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International Journal of Machine
Design and Manufacturing
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! Design/analysis of all types of gears, gear boxes, gear measurement
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! Advanced vibrations
! Tribology and bearing design
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! Computer-aided drafting and electrical drafting
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EDITORIAL BOARD MEMBERS
Dr. Basel Alsayyed
Department of Mechanical Engineering,
UAE University, United Arab Emirates
Dr. R S Jadoun
G. B. Pant University of Agriculture &
Technology, Pantnagar, India
Dr. N. Bose
Department of Mechanical Engineering, Mepco
Schlenk Engineering College, Virudhunagar,
India
Dr. Vasudev Malhotra
Y.M.C.A University of Science and Technology
(State Govt. University), Faridabad (Haryana),
India
Dr. Muthuramalingam Thangaraj
SRM University, Chennai, India
Dr P. M. M. Subrahmanya Sarma
VIZAG Institute of Technology, Dakamarri,
Bheemunipatnam Mandal, Visakhapatnam,
India
Dr. V Sugumaran
Associate Professor, School of Mechanical
Engineering and Building Sciences,
VIT University, India
Dr. Sam Paul
Associate Professor, Department of Mechanical
Engineering, Karunya University, Coimbatore,
India
Bo-Wun Huang
China
Dr. Siva Prasad Kondapalli
Associate Professor, Anil Neerukonda Institute
of Technology & Sciences,Visakhapatnam,
India
Prof. D.S. Robinson Smart
Department of Mechanical Engineering,
Karunya University, Coimbatore,
India

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 Machine Design and Manufacturing. This journal is part
of the Engineering Sciences, and is devoted to the scope of present Machine Design issues,
from theoreticalaspectstoapplication-dependentstudiesand thevalidationofemergingtechnologies.
This new journal was planned and established to represent the growing needs of Machine Design and
Manufacturing 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 Machine Design and Manufacturing in JournalsPub 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 Machine Design in general.
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International Journal of Machine Design and Manufacturing focuses on original high-quality research in
the realm of Turbomachines, Intelligent machines, Shaft design and bearing selection, Power transmitting
shafts,Advancedvibrations,Tribologyand bearingdesign,etc.
The Journal is intended as a forum for practitioners and researchers to share the techniques of Machine
Design and Manufacturingandsolutionsinthearea.
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Engineering 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, reporting
newdevelopmentsinthefieldofMachineDesignandManufacturing.
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editorialstaffofJournalsPub,who supported us ateverystageoftheproject.
It is our hope that this fine collection of articles will be a valuable resource for engineering readers and will
stimulatefurtherresearchintothevibrantareaofMachineDesignandManufacturing.
PuneetMehrotra
ManagingDirector

1. An Experimental Investigation of Optimum Flank Wear of Carbide Inserts for Dry Turning of
EN19 Tool Steel
Saurav Nandi, Nirmal Kumar Mandal 1
2. Total Productive Maintenance (Tpm) Implementation Process in Machining Line
V. Nithiyanandhan, K.M. Senthil Kumar 10
3. Optimization of Weld Bead Geometry in Gas Metal Arc Welding of High Strength Low Alloy Steel Using
Response Surface Methodology
S. Veera Jeyendra Prakash, V. Manivel Muralidaran 19
4. Predictive Modelling and Optimization of Cutting Tool Life and Machine
Vibration for Making a Poppet Valve
Someswar Dey, Nirmal K. Mandal 26
5. A Brief Note on Rover Design
Priyanka Garg 38
Contents

IJMDM (2015) 1–9 © JournalsPub 2015. All Rights Reserved Page 1
International Journal of Machine Design and Manufacturing
Vol. 1: Issue 2
www.journalspub.com
An Experimental Investigation of Optimum Flank Wear of
Carbide Inserts for Dry Turning of EN19 Tool Steel
Saurav Nandi*, Nirmal Kumar Mandal
Department of Mechanical Engineering, National Institute of Technical Teachers’ Training and Research,
Kolkata, India
Abstract
Flank wear of cutting tools is often selected as the tool life criterion because it determines the
diametric accuracy of machining, its stability and reliability. In this work the effect of cutting
parameters like RPM, feed rate and depth of cut is studied on dry turning of EN19 tool steel
and input parameters are optimized for minimum tool wear. RSM technique is employed to
achieve the minimum tool wear. Combined effects of the cutting parameters on tool wear (VB)
are investigated.
Keywords: dry turning, feed rate and depth of cut, RPM, RSM, tool wear
INTRODUCTION
The turning of EN19 tool steel material,
which have high tensile strength yields
desirable results only when optimum
process parameters are selected. This tool
steel has a very high usage in automobile
industry. Turning operation is used and
flank wear as well as optimum condition
are studied.
Tool wear in machining is defined as the
amount of volume loss of tool material on
the contact surface due to the interactions
between the tool and work piece.
Specifically, tool wear is described by
wear rate (volume loss per unit area per
unit time) and is strongly determined by
temperature, stresses, and relative sliding
velocity generated at the contact interface.
Tool wear have significant influences on
the accuracy of the finished product. [1–3]
Response surface method (RSM) is very
useful for modelling and analysis of a
process. It adopts both mathematical and
statistical techniques in which a response
of interest is influenced by several
variables.
Tool Wear
High contact stress between the tool rake-
face and the chip causes severe friction at
the rake face. This results into a variety of
wear patterns and scars which can be
observed at the rake face and the flank
face.
Flank Wear (Clearance Surface)
Flank wear creates inaccuracy of the
product size and results in the formation of
a wear land. It is observed that wear and
formation of wear is not always uniform
throughout the wear land.
In fact, flank wear can be monitored in
production by examining the tool or by
tracking the change in size of the tool or
machined part. Flank wear is generally
measured by using the land size VB and
VBmax (Figures 1, 2). [4, 5]

