ABSTRACT: The first step in machining most working jobs is to cut the stock to the desired length. This cutting operation should be done in the shortest time possible consistent with the desired quality. Similarly the polishing operation in a metal working job should give the desired surface finish in the quickest time possible. There are many methods by which the cutting operation and the polishing operation can be done. The various methods can be explained below.
AMP Unit.3 advanced manufacturing techniques for material processing(badebhau...Er. Bade Bhausaheb
This document provides information on several advanced material processing techniques:
1. Shape Tube Electrolytic Machining (STEM) which uses a shaped cathode tool to electrolytically machine small holes.
2. Electrolytic In-process Dressing (ELID) which uses electrolysis to dress grinding wheels during precision grinding.
3. Electrochemical Grinding (ECG) which utilizes a negatively charged abrasive grinding wheel, electrolyte, and positively charged workpiece to grind materials electrochemically.
Advanced techniques for material processing PDF by badebhau4@gmail,comEr. Bade Bhausaheb
This document provides an overview of several advanced material processing techniques:
1. Shape Tube Electrolytic Machining (STEM) uses an acid electrolyte and cathodic tool to dissolve and remove metal from a workpiece, allowing cylindrical holes to be machined.
2. Electrolytic in-process dressing (ELID) uses electrolysis to dress grinding wheels during precision grinding, improving wheel performance.
3. Electrochemical grinding (ECG) utilizes a negatively charged abrasive grinding wheel, electrolyte, and positively charged workpiece to grind materials electrochemically like ECM.
Thermal cutting processes use heat sources like flames, plasma arcs, or laser beams to cut materials. Some key thermal cutting processes described in the document are flame cutting, which uses a heating flame and oxygen stream to cut materials, and plasma cutting, which uses an electrically conductive plasma gas and arc to cut electrically conductive materials. Laser beam cutting is also discussed, which uses a concentrated laser beam to heat and cut materials, achieving very precise cuts up to 12 mm thick in steel. Thermal cutting processes can be automated and are widely used in manufacturing industries for cutting components and preparing welding edges.
Optimization on Spot Weld Parameters in Resistance Spot Welding Process on AI...Dr. Amarjeet Singh
The spot welding procedure is used in a variety of industrial applications. The most critical elements influencing welding quality, productivity, and cost are the spot welding parameters. This research examines the effect of welding factors such as welding current and welding time on the strength of various welding joint designs. Resistance spot welding (RSW) is used in the automotive industry for manufacturing. This research focused on the optimization of process parameters for resistance spot welding (RSW), as well as the tensile testing and spot weld diameter. The goals of this analysis are to comprehend the physics of the process and to demonstrate the effect of electrical current, weld time, and material type on the resistance spot welding process.
Mechanical Engineering Technical Interview Q & A Material science And Heat Tr...Er. Bade Bhausaheb
Material Science (MS) and Heat Treatment (HT) discusses various metal properties and heat treatment processes. It defines terms like specific gravity, tenacity, machinability, malleability, hardness, and toughness. It describes processes like annealing, normalizing, hardening, tempering, and case hardening. Key points covered include how carbon affects steel properties, uses of cast iron and different alloys, heat treatment purposes, and identifying metals based on sparks from grinding.
Why Phosphor Bronze Is Required For Brass Parts?asianfasteners
Phosphor bronze and brass are alloys used in many electrical, mechanical, and industrial applications due to their corrosion resistance and ductility. Phosphor bronze is used in parts for electronics, communications, and other industries that require electromechanical properties. It can be formed through casting and bending. Brass is also versatile and used in decorative items, valves, gears, and more. Brass manufacturers produce a variety of machine parts, accessories, and hardware through processes like melting, hot rolling, annealing, cold rolling, and finishing. Heating metals affects their electrical resistance, thermal expansion, structure, and magnetism.
Welding and brazing are materials joining processes. Welding involves heating materials to suitable temperatures to produce coalescence, while brazing is performed above 427°C without melting the base materials. There are various welding processes like arc, gas, resistance welding and newer ones like laser and electron-beam welding. Brazing methods include torch brazing, dip brazing and furnace brazing. Recent trends in welding technology development include unmanned robot welding systems, narrow gap welding of heavy plates, and field girth welding of gas pipelines and rails.
This document provides an overview of various joining processes including welding and brazing. It discusses gas welding processes like oxy-acetylene welding in detail. It also covers different arc welding processes such as shielded metal arc welding, gas tungsten arc welding, flux-cored arc welding, and submerged arc welding. Other joining techniques summarized include resistance welding, plasma arc welding, electroslag welding, and thermit welding. Key information about equipment, process parameters, advantages and applications are provided for each welding and brazing process.
AMP Unit.3 advanced manufacturing techniques for material processing(badebhau...Er. Bade Bhausaheb
This document provides information on several advanced material processing techniques:
1. Shape Tube Electrolytic Machining (STEM) which uses a shaped cathode tool to electrolytically machine small holes.
2. Electrolytic In-process Dressing (ELID) which uses electrolysis to dress grinding wheels during precision grinding.
3. Electrochemical Grinding (ECG) which utilizes a negatively charged abrasive grinding wheel, electrolyte, and positively charged workpiece to grind materials electrochemically.
