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i-manager's Journal on Mechanical Engineering (JME)

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Effects of Drill Pipe Length and Weight on Bit on Lateral and Longitudinal Vibrations
Shell Tube Exchanger Parametric Investigation and Performance Simulation using Ansys
Fatigue Life Prediction of Aluminum 6061 Alloy through Experimental and Numerical Analysis under Various Stress Ratios in Axial Tension-Tension Loading Condition
Enhancing the Control of Boron Epoxy Cross-Ply Laminated Composite Plates through Intelligent Implementation of PZT Sensor and Actuator
Ball Mill Energy Efficiency Optimization Techniques: A Review

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Volume 10 Issue 1 November - January 2020

Research Paper

Effects of Parameters on Sourface Roughness and Material Removal in EDM of High Chromium Steel-D7

Palwinder Singh* , Lakhvir Singh**

*-** Department of Mechanical Engineering, Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, Punjab, India.

Singh, P., and Singh, L. (2020). Effects of Parameters on Sourface Roughness and Material Removal in EDM of High Chromium Steel-D7. i-manager's Journal on Mechanical Engineering, 10(1), 1-12. https://doi.org/10.26634/jme.10.1.16576

Abstract

Electrical Discharge Machining (EDM) is one of unconventional processes utilized for machining the electrical conductive materials which cannot be processed by conventional processes. Thus, the study and analysis of EDM variables play an important role to improve the yield and safety of a surface. This research work focuses on the study and analyzes the influence of current, pulse on time T_(on) and pulse off time T_(off) by keeping other parameters constant on Surface Roughness (SR) and Material Removal Rate (MRR). In the present study, machining of high chromium steel-D7 using EDM was experimented with industrial/commercial electrodes of copper material for EDM of high chromium steel-D7. The Central Composite Design (CCD) of Response Surface Methodology (RSM) has been employed for designing the experiments. Scanning Electron Microscopy (SEM) was used. This paper reports the experimentally investigated results during EDM of high chromium steel-D7 with tool material copper electrode. The influence of EDM input variable parameters on SR and MRR were analyzed through different graphs. The Analysis of Variance (ANOVA) were employed to carry out the experiments, identify the significant parameters and optimize the input parameters for both the responses. The optimum parametric combination for smaller SR was found at current 4 A, T_on15 µs, and T_off15 µs and higher MRR was found at current 10 A, T_on 20 µs and T_off 10 µs with copper tool electrode. The surface characteristics on of the machined surface were analyzed by SEM and explained in the paper.

References

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[4]. Kansal, H. K., Singh, S., & Kumar, P. (2006). An experimental study of the machining parameters in powder mixed electric discharge machining of Al–10% SiCP metal matrix composites. International Journal of Machining and Machinability of Materials, 1(4), 396-411. https://doi.org/10.1504/IJMMM.2006.012349

[5]. Kiran, K., Reddy, G., Prasad, A., & Rajendra, R. (2014). Study of surface integrity characteristics on Al and die steel components using copper tool in sink EDM process. International Journal of Current Engineering and Technology, Special Issue-2, 236-241.

[6]. Kumar, S., & Choudhury, S. K. (2007). Prediction of wear and surface roughness in electro-discharge diamond grinding. Journal of Materials Processing Technology, 191(1-3), 206-209. https://doi.org/10.1016/j.jmatprotec. 2007.03.032

[7]. Lee, H. T., & Tai, T. Y. (2003). Relationship between EDM parameters and surface crack formation. Journal of Materials Processing Technology, 142(3), 676-683. https://doi.org/10.1016/S0924-0136(03)00688-5

[8]. Lee, S. H., & Li, X. P. (2001). Study of the effect of machining parameters on the machining characteristics in electrical discharge machining of tungsten carbide. Journal of Materials Processing Technology, 115(3), 344- 358. https://doi.org/10.1016/S0924-0136(01)00992-X

