Review Study and Importance of Micro Electric Discharge

Micro EDM process is one of the micro- machining processes. It can be used to machine micro features and makes a micro parts. There is a huge demand in the production of microstructures by a non-traditional method which known as Micro-EDM. Micro-EDM process is based on the thermoelectric energy between the work-piece and an electrode. Micro-EDM is a newly developed method to produce micro-parts which in the range of 50 μm -100 μm. Micro-EDM is an efficient machining process for the fabrication of a micro-metal hole with various advantages resulting from its characteristics of non-contact and thermal process. A pulse discharges occur in a small gap between the work piece and the electrode and at the same time removes the unwanted material from the parent metal through the process of melting and vaporization. This paper describes the importance, parameters, principle, difference between Macro and micro EDM, applications and advantages of µ-EDM and discuss about the literature reviews based on performance measure in micro- EDMP process. Keywords: Micro EDM, MRR, TWR, S

Study of the Effect of Varying Pouring Rate on Mechanical Properties of Al-Cu and SiCp Reinforced Metal Matrix Composites (MMC)

The investigation studies of Metal Matrix Composites (MMCs) have emerged as an important class of materials for structural, wear, thermal, transportation and electrical applications. Metal Matrix Composites (MMCs) possess significantly improved properties including high specific strength; specific modulus, damping capacity and good wear resistance compared to unreinforced alloys. There are several techniques to produce composites, such as liquid state, solid state and semi solid state production route. In this paper, we studied a composite with cheap and simple production route i.e. stir casting method. We have chosen 5% SiC as the reinforcement material and balanced Al + 4% Cu as matrix phase. The pouring rate is varying 2cm/sec., 2.5cm/sec. and 3cm/sec. The effects of input (independent) variables as pouring rate (2cm/sec.,2.5cm/sec. and 3cm/sec) and material type’s on output (dependent) variables as hardness, impact strength and ultimate tensile strength, statistically analysis were performed by using SPSS 17.0. The best result value of BHN, Impact and UTS has been obtained at optimum pouring rate 2.5cm/sec. The pouring temperature kept constant at 7000C for all composites. The mechanical properties as hardness, impact and tensile strength were enhanced with reinforcement SiC particles. The results were further justified by comparing with other investigators. Keywords: Metal Matrix Composites MMCs, Stir, Pouring Temperature, Pouring Rate, UTM, and Hardness

Design and fabrication of dual chargeable bicycle

With the increase in fuel prices, pollution content in atmosphere and due to gradual end of the non renewable sources of energy we have to alter the source of our energy in our vehicles. Considering all these reasons we have to switch over to other sources of energy instead of using conventional sources such as petrol which in future will be going to extinct. One way to alter the energy source is to go for electric vehicles or e bikes. Electric driven vehicles uses battery as a source of energy which provide power to motor which in turn provide  torque to wheels .The old design of electric bicycle was having only a single mode of charging, it was just capable to travel 15 km through battery and was not ergonomically good. The new design uses a low rpm alternator for charging the battery by keeping it in contact with front wheel .A Motor of 0.5hp provides torque to the rear wheel and the gear ratio is kept 5:2 .battery discharging time is approximately 2 hrs and charging time through alternator is 1 hour and the bicycle can attain a maximum speed of 15 km/hr. This work is more beneficial in hilly region and confined areas like college campus and schools, generating zero pollution, zero noise effect and no fuel consumption. Keywords: Dual chargeable bicycle, EABs, EPBs, Battery, Alternator, Controller

Investigations on Material Removal Rate of AISI D2 Die Steel in EDM using Taguchi Methods

Electrical discharge machining (EDM) process is one of the most commonly used non conventional precise material removal & world class standard non contacting machining processes. The work piece must be a conductive electricity material which is submerged into the dielectric fluid for better erosion. This process widely used for machining of hard, brittle, component   material,  complex geometry, intricate shapes, making moulds & deep holes by arc erosion in all kinds of electro conductive materials. The workpiece material selected in this study is AISI D2 Die Steel. The input parameters are voltage, current, pulse on time and pulse off time. L9 orthogonal array was selected as per the Taguchi method. The data have been analyzed using Minitab15 Software. The effect of above mentioned parameters upon machining performance characteristics such as Material Removal Rate (MRR) is studied and investigated on the machine model C-3822 with PSR-20 Electric Discharge Machine.  The copper alloy was used as tool material. Keywords: EDM, MRR, ANOVA, Taguchi method, AISI D2 Die steel, copper electrod

Investigations on Tool Wear Rate of AISI D2 Die Steel in EDM using Taguchi Methods

EDM has become an important and cost-effective method of machining extremely tough and brittle electrically conductive materials. It is widely used in the process of making moulds and dies and sections of complex geometry and intricate shapes. The workpiece material selected in this study is AISI D2 Die Steel. The input parameters are voltage, current, pulse on time and pulse off time. L9 orthogonal array was selected as per the Taguchi method. The data have been analyzed using Minitab15 Software. The effect of above mentioned parameters upon machining performance characteristics such as Tool Wear Rate (TWR) are studied and investigated on the machine model C-3822 with PSR-20 Electric Discharge Machine.  The copper alloy was used as tool material.The results obtained showed that the optimum condition for tool wear rate (TWR) is A3, B2, C2, D3 i.e. Ton (40µs),Toff (8 µs), Ip (8 amp) and Vg (60V). The order of process parameters influencing the tool wear rate is Toff 12>"> Ip 12>"> Ton 12>"> Vg. Hence, pulse off parameter has more contribution to tool wear rate whereas gap voltage has the least contribution. As per the optimal level of parameters, the optimum value of TWR is 0.117 mm3/min. These results were validated by conducting confirmation experiments and found satisfactory. Keywords: EDM,TWR, MRR, ANOVA, Taguchi method, AISI D2 Die steel, copper electrod