Advanced techniques for material processing PDF by badebhau4@gmail,comEr. Bade Bhausaheb
This document provides an overview of several advanced material processing techniques:
1. Shape Tube Electrolytic Machining (STEM) uses an acid electrolyte and cathodic tool to dissolve and remove metal from a workpiece, allowing cylindrical holes to be machined.
2. Electrolytic in-process dressing (ELID) uses electrolysis to dress grinding wheels during precision grinding, improving wheel performance.
3. Electrochemical grinding (ECG) utilizes a negatively charged abrasive grinding wheel, electrolyte, and positively charged workpiece to grind materials electrochemically like ECM.
Thermal cutting processes use heat sources like flames, plasma arcs, or laser beams to cut materials. Some key thermal cutting processes described in the document are flame cutting, which uses a heating flame and oxygen stream to cut materials, and plasma cutting, which uses an electrically conductive plasma gas and arc to cut electrically conductive materials. Laser beam cutting is also discussed, which uses a concentrated laser beam to heat and cut materials, achieving very precise cuts up to 12 mm thick in steel. Thermal cutting processes can be automated and are widely used in manufacturing industries for cutting components and preparing welding edges.
Optimization on Spot Weld Parameters in Resistance Spot Welding Process on AI...Dr. Amarjeet Singh
The spot welding procedure is used in a variety of industrial applications. The most critical elements influencing welding quality, productivity, and cost are the spot welding parameters. This research examines the effect of welding factors such as welding current and welding time on the strength of various welding joint designs. Resistance spot welding (RSW) is used in the automotive industry for manufacturing. This research focused on the optimization of process parameters for resistance spot welding (RSW), as well as the tensile testing and spot weld diameter. The goals of this analysis are to comprehend the physics of the process and to demonstrate the effect of electrical current, weld time, and material type on the resistance spot welding process.
Mechanical Engineering Technical Interview Q & A Material science And Heat Tr...Er. Bade Bhausaheb
Material Science (MS) and Heat Treatment (HT) discusses various metal properties and heat treatment processes. It defines terms like specific gravity, tenacity, machinability, malleability, hardness, and toughness. It describes processes like annealing, normalizing, hardening, tempering, and case hardening. Key points covered include how carbon affects steel properties, uses of cast iron and different alloys, heat treatment purposes, and identifying metals based on sparks from grinding.
Why Phosphor Bronze Is Required For Brass Parts?asianfasteners
Phosphor bronze and brass are alloys used in many electrical, mechanical, and industrial applications due to their corrosion resistance and ductility. Phosphor bronze is used in parts for electronics, communications, and other industries that require electromechanical properties. It can be formed through casting and bending. Brass is also versatile and used in decorative items, valves, gears, and more. Brass manufacturers produce a variety of machine parts, accessories, and hardware through processes like melting, hot rolling, annealing, cold rolling, and finishing. Heating metals affects their electrical resistance, thermal expansion, structure, and magnetism.
Welding and brazing are materials joining processes. Welding involves heating materials to suitable temperatures to produce coalescence, while brazing is performed above 427°C without melting the base materials. There are various welding processes like arc, gas, resistance welding and newer ones like laser and electron-beam welding. Brazing methods include torch brazing, dip brazing and furnace brazing. Recent trends in welding technology development include unmanned robot welding systems, narrow gap welding of heavy plates, and field girth welding of gas pipelines and rails.
This document provides an overview of various joining processes including welding and brazing. It discusses gas welding processes like oxy-acetylene welding in detail. It also covers different arc welding processes such as shielded metal arc welding, gas tungsten arc welding, flux-cored arc welding, and submerged arc welding. Other joining techniques summarized include resistance welding, plasma arc welding, electroslag welding, and thermit welding. Key information about equipment, process parameters, advantages and applications are provided for each welding and brazing process.
Metal brazing and soldering - processesWaqas Ahmed
Brazing is a metal joining process where a filler metal above 450°C is melted and drawn into the gap between close-fitting metal parts by capillary action. The filler metal interacts with a thin layer of the base metal to form a sealed joint that is generally stronger than the individual filler metals due to metallurgical bonding. Soldering is similar but uses a filler metal with a lower melting point below 400°C, making it suitable for joining thin parts but resulting in weaker joints. Both processes allow dissimilar metals to be joined but have limitations such as appearance differences, toxicity of fluxes, and maximum operating temperatures.
The document discusses different types of mechanical joints used to connect parts in machinery. It describes three main types: bolted joints, which use bolts and nuts; screw joints, which use screws; and welded joints, which permanently fuse parts together. Welded joints include butt, corner, lap, tee, and edge joints. The document also discusses different welding processes like shielded metal arc welding, gas tungsten arc welding, gas metal arc welding, and submerged arc welding. It provides details on how each process works and its advantages and applications.
