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2020 | Book

Proceedings of International Conference on Intelligent Manufacturing and Automation

ICIMA 2020

Editors: Dr. Hari Vasudevan, Dr. Vijaya Kumar N. Kottur, Dr. Amool A. Raina

Publisher: Springer Singapore

Book Series : Lecture Notes in Mechanical Engineering

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About this book

This book gathers selected papers presented at the Second International Conference on Intelligent Manufacturing and Automation (ICIMA 2020), which was jointly organized by the Departments of Mechanical Engineering and Production Engineering at Dwarkadas J. Sanghvi College of Engineering (DJSCE), Mumbai, and by the Indian Society of Manufacturing Engineers (ISME). Covering a range of topics in intelligent manufacturing, automation, advanced materials and design, it focuses on the latest advances in e.g. CAD/CAM/CAE/CIM/FMS in manufacturing, artificial intelligence in manufacturing, IoT in manufacturing, product design & development, DFM/DFA/FMEA, MEMS & nanotechnology, rapid prototyping, computational techniques, nano- & micro-machining, sustainable manufacturing, industrial engineering, manufacturing process management, modelling & optimization techniques, CRM, MRP & ERP, green, lean & agile manufacturing, logistics & supply chain management, quality assurance & environmental protection, advanced material processing & characterization of composite & smart materials. The book is intended as a reference guide for future researchers, and as a valuable resource for students in graduate and doctoral programmes.

Table of Contents

Frontmatter

Manufacturing

Frontmatter
Exploring Ideal Process Parameters to Enhance the Surface Integrity Using Grey Fuzzy Integrated Technique

Inconel 625 belongs to the category of austenitic nickel chromium-based super alloys and is extensively used in sea water applications, including propeller blades in aerospace as well as oil and gas industries. However, the precision machining of Inconel 625 alloy is still a challenge due to high rate of work hardening, which hinders further applications in industries. In this context, this research study was carried out, involving the end milling of Inconel 625 nickel-based alloy, using process parameters, such as cutting speed, feed per tooth, radial depth of cut and radial rake angle. The study explored the ideal process parameters to enhance the surface integrity of machined surface under a dry cutting environment. The grey fuzzy integrated approach followed gave the best experimental performance, using grey relational coefficient and multi-performance criteria index. Combination of cutting and tool geometry parameters at the feed per tooth of 0.1 mm/tooth, cutting speed 90 m/min, radial depth of cut 0.4 mm and radial rake angle of 11° are recommended as part of the result. It minimizes work hardening of the machined surface and could ensure induction of superior surface integrity in the machined surfaces, by inducing compressive residual stress 158 MPa, minimum average roughness 0.906 µm and microhardness 379 HV.

Ramesh R. Rajguru, Hari Vasudevan
Multi-objective Optimization of Dry EDM with Inconel 718 Using Grey Relational Analysis

In dry EDM machining, hollow electrodes are applied to supply gaseous medium at the machining zone. In this paper, an attempt has been made with L27 orthogonal array using compressed air as a dielectric medium, for Inconel 718 workpiece material and with copper tool electrode, to study and investigate the effects of machining parameters like as gas pressure, discharge current, pulse on time and gap voltage to optimize the output variables such as material removal rate (MRR), surface roughness (SR) and tool wear rate (TWR) based on Taguchi grey relational array. Analysis of variance (ANOVA) was carried out to find the significance of process parameters on grey relational grade. Gas pressure at level 2 (2 bar), current at level 1 (13 A), pulse on time at level 3 (200 µs) and gap voltage at level 3 (60 V) were found to be the optimum parameters for this process.

A. S. Bhandare, U. A. Dabade
Predictive Modeling of Surface Roughness in the Machining of Inconel 625 Using Artificial Neural Network

Inconel 625 belongs to the category of nickel-based alloy and it has wide applications in aerospace, defense, marine, nuclear, and oil and gas industries, due to its superior properties at elevated temperatures. However, machinability of Inconel 625 is very poor, because of high strength at higher temperature as well as high rate of tool wear and work hardening. In this context, this research work developed a predictive model using the artificial neural network, during the turning operation on nickel-based alloy Inconel 625, with chemical vapor deposition-coated inserts. Cutting speed, feed rate, and depth of cut were selected as input variables and surface roughness was selected as the response variable. Totally, twenty-seven experiments were performed, based on the design of experiments, using L27 orthogonal array and the measured result was analyzed using statistical software MATLAB. Mean absolute percentage error between predicted results and experimental values was 4.90% for surface roughness. The overall correlation coefficient between the artificial neural network-predicted result and experimental values was 0.97734, which showed good agreement between experimental values and predicted results and was nearly accurate.

Hari Vasudevan, Ramesh R. Rajguru
Measurement of Spur Gear Parameters Using Machine Vision

This paper presents a machine vision approach as a non-contact, automated method of measuring all critical dimensions of a spur gear, using image processing algorithms. Spur gear images are captured using image acquisition devices under backlight illumination and acquired in image processing software (MATLAB). Critical spur gear dimensions, such as addendum circle radius, dedendum circle radius, pitch circle radius, module, number of teeth, pressure angle, tooth thickness, and circular pitch, were extracted using various image processing and feature extraction algorithms. The values obtained using the machine vision approach are found to be in good agreement with those obtained using traditional metrology instruments and standard spur gear formulae. The approach can be adopted for developing an automated inspection system using image data.

Ketaki Joshi, Bhushan Patil
Modeling and Optimization of Cutting Temperature in Hard Turning of AISI 52100 Hardened Alloy Steel Using Response Surface Methodology

This paper analyses the effect of cutting parameters, such as cutting speed, feed and depth of cut on the cutting temperature in dry turning of AISI hardened 52100 alloy steel of 58 HRC using multilayer coated carbide tool insert. The heat generation and temperature at the cutting zone have a significant impact on tool wear, tool life and surface integrity. The cutting temperature is strongly influenced by cutting parameters and increases with their levels. Therefore, it was imperative to optimize the cutting parameters and develop a model for the accurate prediction of cutting temperature. Response surface methodology based on central composite design (CCD) was used to investigate and optimize the cutting parameters on cutting temperature response. The diagnostic tests were carried out to check its validity. The analysis of variance (ANOVA) was performed to analyse the effect of process parameters and their interactions on cutting temperature response. The quadratic regression model in terms of cutting speed, feed and depth of cut for cutting temperature was developed. The predicted values of cutting temperature response are in good agreement with the experimental results.

Sandip Mane, Sanjay Kumar
Optimization of Surface Roughness During High Speed Milling of Inconel 825 Using Grey Relation Analysis

Inconel 825 is extensively used in harsh environment due to outstanding mechanical and chemical properties. However, Inconel 825 belongs to difficult to cut material due to the presence of hard carbide in microstructure that leads to poor machinability. In this context, this study experimentally investigated and optimized machining parameters during end milling using PVD TiAlN coated carbide tool to enhance surface quality and material removal rate. For this, three input variables such as cutting speed, feed per tooth and radial rake angle with three levels are used. L27 orthogonal array-based Taguchi’s design of experiments is used. Responses are analysed using statistical software MiniTab 2017. Grey relation analysis is used to convert multi-objective optimization into single response and is optimized using Taguchi method. It is observed that, during end milling of Inconel 825, the most optimal conditions are the cutting speed of 90 m/min, feed rate of 0.03 mm/rev and radial rake angle of 7°. Using the response table for mean, it was concluded that the feed rate has substantial influence on various performance characters over other milling parameters.

Balagopal Unnikrishnan, Armaan Valjee, Vyankatesh Bagal, Prashantkumar Patankar
Role of Technological Innovativeness in the Manufacturing Performance of Indian SMEs

Technological innovativeness is one of the most important dimensions of a firm’s overall innovativeness, as they look for global competitiveness. This study deployed a survey questionnaire to investigate the role of technological innovativeness in the manufacturing performance of the Indian SMEs. The study also explored various parameters associated with customer orientation, technology orientation, technological alliances, product and process innovativeness of the firms. It was found that SMEs in India have started exploring the latest developments related to technology in their particular sectors, which is one of the good indicators of them having acquired technological innovativeness. Technological innovativeness in this context has in fact increased significantly. The study also found that the majority of the SMEs have reported incremental innovations. The study further revealed that the Indian SMEs give topmost priority to quality in the context of manufacturing performance, product uniqueness and customer orientation.

Anup N. Chawan, Hari Vasudevan
Implementation of 6R Paradigm in the Life Cycle of Automobiles for Sustainability

Meeting the needs of the present without compromising those of future is sustainability. Sustainability has become a critical function as natural resources are depleting at an alarming rate. Sustainability is closely associated with economic, social, and ecological aspects of human life and culture. It inspires businesses to look far beyond the balance sheets of current years and make decisions. The 6R paradigm is a key principle of sustainable design, fabrication, and use. Its use has gained much importance recently in refining the life cycle of various products. In this paper, the same is implemented to automobiles throughout its stages of life to boost sustainable practices.

