Advanced Manufacturing Techniques for Engineering and Engineered Materials

373 Pages·2022·10.726 MB·English

by  R Thanigaivelan (editor), N Rajan (editor), T G Argul (editor)

Advanced Manufacturing
Techniques for
Engineering and
Engineered Materials
R. Thanigaivelan
Muthayammal Engineering College, India
N. Rajan
Vinayaga Mission Kripananda Variyar Engineering College, India
T.G. Argul
St. Mary’s Engineering College, India
A volume in the Advances in Chemical and
Materials Engineering (ACME) Book Series
Published in the United States of America by
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Library of Congress Cataloging-in-Publication Data
Names: Thanigaivelan, Rajasekaran, 1977- editor. | Rajan, N., 1977- editor.
| Arul, T. G., 1976- editor.
Title: Advanced manufacturing techniques for engineering and engineered
materials / Rajasekaran Thanigaivelan, N. Rajan, and T.G. Arul, editors.

Description: Hershey, PA : Information Science Reference, an imprint of IGI
Global, [2022] | Includes bibliographical references and index. |
Summary: “This book highlights the latest trends in manufacturing
processes such as 3D Printing, Casting, Welding, Surface Modification,
CNC, Non- Traditional, Industry 4.0 Ergonomics and Hybrid Machining
Methods”-- Provided by publisher.
Identifiers: LCCN 2021036885 (print) | LCCN 2021036886 (ebook) | ISBN
9781799895749 (h/c) | ISBN 9781799895756 (s/c) | ISBN 9781799895763
(ebk)
Subjects: LCSH: Materials. | Manufacturing processes.
Classification: LCC TA403 .A2565 2022 (print) | LCC TA403 (ebook) | DDC
620.1/1--dc23
LC record available at https://lccn.loc.gov/2021036885
LC ebook record available at https://lccn.loc.gov/2021036886

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2327-5448; eISSN: 2327-5456)
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Materials Engineering (ACME)
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University of Aveiro, Portugal
ISSN:2327-5448
EISSN:2327-5456
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List of Reviewers
R.Boopathi,Mahendra Engineering College, India
S.Chandika,Algonquin College of Applied Arts and Technology, Canada
T.Geethapriyan,SRM Institute of Science and Technology, India
M.Girija,VIT University, India
J.M.Jafferson,VIT University, India
PradeepKumarKrishnan,National University of Science and Technology, Oman
A.RanjithKumar,Sona College of Technology, India
S.Maniraj,Paavai College of Engineering, India
T.Mothilal,KCG College of Technology, India
T.Mythili,Mahendra Engineering College, India
G.SuganyaPriyadharshini,Coimbatore Institute of Technology, India
E.Rajkeerthi,Anna University, India
K.G.Saravanan,Sona College of Technology, India
N.Sivashankar,Kongunadu College of Engineering and Technology, India
M.Soundarrajan,Muthayammal Engineering College, India
S.Sudhagar,Muthayammal Engineering College, India
P.Suresh,Muthayammal Engineering College, India
S.Suresh,Muthayammal Engineering College, India
PraveenKumarV.,VIT University, India
J.R.VinodKumaar,Mahendra Engineering College, India
R.Viswanathan,AVS College of Technology, India
T.Yuvaraj,Muthayammal Engineering College, India

Table of Contents
Preface.................................................................................................................................................xvi
Acknowledgment................................................................................................................................xxi
Section 1
Machining and Surface Modification
Chapter 1
SurfaceModificationTechniquesforImprovingtheMaterialPerformance..........................................1
Thanigaivelan R., Muthayammal Engineering College, India
Saravanan K. G., Sona College of Technology, India
Makesh M., Paavai Engineering College, India
Chapter 2
ElectrochemicalMicromachiningPerformanceOptimization:ImpactofCathodeProfileand
RotationonMachiningSpeedandAccuracy........................................................................................20
Vempannan C., Muthayammal Engineering College, India
Kanish T. C., Vellore Institute of Technology, India
Thirumanikandan D., Muthayammal Engineering College, India
Aswin B., Muthayammal Engineering College, India
Chapter 3
SurfaceModificationTechniquesforBio-Materials:AnOverview.....................................................42
Thanigaivelan R., Muthayammal Engineering College, India
Satya Prakash, Muthayammal Engineering College, India
Maniraj S., Paavai Engineering College, India
Chapter 4
RecentTrendsinNon-TraditionalMachiningofAlloysandComposites............................................61
Vinod Kumaar J. R., Mahendra Engineering College, India
Mythili T., Mahendra Engineering College, India
Suganya Priyadharshini G., Coimbatore Institute of Technology, India