Advanced welding ,casting , forming processes PDF by badebhau4@gmail.comEr. Bade Bhausaheb
The document discusses advanced manufacturing processes including friction stir welding, advanced die casting, and tooling. It provides details on friction stir welding such as how it works as a solid-state welding process without reaching melting point. It also discusses advantages like producing high quality welds with fewer defects compared to traditional welding. The document then covers various types of tooling used for sheet metal pressing, molding, jigs/fixtures, and their applications in press working processes like blanking, piercing, bending, drawing, and others.
Welding of plastics can be done through various methods like hot plate welding, hot gas welding, ultrasonic welding, friction welding, and laser welding. These methods use external heating through hot tools or internal heating through ultrasonic vibrations or friction to melt the plastic interface and join components. Some key advantages are the ability to produce strong bonds with properties similar to the original plastic and suitability for mass production. The appropriate welding method depends on the type of plastics and application.
The document provides an overview of TIG (GTAW) welding. It involves using a tungsten electrode to generate an electric arc that melts the materials to be welded. The welding area is shielded with an inert gas like argon to prevent contamination. TIG welding allows for good control and produces high quality welds, making it suitable for thin metals. However, it is more complex and difficult to learn than other welding techniques. It requires maintaining a small arc gap and feeding a filler rod with one hand while operating the torch with the other.
The document discusses various joining processes including welding, brazing, and soldering. It describes different welding techniques like gas welding, arc welding, resistance welding, and special processes like laser beam and electron beam welding. It also covers brazing and soldering methods, the equipment involved, filler materials and fluxes used for different processes.
The document discusses various joining processes including welding, brazing and soldering. It describes different welding techniques such as gas welding, arc welding and various specialized welding processes. It also discusses resistance welding processes, filler materials, fluxes used and types of adhesive bonding.
This presentation provides an overview of forge welding, including its principles, classification, process parameters, temperature requirements, tools needed, forgeable metals, common hand tools, advantages, disadvantages, and applications. Forge welding is a solid-state welding process that joins two pieces of metal by heating them above 1000 degrees Celsius and hammering them together. It can be done via hammer welding, roll welding, or die welding and is used in industries like aerospace, shipbuilding, and manufacturing.
This 3 sentence summary provides an overview of the 4 month industrial training report submitted by Pushpinder Singh from Gurgaon College of Engineering about their training at a multi-unit manufacturing company with 4 plants. The report details the major learnings in the engineering department including different types of welding and guns used, the implementation of 5S and poka yoke techniques, the study of control plans and laser cutting machines. It also includes a man-machine chart analyzing the idle times on various lines at one of the plants.
Introduction to solid state welding processesMelfway
Welding joins metals through different ways. From arc to oxyfuel, there are various techniques to fasten metal pieces together to create unique products.
Contrary to popular belief, not all welding processes have to melt the metal. One such way of forming metal pieces without increasing the temperature is through solid-state welding, and there are different techniques under this branch too. Here are some of them:
This document discusses joining processes and focuses on welding. It introduces different types of joining processes and classifies them. Welding is described as a process that joins materials by melting and sometimes adding a filler material to form a joint. There are different types of weld joints and welds as well as welding processes. Key welding processes mentioned include oxy fuel gas welding, arc welding, resistance welding, and laser beam welding. The document provides classifications of joining processes and welding processes.
Brazing is a metal joining process where two or more metals are joined together by melting a filler metal with a lower melting point than the adjoining metals and flowing it into the joint. There are different heat sources that can be used for brazing such as induction brazing, continuous brazing furnaces, batch furnaces, and vacuum brazing. Different braze filler metals are used depending on the base material and the desired maximum service temperature, including alloys for stainless steels, carbon steels, nickel alloys, and more. Brazing offers advantages over other joining techniques such as allowing batch processing, minimizing component distortion, and enabling the joining of dissimilar materials.
The document discusses friction stir welding (FSW), a solid-state welding process. FSW involves a rotating cylindrical shoulder tool that is plunged into two abutting metal pieces. Frictional heat and pressure generated by the tool's pin and shoulder forge the plasticized metal together. Key advantages of FSW include a solid-state process that avoids defects of fusion welding and the ability to join dissimilar metals. The document outlines the FSW process, microstructure analysis of welds, tool design considerations, applications, advantages, and challenges of the technique.
Advanced Manufacturing Processes PDF Full book by badebhauEr. Bade Bhausaheb
This document provides a syllabus for an advanced manufacturing processes course. The syllabus covers 6 units: 1) metal forming processes, 2) advanced welding, casting and forging, 3) advanced material processing techniques, 4) micro machining processes, 5) additive manufacturing processes, and 6) measurement techniques for micro machining. Some key processes discussed include roll forming, hydroforming, electromagnetic forming, friction stir welding, vacuum die casting, and additive manufacturing methods like powder bed fusion. Contact information is also provided.