Neel Sanghvi, Jash Patel, Dhairya Vora, Ujwal Sutaria, Satish Takalikar
Evaluating GSCM Practice–Performance Relationship in Chemical, Textile and Rubber/Plastic SMEs in India

Green supply chain management (GSCM) practice–performance relationship has gained a lot of research interest in recent years. Though this practice–performance relationship has been studied in developed and developing countries, there is little empirical evidence about this relationship for small- and medium-scale manufacturing industries in India. This research work presents one of the earliest studies on GSCM practice–performance relationship for SMEs in the chemical, textile and rubber/plastics manufacturing firms in India. A survey questionnaire was developed based on extant literature and feedback from academics and industry experts. Data collected was analyzed using descriptive statistics, one-way ANOVA and Post hoc Scheffe test. From the results of the data analysis, it was concluded that the SMEs are still in the early stage of adoption of GSCM practices. The environmental performance of textile firms and the economic performance of chemical firms are significantly higher than the other two in respective cases, whereas the operational performance is seen similar among the three sectors. This can be attributed to the lack of knowledge, experience and tools available to deploy so as to meritoriously and proficiently improve their business performance through the implementation of GSCM practices.

Meeta Gandhi, Hari Vasudevan
Investigations on Effect of Cutting and Cutting Fluid Application Parameters on Surface Roughness and Microhardness in Hard Turning of AISI 52100 Alloy Steel

The cost, health, and environment concerns associated with the use of cutting fluid calls for minimizing its usage in machining. This research work is aimed to investigate machining performance in turning of AISI 52100 hardened alloy steel with multilayer-coated carbide tool under dry and minimal cutting fluid environments. A Taguchi’s L9 orthogonal array was used to design the experiments. The aim was to identify the optimal combination of the cutting and cutting fluid application parameters. The response measured was the surface roughness and microhardness under different cutting environment. The experimental result showed that the hard turning with minimal cutting fluid application improves surface roughness and reduces the microhardness variation at machines surface which in turn improves fatigue life of the machined components.

Sandip Mane, Sanjay Kumar
Optimization of Cutting Parameters in Dry Turning of AISI 4340 Hardened Alloy Steel with Multilayered Coated Carbide Tool

AISI 4340 has been widely used in automobile and aerospace industries due to their adequate mechanical and chemical properties. This paper investigated the effect of cutting parameters such as cutting speed, feed and depth of cut on cutting force and cutting temperature in dry turning of AISI 4340 hardened alloy steel with a multilayer coated carbide tool. The optimization of cutting conditions is highly important that helps the manufacturing technocrats in process planning as the economy of machining operation defines the competitive advantage. The study investigated the optimum cutting parameters that could produce a significant reduction in cutting temperature and cutting forces leading to improve tool life as well as the surface finish of the machined surface in hard turning. Taguchi’s L9 orthogonal array was used to design the experiment and analysis of variance (ANOVA) was performed to identify the significant factors affecting the cutting forces and cutting temperatures. The experimental results showed that the feed is the most influencing factor on cutting force and cutting temperature followed by the depth of cut and cutting speed.

Sandip Mane, Anjali Mishra, Vaidehi Kannawar
Optimization of Cutting and Cutting Fluid Application Parameters in Turning of AISI 52100 Hardened Alloy Steel Under Minimal Cutting Fluid Application

Hardened alloy steel materials are in great demand in automotive and allied manufacturing industries due to their better strength, wear resistance and high thermal stability. The hard turning offers many potential benefits over conventional grinding operations. During hard turning, the excessive heat generation and temperature affects the tool wear, tool life and surface integrity of the machined components. The cutting force and cutting temperature are the important technological parameter to control the machining process. The cutting fluid removes and reduces the heat from the cutting zone through cooling and lubrication action, but the use of conventional cutting fluid is being restricted due to the cost, health and environmental concern associated with its use in machining processes. The machining performance and cost-effectiveness can be improved by minimizing the cutting fluid. The main objective of this research work was to investigate the effect of cutting parameters and cutting fluid application parameters on cutting force and cutting temperature in turning of AISI 52100 hardened alloy steel with multilayer coated carbide insert under minimal cutting fluid application. The result showed that the minimal cutting fluid application (MCFA) technique significantly reduces the cutting force and cutting temperature compared to dry turning.

Sandip Mane, Sanjay Kumar
Supplier Selection in MSME Gear Manufacturing Industries Using MCDM Technique

This study is an attempt to find out, whether the manufacturing industries follow only the traditional criteria in their supplier selection or they also include green criteria in the supplier selection. Data for the study were collected from 50 different gear manufacturing micro, small, and medium enterprises (MSME) sector and all the criteria were tested using a multi-criteria decision-making technique, such as the analytical hierarchy process (AHP). Results concerning the main criteria followed in the study show that cost, quality, delivery, and environmental manufacturing management are considered prime criteria in the supplier selection. Gear manufacturing MSMEs using various criteria concerning different supplier selection are discussed in this paper. The study is expected to act as a future guide for manufacturing industries, especially in the MSME sector in their evaluation and selection of suppliers, as they adopt various supplier selection criteria.

Ashish J. Deshmukh, Hari Vasudevan
Agricultural Supply Chain Using Blockchain

A constant rise in population has led to exponential growth in the food requirements all over the world. Not only has the demand increased over time, but concerns regarding food quality and safety have also proliferated. Many cases of food contamination like the Sudan Red food colouring and horse meat scandal have caused havoc in the food supply industry. This is not limited to the production sector only, but even the agricultural supply chain has felt the added scrutiny for the safety of crops. Hence, under such circumstances, it is essential to ensure food safety. Customers question the handling of crops during transportation and packaging. Quality of food also becomes priority. Concerns arise regarding, if the farmers get paid adequately. This brings the need of a system that can enable not only the grocery markets, but also the consumers to track the origin of the food they buy and all the other aspects involved in the agricultural supply chain. The current farmer-to-table supply chain model in India is archaic and requires immediate reforms to improve the plight of Indian farmers. Lack of structured transactions has allowed corruption to creep into every stage of food reaching from the farms to a consumer’s table. The current model has almost seven levels of intermediates that affect the transactions. The blockchain model developed here aims to restrict the middleman’s intrusive involvement and aims to improve farmer’s profits. Every transaction will be authenticated and traceable, improving transparency for customers and removing unnecessary monetary leaks, thus optimizing the income of the farmers.

Ahan Fernandez, Ashriel Waghmare, Shweta Tripathi
An Empirical Analysis of the Strategic, Organizational, Financial and Technological Issues in the Implementation of Knowledge Management in Indian Automotive SMEs

Knowledge is considered as the currency in the current knowledge economy. It is a key business asset and is considered vital to creating a sustainable competitive advantage. The growing importance of knowledge-intensive organizations makes knowledge management (KM) an essential strategic tool and a potent competitive weapon for gaining competitive advantage and improved business performance. However, many small and medium-sized enterprises (SMEs) do not realize these benefits, because of an uncertain and unclear idea of knowledge management and most of them lack innovative approaches to knowledge management. Hence, the SMEs still lag in the implementation of KM. SMEs are required to be fully aware and be perceptive of the issues that would hinder the implementation of knowledge management in SMEs. This study investigated the influence of strategic issues, organizational issues, financial issues, and technological issues in the implementation of KM in automotive component manufacturing SMEs across three tiers, i.e., Tier 1, Tier 2 and Tier 3, in India. The overall results of the study show that the strategic issues and financial issues are significant, whereas organizational issues and technological issues are insignificant across the three tiers of SMEs. Moreover, Tier 3 SMEs are found to have several strategic and financial issues in comparison with Tier 1.

Ibrahim Shaikh, Hari Vasudevan
Optimization of CNC Die-Sinking EDM Process Parameters Based on MRR and EWR by Taguchi Method Using Copper Electrode on P20 Tool Steel

Optimization using Taguchi methodology is one of the techniques for industries by which manufacturing for quality products at lower cost is achieved. The process parameters, such as current, pulse-ON and pulse-OFF time in electrical discharge machining (EDM) process, give variations in the performance characteristics, such as material removal rate (MRR) on workpiece and electrode wear rate (EWR) on tool while machining P20 tool steel using copper electrode. By conducting Taguchi design of experiments using L9 orthogonal array, the analysis had been carried out. Using Minitab, its response tables and graphs were observed to find out the optimal levels of parameters in the EDM process. Thus, the process parameters for EDM were optimized during machining of P20 steel for achieving the combined objectives of higher rate of material removal and lower wear rate on tool. The obtained results helped to identify the major and minor parameters affecting MRR and EWR.

Mehul Prajapati, Sowmin Trivedi
Prediction of Surface Roughness and Optimisation of Cutting Parameters in Hard Turning of AISI 52100 Steel Based on Response Surface Methodology

The surface roughness is one of the most important surface characteristics, which affects the quality and its service life of the product. This paper aimed to analyse the effect of cutting parameters, such as cutting speed, feed and depth of cut on surface roughness (Ra) in turning of hardened AISI 52100 steel of 58 HRC with multilayer coated carbide insert under dry environment. Response surface methodology based on central composite design (CCD) was used for the optimisation and development of mathematical models for surface roughness. The analysis of variance (ANOVA) was performed to explore the effect of cutting parameters and their interactions on surface roughness. The RSM-based quadratic regression model in terms of cutting speed, feed and depth of cut for surface roughness (Ra) was developed with 95% confidence level. The adequacy and validity of the developed model were checked on the basis of P-value, F-value and R2-value. The results showed that feed is the most influencing cutting parameter on surface roughness, followed by cutting speed and depth of cut which has no significant effect on surface roughness.

