This seminar report discusses dry machining as an alternative to conventional wet machining. Wet machining utilizes cutting fluids that generate waste and pollution. Dry machining aims to eliminate cutting fluids. However, dry machining is challenging due to high temperatures that reduce tool life and damage workpiece surfaces. Strategies to enable successful dry machining include using advanced tool materials and coatings, minimum quantity lubrication, cryogenic cooling, and thermoelectric cooling. Dry machining has applications in machining various materials and processes, and offers advantages like waste elimination and improved productivity.
Explosive Forming is a manufacturing technique that uses explosions to force metal into dies and molds.
The explosives are typically either detonated underwater or in direct contact with the materials.
The technique is useful for short production runs of conventionally difficult-to-manufacture parts.
In Explosive Forming a punch or diaphragm in conventional forming is replaced by an explosive charge.
Chemical energy from the explosives is used to generate shockwaves through a medium (mostly water), which are directed to deform the workpiece at very high velocities.
Explosive Forming is a manufacturing technique that uses explosions to force metal into dies and molds.
The explosives are typically either detonated underwater or in direct contact with the materials.
The technique is useful for short production runs of conventionally difficult-to-manufacture parts.
In Explosive Forming a punch or diaphragm in conventional forming is replaced by an explosive charge.
Chemical energy from the explosives is used to generate shockwaves through a medium (mostly water), which are directed to deform the workpiece at very high velocities.
welding,Plasma arc welding,Plasma,,Pilot Arc ,Keyhole,Weld bead geometry ,Transferred plasma arc welding process,India,Small Part Welding
Sealed Components
Tool Die & Mold Repair
Tube Mill Welding
Long Strip Metal Welding
Non-transferred plasma arc welding process,Two Modes of operation in PAW,. Melt – In mode
Keyhole mode
conduction mode
,Effect of Various Factors on weld Quality Nozzle shape and size , Features of Plasma Arc Welding,Advantages of Plasma Arc Welding,Disadvantages of Plasma Arc Welding,Application of Plasma Arc Welding
Instability of the keyhole
Tungsten electrode set-back
Composition and flow rate of the plasma gas
Tezpur University
Unit 2 Machinability, Cutting Fluids, Tool Life & Wear, Tool MaterialsMechbytes
Concept of machinability, machinability index, factors affecting machinability
Different mechanism of tool wear types of tool wear (crater, flank etc.), Measurement and control of tool wear
Concept of tool life, Taylor's tool life equation (including modified version)
Different tool materials and their applications including effect of tool coating
Introduction to economics of machining
Cutting fluids: types, properties, selection and application methods
Electron Beam Welding is a fusion welding process in which a beam of high-velocity electrons is applied to the material to be joined. The work-piece melt as the kinetic energy of the electrons is transformed into heat upon impact. The EBW process is well-positioned to provide industries with highest quality welds and machine designs that have proven to be adaptable to specific welding tasks and production environments.
Bearings support moving parts, such as shafts and spindles, of a machine or mechanism.
Bearings may be classed as
(i) Rolling contact (Ball and roller) bearings.
(ii) Plain bearings.
Review of the cryogenic machining in turning and milling processeSAT Journals
Abstract Cryogenic Coolents are used in conventional machining in material removing process can increase tool life, better surface finish, dimensional accuracy, and reduce the cutting temp. Main objectives of this paper is to understand the cryogenic machining operations. Various research scholar has done the experimental investigation on the cryogenic coolants in different materials in turning and milling Process,. At the end of the review obsrved that cryogenic coolant is most favourable methods for material cutting operations in various aspects for future research is proposed. Key Words: Cryogenic coolents and Machining, Literature Review, cryogenic LN2Setup, cryogenic CO2 Setup,
welding,Plasma arc welding,Plasma,,Pilot Arc ,Keyhole,Weld bead geometry ,Transferred plasma arc welding process,India,Small Part Welding
Sealed Components
Tool Die & Mold Repair
Tube Mill Welding
Long Strip Metal Welding
Non-transferred plasma arc welding process,Two Modes of operation in PAW,. Melt – In mode
Keyhole mode
conduction mode
,Effect of Various Factors on weld Quality Nozzle shape and size , Features of Plasma Arc Welding,Advantages of Plasma Arc Welding,Disadvantages of Plasma Arc Welding,Application of Plasma Arc Welding
Instability of the keyhole
Tungsten electrode set-back
Composition and flow rate of the plasma gas
Tezpur University
Unit 2 Machinability, Cutting Fluids, Tool Life & Wear, Tool MaterialsMechbytes
Concept of machinability, machinability index, factors affecting machinability
Different mechanism of tool wear types of tool wear (crater, flank etc.), Measurement and control of tool wear
Concept of tool life, Taylor's tool life equation (including modified version)
Different tool materials and their applications including effect of tool coating
Introduction to economics of machining
Cutting fluids: types, properties, selection and application methods
Electron Beam Welding is a fusion welding process in which a beam of high-velocity electrons is applied to the material to be joined. The work-piece melt as the kinetic energy of the electrons is transformed into heat upon impact. The EBW process is well-positioned to provide industries with highest quality welds and machine designs that have proven to be adaptable to specific welding tasks and production environments.
