International Journal of Fracture and Damage Mechanics vol 2 issue 1

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Fracture and Damage Mechanics
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mechanics and crack-damage repair mechanics. Journals publish both theoretical and experimental
researchand promotepracticalapplicationofappliedmechanics.
Focus and Scope oftheJournal
! Elastic instability
! Gross plastic deformation
! Tensile instability
! Creep damage and creep-fatigue interaction
! Low and high cycle fatigue damage
! Brittle/elastic damage
! Ductile/plastic damage
! Strain softening and strain-rate sensitivity damage
! Impact damage
! Modeling and numerical simulation
! Elastic–plastic fracture mechanics
! Crack incubation and propagation
! Crack and fracture repair techniques
! Damage tolerance and fracture control
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IEC University, Solan, India
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Department of Mining Engineering, College of
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School of Mechanical and Building Sciences,
SMBS, VIT University, Chennai,
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Department of Mechanical Engineering, Mepco
Schlenk Engineering College,
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Clemson University, Clemson, SC,
United States
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School of Chemical Engineering and
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Department of Mechanical Engineering,
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From the Editor's Desk
Dear Readers,
We would like to present, with great pleasure, the inaugural volume of a new scholarly
journal, International Journal of Fracture and Damage Mechanics. This journal is part of
the Engineering Sciences, and is devoted to the scope of present Fracture and Damage
Mechanics from theoretical aspects to application-dependent studies and the validation of
emergingtechnologies.
This new journal was planned and established to represent the growing needs of Fracture and Damage
Mechanics as an emerging and increasingly vital field, now widely recognized as an integral part of
scientific and technical investigations. Its mission is to become a voice of the Engineering Science
community,addressing researchersandpractitionersinthisarea.
The core vision of International Journal of Fracture and Damage Mechanics in Journals Pub is to
propagate novel awareness and know-how for the profit of mankind ranging from the academic and
professional research societies to industry practitioners in a range of topics in Fracture and Damage
Mechanics in general. Journals Pub acts as a pathfinder for the scientific community to published their
papers atexcellently,well-time&successfully.
International Journal of Fracture and Damage Mechanics focuses on original high-quality research in the
realm of Elastic instability, Gross plastic deformation, Tensile instability, Creep damage and creep-fatigue
interaction,Low andhighcyclefatiguedamage, Brittle/elasticdamage etc.
The Journal is intended as a forum for practitioners and researchers to share the techniques of Fracture and
Damage Mechanicsand solutionsinthearea.
Many scientists and researchers have contributed to the creation and the success of the Fracture and
Damage Mechanics community. We are very thankful to everybody within that community who supported the
idea of creating an innovative platform. We are certain that this issue will be followed by many others,
reportingnewdevelopmentsinthefieldofFractureandDamage Mechanics
This issue would not have been possible without the great support of the Editorial Board members, and we
would like to express our sincere thanks to all of them. We would also like to express our gratitude to the
editorialstaffofJournals Pub,who supported us ateverystageoftheproject.
It is our hope that this fine collection of articles will be a valuable resource for engineering readers and will
stimulatefurtherresearchintothevibrantareaofFractureandDamage Mechanics.
PuneetMehrotra
ManagingDirector

1. Noncontact Surface Roughness Measurement of Machined Surfaces Using Grinding
Process by the Application of Digital Image Magnification
N. Bose, D. Palani Kumar 1
2. Optimization of Drilling Process Parameters for Thrust Force: A Review
Y.S. Chouhan, M.A. Saloda, S. Jindal, C. Agarwal 12
3. Failure Mode and Effect Analysis for CNC Machines Used In GG Valves Industry
R.K. Salvi, C. Agarwal, B.P. Nandawana, M.A. Saloda 22
4. A Comparitive Study on Ceramic Powder Over Static and Dynamic Compaction
R. Karthikeyan, M.V. Shanmugam, P. Divyakumar, R. Nirmal Raja 34
5. Durability Aspects of Copper Slag Admixed Concrete
G. Akhil, J. Karthikeyan 40
Contents

