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i-manager's Journal on Material Science (JMS)

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Exploring the Optical and Structural Properties of Chromium (Cr)-Doped Polyaniline
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Volume 4 Issue 4 January - March 2017

Research Paper

Response Surface Modelling of Tool Electrode Wear Rate and Material Removal Rate in Micro Electrical Discharge Machining of Inconel 718

Govindan Puthumana*

*Post-Doctoral Researcher, Department of Mechanical Engineering, Technical University of Denmark, Lyngby, Denmark.

Puthumana, G. (2017). Response Surface Modelling of Tool Electrode Wear Rate and Material Removal Rate in Micro Electrical Discharge Machining of Inconel 718. i-manager’s Journal on Material Science, 4(4), 1-9. https://doi.org/10.26634/jms.4.4.10362

Abstract

Inconel 718 is a corrosion-resistant and high strength nickel-based alloy with wide range of applications, including components for cryogenic tankage, liquid fueled rockets and casings for aircraft engines. The material is characterized by high hardness, high temperature strength, low thermal conductivity and high strength causing it extremely difficult to machine. Micro-Electrical Discharge Machining (Micro-EDM) is a non-conventional method that has a potential to overcome these restrictions for machining of Inconel 718. Response Surface Method (RSM) was used for modelling the tool Electrode Wear Rate (EWR) and Material Removal Rate (MRR) with the input factors, such as voltage (V), peak current (I ) and pulse on-time (T ). The RSM analysis of variance results show that the main input factors’ pulse off-time and p on voltage are significant in controlling the tool electrode wear rate at 95% confidence level. An increase in voltage from 30 to 45 V and pulse on-time from 1 to 3 μs causes a linear decrease in EWR by 35%. Using response surface modeling, a 3 3 minimum EWR of 12.3184 μm /min and a maximum MRR of 37.2151 μm /min is obtained at a current of 1.07 A, pulse ontime of 4.44 μs, pulse off-time of 4.06 μs and voltage of 60 V.

References

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[2]. A. Thakur, and S. Gangopadhyay, (2016). “State-ofthe- art in surface integrity in machining of nickel-based super alloys”. International Journal of Machine Tools and Manufacture, Vol. 100, No. 1, pp. 25-54.

[3]. F. Klocke, D. Welling, A. Klink, D. Veselovac, T. Nothe, and R. Perez, (2014). “Evaluation of Advanced Wire-EDM Capabilities for the Manufacture of fir tree slots in Inconel 718”. Procedia CIRP, Vol. 14, No. 1, pp. 430-435.

[4]. H. Dong, Y. Liu, Y. Shen, and X. Wang, (2016). “Optimizing Machining Parameters of Compound Machining of Inconel 718”. Procedia CIRP, Vol. 42, No. 1, pp. 51-56.

[5]. T. R. Newton, S. N. Melkote, T. R. Watkins, R. M. Trejo, and L. Reister, (2009). “Investigation of the effect of process parameters on the formation and characteristics of recast layer in wire-EDM of Inconel 718”. Materials Science and Engineering A, Vol. 513-514, No. 1, pp. 208-215.

[6]. B. B. Nayak, and S. S. Mahapatra, (2016). “Optimization of WEDM process parameters using deep cryo-treated Inconel 718 as work material”. Engineering Science and Technology, Vol. 19, No. 1, pp. 161-170.

[7]. V. Aggarwal, S. S. Khangura, and R. K. Garg, (2015). “Parametric modeling and optimization for wire Electrical Discharge Machining of Inconel 718 using Response Surface Methodology”. International Journal of Advanced Manufacturing Technology, Vol. 79, No. 1, pp. 31-47.

[8]. S. Rajesha, A. K. Sharma, and P. Kumar, (2012). “On Electro Discharge Machining of Inconel 718 with Hollow Tool”. Journal of Materials Engineering and Performance, Vol. 21, No. 6, pp. 882-891.

