The Solar Power hacksaw machine though being able designed for power. The simplicity in the blade to cut the wood without requiring any human effort motion has kept the price of the saw machine to cut, it does require a human intervention to feed the relatively cheaper than other types of sawing work-piece many times with measurements being machines. The low initial cost coupled with the taken each time before feeding. flexibility and adaptability, has enabled the hacksaw to remain popular in industry. In hacksaw cutting, a Figure No. 2: Fabrication of wood cutting powered single blade is tensioned in the bow, and reciprocated hack saw back and forth over the work piece. The cutting action is achieved only during half of the cycle of operation. Power Hack sawing: A power hacksaw machine is During the second half of the cycle, the return stroke, designed primarily straight-line sawing. A typical the blade is lifted clear of the work piece, giving a sawing operation is lined below: Select a hacksaw discontinuous cutting action, which is considered to blade of proper length for the machine and proper be one of the drawbacks of the operation. Despite this pitch for the material to be cut. Install the hacksaw disadvantage, As compared to the continuous-cutting blade with the teeth pointing downward and toward action of the band saw, hacksaws remain equally or the motor end of the hacksaw machine. Check the even more popular alternative machines. As with alignment of vice and hacksaw blade and mount the many other basic processes, hacksaw cutting is a tried work piece in the vice. Make the vice holds the work and tested method, reliable, consistently accurate, piece securely. Check the stroke of hacksaw machine quick and easy to repair, is less dependent on correct and adjust if necessary. After adjusting the stroke, blade tension and less likely to run-out. Furthermore move the hacksaw blade and sewing machine frame power hacksaws can be left unattended for long through one cycle by hand to check the blade periods when cutting large diameter bar and require clearance at each end of the work piece. Readjust the minimum operator skill. Blade replacement is position of vice if necessary. Position the hacksaw relatively cheap and simple. blade about ¼ inches above the work piece and set the feed control to its lightest feed setting. Set desired Figure No. 1: Schematic diagram of wood cutting speed of hacksaw machine. Start the machine and let powered hack saw the blade feed lightly into the work piece for about ¼ ISBN: 978-93-5620-351-8 84 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 inch. Readjust the feed to whatever the material will direction) in one revolution. stand for normal cutting. Permit the hacksaw blade to cut completely through work piece. The blade frame Figure No. 4: Worm gear will trip a switch on sawing machine bed to stop the Slider crank mechanism: sewing machine. Cutting diameter is more than 20 The slider-crank mechanism is one of the most useful mm is very hard work with a normal hand held mechanisms in modern technology since it appears in hacksaw. Therefore power hacksaw developed to most of the internal combustion engines including carry out the difficult and time consuming work. The automobiles, trucks and small engines. The slider- heavy arm moves forwards and backwards, cutting on crank kinematic chain consists of four bodies linked the backwards stroke. The wood to be cut held in with three cylindrical joints and one sliding or machine vice which is an integral part of base. prismatic joint. It is used to change circular into Turning the handle tightens or loses the vice. The vice reciprocating motion, or reciprocating into circular is very powerful and locks wood in position. motion. SOLAR PANEL Figure No. 3: Solar panel Figure No. 5: slider-crank mechanism A solar panel designed to absorb the sun's rays as a Rechargeable battery: source of energy for generating electricity. A A rechargeable battery, storage battery, or photovoltaic (in short PV) module is a packaged, accumulator is a type of electrical battery. It connected assembly of typically 6×10 solar cells. comprises one or more electrochemical cells, and is a Solar Photovoltaic panels constitute the solar array of type of energy accumulator. It is known as a a photovoltaic system that generates and supplies secondary cell because its electrochemical reactions solar electricity to store in battery and run motor. are electrically reversible. Rechargeable batteries come in many different shapes and sizes, ranging Working of worm gear: from button cells to megawatt systems connected to The worm (screw) continuously rotates and drives the stabilize an electrical distribution network. Several worm wheel (meshed with it). Worm and worm gear different combinations of chemicals are commonly form a lower pair as they have sliding contact with used, including: lead–acid, nickel cadmium (NiCad), each other. In a worm gear drive, power is always nickel metal hydride (NiMH), lithium ion (Li- ion), transmitted from worm to worm wheel. Power cannot and lithium ion polymer (Li-ion polymer). be transmitted from worm wheel to worm. This phenomenon is called self-locking. It is highly useful in many applications. A screw (worm) is said to have one start if it advances one groove (in linear direction), in one complete revolution. It is said to have two starts if it advances two grooves (in linear ISBN: 978-93-5620-351-8 85 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 The energy used to charge rechargeable batteries intended to charge a