IJFDM (2016) 1–11 © JournalsPub 2016. All Rights Reserved Page 1
International Journal of Fracture and Damage Mechanics
Vol. 2: Issue 1
www.journalspub.com
Noncontact Surface Roughness Measurement of Machined
Surfaces Using Grinding Process by the Application of Digital
Image Magnification
N. Bose1
, D. Palani Kumar2
1
Mepco Schlenk Engineering College, Sivakasi, India
2
Kamaraj College of Engineering and Technology, Virudhunagar, India
Abstract
In today’s competitive world, manufacturing requires fast and accurate systems that provide
the feedback to control the machining process and improve product quality and productivity.
One of the parameters to be controlled in machining is surface finish, which is a vital
criterion in the performance and utility of industrial products. The computer vision based
system is used to analyze the pattern of scattered light from the surface to assess the surface
roughness of the component. In recent years the advent of high speed digital computers and
vision systems has made image analysis easier and flexible. Unlike the stylus instruments, the
computer vision systems have the advantages of being non-contact and are capable of
measuring an area of the surface rather than a single line which makes it a 3D evaluation. In
this research work, a machine vision system has been utilized to capture the images of
ground surfaces and then the quantification of digital pictures of ground surfaces is done.
Subsequently, original images of ground surfaces have been magnified using cubic
convolution, Nearest Neighbor and Bilinear interpolation techniques. Then the optical
surface roughness parameter Ga has been estimated for all the captured surface images and
for the magnified quality improved images. Finally, a comparison has been done to find
correlation between the magnification factor and optical surface roughness parameter Ga for
the three interpolation algorithms.
Keywords: Bilinear interpolation, cubic convolution, magnification factor, surface
roughness.
INTRODUCTION
Surface roughness is usually a detrimental
by-product of all machining processes.
Surface roughness also affects several
functional attributes of parts, such as
friction, wear and tear, light reflection,
heat transmission, ability of distributing
and holding a lubricant. In manufacturing,
the surface finish is adopted as finger print
of the machining process.[1,2]
Surface
finish measurement is also useful in
providing an index of process stability.
The proper functioning of a machined part
is in many instances largely dependent on
the quality of its surface. Surface
roughness is one of the key factors for
overall work piece quality evaluation. The
study of surface texture is commonly
referred to as Surface Metrology. It
involves the measurement and
characterization of surfaces and their
relationship to the manufacturing process
that generated the part and functional
performance measures of the component.
Surface analysis relies on the assumption
that the surface geometry irregularities can

Vol. 2: Issue 1
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Optimization of Drilling Process Parameters for Thrust Force: A
Review
Y.S. Chouhan*, M.A. Saloda, S. Jindal, C. Agarwal
College of Technology and Engineering, Maharana Pratap University of Agriculture and Technology, Udaipur,
Rajasthan, India
Abstract
The big challenge of the industries is concentrated for achieving less wear and thrust force
on the drilling tool and more tool life. In this paper an effort is made to review the literature
work on investigating the effect of drilling and tool parameters on thrust force in drilling
process on lathe machine with different-2 work piece materials, for optimization of thrust
force. Most of experiments have been carried out by considering various independent
parameters namely spindle speed, drill bit diameter and feed rate. Finally most significant
variable is found out among different input parameter for affecting thrust force by using
various mathematical and statistical techniques.
Keywords: drilling, feed rate, thrust force, spindle speed
INTRODUCTION
Now a day’s main drawback of industries
is machine tools, because machine tools
are not operating at their optimum
operating conditions and due to this there
is loss of man power, material and time.
Often, the drilling parameters such as
spindle speed, feed and depth of cut are
selected based on the worker’s
experiences. However, the performance of
machine and drill bit are not sure to be
acceptable. It has been recognized that
parameters during metal drilling such as
feed and drilling speed should be chosen
well to optimize the cost of drilling
operations. At present manufacturing
enterprises have to deal with increasing
demands for improved product quality,
tool life, less wear and less drilling force.
In today, applications of optimization
techniques in metal drilling process is
necessary for a manufacturing unit to work
effectively for severe competitiveness and
growing demand of quality product in the
market.
Drilling is a standard process for
producing holes and most common
material removal process in manufacturing
industries. Drilling is performed by a tool
(named “drill bit”) which is rotated by the
spindle of a machine. The work-piece and
the revolving drill (although in some cases
the work-piece can be revolving and
attached to the spindle) are positioned by
movements of the machine table and/or the
spindle assembly. When drilling start, a
linear movement occurs between the
rotating drill and work-piece. Most of the
time drilling operations are performed on
specialized drilling machines of different
configurations (upright, radial or
specialized), but drilling can also be
performed on lathes, boring mills and
milling machines. With all the view points
above, this paper present review on effect
of drilling parameters like feed, spindle