Sandip Mane, Sanjay Kumar
Productivity Improvement in Blow Molding Process Through Energy Savings

Rapid urbanization has resulted in enormous demand for energy in all sectors. There is a need to break the gap between demand and supply by devising energy-efficient approach. Through this study, an attempt has been made to bring down the power and to save energy utilized for cooling in the blow molding process. Cooling of the products was the biggest hurdle in plastics processing technology, which consumes the maximum amount of energy. Geothermal cooling system was explored for cooling of water used for blow molding process in lieu of the prevailing system using a chiller. Underground soil was used as a cooling medium for cooling the water emerging out from the molds. The system was thus analyzed with software simulation using ANSYS. The results have indicated a substantial reduction in energy utilization. The percentages of saving energy amounted to 15.28 and 24.27% when the geothermal system was implemented partially and fully. In the future, there is a scope to implement the geothermal cooling system in the plant in order to get a clear picture of the energy benefits.

Hari Vasudevan, Rajendra Khavekar, Nida Sayed
Effect of Cutting Parameters on Microhardness in Turning of AISI 52100 Hardened Alloy Steel with Multilayer Coated Carbide Insert

The microhardness (μH) and surface roughness (Ra) constitute the surface integrity aspect, which affects the quality and service life of a product. This paper aimed to analyse the effect of cutting parameters, such as cutting speed, feed and depth of cut on microhardness (μH) in hard turning of AISI 52100 steel of 58 HRC, with multilayer coated carbide tool insert under dry environment. Response surface methodology based on central composite design (CCD) was employed to design the experiment and develop the mathematical models for microhardness (μH). The analysis of variance (ANOVA) was used to explore the main and interaction effect of cutting parameters on microhardness (μH). The (ANOVA) results revealed that the microhardness of the machined surface is significantly influenced by the cutting speed, feed rate and depth. A quadratic regression model in terms of cutting speed, feed and depth of cut for microhardness (μH) was developed with 95% confidence level. The adequacy and validity of the developed model were checked on the basis of P-value, F-value and R2-value.

Sandip Mane, Sanjay Kumar
Analysis and Manufacturing of Aerodynamic Components

Aerodynamic components are extensively used in motorsport, such as Formula One to increase the downforce, thereby ensuring traction of the tires, which increases the performance of the race car during cornering. However, these aerodynamic components that provide the downforce also increase drag. An ideal solution, therefore, is dynamically adjustable aerodynamic components, which have the ability to change the amount of downforce and drag. Such components have been used as aerodynamic components for an FSAE car as part of this study. After completing an extensive research on current car design without aerodynamic components, preliminary design concepts were formulated and full car solid model was designed on SOLIDWORKS software. These designs were then compared against each other based on the analysis performed on STAR CCM+ software on the basis of downforce, and drag was then generated. The software analysis was used to compare and conclude the final design from each iteration to get an optimum aerodynamic package which consists of all components for the car. The product was manufactured using some advanced manufacturing techniques to save cost, time as well as to provide it for further development.

Rajnarayan Yadav, Vinit Katira, Ruchit Doshi, Shakshi Himmatramka, Parshva Mehta, Harshil Mody
Design and Manufacturing of Compact and Portable Smart CNC Machine

Nowadays, due to the advent of technology, there is huge importance given to compact machinery. World is moving towards the compact, portable and multipurpose machinery. A large number of SMEs are getting engaged in high-precision manufacturing jobs. They need high-end CNC machines. The cost of such machines is very high. In a small-scale industry, it is very difficult to install a computerized or intelligent machine-like CNC because they are very costly and also requires scheduled maintenance. We are aiming to provide an option for compact and portable machines. So, by using this projected machine, an option can be given to all those small-scale industries who aim to machine the job economically and also want to save their time with a significant increase in production and accuracy to contribute to Indian GDP in the manufacturing sector.

Amit Choudhari, Shamir Talkar, Pavan Rayar, Aditya Rane
Effect of Plunging and Dwelling Period on Temperature Profile and Energy Dissipation in FSSW and Its Relevance in FSW

FSW is the welding technique, where filler material for welding is not required resulting into no additional mass being added, which proves very useful in the industry where the addition of small material plays a significant difference on the performance of the working unit. Energy generation and its utilization during welding are crucial in understanding the physics behind the process and further extended to know the effect of process parameters on a way of effective welding to achieve sound weld. FSW experiments are costly as well as tedious where the requirement of the accurate plasticized stage should be reached so that the tool can travel flawlessly in traverse direction to achieve sound weld. Computational modelling and numerical simulation are the solution to the above problem. In this research paper, numerical simulation on FSSW is carried out first for better understanding of energy generation and its utilization at plunge and dwell stage before going further for next step in FSW that is traverse movement of the tool in the direction of the weld line. During the plunging stage, the friction causes the metal around the contiguity area to soften. It transforms the material into the plasticized stage during dwell stage, so the temperature profile obtained during those stages is validated with experimental results for the accuracy of the numerical model. Also, energy generation and its utilizations are confirmed with the experimental values for accurate validation of the numerical model. CEL approach is used for simulation of FSS welding of the aluminium sheet. Plunge speed and dwell time were chosen as different parameters. Simulation results showed that thermal response, along with energy history, varies with simulation parameters used in FSSW. To conclude, this numerical model can be effectively used to predict the FSW process for any other material.

Niyati N. Raut, Vivek Yakkundi, Akshay Vartak, S. N. Teli
Prediction of Optimum Sheet Metal Blanking Clearance for IS513CR Steel Using Artificial Neural Network

In a quest for higher productivity, sheet metal manufacturing industry is undergoing significant development in the field of sensing and automation. One of the sheet metal operations is blanking, which is affected by an uneven crack which leads to a loss in productivity. In present work, an experiment is carried using the uni-punch tool on power press for varied punch penetration, to observe crack initiation and to find optimum clearance for IS 513 cold-rolled steel. The crack initiation is measured using shear angle, fracture angle and punch penetration. As the blanking process is complex and nonlinear, artificial neural network (ANN) is employed to predict clearance for input parameters. The predicted values are well within the experimental values.

Pradip P. Patil, Vijaya P. Patil, R. Ramaswamy
Improving the On-Time Delivery of Projects in a Complex Industrial Environment

In companies, where a large number of projects are undertaken, the environment starts depicting characteristics of projects and batch manufacturing. Thus, traditional models which solve problems in a singular environment prove to be insufficient, when applied on environments of such nature. In this study, a similar case is presented, wherein the company works in a multi-project environment. Due to the repetitive nature of the product portfolio, the aforementioned complexity was seen to be present. Thus, an attempt has been made to solve this, by creating a generalized process flow, which holds true for any product that is dispatched. The results of the study showed that for the PERT chart, each singular flow finishes with the same three or four activities at the end. Thus, by using the backward planning approach, the due dates for each flow could be accurately determined, thereby shifting the emphasis on how much is left to be done rather than how much is finished.

Hari Vasudevan, Rajendra Khavekar, Krishnan Kaushik
Investigating the Influence of Infill Pattern on the Compressive Strength of Fused Deposition Modelled PLA Parts

The research work presents an analysis of the optimal infill pattern of 3D-printed Polylactic Acid (PLA) based on its compressive strength. Samples with varying infill percentages and types are loaded in different directions. The samples are built using fused deposition modelling process (FDM) on a Creality Ender-3 3D printing machine. Strength is calculated based on the results of testing and feasibility of infill type and pattern according to application is analysed. The testing shows triangular infill to be superior to the default line infill pattern in every condition. Gyroid infill shows nearly isotropic properties, thus being a useful pattern to select when the part is subjected to multiple loading directions.

Sanket Parab, Nilay Zaveri
Analysis of Compound Column-Based Supporting Structures Used in Suburban Railway Transport System: Use of Stiffener Plates

This paper documents a comparative numerical analysis aimed at verifying the application of stiffener plates in a compound column, which is being used as a supporting member at multiple railway stations in the Mumbai Suburban Railway Network. Stiffener plate is a term used for a group of plate-like structural elements that are used to increase the rigidity of a beam or column. These stiffener plates are installed at specific locations in the column to decrease mainly the total deformation, equivalent stress, equivalent elastic strain, and the shear stress. Linear and non-linear analyses were performed for the compound column, both with and without the presence of the stiffener plates. It was concluded that with a 3% increase in the weight of the structure, the total deformation decreases by 8% and the equivalent stress decreases by 28%.

