Dynamics of machines and mechanisms, industrial research

2786 Pages·2014·305.319 MB·English

Dynamics of
Machines and Mechanisms,
Industrial Research

Edited by
K.R. Balasubramanian
S.P. Sivapirakasam
R. Anand
Dynamics of Machines
and Mechanisms,
Industrial Research

Selected, peer reviewed papers from the
2014 International Mechanical Engineering Congress
(IMEC 2014),
June 13-15, 2014, Tamil Nadu, India
Edited by
K.R. Balasubramanian, S.P. Sivapirakasam and R. Anand
Copyright  2014 Trans Tech Publications Ltd, Switzerland

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Volumes 592-594 of
Applied Mechanics and Materials
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PREFACE

We are pleased to bring before you the proceedings of the International Mechanical
Engineering Congress (IMEC) - 2014 which is scheduled during 13-15 June 2014. The IMEC
2014 is organized by the Department of Mechanical Engineering, National Institute of
Technology, Tiruchirappalli, Tamil Nadu, India during the year of Golden Jubilee celebrations.
The congress aims to bring together the researchers, faculty, students and industrial
professionals from all over the world to share their research findings, experience and to discuss
the emerging issues facing in different spheres of Mechanical Engineering . This event primarily
focuses on today’s technical challenges, research updates and breakthrough innovations that are
shaping the future of Mechanical Engineering. The theme - "Advancement of Mechanical
Engineering to meet global challenges" has been selected keeping worldwide share of ideas and
sustainability in context to present day impact of the same on the environment.
We are sure that the participants in this conference will draw maximum benefit from the
conference and their exposure to this will inculcate in them the habit of analyzing critically the
day to day practical problems and get the proper solution for the same. This will further improve
the technical brilliancy. IMEC 2014 will provide a platform for sharing and exchange of ideas
and information between all the stake holders of technical education and research.
The selected and peer reviewed papers of IMEC 2014 focused on 11 Major topics and
are presented in 11 chapters: (1) Advanced Material and Manufacturing Processes (2)
Nanomaterials and Nanotechnology in Machinery (3) Dynamics and Applied Mechanics (4)
Tribology (5) Thermodynamics and Thermal Engineering, Fuel and Diesel (6) Applied Fluids
Mechanics in Design of Machines and Equipment (7) Vibration and Control (8) Drive Systems
of Machines, Mechatronics, Robotics and Control (9) Engineering Development on Sustainable
Energy (10) Labour Safety, Ergonomics, Reliability and Safety of Machines and Mechanisms
(11) Industrial Engineering
The major sponsor for this conference is Technical Education Quality Improvement
Programme (TEQIP) - II, besides others and the proceedings are published by International
Journal Applied Mechanics and Materials.
We would like to thank the organizing committee members, staff, students and reviewers
for their continuous support and guidance without whom all this wouldn’t have been possible.
We understand that all participants and readers will benefit from the proceedings of
IMEC 2014, which will enrich their knowledge with the advanced technology developments.

Dr. K. R. Balasubramanian
Dr. S. P. Sivapirakasam
Dr. R. Anand

Editors
IMEC 2014 Organizing Committee

Chief Patron Advisory Committee
Dr. Rajaram Nityananda, Chairman, Dr. J. Paulo Davim, Aveiro, Portugal
Board of Governors, NITT, India
Dr. Michele Trovato, Bari, Italy

Dr. R. Prabhakaran, Norfolk, VA
Patron
Dr. Krishnaswami 'Hari' Srihari, N.Y., USA
Dr. Srinivasan Sundarrajan, Director,
Dr. Ram Bishu, Lincoln, USA
NITT, India
Dr. C. Ravi Ravindran, Ontario, Canada
Conveners Dr. Raju Dandu, Salina, United States
Dr. K.R. Balasubramanian, NITT, India Dr. S. K. Salwan, DRDO, India
Dr. S. P. Sivapirakasam, NITT, India
Dr. S. Kumaraswamy, IITM, India
Dr. R. Anand, NITT, India
Dr. A. Ramesh, IITM, India