Chapter 5
RecentDevelopmentsinConventionalMachiningforMetalsandCompositeMaterials....................82
Soundarrajan Madesh, Muthayammal Engineering College, India
Clement Christy Deepak Charles, Eppinger Tooling Asia Pvt Ltd, India
Sathishkumar D., Nehru Institute of Engineering and Technology, India
Chapter 6
EffectofToolElectrodesonElectrochemicalMicromachiningProcesses........................................103
Geethapriyan T., SRM Institute of Science and Technology, India
Chapter 7
ElementsofIndustrialAutomationandRobotics...............................................................................113
Chandika Samynathan, Algonquin College, Canada
Kavitha G., Muthayammal Engineering College, India
Section 2
New Materials and Processes
Chapter 8
FabricationandApplicationofAluminumMetalMatrixComposites...............................................133
Pradeep Kumar Krishnan, National University of Science and Technology, Muscat, Oman
Chapter 9
EmergenceofAdvancedManufacturingTechniquesforEngineeredPolymericSystemsinCancer
Treatment............................................................................................................................................152
Mohamad Taleuzzaman, Faculty of Pharmacy, Maulana Azad University, India
Ali Sartaz, Independent Researcher, India
Md. Jahangir Alam, Radiant Institute of Pharmaceutical Sciences, India
Md. Noushad Javed, K.R. Mangalam University, India
Chapter 10
MonitoringoftheFrictionStirWeldingProcess:UpgradingTowardsIndustry4.0..........................173
Sudhagar Sukkasamy, Muthayammal Engineering College, India
Gopal P. M., Karpagam Academy of Higher Education, India
Chapter 11
AdvancesinWeldingTechniquesforSimilarandDissimilarMaterials............................................183
Soundarrajan Madesh, Muthayammal Engineering College, India
Arul T. G., St. Mary’s Engineering College, India
Varatharaju Perumal, Ethiopian Technical University, Ethiopia
Chapter 12
AnOverviewofWeldingMethodsforAdvancedMaterials:TestingandEvaluation.......................198
Thiraviam Rayapandi, PT Saipem Indonesia, India
Suresh P., Muthayammal Engineering College, India

Chapter 13
InfluenceofAdditiveManufacturinginReentryLaunchVehicle......................................................226
Prasad G., Dayananda Sagar University, India
Sahana Jawahar, Delft University of Technology, The Netherlands
Sripad Kulkarni S., Dayananda Sagar University, India
Deepika G. N., Dayananda Sagar University, India
Mirzada Mahaz Ahmed, Dayananda Sagar University, India
Likitha S., Dayananda Sagar University, India
Chapter 14
StudyofDifferentAdditiveManufacturingProcessesandEmergentApplicationsinModern
Healthcare...........................................................................................................................................239
Ranjit Barua, Center for Healthcare Science and Technology, Indian Institute of Engineering
Science and Technology, Shibpur, India
Amit Roychowdhury, Indian Institute of Engineering Science and Technology, Shibpur, India
Pallab Datta, National Institute of Pharmaceutical Education and Research, Kolkata, India
Chapter 15
FlammabilityIndexofNigeriaAgroWasteProcessedWithPolymerandGumArabicHybridized
FlameRetardantsforBuildingApplications......................................................................................260
Timine Suoware, Federal Polytechnic, Ekowe, Nigeria
Chapter 16
AReviewoftheFireBehaviourofAgro-WasteFibreCompositeMaterialforIndustrial
UtilizationinNigeria..........................................................................................................................278
Timine Suoware, Federal Polytechnic, Ekowe, Nigeria
Charles O. Amgbari, Federal Polytechnic, Ekowe, Nigeria
Compilation of References...............................................................................................................301
About the Contributors....................................................................................................................343
Index...................................................................................................................................................349
Detailed Table of Contents
Preface.................................................................................................................................................xvi
Acknowledgment................................................................................................................................xxi
Section 1
Machining and Surface Modification
Chapter 1
SurfaceModificationTechniquesforImprovingtheMaterialPerformance..........................................1
Thanigaivelan R., Muthayammal Engineering College, India
Saravanan K. G., Sona College of Technology, India
Makesh M., Paavai Engineering College, India
Surfacemodificationtechniquesaremainlyconsideredtochangethesurfaceofthematerialbasedonthe
application.Thesurfacemodifiedmaterialspossessexcellentmechanical,tribological,andbiological
characteristics.Inthischapter,theprincipleofvarioussurfacemodificationtechniquesincludingtheir
outcomes,advantages,andlimitationsarereviewed.Amongthevarioussurfacecoatingtechniques,the
mostfrequenttechniquessuchaschemicalvapordeposition(CVD),physicalvapordeposition(PVD),
micro-arcoxidation(MAO)coating,andelectro-depositioncoatingwerediscussedindetail.Theeffect
ofsurfacemodificationonmechanicalandtribologicalcharacteristicsalongwithrecentapplications
aredescribedindetail.Finally,themajorsurfacecharacterizationtechniquesandtheiroutcomesare
elaboratedinthischapter.
Chapter 2
ElectrochemicalMicromachiningPerformanceOptimization:ImpactofCathodeProfileand
RotationonMachiningSpeedandAccuracy........................................................................................20
Vempannan C., Muthayammal Engineering College, India
Kanish T. C., Vellore Institute of Technology, India
Thirumanikandan D., Muthayammal Engineering College, India
Aswin B., Muthayammal Engineering College, India
Micromachinedcomponentsarefindingapplicationinavarietyoffieldssuchasmedical,semiconductor,
andaerospace.Electrochemicalmicromachining(ECMM)isatechnologyusedtorealizethemicro
componentswithenhancedfeaturesandfunctionality.Thischapterreviewstheimpactofcathode
profileonthemachiningrateandaccuracy.AnindigenousdevelopedECMMsetupisusedwithspecial
attachmentofrotatingelectrode.Thecontrolparameterssuchasmachiningvoltage,dutycycle,electrolyte