Herin Savla, Neel Sanghvi, Saurabh Rasal, Vinayak H. Khatawate
Drilling Process Quality Improvement by Grey Relation Analysis

It is very important to take an optimum process parameter to improve the quality of machined products with a maximum tool life and less defects. Production of hole by drilling operation is a key process in composite manufacturing because drilling operation is being performed after cure/solidification process. Poor hole quality leads to rejections up to 60% of all products manufactured. Carbon fibre-reinforced plastic (CFRP) composite have large range of application in aircraft, automotive and medical industries. This work deals with a selection of optimum process parameters in drilling of CFRP to minimize defect, thrust and torque by using grey relational analysis (GRA). After conducting the study using multi-objective GRA, gave optimum process parameters such as spindle speed—3200 rpm, feed rate—0.15 mm/rev., delamination—1.2311, torque—1.483331 N-m and thrust—7.897 N.

Janak Suthar, S. N. Teli, Siddesh Lad, Vijaya Kumar N. Kottur
Enabling Technologies and Current Research Scenario of Industry 4.0: A Systematic Review

This research was carried out to review the Industry 4.0 enabling technologies. This study incorporates the recently published research articles on Industry 4.0 enabling technologies and applications of these enabling technologies. To perform this research work, bibliometric analysis was carried out. Further, content analysis was used to identify the various domains within the literature on smart manufacturing. These techniques were used to identify the current trends, various research works and the contribution of researchers in Industry 4.0 domain. It was observed that many research articles on Industry 4.0 are theoretical in nature which did not give a strong benchmark for policymakers. It was found that Germany was the leading country in the publication of research articles on Industry 4.0 followed by USA, UK, and China.

Bhaveshkumar N. Pasi, Subhash K. Mahajan, Santosh B. Rane
Evaluation of Green Supply Chain Management Practices in Small and Medium Enterprises in Pune Region

. This paper presents the study on GSCM practices in SMEs in Pune region (India). The components for the study (survey) were based on the literature review and also from the feedback received from the academicians and executives from the corporate world. From the survey, it was found that the adoption of GSCM practices in SMEs was still in the early stage. The environmental sustainability awareness was very low among the customers. The legislation and regulatory framework is also lagging in promoting the sustainability of the environment. Data analysis results revealed that vendor–vendee relationship has positive impact on sustainability of product design and the logistics, which further was positively related to economic performance and competitiveness of the organization. This study was conducted with 120 manufacturing industries under SMEs category. AMOS, a statistical software, which stands for Analysis of Moment of Structures is used for structural equation modeling and path analysis, and confirmatory factor analysis was used to measure the overall respondents view on sustainable supply chain management.

Malleshappa T. Bhagawati, P. Venkumar
Review on Perspectives in Supply Chain Trust Evaluation

Trust is an obligatory requirement for each supply chain (SC), as it can greatly improve the overall SC performance. Evaluation of trust among SC actors is not an easy task, but it is essentially needed to take crucial SC decisions. To this point in time, many researchers have attempted to evaluate trust through different perspectives. The purpose of this work is primarily to review the various perspectives of researchers in evaluating SC trust. This paper particularly targets the trust in buyer–supplier relationship. Review reveals that researchers mainly adopt two approaches in evaluating trust, which are survey based and mathematical model based. Benevolence, credibility, ability, integrity, goodwill, and openness are the key trust factors considered by most of the researchers.

Manu Mathew, Justin Sunny, V. Madhusudanan Pillai
Building Envelope Optimization and Cost-Effective Approach in HVAC to Support Smart Manufacturing

To fulfill the demand for modern products, nowadays industries are growing and expanding their manufacturing units at very faster rate. But due to space constraints, there are some restrictions in expanding longitudinally so the only option is to expand laterally, i.e., increasing the number of floors. In many manufacturing units, there is a need to implement optimized and effective HVAC system. The main power consumers in most buildings are HVAC, apart from lighting systems which accounts nearly 60–65% of the total building load. The first step in energy savings on HVAC systems is to reduce the cooling load. The amount of electricity for air-conditioning systems used depends on the cooling load, i.e., the amount of heat the system must remove. In order to support the purpose of a smart and intelligent manufacturing process refining the measurement of heat loads using different methods, and enhancing the insulation used in the building envelope will result in enormous energy savings in HVAC by reducing the tonnage of heat load by creating a stronger and effective barrier to minimize the heat contribution from the air and results in saving money.

Shamir Talkar, Amit Choudhari, Pavan Rayar
A Review of the Reliability Techniques Used in the Case of Casting Process Optimization

Foundry industries nowadays face problems, such as poor quality of the castings produced as well as wrong practices followed, which finally lead to decrease in productivity. Castings with minimum production cost and no defects have emerged as prime requirements in this vital manufacturing industry. This includes improving productivity and reducing cost by minimizing rejections. To achieve these improvements, various process parameters are necessary to be optimized. Simulation of casting process has become an irreplaceable tool in the production of cost-effective and high performance castings. Most of the casting simulation is based on a purely deterministic approach, in which shop floor iterative trial and error methods are replaced with iterations on computer. Optimization in casting process lacks consideration of reliability of casting production process and casting model. Reliability-based design optimization (RBDO) is an approach for the development of components, which aims to minimize the cost, while constraining the probability of failure. This study provides for a review of the casting process optimization through a reliability approach and concludes that the future studies could develop a comparative analysis of reliability with conventional techniques used in casting process optimization.

Amit Chaudhari, Hari Vasudevan
Reinforcement Learning for Inventory Management

A comparison between four common reinforcement learning algorithms, namely deep Q network (DQN), double deep Q network (DDQN), prioritized experience reply (DQN + PER) and double DQN + PER; and discussion on the methodology with the limitations and advantages of each algorithm are included in this paper. In order to provide these insights, OpenAI environments that demonstrate the working of these algorithms was used. Mountain car environment was used to generalize our results and prove the consistency of our insights. Insights were derived by evaluating basic parameters like, episode length, minimum rewards, maximum rewards and average rewards. This study discusses strategies for including reinforcement learning in supply chain management by using it for inventory management.

Siddharth Singi, Siddharth Gopal, Shashikant Auti, Rohit Chaurasia
Implementation of 5S to Set Up Inventory Control System with HTML Coded Spare Management System

This research paper has brought out the importance of inventory management considering the availability of stock in absence of its data or improper accessibility of data that transforms the asset into liability. Process proposed in this paper helped in identifying over inventory and eliminating dead inventory thereby raised level of optimum inventory significantly within two months of process implementation. This process helped to maintain available spares in a systematic manner as well as handle inventory management effectively, which is an important link in supply chain. Inventory models are based on the assumptions. A number of inventory models were analyzed, but none could be implemented because of invalid assumptions. The new inventory model was proposed based on assumptions mentioned in this paper. The proposed model can be implemented effectively in a short span to control the inventory.

Sandip Mane, Jay Bhuva, Smit Patel

Automation

Frontmatter
Production of Composite Repair Patches for Large Aircrafts Using Advanced Automation Techniques

This paper addresses the development of an automated production cell for manufacturing composite patches which are used to repair damages caused on large aircrafts. A step-by-step approach for each process step is provided in detail including damage scanning, sizing and cutting of carbon fibre fabric, kitting and packing of the repair patch.

Amool A. Raina, Boris Manin, Thomas Gries
Autonomous Real-Time Navigation Based on Dynamic Line and Object Detection

An Android application has been developed that captures images, detects a line and computes the lateral deviation as well as angular deviation from the path. It also takes into consideration the intensity variation of the surroundings which has been explained in the following paper. We have used the Sobel edge detection algorithm and Hough transform for the angular inference. Colour thresholding and matrix manipulation are done for calculating the lateral deviation. Finally, the counter-active actions and inferences are sent via BLE (low energy Bluetooth). An application was developed for directing the autonomous quadruped robot. The rare-view camera of the mobile was used for taking the input. This Android application can have multiple implementations apart from robotics with slight manipulations, such as the automobile industry, military, industrial automation and blind assistance, and these kinds of researches will boost concept of smart manufacturing.

Pavan Rayar, Adarsh Prabhudesai, Samruddhi Pai, Shaival Parikh
Machine Learning as a Smart Manufacturing Tool

In smart manufacturing, machine learning is used in various manufacturing fields at various stages such as for future prediction in the manufacturing system, pattern recognition, fault detection, quality control and monitoring. Machine learning (ML) is used for classification and regression purpose which can be achieved using the past data. Machine learning algorithms and combination of algorithms are widely used in various machining processes. This paper reviews different machine learning algorithms used for specific applications in the product life cycle.

Meera B. Kokate, Bhushan T. Patil, Geetha Subramanian
Tool Changer Selection for the Robot to Attach and Detach the End of Arm Tooling

In today’s world, industrial revolution is changing to the industry 4.0. Humanless manufacturing has started to increase the productivity and reduce the cost of the production. Automobile industry is one of the areas, in which such drastic changes are happening day by day. As per the requirement of the customers, a number of variants are produced by the organization to sustain in the market, and such operations are performed by the robots. Fixture and grippers are used for holding and material handling of the parts, respectively. Tool changer is the part, which is used in between the robot and gripper. Signals from robot to gripper and gripper to robot are transferred by the tool changer. Fast and automatic tool changing is done by using it. This paper deals with the study of proper selection of tool changer of robot and how this action enhances the flexibility and productivity.