IJMDM (2015) 10-18 © JournalsPub 2015. All Rights Reserved Page 10
Vol. 1: Issue 2
www.journalspub.com
Total Productive Maintenance (Tpm) Implementation Process in
Machining Line
V. Nithiyanandhan*, K.M. Senthil Kumar
Department of Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India
Abstract
The core of this paper is doing a study on CNC machining line of automobile components
production industry and coming up with suggestions to implement total productive
maintenance on the Machining line. Companies around the world spend a lot of money on
buying new equipments to increase production but a little is done to get hundred percent
output from the machine for which it is designed for. Small losses in time or small deviations
from designed capability are taken as normal machine behaviour. But now because of
increased competency levels and demand of quality products at lower costs, buying latest
equipment is not a solution unless it is fully utilized. Total Productive Maintenance (TPM) is
a plan which concentrates on total involvement of everyone from top management to all
employees to implement a comprehensive maintenance program for all equipment throughout
its life. This plan results in maximum effectiveness of equipment, tidier, neat and clean work
place and morally boosted employees. In this report over all equipment effectiveness OEE is
measured before implementing TPM and after implementing TPM. At the end of the report
over all equipment effectiveness OEE is compared with previous results.
Keywords: autonomous maintenance, preventive maintenance, overall equipment
effectiveness, total productive maintenance, 5S
INTRODUCTION
In order to be successful in today’s world-
class manufacturing environment
companies have to fulfil several
requirements. Maintaining a reliable
manufacturing process is a key success
factor to satisfy these requirements which
can be achieved through implementing a
proper maintenance strategy. Any
operation or process done on machine or
its parts to enhance the efficiency of
machine before or after the breakdown is
called maintenance. In the recently
released European Standards regarding
maintenance, maintenance is defined as
“the combination of all technical,
administrative and managerial actions
during the life cycle of an item intended to
retain it in, or restore it to, a state in which
it can perform the required function”. A
manufacturing business is said to be
prosperous over the years, when it runs
non-interrupted and always maintains a
stable and high productive production
flow. Plant can achieve productivity up to
a satisfactory level by proper maintenance
work. An efficient maintenance strategy
not only reduces the probability of
breakage of machine elements or
shutdown of machines which hinders the
production’s schedule, but also such a
strategy enhances the efficiency and life-
span of machines, process quality and
labour force productivity. Total Productive
Maintenance (TPM) has widely been
accepted as an effective strategy for

Vol. 1: Issue 2
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Optimization of Weld Bead Geometry in Gas Metal Arc Welding
of High Strength Low Alloy Steel Using Response Surface
Methodology
S. Veera Jeyendra Prakash1
*, V. Manivel Muralidaran2
1
Industrial Engineering, Kumaraguru College of Technology, Coimbatore, India
2
Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India
Abstract
The input parameters of welding play a very important role in determining the quality of a
weld joint. The weld joint quality can be defined in terms of weld-bead geometry, mechanical
properties, and distortion. Generally, all type of welding processes is used with the aim of
obtaining a welded joint with the desired weld-bead parameters, excellent mechanical
properties with minimum distortion. Response surface methodology is used to develop a
mathematical relationship between the welding process input parameters and the output
variables of the weld joint in order to determine the welding input parameters that lead to the
desired weld quality.
Keywords: gas metal arc welding, regression equation, response surface methodology
INTRODUCTION
The gas metal arc (GMA) welding process
is a welding process that yields
coalescence of metals by heating with a
welding arc between continuous filler
metal (consumable) electrode and the work
piece. Molten weld pool and electrode
wire are protected from contaminants in
the atmosphere by a shielding gas obtained
from various combinations. [1–8]
The
quality, efficiency and overall operating
acceptance of the welding operation are
strongly dependent on the shielding gas,
since it dominates the mode of metal
transfer.
The shielding gas not only affects the
properties of the weld but also determines
the shape and penetration pattern as well.
Various techniques such as gas, slag, gas
and slag, vacuum and self-protection can
be used to protect the weld pool during the
fusion welding. Obviously, different
protection techniques provide different
degrees of weld pool protection (Kacar et
al., 2005)
Since empirical optimization of welding
parameters is both time-consuming and
costly, the application of statistical
methods such as design of experiments
(DOE) is preferred. Response surface
methodology (RSM) which is one of the
main applications of DOE can be used to
estimate unknown mechanisms through
the use of an empirical model. [9–12]
Using
RSM, it is possible to evaluate effects of
many parameters on weld mechanical
properties and to optimize them to achieve
suitable results. [13]
The use of a statistic
approach (response surface methodology)
to correlate welding parameters to weld
joint properties is considered by
researchers. Correia et al. [13]
presented
comparison between genetic algorithms
and response surface methodology in