Design and fabrication of variable steering ratio mechanism for light Motor vehicle

To facilitate easy and proper steering of the vehicle while negotiating a turn, as per the requirements of driver in different situations like hair pin bends in hilly regions, sudden turns in highways and city streets or in sports car during race events an improved steering system is needed to address these problems. The steering arrangement used in a normal automobile was investigated and to solve the above problems a variable steering ratio mechanism was designed and fabricated, with the aim to determine if incorporation of variable steering ratio mechanism will make an improvement in the steady and transient state handling of the automobile. The size of the pinion gear and the number of teeth on the gear determine the rack-and-pinion steering ratio. The steering wheel must be turned one revolution to turn the front wheels one sixteenth of a turn, the steering ratio is 1 to 1/16. Reversing the numbers gives a ratio of 16 to 1, or 16:1. This steering ratio is always fixed. A variable steering ratio mechanism was fabricated by using constant mesh type gears from Bajaj-Super and steering mechanism from Tata-Nano. Gear housing using wood is created and gear shifting arrangement incorporated. It was observed that on engaging the 1st gear steering ratio is increased to 9.92:1. On engaging the 2nd gear steering ratio is increased to 7.20:1, On engaging the 3rd gear steering ratio is increased to 4.96:1 On engaging the 4th gear steering ratio is increased to 3.52:1. The effort required for steering is increased due to these ratios as energy is lost due to friction. This mechanism can only be practical if used in conjugation with power assist.   Keywords: - Variable Steering Ratio Mechanism, Constant Mesh Gear Box, Steering Wheel, Power Assis

Thermal analysis of various duct cross sections using altair hyperworks software

In this work thermal analysis and comparison of various duct cross sections is done computationally using Altair Hyperworks Software. Simple Analytical results were obtained for conduction and convection through the ducts which can be used to build up thermal circuit. The inner surface of all ducts is maintained at constant temperature and ambient air is at certain temperature that is less than inner surface temperature of pipe. Due to temperature difference heat will flow from higher temperature to lower temperature. Due to temperature difference heat will flow from higher temperature to lower temperature. The material of pipe provides conductive resistance and air provides convective resistance. Hence this is a mix mode of heat transfer. The heat transfer takes place in one dimension only and properties are considered to be isotropic. The ducts are assumed to be made of aluminium having known thermal conductivity and density. The surroundings of ducts have known convective heat transfer coefficient and temperature. The results are obtained on hyperview which are for heat flux, temperature gradient and grid temperature. The different characteristics can be obtained by varying the material of the ducts. Keywords: Ducts, Altair Hyperwork

Computer Govern Maintenance System for a Process Industry

The present paper deals with development of Computer Govern Maintenance System (CGMS) for a Process Industry. The developed software is easy to use, less complicated, less costly and less time consuming and consisting of number of modules like detailed information of equipment,  procedures of maintenance tasks, employees, work order, and calendar facility etc. The software has been developed in Microsoft Visual Studio.NET. The development of CGMS Software i.e. ‘IOCL CGMS’ at “IOCL Panipat   Refinery”, Panipat, may furnish good results. The currently developed CGMS aims to reduce total downtime, overall annual maintenance cost, frequency of failures of the machines, to get day-by-day maintenance schedule, maintenance policy. Keyword   : Computer Govern Maintenance System, Maintenance Schedule, Maintenance Policy

Design & Fabrication of Manually Driven Pedal Powered Washing Machine

Cloth washing is one of the essential parts of the life but it is considered undesirable because of the involvement of efforts, time, energy and cost. Nowadays a wide variety of washing machines are available in the market and there is a tough competence among the manufacturers. The cost of washing machine varying from Rs.10,000 to 1,50,000 depending upon features and capabilities. Very costly washing machines are equipped with facility of dry cleaning too. All of the washing machines available in the market are electric power driven and basic principle of their operation depends upon creation of the turbulent flow of detergent around the dirty clothes. Drying of the clothes is based upon rotation of wet clothes at very high rpm so that water droplets can be separated out due to centrifugal action. In our country where approximately 70% population is living with very poor economic status, those people cannot have a washing machine because of cost constraints and unavailability of electricity due to any reason. The present work is an attempt to develop a concept to make a cloth washing mechanism which can meet out the requirements of above mentioned 70% population of the nation. Working principle of this concept is no more different from available similar type of machine with a difference driving mechanism of the machine. The objective of bringing down the initial cost and operating cost of washing machine is almost achieved in present work within the limitation of work as mentioned. Key word: CWT, CEA, 1. Introductio

Designing the Process of Stores Management for Implementing ERP in Manufacturing Organization: Case Study

This paper describes the importance of ERP in manufacturing industries and examines the various articles published by eminent Researchers in the field of ERP. Enterprise Resource Planning (ERP) software presents a frame work for organizations to better utilize their processes. The report is about windows based application. The main idea of this paper is to handle the all details of stores management system. In this project software package has been developed to smoothen the processing of item transaction in stores such as item receive, item issue & report generation such as stock statement, issue register & receive register etc. This Software will help in automating all the process like receiving and issuing application in stores. Keywords – SQL, ERP, RM Stores, PM Stores, Client/Server technology