Dhanesh Dhanawade, Nilesh Vijay Sabnis, Pankaj Gavali
Remote Data Acquisition System for Measurement of Ambient Climatic Conditions and SPV Battery Status

The cost of solar PV (SPV) systems has reduced drastically over the years on account of efficient PV cell manufacturing technologies. Its suitability and economic viability for the installation site have strong correlation to local climatic resources. The access to data on solar insolation, wind speed and other climatic parameters is hence essential for site selection and SPV installation. The remotely accessible data of ambient temperature and solar irradiance at target location was acquired through Arduino-GSM hardware loaded with compatible software. The study showed that temperature and solar irradiance measured through developed system was within 2.23% and 5.83%, respectively, as compared to conventional measurement techniques. The novelty of the device is envisioned in its application to monitor small-scale as well as large-capacity renewable energy systems that have a strong dependence on climatic factors.

Mahesh B. Gorawar, Veeresh G. Balikai, Vinayak H. Khatawate, P. P. Revankar
Force Sensitive Resistor Based Design and Modeling of Smart Walking Assistance Device by Axial Direction Control for Osteoarthritis

Walking is a very important activity in human life which reduces many problems related to blood pressure regulation and heart diseases, but osteoarthritis patients suffer from mobility deficiency. The smart walking assistance (SWA) device was developed for mobility assistance. It is necessary to identify the intended direction of the user by the SWA device. While walking in the intended direction, human body reflects certain forearm movement, which can be recognized in terms of force. In this work, a method was proposed to identify the direction for the movement according to the forces exerted by the user’s forearms, which are acknowledged by the force-sensitive resistor (FSR) placed on the walker’s armrest. Depending on the FSR outputs in the range of 0–1023 scaled by Arduino, an algorithm was implemented for the direction control of the walker-based threshold. The user intended direction was validated by the experiment and monitored using MATLAB.

Akshay Vasage, Onkar Padhye, Gajanan Kulkarni, Shivram Kerkar, Mahesh Kumar
Autonomous Package Dispatcher Bot Using Video Processing

Basic services, which are provided by hospitals to patients, are food, medicine, blood checks, hospital clothes, etc. To carry out these patient care services, there are other support services that are managed by the hospital. These services are most of the time invisible to users but they do affect the patient care services. The autonomous medical bot described in this paper uses camera and QR codes to dispatch packages in a specified geography. It takes the aid of a line marked on the floor to follow the required path using a camera. Along with delivery, locker security is provided which can only be opened by the one requesting for the service. An attempt to improve the quality of healthcare services provided by hospitals is made by efficiently managing all the logistics tasks.

Manthan Tambe, Sahil Vora, Shaunak Thakar, Manish M. Parmar
Improvement in Material Feeding by Introducing Kitting in the Assembly Line

The concept of kitting is to ensure the supply of all complete sub-assemblies in the form of kits to the assembly station/line. The main purpose of this study was to analyze the business case and the possibility of the company to implement lean kit assembly concept. Inceptive part of the study was to understand the kitting concept completely and simultaneously study the current material feeding system, where improvement had to be incorporated. The study shows that kitting results in reduction of operator walk time, material search time and material fetch time. It also leads to better planning for material, manpower, and enhancement in productivity through appropriate work allocation. Although the benefits achieved from the implementation of kitting concepts are specific to the company’s needs, results make it clear that kitting goes hand in hand with the lean manufacturing process.

Chinmay Kule, Shantanu B. Patil, Sandeep Vaity

Advanced Materials

Frontmatter
Microstructure and Roughness Analysis of Drum Brakes of Maruti 800

The purpose of this paper was to focus on the basics of drum brake systems, so as to provide an in-depth microstructure analysis of the drum brake and the roughness value of the drum surface. As the roughness affects the braking capacity of linings on drum surface, it also allows the duration of service for the drum. This study has helped to know the amount of wear on drum and to minimum roughness value of drum surface that is required for safe braking.

Atul D. Dhale, Swapnil S. Phadnis
A Review on Stress Relaxation Cracking in Austenitic Stainless Steel

Stress relaxation cracking (SRC) is a high-temperature failure mode occurring in equipment, operational in industries at high service temperature for a long time. SRC has been noticed in thick-walled welded components of austenitic stainless steel, ferritic stainless steel, heat-resistant steel, and nickel-based alloys for many years. Understanding SRC phenomenon is necessary to improve the lifetime of equipments and to save resources. In order to improve the lifetime of the equipments, understanding SRC mechanism and its characteristics is important. In this paper, past experience of SRC in austenitic stainless steel has been reviewed to understand why and how SRC occurs and what are the major causes for cracking. Preventive measures can be taken that could avoid stress relaxation cracking and extend the lifetime of the equipment’s working at high temperature.

Indhumathi Dayalan, Prashant Frank Crasta, Sritam Pradhan, Renu Gupta
Selection of Materials for Manufacturing of Disc Brake Rotor for a Racing Go-Kart Having Single Hydraulic Disc Brake System

Disc brake or rotor is a common device used in a racing go-kart with single hydraulic brake system for slowing down or stopping the motion of wheel running at a certain speed. In this paper, an extensive study was carried out to develop material selection methods for disc brake rotor. Materials, namely grey cast iron, stainless steel 420, aluminium 7075 T6 and titanium grade 5 alloys, were studied for general performance requirement, thermal and mechanical properties and static structural analysis (FEA). The results obtained were used to identify the promising material among the candidate materials for disc brake rotor.

Aman Dharmendra Chheda, Ravikant Hattale
Comparative Study of Aluminum and Composite Stub Axle Using FEA

This paper includes the analysis of a front stub axle used in a rear wheel drive BAJA ATV (all-terrain vehicle). An ATV is a vehicle developed to be used on rough terrains and low traction. These types of vehicles are generally known and used for their off-roading ability and maneuverability of the vehicle on rough terrains. The stub axle used in such a vehicle is subjected to different types of loads, depending upon the motion and terrain the vehicle is running on. The analysis of the structure was compared with two different models, on the basis of their strengths and rigidity of the axle during the action of bump force subjected on the tire, change in weight of the axle and cost. This paper deals with the structural analysis of stub axle of BAJA ATV using finite element analysis approach. The objective of this analysis was to study and evaluate the performance of two stub axles made of aluminum and composite material respectively, under severe conditions.

Rajnarayan Yadav, Vinayak H. Khatawate, Deval Patel, Sahil Thonse, Danish Sunsara
A Review on Carbon Nanotubes as Novel Drug Carriers in Cancer Therapy

Cancer causes one of the pre-eminent health problems all over the world currently. Chemotherapy is used as a conventional treatment, which uses one or more anti-cancer drugs as part of a standardized procedure. The idea of selective treatment to cure cancer is established by carbon nanotube (CNT). In this review paper, the advances in the application of carbon nanotubes as target carriers and drug delivery system for cancer therapies have been studied. CNTs due to their physicochemical and selective targeting abilities and shape act as drug delivery systems. Internal drug loading encompasses decoration utilizes capillarity, encapsulating anti-cancer drugs like Cisplatin. The external loading takes place by linkers. The biocompatible drug targeting mechanisms like active and passive lead to targeted delivery. Hence, eliminating any damage to healthy tissues resulting in negligible side effects. The functionalization of CNTs being crucial in penetrating and increasing hydrophilicity entails non-covalent and covalent methods. This also helps them to penetrate through immunity barrier and ensure a targeted release.

Dhyey M. Rajani, Frank Crasta, Vijaya Kumar N. Kottur
A Review on Squeeze Casting of Aluminium-Based Alloys and Its Composites

Aluminium-based alloys have a better strength-to-weight ratio and hence are widely used in aerospace and automotive industries. Squeeze casting is one of the most suited options for manufacturing of aluminium-based alloys and its composites. This paper provides a review on squeeze casting and its advancements, like ultrasonic squeeze casting. Optimization of various process variables and their influence on output parameters carried out by various authors are also discussed.

Dhiraj Nigade, Dhananjay Shukla, Ravikant Hattale
A Review on Carbon Fibre Reinforced Polymer Composites and the Methods of Their Manufacture, Disposal and Reclamation

Fibre reinforced composites can be tailored to meet the demands of the industry for various applications. Carbon fibre reinforced polymer (CFRP) holds the advantages of being lightweight, possessing high tensile strength, superior corrosion resistance and anti-fatigue properties. Their unique ability to possess customisable directional strength is a major factor, which promotes their use. Through bonding CFRP sheets, the ultimate load and post-elastic stiffness of specimens can be significantly increased. However, the carbon footprint and direct cost are the biggest obstacles in the way of adopting CFRP in industrial application. In this paper, the prevalent techniques of manufacture and disposal of CFRP have been studied. New techniques like inculcating thermoplastic matrix-based CFRP in additive manufacturing and manufacture of CFRP sheets by electro-activated deposition resin holding increase the scope of use of the composite. Despite its tremendous capabilities, CFRP and its products pose an issue at the end of their life cycle due to the difficult and cumbersome methods of disposal. Also, hampering their value in the industry is their high purchasable cost and the lack of a method of manufacture which provides high productivity and formability.