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[10]. Liu, Y. H., Ji, R. J., Li, X. P., Yu, L. L., Zhang, H. F., & Li, Q. Y. (2008). Effect of machining fluid on the process performance of electric discharge milling of insulating Al2O3ceramic. International Journal of Machine Tools and Manufacture, 48(9),1030-1035. https://doi.org/10.1016/ j.ijmachtools.2007.12.011

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[15]. Morankar, K. S., & Shelke, R. D. (2017). Optimization of electrical discharge machining process parameters using SCM420 low alloy steel by response surface methodology. IOSR Journal of Mechanical and Civil Engineering, 14(1), 75-79. https://doi.org/10.9790/1684-1401047579

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[17]. Pandey, P. C., & Shan, H. S. (2004). Modern Machining Processes. Tata McGraw-Hill Education.

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[19]. Pradhan, M. K. (2010). Experimental Investigation and Modelling of Surface Integrity, Accuracy and Productivity Aspects in EDM of AISI D2 Steel (Doctoral Dissertation), National Institute of Technology, Rourkela, India.

[20]. Puertas, I., Luis, C. J., & Alvarez, L. (2004). Analysis of the influence of EDM parameters on surface quality, MRR and EW of WC–Co. Journal of Materials Processing Technology, 153, 1026-1032. https://doi.org/10.1016/j.jm atprotec.2004.04.346

[21]. Rajendran, S., Marimuthu, K., & Sakthivel, M. (2013). Study of crack formation and resolidified layer in EDM process on T90Mn W50Cr45 tool steel. Materials and 2 Manufacturing Processes, 28(6), 664-669. https://doi.org/ 10.1080/10426914.2012.727120

[22]. Rajesha, S., Jawalkar, C. S., Mishra, R. R., Sharma, A. K., & Kumar, P. (2014). Study of recast layers and surface roughness on Al-7075 metal matrix composite during EDM machining. International Journal of Recent Advances in Mechanical Engineering, 3(1), 53-62.

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[28]. Shather, S. K., Aghdeab, S. H., & Khudhier, W. S. (2019, May). Enhancement the thermal effects produce by EDM using hybrid machining. In IOP Conference Series: Materials Science and Engineering (Vol. 518, No. 3, pp. 032016). IOP Publishing. https://doi.org/10.1088/1757- 899X/518/3/032016

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Research Paper

Evaluation of Metallographic Properties for Welding of AISI 1040 Steel

Saurabh Gandhe* , V. S. Aher, V. D. Wakchaure*

*-*** Department of Mechanical Engineering, Amrutrahini College of Engineering, Maharashtra, India.

Gandhe, S., Aher, V. S., and Wakchaure, V. D. (2020). Evaluation of Metallographic Properties for Welding of AISI 1040 Steel. i-manager's Journal on Mechanical Engineering, 10(1), 13-20. https://doi.org/10.26634/jme.10.1.16668

Abstract

Welding process is one of the important processes in the joining of steel metals. Weld ability of steel is the main factor to use it for various applications. In a previous work by this author, optimization of process parameters for AISI 1040 steel VIZ weld current, arc voltage and wire feed rate for attaining the tensile strength was carried out. Same optimized parameters are used to prepare welding samples with throat thickness of 5 mm. Samples are prepared and tested for micro hardness test and microstructure test in order to check the quality of welded joint and more validation in addition with the tensile test. All the results of hardness and microstructure test are discussed in this paper.

References

[1]. Bharadwaj, R., Gaur, M. K., Agrawal, S., & Chaturvedi, V. (2018). Simultaneous optimization of multiple performance characteristics in MIG welding for machining AISI-304 stainless steel by weighted principle component analysis. Journal of Experimental & Applied Mechanics, 9(3), 77-85.

[2]. Cawley, P. (2001). Non-destructive testing-current capabilities and future directions. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 215(4), 213-223. https://doi.org/ 10.1177%2F146442070121500403

[3]. Dwivedi, S. K., Vishwakarma, M., & Soni, A. (2018). Advances and researches on non destructive testing: A review. Materials Today: Proceedings, 5(2), 3690-3698. https://doi.org/ 10.1016/j .matpr.2017.11.620

[4]. Gandhe, E. S., Aher, V. S., & Wakchaure, V. D. (2019a). Analysis & FEA simulation for effect of throat thickness on MIG welded joint strength. International Journal of Research and Scientific Innovation (IJRSI), 6(9), 39-44.