[9]. E. Bassoli, L. Denti, A. Gatto, and L. Luliano, (2016). “Influence of electrode size and geometry in Electrodischarge drilling of Inconel 718”. International Journal of Advanced Manufacturing Technology, DOI: 10.1007/s 00170-016-8339-4, Vol. 86, No. 5, pp. 1-9.

[10]. R. Ramakrishnan, and L. Karunamoorthy, (2009). “Performance studies of Wire Electro Discharge Machining (WEDM) of Inconel 718”. International Journal of Materials and Product Technology, Vol. 35, No. 1-2, pp. 199–215.

[11]. P. Kuppan, A. Rajadurai, and S. Narayanan, (2008). “Influence of EDM process parameters in deep hole drilling of Inconel 718”. International Journal of Advanced Manufacturing Technology, Vol. 38, No. 1, pp. 74–84.

[12]. H. S. Liu, B. H. Yan, F. Y. Huang, and K. H. Qiu, (2005). “A study on the characterization of high nickel alloy microholes using micro-EDM and their applications”. Journal of Material Processing Technology, Vol. 169, No. 1, pp. 418–426.

[13]. E. O. Ezugwu, D. A. Fadare, J. Bonney, R. B. D. Silva, and W. F. Sales, (2005). “Modelling the correlation between cutting and process parameters in high-speed machining of Inconel 718 alloy using an Artificial Neural Network”. International Journal of Machine Tools and Manufacture, Vol. 45, No. 12–13, pp. 1375–1385.

[14]. D. K. Aspinwall, S. L. Soo, A. E. Berrisford, and G. Walder, (2008). “Workpiece surface roughness and integrity after WEDM of Ti–6Al–4V and Inconel 718 using minimum damage generator technology”. CIRP Annals- Manufacturing Technology, Vol. 57, No. 1, pp. 187–190.

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[16]. L. Li, Y. B. Guo, X. T. Wei, and W. Li, (2013). “Surface Integrity Characteristics in Wire-EDM of Inconel 718 at different discharge energy”. Procedia CIRP, Vol. 6, No. 1, pp. 220-225.

[17]. Anderson MJ, and Whitcomb PJ. (2016). RSM Simplified: Optimizing Processes using Response Surface Methods for Design of Experiments, 2^nd ed. New York: Productivity Press.

[18]. Kalpakjian S, and Schmid SR. (2008). “Materialremoval processes: Abrasive, chemical, electrical, and high-energy beams”. In Manufacturing Processes for Engineering Materials, 5^th ed. Pearson Education, pp. 561–565.

[19]. R. Ramakrishnan, and L. Karunamoorthy, (2008). “Modeling and multi-response optimization of Inconel 718 on machining of CNC WEDM process”. Journal of Materials Processing Technology, Vol. 207, No. 1-3, pp. 343–349.

20]. M. Lin,C. Tsao, C. Hsu, A. Chiou, P. Huang, and Y. Lin, (2013). “Optimization of micro milling Electrical Discharge Machining of Inconel 718 by Grey-Taguchi method”. Transactions of Nonferrous Metals Society of China, Vol. 23, No. 3, pp. 661-666.

[21]. G. E. P. Box, and K. B. Wilson, (1951). “On the experimental attainment of optimum conditions”. Journal of the Royal Statistical Society - Series B (Methodological), Vol. 13, No. 1, pp. 1–45.

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[23]. G.E.P. Box, and J.S. Hunter, (1957). “Multi-Factor Experimental Designs for Exploring Response Surface”. The Annals of Mathematical Statistics, Vol. 28, No. 1, pp. 195–241.

[24]. Montgomery DC. (2004). Design and Analysis of Experiments, 8^th ed. New York: Wiley.

[25]. D. DiBitonto, P. T. Eubank, M. R. Patel, and M. A. Barrufet, (1989). “Theoretical models of the Electrical Discharge Machining Process I: A simple cathode erosion model”. Journal of Applied Physics, Vol. 66, No. 9, pp. 4095-4103.

[26]. M. Kiyak, B. E. Aldemir, and E. Altan, (2015). “Effects of discharge energy density on wear rate and surface roughness in EDM”. International Journal of Advanced Manufacturing Technology, Vol. 79, No. 1, pp. 513-518.

