ETIME 2021 Proceedings E-Book

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) 2.2 Cutting Tool Fig 7 Carbide Tip Single point cutting tool Fig 6 SS-314 work pieces The cutting tools used is carbide tip Single point cutting tool with a mild steel shank. It is of very high hardness and good toughness and it is principally intended for machining of super alloys and steel alloys. 2.3 Cutting Fluid The cutting fluid used in this experimentation is the combination of vegetable oil(sunflower oil) and water in the ratio 1:20 i.e., for example when the oil is taken for 1 liter then the quantity of water will be 2 liters. Sunflower oil is the non-volatile oil pressed from the seeds of sunflower (Helianthus annuus). 2.4 Design Of Experiments A total of three process parameters with three levels are chosen as the control factors such that the levels are sufficiently far apart so that they cover wide range. The process parameter and their ranges are finalized using literature, books and machine operator's experience. The four control factors selected are cutting condition (A), spindle speed (B), feed rate (C) and depth of cut(D). SS-314 work pieces are used in experimentation. The machining is performed individually. The control levels and their alternative levels are listed in table 2 TABLE 2: CONTROL FACTORS AND LEVELS FACTORS/LEV CUTTING SPEED (B) FEED (C) DEPTH OF CUT (D) ELS CONDITIONS (A) (rpm) (mm/min) (mm) 1 1500 0.1 CRYO 0.4 2 1100 0.3 3 MQL 700 0.5 0.5 FLO ODED 0.6 Selection of particular orthogonal array from the standard O.A depends on the number of factors, levels of each factor and the total degrees of freedom. i. Number of control factors = 4 ii. Number of levels for each control factors = 3 iii. Total degrees of freedom of factors = 4x(3-1)=8 Based on the above degrees of freedom the required minimum number of experiments to be conducted 9, the nearest OrthogonalArray fulfilling this condition is L9 (34). It can accommodate a maximum four number of control factors each at three levels with 9 numbers of experiments. Here the requirement is to accommodate four control factors at three levels, which can be easily done in this Orthogonal Array. In L9 (34) orthogonal array, 9 represents number of experiments, 3 represents number of levels and 4 represents number of factors. 116 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Factor assignment for L9 (34) has been done as shown in Table, TABLE 3 EXPERIMENTALDESIGN Experiment CUTTING SPEED (A) FEED (B) DEPTH OF CUT (C) No. COND ITIONS (m/min) (mm/rev) (mm) 1 1500 0.1 2 Cryogenic 1100 0.4 0.3 3 Cryogenic 700 0.5 0.5 Cryogenic 0.6 4 1500 0.5 5 Flooded 1100 0.5 0.1 6 Flooded 700 0.6 0.3 Flooded 0.4 7 1500 0.3 8 MQL 1100 0.6 0.5 9 MQL 700 0.4 0.1 MQL 0.5 2.5 PLAN OF EXPERIMENTS The scope and objectives of the present work have already been mentioned in the fore going chapter. Accordingly, the present study has been done through the following plan of experiment. 1. Cutting steel bars by electric saw and performing initial turning operation in Lathe machine to get desired dimension of the work piece. 2. Checking and preparing the Lathe machine ready for performing the machining operation. 3. A detailed study has been carried out for the selection of the cutting parameters i.e. Cutting conditions, speed, feed and depth of cut are taken according to the machine standards. 4. Selection of appropriate tool depending upon the cutting parameters i.e., speed, feed, depth of cut is changed depending upon the experimental design. 5. Performing operations on specimens in various cutting environments involving different tools and various combinations of process control parameters like: cutting conditions, speed, feed and depth of cut. Steel bars of 30mmdia X150mm length are prepared for conducting the experiment. Using different levels of the process parameters the specimens have been machined in LatheMachine accordingly, depending upon L 9 34 orthogonal array. The results of the experiments have been shown in table. Optimization of cutting temperature is carried out using Taguchi method. Confirmatory test have also been conducted to validate optimal results TABLE 4 EXPERIMENTALDATARELATED TO CUTTINGTEMPERATURE EXP NO. `Cutting Temperature 1 MEAN S/N RATIO 2 3 30 -29.54 4 5 31 -29.82 6 7 28 -28.94 8 9 39 -31.82 38 -31.59 34 -30.62 31 -29.82 30 -29.54 26 -28.29 ISBN: 978-0-13-601970-1 117

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) TABLE 5 SUMMARYOF S/N RATIOS Factor Level 1 Level 2 Level 3 Cutting condition(A) -29.43 -31.34 -29.21 -30.39 -30.31 -29.28 S peed(B ) -29.90 -29.97 -30.11 Feed(C) -29.80 -30.08 -30.1 Depth of Cut(D) The best condition for Cutting condition is level 3 (MQL), for Speed is level 3 (700rpm), for Feed Rate is level 1 (0.4mm/min), for Depth of Cut is level 1 (0.1mm). Thus, the optimum conditions chosen were: A3-B3- C1-D1. TABLE 6 OPTIMUM SETOFCONTROLFACTORS Factors/ Levels Cutting Speed(A) Feed(B) Depth of Optimum Value condition (rpm) (mm /min) Cut(C) (mm) 700 MQL 0.4 0.1 From table 6 the following calculations are done, for all the cases the predicted value is calculated in the same procedure. A3-B3-C1-D1  =predicted Y+ (A3-Y) + (B3-Y) + (C1-Y) + (D1-Y) = A3+B3+C1+D1-3Y = [(-29.21) + (-29.28) + (-29.90) + (-29.8)] -[3X. (-29.99)]  =-28.22 predicted Therefore, the predicted average for optimum condition of Cutting temperatures is -28.22 A confirmation test is performed with the obtained optimum cutting parameters (cutting conditions MQL, speed 700rpm, feed rate 0.4 mm/min and depth of cut 0 1mm). The cutting temperature values are taken and the S/N ratio is calculated for this condition. TABLE 7 CONFORMATIONTESTRESULTS CT S/N Ratio 25 -27.95 TABLE 8 COMPARISON OF S/N RATIOS η predicted -28.22 η conformation -27.95 3. RESULTS & DISCUSSIONS In the present work, the performance characteristics namely cutting temperature is to be minimized; hence smaller the better type quality characteristic has been selected for response. Figure 8 to 11 shows the variation between cutting temperature verses cutting condition, cutting speed, feed rate and depth of cut. It is observed that the cutting temperature is low at MQL cutting condition when compared with the other cutting conditions i.e., at the flooded and cryogenic. From figure 9, it is observed that, the cutting temperature is low at low cutting speed and it is increasing at moderate cutting speed conditions, again from moderate to high cutting speeds, the Cutting Temperature increases. 118 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Fig 8 CT V/S Cutting Conditions Fig 9 CT V/s Cutting Speed Fig 10 CT V/s feed rate Fig 11 CT V/s Depth of cut From figure 10, it is observed that, the cutting temperature is low at low feed rate and certainly increasing from low feed rate to moderate feed conditions, but again from moderate to high feed rate, the cutting temperature increases. From figure 11, it is observed that, the cutting temperature is low at low depth of cut and certainly increasing from low depth of cut to moderate depth of cut conditions, but again from moderate to high depth of cut, the cutting temperature decreases. Taguchi robust design methodology has been successfully implemented to identify the optimum settings for control parameters in order to reduce cutting temperature of the selected workpiece material for their improved performance. The optimum settings combination is validated by conducting conformation test, which concluded that the results were within the acceptable limits of the predicted value and can be implemented in the real time application. 4. CONCLUSIONS The objective of the project work is to find out the set of optimum values for the selected control factors in order to reduce cutting temperature, using Taguchi's robust design methodology considering the control factors and Stainless steel of SS-314 grade work piece. Based on the results of the present experimental investigations the following conclusions can be drawn: • The cutting conditions used for this experimentation are Cryogenic, flooded, MQL, in this MQL is the optimum environment of cutting condition • The cutting speed used for the experimentation 1500rpm, 1100rpm, 700rpm, in this 700 rpm is the optimum speed for obtaining the optimum value of cutting temperature. ISBN: 978-0-13-601970-1 119

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) • For obtaining the optimum value of cutting temperature. The optimum feed is 0.4 mm/min among used feeds 0.4mm/min, 0.5 mm/min, 0.6mm/min. • Depth of cut 0.1 is the optimum depth of cut for obtaining optimum cutting temperature in the values 0.1mm, 0.3mm, 0.5mm • The S/N ratio of predicted value and verification test values are valid when compared with the optimum values. It is found that S/N ratio value of verification test is within the limits of the predicted value and the objective is full filled for cutting temperature. • Taguchi method has been successfully applied in optimizing cutting temperature for Turning operation. 5. REFERENCES 1. M. Venkata Ramana, A. Venkata Vishnu, G. Krishna Mohan Rao, D. Hanumantha Rao, \"Experimental Investigations, Optimization of Process Parameters and Mathematical Modeling in Turning of Titanium Alloy Under Different Lubricant Conditions\", IOSR Journal of Engineering (IOSRJEN), ISSN : 2250-3021, Vol. 2, Issue 1, Jan.2012, pp. 086-101. 2. S. Syahrullail. \"Experimental Investigation on Effect of Machining Parameters of 20MnCr5 Alloy Steel Using vegetable oils\" International Journal of Advance Research and Innovative Ideas in Education Volume 2 Issue 2 2017 Page 20-27. 3. Abhang L B and Hameedullah M, (2011), \"Modeling and Analysis for Surface roughness in Machining en-36 steel Alloy using Response Surface Methodology\", International Journal of Applied Research in Mechanical Engineering, Volume-1, Issue-1. 4. Kamal, Anish and M.P. Garg (2012), \"Experimental investigation of Material removal rate in CNC Turning using Taguchi method \"International Journal of Engineering Research and Applications (IJERA) Vol. 2, Issue 2,Mar-Apr 2012, pp.1581- 1590 5. Sijo M.T and Biju.N (2010), \"Taguchi Method for Optimization of Cutting Parameters in turning Operations\" Proc. of. Int.Conf.on Advances in Mechanical Engineering 2010. 6. Ballal, Inamdar and Patil P.V. (2012), \"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 36 7. Ashish Yadav, Ajay Bangar, Arjan Sharma, Deepak Pal,\" Optimization of turning Process Parameters for Their Effect on En 8 Material Work piece Hardness by Using Taguchi Parametric Optimization Method,\" International Journal of Mechanical and Industrial Engineering (IJMIE), ISSN No. 2231 -6477, Volume-1, Issue-3, 2012. 8. HMT \"Production Technology\", Tata McGraw Hill, 2004. 9. Phillip j. Ross \"Taguchi Techniques for Quality Engineering\", Tata McGraw Hill, Second Edition, 2005. 10. S.A Lawal, I.A Choudary, \"Application of vegetable oil-based metalworking fluids in machining ferrousmetals\". 11. VenkataVishnu,J.Akhil,A.S.Akhil,B.Raju, Ch.Praveen, and A.Pavan. "Experimental Investigation on Effect of Machining Parameters of EN353 Alloy Steel Using vegetable oils"International Journal of Advance Research and Innovative Ideas in Education 120 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Design and Fabrication a Two Stroke Working Model of a Cut Section Engine Using a FDM 3D Printer A.Bala Raju1, M.Niharika2, Rayudu Peyyala3 1Associate Professor, Sreenidhi Institute of Science and Technology, Hyderabad 2P. G Student, Department of Mechanical, VNR Vignana Jyothi Institute of Engineering and Technology, Hyderabad. 3Professors, Anantha Lakshmi Institute of Technology and Sciences, Anantapur. Corresponding author: [email protected] ABSTRACT 3 D printing technology is the process of making a components or things, which are making prototypes by adding the material layer by layer. Three-dimensional printers are mainly used to make physical models and prototypes from designers, engineers, and new product development teams, capable of printing parts and accessories from various materials with different mechanical and physical properties and often in a single manufacturing process. 3D printing in addition to the printer, a three-dimensional design program (eg Solid works) is required to design the model and a print program (eg Makerbot) to guide and adjust the various parameters for the proper process printing. In this paper first part is design connecting rod ,piston and cylinders etc as per standards. For that use the NX software and converted in to STL File. Next part is generating the sectional prototype of IC Engine parts such as connecting rod , piston and cylinders etc by using 3D printer. Finally assemble the all components and made cut section of Two stroke diesel engine. Key words: 3 D printer, connecting rod, Piston, IC engine 1. INTRODUCTION Additive manufacturing or rapid prototype is a method of manufacture or crate an object by layer by layer. In generally many methods are existed for create an object such as 3 D printer, FDM etc..This paper is gives the procedure for design 2 stroke internal combustion engine parts. CAD tool is used for produce digital model of the IC engine parts; in this paper use NX software as to design the models. For generating digital model through 3D scanner, For converting CAD model in to STL file by traditional manufacturing method so that convert the file and save in STL format. Main components in 3D Printers as follows Filament Filament is the first basic material which is making the prototype of the components. Generally ink jet wire 3D printer emits melted filament with diameter 1.75mm & 2.85mm. These filaments are available in different colours in the market. ISBN: 978-0-13-601970-1 121