Optimization of Process Parameters in MIG Welding of Two Dissimilar Materialsijtsrd
The joining of dissimilar Aluminum Alloy and Copper aluminum plates of 5mm thickness was carried out by technique. Optimum process parameters were obtained for joints using statistical approach. Five different tool designs have been employed to an alyse the influence of rotation speed and traverse speed over the micro structural and tensile properties. In FSW technique, the process of welding of the base material, well below its melting temperature, has opened up new trends in producing efficient dissimilar joints. Effect of welding speed on microstructures, hardness distribution and tensile properties of the welded joints were investigated. By varying the process parameters, defect free and high efficiency welded joints were produced. The ratio between tool shoulder diameter and pin diameter is the most dominant factor. From micro structural analysis it is evident that the material placed on the advancing side dominates the nugget region. The hardness in the HAZ of 6061 was found to be minimum, where the welded joints failed during the tensile studies. M. S. Amarnath Reddy | Mr. J. Sree Hari | Mr. K. Sai Kiran "Optimization of Process Parameters in MIG Welding of Two Dissimilar Materials" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-6 , October 2018, URL: http://www.ijtsrd.com/papers/ijtsrd18749.pdf
This document provides an overview of various joining processes including fusion welding, brazing, soldering, and adhesive bonding. It discusses the key characteristics and applications of these processes. Fusion welding joins metals through melting. Brazing and soldering also use filler metals but do not melt the base metals. Adhesive bonding uses non-metallic fillers and forces of attachment between closely spaced surfaces. Each process has advantages and limitations for different material types and joint designs. Surface preparation is important for maximizing bond strength.
This document provides an overview of nontraditional machining processes including electrochemical machining (ECM), electro discharge machining (EDM), electron beam machining (EBM), and laser beam machining (LBM). It discusses the basic principles, mechanisms, advantages, limitations and applications of each process. Examples of parts made using these advanced processes and diagrams illustrating the setup and operation are also included. The document is intended to teach students about nontraditional machining as part of a manufacturing technology course.
AMP Unit 2. Stir welding ,casting ,forming(badebhau4@gmail.com)Er. Bade Bhausaheb
This document provides information on various welding and advanced manufacturing processes. It begins with an introduction to friction stir welding, including its key features such as being a solid-state process. It then discusses advanced die casting techniques like vacuum die casting and squeeze casting. The rest of the document discusses friction stir welding in more detail, including its process characteristics, parameters, tooling, applications in industries like automotive and aerospace, and advantages over other welding techniques. It also provides an introduction to tooling used for sheet metal pressing, plastic molding, die casting, forging, and machining operations.
This document is a laboratory manual for an Engineering Practices course covering topics like plumbing, carpentry, welding, machining, and machine assembly. It includes an index, contents section, and chapters on safety precautions, plumbing tools and components, and descriptions of common pipe fittings. The manual provides information to students on exercises and demonstrations for various mechanical engineering skills and trades.
The document describes the process of fabricating and assembling switch gear panels. First, steel is cut into proper shapes using a cutting machine. The pieces are then welded together to form the panel body. The body is treated with chemicals and coated with powder for protection. It is then placed in an oven to cure the powder coating. Sheet metal covers are added using presses. Wiring is done according to diagrams. The fully assembled switch gear is tested to verify proper function and that performance meets specifications before being put into operation.
This document describes the design and fabrication of a banana leaf cutting machine. The conventional banana leaf cutting machine is complex, bulky, and requires a lot of space. The main goal of this project was to create a machine that is simpler, smaller, lighter, and requires less floor space. The machine was designed to cut banana leaves into circular shapes using sheet metal parts and a cutting tool. Mild steel was selected as the primary material for its strength, formability, and weldability. Springs and welding were also incorporated into the design. The experimental setup and testing showed the machine successfully cuts banana leaves while having advantages of less space, low cost, and simplicity.
Metal brazing and soldering - processesWaqas Ahmed
Brazing is a metal joining process where a filler metal above 450°C is melted and drawn into the gap between close-fitting metal parts by capillary action. The filler metal interacts with a thin layer of the base metal to form a sealed joint that is generally stronger than the individual filler metals due to metallurgical bonding. Soldering is similar but uses a filler metal with a lower melting point below 400°C, making it suitable for joining thin parts but resulting in weaker joints. Both processes allow dissimilar metals to be joined but have limitations such as appearance differences, toxicity of fluxes, and maximum operating temperatures.
The document discusses different types of mechanical joints used to connect parts in machinery. It describes three main types: bolted joints, which use bolts and nuts; screw joints, which use screws; and welded joints, which permanently fuse parts together. Welded joints include butt, corner, lap, tee, and edge joints. The document also discusses different welding processes like shielded metal arc welding, gas tungsten arc welding, gas metal arc welding, and submerged arc welding. It provides details on how each process works and its advantages and applications.
Advanced welding ,casting , forming processes PDF by badebhau4@gmail.comEr. Bade Bhausaheb
The document discusses advanced manufacturing processes including friction stir welding, advanced die casting, and tooling. It provides details on friction stir welding such as how it works as a solid-state welding process without reaching melting point. It also discusses advantages like producing high quality welds with fewer defects compared to traditional welding. The document then covers various types of tooling used for sheet metal pressing, molding, jigs/fixtures, and their applications in press working processes like blanking, piercing, bending, drawing, and others.