Vol. 2: Issue 1
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Failure Mode and Effect Analysis for CNC Machines Used In GG
Valves Industry
R.K. Salvi*
, C. Agarwal, B.P. Nandawana, M.A. Saloda
Department of Mechanical Engineering, College of Technology and Engineering, Maharana Pratap University
of Agriculture and Technology, Udaipur, Rajasthan, India
Abstract
The Failure Mode and Effect Analysis (FMEA) is widely used technique due to enhance
reliability and safety of complex system to identify and eliminate known or potential failure
modes. In the present work, the FMEA were performed with two approaches. (1)
Conventional FMEA approach and (2) Grey Relational Analysis approach. The rankings of
the failure modes are both determined by conventional FMEA and the Grey Relational
Analysis. The CNC machine failure is provided, the failure data have been collected and
analysed, and the results show that the evaluation of failure modes by both conventional
FMEA and Grey Relational Analysis. These theories are proposed in this paper helps to
enhance the reliability of the prediction, and the predicted ranking of CNC machines failure
can be used for better decision-making concerning inspection and maintenance.
Keywords: grey relational analysis, CNC machine failures, FMEA, RPN
INTRODUCTION
A CNC machine is a complex mechanical
system with high level automation and
complicated structure which employs
mechanics, electronics and hydraulics
mechanism. Now-a-days almost all the
industries are depended on CNC machines
for their manufacturing processes. A single
CNC machine is fails, when results in
halting in the production process and
requires time for repairing of the machine.
The breakdown in CNC machine in any
manufacturing plant may hamper normal
production rate, which results in loss of the
resources and manufacturing cost.
Therefore, it is unavoidable to ensure the
reliability of the machine operation during
the process. A lot of work has been carried
out to reduce the failure rate in the
machine but it requires timely maintenance
of the machine. The breakdowns in the
CNC machines are not beneficial for
manufacturing industries.
The present work is based on the CNC
machine failures of CNC machines in GG
(Gerhard Gabriel) Valves industry and its
analysis to reduce the failure rate. To
reduce the failure rate of CNC machines
different approaches have been carried out
by many researchers. The efforts to
optimize the failure of CNC machines
increase the efficiency of production. This
work would help to concern the industries
which rely majorly on CNC machines for
their manufacturing process.
The Failure Mode and Effect Analysis
(FMEA) approach helps in identification
of occasions of malfunction of
equipments. FMEA shows the causes and
effects of potential failure modes. It also
helps to identify the occurrence of failures
in CNC machines. This technique was

