Informatics Publishing Limited

S. Jeevanantham ¹, J. David Rathnaraj ², D. S. Robinson Smart ³, S. Nallusamy ⁴, N. Manikanda Prabu ⁵

Affiliations
1 Department of Mechanical Engineering, Karpagam University, Coimbatore - 641021, Tamil Nadu, IN
2 Department of Mechanical Engineering, Sri Ramakrishna Engineering College, Coimbatore - 641022, Tamil Nadu, IN
3 3School of Mechanical Sciences, Karunya University, Coimbatore - 641114, Tamil Nadu, IN
4 Department of Mechanical Engineering, Dr. M G R Educational and Research Institute, Chennai - 600095, Tamil Nadu, IN
5 Department of Mechanical Engineering, Nehru institute of Engineering and Technology, Coimbatore - 641105, Tamil Nadu, IN

Abstract

Objective: To generate the information about the process of internal grinding applied to envisage the grinding performance and accomplish the optimal operating procedure characteristics. In recent engineering and technology surface finish and precision are playing a major role in the manufacturing organizations. Method/Analysis: Different methods such as burnishing, honing, lapping and grinding are exercised for accomplishing good quality of surface finish. Grinding is the appropriate method for improving the surface finish and precision concurrently between all of those constraints. Recently lot of researches has been carried out on surface grinding process, but only few articles were elaborately described about the internal grinding procedure. In view of the fact the internal grinding processes was chosen as a main tool to characterize throughout this study. Findings: Similar to surface grinding various process parameters are used to get high surface finish and it could be achieved for the various components. This article relating the possibilities to get greater surface finish in internal grinding process and also it demonstrates the machining parameters involved in this process. Application/ Improvements: The machining parameters involved in these abrasive machining technologies were speed, feed, depth of cut and material removal rate and also these constraints were considered throughout the theoretical investigation.

Keywords

Internal Grinding, MRR, Process Constraints, Surface Roughness, Surface Finish.

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S. Nallusamy ¹, A. Karthikeyan ¹

Affiliations
1 Department of Mechanical Engineering, Dr. M G R Educational and Research Institute, Chennai - 600095, Tamil Nadu, IN

Abstract

Objective: In modern manufacturing technology, now a day’s metal matrix composites are being increasingly identified as new wear resistant material. The main purpose of this article is to investigate the wear down and depth of indentation of the composite material of Al-6061 alloy strengthened with silicon carbide particulate and supported with alumina particulate constructed by stir casting method. Method/Analysis: The wear down rate and frictional properties of the composite were learned by using the dry sliding wear test with a pin on disk wear tester. The investigation was carried out with 1750 meters of sliding distance and 1.55m/s of stable sliding velocity over different loads by 10N and 20N for aluminium metal matrix composite. Findings: The testing result indicated that the wear resistance increases when there is increase in the load as well as in the sliding distance. Additionally an effort was made by keeping 7% of Al2O3 constant along with increase in 10, 15 and 20% of SiC. It was observed that, the strengthened aluminium metal matrix in addition of SiC and Al2O3 decreases the range of wear rate. Also found that the coefficient of friction increased by means of raising the load and quantum of reinforcement. Application/Improvements: By using scanning electron microscope the wear surfaces were examined and it was observed that the micro and transverse cracks, mild and severe wear occurred in the composite worn surfaces and wear structure of the composite.

Keywords

Al-6061Alloy, Hardness, Hybrid Composite, Stir Casting, SEM, Wear & Crack.

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S. Nallusamy ¹, V. Saravanan ¹

Affiliations
1 Department of Mechanical Engineering, Dr. MGR Educational and Research Institute, Chennai - 600095, Tamil Nadu, IN

Abstract

Objective: To study and implement the lean tools and to reduce lead time without much affecting the current working systems in a small scale automotive component manufacturing industry. Method/Analysis: An attempt was made in increasing the capacity of a machining cell with appropriate lean techniques. The enhancement of capacity was to be completed with zero capital investment. Findings: A lean approach by using value stream mapping and line balancing was adopted to improve the performance of the manufacturing cell. By collecting the past production data and deciphering the information, gaps were identified for enhancement. Single Minute Exchange of Dies (SMED) was used to regulate the production and Kaizen was also introduced in all work stations. Leveled operator loading for output consistency was suggested. Finally capacity intensification was achieved without any major capital investment. Application/Improvements: Implementation of lean tools reduced the setup time and idle time. The overall lead time got reduced from 6.9 days to 3.6 days and total cycle time got reduced from 170 to 140 minutes and the customer demand was also met on time by the execution of lean tools.

Keywords

Cycle Time, Lead Time, Line Balancing, SMED, TAKT Time, VSM.