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Slicer (3D printing) Slicer is main slicing software, which is meant for conversion of 3 D object in to STL format and specified fritter commands. Finally programme is prepared by G-code files that can after be transferred to the printer. Flow chart of the 3D printer The below procedure is describing the Transforming the digital file in to solid 2. LITERATURE REVIEW [1] Sachidananda and D.R.K Parhi, were demonstrated procedure to fabrication the the 3 D printer and conversion of STL format and also given information about selection of materials such asABA,PLA and composites. Rapid development in additive manufacturing field, presenting the cost optimization of a 122 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) components. Studied the types of 3D printing machines and selection of materials, soft ware's which are used for converting in to STL files. [2] Medhavi Kamran,Abhishek et.al are presenting the AComprehensive Study on 3D Printing Technology and describes the different mechanism and process related information, supporting material, for making components which software used also recants developments in 3D printer. 3. MODELING OF IC ENGINE COMPONENTS List of IC engine components: Connecting rod, piston, piston rings, cylinder, crank pin and Gudgeon pin. Two stroke engine parts are designed in NX software than exported to stl to save in .stl format which is a stereo lithography format. Then the model .stl file is processed through slicer software (flash print) under various conditions such as the thickness of the layers, in fill, number of layers in the top and bottom, temperature of nozzle, and the speed of extruder. Fig 3.1 NX model for Cylinder (engine) Fig 3.2 NX model for Piston Fig 3.3 NX model for piston rings Fig 3.4 model for connecting rod ISBN: 978-0-13-601970-1 123

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Fig 3. 5 NX model for Gudgeon pin Fig3.6 NX model for Crankpin Fig 3.7NX model for Crankshaft with Counter weight Fig 3.8NX model for Bearing Fig 3.9 NX model for handle Fig 3.10 slicing of Cylinder (engine) in flash print Fig 3.11 slicing of Cylinder (engine) rotation in flash print 124 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Fig3.12slicing of Cylinder (engine)scale in flash print Fig 3.13 slicing of Cylinder (engine) supports generating in flash print Fig 3.14 slicing of Cylinder (engine) supports generated in flash print Fig 3.15 slicing of Cylinder (engine)print speed conditions in flash print Fig 3.16 sliced Cylinder (engine)cut section at 41 layer Fig 3.17 sliced Cylinder (engine)cut section at 90 layer Slicing of 2stroke engine parts in flash print flash forge slicing software. ISBN: 978-0-13-601970-1 125

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) RESULTS 3D Parts of 2 stroke engine : Fig 4.1 3D Cylinder (engine) Fig 4.2 3D Piston Fig 4.3 3D Piston ring Fig 4.4 3D Gudgeon pin Fig 4.5 3D Connecting rod Fig 4.6 3D Impeller Crankshaft with Counter weigh Fig 4. 7 3D Crank pin Fig 4.8 3D Bearing 126 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Fig 4.9 Final assembled parts of a 2 stroke engine CONCLUSIONS • As per the slandered first modeling the IC Engine Parts with Unigraphics • Made a all IC components by 3D printing as per standard and assembly the final model • Proto type of the IC Engine parts are developed with optimum cost REFERENCES 1. Study, Design and Fabrication of A 3d Printer by Sachidananda hota and Dr D.R.K Parhi. 2. A Comprehensive Study on 3D Printing Technology by Medhavi Kamran and Abhishek Saxena, MIT International Journal of Mechanical Engineering. ISBN: 978-0-13-601970-1 127

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Static StructuralAnalysis and Optimisation of Single Cylinder Spark Ignition Engine Crankshaft Milan Motta1, K.Naga Prathyusha2, G.Mamatha3, G.Mukesh4 1Associate Professor, 2,3,4B.Tech. Scholars 1,2,3,4Department of Mechanical Engineering, Sreenidhi Institute of Science and Technology Hyderabad, India. Email: [email protected] ABSTRACT Effective and accurate functioning of IC engine is the ultimate choice of any designer and to ensure it for crucial components like Crankshaft needs utmost design care. Here, a crankshaft of petrol fuelled 4S engine with single cylinder is considered for static structural analysis. A 3-D solid modeling of the considered component was shaped according to the standard dimensions. For the purpose of analysis and FEA was performed under the static as well as dynamic condition to attain the variation in stresses at special significant spots of the considered component. To have the optimal condition optimization analysis performed considering geometry and shape with focus on the area of material variation to observe equivalent stress, deformation and weight to cost ratio further optimization done for geometry, material properties, processes considering various constraints. The obtained results were encouraging, optimised crankshaft proved to be an improved version becomes a reason for reduction in weight. Keywords: Static Structural Analysis, Material Variation, equivalent stress. INTRODUCTION Considered object is deemed to be large component with a complicated geometry in the engine that uses a 4 link mechanism to have rotary motion from an initial reciprocating displacement. In view of the fact that the considered component is always subjected to a good number of load cycles during its lifespan, fatigue performance and durability of this component has to be considered in the design process. Design and developments has always been a crucial subject in the business that are involved in fabrication and building of crankshaft, in order to fabricate a economical component with least possible weight and appropriate fatigue strength including other indispensable functional requirements. Appropriate enhancements results in lighter and slighter engines with enhanced energy efficiency and higher power productivity. Crankshaft experiences large forces applied at piston crown by gases as a result of fuel ignition. As a result of the fact of the linkage between piston, crankshaft and connecting rod the force will be conveyed to the crankshaft. The extent of theforce is function of several controllable and uncontrollable factors which includes specification and dimensions of crank, connecting rod, piston, piston rings, and pin. Chemical reaction and ignition along with inertia forces causes two types of loading on the structure of considered component namely torsional and bending loads. This paper deals with the analysis and optimisation of petrol fuelled 4S engine with single cylinder. This piece of work essays the finite element analysis of 2 different crankshafts from similar. The outcomes in the form of stresses were exercised for superposition for dynamic load applied to the considered component. Investigation was carried out on crankshaft made up of forged steel in order to have optimal results for the considered parameters of weight and cost. This paper serves finding for fatigue fulfillment and optimization of crankshafts made up of forged steel and ductile cast iron and a review on fatigue, robustness, assessment of different processes with regard to manufacturing cost was analysed. This paper aims at identification of the significant spot of fatigue failure under the loading condition and determining the working stress bound at identified spot. 128 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) MATERIAL PROPERTIES Below Table I show the material properties of Forged steel Table I Compressive and Tensile properties of Material Ductile Cast Iron is shown in Table II Table II METHODLOGY There are various means of software to generate a practically representing 3-D model. The most popular amongst them are CAD, AUTODESK FUSION360, AUTODESK INVENTOR, SOLIDWORKS, SKETCHUP etc.because of the accessibility and user friendly nature of solid works is chosen and a model generated by adhering to various commands. Since a crankshaft design involves various complex geometries we took the following two geometries as reference. Figure 1: Detailed Dimensions of cast iron crankshaft ISBN: 978-0-13-601970-1 129

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Figure 2: Detailed Dimensions of forged steel crankshaft Considering the simplicity of manufacturing a model generated as shown in the isometric view. Figure 3: The generated geometry of cast iron crankshaft SIMULATION AND ANALYSIS The FEA method is analysis and simulation scheme that studies the behaviour of a part or structure under the specified and applied condition of some problems in engineering. The essential theory that works behind FEA involves dividing the selected part or structure into predetermined number of parts and thereby reducing the necessity of having physical models and at the same time the dynamic analysis provides all the intermediate variations bydoing simulations. 130 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Figure 4: Stages Involved in Simulation Factor of safety It is the ratio of ultimate stress to working stress. It is affected by factors like material strength, type of loading (impact, repeated etc). Figure 5: Safety factor of designed forged steel crankshaft Equivalent stresses Equivalent stress represents the situation of multiaxial stress with multiple stress mechanism acting on selected part. Stress tensor is converted into distinct corresponding component.In static structural analysis we give two supports( Here X,Y are two fixed supports). Figure 6: Equivalent stress of designed forged steel crankshaft 131 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Total Deformation The deformation is checked in 3 directions (X,Y, Z these are directional deformations).The total deformation is the resultant of all movements of the system in assumed direction. Figure 7: Total deformation of designed forged steel crankshaft Total heat flux Heat flux or heat flux density is the total heat conveyed per unit area in unit time for a surface in either direction i.e. into or out of surface that depends upon the amount of heat transfer and contact area of component. Figure 8: Total heat flux of designed forged steel crankshaft CONCLUSION The objective of generating crankshaft as a considered study object that too of two dissimilar materials like forged steel and ductile cast iron is accomplished and also structural analysis is investigated usingANSYS 16.0. The study and analysis carried out reveals and reconfirms that for every material of different characteristic the equivalent stress and total deformation differs. Ductile Cast Iron is preferred under the same load conditions. Average life of Crankshafts depends upon the material properties. Hence selection of suitable material is of utmost importance and accordingly one selected here. For ductile cast iron, the factor of safety is 15; equivalent stress is 8.989MPa. An aforementioned conclusion is behavioural evidence in order to confirm FEAresults go well with theoretical results. Results of optimized crankshaft are judged against the accessible and available design and it is assured that under static loading condition all the analysed and optimized cases were safe and sound. 132 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) REFERENCES [1]. Khatri, S., Kharde, D., Varpe, K.: Review on optimization of crankshaft. Int. J. Adv. Technol. Eng. Sci.4 (4), ISSN 2348-7550 (2016) [2]. Ramkumar, R., Lenin V.R., Krishnaraju, A.: Finite element analysis and optimization of crankshaft of briquette machine. Int.J. Technol. (IJEET) 21(2015) [3]. Solanki, A., Dodiya, J.: Design and stress analysis of crankshaft for single cylinder 4-stroke diesel engine. Int. J. Res. Appl. Sci. Eng. Technol.2 (V) ISSN 2321-9653. (2014) [4]. Thriveni, K., Chandraiah, J.B.: Frequency comparison and optimization of forged steel and ductile cast iron crankshafts. Int. J. Eng. Sci. Inven.2 (11), ISSN 2319-6720 (2013) [5]. Keskin, A., Aydin K.: Crank analysis of a gasoline engine crankshaft. Gazi Univ. J. Sci.2, ISSN 487-492 (2010) [6] Mukund Hingne et.al. \"Analysing the effect of weight reduction of Crankshaft on the pressure parameter inside cylinder of single cylinder SI engine\", Materials Today: Proceedings, 2021 ISBN: 978-0-13-601970-1 133