Dr. V. Babu, IITM, India
Co- Conveners
Dr. K. Sankaranarayanasamy, NITT, India Dr. C. Balaji, IITM, India
Dr. J. Sarangan, NITT, India Dr. N Ramesh Babu , IITM, India
Dr. K. Srinivas Reddy, IITM , India
Members Dr. G.K. Ananthasuresh, IISc, India
Dr. S. Shanmugam, NITT, India
Dr. Satish Vasu Kailas, IISc, India
Dr. M. Udayakumar, NITT, India
Dr. S. Iniyan, Anna University, India
Dr. T. Suthakar, NITT, India
Dr. R. Velraj, Anna University, India
Prof. S. S. Arulappan, NITT, India
Dr. K. Pannir Selvam, NITT, India Dr. M. Suriyanarayanan, CLRI, India
Dr. R. B. Anand, NITT, India Dr. K. K. Satpathy, IGCAR, India
Dr. S. Venkatachalapathy, NITT, India Dr. G. Buvanashekaran, BHEL, India
Prof. M. Shahul Hameed, NITT, India
Dr. M. Vasudevan, IGCAR, India
Dr. AR. Veerappan, NITT, India
Dr. K. Nandakumar , ISRO, Trivandrum , India
Dr. T. Ramesh, NITT, India
Dr V Shankar , GTRE, India
Dr. S. Suresh, NITT, India
Shri. C. Prakash, Ashok Leyland, India
Dr. V. Arul Mozhi Selvan, NITT, India
Prof. V. Mariappan
Prof. Nanda Naik Korra
Dr. N. Siva Shanmugam
Table of Contents
Preface and Organizing Committee
Chapter 1: Advanced Material and Manufacturing Processes
A Finite Element Simulation Study on Effects of Variation in Machining and Geometrical
Parameters in Turning
N. Senthilkumar, A. Pon and T. Tamizharasan 3
A Fuzzy Logic Based Model to Predict Weld Width – A Case Study of Hard Facing Process
Using MIG Welding on Dual Plate Check Valve
S. Sheth, B.S. Modi, T. Patel and P.M. George 8
A Study of Preparation and Characterization of Nano-Sized SiC Powder Using High Energy
Ball Milling
S. Manikandan and J. Jancirani 13
A Study on Edge Milling Operation of NEMA G11 GFRP Composites Based on Grey-
Taguchi Method
H. Vasudevan, R. Rajguru and N. Deshpande 18
A Study on White Layer Thickness and Surface Crack Density in Rotary EDM of RENE80
Nickel Superalloy
U.S. Balraj, P. Anitha and A. Gopalakrishna 23
Aerostatic Spherical Bearing Manufacturing Methods and Criticalities - An Approach
K.S. Arun, A. Sekar and K.V. Govinda 28
An Analysis on Bead Characteristics in Material Deposition by PTAW Process
S. Mandal, S. Kumar, P. Bhargava, C.H. Premsingh, C.P. Paul and L.M. Kukreja 33
An Analysis on Temperature & Surface Roughness during End Milling of Ti-6Al-4V Alloy
S. Samsudeensadham and V. Krishnaraj 38
An Assessment on Friction Stir Welding of High Melting Temperature Materials
K.K. Ramachandran, N. Murugan and K.S. Shashi 43
An Experimental Investigation on Mechanical Properties and Microstructure of Friction
Stir Welding of AA5052
C. Chanakyan, P.D. Babu, M.P. Jenarthanan and K. Jagathesh 48
An Investigation of the Effect of Surface Refining on the Hardness and the Wear Properties
of Al-Si Alloy
R. Saravanan and R. Sellamuthu 53
An Investigation on the Effect of Process Parameters on Microstructure, Hardness and
Wear Properties of Surface Modified Cu-Sn Bronze Alloy
P. Cherian and R. Sellamuthu 58
Analysis of AISI 1035 Grade Joints Welded Frictionally with Varying Forging Pressure
S.T. Selvamani, K. Umanath, K. Palani Kumar, K. Vigneswar and S.K. Ghosh 63
Analysis of Mechanical Properties in Zea Mays Straw Fiber Composites
P.G. Karuppanna Raja and M. Rajkumar 67
Analysis of Powder Metallurgy Process Parameters for Relative Density of Low Carbon
Alloy Steel Using Design of Experiments Tool
Sandeep, U. Prakash, P.C. Tewari and D. Khanduja 72
Application of Desirability Analysis for Optimizing the Micro Wire Electrical Discharge