Vol. 2: Issue 1
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A Comparitive Study on Ceramic Powder Over Static and
Dynamic Compaction
M.V. Shanmugam 1
*, R. Karthikeyan 2
, P. Divyakumar3
, R. Nirmal Raja1
1
Department of Mechanical Engineering, K S R Institute for Engineering and Technology, Tiruchengode, India
2
Department of Mechanical Engineering, Dr. N.G.P. Institute of Technology, Coimbatore, India
3
Department of Mechanical Engineering, K S Rangasamy College of Technology, Tiruchengode, India
Abstract
The unique microstructure of dense ceramic powders are studied with the help of both static
and dynamic process. Initial density, particle size distribution, particle morphology, and
loading path are the various effects that are investigated in the static experiments. At very
low velocity steady structured compaction waves are traveling in dynamic experiment. When
compared with static response the ceramic powder are found to be significantly stiffer at
dynamic response. As deformation is confined to the relatively narrow compaction wave
front, density and mechanical properties such as Vickers micro hardness and bending
strength of the powder samples were investigated. The increase in impact force tends to
decrease springback of the compaction.
INTRODUCTION
At present there are several developments
are undergoing in industries by changing
the materials in order to improve in both
mechanical and physical properties. In
such cases, ceramics are been replaced for
various different materials and even
several matrix composites are used.
Combination of compaction and sintering
are taking place for ceramic parts.
Basically cracks are originated during the
compaction process in powder metallurgy
(P/M). But the cracks will not be visible
until the sintering process is done. Since
only after the sintering process there will
takes place some changes in boundary
conditions and micro structure. The root
cause is most likely the poor inter-particle
bonding obtained prior to the sintering.
The compaction of ceramic powders using
both static and dynamic processes has been
extensively studied from the standpoint of
the manufacture of nearly fully dense
ceramics with unique microstructures from
precursor ceramic powders. In these
investigations, the change in properties can
be determined by the pressure applied
during the compaction and also depends on
the temperature during the sintering
process. Besides manufacturing issues, the
behaviour of ceramic powders under
dynamic loading is important for
understanding the behaviour of geological
materials for seismic coupling, penetration,
and planetary science applications, as well
as the performance of ceramic armour.
Ceramic Powder
Basically in powder metallurgy, the
powders have to be fine grained. Similarly
the ceramic powder characteristic and
process which includes compaction and
sintering are to be decided before the start
of operation. If not there may produce a
strong impact over mechanical behaviour
of the parts that may produce some defects
(i.e.) pores, micro cracks, density gradient
and agglomerates) In particular, the

Vol. 2: Issue 1
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Durability Aspects of Copper Slag Admixed Concrete
G. Akhil*, J. Karthikeyan
Department of Civil Engineering, NIT Tiruchirappalli, Tiruchirappalli, Tamil Nadu, India
Abstract
This research work reports the results of a study undertaken in enhancing properties of
concrete with partial replacement of fine aggregate with copper slag. In this context an
experimental investigation to study the durability effects of replacement fine aggregate (by
weight) with zero, optimum (40%) and full (100%) percentages of copper slag were taken up.
Durability properties like permeability, elevated temperature effect, sorptivity, water
absorption were conducted along with these test Young’s Modulus and size effect ratio is also
conducted. A control mixture of proportions 1:2.10:3.18 with w/c of 0.45 was designed for
the M30 concrete. Fine aggregate (Sand) was replaced with 40% and 100% of copper slag as
optimum and full replacement. Test results showed that the replacement of fine aggregate
with copper slag reduced permeability, sorptivity and water absorption up to 100%. In
addition to this Young’s Modulus and elevated temperature test gives good result at 40%
replacement. These findings suggest that copper slag in the range 40% could potentially
replace sand in concrete without compromising the strength and durability aspects.
Keywords: copper slag, permeability, sorptivity, water absorption, elevated temperature
effect, Young’s modulus
INTRODUCTION
Sustainable development is mandatory to
protect the environment. Aggregate,
besides cement and water, forms one of
the main constituent materials of concrete
since it occupies nearly 55%–80% of
concrete volume, Aggregates which are
used in concrete are obtained either from
natural sources or by crushing large size
rocks. The rapid increase in the natural
aggregates consumption every year due to
the increase in the construction industry
worldwide means that the aggregate
reserves are being depleted, the concrete
industry globally will consume 8–12
billion tons annually of natural aggregates.
This large consumption of natural
aggregates will cause destruction of the
environment. Therefore there is an urgent
need to find and supply alternative
substitutes for natural aggregates by
exploring the possibility of utilization of
industrial by-products and waste materials
like copper slag in making concrete. This
will lead to sustainable concrete design
and greener environment. [1–3]
MATERIALS USED
1) Cement
Ordinary Portland Cement (OPC) of grade
53 conforming to IS 12269:1987 was used.
The specific gravity of the cement is found
to be 3.11
2) Fine Aggregate
Good quality river sand was used as fine
aggregate conforming to grading zone I of
IS 383:1970 was used. Its specific gravity
is 2.68

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