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Characterization of Mechanical Behavior ofABS/ Calcium Sulphate Particulate Composites S.Sreenivasulu1, A. Chennakesava Reddy2 1Research Scholar, Department of Mechanical Engineering, 2Professor, Department of Mechanical Engineering ABSTRACT In this research paper, Acrylonitrile-butadiene-styrene (ABS) a matrix material, and calcium sulfate (CaSO4) as a filler material to prepare composite. Composite specimens prepared with the utilization of an injection molding machine. Tensile and hardness tests led to explore the mechanical behavior of composites. The foremost contributions of this work are the decrease of ultimate strength with increasing content of calcium sulfate within the composites. Mixture mode of ductile-to-brittle fracture has been noticed within the ABS/ CaSO4 polymer composites. It likewise shows the effect of other parameters to measure the improvement of the mechanical properties. Utilizing CaSO4 as filler material to ABS, the properties improved, which brings a few more extensive applications. Keywords: ABS, CaSO4,Tensile strength, Hardness, SEM 1. INTRODUCTION Acrylonitrile butadiene styrene (ABS) (C8H8)x·(C4H6)y·(C3H3N)z) is a thermoplastic polymer.Impact resistance and toughness are the most essential mechanical qualities ofABS.ABS is utilized in golf club heads, automotive trim components, and vehicle bumper bars because of its excellent shock absorption.ABS is simple to manufacture and injection mold. The use of metallic fillers can improve the mechanical characteristics of thermoplastic polymers. Because of the increased surface area, nanoscale fillers outperform microscale fillers. Fillers such as TiO2 [1], CuO [2], CuS [3], CaCO3 [4], Al [5], Fe [6],] are employed with various polymers to improve wear resistance. In many industrial processes, calcium sulphate is one of the most prevalent inorganic salts with a strong scaling potential. Increased tensile strength from 4.2 to 5 Mpa and elongation at break from 210 to 590 % are among the features of vulcanizedsilica rubber with calcium sulphate whisker [7].PTFE (polytetrafluoroethylene) is a solid lubricant that is extensively used in bearing and seal applications. Under normal friction circumstances, PTFE has a high wear rate, which limits its application sectors. PTFE/ZnO nano composites were created by Li et al. in 2002. The wear resistance was increased by twice, with a maximum wear resistance of 15 vol% ZnO.At a loading of 20%, Sawyer et al. (2003) used a 38 nmAl2O3 filler to improve the wear performance of PTFE, and the wear resistance rose 600 times over that of unfilled PTFE. To lower the friction coefficient and wear rate of PTFE, graphite and molybdenum disulfide (MoS2) have been utilised (Bijwe, 2000).Wang et al. (1997) investigated poly-etheretherketone (PEEK) composites containing varied weight fractions of SiC, Si3N4, SiO2, and ZrO2. With the addition of the filler in fractions less than 10% wt, they noticed an improvement in wear resistance and a drop in friction coefficient. Cho and Bahadur (2004) found that adding 2vol % nano-CuO to short fiber- reinforced polyphenylene sulphide improved wear resistance. The fabrication of sleeve bearings and thrust washers using ABS 6 and Calcium Sulphate as matrix materials and graphite as a filler material is discussed (Reddy, 2015). 134 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) ABS is used in a wide range of items that require high-strength materials. Gears, fittings, and bearings are all made of it.ABS combined with Calcium Sulphate was tested in this experiment, with the percentage of calcium sulphate varied by weight. Mechanical properties are put to the test. After using SEM microstructures, the morphology of the wear track was estimated, as well as the best conditions for the parameters. 2. MATERIAL ANDMETHODS The matrix material was ABS and the filler material was Calcium Sulphate. The melting point ofABS 6 is 200oC and density at 25oC is 1.53 g/cc. The melting point of Calcium Sulphate 1460oC and density at 25oC is 2.96 g/cc. 2.1 Preparation of ABS- Calcium Sulphate composites Figure 1 shows how several matrix/filler blends were created in a torque rheometer with a twin-rotary mixer (a).ABS and Calcium Sulphate were dried separately in the oven at 750°C for 4 hours prior to melt processing. The Calcium Sulphate was added in 3 minutes at the same temperature and at 50 rpm after theABS was melted at 220oC for 5 minutes at 75 rpm. For another 5 minutes, the blend was held at 75 rpm. The extruded sample was palletized and stored in desiccant-filled sealed packets.As indicated in figure 1, the test specimens for tensile and hardness testing were manufactured using an injection molding machine at 2200C-2300C and a 100 bar injection pressure (b). 2.2 Conduction ofTests The metal matrix composites were put through the following tests: • Tensile test for elastic modulus and ultimate tensile strength • Rockwell hardness test Figure 1(c) depicts the as-mold test samples (perASTM D 618) as well as two die halves. The tensile test was performed using a computer-interfaced tensometer, as indicated in figure 2. The loads at which the specimen broke due to reaching the yield point were recorded. The elongation was measured with an extensometer. The load vs. deflection graph for each specimen was also acquired from the machine's computer. The porosity and voids in the test materials were investigated using an optical microscope. The fracture of thetested tensile specimens was examined using a scanning electron microscope. 3. RESULT ANDDISCUSSION To account for manufacturing effects, the experiments were arranged at random (like mixing of ingredients and variation of temperature, density and particle size). For each experiment, two trials were conducted. 3.1 Mechanical behavior of ABS/Calcium Sulphate composites Figure 3 depicts the load-displacement relationship forABS/Calcium Sulphate composites. With an increase in the Calcium Sulphate content in the composite, the load increases. This is owing to the rigidity that the Calcium Sulphate has caused in the composite. Figure 4 depicts the effect of calcium sulphate addition on tensile strength (a). With increasing Calcium Sulphate content in the composite, engineering tensile strength, real tensile strength, and breaking strength all improve. It could be because of the good interface bonding between ABS and Calcium Sulphate, which results in good particle adhesion. Calcium sulphate is made up of. In single bond organic chemistry, the calcium-sulphate and calcium-calcium bonds are among the strongest. This explains a lot of its characteristics. Because of the ISBN: 978-0-13-601970-1 135