[5]. Gandhe, E. S., Aher, V. S., & Wakchaure, (2019b). Parametric optimization of mig welding process to improve its tensile strength. EPRA International Journal of Research and Development (IJRD), 4(9), 75-82

[6]. Ghosh, N., Pal, P. K., & Nandi, G. (2016). Parametric optimization of gas metal arc welding process by PCAbased Taguchi method on ferritic stainless steel AISI409. Materials Today: Proceedings, 4(9), 9961-9966. https://doi. org/10.1016/j.matpr.2017.06.302

[7]. Ghosh, N., Pal, P. K., & Nandi, G. (2017). GMAW dissimilar welding of AISI 409 ferritic stainless steel to AISI 316L austenitic stainless steel by using AISI 308 filler wire. Engineering Science and Technology, an International Journal, 20(4),1334-1341. https://doi.org/10.1016 /j.jestch. 2017.08.002

[8]. Hardness Test of Welds (2006). Hardness of Welds Retrieved from https://fdocuments.in/document/hardness -test-of-welds.html

[9]. Hooda, A., Dhingra, A., & Sharma, S. (2012). Optimization of MIG welding process parameters to predict maximum yield strength in AISI 1040. International Journal of Mechanical Engineering and Robotics Research (IJMERR), 1(3), 203-213.

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[11]. Kanakavalli, P. B., Babu, B. N., & Sai, C. P. V. (2019). A hybrid methodology for optimizing MIG welding process parameters in joining of dissimilar metals. Materials Today: Proceedings (pp.1-6). https://doi.org10.1016/j.matpr.2019 05. 396

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[14]. Meena, S. L., Butola, R., Murtaza, Q., Jayantilal, H., & Niranjan, M. S. (2017). Metallurgical investigations of microstructure and micro hardness across the various zones in synergic MIG welding of stainless steel. Materials Today: Proceedings, 4(8), 8240-8249. https://doi.org/ 10.1016/j.matpr.2017.07.166

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[16]. Naik, A. B., & Reddy, A. C. (2018). Optimization of tensile strength in TIG welding using the Taguchi method and Analysis of Variance (ANOVA). Thermal Science and Engineering Progress, 8, 327-339. https://doi.org/10.1016/ j.tsep.2018.08.005

[17]. Pavani, P., Sivasankar, P., Lokanadham, P., & Mhahesh, P. U. (2015). Finite element analysis of residual stress in butt welding of two similar plates. International Research Journal of Engineering and Technology, 2(7), 479-486.

[18]. Rao, P. S., Gupta, O. P., Murty, S. S. N., & Rao, A. K. (2009). Effect of process parameters and mathematical model for the prediction of bead geometry in pulsed GMA welding. The International Journal of Advanced Manufacturing Technology, 45(5-6), 496-505. https://doi. org/10.1007/s00170-009-1991-1

[19]. Sen, R., Choudhury, S. P., Kumar, R., & Panda, A. (2018). A comprehensive review on the feasibility study of metal inert Gas Welding. Materials Today: Proceeding, 5(9), 17792-17801. https://doi.org/10.1016/j.matpr.2018.0 6.104

[20]. Shveyov, A., Shveyov, I., Kazantsev, R., Shveyova, E., & Shveyova, T. (2017). The study of hardness of welded joints of parts in the automotive industry. International Journal of Applied Engineering Research, 12(6), 912-917.

[21]. Sivaraman, A., & Paulraj, S. (2017). Multi-response optimization of process parameters for MIG welding of AA2219-T87 by Taguchi Grey relational analysis. Materials Today: Proceedings, 4(8), 8892-8900. https://doi.org/ 10.1016/j.matpr.2017.07.240

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Research Paper

Navier–Stokes Computations on Type-IVr Shock-Shock Interaction mechanism over Double Wedge (15-60) at High Speed Flows

Sravan Kumar Kota* , Sameer Ahamed Shaik**

*-** Samhams Technologies, Nellore, Andhra Pradesh, India.

