International Journal of Manufacturing Research (13 papers in press)

Regular Issues

• Investigations on the Machining Characteristics of Ti-6Al-4V Alloy during High Speed End Milling Process  
  by Samsudeensadham S, V. Krishnaraj, Thilak R, Prasath V 
  Abstract: In recent years’ titanium alloys have gained prominence in aircraft component manufacturing because of their higher specific strength and aversion to oxidation. High speed machining of high hardness materials like titanium alloys under dry environmental conditions takes through a lot of challenges in maintaining a better surface integrity. This machining study emphasises the analysis of surface integrity concerning high speed machining conditions during end milling of Ti-6Al-4V alloy in dry cutting environments. The experiments were carried out under the cutting speeds of 100 to 140 m/min. The milling forces were measured in the feed, tangential and axial directions. Virtual measurement of temperature was performed through a thermal camera. Experimental tests reveal that machining parameters such as feed and speed have a higher influence on milling force and surface roughness when compared with the axial depth of cut; simultaneously cutting speed has a higher influence on the temperature induced micro harness.
  Keywords: high speed machining; Ti-6Al-4V alloy; temperature; milling forces; surface integrity.
  DOI: 10.1504/IJMR.2023.10041624
   
  
• Integration of Augmented Reality Smart Glasses as Assembly Support: A Framework Implementation in a Quick Evaluation Tool  
  by Oscar Danielsson, Anna Syberfeldt, Magnus Holm, Peter Thorvald 
  Abstract: Augmented reality smart glasses (ARSG) have been successfully used as operator support in production. However, their use is not yet widespread, likely in part due to a lack of knowledge about how to integrate ARSG into production. This lack of knowledge can also make it hard to estimate whether this is a worthwhile investment. Our solution is to provide an online evaluation tool to help production planners estimate the likelihood that ARSG will be worth the investment cost in specific production cases. Based on a strawman design, multiple design iterations were followed by a pilot test performed by participants from different manufacturing companies involved in planning production for operators. A Likert scale survey was used to evaluate the tool. The results show a slightly positive evaluation of the tool with suggestions for improvement, including widening the scope and granularity of the tool. Future works include further iterations and case studies.
  Keywords: augmented reality; AR; augmented reality smart glasses; ARSG; assembly operator; framework; evaluation tool; focus groups.
  DOI: 10.1504/IJMR.2023.10043701
   
  
• Optimization of EDMed fly ash and Rice husk ash reinforced hybrid Al-based composite using improved COPRAS and Entropy method  
  by Mohan Kumar Pradhan  
  Abstract: Rice husk ash (RHA) and fly ash (FA) pose a hazard to human health environment and are available abundantly across the globe. Attempts are being made to use such waste materials to create aluminum-based composite materials that can be used in a spectrum of uses. The Al6061/RHA/FA hybrid composite was prepared with 2.5 wt.% of each RHA and FA particle using a stair casting technique. This paper discusses mechanical characteristics like tensile strength, hardness, percentage elongation, and surface morphology were investigated using SEM. Besides, machinability investigations have been carried out using electric discharge machining, targeting the productivity of the component, quality, and accuracy. Taguchi’s L9 array was used to investigate the impact of parameters like pulse current, duty-cycle, pulse ontime, and gap voltage on output parameters MRR, tool eroded, and radial overcut. Enhancements in tensile strength and harshness have been observed by the reinforcement of FA and RHA particles.
  Keywords: die-sinking electro discharge machining; EDM; metal matrix composite; MMC; material removal rate; MRR; aluminium matrix composites; AMC.
  DOI: 10.1504/IJMR.2023.10043826
   
  
• Finite Element based Comparative Investigation of Incremental Forming and Elevated Temperature Incremental Forming  
  by Swarit Anand Singh, Satwik Priyadarshi, Puneet Tandon 
  Abstract: Incremental forming (IF) is a non-traditional forming process to transform sheets into useful components without using devoted tooling and die arrangements. The execution of IF at higher temperatures is known as elevated temperature incremental forming (ET-IF). This work compares the IF and ET-IF processes through the finite element analysis (FEA) approach. The FEA results are compared in terms of stress, plastic strain, and sheet thickness distribution, along with forming depth achieved for the two processes. A descriptive statistical analysis of the results has been performed to strengthen the outcomes. Also, some of the results are compared with the outcome of experimentation available in the literature. It is perceived that the formability extensively improves with the ET-IF process in comparison to that of IF at room temperature. Besides, it has been observed that increased temperatures prominently enhance the quality of the IF process.
  Keywords: incremental forming; elevated temperature incremental forming; ET-IF; aluminium alloys; finite element analysis; FEA.
  DOI: 10.1504/IJMR.2023.10046604
   