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) material's tight connections, it takes a lot of heat to break it down. It's also non-polar, which makes it chemically inert. Calcium Sulphate has a low coefficient of friction due to low interfacial forces between its surface and another material, as well as a low force to deform. Figures 4(b)and 4(c) indicate the effect of Calcium Sulphateon percentage elongation (ductility) and hardness, respectively. The % elongation (ductility) of the composite reduces as the calcium sulphate concentration rises, but the composite's hardness rises. This is due to the fact that the hardness of Calcium Sulphate is greater than the ABS hardness. The composite grows tougher as the calcium sulphate level rises Figure 1: Preparation of test samples: (a) Torque rheometer with a twin-rotary mixer, (b) Injection molding machine and (c) Two mold halves and test specimens. Figure 2: Tensometer. 136 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) 4. RESULTS AND DISCUSSION: 4.1 Effect of loading rates on tensile behaviour of composite 1600 35 1400 30 1200 25 1000 20 elongation,% Load(N) 800 15 Ultimate strenth 600 10 ABS96-CASO4-4% 5 400 ABS92-CASO4-8% ABS88-CASO4-12% 200 ABS84-CASO4-16% 0 ABS80-CASO4-20% 0 5 10 15 20 25 0.0 0.5 1.0 1.5 Caso4,% wt Displacement (mm) Figure 3 Displacement vs load curve of ABS/CaSO4 Figure 4: Influence of CaSO4 on mechanical properties (a) tensile strength elongation ,% 2500 peak break 2000 1500 5 10 15 20 25 1000 Caso4,% wt 500 0 0 Figure 4: Influence of Calcium Sulphate on mechanical properties (b) ductility and (c) hardness. 4.1.1 Fracture Behavior of ABS/CASO4 polymer composite Figure 5: Fracture surfaces of ABS/Calcium Sulphate composites 137 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Figure 5 shows the cracked surfaces ofABS/Calcium Sulphate specimens exposed by SEM. The fracture is caused by interface debonding, as seen by SEM images. The severity rises as the amount of Calcium Sulphate in the composite rises. Figures 5(a) and 5(b) show 4 percent calcium sulphate, 8 percent calcium sulphate, respectively and Figures 5(c) and 5(d) show 16 percent calcium sulphate, and 20 percent calcium sulphate, respectively. Elongation voids in the composite are also to blame for the fracture.Agglomeration can also be seen in composites containing 16 to 20 percent Calcium Sulphate. Figure 5 (c & d) shows the adhesive force between the particles, which strengthens particle agglomeration, and the shear force applied on the particles during mixing, which causes aggregate breakup. Dimples can also be seen on cracked surfaces. ABS/Calcium Sulphate polymer composites show mixed-mode ductile-to-brittle fracture. 4. CONCLUSIONS The current study demonstrates the injection molding technique's efficacy in producing ABS/ CaSO4 composites of various compositions. • Tensile strength was highest at 4% wt CaSO4 and steadily decreased as CaSO4 concentration increased. • A hardness test was performed on several Nylon-6/ CaSO4 composite compositions, with the higher Rockwell hardness number of Nylon-6/ CaSO4 composite observed at 20% wt. • Scanning electron micrographs further revealed that the majority of microparticle variation happens in a homogeneous manner from the matrix. The surface of composites can be better understood via SEM pictures when different input parameters are used. • Agglomeration of Calcium Sulphate particles occurs as a result of Sulphate atoms in Calcium Sulphate preferring to make bonds with other Sulphate atoms in Calcium Sulphate. REFERENCES [1] Sudeepan, J; Kumar, K; Barman, T. K; Sahoo, P. (2014). Tribological behavior of ABS/TiO2 polymer composite using Taguchi statistical analysis, International Conference on Advances in Manufacturing and Materials Engineering (AMME 2014), Procedia Materials Science, 5, pp.41-49. [2] Zabihi, O; Ghasemlou, S. (2012). Nano-CuO/Epoxy Composites: Thermal Characterization and Thermo-Oxidative Degradation, International Journal of Polymer Analysis and Characterization, pp. 108-121,doi.org/10.1080/1023666X.2012.639930. [3] SalavatiNiasari, M. (2011). Effect of CUS nanoparticles as filler on the thermal stability ABS, Nanomaterials: Applications and Properties (NAP-2011). 1(1),pp.98-101. [4] Jiang, L.; Lam, Y.C.; Tam, K.C; Chua, T.H; Sim, G.W; Ang, L.S. (2005). Strengthening acrylonitrile-butadienestyrene (ABS) with nano-sized and micron-sized calcium carbonate, Polymer Journal, 46,243-252. [5] Meena, L; Vijaykumar, S. J. (2015). Investigation into the effect of Aluminium powder on Mechanical, Tribological and Electrical properties of Al-ABS composites, WSEASTransactions on Applied and Theoretical Mechanics, 10, pp.47-53. [6] Ahn, S;. Park, S. J; Lee, S; Atre, S. V; German, R. M. (2009). Effect of powders and binders on material Properties and Molding Parameters in iron and stainless-steel Injection Molding Process, Journal of Powder Technology, 193,pp.162-169. 138 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Experimental Investigation of Process Parameters of AWJM on SR, MRR and DOC by Using Analytical Heirarchy Process S. Sivasankar1, T. Hari Prasad2 1Ph. D scholar, Jawaharlal Technological University Anantapur, Anantapuramu, Anantapur, Andhra Pradesh, India. 2Professor, Department of Mechanical Engineering, Sree Vidyanikethan Engineering College, Tirupati, Chittoor, Andhra Pradesh, India. Email: [email protected], [email protected] ABSTRACT Abrasive water jet machining (AWJM) is a non-conventional machining process which has been used in industry applications. The high velocity stream of abrasive particles impinged on the work material is removed by erosion. In this process used abrasive particles such as sand (SiO2), beads of glass, aluminum oxide (Al O ) and silicon carbide (sic) are generally used. The present work has 23 been carried out to know the effect of input process parameters such as abrasive pressure, traverse speed, abrasive flow rate and stand of distance (SOD) on material removal rate (MRR) and surface roughness (SR) by using full factorial orthogonal design of experiments. Finally, the optimization of process parameters was carried out by using analytical hierarchy process(AHP). Keywords: AWJM, AHP, MRR, SR. 1. INTRODUCTION 1.1 Introduction: Abrasive water jetmachines on track to operate in the early 1970s for cuttingwood and plastic material andcut byabrasive water jet machine was first commercialized in the late 1980s as the revolutionary innovation in the area of un- conventional processing technologies. Fig 1.1 Schematic diagram of AWJM. ISBN: 978-0-13-601970-1 139

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) In the early1980s,AWJ machiningwasdeliberatedasan unrealistic application. Today, state-of the art abrasive jet technology has grown-up into a full-scale production process withprecise,reliableresults. Working principle ofAWJM is a highly pressurized water jet accelerates the air driven abrasive particles to from a very high energy abrasive water jet which strikes the work-piece and removes the material. Abrasive water jet is widely used in the machining of materials such as titanium, steel, brass, aluminum, stone, Inconel, any kind of glass and composites, concrete ceramics and even diamonds the minimal stresses on the work piece.AWJ finds its use for machining operations such as cutting milling drilling, turning, shot-peening, threading, hybrid machining 1.2 Literature Survey Hariprasad T, G. Dharmalingam, and P. Praveen Raj. [1] it was concluded that an alkali-treated banana-coir epoxy hybrid composite has greater tensile strength and impact strength than an untreated banana- coir epoxy hybrid composite.However, the alkali-treated banana-coir epoxy hybrid composite has less flexural strength than the untreated banana-coir epoxy hybrid composite. The properties were improved by the alkali treatment process. In this study, the fiber weight fraction of % has been used. This could be increased further to establish the optimum filler volume fraction depending on the application. The simulated stress distribution for the mechanical properties of the treated and untreated banana-coir hybrid samples, under different loading conditions, was obtained. K.S. JaiAultrin, M. DevAnand.[2] it was observed that from the experimental work they have concluded that effects of pressure, abrasive flow rate, orifice diameter, focusing nozzle diameter and standoff distance on material removal rate is more. From the experimental results an empirical model for the prediction of material removal rate in abrasive waterjet cutting process of copper iron alloy has been developed using regression analysis. Akkurt, Adnan.[3] Surface roughness of carbides produced by abrasive water jet machine. In this article the work aims to evaluate the effect of jet of pressure, abrasive flow rate and work feed rate on smoothness of the surface produced by abrasive water jet machining of carbide of grade P25 is a very hard and cannot be machined by conventional machining techniques cutting was performed on a water jet machine model WJ4080. The abrasive used in investigations that with an increase in jet pressure the surface becomes smoother due to the higher kinetic energy of the abrasive. But the surface near the jet entrance is smoother and the surface gradually becomes rougher downwards and is the roughest near the jet exit. The increase in abrasive flow rate also makes the surface smoother which is due to the availability of a higher number of cutting edges per unit area per unit time. Feed rate did not show anysignificance influences on the machined surface, but it was found that surface roughness increases drastically near the jet entrances. Finally, they have concluded that A jet Pressure and Abrasive Flow rate are the Most influencing parameter on the surface roughness, the work feed rate is less insignificant as compared to jet pressure and abrasive flow rate. Jiuan-Hung Kea, Feng-CheTsaia, and Jung-Chou Hungb. [4]Characteristics Studyof Flexible Magnetic abrasive inAbrasive jet machining”. In the present research, they had presented a novel hybrid method that self- mademagnetic abrasivewith elasticitywas utilized to investigatemachining characteristics in abrasive jet machining. According to Taguchi method and experimental results, flexible magnetic abrasive is adopted in abrasive jet machining not only restrains the abrasive jet direction to enhance move uniform main processing area and material removal rate but also has the slip-scratch effect to obtain better surface roughness than traditional machining. With the help of flexible magnetic abrasive, we can obtain better surface roughness than traditional machining, and it (flexible magnetic abrasive) is used for restrains the abrasive jet direction for more uniform processing area 140 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) and material removal rate. The magnetic field is the main factor for surface roughness (Ra), material removal rate (MRR). M.A Azmir and A.K Khan. [5] It was found that the type of abrasive materials, hydraulic pressure, standoff distanceand traverse rate werethe significant control factors and the cutting orientation was the insignificant control factor in controlling the Ra. For noise factors effect of parameters on Different From of E-Glass fibers namely woven (plain with the help of Taguchi method on Abrasive Water jet machined glass/epoxy laminate within the limit of this study. Verification of the improvement in the quality characteristics has been made through confirmation test with respect to the chosen reference parameter setting. It was confirmed that the determined optimum combination ofAWJM parameters satisfy the real need for machining of glass fiber reinforced epoxy composites in practice. Conclusion derive from this article is Abrasive types is the most significant controlling factor on surface roughness (Ra), hydraulic pressure and traverse rate are the equally significant factor while Standoff distance, abrasive material flow rate and cutting orientation are the insignificant factor. 2. EXPERIMENTATION 2.1 Material Selection: The work piece is used to do this experiment TI-6Al-4V used to machining theprocess. Chemical composition of the TI-6AL-4V,table 2.1shows the chemical composition of TI-6AL-4V. Table 2.1. Chemical composition of Titanium alloy-TI-6AL-4V ELEMENTS CONTENT (%) Al 6.321 V 3.714 C 0.006 Fe 0.091 Si 0.010 Mn 0.0053 Cr 0.021 Sn 0.001 Ti 90 Selection ofmaterial based on theproperties and applications. It is high strength, excellent corrosion resistance, light weight and fire resistance material. Due to its higher temperature withstanding capacity, Titanium alloy is being widely used in high performance automotive parts, marine, medical, aircraft- industries. It can be used to machine titanium alloy with complex shape for enhancing the machinability. Owing to its ability of producing micro level of material removal, micro machining can produce better surface finish than conventional machining. 2.2 Selection of input process parameters: The importance of the process parameters in theAWJM process,Abrasive water, Traverse speed,Abrasive flow rate, standoff distance has been selected as the input process parameters for the present study. The titanium plate of 5mm thickness has been made to cut for producing rectangular specimens. The trail experiments have to be conducted in smaller, medium, larger level rating of energy;Abrasive pressure has been selected as 300Mpa, 325Mpa and 350Mpa with traverse speed of 80mm/min, 100mm/min and 120mm/min. The abrasive flow rate has been chosen as 300gm/min, 350gm/min and 400gm/min. The standoff distance has been selected as 2.5mm, 2.75mm and 3mm. 2.3 Experimental setup: Experimentation is done on AWJM center manufacture by M/s OMAX corporation, USA is used for this work. TheAWJM shown in fig 2.1. The equipment details given table 2.2. ISBN: 978-0-13-601970-1 141

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Fig 2.1 Abrasive water jet machine. Table2.2 AWJM details Machine used OMAX 2626 precision jet machining center Po we r 220Kw,50Hz Min Water jet Pressure 138Mpa Max Water jet Pressure 413Mpa CNC work Table Size 116mm*787 mm X-Y cutting travel of 737mm*660mm Work Envelope 0 .76mm Focusing Nozzle Diameter 0 .35mm Orifice Diameter Machining parameters for experimentation is considering with of three levels of process parameters for the experiment is used given table 2.3. Table2.3. variable process parameters at different levels S.No Variable process parameters Low level Medium level High level A Abrasive Water Pressure (MPa) 300 325 350 B 80 100 120 C Traverse Speed (mm/min) 300 350 400 D Abrasive flow rate (gm/min) 2.5 2.75 3 Standoff distance (mm) 2.4 Design of experiments: The DOE L27 orthogonal array (OA) design of experiments is used to doing the machining on work piece. As shown in fig2.2. 142 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Fig 2.2. Machining pieces of Ti- 6 Al- 4V In the present experimental studyAbrasive water pressure, Traverse speed,Abrasive flow rate and standoff distance have been considered as process variables. 2.5 Calculation of MRR and SR: 2.5.1 Material removal rate: MRRis calculated bymeasuring the time of machining. Material removal rate can be calculated using this formula. MRR = volume/time = l*b*h/t mm3/min Here l=length of the specimen b=breadth of the specimen h=height of the specimen t=machining time 2.5.2 Surface roughness: It is quality of the machining surface related to the geometric irregularities of the surface. It is measured by TALYSURF as shown in fig 2.3. Fig 2.3 Talysurf surface roughness measuring instrument ISBN: 978-0-13-601970-1 143