Kota, S. K., and Shaik, S. A. (2020). Navier–Stokes Computations on Type-IVr Shock-Shock Interaction mechanism over Double Wedge (15-60) at High Speed Flows. i-manager's Journal on Mechanical Engineering, 10(1), 21-31. https://doi.org/10.26634/jme.10.1.16708

Abstract

In this paper, the new concept of shock/shock and shock/boundary layer interactions at hypersonic flow, i.e Type IVr Interaction has been analyzed. The investigation is restricted to stream at Mach 9 around a two-fold wedge chose to produce an interaction of type IVr that does not fit into Edney's (I-VI) order. It is generally known that the interaction of type IV is associated with very high local loads in pressure and heat transfer. The numerical goals of the Navier Stokes conditions permit the forecast of the structure of stream fields like shear layer, expansion fan, slip line, adverse pressure gradient, and separation bubble. The numerical method used is based upon a finite-volume formulation defined on a structured mesh, and analysis is carried out through linear and non-Linear Eddy Viscous Methods. Unlike other interactions held by Edney, the Type-IVr is completely contradicting the flow phenomena obtained during and after the interaction region. Interaction took place in the first wedge itself and the Supersonic Jet will continue three fourth along with the second wedge. The flow will be transonic exactly at the wedge. Specific accentuation is given to the commitment of Reynolds number on the topological qualities and dynamic structure of the stream field. A comparative analysis of the contours and vectors of Mach number, Skin friction, and pressure co-efficient is shown. The results acquired and indicated that the flow field is exceptionally delicate to disturbance impacts.

References

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Research Paper

Mechanical Properties of Hybrid Fiber Reinforced Epoxy Composites

R. Srinivasan * , Thirugnanam S.**

*-** Department of Mechanical Engineering, SRM Valliammai Engineering College, Chennai, Tamil Nadu, India.

Srinivasan, R., and Thirugnanam. S. (2020). Mechanical Properties of Hybrid Fiber Reinforced Epoxy Composites. i-manager's Journal on Mechanical Engineering, 10(1), 32-40. https://doi.org/10.26634/jme.10.1.16744

Abstract

Natural fibers possess vital benefits, such as low density, required stiffness, high disposability, and renewability. Additionally, they are recyclable and biodegradable. Banana fiber is, a natural fiber, obtained from the pseudo-stem of banana plant. Banana fiber has very high cellulose content. Its cost is very low and it is extensively available. It can also be easily blended with any material to obtain desired properties. Hence, it becomes a suitable option as a reinforcing material in polymer composites. The materials epoxy, hardener, banana fiber, and nylon fiber, are used and hand layup method is adopted to manufacture the composite. In this research, Banana fiber is mixed as reinforcement with nylon fiber in epoxy polymer composite. The weight fraction of banana fiber is 20% and 30%. The tensile strength, flexural strength, flexural modulus, and impact properties are studied through relevant experiments. It is observed that the above mechanical properties of hybrid natural fiber composites were increased with an increase in banana fiber weight fraction following rule of mixtures.

References

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[10]. Liu, W., Misra, M., Askeland, P., Drzal, L. T., & Mohanty, A. K. (2005). 'Green' composites from soy based plastic and pineapple leaf fiber: Fabrication and properties evaluation. Polymer, 46(8), 2710-2721. https://doi.org/ 10.1016/j.polymer.2005.01.027

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[12]. Rojo, E., Alonso, M. V., Oliet, M., Del Saz-Orozco, B., & Rodriguez, F. (2015). Effect of fiber loading on the properties of treated cellulose fiber-reinforced phenolic composites. Composites Part B: Engineering, 68, 185-192. https://doi.org/10.1016/j.compositesb.2014.08.047

