Modern manufacturing processes

249 Pages·2020·7.815 MB·English

by  Davim, J. Paulo, Kumar, Kaushik

M M
ODERN ANUFACTURING
P
ROCESSES
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Woodhead Publishing Reviews: Mechanical
Engineering Series
M M
ODERN ANUFACTURING
P
ROCESSES
Edited by
KAUSHIK KUMAR
J. PAULO DAVIM
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Contents
Listofcontributors ix
Preface xiii
Section 1 Advances in Manufacturing
Processes
1. Advanced manufacturingtechniques for compositestructures
used in aerospaceindustries 3
RaghuRajaPandiyanKuppusamy,SatyajitRoutandKaushikKumar
1.1 Polymermatrixcomposites 3
1.2 Processingmethods 5
1.3 Moldingtechniques 6
1.4 Handlay-upprocess 7
1.5 Resintransfermoldingprocess 8
1.6 Compressionmolding 9
1.7 Vacuumbagging 10
1.8 Vacuumenhancedresintransfermoldingtechnology 10
References 12
2. Advances inmanufacturing analysis:fractal theory in modern
manufacturing 13
FredrickM.Mwema,EstherT.Akinlabi,OluseyiP.Oladijo,OlawaleS.Fatoba,
StephenA.AkinlabiandStefanTa˘lu
2.1 Introduction 13
2.2 Theoryoffractals 14
2.3 Casestudies:fractalanalysesinmanufacturing 24
2.4 Conclusions 34
Acknowledgment 34
References 35
v
vi Contents
Section 2 Application in Modern Manufacturing
Processes
3. Weldability appraisement of dissimilarmetal joints: application
of ultrasonic spot welding to Li-ionbatteries 43
MantraPrasadSatpathy,BharatChandraRoutaraandSusantaKumarSahoo
3.1 Introduction 43
3.2 USWprocess 44
3.3 USWsystem 45
3.4 Generalprocessparameters 47
3.5 Mechanicalanalysisofjoints 49
3.6 Microstructuralanalysisofjoints 53
3.7 Conclusions 64
References 67
4. Applications of coconut shell ash/particlesinmodern
manufacturing: acasestudy of friction stir processing 69
OmolayoM.Ikumapayi,EstherT.Akinlabi,JyotsnaD.Majumdarand
StephenA.Akinlabi
4.1 Introduction 69
4.2 Applicationofcoconutshellashasactivatedcarbonorascharcoal 72
4.3 Applicationofcoconutshellparticleaswaterpurificationandheavy
metalsremoval 74
4.4 Applicationofcoconutshellinmetal,polymer,andceramicmatrix
composites 76
4.5 Materialsandmethods 80
4.6 CharacterizationofthefrictionstirprocessedAl7075/CCSA 83
4.7 Resultsanddiscussion 85
4.8 Conclusion 93
Conflictofinterest 93
References 93
5. Fractography analysis and constitutive modeling for dynamic
plasticity of austenite stainlesssteel (ASS304) athot-working
temperatures 97
TanyaBuddi,A.AnithaLakshmiandSrinivasRao
5.1 Introduction 97
5.2 Materialandexperimentaldetails 100
5.3 Microstructureexaminationandfractography 101
5.4 Constitutivemodels 106
5.5 Constitutivemodel(m-FB)modifiedFields(cid:1)Backofen 107
5.6 Constitutivemodel(KHL)Khan(cid:1)Huang(cid:1)Liang 111
Contents vii
5.7 Johnson(cid:1)Cook(JC)model 116
5.8 Constitutiveequation(m-Arr.)type 117
5.9 Zerilli(cid:1)Armstrong(m-ZA)model 119
5.10 Constrainedoptimization 119
5.11 Resultanddiscussion 120
5.12 Conclusion 127
Acknowledgment 127
References 127
6. Laser transmission welding ofdissimilar plastics:analyses of
parametric effectsand process optimizationusinggrey-based
Taguchimethod 131
BappaAcherjee
6.1 Introduction 131