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) 3. METHODLOGY 3.1 Analytical hierarchy process: AHP is multiple-criteria technique which is based on the need of complex problems branchinginto hierarchical structure of specific elements that are objective (goal), criteria (sub-criteria) and alternatives. AHP method applications can be explained in four simple steps: 1. It is developing a hierarchical problem model for which we should make decision. The objective (goal) is located at the top of the hierarchy, criteria and sub-criteria are put at the lower levels and alternatives are at the bottom model. 2. At each level of hierarchy, comparison in pairs of structure elements is done, where the preference of the decision maker is expressed using safety scale of relative importance levels. The scale contains 5 levels and 4 sub-levels, which verbally describe the intensity, with corresponding numeric values in the range of 1 to 9 (table.3.1). Table 3.1 safety scale Importance Definition Explanation Both elements have equal contribution in the 1 Equally important. objective. Moderate advantage of the one element compared 3 Moderately important. to the other. Strong favoring of one element compared to the 5 Strong important. other. One element is strongly favored and has 7 Very strong and proven importance. domination in practice, compared to the other element. 9 Extreme important. One element is favored in comparison with the other, based on strongly proved evidences and 2, 4, 6, 8 Inter-values facts. This is useful for certain comparison. 3. The assessments of the relative importance to the element from each level of the hierarchical structure could be applied for calculation of the local criteria, sub-criteria and alternatives.After that, the overall priorities of the alternatives are synthesized. The total priority of each alternative is calculated with the sum of local priorities that are weighted with weights of elements from higher levels. 4. Sensitivity analysis is conducted. 3.2 TAGUCHI METHOD: Beginning in the mid-1920s, Sir R.A. Fisher presented the Design of Experiments (DOE) strategy in ancient agricultural sciences as to decide the trial conditions or treatments keeping in mind the end goal to create the best yield [2]. Fisher's first thought was to lay out all blends of the included parameters in theexploratory study and changed every one of the variables all the while in a full factorial outline. The point of trial outline is to think about the impacts of collaboration between the variables which have generally been overlooked in the trial-and error strategy. The customary Design of experimentation is a measurable way to deal with examination of a framework or procedure in which it permits a judgment on the hugeness of information variables to the yield, either all alone impacts, the communications between the sources of information, or not in any manner. Researchers which were done on the optimization by means of conventional Design of Experimentation technique can be partitioned into full factorial design and fractional factorial design [3]. 144 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) A full factorial design will recognize all the conceivable blends for a given arrangement of variables. In perspective of the way that most modern experiments demand a significant many number of factors, a full factorial design brings about executing out a large number of experiments. In any case, it is unreasonable and tedious [4]. Accordingly, fractional factorial outline is proposed by selecting a set number of experiments from every one of the potential outcomes that create the most data with a specific end goal to decrease the quantity of experiments to a viable level. Though fractional factorial configuration is notable, it is excessively mind boggling and there are no broad rules for its application or the investigation of the outcomes got by performing out the experiments. Considering these challenges, Dr. Genichi Taguchi has built up another trial technique, Taguchi strategy which uses an altered and institutionalized type of Design of Experiments in the late 1940s. The use of Taguchi strategy has pulled in more consideration in the writing for as long as 20 years and these days the Taguchi technique has been broadlyconnected to different fields, for example, fabricating framework, mechanical segment plan, and process enhancement. The prominence of Taguchi strategy is because of its common sense in outlining excellent systems that give highly diminished fluctuation to tries different things with an ideal setting of procedure control parameters. Standalone Taguchi technique is receiving the Taguchi's components without any help from the exploratory planning stage to the last improvement process. The parameter configuration of the Taguchi technique uses orthogonal array (OA). 3.3 Mathematical model: There are n elements which are compared, the comparison results create matrix from Awith dimension If n*m A= A= The elements of matrix or ratio between compared criteria are expressed by the formula: Considering the first axiom for reciprocal we have: The next step is to obtain a normalized matrix B= . The elements of the matrix B are calculated as: The calculation of the weights i.e. Eigen vector w= from normalized matrix B is performed bycalculating the arithmetic mean for each row of the matrix according to the formula: 3.4 Consistency of the comparison matrix: Consistencyimplies coherent judgment on the part of the decision maker regarding the pair wise comparisons. Mathematically, we say that comparison matrix Ais consistent if for all i, j and k. ISBN: 978-0-13-601970-1 145

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) To determine whether or not a level of consistency is \"reasonable\", we need to develop a quantifiable measure for the comparison matrixA. when matrixAis perfectly consistent then produces a normalized matrix C in which all the columns are identical-that is It then follows that the original comparison matrix Acan be determined from C by dividing the elements of column I by . We thus have: The resulting ratio comparison are depicted in In order to obtain the term n*w the matrix is multiplied by w on the right. More compactly, given that w is the column vector of the relative weights i 1,2,…..,n,Ais consistent if: Aw = nw For the case where A is not consistent, the relative weights is approximated by the average of the n elements of row I in the normalized matrix C. letting w be the computed average vector, it can be shown that Aw w, n In this case, the closer is to n, the more consistent is the comparison matrix A. based on the observation, andAHP compute the consistency ratio as: CR Where CI =consistency index RI=random index 146 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) CI is calculated as: CI Attributes 3 Table 3.1 random consistency index 8 9 10 RI 0.52 1.4 1.45 1.49 45 67 0.89 1.11 1.25 1.35 If CR 1the level of inconsistency is acceptable. Otherwise, the inconsistency is high and decision maker may need to reestimate the elements ofA to realize better consistency. This means that the value of can be determined by first computing the column vectorAw and then summing its elements. 4. RESULTS 4.1 Results: A. P = abrasive water pressure (MPa) T. P= traverse rate (mm/min) A.F. R = abrasive flow rate (gm/min) SOD = standoff distance (mm) MRR = material removal rate (mm3/min) SR = surface roughness (µm) ISBN: 978-0-13-601970-1 147

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Table 4.1 Design of Experiment data with outcomes S. No A.P T.P A.F.R SOD TIME MR R SR 2.5 2.27 25.69 5.56 1 300 80 300 2.5 2.26 25.81 5.92 2.5 2.24 26.04 6.2 2 300 80 300 2.75 1.98 29.46 6.161 2.75 1.97 29.61 6.27 3 300 80 300 2.75 1.97 29.61 6.24 3 1.78 32.77 6.30 4 300 100 350 3 1.76 33.14 6.45 3 1.75 33.33 6.61 5 300 100 350 3 2.24 26.04 6.29 3 2.23 26.15 6.30 6 300 100 350 3 2.21 26.39 6.49 2.5 1.98 29.46 5.77 7 300 120 400 2.5 1.97 29.61 5.85 2.5 1.96 29.76 6.53 8 300 120 400 2.75 1.39 41.96 6.20 2.75 1.39 41.96 6.40 9 300 120 400 2.75 1.40 41.66 6.40 2.75 2.65 22.01 6.12 10 325 80 350 2.75 2.65 22.01 6.25 2.75 2.64 22.09 6.30 11 325 80 350 3 1.98 29.46 5.40 3 1.98 29.48 5.52 12 325 80 350 3 1.95 29.91 5.59 2.5 1.4 41.67 6.17 13 325 100 400 2.5 1.4 41.67 6.30 2.5 1.39 41.96 6.72 14 325 100 400 15 325 100 400 16 325 120 300 17 325 120 300 18 325 120 300 19 350 80 400 20 350 80 400 21 350 80 400 22 350 100 300 23 350 100 300 24 350 100 300 25 350 120 350 26 350 120 350 27 350 120 350 Acollection of data is accomplished after cutting of titanium alloy (TI-6AL-4V) material byAWJM. Based on machining time the material removal rate has beenobserved. These collected data was to analyze using statistical software minitab17. In this software, Taguchi method has been considered for analysis of collected values of response parameter. Table 4.2 Pair wise comparison matrix A.P T.S A.F SOD A.P 1 1/7 1/6 1/5 T.S 7 1 2 3 A.F 6 1/2 1 3 SOD 5 1/3 1/3 1 Table 4.3 Optimization using Analytical Hierarchy Process (AHP): S. N o A.P T .S A .F.R S OD M RR SR 1 325 120 300 2.75 41.96 6.20 2 300 100 350 2.5 29.46 6.161 3 350 80 400 2.75 22.01 6.120 By using this technique, the orthogonal arrayoptimizing process parameters based on the material removal rate and surface roughness. If material removal rate increases surface roughness decreases. Various combination of input parameters gives better removal rate and surface roughness. 148 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) 4.2 SEM ANALYSIS: A scanning electron microscope is a type of electron microscope that produces images of a sample by scanning the surface with a focused beam of electrons. The electrons interact with atoms in the sample, producing various signals that contain information about the surface topography and composition of the sample. Fig 4.1 Scanning Electron Microscope By using the SEM Analysis, the surface texture andthe roughness of texture were found. This analysis is used to find surface texture is increased or decreased. In this work surface roughness is increased from 6.12 to 6.20. The diagram shown below. Fig 4.2 Images of surface roughness ISBN: 978-0-13-601970-1 149