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[19]. Wu, Y., Xia, C., Cai, L., Garcia, A. C., & Shi, S. Q. (2018). Development of natural fiber-reinforced composite with comparable mechanical properties and reduced energy consumption and environmental impacts for replacing automotive glass-fiber sheet molding compound. Journal of Cleaner Production, 184, 92-100. https://doi.org/10.1016/j.jclepro.2018.02.257

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Effect of Variation of Alloying Elements on Hardness and Impact Strength Characteristics and Application of Taguchi Technique for Optimization of Drilling Parameters of Aluminum Alloy Al6463

Amardeepak M.* , Narayana B. Doddapattar, Sanjeeva Murthy*

- Cambridge Institute of Technology (North Campus), Bangalore, Karnataka, India.

Department of Mechanical Engineering, Sri Siddhartha Institute of Technology, Tumkur, Karnataka, India.

Amardeepak, M., Doddapattar, N. B., and Murthy, S. (2020). Effect of Variation of Alloying Elements on Hardness and Impact Strength Characteristics and Application of Taguchi Technique for Optimization of Drilling Parameters of Aluminum Alloy Al6463. i-manager's Journal on Mechanical Engineering,10(1), 41-50. https://doi.org/10.26634/jme.10.1.16841

Abstract

Aluminium was a late comer to the industry due to the fact that its commercial production began only towards the end of 19^th century. It is the third most abundant metal in the earth's crust, which is combined with oxygen and other elements in its natural form. It has a face centred cubic structure and is easier to machine. The most widely used non-ferrous metals in engineering are aluminium alloys, which are widely used in the automotive and aerospace industries. These alloys possess some important characteristics like good ductility and corrosion resistance, high strength to weight ratio and can be heat treated to enhance the mechanical properties while maintaining low weight. The present work mainly focuses on the study of mechanical properties by conducting the Impact and Hardness tests on the aluminium alloy Al6463 by varying the compositions of the two major elements, Mg and SI in the alloy. The Impact energy absorbed and hardness of the aluminium alloy Al6463 by varying the Magnesium composition b/w (0.5 to 0.875%) and Silicon composition b/w (0.2 to 0.575%) is studied in this research work. The specimens were prepared as per ASTM standard size for hardness and impact tests. The results indicate that highest impact strength of the alloy Al6463 was obtained for 0.750% Mg and 0.2% Si compositions whereas the highest hardness was obtained for Mg compositions of 0.5% and 0.875% Mg and SI composition of 0.575%. Drilling of Al6463 alloy was carried out with the experiments conducted based on Taguchi's L₁₆ Orthogonal Array to get the optimized values of the drilling parameters. The drilling parameters selected were feed, speed, depth of cut, drill bit diameter, and material composition, which were varied in 4 levels. The main effect plots were studied to determine the influence of the drilling parameters on machining responses, such as surface roughness, material removal rate, machining time, machining force, and machining power.

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Review Paper

A Study on Optimization of Machining Parameters in Cylindrical Traverse Rough and Finish Cut Grinding Processes

Manikandan M.* , S. Prabagaran, N. M. Sivaram*, Milon Selvam Dennison****

- Department of Mechanical Engineering, Karpagam Academy of Higher Education, Coimbatore, Tamil Nadu, India.

Department of Mechanical Engineering, National Institute of Technology, Puducherry, Karaikal, Tamil Nadu, India.

**** Department of Mechanical Engineering, Kampala International University, Uganda.

Manikandan, M., Prabagaran, S., Sivaram, N. M., and Dennison, M. S. (2020). A Study on Optimization of Machining Parameters in Cylindrical Traverse Rough and Finish Cut Grinding Processes. i-manager's Journal on Mechanical Engineering, 10(1), 51-65. https://doi.org/10.26634/jme.10.1.16626

Abstract

Grinding is one of the most important and widely used manufacturing processes. In grinding operation, the selection of optimum process parameters is vital. Achieving optimum Material Removal Rate and surface finish at minimum possible machining cost and time is a challenging task. Various researchers are working in this field to get optimum yields and optimum planning of experiments. The optimum conditions could be yielded using traditional and nontraditional optimization techniques, such as Taguchi, Response Surface Methodology, Genetic Algorithm, etc. In this article, an attempt is made in reviewing the effect of various process parameters on various grinding operation on different steel alloy materials. This review relies on notable academic publications and conference proceedings.