Machining (μWEDM) Parameters
M. Santhanakumar, R. Adalarasan and M. Rajmohan 77
Calculations of Equilibrium and Non-Equilibrium Properties of Molecule-Cluster Mixtures
of Oxygen
L. Kurlapov and A. Kassymov 82
Compaction Characteristics of Tungsten Carbide Based Self-Lubricant Cutting Tool
Material
A. Muthuraja and S. Senthilvelan 87
b Dynamics of Machines and Mechanisms, Industrial Research
Comparative Investigation on Mechanical Properties of Natural Fiber Reinforced Polyester
Composites
V. Muthukumar, R. Venkatasamy, V. Mariselvam, A. Sureshbabu, N. Senthilkumar and A.A.G.
Fernando 92
Comparison of Machining Responses Using Multiple Regression Analysis and Group
Method Data Handling Technique of EN-19 Material in WEDM
G. Ugrasen, H.V. Ravindra, G.V.N. Prakash and R. Keshavamurthy 97
Comparison Study of As-Cast and T6 Condition of Microstructure, Bending Strength and
Double Shear Strength of A356 Alloy by Gravity, Vacuum and Squeeze Casting
K. Sekar, A. Kanjirathikal and M.A. Joseph 102
Control of Stand-off-Distance in Abrasive Jet Machining - A Fuzzy Approach
K.S. Kumar and S. Karthick 106
Densification and Consolidation of Al 5083 Alloy Powder by Equal Channel Angular
Pressing
K. Gudimetla, B. Chaithanyakrushna, K. Chandra Sekhar, B. Ravisankar and S. Kumaran 112
Densification Behavior in Forming of Stir Casted Aluminium Boron Carbide Composite
Perform during Cold Upsetting
K.R. Thangadurai and A. Asha 117
Design, Fabrication and Analysis of Advanced Polymer Based Kevlar-49 Composite
Material
M. Kaliraj, P. Narayanasamy, M. Rajkumar, M.M. Mohaideen and I.N. Manickam 122
Desirability Fuzzy Approach for Optimizing Multiple Performance Characteristics in
Machining Metal Matrix Composites
S. Tamang and M. Chandrasekaran 128
Determination of Delamination and Tensile Strength of Drilled Natural Fiber Reinforced
Composites
G. Dilli Babu, K. Sivaji Babu and B. Uma Maheswar Gowd 134
Determination of Melting Efficiency of Mild Steel in GTA Welding Process
G.S. Kumar, R. Sellamuthu and S. Arul 139
Developing Empirical Relationships to Predict Tensile Properties of Friction Welded AISI
52100 Grade Steel Rods
S.T. Selvamani, K. Umanath, K. Palani Kumar and K. Vigneswar 144
Development of Al-TiC Metal Matrix Composite by In Situ Reaction
A.K. Kumar and S. Balasivanandha Prabu 148
Development of Guided Wave Ultrasonic Inspection Method for Thick Composite
Structures
U. Saikrishna, K. Srinivas and Y.L.V.D. Prasad 153
Development of Shape Memory Alloy Polymer Composite and Influence of Material
Parameters on Shape Memory
C.S. Jithin, S.B. Prabu and R. Velmurugan 158
Development of Tool Based Micromilling/Microdrilling Machine with Piezoactuated
Workpiece Feeding System
R.K. Veeresha, Muralidhara and R. Rao 164
Dry Sliding Wear Behavior of Graphite Particulate Reinforced Al6061 Alloy Composite
Materials
M. Nagaral, V. Auradi and S.A. Kori 170
Dry Sliding Wear Performance of A356 Alloy with Minor Additions of Magnesium
M.S. Prabhudev, V. Auradi, K. Venkateshwarlu, S.M. Suresha and S.A. Kori 175
Effect of Boron Carbide and Graphite on Machining Characteristics of Aluminium Boron
Carbide Composite
K. Rajkumar and P. Rajan 181
Effect of Carbon Fiber, Silica and Fly-Ash Particulate Addition on Tensile and Impact
Behaviour of Polyester and Epoxy Resin
P.N. Kumar and A. Rajadurai 186
Effect of Chills on the Microstructure and Mechanical Properties of Carbidic Austempered
Ductile Iron