  
• Experimental investigation and multi-response optimization of end milling in Aluminium-5083 alloy using desirability analysis  
  by ABHIMAN DEBNATH, Siddhartha Kar, Uttam Kumar Mandal, Vidyut Dey 
  Abstract: The present study deals with end milling of aluminium alloy (Al 5083-H112) with carbide tools in dry condition. Process parameters, such as cutting speed, feed rate, depth of cut, and tool parameters such as nose shape and number of flutes are varied to investigate their effect on material removal rate (MRR), resultant cutting force (CF) and surface roughness (Ra). Analysis of variance is employed to find the significance of the individual process parameters on the responses. The concept of desirability function analysis is employed to optimise the process parameters for machining. The composite desirability value determines the optimum combination of parameters obtained from all the responses’ simultaneous optimisation. A confirmation test is conducted based on the optimal parameter setting to exemplify the potency of the approach. The confirmation test results are convincingly close to the predicted ones as the errors are less than 5%, which signifies the robustness of the model.
  Keywords: aluminium alloy; end milling; carbide tool; material removal rate; MRR; cutting force; surface roughness; desirability.
  DOI: 10.1504/IJMR.2023.10046713
   
  
• Effectiveness of Frequency Domain Parameters in Decision Tree Based Classification of GMAW Defects  
  by Thomas Rajan P, K. Sundareswaran, P.R. Venkateswaran 
  Abstract: Capability of frequency domain parameters obtained through Fourier analysis of weld signature (current and voltage signals) in decision tree-based real-time weld defect classification is investigated. GMAW under standard weld conditions and with disturbance induced conditions are conducted. Three types of disturbances are introduced
  Keywords: gas metal arc welding; GMAW; defect classification; discrete Fourier transform analysis; frequency spectral parameters; decision tree classifier.
  DOI: 10.1504/IJMR.2023.10049617
   
  
• Surface Study of the Burnishing Process when Vertical High Power Ultrasonic applied  
  by Saber Saffar, Mohammad Emadi, Mohammad Khosroabadi 
  Abstract: The effects of the high-power ultrasonic-assisted ball-burnishing process on a cylindrical 2024 aluminium specimen subjected to T4 heat treatment were investigated. Surface roughness, surface hardness, and hardened surface depth were taken as responses. The feed rate (0.05
  Keywords: ball burnishing; high-power ultrasonic vibrations; surface hardness; surface roughness; response surface methodology; RSM; 2024 aluminium alloy.
  DOI: 10.1504/IJMR.2023.10050210
   
  
• Determination of cost-effective range in surface finish for single pass turning  
  by Mazin Fahad Alahmadi, Bhaskaran Gopalakrishnan, Sabin Wagle 
  Abstract: The machining of parts has to satisfy the surface finish as it affects functionality and robustness of the parts. Managers often focus on the surface finish requirements, subject to minimisation of cost. The objective of this research is to provide a cost-effective range in surface finish for single pass turning, catering to both managers and designers. The proposed methodology, which is based on geometric programming, would provide a range of cutting condition solutions that satisfy the economic and functional needs of the stakeholders. This can be achieved by switching cost reduction focus from tooling to labour cost. An algorithm has been developed to determine the most suitable values for the variables for the purpose of cost minimisation. A sensitivity analysis model, based on metaheuristic techniques is developed to further provide a set of potential solutions that are practically preferable to the practitioners in design and manufacturing.
  Keywords: machining; manufacturing; turning; surface finish; geometric programming; sensitivity analysis; metal cutting; optimal solution; machining parameters.
  DOI: 10.1504/IJMR.2023.10050481
   
  
• Novel tool condition identification based on finite element modeling and support vector machine  
  by Jicai Wang, Bintao Sun, Huan Zhang 
  Abstract: Timely and accurate recognition of tool wear condition could reduce the machining cost greatly. However, the problem of sample missing and imbalance affects the classification accuracy of AI models seriously. A novel strategy based on finite element method (FEM) and support vector machine (SVM) is proposed to overcome the above problem. Firstly, several tool wear experiments are carried out to obtain experimental samples. Then, a FEM model is established and verified through experimental samples. Based on the verified FEM model, several simulated sample of missing and imbalanced samples in experiments could be supplemented to compose a complete training set. The SVM model is trained by the complete training set to tool wear condition identification. Milling tool experiments demonstrate that the proposed method can obtain above 96% identification accuracy with a small number of experiments, which is 28% higher than that based on experimental samples. [Submitted 5 July 2017; Accepted 24 December 2017]
  Keywords: tool wear condition; sample missing and imbalance; finite element modelling; FEM; support vector machine; SVM.
  DOI: 10.1504/IJMR.2023.10050482
   