temperature,androtatingRPMwereconsideredonimprovingtheoutputperformance.Theinteraction
betweentheinputparametersandmachiningspeedandovercutwasstudied.Theinputparameters
consideredaremachiningvoltage,dutycycle,electrolyteconcentration,andcathodetoolrotation.There
arevariousoptimizationprocessesconsideredtoevaluatetheworkingrangeofcontrolfactorsforthe
machineonoutputperformance.Inthischapter,variousmulti-objectiveoptimizationtechniquesapplied
inoptimizationofECMMprocesswerereviewed.
Chapter 3
SurfaceModificationTechniquesforBio-Materials:AnOverview.....................................................42
Thanigaivelan R., Muthayammal Engineering College, India
Satya Prakash, Muthayammal Engineering College, India
Maniraj S., Paavai Engineering College, India
Theincreasingpopulationdemandsmaterialswithhigherexpectationsassociatedtoqualityoflifecropping
upfromanagingpopulation.Recentlytherehasbeenanever-increasingsearchfornovelbiomaterials
asthematerialneedsforcomplexbiomedicaldevicesshootsupwithtime.Thischapterdiscussesthe
differenttechnologyusedforsurfacemodificationofmaterialforbiomedicalapplications.Thesurface
modificationprocessisgenerallyusedtoobtaintheantibacterialproperties,antifouling,enhanced
mechanicalproperties,reducedcytotoxicity,anti-inflammatorypotential,improvedhemocompatibility,
andosseointegrationcapabilities.Variousmetallicmaterialsareconsideredasbiocompatiblematerials
suchastitaniumalloys,stainlesssteelalloys,andmagnesiumalloys.Moreover,surfacemodification
ofdentalimplantsandpolymerswerereviewed,andrecentprogressandchallengesinapplicationof
biomaterialsarereportedrelatedtothesurfacemodificationprocess.
Chapter 4
RecentTrendsinNon-TraditionalMachiningofAlloysandComposites............................................61
Vinod Kumaar J. R., Mahendra Engineering College, India
Mythili T., Mahendra Engineering College, India
Suganya Priyadharshini G., Coimbatore Institute of Technology, India
Inthemodernmanufacturingera,machiningalloysandcompositematerialsenablepropermachining
methodstogettherequiredshapeanddimensions.Theusageofalloysandcompositematerialsis
increasinginseveralindustriesincludingaerospace,automobile,MEMS,electronics,medical,biomedical,
pharmaceuticalindustries,andsoonbecauseoflessweightandmorestrength.Thoughvariousmethods
areavailableformachiningofcompositesmaterialsandalloys,onlyelectrochemicalmicro-machining
(ECMM)andwireelectricaldischargemachining(WEDM)areaptformicron-levelmachiningofthese
materialsbycomplexshapeswithgoodsurfacequality.Thischapterattemptstoprovideinsightinto
therecentdevelopmentsinmachiningofthesealloysandcompositematerialsbyECMMandWEDM.
Chapter 5
RecentDevelopmentsinConventionalMachiningforMetalsandCompositeMaterials....................82
Soundarrajan Madesh, Muthayammal Engineering College, India
Clement Christy Deepak Charles, Eppinger Tooling Asia Pvt Ltd, India
Sathishkumar D., Nehru Institute of Engineering and Technology, India
Applicationofnovelengineeringmaterialsandadvancedtechnologyhasbeenincreasingtremendously
inmanyindustrialneeds.Amongthosechallengingmanufacturingmethods,conventionalmachining
isoneoftheprovenandprominentprocesses.Although,fastgrowingandnewerdevelopmentsin