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) 5. CONCLUSION 5.1 Conclusion In this paper four process parameters such as abrasive water pressure, traverse speed, abrasive flow rate and standoff distance are used to analyze different values of material removal rate and surface roughness. The analytical hierarchy process (AHP) was used for optimization. Following conclusions were made. 1. By increasing abrasive water pressure and traverse speed, material removal rate (MRR) is increased.Also, it can also be seen that material removal rate is decreases with increases in standoff distance. 2. By increasing traverse speed and standoff distance parameter surface roughness is increased and also can be seen that surface roughness with decrease of abrasive flow rate. REFERENCES 1. Hariprasad T, G. Dharmalingam and P.Praveen Raj. \" Study of mechanical properties of banan-coir hybrid composite using experimental and fem techniques\". Journal of Mechanical Engineering and Sciences 4 (2013), 518-531. 2. K.S. Jai Aultrin, M. Dev Anand. \"Optimization of Machining Parameters in AWJM Process for a Copper Iron Alloy Using RSM and Regression Analysis\". International Journal of Emerging Engineering Research and Technology Volume 2, Issue 5, August 2014, PP 19-34 ISSN 2349-4395 (Print) & ISSN 2349-4409. 3. Akkurt, Adnan. \"The effect of cutting process on surface microstructure and hardness of pure and Al 6061 aluminum alloy. \"Engineering Science and Technology, an International Journal (2015). 4. Jiuan-Hung Kea, Feng-CheTsaia, and Jung-Chou Hungb.SOM/SEM based characterization of internal delamination's of CFRP samples machined by AWJM. ? The Manufacturing Engineering Society International Conference, MESIC. Procedia Engineering 132 (2015) 693 - 700. 5. M.AAzmir and A.K Khan?Performance Analysis of Process Parameters on Machining Titanium (Ti-6Al-4V) Alloy Using Abrasive Water Jet Machining Process. 7th HPC 2016 - CIRP Conference on High Performance Cutting.Procedia CIRP 46 (2016) 139 - 142. 150 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Design and StaticAnalysis of Prosthetic Foot Vijay Kumar Pingili1, Venkata Narayana Yenugula2, Ravinder Reddy Visaka3 1,2,3Sreenidhi Institute of Science and Technology, Yamnampet, Ghatkesar, Telangana State, PIN-501301, INDIA Email: [email protected], [email protected], [email protected] ABSTRACT In this study, a statistical analysis of the artificial foot structure was performed using a finite element method. The artificial foot design consists of a Base plate, Top plate and s plate. Solid works software is used for designing. The prosthetic foot analysis was performed using Ansys workbench. Static analysis is performed with a load capacity of 750 N representing the amount of power the base plate supports at the edges. In the original design, the maximum pressure that occurs during static loading is 353.96 MPa, which exceeds the production capacity of aluminum 6061 of 276 MPa. The type of reinforcement that provides the least pressure is selected in the transformation of the prosthetic foot design to be used on the robotic prosthetics ankle. Equal strength of the final artificial foot design is calculated to be used in the control system. Keywords: Prosthetic Foot, Static Analysis, Finite element method. INTRODUCTION In recent years, disability has become a problem because of an accident or disease.Approximately 10% of the world's population experience some form of disability[1]. Despitethe growing number ofpeople with disabilities worldwide, there has been little attention given to various causes in testing, management and prevention. Therefore, a prosthetic foot is important for those who have amputated limbs to perform daily activities such as walking, jogging, jogging, cycling and other activities [2]. The concept of artificial foot design is increasingly varied, for example SolidAnkle Cushion Heel (SACH), SingleAxis (SA), and Energy Storage and Release (ESAR) artificial [3]. SACH feet are the most common and basic of implanted implanted feet [4] with no moving parts and internal keel [5]. One-axis feet are artificial pads for feet that have fewer cosmetics but are heavier than SACH. However, the feet of the implants mentioned are expensive. Therefore, Research Groups are trying to develop an inexpensive prosthetic foot that can be used by amputators. The developmental foot control system developed for the previous study [6]. Therefore, this paper discusses the construction of an artificial foot as a complement to the previous work. Patients Demographic Data The age of amputation ranges from less than 20 to over 70. The most common age group for amputation was 21 - 30 years and 31 - 40 years old was placed in second place. There are more male amputations than women with amputations. ISBN: 978-0-13-601970-1 151

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Prevalence of amputation by age. Amputations due to trauma were most common in the 21-30 years age group, whereas due to vascular causes were most among those over 50 years of age. Site of Amputation Lower limb amputations are much more common than the upper limb amputations, the former accounting for 94.8% of all amputations and the latter only for 5.2%. Prevalence of amputation by site. METHODS In developing an artificial foot for amputees, the concept of energy retention and recovery (ESAR) in the artificial limb was used as a reference. Byusing the ESAR keel in artificial insemination, the biomechanical energy regeneration principle can be applied to the current work to improve the strength of amputees. In general, the foot prosthesis has three main components: top plate, s-plate, base plate as shown in Figure 1. The longitudinal length of the prosthesis is adjusted to Indian anthropometry. However, the thickness of the components affects the pressure of the implant when loading. Therefore, the thickness of the implant was made in the present work in view of the pressure of the implant site and the strength of its equipment. When the pressure is greater than the material strength, a change in its size or structure is made. 152 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Figure 1. Basic Model Figure 1(a). SolidWorks Model For modelling, SOLIDWORKS software was hired. The material used in all parts of the implant foot was aluminum 6061 - T6 to reduce the cost of the implant. The mechanical features of these summaries are summarized in Table 1. Prior to the pressure analysis byANSYS Workbench with a fixed structure, interactions between these components were performed.All plates were connected via bonded connections. Moreover, the interaction between the plates was measured by the contrasting contacts. TABLE 1. Material Properties of Aluminum 6061 - T6 [7] Density Yield strength Ultimate tensile strength Tensile modulus Poisson’s ratio 2.7 g/cm3 276 MPa 310 MPa 68.9 GPa 0.33 The next step in preparing a stress analysis is to define the state of the simulation parameters. The ankle was modelled as a constant support as shown in Figure 2. Then, the power provided to the input depends on the upper Ground Reaction Force (GRF) in the motion function. The Indonesian GRF limit, i.e., 750 N occurs in the flat foot section with the Centre of Pressure (CoP) shown in Figure 2. The meshing was subsequently performed with 112,627 items. The number of nodes was 180,481 and element skewness was 0.25. To confirm the result of the pressure analysis, a combination test was performed until the remaining error was less than 0.1%. FIGURE 2. Loading force and support in simulation RESULTS AND DISCUSSIONS According to the simulation usingANSYS, the highest pressing value is 353.96 MPa and is available in the base plate and s-plate, as presented in Figure 3. This value exceeds the production capacity of aluminum 6061- T6, i.e., 276 MPa. Therefore, the initial design of the prosthetic foot cannot withstand the load under normal conditions. Therefore, structural coercion was required to reduce stress due to the ability to respond to the floor. ISBN: 978-0-13-601970-1 153

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) FIGURE 3. Result of Basic model The purpose of the constraint was to reduce the stress that occurs on the large plate and on the s-plate parts. There were two types of building reinforcement considered for design modification. Since reinforcement should not significantly increase the weight of the implant, reinforcement is only done at the most traumatized points. There are three other ways to improve artificial limb development.Alternatively, two notches have been added to the rear part of the s-plate as shown in Figure 4a.After pressure analysis, the maximum pressure of the prosthesis was 260 MPa (see Figure 4b) slightly lower above the yield strength of aluminum 6061 - T6. However, advances in artificial construction are still being tried due to the low security factor. (a) (b) FIGURE 4. The first alternative in the structural enforcement: (a) Two notched was added to rear part of s-plate, and (b) The result of stress analysis Another second way to reduce the pressure on the installation site is to install an additional plate on the curved part of the large plate as described in Figure 5a. The thickness of the reinforcing plate was 6 mm. After that, imitate it was also performed to obtain high pressure suppressed by the prosthesis.As shown in Figure 5b, size stress occurred near the reinforcement plate at a rate of 242.2 MPa. Although high pressure was already present is less than the yield strength of aluminum 6061, further improvements have tried to intensify the fatigue capacity with less than yield strength. 154 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) (a) (b) FIGURE 5. The second alternative in the structural enforcement: (a) Areinforcement plate in the bended section of main plate, and (b) The result of stress analysis The effect of building reinforcement on the first and second was as promising as they could be severe prosthesis stress. The combination of the first and second methods raises the view of the third other.Alternatively, two reinforcing plates with a diameter of 3 mm are raised on the s-plate again large plate, as shown in Figure 6a. In addition, major changes in geometry in the prosthesis have been removed to avoid stress concentration.After performing a pressure analysis, the maximum pressure on the prosthesis can be reduced remarkably.The maximum pressure obtained in the simulation was 185.57 MPa in the area shown in the Figure 6b. Since high pressure occurred in the prosthesis it was very small compared to the yield potential ofaluminum 6061 - T6, another third option was chosen as the final design of the artificial foot. (a) (b) FIGURE 6. The third alternative in the structural enforcement: (a) Two reinforcement plate on the s-plate and main plate, and (b) The result of stress analysis In addition to stress analysis, the equivalent stiffness of the prosthesis was also tested. Equal value durability was found in the combination between loading forces and the vertical deformation. In this study, equal stiffness is achieved by using numerical simulations in theANSYS software. ESAR keel file for the implant foot was loaded with several power values and the ESAR keel was lowered. Linear regression of loading forces structure - power loading (see Figure 7) used to obtain equal value firmness. The equivalent stiffness of the ESAR artificial limbs is then used to calculate the potential control system ankle prosthesis. FIGURE 7. The equivalent stiffness curve which is equal to 72.58 N/mm CONCLUSIONS In this study, an artificial foot was developed to match the anthropometry. The prosthesis was modelled as three main parts, namely- top plate, s-plate, base plate. Pressure analysis was performed to assess the maximum pressure occurring in the prosthesis while loading the maximum turning force down to 750 N.Also, two reinforcing plates are placed on a large plate and on a s-plate to reduce the maximum stress that has occurred. In the final design, the maximum pressure was 185.57 MPa much lower than the production capacity of aluminum 6061 - T6, i.e., 276 MPa. ISBN: 978-0-13-601970-1 155

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) REFERENCES 1. Myer Kutz. Biomedical Engineering and Design Handbook, Volume 2. DESIGN OF ARTIFICIAL LIMBS FOR LOWER EXTREMITYAMPUTEES, Chapter 21 (The McGraw-Hill Companies, Inc., 2009, 2003). 2. Design and manufacturing of prosthetic feet for children as multidisciplinary project for mechanical engineering students by Bourgain, M., Provot, T., Bonnet, X. in International Journal Engineering Education,2020. 3. F Ferryanto et al, \"Design and Manufacturing of a Low-cost Robotic Ankle for Indonesian Trans Tibial Amputees\", 11th Australasian Biomechanics Conference 2018. 4. R. Versluys, P. Beyl, M.V. Damme, A. Desomer, R.V. Ham and D. Lefeber, Prosthetic feet: State-of-the-art review and the importance of mimicking human ankle-foot biomechanics, Disability and Rehabilitation: Assistive Technology 4, 65-75 (2009). 5. Burgess E, Hittenberger DA, Forsgren SM, Lindh D: Seattle Prosthetic Foot-design for active sports: preliminary studies. Orthotics Prosthet 37:X-31, 1983. 156 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Procedure for Design and Development of Automated CAD Model Using Solid WorksAPI Jayakiran Reddy Esanakula1, Bill Christopher Sirigiri2 1Assistant Professor, 2PG Student 1,2Department of Mechanical Engineering, Sreenidhi Institute of Science and Technology, Hyderabad, Telangana, India. ABSTRACT The process of making a 3D representation of a part has been improved thanks to the usage of Computer-Aided Design (CAD) software. However, in this current world of automation, there are still just a few research articles on the subject of automation for the development of 3D models in CAD software. Many manufacturing industries produce similar components, which requires the designer to model the same products over and over again, which wastes time, causes operator fatigue and reduces the designer's productivity. Additionally, hiring a professional CAD designer costs a lot of money and experience. As a result, CAD model automation has been developed to address this issue. This paper's major goal is to demonstrate the design process for building an automated CAD model. An Application User Interface (API) included within the SolidWorks CAD software is utilized to create an automated CAD model in this paper. Microsoft's Visual Basic programming language can be used to create the SolidWorks API. Visual Basic is written in macros, which makes it simple to understand. Many processes that take a long time can be automated with the help of SolidWorks API and macros. This will save a lot of time and money compared to the traditional technique of completing a design. Keywords: Design Automation, Automated CAD modeling, SolidWorks Application Programming Interface (API), macros, Visual Basic. 1. INTRODUCTION 1.1 Knowledge Based Engineering: KBE is an engineering method that illustrate a combination ofArtificial Intelligence (AI) techniques and CAD technologies, giving advantage to customized or alternative design automation solutions [5]. With the help of evolution of the Knowledge Based Systems (KBS), the designing time is further reduced. Moreover, KBS has become the practical method for visualizing and analyzing the design process with the help of simulation tools. Knowledge Based Engineering is one of the technologybased applications of KBS pertaining to the domains of design, manufacturing and production. KBE is indeed used for mass customization as it is one of the best technologies available for rapid design. The ultimate aim of the KBE system should be able to capture the best design practices and engineering expertise into a corporate knowledge base [5]. 1.2 CAD-Modeling in SolidWorks: CAD Modelling is a very time consuming and tedious process which every industry tries to minimize cost as far as possible. Generally, conventional wayof designing for the industries is to hire a designer and create a design based on their requirements. This process is high time and money consuming process. In order to create a new design conventional process is efficient but for old design which need some modification in dimension, conventional process will not be effective. Here we are aiming for the specific part design which can be easily modeled, ISBN: 978-0-13-601970-1 157