Aman M. Chulawala, Frank Crasta, Vijaya Kumar N. Kottur
A Review: In Vitro Investigation of Dental Composite Materials and Tooth Enamel by Using Pin-on-Disc Tribometer

Present study mainly deals with the review of in vitro investigation for assessing the wear action of different dental materials. With in vitro testing, the researcher gets more control over the experimental variables leading to more accurate results. Whereas, other methods have limited contribution towards the tribological study of dental materials. Therefore, in vitro method was developed for studying the wear mechanisms. The wear testing devices like pin-on-disc or artificial mouth were used in the study of in vitro. By selecting different test parameters like load, speed, temperature and use of artificial saliva, an artificial oral environment can be created on a pin-on-disc tribometer. The filler particle percentage is an essential parameter for studying the tribological and mechanical characteristics of dental composite materials.

Abhijeet Suryawanshi, Niranjana Behera

Design

Frontmatter
Development of Spring Life Test Apparatus and Life-Cycle Assessment of Extension Springs

Life-cycle test of moulded case circuit breakers (MCCB) on mechanical endurance test apparatus exhibited springs as the weak links. Therefore, improvement in the reliability of the circuit breaker mechanism was possible only with an improvement in the life of the springs. To evaluate spring life, a life-cycle test apparatus was developed which subjected springs to actual load conditions as experienced in MCCB. This paper describes the development and working of the test apparatus. The paper also explains how reliability of springs can be estimated using life data provided by the apparatus.

Greegory Mathew, Santosh B. Rane, Yogesh Patil, Sanjay V. Mohan
Design and Manufacturing of Test Rig for Pyrolysis of Waste Tyres of Two-Wheeler Vehicles (ELVs)

The automobile industry works as a pillar in the manufacturing sector in a developing country like India. Due to a huge number of vehicles on the verge of the end-of-life, guidelines for the management of it came in existence with a law, AIS132, a couple of years back. This research has focused on environment-friendly methods for tyre recycling in the automobile industry. In pyrolysis process, the tyre is heated to 500–600 °C in the absence of oxygen, which leads to thermal cracking of waste tyres, and the output of this process was oil after condensing of the evolved gases. The properties which were considered to compare with diesel properties were cetane number, flashpoint, pour point, viscosity at 40 °C, calorific value, carbon content, sulphur content and density. Results of the study show that tyre pyrolysis liquid generated during the process has the properties like that of diesel. Hence, the generated liquid can be blended with diesel and this increases the commercial value of waste tyres and further helps in alleviating the ELV problem.

S. M. Auti, W. S. Rathod
Development of Mathematical Model for Reduction of Process Time for Peddle-Driven Sewing Machine

By using response surface curve (RSM) method of regression, a model is developed. In the present investigation, a fairly large data of workstations is collected. Based on collected data in terms of independent parameters and dependant parameters, the mathematical co-relationships of effects as function of causes are established. Since the data based on which these relationships are established is a field data, the deduced models are conceptualized as field data-based models. Pedal sewing operation is a man–machine system, comprising of (1) an operator, (2) pedal sewing machine, (3) workstation, and (4) environmental conditions. This operation takes place at a workstation usually known as single person owned premises meant for stitching clothes of the clients of the shop owner. The field study indicated that there is a considerable musculo-skeletal disorder on the part of the operator. Hence, it was decided to execute an assignment in which substantially large field data of this operation is collected. Based on this data, mathematical co-relationships are established between various causes and effects of this activity. The paper reports on: (1) Planning of collection of data. (2) Execution toward collection of data. (3) Presentation of collected data. (4) Processing of the data for formulation of cause–effect relationships. Upon formulation of model, the reliability of model and its optimization is executed. The data collected comprises of 30 sewing machine operators working on stand-alone pedal-driven sewing machines. The collection of data was done on 36 causes/input parameters/independent variables and 1 effects/output parameters/dependant variables. The causes are clubbed and converted into 5 independent dimensionless terms known as Pi terms such as Π1, Π2, Π3, Π4, and Π5. The effects/output/dependant parameter is nomenclated as Z1.

Swapna Ghatole, Yashpal, Mahesh Bundele, J. P. Modak
Design and Development of an Anti-rolling Mechanism for Hand-Driven Tricycles

Most disabled individuals depend on hand-driven tricycles for their commute between their house of residence and office. They often need to drive over flyovers or slopes during commute. Road conditions or other traffic situation may sometimes force the disabled driver to halt the tricycle on the slope. Starting the tricycle from this stop condition is more difficult as the tricycle has a natural tendency to roll down along the slope. This paper discusses the design and development of an anti-rolling mechanism to prevent the self-roll of the tricycle in the reverse direction. The mechanism is based on the principle of working of a pawl and ratchet. Solidworks software was used to model the mechanism and to evaluate the induced stresses and strains. Calculation for limiting values of deceleration to prevent self-roll is presented for different slope inclinations.

Vishal Nadar, E. Narayanan, Greegory Mathew, Rameshbabu Udayar
Investigating Red X Parameter for Short Shot-Type Defect in Plastic Injection Moulds Using Shainin’s Design of Experiments

The study has investigated key parameter(s), which causes short shot-type defect in the case of a plastic injection moulding process using Shainin DoE methodology. An average rejection rate of around 11% was recorded over a period of three months, due to the presence of short shot-type defect for a bulb holder component (E27). Shainin’s DoE methodology of Red X, based on progressive elimination search principle, was adopted to identify key parameter (s), which caused such defect among the variables selected for the study. Selective tools from Shainin’s DoE methodology were adopted and a particular variation reduction roadmap was prepared to investigate the process. The influential factor identified was the injection time, a solid Red X, i.e. a dominant variation causing variable.

Rajendra Khavekar, Hari Vasudevan, Dharam Ranka
Structural Analysis of the Upright of a FSAE Race Car

Upright of a FSAE car is normally subjected to various mechanical loads as it handles tire forces as well as the reaction forces from wishbones. This paper aims to analyze the structural integrity of the rear upright for a FSAE vehicle. The upright has been modeled using 3D modeling software SOLIDWORKS and its finite element analysis (FEA) was done using ANSYS. The methodology consisted of generating good quality mesh, considering various mesh quality criteria, applying forces and moments for different load scenarios and further analyzing their effects.

Vinayak H. Khatawate, Jinesh Sheth, Prakriti Tulasyan
Design and Analysis of Components of a Rotary Car Parking System

Parking infrastructure has been unable to keep with the rapid rise in the vehicle sales numbers. This often leads to an increased strain on current parking resources and further causes inconvenience to the general public. Research efforts were channeled into the development of newer technology capable of providing and handling parking spaces to ensure that the current demand is satisfied. This success of the implementation of a parking system depends on various factors viz. effective utilization of area, power requirements, ease of access, and most importantly, cost. One such technique, which ticks all the right boxes is the ‘Rotary Car Parking System.’ The ‘Rotary Car Parking System’ features a mechanism that is like the concept of a Ferris wheel, commonly seen in fun-fairs. A modular design, low power consumption, ease of use, and installation are some of its salient features. The parking pallets will be sized, such that they could accommodate vehicles of all dimensions available in India.

Rajnarayan Yadav, Sanjay Kumar, Salil Gavankar, Suraj Amin
Designing a Cowl Template with DFSS Methodology

This paper illustrates the application of modern ideas along with the integration of new techniques to achieve optimum process cycle efficiency. The paper uses design for six sigma (DFSS) methodology in designing a metal template for tack welding of brackets on the cowl. The cowl is a part of the fork truck located near the driver’s position. The design uses six sigma methodology, considering five steps known as DMADV, which resembles define, measure, analyze, design and verify. Lean and six sigma tools, 3D modeling software, finite element analysis, jigs and fixtures theories were utilized to determine and eliminate bottlenecks with the help of the proposed methodology. The sample readings were recorded and analyzed. A detailed comparison showed a surge of 27% in the process cycle efficiency resulting in savings of manpower cost and reduction in time required for the overall process.

Sandip Mane, Smit Patel, Jay Bhuva
Reliability Estimation of Molded Case Circuit Breaker in Development Phase

Life test of molded case circuit breakers (MCCB) on mechanical endurance test setup showed degradation in the functional deliverables of a MCCB, such as reset force and contact pressure. Degradation in functional deliverables affects the satisfactory working of the circuit breaker and decreases its reliability. Functional deliverables of a MCCB in development phase can be measured using two systems of measurement. A gage repeatability and reproducibility study using 2 operators, 5 parts and 3 trials was performed to select the best measurement system. MCCBs were then tested on a life cycle test setup, and the degradation in the deliverables was measured using the selected measurement system. These measured values were analyzed, and the circuit breaker reliability was then predicted using Minitab software.