6.2 Grey-basedTaguchimethod 133
6.3 Experimentalwork 135
6.4 Parametricanalysis 137
6.5 Multiobjectiveoptimization 140
6.6 Conclusion 142
References 143
7. Investigations on effectof thicknessandrollingdirection of
thin metal foil on forming limit curves in microforming process 145
GyanPatelandGaneshKakandikar
7.1 Microforming 145
7.2 Experimentalinvestigations 147
7.3 Conclusions 154
References 154
8. Evaluationand characterization of rollingof brass at cryogenic
conditions 157
SwadeshKumarSingh,SatyanarayanaKosaraju,JayahariLade,
V.DineshVarmaandM.Sandeep
Nomenclature 157
8.1 Introduction 157
8.2 Materialsandmethods 159
8.3 Resultsanddiscussion 162
8.4 Analysisofvarianceandregressionequation 164
8.5 Conclusions 165
References 166
viii Contents
9. Multiaxis CNC programming andmachining 167
T.VishnuVardhanandB.SridharBabu
9.1 Numericalcontrolofmachinetools 167
9.2 IntegratingCNCandautomation 168
9.3 Flowofcommandsfor5-axismachine 169
9.4 CNCprogrammingvalidation 170
9.5 ContinuousimprovementwithouteditingtheCNCprogram 174
References 175
Section 3 Sustainability in Modern Manufacturing
Processes
10. Recyclingofpolyethylene: an attempt to sachet and bottled
watersustainability in Ghana 179
EmmanuelBaffour-Awuah,StephenAkinlabiandTien-ChienJen
10.1 Introduction 179
10.2 SachetwaterinGhana 181
10.3 ChallengesofwaterPE-packaging 182
10.4 Recycling 186
10.5 Thewayforward 197
References 200
11. Sustainability and survivability inmanufacturing sector 205
AnkitaAwasthi,KuldeepK.SaxenaandVanyaArun
11.1 Introduction 205
11.2 Elementaryconceptsofsustainabilityinmanufacturing 207
11.3 Manufacturingprocess 212
11.4 Survivabilityofacommunicationnetwork 215
11.5 Challengesinsustainabledevelopment 217
References 218
Index 221
List of contributors
BappaAcherjee
DepartmentofProductionEngineering,BirlaInstituteofTechnology,Ranchi,India
EstherT.Akinlabi
DepartmentofMechanicalEngineeringScience,UniversityofJohannesburg,Auckland
ParkKingswayCampus,Johannesburg,SouthAfrica
StephenAkinlabi
DepartmentofMechanical&IndustrialEngineeringTechnology,Universityof
Johannesburg,Johannesburg,SouthAfrica
StephenA.Akinlabi
DepartmentofMechanicalEngineering,FacultyofEngineeringandTechnology,
ButterworthCampus,WalterSisuluUniversity,SouthAfrica
VanyaArun
CollegeofEngineeringandTechnologyIILM,GreaterNoida,India
AnkitaAwasthi
CollegeofEngineeringandTechnologyIILM,GreaterNoida,India
B.SridharBabu
CMRInstituteofTechnology,Hyderabad,India
EmmanuelBaffour-Awuah
DepartmentofMechanicalEngineeringScience,UniversityofJohannesburg,
Johannesburg,SouthAfrica
TanyaBuddi
GokarajuRangarajuInstituteofEngineeringandTechnology,Hyderabad,Telangana,
India
BharatChandraRoutara
SchoolofMechanicalEngineering,KIITDeemedUniversity,Bhubaneswar,India
OlawaleS.Fatoba
DepartmentofMechanicalEngineeringScience,UniversityofJohannesburg,
Johannesburg,SouthAfrica
OmolayoM.Ikumapayi
DepartmentofMechanicalEngineeringScience,UniversityofJohannesburg,Auckland
ParkKingswayCampus,Johannesburg,SouthAfrica
Tien-ChienJen
DepartmentofMechanicalEngineeringScience,UniversityofJohannesburg,
Johannesburg,SouthAfrica
ix