[27]. R. Das, M. K. Pradhan, and C. Das, (2013). “Prediction of surface roughness in Electrical Discharge Machining of SKD11 Tool steel using Recurrent Elman Networks”. Jordan Journal of Mechanical and Industrial Engineering, Vol. 7, No. 1, pp. 97-104.

[28]. J. Anitha, R. Das, and M. K. Pradhan, (2016). “Multi- Objective Optimization of Electrical Discharge Machining Processes using Artificial Neural Network”. Jordan Journal of Mechanical and Industrial Engineering, Vol. 10, No. 1, pp. 11-18.

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Research Paper

Abrasion Wear Characterization of Natural Stones Subjected to Foot Traffic and Correlation Between Abrasion and Mechanical Properties

Bhargav Prajwal* , R. Chaudhary, H.S. Mali*, R. Nagar****

* Research Scholar, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur, India.

Assistant Professor, Department of Mechanical Engineering, Northern India Engineering College, Delhi, India.

* Assistant Professor, Department of Mechanical Engineering, Malaviya National Institute of Technology, Jaipur, India.

**** Professor, Department of Civil Engineering, Malaviya National Institute of Technology, Jaipur, India.

Pathri, B. P., Chaudhary, R., Mali, H. S., and Nagar, R. (2017). Abrasion Wear Characterization of Natural Stones Subjected to Foot Traffic and Correlation Between Abrasion and Mechanical Properties. i-manager’s Journal on Material Science, 4(4), 10-17. https://doi.org/10.26634/jms.4.4.10364

Abstract

Abrasion resistance is a property of a marble which gives an indication of the marble wearing quality when it is exposed to foot traffic. This property is tested according to ASTM C241 standards. Abrasion further helps in determining whether a marble is economically desirable and practical for floors, stairs, etc. For this, 48 samples were selected from different processing units of Rajasthan and were tested. Regression analysis was carried out to investigate the relation between the abrasion resistance and the mechanical properties of marbles determined according to ASTM standards. Although, it is believed that abrasion resistance of many materials are greatly affected by its hardness and it increases with the increase in the hardness. The correlations of abrasion resistance was found to be highly related with mechanical 2 2 2 properties like modulus of rupture (R = 0.96), compressive strength (R = 0.94), flexural strength (R = 0.96) along with 2 2 2 hardness (R = 0.84) while the water absorption (R = 0.08) and density (R = 0.44) were found to be less correlated.

References

[1]. K. G. Budinski, (2007). Guide to Friction, Wear, and Erosion Testing. PA: A STM International, West Conshohocken, p. 132.

[2]. R. Kuisma, I. Redsven, E. Pesonen-Leinonen, A.M. Sjöberg, and M. Hautala, (2005). “A practical testing procedure for durability studies of resilient floor coverings”. Wear, Vol. 258, No. 5–6, pp. 826–834.

[3]. K. Adachi, and I.M. Hutchings, (2003). “Wear-mode mapping for th micro-scale abrasion test”. Wear, Vol. 255, No. 1–6, pp. 23–29.

[4]. ASTM International, (2013). Standard Terminology relating to Wear and Erosion (ASTM-G40-13). West Conshohocken, PA, Vol. 03, No. 02, pp. 1-8.

[5]. Z. Karaca, N. Günes Yilmaz, and R. M. Goktan, (2012). “Abrasion wear characterization of some selected stone flooring materials with respect to contact load”. Constr. Build. Mater., Vol. 36, pp. 520–526.

[6]. S. Das, D.P. Mondal, and G. Dixit, (2001). “Correlation of abrasive wear with microstructure and mechanical properties of pressure die-cast aluminum hard-particle composite”. Metall. Mater. Trans. A, Vol. 32, No. 3, pp. 633–642.

[7]. X. Ma, R. Liu, and D. Y. Li, (2000). “Abrasive wear behavior of D2 tool steel with respect to load and sliding speed under dry sand/rubber wheel abrasion condition”. Wear, Vol. 241, No. 1, pp. 79–85.