Greegory Mathew, Santosh B. Rane
Design and Development of Easy Access Crisper/Shelf in a Refrigerator

The category of premium refrigerators available in market is different from regular household refrigerators, with the former being bigger in size. In such refrigerators, the depth can go up to 70–80 cm, and the items placed at the back side or in corners are ergonomically less accessible. The taller items need to be placed at the back side of the refrigerator to easily access the short items. Also, due to the limitations of the support structure, the full extension of the crisper is not achievable. Currently, the crisper is pulled out only in a linear manner. Hence, it is advantageous to make the crisper rotate to make it accessible from more number of sides. In this paper, a mechanism to achieve the rotational motion of the crisper was developed. Finite element analysis (FEA) was carried out to check the permissible deflection of the crisper and is validated using experimentation.

Addanki Sambasiva Rao, Vinayak H. Khatawate, Sumit Mane
Design, Analysis and Optimization of a Single-Pass Straight Pipe Resonator for an Exhaust System of a Single Cylinder Engine

The purpose of this research was to design a method to attenuate exhaust sound waves within a specified frequency range, in an exhaust system of an internal combustion engine for a formula-type car by resonance. A resonating chamber was designed along with the muffler that targets the frequency range of the exhaust sound. The engine data obtained through dynamometer was used as an input to Ricardo WaveBuild software which provided the data and was further analyzed by a fast Fourier transform model. The resonating chamber design was finalized after iterations of the same which were tested virtually for their transmission loss. The parameters such as location and orientation of exit pipe, length of perforation (internal structure) start and the distance between holes were observed to have a significant effect on transmission loss.

Omkar Samant, Gulammoin Kasmani, Jay Saple, Jayraj Ranade, Vinit Katira
Design and Development of Cost-Effective Solar Water Heating System

One of the major problems faced by the thermosiphon solar water heating system is mixing of hot and cold water. The mixing is often caused due to the disturbance in the stratification layers. The incoming cold water jet creates turbulence that causes the mixing of hot and cold water. The current work is based on the development of effective control system which controls the flow of incoming cold water. A solenoid valve is actuated according to the temperature and water level inside the tank. With 10-bit microcontroller, the programming was done with the help of mikroC PRO software, and the circuit diagram was developed with the help of Proteus Design Suite software. The compact device which detects level was developed that controls the flow of incoming cold water. A thermistor was incorporated in the system separately to monitor the temperature inside the tank.

Sarvesh Kulkarni, Vijaya Kumar N. Kottur, Prasad Shirodkar
Development of Storage System by Designing a Magazine for Forged Rings

A forged groove ring is one of the vital parts, widely used item in aerospace engineering. It is an essential step to store these rings carefully and keep them handy, when they are required. This paper helps the manufacturing shop to store these rings efficiently and keep it handy, whenever they are needed. By designing a magazine for storage system, stresses were calculated by selecting proper material and its availability. This provides machine shop safety as well as helps in efficiently handling the rings.

Meet Karelia, Mehul Prajapati, Vinayak Salian
Design of Shredder Machine for ELV Tyres

Waste tyres generated in India make up around 7% of the total waste tyres of the world. With the advancements in the automotive industry, the tyre industry is rapidly increasing through projected growth of 6–8%. With this development, the amount of tyre’s waste increases and the risk to the environment increases. Recycling of tyres helps to reduce the negative effects. Tyre shredding is the first step towards recycling as well as reducing the space needed by waste tyres. This study has mainly focused on detailed shredder machine design and analysis. The components of the system were modelled using 3D modelling software, and ANSYS was used for its finite element analysis (FEA). In this analysis, a couple of criteria for cost-effective shredding of scrap tyres were addressed. More emphasis was on cutting blade design. Analysis revealed that design was safe taking into account safety and strength criteria.

S. M. Auti, Jinesh Sheth, Prakriti Tulasyan, Asmita Gaikwad, Purnima Bagwe
Design and Development of a Foldable Hand-Driven Tricycle

Hand-driven tricycles are a primary mode of transportation for most disabled individuals. These tricycles provide a good riding experience and have solved the mobility issues of disabled individuals to a great extent. However, these tricycles cannot be folded. They can neither be carried along in trains and buses, nor be stored in small residential and office spaces. This research paper focusses on the design and development of a foldable tricycle. The paper also explains the procedure to fold the tricycle, the FEA analysis of the frame and the calculation for the time taken to fold and unfold the tricylce.

Vishal Nadar, E. Narayanan, Greegory Mathew, Pascol Fernandes
Assessment of Local Stresses and Strains Using NSSC Rules

Practically, many machine components and structures contain irregularities in spite of careful and detailed design. Such stress concentration site drastically diminishes the properties of the material. The service cracks get initiated in the vicinity of stress raiser sites. For the reliable design of machine components, the knowledge of stress and strain near the stress raising site is essential. In particular, for high-strength and high-performance components, better insights of the behavior of these components are required for the reliable design. In this paper, the criteria commonly used to estimate the local stresses and strains, viz Neuber’s rule and equivalent strain energy density (ESED) methods, are presented. An Excel-based program for the stress-strain response was developed which used a constitutive equations together with Neuber and the ESED method.

Vinayak H. Khatawate, M. A. Dharap, Atul Godse, Veeresh G. Balikai, A. S. Rao
Numerical Comparison of Tube Bank Pressure Drop of an SHTX Using Elliptical and Flat Face Header with Different Nozzle Positions

Among distinguishing types of a heat exchanger, this report analyzes the pressure drop in the tube bank in a shell and tube heat exchanger. Pressure drop is one of the most important parameters that describe the efficiency of a shell and tube heat exchanger and its acceptance in any engineering application. Studies show that if the pressure drop across the tube side is more, the heat transfer rate decreases; hence, it affects the performance of the heat exchanger, and a greater pumping power is required, thereby increasing the cost. This paper numerically compares pressure drop in the tube bank in single-pass shell and tube heat exchanger using: (1) Elliptical face header (2) flat face header at different nozzle position, i.e., conventional nozzle position and inline nozzle position. The numerical comparison is done with the help of ANSYS 14.5, considering the flow to be steady and isothermal.

Kartik Ajugia, Mihir Sanghvi
Modal and Static Analysis of Luggage Rack Systems Used in Mumbai Suburban Railway Trains

In this study, the authors have made an attempt to perform a numerical investigation of a luggage rack system, which is used in Mumbai suburban railway trains. The first part of the investigation focuses on modal analysis to calculate the natural frequencies of the system, which then is studied in comparison with the phenomenon of hunting oscillation observed in railway trains. The second part of the exercise focuses on the stress-strain behavior of the system, total deformation, stress, and strain under a given load. It is observed that the given system performs safely for the given practical load, and also for the excitation frequencies observed in trains.

Jash Patel, Neel Sanghvi, Ujwal Sutaria, Deven Shetty, Vaibhav Shah, Vijaya Kumar N. Kottur
Design and Analysis of Onion Harvester

The harvesting of any plant is equally important as the seeding and taking care of it. It is of paramount importance to extract the onion bulb from the soil without any damage to the onion. If the bulb is damaged, it would be rejected leading to increased waste and decreased farm productivity. This study was conducted to bring out the reliable solution for harvesting onions with minimal or no damage to the onion bulb, effectively amplifying farming efficiency. By loosening the soil, the harvesting machine digs the onion bulb out and pushes it onto the conveyor belt, which ultimately transits the onion from front to rear. The size of the harvester was decided with respect to the agro-technical features of the crop. Software used for analysis was ANSYS. Strength analysis revealed that strength point of view design is safe.

Dhairya D. Mehta, Omkar Atale, Tanvi Hodage, S. M. Auti, Rohit Chaurasia
Design, Analysis, Prototyping and Testing of Aerofoils for High-Lift at Low Reynolds Number

Increased payloads, reduced aircraft noise, shortened takeoff and landing distances and lowered stall speeds can all be achieved from the direct effects of improved high-lift aerofoil aerodynamics. It is, therefore, not surprising that the high-lift aerofoil design has been and will remain a topic of interest. Along with the interest, the opportunity is to make it more cost-effective. One possible way to achieve the objective is to build a cheaper yet simpler high-lift system. This presents a challenge to the high-lift aerodynamicist: to design a less complex flap that maintains high-lift and meanwhile lowers the flow separation. Furthermore, by designing the high-lift system to achieve longer attachment of flow onto the flap, aircraft noise will be reduced. This research article presents the design, analysis and prototyping and testing of aerofoil which was carried out after performing a literature survey on the performance of many aerofoils at low Reynolds number. This research was achieved using Vortex generators for high lifts. The prototype was tested in the wind tunnel.

Pavan Rayar
A Review on Vibration Suppression of Flexible Structures Using Piezoelectric Actuators

Piezoelectric Actuators are devices that convert electrical energy into a mechanical displacement or stress by a phenomenon known as Piezoelectric Effect. These crystals generate energy when mechanical stress is applied. This paper reviews the application of piezoelectric actuators in vibration suppression of flexible lightweight structures. Feedback control strategies are used for suppressing periodic and aperiodic vibrations. Negative velocity feedback and positive position feedback are two such common strategies employed for controller design. A finite element is defined for modelling of a uniform cantilever beam and a thin, flexible plate. The appropriate controller frequency is obtained by modal analysis, for monomodal vibration control.