  
• Line-seru conversion of seed packaging workshop?A case study of company A in China  
  by Yiran Xiang, Zhe Zhang, Xue Gong, Yong Yin 
  Abstract: Seru is a new type of production system that is more efficient, flexible and cost-effective than assembly line, and can quickly respond to fluctuating markets and customer demand. This paper uses the seed packaging workshop of company A in China as a case, proposes to build a line-seru conversion model with the goal of optimal balance rate, implement seru production in the seed packaging industry from the perspective of production practice, to study line-seru conversion. The current production situation of the seed packaging workshop of company A is analysed, and it is found that there are many problems in the existing assembly line. Under this production dilemma, the seru production feasibility study is carried out on the seed packaging workshop, and the line-seru conversion is carried out to obtain the final converted seru simplified diagram of the production mode. After the line-seru conversion, it was concluded that the efficiency of the packaging production was increased by 35.86%, 48.03%, 37.42% and 35.87% respectively and the number of workers has been reduced by 5, 6, 4, and 3 respectively.
  Keywords: seru production; assembly line; line-seru conversion; optimal balance rate; seed packaging workshop.
  DOI: 10.1504/IJMR.2023.10051238
   
  
• Cutting force modeling for peripheral milling with a disk cutter considering instantaneously-engaged area  
  by Xinfeng Liu, Riliang Liu, Jiaming Feng 
  Abstract: Peripheral milling process with a disc milling cutter can be used for the manufacture of freeform surface. In this paper, a cutting force model for this milling process is proposed considering instantaneously-engaged area. Firstly, the peripheral milling process with the cutter is described. Secondly, the geometrical and mathematical models of the cutting tools and chip are modelled. To obtain instantaneous cutting forces, three related geometrical parameters including the instantaneous cutting thickness, instantaneously-engaged height of right-side edge and instantaneously-engaged area are defined and solved. Then the cutting force model is established with the cutting force coefficients solved using the data from cutting tests. Finally, series of cutting experiments are performed on H59 brass to verify the effectiveness of the proposed analytical model. The errors in the predicted result are within 5.97%, 8.06% and 16.14% in the x, y and z directions.
  Keywords: cutting force model; peripheral milling; disc milling cutter; cutting edge; instantaneously-engaged cutting area.
  DOI: 10.1504/IJMR.2023.10052034
   
  
• Improved mechanical properties of steel/aluminum laser welding joint by Ti powder addition: experimental and first-principles investigations  
  by Dianwu Zhou 
  Abstract: The generation of brittle intermetallic compounds (IMCs) need be solved for steel/aluminium welding quality. In this study, Ti powder was selected as interlayer and the experiments of laser penetration welding for steel/aluminium through addition of interlayer were carried out. The effect of adding Ti powder on mechanical properties of the weld was investigated. Experimental results showed that the increased penetration depth was obtained, and the average tensile-shear strength of Ti-added joint was 10% higher than that of No-added joint. First-principle calculations revealed that the effect of reduced brittleness of IMCs with the addition of alloying elements was in accordance with the improved mechanical properties. When Ti powder was added, the grain was small, the layer thickness and brittleness of IMCs decreased, ductile phase Fe2Ti were formed. Hence, mechanical properties of the weld were significantly improved.
  Keywords: laser welding; powder; micro-structure; mechanical properties.
  DOI: 10.1504/IJMR.2023.10053013
   
  
• Development of Hybrid Locomotive In-pipe Robot  
  by ATUL GARGADE, Saantipal Ohol 
  Abstract: This paper describes the development of an autonomous hybrid locomotive In-pipe Inspection Robot (IPIR) version 4. The novelty of version 4 is its hybrid steering mechanism and stability, maneuverability, mobility, flexibility, and diameter adjustability inside the different pipe elements. The vertical mobility and diameter adjustability of IPIR are improved by optimizing its spring design in such a way that version 4 can pass through 8-inch to 10-inch diameter pipe elements at 0-degree, 45-degree, and 90-degree inclinations. The IPIR version 4 is composed of a front leg system, a back leg system, connectors, and two DC motors. To verify the potency of the steering mechanism, several experiments of version 4 are conducted through basic structures such as straight pipes, couplings, and bends of 8-inch, 9-inch, and 10-inch in diameter. This robot will be utilized for the inspection of water pipelines, gas pipelines, and drain pipes.
  Keywords: Autonomous; bends; couplings; maneuverability; steering mechanism; hybrid locomotive.
  DOI: 10.1504/IJMR.2023.10054117