R. Prem Kumar, S.S. Mohamed Nazirudeen and J. Anburaj 192
Effect of Deep Cryogenic Treatment on Machinability of NiTi Shape Memory Alloys in
Electro Discharge Machining
V.S. Jatti and T.P. Singh 197
Applied Mechanics and Materials Vols. 592-594 c
Effect of Fiber Parameters on the Mechanical Properties of Banana-Glass Fiber Hybrid
Composites
V. Santhanam, M. Chandrasekaran and N. Venkateshwaran 202
Effect of Filler Materials on the Mechanical and Thermal Properties of Epoxy Resin
S. Siva Sankari, N. Murugan and S. Sivaraj 206
Effect of Offset Distance on Cutting Forces and Heat Generation in Multi-Tool Turning
Process
R. Kalidasan, M. Yatin, D.K. Sarma and S. Senthilvelan 211
Effect of Operational Parameters on AA2014 Friction Stir Weldments Using Plain
Cylindrical Tool
N. Ramesh and K.P. Reddy 216
Effect of Process Parameters on Heat Affected Zone in Micro Machining of Borosilicate
Glass Using μ-ECDM Process
P. Lijo and S.H. Somashekhar 224
Effect of Process Parameters on Quality of Micro Holes Machined on Copper Plate Using
Developed μ-EDM Setup
L. Raju, V.S. Sanghvi, S.H. Somashekhar and M. Singaperumal 229
Effect of Tool Rotational Speed on Microstructure and Microhardness of AA6082/TiC
Surface Composites using Friction Stir Processing
A. Thangarasu, N. Murugan, I. Dinaharan and S.J. Vijay 234
Effect of Upset Current in Magnetically Impelled Arc Butt (MIAB) Welding of Carbon
Steel Tubes
R. Sivasankari, V. Balusamy and G. Buvanashekaran 240
Effect of Weight Percentage on Mechanical Properties of Fused Silica Particulate
Reinforced Nickel Alloy (M 35-1) Composite, with Influence of Chills
G. Purushotham and J. Hemanth 245
Effect of Welding Parameters on Mechanical and Microstructural Properties of Dissimilar
Aluminum Alloy Joints Produced by Friction Stir Welding
S. Jannet and P.K. Mathews 250
Effect of Zinc Coating on Mechanical Behavior of Al 7075
B.P. Dileep, V.R. Kumar, M. Prashanth and M.V. Phanibhushana 255
Empirical Modelling and Optimization of Sliding Wear Behaviour of Copper-Graphite
Composites Using RSM
A. Doraisamy, S. Thiyagarajan and S. Sampath Kumar 260
Enhancement of Porosity of the Ceramic Shell in Investment Casting Process Using Needle
Coke and Camphor
K. Tamta and D.B. Karunakar 269
Evaluation of Flexural and Interlaminar Shear Strength of Laminated Hybrid Composites
R. Selvam, N. Arunkumar and L. Karunamoorthy 276
Evaluation of Optimal Parameters for Machining Aluminium Alloy Al6061 in Wire EDM
T. Bharathy, K. Thiruppathi and S. Raghuraman 282
Evaluation of Quality Diffusion Bonding in Similar Material (Cu/Cu) Using Ultrasonic ‘C’
Scan Testing Method
S.S. Kumar and B. Ravisankar 289
Experimental Analysis of Hole Ovality in Drilling of Carbon-Carbon Composites
K.V. Krishna Sastry, V.S. Rao, M.S. Kumar and A. Velayudham 294
Experimental Investigation on Formability of Cryorolled and Room Temperature Rolled
AA 6061 Sheet Metal with 50% and 75% Thickness Reduction
T.P. Saju 302
Experimental Investigation on Optimisation of Parameters of Thermo-Catalytic Cracking
Process for H.D.P.E. & P.P. Mixed Plastic Waste with Synthesized Alumina-Silica Catalysts
K.S. Narayanan and R.B. Anand 307
Experimental Investigation on the Impact of the Tool Material & Geometry in Joining of Al
63400 Alloy Using Friction Stir Welding Process
P. Sevvel and V. Jaiganesh 312
Experimental Investigations on Cryogenic Cooling in Drilling of Aluminium Alloy
N. Govindaraju, A.L. Shakeel and K.M. Pradeep 316