Bearings support moving parts, such as shafts and spindles, of a machine or mechanism.
Bearings may be classed as
(i) Rolling contact (Ball and roller) bearings.
(ii) Plain bearings.
Review of the cryogenic machining in turning and milling processeSAT Journals
Abstract Cryogenic Coolents are used in conventional machining in material removing process can increase tool life, better surface finish, dimensional accuracy, and reduce the cutting temp. Main objectives of this paper is to understand the cryogenic machining operations. Various research scholar has done the experimental investigation on the cryogenic coolants in different materials in turning and milling Process,. At the end of the review obsrved that cryogenic coolant is most favourable methods for material cutting operations in various aspects for future research is proposed. Key Words: Cryogenic coolents and Machining, Literature Review, cryogenic LN2Setup, cryogenic CO2 Setup,
COMPARISON OF MAIN EFFECT OF VEGETABLE OIL AND AL2O3 NANOFLUIDS USED WITH MQL...IAEME Publication
The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Application of cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions. But the conventional cutting fluids are not that effective in such high production machining, particularly in continuous cutting of materials likes steels. So Nanofluids have novel properties that make them potentially useful in heat transfer medium in cutting zone and Minimum quantity lubrication (MQL) presents itself as a viable alternative for turning with respect to tool wear, heat dissipation, and machined surface quality.
Determining the influence of cutting fluids on tool wear and surface roughnes...Lepuufu
Knowledge of the performance of cutting fluids in machining different work materials is
of critical importance in order to improve the efficiency of any machining process. The
efficiency can be evaluated based on certain process parameters such as flank wear, surface
roughness on the work piece, cutting forces developed, temperature developed at the tool
chip interface, etc. The objective of this work is to determine the influence of cutting fluids
on tool wear and surface roughness during turning of AISI 304 with carbide tool. Further
an attempt has been made to identify the influence of coconut oil in reducing the tool
wear and surface roughness during turning process. The performance of coconut oil is also
being compared with another two cutting fluids namely an emulsion and a neat cutting oil
(immiscible with water). The results indicated that in general, coconut oil performed better
than the other two cutting fluids in reducing the tool wear and improving the surface finish.
Coconut oil has been used as one of the cutting fluids in this work because of its thermal
and oxidative stability which is being comparable to other vegetable-based cutting fluids
used in the metal cutting industry.
IJERA (International journal of Engineering Research and Applications) is International online, ... peer reviewed journal. For more detail or submit your article, please visit www.ijera.com
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
International Journal of Engineering Research and Development (IJERD)IJERD Editor
journal publishing, how to publish research paper, Call For research paper, international journal, publishing a paper, IJERD, journal of science and technology, how to get a research paper published, publishing a paper, publishing of journal, publishing of research paper, reserach and review articles, IJERD Journal, How to publish your research paper, publish research paper, open access engineering journal, Engineering journal, Mathemetics journal, Physics journal, Chemistry journal, Computer Engineering, Computer Science journal, how to submit your paper, peer reviw journal, indexed journal, reserach and review articles, engineering journal, www.ijerd.com, research journals,
yahoo journals, bing journals, International Journal of Engineering Research and Development, google journals, hard copy of journal
Analysis Of The Structure Of A Material Used In The Manufacture Of Thermal Ch...IJERA Editor
The dynamic stability of machine has its own importance in the quality of the machined product. With the development of new technologies for cutting tools, as the geometries and materials, cutting speeds used today reach values inconceivable for two decades. In the automotive industry steel and cast iron are gradually being replaced by lower density material and even lower costs. In complex shapes tools, heterogeneous material removal in roughing, sudden changes of sections, etc. Stress relieving treatment should be carried out to minimize dimensional variations of form during quenching and tempering. Materials for manufacture of thermal fixing most appropriate for that operating system still needs to be further investigated. Therefore, this study investigated the elastic behavior of the material used in the manufacture of tooling systems for cutting tools. Has been evaluated In fastening system, the temperature variation exerted on the mandrel body region and the thermal expansion where H13 steel can withstand the assembly process by thermal interference. This method can determine the amount of number of cycles until the onset of fatigue that material.
Explore the innovative world of trenchless pipe repair with our comprehensive guide, "The Benefits and Techniques of Trenchless Pipe Repair." This document delves into the modern methods of repairing underground pipes without the need for extensive excavation, highlighting the numerous advantages and the latest techniques used in the industry.