[8]. S. M. Nahvi, P. H. Shipway, and D. G. McCartney, (2009). “Particle motion and modes of wear in the dry sand-rubber wheel abrasion test”. Wear, Vol. 267, No. 11, pp. 2083–2091.

[9]. A. Luque, E. Ruiz-Agudo, G. Cultrone, E. Sebastián, and S. Siegesmund, (2011). “Direct observation of microcrack development in marble caused by thermal weathering”. Environ. Earth Sci., Vol. 62, No. 7, pp. 1375–1386.

[10]. S. Sharma, (2012). “Abrasive Wear Study of Rare Earth Modified Coatings by Statistical Method”. J. Therm. Spray Technol., Vol. 21, No. 5, pp. 773–781.

[11]. A. Aherwar, D. Unune, B. Pathri, and J. Kishan, (2014). “Statistical and Regression Analysis of Vibration of Carbon Steel Cutting Tool for Turning of En24 Steel using Design of Experiments”. Int. J. Recent Adv. Mech. Eng., Vol. 3, No. 3, pp. 137–151.

[12]. B. Prajwal, M. H.S, and R. Nagar, (2016). “Prediction and calculation of specific cutting energy while performing milling operation on natural stone”. Wulfinia J., Vol. 23, No. 12, pp. 1-19.

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Research Paper

Laboratory Studies on Warm Mix Asphalt (WMA) using ZycoTherm Additive with Partial Replacement of Reclaimed Asphalt Pavement (RAP)

Meghana A.N* , G. Kavitha**

* M.Tech Graduate, RASTA-Center for Road Technology, Volvo Construction Equipment Campus, Bengaluru, India.

** Faculty, RASTA-Center for Road Technology, Volvo Construction Equipment Campus, Bengaluru, India.

Meghana, A. N., and Kavitha, G. (2017). Laboratory Studies on Warm Mix Asphalt (WMA) using ZycoTherm Additive with Partial Replacement of Reclaimed Asphalt Pavement (RAP). i-manager’s Journal on Material Science, 4(4), 18-24. https://doi.org/10.26634/jms.4.4.10366

Abstract

Roads are the backbone of country's development, but the high level of emission generated in paving conventional bituminous pavements is always a major concern. For decades, Hot Mix Asphalt (HMA) had an upper hand in pavement construction all over the world. Hot mix asphalt was easy to produce, but required high temperatures to be maintained during transportation and laying. As HMA production involves high-energy consumption, production of bituminous mix with lower temperatures using different process is developed which is labeled as Warm Mix Asphalt Technology. In the present study, ZycoTherm additive, has been used in different dosages at different temperatures to prepare warm mix asphalt in the laboratory. ZycoTherm additive can be used with an optimal dosage of 0.07% by weight of bitumen at o o 135 C mixing temperature for WMA, and 30% RAP with 70% virgin aggregates containing 0.07% ZT WMA at 135 C, gives better stability and performance than other mixes. Hence, 30:70 is the most optimum blend. From the cost analysis, the construction cost for the 30:70 combination works out to be 9.5 lakhs per km, which shows a saving of 33.25% compared to HMA construction.

References

[1]. B. Harish Kumar, K. Alekh Kumar, G. Sumanth Kumar, and M. Vidya Reddy, (2015). “Laboratory Investigation on WMA using ZycoTherm as an Additive”. International Journal on Engineering Studies and Research. Vol. 5, No. 12, pp. 1469-1476.

[2]. Rohith N, and J Ranjitha A, (2013). “Study on Marshall Study Properties of WMA using ZycoTherm, a Chemical Additive”. IJRET. Vol. 2, No. 7, pp. 808-813.

[3]. Parveez, Prateek M C, Srikanta T K, Yathiraj N, Shreekant Konnur, Dinesh S V, (2014). “Study on the Effect of Reclaimed Asphalt Pavement (RAP) on the Mechanical Behaviour of Hot Mix Asphalt (HMA)”. Proceeding of th International Conference on 11 Transportation Planning and Implementation Methodologies for Developing th Countries (11 TPMDC), (Paper ID: 95).