Welding of plastics can be done through various methods like hot plate welding, hot gas welding, ultrasonic welding, friction welding, and laser welding. These methods use external heating through hot tools or internal heating through ultrasonic vibrations or friction to melt the plastic interface and join components. Some key advantages are the ability to produce strong bonds with properties similar to the original plastic and suitability for mass production. The appropriate welding method depends on the type of plastics and application.
The document provides an overview of TIG (GTAW) welding. It involves using a tungsten electrode to generate an electric arc that melts the materials to be welded. The welding area is shielded with an inert gas like argon to prevent contamination. TIG welding allows for good control and produces high quality welds, making it suitable for thin metals. However, it is more complex and difficult to learn than other welding techniques. It requires maintaining a small arc gap and feeding a filler rod with one hand while operating the torch with the other.
The document discusses various joining processes including welding, brazing, and soldering. It describes different welding techniques like gas welding, arc welding, resistance welding, and special processes like laser beam and electron beam welding. It also covers brazing and soldering methods, the equipment involved, filler materials and fluxes used for different processes.
The document discusses various joining processes including welding, brazing and soldering. It describes different welding techniques such as gas welding, arc welding and various specialized welding processes. It also discusses resistance welding processes, filler materials, fluxes used and types of adhesive bonding.
This presentation provides an overview of forge welding, including its principles, classification, process parameters, temperature requirements, tools needed, forgeable metals, common hand tools, advantages, disadvantages, and applications. Forge welding is a solid-state welding process that joins two pieces of metal by heating them above 1000 degrees Celsius and hammering them together. It can be done via hammer welding, roll welding, or die welding and is used in industries like aerospace, shipbuilding, and manufacturing.
This 3 sentence summary provides an overview of the 4 month industrial training report submitted by Pushpinder Singh from Gurgaon College of Engineering about their training at a multi-unit manufacturing company with 4 plants. The report details the major learnings in the engineering department including different types of welding and guns used, the implementation of 5S and poka yoke techniques, the study of control plans and laser cutting machines. It also includes a man-machine chart analyzing the idle times on various lines at one of the plants.
Introduction to solid state welding processesMelfway
Welding joins metals through different ways. From arc to oxyfuel, there are various techniques to fasten metal pieces together to create unique products.
Contrary to popular belief, not all welding processes have to melt the metal. One such way of forming metal pieces without increasing the temperature is through solid-state welding, and there are different techniques under this branch too. Here are some of them:
This document discusses joining processes and focuses on welding. It introduces different types of joining processes and classifies them. Welding is described as a process that joins materials by melting and sometimes adding a filler material to form a joint. There are different types of weld joints and welds as well as welding processes. Key welding processes mentioned include oxy fuel gas welding, arc welding, resistance welding, and laser beam welding. The document provides classifications of joining processes and welding processes.
Brazing is a metal joining process where two or more metals are joined together by melting a filler metal with a lower melting point than the adjoining metals and flowing it into the joint. There are different heat sources that can be used for brazing such as induction brazing, continuous brazing furnaces, batch furnaces, and vacuum brazing. Different braze filler metals are used depending on the base material and the desired maximum service temperature, including alloys for stainless steels, carbon steels, nickel alloys, and more. Brazing offers advantages over other joining techniques such as allowing batch processing, minimizing component distortion, and enabling the joining of dissimilar materials.
The document discusses friction stir welding (FSW), a solid-state welding process. FSW involves a rotating cylindrical shoulder tool that is plunged into two abutting metal pieces. Frictional heat and pressure generated by the tool's pin and shoulder forge the plasticized metal together. Key advantages of FSW include a solid-state process that avoids defects of fusion welding and the ability to join dissimilar metals. The document outlines the FSW process, microstructure analysis of welds, tool design considerations, applications, advantages, and challenges of the technique.
Advanced Manufacturing Processes PDF Full book by badebhauEr. Bade Bhausaheb
This document provides a syllabus for an advanced manufacturing processes course. The syllabus covers 6 units: 1) metal forming processes, 2) advanced welding, casting and forging, 3) advanced material processing techniques, 4) micro machining processes, 5) additive manufacturing processes, and 6) measurement techniques for micro machining. Some key processes discussed include roll forming, hydroforming, electromagnetic forming, friction stir welding, vacuum die casting, and additive manufacturing methods like powder bed fusion. Contact information is also provided.