Experimental Investigations on Wire EDM of Al7075-TiB In Situ Metal Matrix Composite
2
V.R. Dalve, R. Keshavamurthy, G. Ugrasen and C.P.S. Prakash 321
d Dynamics of Machines and Mechanisms, Industrial Research
Experimental Studies of Mechanical and Microstructure Properties of Plasma Sprayed
Thermal Barrier Coatings
A. Aravind and G.R. Kannan 326
Experimental Study on Temperature Effect and Tool Wear on Edge Trimming of Carbon
Fiber Reinforced Plastics
R. Prakash, V. Krishnaraj, G.S. Tarun, M. Vijayagopal and G.D. Kumar 333
Experimental Testing on Hybrid Composite Materials
S. Sathish, T. Ganapathy and T. Bhoopathy 339
Fabrication and Comparison of Mechanical Properties of Jute and Glass Fibre Reinforced
Composites
R. Rohit, L. Pinto, K.M. Babu, M. Jebraj and H.R. Gudi 344
Fabrication and Investigation on Properties of TiC Reinforced Al7075 Metal Matrix
Composites
V.R. Rao, N. Ramanaiah and M.M.M. Sarcar 349
Fatigue Performance in Abrasive Flow Machining
J. Cherian and J.M. Issac 354
Finite Element Analysis of Jute Fibre Made Hybrid Polymer Matrix Composite
V. Prasad, G. Venkatachalam, A. Rathi and S. Rajakumar 363
Finite Element Modeling of TIG Welding of Aisi 304l Stainless Steel and Experimental
Validation
V.V. Narayanareddy, M. Vasudevan, S. Muthukumaran, K.C. Ganesh, N. Chandrasekhar and P.
Vasantaraja 368
Finite Element Simulation of A-TIG Welding of Duplex Stainless Steel 2205 Using
SYSWELD
K.N. Naik, K.R. Balasubramanian and M. Vasudevan 374
Fire Properties of Elephant Grass Fiber and Glass Fiber Reinforced Polyester Composites
K. Ramanaiah, A.V.R. Prasad and K.H.C. Reddy 380
Formation and Structural Characterization of Electroless Ni-B-P Ternary Alloy Coatings
P.G. Venkatakrishnan, S.S.M. Nazirudeen and T.S.N.S. Narayanan 385
Gravitational Search Algorithm - Based Optimization of Process Parameters in Micro
Turning Process
M. Durairaj and S. Gowri 391
Heat Transfer Modelling and Investigation of the Effect of Pulse Frequency and Current in
Pulsed Current Gas Tungsten Arc Welding
A. Prabakaran, R. Sellamuthu and S. Arul 395
Influence of Built Orientation on Mechanical Properties in Fused Deposition Modeling
S.V. Raut, V.S. Jatti and T.P. Singh 400
Influence of Electrical Discharge Machining Parameters on Surface Roughness in
Machining of Al 6061-TiB /ZrB In Situ Metal Matrix Composite
2 2
A. Mahamani, N. Sakthivelon, J. Sai Kumar, M.V. Sekar Reddy, P.V.K. Naidu, M. Rithesh and
K. Veeranagaiah 405
Influence of Experimental Environment on the Enhancement of Ultra Fine Grain Structure
with Optimum Ductility of Equal Channel Angular Pressed Copper
A.T. Vijayashakthivel, T.N. Srikantha Dath and B. Ravishankar 410
Influence of Pulse-on-Time on the Performance of Wire Electrical Discharge Machining of
Ti-6Al-4V Using Zinc Coated Brass Wire
S.D. Lenin, A. Uthirapathi, R.R.P.S. Venkata and M. Durai Selvam 416
Influence of Silicon on Performance of Al/SiC Composites
G.G. Sozhamannan, M. Muttharasan, K. Kaviarasan, S.B. Prabu and V.S.K. Venkatachalapathy 421
Investigation into Coal Cutting Operation by Using Conical Pick of Cast Iron with LH710
Coated Tip
S. Dewangan, S. Chattopadhyaya and S. Hloch 426
Investigation of Laser Dressed Super Abrasive Grinding Wheel by Using SEM & Raman
Spectroscopy
R.D. Joel Johnson and G. Ugrasen 432
Investigation of Optimal Processing Condition for Abrasive Water Jet Machining for
Stainless Steel AISI 304 Using Grey Relational Analysis Coupled with S/N Ratio
D. Singh and V. Chaturvedi 438