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Volume 10 Issue 1 November - January 2020

Effects of Parameters on Sourface Roughness and Material Removal in EDM of High Chromium Steel-D7

Palwinder Singh* , Lakhvir Singh**

*-** Department of Mechanical Engineering, Baba Banda Singh Bahadur Engineering College, Fatehgarh Sahib, Punjab, India.

Singh, P., and Singh, L. (2020). Effects of Parameters on Sourface Roughness and Material Removal in EDM of High Chromium Steel-D7. i-manager's Journal on Mechanical Engineering, 10(1), 1-12. https://doi.org/10.26634/jme.10.1.16576

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Evaluation of Metallographic Properties for Welding of AISI 1040 Steel

Saurabh Gandhe* , V. S. Aher**, V. D. Wakchaure***

*-*** Department of Mechanical Engineering, Amrutrahini College of Engineering, Maharashtra, India.

Gandhe, S., Aher, V. S., and Wakchaure, V. D. (2020). Evaluation of Metallographic Properties for Welding of AISI 1040 Steel. i-manager's Journal on Mechanical Engineering, 10(1), 13-20. https://doi.org/10.26634/jme.10.1.16668

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Navier–Stokes Computations on Type-IVr Shock-Shock Interaction mechanism over Double Wedge (15-60) at High Speed Flows

Sravan Kumar Kota* , Sameer Ahamed Shaik**

*-** Samhams Technologies, Nellore, Andhra Pradesh, India.

Kota, S. K., and Shaik, S. A. (2020). Navier–Stokes Computations on Type-IVr Shock-Shock Interaction mechanism over Double Wedge (15-60) at High Speed Flows. i-manager's Journal on Mechanical Engineering, 10(1), 21-31. https://doi.org/10.26634/jme.10.1.16708

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Mechanical Properties of Hybrid Fiber Reinforced Epoxy Composites

R. Srinivasan * , Thirugnanam S.**

*-** Department of Mechanical Engineering, SRM Valliammai Engineering College, Chennai, Tamil Nadu, India.

Srinivasan, R., and Thirugnanam. S. (2020). Mechanical Properties of Hybrid Fiber Reinforced Epoxy Composites. i-manager's Journal on Mechanical Engineering, 10(1), 32-40. https://doi.org/10.26634/jme.10.1.16744

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Effect of Variation of Alloying Elements on Hardness and Impact Strength Characteristics and Application of Taguchi Technique for Optimization of Drilling Parameters of Aluminum Alloy Al6463

Amardeepak M.* , Narayana B. Doddapattar**, Sanjeeva Murthy***

*-** Cambridge Institute of Technology (North Campus), Bangalore, Karnataka, India. *** Department of Mechanical Engineering, Sri Siddhartha Institute of Technology, Tumkur, Karnataka, India.

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A Study on Optimization of Machining Parameters in Cylindrical Traverse Rough and Finish Cut Grinding Processes

Manikandan M.* , S. Prabagaran**, N. M. Sivaram***, Milon Selvam Dennison****

Manikandan, M., Prabagaran, S., Sivaram, N. M., and Dennison, M. S. (2020). A Study on Optimization of Machining Parameters in Cylindrical Traverse Rough and Finish Cut Grinding Processes. i-manager's Journal on Mechanical Engineering, 10(1), 51-65. https://doi.org/10.26634/jme.10.1.16626

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Saurabh Gandhe* , V. S. Aher, V. D. Wakchaure*

Amardeepak M.* , Narayana B. Doddapattar, Sanjeeva Murthy*

- Cambridge Institute of Technology (North Campus), Bangalore, Karnataka, India.

Department of Mechanical Engineering, Sri Siddhartha Institute of Technology, Tumkur, Karnataka, India.

Manikandan M.* , S. Prabagaran, N. M. Sivaram*, Milon Selvam Dennison****