Learn about the cost savings, reduced environmental impact, and minimal disruption associated with trenchless technology. Discover detailed explanations of popular techniques such as pipe bursting, cured-in-place pipe (CIPP) lining, and directional drilling. Understand how these methods can be applied to various types of infrastructure, from residential plumbing to large-scale municipal systems.
Ideal for homeowners, contractors, engineers, and anyone interested in modern plumbing solutions, this guide provides valuable insights into why trenchless pipe repair is becoming the preferred choice for pipe rehabilitation. Stay informed about the latest advancements and best practices in the field.
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxR&R Consult
CFD analysis is incredibly effective at solving mysteries and improving the performance of complex systems!
Here's a great example: At a large natural gas-fired power plant, where they use waste heat to generate steam and energy, they were puzzled that their boiler wasn't producing as much steam as expected.
R&R and Tetra Engineering Group Inc. were asked to solve the issue with reduced steam production.
An inspection had shown that a significant amount of hot flue gas was bypassing the boiler tubes, where the heat was supposed to be transferred.
R&R Consult conducted a CFD analysis, which revealed that 6.3% of the flue gas was bypassing the boiler tubes without transferring heat. The analysis also showed that the flue gas was instead being directed along the sides of the boiler and between the modules that were supposed to capture the heat. This was the cause of the reduced performance.
Based on our results, Tetra Engineering installed covering plates to reduce the bypass flow. This improved the boiler's performance and increased electricity production.
It is always satisfying when we can help solve complex challenges like this. Do your systems also need a check-up or optimization? Give us a call!
Work done in cooperation with James Malloy and David Moelling from Tetra Engineering.
More examples of our work https://www.r-r-consult.dk/en/cases-en/
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Immunizing Image Classifiers Against Localized Adversary Attacksgerogepatton
This paper addresses the vulnerability of deep learning models, particularly convolutional neural networks
(CNN)s, to adversarial attacks and presents a proactive training technique designed to counter them. We
introduce a novel volumization algorithm, which transforms 2D images into 3D volumetric representations.
When combined with 3D convolution and deep curriculum learning optimization (CLO), itsignificantly improves
the immunity of models against localized universal attacks by up to 40%. We evaluate our proposed approach
using contemporary CNN architectures and the modified Canadian Institute for Advanced Research (CIFAR-10
and CIFAR-100) and ImageNet Large Scale Visual Recognition Challenge (ILSVRC12) datasets, showcasing
accuracy improvements over previous techniques. The results indicate that the combination of the volumetric
input and curriculum learning holds significant promise for mitigating adversarial attacks without necessitating
adversary training.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
2. CONTENT
Introduction
Conventional Wet Machining
Purpose of Cutting Fluid
Cost of Wet Machining
Major Problems with Wet Machining
Dry Machining
Challenges
Strategies and Solutions for Successful Dry Machining
Application of Dry Machining
Advantages
References
2
3. Introduction
Manufacturing activity is a major consumer of energy and natural resources.
In machining process, a large amount of heat is produced whose removal requires the use of
suitable cooling agents or cutting fluids.
These cutting fluids are a major source of waste generation and environmental damage.
To eliminate hazardous cutting fluids during machining operations, researchers have tried
machining components without applying cutting fluids, which is known as dry
machining.
3
4. 4
Conventional Wet Machining
Conventional wet machining process involves use of cutting fluid.
Purpose of using Cutting Fluid
Metal
Working
fluids
Removal of heat
generated during
Cutting
Removal
of chips
Reduction of
tool wear
Better surface
finish
6. 6
Major Problems with Conventional Process
Wetting and dirtiness
Corrosion and contamination of the lubricating system
Need of storage, additional floor space, pumping system,
recycling and disposal
Environmental pollutions and health hazards.
8. 8
Challenges
Dry machining often causes excessive temperature rise leading to poor tool life and
machined surface damage.
The main issues which restricts the practical implementation of dry machining are
1. Tool Life
2. Work-piece Geometrical Accuracies
3. Work-piece Surface Integrity
4. Machinability of Materials
9. 9
1. Tool Life
Average temperature near cutting tool edge is much higher
It cause softening of tool cutting edge since the tool materials lose their hardness
at elevated temperature.
2. Work-piece Geometrical Accuracies
Heat retention in work piece material
Retained heat cause thermal deformations in machined parts
3. Work-piece Surface Integrity
Excessive heat built up during dry machining raises the temperature of the
surface layer to level where phase transformation and microstructure alteration.
It also cause the formation of hard layer on surface ( white layer when
observed under microscope)
10. 10
4. Machinability of Materials
Most commonly used metals in engineering applications are LCS, MCS,
Austenitic stainless steel, CI, nickel, titanium, copper and aluminium alloys etc.