Vol. 2: Issue 1
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Predictive Modelling and Optimization of Cutting Tool Life and
Machine Vibration for Making a Poppet Valve
Someswar Dey*, Nirmal K. Mandal
Department of Mechanical Engineering, NITTTR, Kolkata (WB), India
Abstract
The present work has been done to investigate experimentally the relationship between
Machine Vibration and Tool Life in turning of EN 31 steel for making a Poppet Valve using
Response Surface Methodology (RSM) & Fuzzy Logic. Response Surface Methodology (RSM)
is a method of obtaining the best suited result from minimal number of experiments and
Fuzzy logic is used for optimization. Thus the work process becomes less tedious, i.e., with
minimal effort one can come to an almost precise outcome. In this case, RSM has been used
to predict the Machine Vibration and Tool Life under various machining conditions. Machine
Vibration and Tool Life are the main parameters that have been dealt with in this work. The
proposed work is mainly based on finding a relationship about how machine vibration can
affect the tool life of the cutting tool. The proposed method is easy to carry out in the
workshop area, easy to maintain and easy to understand because assessing the images of
cutting tool is easy. Also, this method is flexible to use for different machining process using
this Carbide Insert (CNMG 120408 EA TT5080). After the experiments has been done the
following results has been found: the levels of process cutting parameters in the study are
limited to the following data Speed (900, 1400, 1900 rpm), Feed rate (0.07, 0.12, 0.17
mm/rev.), Depth of Cut (0.08, 0.18, 0.28 mm).
Keywords: Machine Vibration, Tool Life, Response Surface Methodology (RSM), Fuzzy
Logic, EN 31, Carbide Insert.
INTRODUCTION
Increase of efficiency and decrease of
production costs are the two primary goals
of mechanical machining. Cutting tools
and the whole system of machine-tool-
work piece are constantly improving to
reach this aim. Surface finish and Quality
of machined part are depended on
parameters such as cutting forces,
temperature in contact surfaces, and wear
of cutting tool, friction between tool and
chip etc. These parameters give the
measure of performance of machining.
During the search for more effective
cutting methods it was found that cutting
quality can also be improved. It is seen
that if vibration cutting method is used, the
cutting force magnitude can be reduced
significantly. [21]
Hence, it is important not only to increase
efficiency, but also to meet ecological
requirements. During vibration-assisted
cutting temperature in work piece &
contact tool is decreasing together with
decreasing friction forces. This results in
lower consumption of cutting oil, which in
turn reduces costs for oil removal, storage
and utilization.
Vibration is a frequent problem in the
turning operation, which influenced the

Vol. 2: Issue 1
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A Brief Note on Rover Design
Priyanka Garg
University of Madras, Tamil Nadu, India
INTRODUCTION
Traditionally, the space exploration is
accustomed to the use of orbiting
spacecraft for the fact that, it is efficient in
taking humans with the much needed
amenities in bulk to other space environs.
However, their design prospects limit the
capability to do more exhaustive tasks on
erratic planetary surfaces along with
making insightful and distinctive
observations.
An urge to optimize accountability on
planetary research was realized and a
novel design of space exploration vehicle
known as surface rover spacecraft was
proposed which not only maneuver across
the wide surface area of a planet as well as
other celestial bodies but persuade many
important tasks that seemed to be as
forlorn as might expected to be.
A rover is a well-equipped vehicle having
wheels with some kind of lateral
propulsion i.e. powered wheels.
The wheels help the rover to move across
the unusual terrestrial surface except on
the surface of sun or gas planets, in spite
of the difficulty to operate in extremely
low gravity surface such as of moon and
other planetary bodies.
Rover spacecraft composes of a Solar-
powered electrical system in the form of
solar panels, an autonomous command
module and wheelers. Figure 1 shows
Mars Pathfinder spacecraft that includes
rover as a small mobile instrument to be
deployed on Mars.[1–3]
Fig. 1. Mars Pathfinder Spacecraft.
Source: http://pics-about-
space.com/pathfinder-mars-
probe?p=4#img12328159915946181149.
Although, rovers used for Mars
Exploration usually invoke same principle
as that of landed spacecraft, for landing
and taking off, they possess high mobility
and are capable to make detailed
observation to wider planetary surface
area, to take samples for laboratory
examination such as dust, rocks and other
substances as well as to even take pictures.
Figure 2 illustrates well-labelled Mars
Pathfinder Rover with all its structural and
operational components.
In the present paper, we are leaving the
technical aspect of the rover operation and
concentrating on its physical design.

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