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) assembled and drafted to the industry standards requirements with just by entering the corresponding values in a custom-made user interface which can be quickly accessed with the help of macro within the Solidworks. The main motive of this paper is to create a design template for every design which need a small modification in their values. Solidworks has a feature called API (Application Program Interface). SOLIDWORKS Application Programming Interface (API) is simply libraries which are exposing the public functions to be used by 3rd party software for invoking the SOLIDWORKS macro commands. Programmers can make use of this functionality of SolidWorks API in order to automize certain design process and also modify the different modules whenever needed. SolidWorksAPI functionality can be used in almost all design needs in CAD with some exceptions and limitations [2]. 1.3 Design Automation: Design automation can be explained as the process of using predefined set of codes which can be further used to run automatic design steps which generally takes a lot of time in actual time manual design process. The process of building such applications can be made easier with the help of traditional CAD methodology. Through this CAD techniques, previous changes, conditions are preserved in server cloud or local machines so that it can be reprocessed again when required [2]. In general terms a design automation is used to automate conventional manual design process with the help of computer or by withdrawing knowledge from knowledge base. This knowledge can be of standard design procedure, past experience, manuals, charts, etc. In this design knowledge, past experience, condition is stored in computer database or programmed so that it can be reuse again whenever needed [8]. 1.4 Application Programming Interface: API (Application Programming Interface) is software development technique for integrating two different software. With the assistance of an API we can develop custom distinct windows executable files, for API programming we can use VB.NET, C#, Visual C++ languages [8]. In this paper Visual Basic or VB is chosen which needs onlyfundamental programming knowledge. Macro feature alongside withAPIflexibility is available in almost all CAD softwares. In this project SolidWorks 2020 has been used because of its usability and transition over various software packages. SolidWorks 2020 has an integral VB Interface [2]. The SolidWorksApplication Programming Interface, orAPI, is used to automate and customize the SolidWorks software. The SolidWorks Application Programming Interface (API) is a COM programming interface to the SOLIDWORKS software. The API comprise hundreds of functions that can call from Visual Basic (VB), Visual Basic for Applications (VBA), VB.Net, C++, C#, or SolidWorks macro files. These functions provide the programmer with direct access to the SolidWorks functionality, which suggests that you can automate SolidWorks to perform specific functions or tasks [4]. 1.5 Visual Basic: Visual Basic is the key tool in supporting this project and furthermore, Visual Basics is the simplest and best programming tool in building of macros. For this purpose, VB has become a very convenient tool for generating different programming codes for numerous applications. With the help ofActiveX dynamic link libraries or DLL engineers can integrate VB with different windows applications and can also make new UI [2]. With the support of VBA (Visual Basic for Application) and API (Application Programming Interface), the CAD software SolidWorks provide the modeling automation. Moreover, a custom-made GUI can also be developed. Visual Basic (VB) is one of the software of Microsoft helps to generate the macro code which is functionally valuable and helpful for executing the rehashed activities.A macro can store any action done on SolidWorks screen and be able to reproduce the same later whenever needed [3]. 158 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) 1.6 Macros: Macro stands for rule or pattern that defines how a certain input sequence should be mapped to an output sequence according to determined procedure [4]. This macro which is used for automated modelling is coded in Visual Basic (VB) Script [6]. Using the specified command of Macro Operations in SolidWorks, a program of for the selection of the material could be generated in Visual Basic Language [7]. Sometimes, capturing the macro in SolidWorks helps to acquire the code for the following parameters, sometimes the algorithm has to be based on self-developed algorithm [1]. 2. LITERATURE REVIEW: In this section, the literature review on the design automation of the specified part design is presented. Dwaipayan Roy Chowdhury et al. [1] has presented a methodology for design automation of a cube using SolidWorks and VB.net. Macro codes was used for automating the design procedure of cube.A cube of desired dimensions, material, and color can be obtained with the help SolidWorks API (Application for Programming Interface). Balachandar Krishnamurty et al. [2] has developed atool for the design automation of piston and connecting rod by using SolidWorks API with the assistance of macro codes. In order to do some modifications in an old design byusing conventional method will take a lot of time and money. With the help of the custom made user interface the piston and connecting rod can be modelled and assembled easily. This will be saving a lot of time and money and eliminates the process of hiring a design engineer. Jayakiran Reddy et al. [3]Adesign approach for the spur gear is developed with the help of knowledge based system byusing SolidWorks API and macro codes. knowledge base systems are developed which consists of Graphical User Interface, Inference Engine, and Knowledge Base. The Graphical User Interface consists of the data required for the user. The knowledge base gets knowledge form design experts and Standardisation of the components. So now the client or user can get the desired component by reducing the time. Andrijana Bocevska et al. [4] A CAD system has been built for the application design of car rim.ACAD system has an interface which makes the user to interact with the help of macros. It will help the engineers to present a completely new level of possibilities for faster modelling of superior products with less error. Jayakiran Reddy et al. [5] carried the development of CAD model of Universal coupling by automatic generation using SolidWorks API frame work. In order to reduce the modelling time of the existing part with small changes in its design a knowledge base systems are created. By using knowledge base systems a parametric modelling of the part can be regenerated taking very less time when compared to human. Joshi et al. [6] presented the automation of a CAD modelling of mechanical components. The design automation achieves increase in productivity, robustness and qualityalong with reduction in time and labour costs. The design automation of the cotter joint is created by saving time and achieving superior performance than conventional modelling. The calculations are made in the backend of the software to make a safe design and eliminating the modelling errors. Rui Lyu et al. [7] has done the automation of the simulation of vehicle chassis frame structure using SolidWorks SimulationApplication Programming Interface. In SolidWorks the program for selection of materials is generated in Visual Basic Language and the properties of the material can be rewritten in directly by using macro codes. Abhishek et al. [8] has generated the design and design automation ofwinding machine using SolidWorksApplication User Interface.The winding machine consists of a large number of components. Therefore by using design automation the CAD model is generated within two hours. It can save 80 percent of the time required for overall design process and save up to 25 percent in overall cost. ISBN: 978-0-13-601970-1 159

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) 3. METHODOLOGY: At present, the majority of the commercial CAD software makers are looking for developing the software in such a way that the software has to produce or reproduce the part model of any commercial component on the basis of the text input data regarding to the model along with the traditional approaches. For example, to draw a line on the screen need not require to give the input data such as starting and ending points while using the mouse, they can also be specified in the form of text by entering the 3-dimensional coordinates of the starting and ending points with the help of keyboard. Moreover, these input texts can also be given through computer program. Therefore, by using the present CAD software the automation required for any design system can be achieved with the help of computer program. But only some specific programming languages like VBA can be used to program. One of the easiest and powerful programming language is VBA. The programming editor for the commercial CAD software like SolidWorks uses VBA. So, the SolidWorks software has been chosen for developing the present KBS for developing CAD modeling. 3.1 Developing a generic 3D model: Firstly, A standard model of specific design is generated in CAD manually by keeping all the features and constraints of the model while its macro file is being recorded. The equations of the generating CAD model should be established between the related parameters of the given design. The recorded macro file should be edited for parameterizing and incorporating it into VB code for SolidWorks API. Later, the same code will be used to make 3D CAD model for the given design specifications. 3.2 Creating Graphical User Interface: With the help of the VB language, SolidWorks allows the user to build and develop their own GUI. The GUI for the input data was developed using standard VB tools like textbox, combo box, button etc. The GUI was developed in such a manner that it should be able to gather all the needed data from the user and pass on the same to the developed logical algorithm for design calculation. All the calculations for the design are done only after clicking submit button. If the minimum essential input data required for the design calculations is not obtainable from the user then the GUI will not allow procedure to move further for design calculations. 3.4 Program development for design calculations As previously discussed, the developed KBS can assist logical algorithms for design calculations. This characteristic property helps the system in computing the design calculations. Design calculations done manually are verytedious and time consuming to calculate the acceptable dimensions by using standard empirical formulas. In order to get rid of this difficulty, a computer program is developed for design calculations and establish the geometrical dimensions of the required design. The output data obtained from this program will be directed to the SolidWorks software to create the corresponding 3D CAD model as per the given geometrical dimensions which are calculated. Hence, the design and modelling of the work is automated. 4. CONCLUSION Hence the automation of part design will be very helpful for the design engineer who are working in R&D. It will also increase the productivity of the company. The recruitment for the design professional will not be required which will reduce the amount of cost. The time will be drasticallysaved with this method when compared to conventional design process. It will make the work of an CAD engineer easy by reducing the time required for the design calculation and by increasing the efficiency of the design. The number of errors can be reduced as the calculations required for design are already defined.Any individual who has obtained basic knowledge can make use of it with ease. So in future the automation plays an important role and hence it is required for the development of CAD models. 160 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) 5. REFERENECS [1] Dwaipayan Roy Chowdhury \"Design Automation Methodology of a Cube using SolidWorks and VB.net\", International Journal of Engineering Research & Technology (IJERT) ISSN: 2278-0181 Vol. 9 Issue 06, June-2020 [2] Balachandar Krishnamurty, Joshuva Arockia Dhanraj, J.Gangadharan, S.Arjun, P.Jayaraman, V.Ezhil Krishna, S.Aravinth \"Macro Assisted Design Automation of Piston & Connecting Rod Using SolidWorks API\", The Mattingley Publishing Co., Inc. ISSN: 0193-4120 PP. 12964 - 12969, May - June 2020. [3] Jayakiran Reddy, V. Pandu Rangadu \"Development of knowledge based parametric CAD modeling system for spur gear: An approach\", Alexandria Engineering Journal Vol. 57, PP. 3139-3149, December 2018 [4] Andrijana Bocevska, Stefan Krsteski and Snezana Savoska \"An Example of Application Design Using SolidWorks Application Programming Interface\", ISGT 2020 Information Systems and Grid Technologies ISSN: 1613-0073, Vol. 2656, Oct 2020 [5] Jayakiran Reddy, Nikhil Gaddi \"DEVELOPMENT OFAPRELIMINARY SYSTEM FORAUTOMATIC GENERATION OF CAD MODEL OF THE UNIVERSAL COUPLING\", International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN(P): 2249-6890; ISSN(E): 2249-8001, PP. 8701-8710 Vol. 10, Issue 3, Jun 2020. [6] H. Joshi, P. Ghole, S. Shirse, S. Madke \"Automated CAD Modelling of Mechanical Components\", Atlantis Press, B. Iyer, S. Nalbalwar and R. Pawade (Eds.) ICCASP/ICMMD-2016. Advances in Intelligent Systems Research. Vol. 137, Pp. 229-233. [7] Rui Lyu, Otake Minoru and Dongying Ju \"Application of Solidworks Application Programming Interface in Automobile Structural analysis\",Atlantis Press, Advances in Engineering Research, ISSN: 2352-5401, ISBN: 978-94-6252-381-4, Volume 141, 5th International Conference on Mechatronics, Materials, Chemistry and Computer Engineering (ICMMCCE 2017),September 2017. [8] Abhishek C. Lad, A.S.Rao \"Design and Drawing Automation Using Solid Works Application Programming Interface\", International Journal of Emerging Engineering Research and Technology Volume 2, Issue 7, PP 157-167 ISSN 2349-4395 (Print) & ISSN 2349-4409, October 2014. ISBN: 978-0-13-601970-1 161