Some of these materials exhibits difficulties in machining without aid of cutting
fluids due to excessive generation of heat and high interfacial temperature.
Strategies and Solution for Successful Dry Machining
1. Tool Materials
2. Tool Coatings
3. Hybrid Machining
4. MQL Machining
5. Cryogenic Machining
6. Under-Cooling Machining
7. Internal cooling by a vapourisation system
8. Thermoelectric Cooling System
11. 11
1. Tool Materials
Dry cutting typically results in elevated tool temperature as compared to wet
machining.
Primary requirement of a suitable tool for dry machining is the ability to retain
hardness at high temperature or hot hardness.
the tool should be able to resist high stresses
Most widely used tool materials in dry machining are :
a. Carbide of tungsten, titanium and tantalum
b. Ceramics
c. Cubic boron nitride
d. Diamond
12. 12
A. Carbide of tungsten, titanium and tantalum
grain size in range 10µm- 1µm
high hot hardness and wear resistance
B. Ceramics
withstand at higher temperature and retain the sharpness of cutting edge for
longer duration even at elevated temperature
high hardness and wear resistance
suitable for high speed dry machining
C. Cubic Boron Nitride
harder than cemented carbide and ceramics at high temperature
chemically inert at high temperature
high wear resistance
13. 13
D. Diamond
hardest material known
high thermal conductivity
very high wear resistance to abrasive wear
fig. adapted from
P.S. Sreejith, B.K.A. Ngoi / Journal
of Materials Processing Technology
101 (2000) 288
14. 14
2. Tool Coatings
coating helps to reduce friction at tool-work interface and hence compensate for
lubricating effects of cutting oils
coatings are made from hard materials such as TiN, TiCN, CrN, CBN and
Diamond
a. Multilayered nano-coatings : avoid catastrophic fracture
b. Self lubricating coatings
c. cubic boron nitride and diamond coatings
3. Hybrid Machining
a. Vibration assisted machining
b. laser and plasma assisted machining
15. 15
4. MQL Machining
very small quantity of lubricant is applied to the cutting area in the form of
drops or as a mixture with compressed air or other gasses, forming a fine spray.
Normal consumption of cutting oil is restricted in the range 10-100 ml per hour
fig. adapted from Wakabayashi et al (2006), Machining Science and Technology, Vol 53, No. 2, PP- 511-37
16. 16
5. Cryogenic Machining
machining with liquid nitrogen at cryogenic temperatures at about -196ºC
Liquid nitrogen evaporates into the air as it comes in contact with the tool and
work-piece leaving no trace of any harmful agents
it provides an excellent cooling effect in machining due to its very low temperature
6. Under-cooling System
the coolant flows through channels located under the insert, then out to the
environment, without any direct contact with the cutting zone.
7. Internal cooling by a vapourisation system
in which a vapourisable liquid is introduced inside the shank of the tool and
vapourised on the underside surface of the insert
17. 17
8. Thermoelectric cooling systems
using a module of couples of thermoelectric material elements. When an electric
current is passed through the thermoelectric elements, a cold junction
and a hot junction is produced at the opposite ends of each of these elements.
fig. adapted from G.S.Goindi, P.Sarkar
Journal of Cleaner production 165
(2017) 1566
18. 18
Application of Dry Machining Technology
1. Machining of different work piece materials in dry and semi dry conditions
Magnesium and its alloys
Copper alloys
Cast iron
Aluminium alloys
Alloy steels
Nickel and Titanium alloys
19. 19
2. Adaptation of machining processes for dry and MQL machining
Milling
Turning
Drilling
Grinding
Advantages
Complete elimination of harmful cutting fluid
It eliminates cost involved in purchase, storage, handling, utilizing and safe
disposal of the fluid
High cutting speeds can be achieved with improved surface finish
Reduction in overall production time and improved working conditions
20. 20
References
P.S. Sreejith, B.K.A. Ngoi, Dry machining: Machining of the future, Journal of
Materials Processing Technology 101 (2000) 287-291
Gyanendra Singh Goindi, Prabir Sarkar, Dry machining: A step towards sustainable
machining - Challenges and future directions, Journal of Cleaner Production 165
(2017) 1557-1571
Bhanot, N. Rao, P.V. Deshmukh, S.G. 2015. Sustainable manufacturing: an
interaction analysis for machining parameters using graph theory. Oper. Manag.
Digit. Econ. 189, 57-63.
Banerjee, N., Sharma, A., 2014. Identification of a friction model for minimum
quantity lubrication machining. J. Clean. Prod. 83, 437-443.
Daniel, C. M., Olson, W. W., & Sutherland, J.W. (1997). Research advances in dry
and semi-dry machining (Technical Paper No.970415) Society of Automotive
Engineers.
Wakabayashi et al (2006), Machining Science and Technology, Vol 53, No. 2, PP-
511-37