Optimization of Process Parameters in MIG Welding of Two Dissimilar Materialsijtsrd
The joining of dissimilar Aluminum Alloy and Copper aluminum plates of 5mm thickness was carried out by technique. Optimum process parameters were obtained for joints using statistical approach. Five different tool designs have been employed to an alyse the influence of rotation speed and traverse speed over the micro structural and tensile properties. In FSW technique, the process of welding of the base material, well below its melting temperature, has opened up new trends in producing efficient dissimilar joints. Effect of welding speed on microstructures, hardness distribution and tensile properties of the welded joints were investigated. By varying the process parameters, defect free and high efficiency welded joints were produced. The ratio between tool shoulder diameter and pin diameter is the most dominant factor. From micro structural analysis it is evident that the material placed on the advancing side dominates the nugget region. The hardness in the HAZ of 6061 was found to be minimum, where the welded joints failed during the tensile studies. M. S. Amarnath Reddy | Mr. J. Sree Hari | Mr. K. Sai Kiran "Optimization of Process Parameters in MIG Welding of Two Dissimilar Materials" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-6 , October 2018, URL: http://www.ijtsrd.com/papers/ijtsrd18749.pdf
This document provides an overview of various joining processes including fusion welding, brazing, soldering, and adhesive bonding. It discusses the key characteristics and applications of these processes. Fusion welding joins metals through melting. Brazing and soldering also use filler metals but do not melt the base metals. Adhesive bonding uses non-metallic fillers and forces of attachment between closely spaced surfaces. Each process has advantages and limitations for different material types and joint designs. Surface preparation is important for maximizing bond strength.
This document provides an overview of nontraditional machining processes including electrochemical machining (ECM), electro discharge machining (EDM), electron beam machining (EBM), and laser beam machining (LBM). It discusses the basic principles, mechanisms, advantages, limitations and applications of each process. Examples of parts made using these advanced processes and diagrams illustrating the setup and operation are also included. The document is intended to teach students about nontraditional machining as part of a manufacturing technology course.
AMP Unit 2. Stir welding ,casting ,forming(badebhau4@gmail.com)Er. Bade Bhausaheb
This document provides information on various welding and advanced manufacturing processes. It begins with an introduction to friction stir welding, including its key features such as being a solid-state process. It then discusses advanced die casting techniques like vacuum die casting and squeeze casting. The rest of the document discusses friction stir welding in more detail, including its process characteristics, parameters, tooling, applications in industries like automotive and aerospace, and advantages over other welding techniques. It also provides an introduction to tooling used for sheet metal pressing, plastic molding, die casting, forging, and machining operations.
This document is a laboratory manual for an Engineering Practices course covering topics like plumbing, carpentry, welding, machining, and machine assembly. It includes an index, contents section, and chapters on safety precautions, plumbing tools and components, and descriptions of common pipe fittings. The manual provides information to students on exercises and demonstrations for various mechanical engineering skills and trades.
The document describes the process of fabricating and assembling switch gear panels. First, steel is cut into proper shapes using a cutting machine. The pieces are then welded together to form the panel body. The body is treated with chemicals and coated with powder for protection. It is then placed in an oven to cure the powder coating. Sheet metal covers are added using presses. Wiring is done according to diagrams. The fully assembled switch gear is tested to verify proper function and that performance meets specifications before being put into operation.
This document describes the design and fabrication of a banana leaf cutting machine. The conventional banana leaf cutting machine is complex, bulky, and requires a lot of space. The main goal of this project was to create a machine that is simpler, smaller, lighter, and requires less floor space. The machine was designed to cut banana leaves into circular shapes using sheet metal parts and a cutting tool. Mild steel was selected as the primary material for its strength, formability, and weldability. Springs and welding were also incorporated into the design. The experimental setup and testing showed the machine successfully cuts banana leaves while having advantages of less space, low cost, and simplicity.
The document discusses conventional and unconventional machining processes. Conventional machining involves direct contact between the tool and workpiece and removal of metal through chip formation, which produces chips as waste. Unconventional processes do not require direct contact and instead use various forms of energy like thermal, electrical or electrochemical to remove metal. Common unconventional processes described include EDM, ECM, laser beam machining and water jet machining. The document also covers CNC machines and how part programs control automated machining through coded G and M commands.
1. Forming is a metalworking process that shapes metal by deforming it without removing material. Common forming processes include rolling, extrusion, forging, and die forming.
2. Joining processes like welding, brazing, and adhesive bonding are used to connect metal components together. Welding involves melting materials to join them, while brazing uses a filler metal below the melting point of the base materials.
3. Machining removes material using tools like lathes, mills, drills and grinders to shape a workpiece. It allows for tight tolerances but incurs significant material removal and waste.
The document discusses electromagnetic pulse technology (EMPT) as a cutting tool. EMPT uses powerful electromagnetic pulses generated by charging and discharging capacitors through a coil to cut materials. It can cut steel 7 times faster than lasers without leaving burrs. The cutting process involves generating a strong electromagnetic field that hits the steel with 3,500 bars of pressure, expelling the material. EMPT shows potential for cutting complex hollow profiles in high-strength steels for automotive body parts faster and with lower energy costs than traditional cutting methods. While offering advantages like no heat or added fluids, high cutting pressures are required.
The document discusses several topics related to industrial processes and materials. It describes how industrial ovens work by transferring heat energy to increase temperature. It also discusses industrial wheels made of different materials like rubber and polyurethane used for machinery. The document outlines the machining process for removing excess metal from parts and notes considerations for complex, fragile, or high tolerance workpieces. It also provides a brief overview of common machine tool methods like electric discharge machining, cutting, and stamping to shape metals.