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Design and Analysis of Spindle in Milling Machine Y. Mohan Murali1, T. Nikhil2, B. Anil Kumar3 1,2U.G Students, 3Assistant Professor 1,2,3Department of Mechanical Engineering, Aurora`s Technological and Research Institute, Hyderabad, India Email: [email protected], [email protected], [email protected] ABSTRACT In today's prosperous industrial development, with the multifarious design of products and reduction of production cycle, high speed machining technology has been widely adopted by manufacturers. With the development of the science and technology, the high frequency spindles have been taken place of the normal mechanical spindles more and more, and also be used of the numerical control machine with great effects. In this project work high speed motorized spindle is designed and analyzed under the given load conditions. The spindle used in this thesis is that used in a milling machine. The 3D modeling of spindle is designed in CATIA. The material used for spindles is Steel. In this project, different materials are analyzed for spindle. Carbon fiber and aluminum alloy7075 are replaced with steel. By replacing the steel with aluminum alloys, the weight of the spindle decreases. Structural analyses are done using ANSYS software. Modal analysis also is done to determine the frequencies. Keywords: High Speed Motorized Spindle, Milling Machine, CATIA, ANSYS Software. 1. INTRODUCTION Milling machine is one of the most versatile conventional machine tools with a wide range of metal cutting capability. Manycomplicated operations such as indexing, gang milling, straddle milling etc. can be carried out on a milling machine. Milling machines were first invented and developed by Eli Whitney to mass produce interchangeable musket parts.Although crude, these machines assisted man in maintaining accuracyand uniformity while duplicating parts that could not be manufactured with the use of a file. Development and improvements of the milling machine and components continued, which resulted in the manufacturing of heavier arbors and high- speed steel and carbide cutters. These components allowed the operator to remove metal faster, and with more accuracy, than previous machines. Variations of milling machines were also developed to perform special milling operations. During this era, computerized machines have been developed to removing the errors and provide better quality in the finished product. Fig:1.1 Milling Machine 162 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Milling is a cutting process that uses a milling cutter to remove material from the surface of a workpiece. The milling cutter is a rotary cutting tool, often with multiple cutting points.As opposed to drilling, where the tool is advanced along its rotation axis, the cutter in milling is usually moved perpendicular to its axis so that cutting occurs on the circumference of the cutter.As the milling cutter enters the workpiece, the cutting edges (flutes or teeth) of the tool repeatedly cut into and exit from the material, shaving off chips (swarf) from the workpiece with each pass. The cutting action is shear deformation; material is pushed off the workpiece in tiny clumps that hang together to a greater or lesser extent (depending on the material) to form chips. This makes metal cutting somewhat different (in its mechanics) from slicing softer materials with a blade. 1.2 SPINDLE In machine tools, a spindle is a rotating axis of the machine, which often has a shaft at its heart. The shaft itself is called a spindle, but also, in shop-floor practice, the word often is used metonymically to refer to the entire rotary unit, including not only the shaft itself, but its bearings and anything attached to it (chuck, etc.). A machine tool may have several spindles, such as the headstock and tailstock spindles on a bench lathe. The main spindle is usuallythe biggest one. References to \"the spindle\" without further qualification implythe main spindle. Some machine tools that specialize in high-volume mass production have a group of 4, 6, or even more main spindles. These are called multi spindle machines. For example, gang drills and many screw machines are multi spindle machines. Fig:1.2 Cross Section Of Spindle 1.3 HIGH SPEED SPINDLE A high- speed spindle that will be used in a metal cutting machine tool must be designed to provide the required performance features. The major performance features include: Desired Spindle Power, Peak and Continuous Maximum Spindle Load,Axial and Radial Maximum Spindle Speed Allowed Tooling Style, Size and Capacity forATC Belt Driven or Integral Motor-Spindle Design ISBN: 978-0-13-601970-1 163

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) The machine tool, also, will present design constraints to the spindle. The amount of available space in the head, cost considerations, complexity and market demands will affect the ultimate spindle design. Cost will have a significant impact on the final spindle design. Consequently, an advanced machine tool design can justify the higher cost of a more capable and complex spindle package. In fact, a fast and accurate machine tool will demand a reliable high-speed spindle system. 1.4 HIGH SPEED SPINDLE DESIGN The major components required for a highspeed milling spindle design include: Spindle Style; Belt Driven or Integral Motor-Spindle Spindle Bearings; Type, Quantity, Mounting, and Lubrication Method Spindle Motor, Belt-Type, Motor-Spindle, Capacity, Size Spindle Shaft; Including Tool Retention Drawbar and Tooling System Used Spindle Housing; Size, Mounting Style, Capacity Each of these components will be discussed, with emphasis on selection criteria and effectiveness for a given machine tool specification. SPINDLE STYLE: BELT DRIVEN ORINTEGRAL MOTOR SPINDLE The first decision which must be made is if a belt-driven spindle or integral motor-spindle design will be required This must be determined by evaluating the requirements of the machine tool, including the maximum speed, power and stiffness required. 2. LITERATURE SURVEY Osamu Maedaet.al discussed an Expert spindle design system strategy which is based on the efficient utilization of the laws of machine design, dynamics and metal cutting mechanics. The configuration of the spindle is based on the specification of the work piece material, necessary cutting conditions and commonly used tools on the machine tool. The spindle drive mechanism, driving motor, bearing type and spindle shaft dimensions were selected based on the required applications. They iteratively find out the Frequency Response Functions (FRF) of the spindle at the tool tip using the Finite Element Method (FEM). This work predicted the cutting operation at the required speed and depth of cut for different flutes of cutters. The arrangement of bearings was optimized using Sequential Quadratic Programming (SQP). Chi-Wei Lin et.al discussed that Development ofhigh-speed spindletechnologyis critical totheimplementation of High-speed machining (HSM).As Compared to the conventional spindles, motorized spindles are equipped with a built-in motor for good power transmission but the built-in motors produce large amount of heat into the spindle system as well as extra mass to the spindle shaft, thus it affects to the dynamic behavior of the spindle. The author presents an integrated model with experimental validation and sensitivity analysis for studying various thermo mechanical dynamic spindle behaviors at high speeds and the fallowing effects are observed that is the bearing preload effects on bearing stiffness, and overall spindle dynamics, high speed rotational effects. The results of this paper show that a motorized spindle softens at high speed because of the centrifugal effect on the spindle shaft. Dr. S. Shivakumaret.al discussed the Design and analysis of lathe spindle in which alloy steel material was used for the spindle. Two bearings were supported by spindle with different spans. Bearings consist of balls with the certain amount of stiffness, which acts as cushioning effect to the spindle so they considered the spring in the 164 ISBN: 978-0-13-601970-1

Proceedings of the 3rd National E-Conference on Emerging Trends in Mechanical Engineering (ETIME-2021) Ansys for the analysis and also carried out static analysis and dynamic analysis of a spindle supported by the front and rear bearing. Bearing stiffness value was calculated by an iteration procedure and using numerical relations life of bearings was calculated. Y. Lu Y.X. Yao and R.H. Hong et al has reviewed that thermal characteristic like the thermal stress and thermal deformations. Thermal characteristics are of great significance to increase the accuracy of high-speed machine tool. The heat generation developed in the built-in motor and the bearings is calculated. The motorized spindle is modeled and its thermal characteristics analysis by finite element method is done usingANSYS software, in the foundation of analyzing its configuration and heat transfer. The variation regularity of its temperature-rise and temperature field is also summarized. There byit provides a powerful theoretical basis for reducing temperature- rise, calculating thermal deformations and improving working conditions. The heat generated in motor mainly is the heat generated due to copper loss in stator winding and iron loss in rotor, and the heat generated due to copper loss in stator winding almost has 2/3 among total heating value 3. DESIGN AND MATERIALS OF SPINDLE In milling machine, spindle is an important element in influencing the accuracy of the machining and the productivity The geometric quality of high-precision parts is highly dependent on the dynamic performance of the entire machining system, which is determined by the interrelated dynamics of machine tool mechanical structure and cutting process. Materials Young’s Poisson’s Deformation Stress Strain modulus(Mpa)) ratio (mm) (Mpa) Aluminum 7075 0.33 5 .565 1.970 0.987 AISI 1050 71700 0.29 0 .839 2.97 0.0022 Carbon fiber 700000 0.30 0 .038 1.48 0.9999 70000 Fig: 3.1 2D Model Of Spindle In 2d model spindle, length 450mm, diameters of spindle 230mm and 60mm. Materials used for spindle analysis areAISI 1050 steel,Aluminum alloy 7075 Carbon fiber. MEHANICALPROPERTIES OFMATERIALS:cutting speeds and feed for some materials: Materials Young’s Tensile Poisson’s Density(kg /mm3) Material Utting speed (m/min) Feed rate modulus(Mpa) strength(Mpa) ratio Steel 25 0.05 AISI 1050 steel 0.29 0.00000785 100 0.15 Aluminum 7075 205000 690 0.33 0.00000028 Aluminum 75 0.2 71700 280 0.30 0.00000020 Carbon fiber Carbon fiber 70000 3900 ISBN: 978-0-13-601970-1 165