battery using the solar energy and usually comes from a battery charger using AC mains also utilized for operating the single phase wood electricity, although some are equipped to use a cutter dc motor. After fully charging the battery, the vehicle's 12-volt DC power outlet. Regardless, to motor is operated by turning the switch. The motor store energy in a secondary cell, it has to be connected rotates at 100 rpm and gears associated with it rotate to a DC voltage source. the crank. Here the connecting rod moves in to and from motion and hence it moves the slider. Thus the D.C. Motor: hack saw connected to slider cuts the wood which is A DC motor uses electrical energy to produce fixed in bench vice. mechanical energy, very typically through the interaction of magnetic fields and current-carrying conductors. The reverse process, producing electrical energy from mechanical energy, is accomplished by an alternator, generator or dynamo. Many types of electric motors can be run as generators, and vice versa. The input of a DC motor is current/voltage and its output is torque (speed). Figure No. 6: D.C. Motor Figure No. 5: Animated version of hack saw 8. DESIGN OF EXPERIMENT: Advantages: schematic diagram and interfacing of circuit with each module is considered. 1. Conservation of Non Renewable energy sources. 2. Maximum workdone can be obtained. 3. It does not cause any environmental pollution like the fossil fuels and nuclear power. 4. Solar cells last a longer time and have low running costs 5. Low power consumption. 6. Utilization of free available source of energy from sun 8. Storage of energy into rechargeable battery. 9. Stored energy is used for using wood cutter motor. 10. High efficiency can be achieved using inverter. 11. The electricity generated by the solar cell panel is stored during the day with the help of storage batteries which give us only direct current. But to operate our devices we need alternating current. Therefore we need to convert DC to AC before using any appliance using inverter. Figure No. 7: Schematic diagram of solar wood Disadvantages: cutter 1. Periodic Monitoring and Maintenance is required. Our project “Solar powered wood cutter” is mainly 2. A drastic environmental change cannot be tolerated by the equipment. 3. The entire process of manufacture is still very expensive as silver is used for interconnection of these cells in the panel, which is a very expensive metal. 4. A practical problem linked with the use of solar cell panels is regarding the storage of electricity general by them. ISBN: 978-93-5620-351-8 86 Department of Mechanical Engineering, NNRG.

Proceedings of RTIME-2K22 5th National Conference on Recent Trends & Innovations in Me6cthha&nic7atlhEMngaiyn,ee2r0in2g2 5. The conversion of DC to AC uses inverter before effectiveness of recovery strategies,” International using any appliance and thus it increases the cost of Journal of Contemporary Hospitality Management, such solar panels as the sources of electricity. vol. 11, no. 1, 1999, pp.6-15. [4] S. Michel, “Analyzing service failures and Applications: recoveries a process approaches,” International Journal of Kinematic Links, vol. 12, no. 1, 2001, 1. This energy can be utilized for simple house hold pp.20-33. appliances. [5] Janis L. Miller, Christopher W. Craighead, Kirk R. 2. This energy can be stored and utilized as backup Karwan, “Service recovery: a framework and power supply mainly in industries. empirical investigation,” Journal of Operations Management, vol. 18, 2000, pp.387-400. 9. RESULTS AND DISCUSSIONS [6] Chase, Stewart, “Six types of service scotch-Yoke The project “wood cutting powered hack saw mechanism and rack and pinion mechanism,” 1994 using solar energy” was designed such that the solar plate generates solar energy and utilizing this energy for running the wood cutter motor. Machine is driven by .67 HP and 70 rpm electric motor. Test was carried out on machine using different metal. For the loaded test, a shaft of diameter 25 mm and length 12 inch and the material of the shaft was mild steel was clamped on the vice of the machine. It took the machine 240 seconds to cut the with a new hacksaw blade. The cut was observed to be neat and straight. The total cost of equipment of the machine is Rs 4280. The total cost of producing the machine was estimated to be Rs10000. Recommendation has been made on the operation and parameters of the machine. Suggestion have been offered on overall machine performance optimization and further work on the machine. 10. CONCLUSION Integrating features of all the hardware components used have been developed in it. Presence of every module has been reasoned out and placed carefully, thus contributing to the best working of the unit. Secondly, using highly advanced IC’s with the help of growing technology, the project has been successfully implemented. Thus the project has been successfully designed and tested. Future scope: This project can be extended in a way such that the output from the solar plate is increased. This can be done by increasing the dimensions of the solar plate. The output voltage can be displayed on LCD. 7. REFERENCES [1] R. Mack, R. Mueller, J. Crotts, “A Broderick. Managing Service Quality,” Managing Service Quality: An International Journal, vol. 10, no. 6, 2000, pp.339-346. [2] Anna S. Mattila, “The Effectiveness of Service Recovery in a Multi‐industry Setting,” Journal of Services Marketing, vol. 15, no. 7. 2001, pp. 583-596. [3] Gordon H. G. McDougall, “Waiting for service: the ISBN: 978-93-5620-351-8 87 Department of Mechanical Engineering, NNRG.