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K. Balakannan ¹, S. Nallusamy ², P. S. Chakraborty ³, Gautam Majumdar ⁴

Affiliations
1 Department of Mechanical Engineering, Sri Muthukumaran Institute of Technology, Chennai - 600069, Tamil Nadu, IN
2 Departments of Mechanical Engineering, Dr. M.G.R. Educational and Research Institute, Chennai - 600095, Tamil Nadu, IN
3 Department of Adult and Continuing Education and Extension, IN
4 Department of Mechanical Engineering, Jadavpur University, Kolkata - 700032, West Bengal, IN

Abstract

Objective: In universal spirited environment, automotive industries are desired to perform efficiently to meet the maximum percentage of demand by minimum cost. The objective of this article is to create a balance scorecard model for the evaluation of reliability and performance of automotive manufacturing industries to evaluate their supply and demand chain system. Method/Analysis: Using this new idea, the performance of industries should be assessed regarding their supply and demand chain system with the major four criteria like design and development, manufacturing point, financial requirement and consumer’s point of view. The main four features of the industries are policies and firm coordination, design and execution, effectiveness of shipment and information technology usagetotally covers by the new designed balanced scorecard with twenty five evaluation points. Findings: Abroad survey was carried out in Indian automotive manufacturingindustries with well structured questionnaires to collect the necessary data. Application/Improvements: The comparison between multinational, public limited, private limited and small scale organizations were carried out tomeasure the performance variation of their supply and demand chain system. Based on the correlation of above four features, a structural equation model was designed toimprove the supply and demand chain management systemfor automotive manufacturing industries and found that the α coefficient was above 0.80 hence, the balanced score card was reliable.

Keywords

Evaluation, Efficiency, PSPP Software, Reliability, SCM, Score Card.

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R. Suganthini Rekha ¹, P. Periyasamy ¹, S. Nallusamy ²

Affiliations
1 Department of Mechanical Engineering, St. Peter’s University, Chennai-600 054, Tamilnadu, IN
2 Department of Mechanical Engineering, Dr. M G R Educational and Research Institute, Chennai-600 095, Tamilnadu, IN

Abstract

Objective: To examine the existing system of a production line in a shop floor of steering gear box manufacturing industry and to improve the productivity using lean methodology without much affecting current working systems. Method/ Analysis: An extensive range of lean manufacturing tools are available to take care of all kinds of issues faced by different manufacturing industries. It also helps for successful cost reduction of the manufacturing component and to assure the quality of manufacturer and customer. Findings: The critical Non-Value added Activities (NVA) were recognized and probabilities required for development has been recognized. Value Stream Mapping (VSM) has the reputation of finding waste during manufacturing and business process which facilitate to identify and remove or stream the value added steps and to eliminate the non-value added steps. Application/Improvements: After accomplishment of appropriate lean tools, it was found that the total setup time was condensed by about 180 minutes and cycle time was condensed by about 98 minutes which ultimately reduces the lead time and increases the productivity.

Keywords

CNC, Gear Box, Lead Time, Line Balancing, VSM, Work Standardization.

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S. Nallusamy ¹, Saurabh Kumar ¹

Affiliations
1 Department of Mechanical Engineering, Dr. M.G.R. Educational and Research Institute, Chennai - 600 095, Tamil Nadu, IN

Abstract

Objective: The objective of this study is to create ecological awareness in selection of different materials that go into a product through an organized method to achieve the satisfaction level of performance and product life cycle. Method/Analysis: Ecological collision of carbon dioxide, sulfur dioxide, phosphate, abiotic depletion fossil and dichlorobenzene was evaluated using Centrum Voor Milieukunde Leiden (CML) methodology during the product life cycle. The analysis was carried out on the impeller of a subassembly component of the product chosen. LCA software GaBi was used to estimate the emission levels and compared with the existing subassembly while arithmetical simulation test was carried out using ANSYS 14.5 to ensure the life time and efficiency of the product. Findings: The main focus of this study which is to assess the overall ecological collision through the CML/LCA methodology revealed diminution in pollutant emission and ecological collision was observed to have reduced by thirty eight percentage of carbon dioxide, thirty seven percentage of sulfur dioxide, thirty eight percentage of phosphate and six percentage of dichlorobenzene. With arithmetical simulation test it was found that material alteration to aluminum silicon carbide from brass increases the life span and efficiency with imperative diminution in stress, stress intensity and deformation. Application/Improvements: The results show that the reduction in pollutant emission levels helping in the reduction of the global warming and also allows the users and manufactures of various subassembly components in choosing better alternate material.

Keywords

CML Methodology, Dissimilar Material, Efficiency, LCA, Life Span

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