The document discusses various non-traditional machining processes including chemical machining, electrochemical machining, electrical discharge machining, laser beam machining, electron beam machining, water jet machining, abrasive jet machining, and ultrasonic machining. These processes are used for hard materials, complex shapes, or where heat and stresses from traditional machining would cause damage. Each process removes material in unique ways such as through chemical dissolution, electrochemical erosion, electrical sparks, focused light/electron beams, or abrasive particle impact.
This document provides instructions on manuals for workshop practice in a welding shop. It discusses various welding processes like arc welding and gas welding. It describes shaping methods for metals like blanking, pressing, rolling and casting. It also discusses joining methods for metals including mechanical joining and metallurgical joining. Key tools used in welding are described. Welding positions, joints, edge preparations and defects are outlined. Safety precautions for welding are also provided.
Surface treatment of metals is an important process that dates back thousands of years. It involves changing the surface properties of metals for purposes such as decoration, hardness, and corrosion prevention. Common surface treatment methods include case hardening to harden surfaces while leaving interiors soft, electroplating to deposit different metals on surfaces, and vapor deposition to apply coatings through chemical reactions with gases. Joining and cutting are also important manufacturing processes that involve combining or shaping materials.
Report on Industrial visit at Aditya Auto products, Doddballapura, Bangalore.abhishekPatne2
1. Aditya Auto Products manufactures automotive components like window regulators, door latches, and cables.
2. The production process involves raw materials undergoing rolling, pressing, welding, and assembly into finished products.
3. Quality inspection and testing is conducted at various stages to ensure product quality meets standards before dispatch.
Die casting is a casting method that uses specialized die casting machines to inject liquid metal into a mold cavity under high pressure. This allows the metal to fill the cavity and take on its shape. It also improves mechanical properties by eliminating shrinkage defects and refining grain structure. Die casting produces parts with consistent dimensions, appearance, and internal quality according to design requirements.
Zinc alloys are commonly used for die casting. They have good fluidity and mechanical properties at room temperature but weaker properties at high and low temperatures. Zinc alloys are suitable for parts that don't require high strength, such as toys and lamps. They can also be used for some automotive and machinery parts. Different zinc alloys have varying physical
The abrasive particulates on the cutting wheel influence the quality of cut. The surface finish, and the temperature raise during the cutting processes is governed by various parameters such as size of the particulates, its shape, roundness of edges at the particulates and strength of the bond between particulates and resins. The composite parting-off wheel is superior to that of commercial counterparts. A composite parting-off wheel was fabricated using powder metallurgy technique. The composite powders were prepared using an ingeniously designed and developed horizontal axis ball mill. The parting-wheel was able to cut metals bars such as aluminium, copper and mild steel with relative ease. It was found out that the mechanical properties such as compressive strength, hardness and tensile strength was better than conventional abrasive wheels. The cutting ratio was superior to the abrasive wheels and CZT was lower in comparison
Optimization of cutting tool material in lathe machine by T-testIJMER
Modern manufacturers, seeking to remain competitive in the market, rely on their
manufacturing engineers and production personnel to quickly and effectively set-up manufacturing
processes for new products. T-test method is a powerful and efficient method for optimizing quality and
performance output of a manufacturing process, thus a powerful tool for meeting this challenge. This
paper discusses an investigation into the use of t-test method for optimizing controlled dia of workpiece in
a lathe machine. Control parameters being considered in this paper are spindle speed, feed rate and
depth of cut. After experimentally turning sample work pieces using the selected parameters, this
investigation produced an optimum combination of controlled parameter for the cutting tool.
1. Metal cutting, also known as machining, involves removing unwanted material from a workpiece using a cutting tool to give it the required shape and dimensions.
2. The cutting tool must have properties like hardness, toughness, heat and wear resistance to withstand the high temperatures and pressures of metal cutting.
3. Factors like cutting tool geometry, workpiece and cutting conditions influence the metal cutting process and generation of heat. Excessive heat can damage tools or reduce accuracy.
Similar to Fabrication of Cutting And Polishing Machine (20)
Modeling And Simulation Swash Plate Pump Response Characteristics in Load Sen...IJMERJOURNAL
ABSTRACT: Fluid Power is widely employed in applications required high loads such as tractors, cranes, and airplanes. In load sensing hydraulic systems, loads are controlled by adjusting a pump-valve arrangement. In this paper, the swash plate pump hydraulic characteristics will be determined, the pump and its fluid gains will be derived to obtain the pump overall transfer function. Firstly, the swash plate pump mechanism is analyzed and its dynamic model is constructed; the pump pressure and flow rate are plotted and the possible improvement is introduced. The load sensing unit parameters such as orifice width, orifice area, maximum passage area, and piston area at X and Y will be examined to identify their influence on the pump characteristics; and the optimum parameters will be introduced. All results are developed and simulated numerically.