Aniruddha Mallick, Frank Crasta, Vijaya Kumar N. Kottur
Topology Optimization of Wheel Hub Used in Automobiles

The wheel hub is a vital element of a vehicle that attaches the wheel to the motor shaft. Its main function is to keep the wheel running freely on the bearing while keeping it attached to the vehicle. It experiences a lot of shearing and bending forces when the vehicle in motion. The focus of this paper was to reduce the load on the components due to these forces on the wheel hub by optimizing its design and topology. A solid model was created in accordance with the optimized design and FEA was performed to determine its strength.

Jash H. Patel, Rohan Poojari, Monil K. Shah, Aagam H. Shah, Vinayak H. Khatawate
Modelling, Investigation and Refinement of Three Stage Helical Gearcase Housing Utilizing Numerical Approach Contemplating Various Relevant Substances

The endeavour was undertaken to model and investigate ternary reduction helically coiled gear case body. To initiate the process, examinations were conducted for interrogating and recognizing constructional functioning on the differential gearbox. Afterwards, through a review of various research papers, it was established that majorities of the organizations at present are overlaying the trouble of their prevailing gearbox integrated weight and stability. Thus, drafting and inspection of gearbox housing have emerged as an influential domain for exploration of the causes and optimizing gearbox. This necessitates the accomplishment of various types of analysis for prevailing helically shaped gear housing (S.S.A36) and transformed model (H.C.S and S.S.A36) for forecasting performance of enclosures exposed to discrete charging and discharging environment. Hence, from the viewpoint of drafting and analyzing, reformed drawing having carbon tool steel material is ideally suitable because of flexibility, weight, reverberation, permanence and costing, in comparison with the existing design.

Ronak D. Gandhi, Ghanshyam V. Patel, Sanket K. Patel
Lateral Force Modelling Using Magic Formula Tire Model

The aim of this paper is to explain one of the methods that can be used to fit the Pacejka Magic Formula Model for the lateral behaviour of the tire. The content gives the readers an idea in order to utilize data and model tire behaviour. The tool used for the purpose of explanation is MATLAB.

Aditya H. Bhatt, Prasad S. Shirodkar
Static Analysis of Tripod Housing Using FEA and Its Validation

Tripod housing plays a major role in transmitting power from the transmission system to the drive wheel and hence it undergoes severe torsion and bending type of deformation. In this paper, a design of Tripod housing for an off-road vehicle was analyzed using a finite element analysis (FEA) and verified mathematically using the principle of impulse-momentum and maximum shear stress theory. For any mechanical component, Factor of Safety (F.O.S.) gives the degree of safeness of the component under consideration. Thus, the focus of concern of this paper was on the value of F.O.S. by FEA and its verification using analytical calculations.

Jash H. Patel, Vinayak H. Khatawate, Gaurav Jain, Param Shah
Design and Performance Evaluation of a Cost-Effective Radiant Cooling System

Air conditioning or simply cooling is essential to maintain human comfort in a hot and humid climate. Thus, a system is to be designed that at a minimum energy input gives more efficient cooling along with being highly eco-friendly as compared to conventional Air Conditioners (AC). Hence an idea of cooling by the exchange of sensible heat to the surrounding from one’s body can be put in use. During design, various factors were considered so as to accurately find the total cooling load required to cool the space. After successful fabrication and installation of the system, readings were taken to compare both conventional AC system and our designed radiant cooling system and comparisons with respect to human comfort and the cost of operation incurred while running the systems were made. It was concluded that radiant cooling systems save 34% of energy while maintaining superior human comfort.

Rohit A. Rawool, Siddharth Saini, Aksheshkumar A. Shah, Tejas P. Shah, Vinit Katira
Design and Analysis of ‘Kangaroo’ Boots

Superman is a hypothetical concept with exceptionally supreme powers. How would it be to have one of his powers? Ever imagined yourself of running at a smeared lightning speed? Well, now you can! ‘Kangaroo boots’ is a solution to this. Inspired from kangaroos who have a unique back feet structure, these boots are a replica of the same feature which would store and release the elastic energy and increase the running speed of a human up to 25–30 mph. The main perspective of this study is to provide more agility while running off-road and climbing steep roads. It will also make humans more active and travel short distances in minimal time reducing the use of fossil fuels. Keeping in mind the future scope, these boots can be used in human enhancement, military, sports and robotic applications.

Mihir Sanghvi, Hamza Neemuchwala, Md Husain Thekiya, Dinesh Papal, Kartik Ajugia
Optimization of Brake Rotor Slotting Using Finite Element Analysis

The disc braking system in a vehicle is used for either retarding the motion of a vehicle or to bring it to a halt. Due to the application of brakes for number of times, there is a generation of heat, which may result in the failure of brake rotor. In this study, the thermal analysis of the brake rotor was done using Finite Element Analysis (FEA). The primary aim of the project was to compare the effect of different types of slotting on the rotor. The two designs of the rotors with different slotting were considered for analysis. The two designs were compared by their thermal values obtained from the thermal analysis by FEA and the best suitable design was selected for better performance disc brakes.

Ujwal Sutaria, Vaibhav Shah, Karan Shah, Chaitanya Shah, Vinayak H. Khatawate
Evaluation of Piping Isometric Drawings Using Six Sigma Process

Six Sigma is a business strategy that helps organizations to improve its organizational efficiency and customer satisfaction; it decreases operating cost and increases profits. Six Sigma is a widely used method to improve processes from various industrial sectors. The target failure rate for Six Sigma projects is 3.4 parts per million. Numerous practitioner studies claim that Six Sigma improves organizational performance. However, its implementation to design process is limited. So, in this study, we have implemented the Six Sigma philosophy in piping design process. Piping isometric drawings, which feature their intrinsically topological relation rather than just geometrical shape, are important industrial artworks in the field of Computer-Aided Design (CAD). This study suggests that the link between Six Sigma and piping design process performance can be explained and developed by integrating organizational knowledge creation processes. We have quantified the performance of a design process in terms of sigma level and tried to find the possible ways to improve it. The method used in this study is based on five main steps summarized in the acronym (DMAIC): Define Measure, Analyze, Improve and Control. Application of the method on the design process during the five phases of the method will help to reduce costs and losses of man-hours to strive for optimum results in terms of profit and quality.

Abrar Khulli, Prasad Shirodkar, Vijaya Kumar N. Kottur, Rajendra Khavekar
Design of an Accumulator Container for a Formula Student Electric Race Car

Growing concerns over carbon emission have lately sparked worldwide interest in more efficient and cleaner transportation systems. Industrialization is increasing exponentially, making energy resources the primary concern of every nation of the globe. Non-renewable sources are on the verge of being extinct, and carbon emissions are becoming a trigger for global extinction. One such effort of reducing the concern is a shift of the automobile industry from a combustion powertrain to the electric counterpart. Challenges accompanied by the electric powertrain include humongous size, reduced safety and sophisticated electronics involved in the electric powertrain relative to the combustion powertrain for the same amount of energy. This paper explores the use of electric powertrain, particularly the battery pack and the accumulator of a Formula Student electric race car. It has also highlighted the intricate design of an accumulator container for a Formula Student electric car.

Harshal Mehta, Ratan Soni, Parvez Shaikh, Raunak Bhanushali, Jobin Abraham, Dhaval Birajdar
Design and Fabrication of Small Size Parabolic Reflector

This study presents the design and development aspects of 3.2 m2 small size parabolic reflector, used in domestic solar cooker for single family having four members. The study focused on design, proper material selection, and fabrication of reflector. The proposed reflector is based on Scheffler reflector. It was found that glass mirror has highest reflectivity and hence, is the best suitable material for reflector. Material for supporting frame is taken from scraps which reduces the cost of fabrication. Also, fabrication is simple and model is easy to transport from one place to another. The proposed model of the reflector is suitable for rural area applications and also doesn’t require skilled labor to fabricate.

Harshal Patil, Nishikant Kale
Analysis of Brake Hub Used in Automobiles

This paper presents the design and analysis of a brake hub used in an automobile vehicle. While the vehicle is being driven, the power is transmitted from the hub to the rotor. In vehicles, when the brake is applied, the brake rotor receives the braking torque and communicates it to the shaft through the hub. Brakes in automobiles are associated with safety. They play a vital role in the overall performance of the vehicle and also provide comfort and serviceability. The present work consists of the weight optimization of the brake hub and weight optimized part was considered for the structural analysis. It was found that stresses induced in the brake hub were within the permissible values.

Dhairya K. Vora, Rishikesh K. Patil, Vinayak H. Khatawate
Metadata
Title
Proceedings of International Conference on Intelligent Manufacturing and Automation
Editors
Dr. Hari Vasudevan
Dr. Vijaya Kumar N. Kottur
Dr. Amool A. Raina
Copyright Year
2020
Publisher
Springer Singapore
Electronic ISBN
978-981-15-4485-9
Print ISBN
978-981-15-4484-2
DOI
https://doi.org/10.1007/978-981-15-4485-9

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