[4]. H Ziari, and M M Khabiri, (2005). “Effect of Bitumen and RAP Content on Resilient Modulus of Asphalt Concrete”.

[5]. Asphalt Institute MS-2. Mix Design Methods for Asphalt Concrete and Other Hot-Mix Types. Super-Pave Manual th Series No. 2 (MS-2), 6 ed. Lexington, USA: Asphalt Institute.

[6]. S.K Khanna, C.E.G Justo, and Veeraragavan, (2010). Highway Material Testing Laboratory Manual. Nemchand and Brothers, Roorkee.

[7]. Ministry of Road Transport and Highways (MoRT&H), (2013). Specification for Roads and Bridge Work, th Government of India. Indian Road Congress, 5 revision, New Delhi, India.

[8]. Prithvi Singh Khandal, (2010). “Warm Mix Asphalt Technologies: An Overview”. Journal of Indian Road Congress (IRC), Vol. 71, No. 2, pp. 143-151.

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Research Paper

Mechanical Characterization and Microstructure Exploration of the Aluminum-Tungsten Carbide-Cobalt Composites

Ch.Siva RamaKrishna*

*Associate Professor, Department of Mechanical Engineering, Vignan's Institute of Information Technology, Andhra Pradesh, India.

RamaKrishna, C. S. (2017). Mechanical Characterization and Microstructure Exploration of the Aluminum-Tungsten Carbide-Cobalt Composites. i-manager’s Journal on Material Science, 4(4), 25-30. https://doi.org/10.26634/jms.4.4.10369

Abstract

The demand in usage of advanced material in lightweight Aluminum (Al) has increased drastically in the present, especially in automobile and aerospace applications. Aluminium based Metal Matrix Composites (MMCs) has its own advantage that it offers a very low thermal expansion coefficient, high specific strengths, wear and heat resistance as compared to conventional Al alloys. To group all these properties, Aluminum based MMCs have become a very useful method for various industrial applications. Therefore, a combination of Aluminum (Al) and Tungsten carbide-cobalt (WC-Co) is of interest. Al-WC-Co composites with 10 to 35 weight % of WC-Co were fabricated using powder metallurgy o process. Then, the powder mixtures were pressed and sintered by using vacuum sintering technique at above 600 C. In this present research, the samples were tested for its hardness by rock well hardness test. It was found that the hardness increased with increase in percentage of WC-Co. The surface morphology of the samples were investigated by Scanning Electron Microscopy (SEM). PXRD (Powder X-Ray Diffraction) analysis reveals that, uniform structure of composites was formed in Al-WC-Co.

References

[1]. P.H.P Rao, A Balamurugan, and B.A Syed Bava, (2012). “Microstructure exploration of the aluminum-tungsten carbide composite with different manufacturing circumstances”. Int. J. Soft. Comp. Eng., Vol. 2, No. 6, pp. 257-261.

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Research Paper

Optimization of Control Parameters for Mechanical and Abrasive Wear Behavior of Graphite Filled Carbon Epoxy Composite using Grey Relational Analysis

Sudarshan Rao K.* , Y.S. Varadarajan, N. Kiran Bhat*

* Professor and Head, Department of Mechanical Engineering, Shri Madhwa Vadiraja Institute of Technology and Management, Karnataka, India.

Professor, Department of Industrial and Production Engineering, NIE, Karnataka, India.

* Assistant Professor, Department of Mechanical Engineering, Shri Madhwa Vadiraja Institute of Technology and Management, Karnataka, India.

Rao, K. S., Varadarajan, Y. S., and Bhat, N. K. (2017). Optimization of Control Parameters for Mechanical and Abrasive Wear Behavior of Graphite Filled Carbon Epoxy Composite using Grey Relational Analysis. i-manager’s Journal on Material Science, 4(4), 31-42. https://doi.org/10.26634/jms.4.4.10373

Abstract

Mechanical and tribological behaviors of graphite filled carbon fabric reinforced epoxy composite were investigated in the present study. Three body abrasive wear tests were conducted with four process parameters, filler content, normal load, abrading distance, and abrasive particle size. Grey Relational Analysis is used to optimize the multi performance characteristics to minimize the specific wear rate and density, and to maximize the tensile, flexural and impact strength of graphite filled carbon epoxy composite. The experiments were designed according to Taguchi's L orthogonal array 9 to optimize experimental runs. The results indicated that tensile, flexural and impact strength, and the specific wear rate of composite increased with increase in graphite filler content. Analysis of variance was applied to determine the parametric influence on the performance output. From the ANOVA it is observed that, graphite filler content has the most significant factor influencing the mechanical and wear behavior of composites. An optimized parameter combination was obtained by grey relational analysis. Finally, a confirmation test was performed according to predicted optimal parameter setting and found the successful implementation of grey based Taguchi approach.

References

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i-manager's Journal on Material Science (JMS)

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Volume 4 Issue 4 January - March 2017

Response Surface Modelling of Tool Electrode Wear Rate and Material Removal Rate in Micro Electrical Discharge Machining of Inconel 718

Govindan Puthumana*

*Post-Doctoral Researcher, Department of Mechanical Engineering, Technical University of Denmark, Lyngby, Denmark.

Puthumana, G. (2017). Response Surface Modelling of Tool Electrode Wear Rate and Material Removal Rate in Micro Electrical Discharge Machining of Inconel 718. i-manager’s Journal on Material Science, 4(4), 1-9. https://doi.org/10.26634/jms.4.4.10362

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Abrasion Wear Characterization of Natural Stones Subjected to Foot Traffic and Correlation Between Abrasion and Mechanical Properties

Bhargav Prajwal* , R. Chaudhary**, H.S. Mali***, R. Nagar****

Pathri, B. P., Chaudhary, R., Mali, H. S., and Nagar, R. (2017). Abrasion Wear Characterization of Natural Stones Subjected to Foot Traffic and Correlation Between Abrasion and Mechanical Properties. i-manager’s Journal on Material Science, 4(4), 10-17. https://doi.org/10.26634/jms.4.4.10364

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Laboratory Studies on Warm Mix Asphalt (WMA) using ZycoTherm Additive with Partial Replacement of Reclaimed Asphalt Pavement (RAP)

Meghana A.N* , G. Kavitha**

* M.Tech Graduate, RASTA-Center for Road Technology, Volvo Construction Equipment Campus, Bengaluru, India. ** Faculty, RASTA-Center for Road Technology, Volvo Construction Equipment Campus, Bengaluru, India.

Meghana, A. N., and Kavitha, G. (2017). Laboratory Studies on Warm Mix Asphalt (WMA) using ZycoTherm Additive with Partial Replacement of Reclaimed Asphalt Pavement (RAP). i-manager’s Journal on Material Science, 4(4), 18-24. https://doi.org/10.26634/jms.4.4.10366

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Mechanical Characterization and Microstructure Exploration of the Aluminum-Tungsten Carbide-Cobalt Composites

Ch.Siva RamaKrishna*

*Associate Professor, Department of Mechanical Engineering, Vignan's Institute of Information Technology, Andhra Pradesh, India.

RamaKrishna, C. S. (2017). Mechanical Characterization and Microstructure Exploration of the Aluminum-Tungsten Carbide-Cobalt Composites. i-manager’s Journal on Material Science, 4(4), 25-30. https://doi.org/10.26634/jms.4.4.10369

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Optimization of Control Parameters for Mechanical and Abrasive Wear Behavior of Graphite Filled Carbon Epoxy Composite using Grey Relational Analysis

Sudarshan Rao K.* , Y.S. Varadarajan**, N. Kiran Bhat***

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Bhargav Prajwal* , R. Chaudhary, H.S. Mali*, R. Nagar****

* M.Tech Graduate, RASTA-Center for Road Technology, Volvo Construction Equipment Campus, Bengaluru, India.

** Faculty, RASTA-Center for Road Technology, Volvo Construction Equipment Campus, Bengaluru, India.

Sudarshan Rao K.* , Y.S. Varadarajan, N. Kiran Bhat*