Generation of Electricity Through A Non-Municipal Solid Waste Heat From An In...IJMERJOURNAL
ABSTRACT: Energy production, waste disposal, and pollution minimization are key problems that must be addressed for sustainable cities of the environment. Waste management has become a major concern worldwide, and incineration is now being used increasingly to treat waste that cannot be recycled economically. The total heat content of non- municipal waste varies from countries to countries. The tonnage of generation in Nigeria is expected to soar over the next few years and the exploitation of this renewable energy locked up in urban solid municipal waste into grid energy can be taken advantage off.The heat generated from this incinerated plant can be used to generate electricity which will reduce overdependence on fossil fuel and the use of generator which in turn reduces pollution disposal of this waste is incinerated plant for the production of electricity. Hence, this paper intends to review the nonmunicipal waste potential in Nigeria, evaluate its environment and economic cost, and energy content of municipal solid waste deposits in Nigeria.
A New Two-Dimensional Analytical Model of Small Geometry GaAs MESFETIJMERJOURNAL
ABSTRACT : In this paper, a simple and exact analytical model for Small Geometry GaAs MESFET is developed to determine the potential distribution along the channel of the device. The model is based on the exact solution of two-dimensional Poisson’s equation in the depletion region under the gate. Then the obtained model is used to study the channel potential and threshold voltage of the device. Using the analytical model, the effect of the device parameter and bias conditions on performance of the device is investigated. The obtained results are graphically exhibited and discussed. In order to verification of the analytical results, TCAD device simulator is used and good accordance is observed.
Design a WSN Control System for Filter Backwashing ProcessIJMERJOURNAL
ABSTRACT: Day by day, there is a higher rate of need for accurate automation system to be used in industries and environment monitoring and control. In water treatment plants during the filtration phase, there is a process called backwashing, which particles suspended in the filter basin are removed. in this process the water are forcedly pumped through the filter in upward direction at enough speed to expand the filter media. Therefore, various types of valves used, which are opened and closed in a time sequencing manner. The paper proposed an automation control system for the backwashing process to be initiated and completed automatically using PLC, level sensors and valves installed inside the filter basin. Practically, a control system has been applied which all valves are opened and closed according to wireless signals coming from PLCs on its suitable time. In summary, the control in the process demonstrated that the proposed system is efficient, effective, and able to be reliable. Besides, the results increase the productivity at a low-cost mode.
Application of Customer Relationship Management (Crm) Dimensions: A Critical ...IJMERJOURNAL
ABSTRACT”: Customer relationship management is crucial due to the competitive environment. For this reason, it has become a widely implemented strategy across the hotel industry in retaining customers and maintaining good relationships with them. It also promotes customer satisfaction and loyalty which lead to the achievement of competitive business performance. However, due to the ever-increasing competition and the continuous changing customers’ needs in the hotel industry, the ability to achieve customer satisfaction is becoming a major challenge. Using 40 respondents from 20 hotels, this paper, therefore, explores the managers’ perspective into how the application of CRM dimensions impact on the performance of hotels and also examines the relationships between them since studies evaluating their relationships are limited. It studies CRM from the hotels’ perceptive as Guest Services Managers and Marketing Managers were the respondents. This study employed an exploratory research design and quantitative technique. The survey was conducted in New Delhi and simple random sampling was the sampling technique used to select respondents. With the study’s objectives in mind, the developed research hypotheses constructed were tested using multiple regression analysis as the statistical tool. Through the results, it has been revealed that CRM dimensions are positively related to the performance of hotels. Finally, CRM dimensions are highly recommended as a competitive strategic tool to enhance competitiveness.
Comparisons of Shallow Foundations in Different Soil ConditionIJMERJOURNAL
ABSTRACT: Soil is considered by the engineer as a complex material produced by weathering of the solid rock. Footings are structural elements that transmit column or wall loads to the underlying soil below the structure. Footings are designed to transmit these loads to the soil without exceeding its safe bearing capacity. Each building demands the need to solve a problem of foundation on different types of soil. The main aim of this project is to design the appropriate foundation as per size and shape on cohesive, non-cohesive and rocky soil. In this paper different foundation are studied for a middle side and corner column of a building with different bearing capacities. Based on the study and judicial judgment the type of foundation is decided as per depth, quantity of steel and quantity of concrete and try to find which shape of the foundation is more stable, economical and ways to reduce the ease of construction of the building
Place of Power Sector in Public-Private Partnership: A Veritable Tool to Prom...IJMERJOURNAL
ABSTRACT: Public Private Partnership involves private sector engagement in infrastructural development. Though in the past, the country infrastructure had been experiencing a decline in the system, this is because, government had been the sole contributor to infrastructural finance and had often taken responsibility for implementation, operations and maintenance as well. This decline in the system is caused by escalating population growth depending on available infrastructure, decaying of existing power infrastructure, political instability and corruption in the system. The ongoing reform is about bringing the system to a lime light. Hence, Public Private Partnership participation in the infrastructural development in Nigeria, will create favorable environment for an investors, provide job opportunities, long time policy, decision making and efficient use of the available resources. This paper therefore dwells on overview of the public private partnership with regards to energy and other infrastructural development of Nigeria. Challenges of the partnership and possible solutions towards subduing the problems are proffered.
Study of Part Feeding System for Optimization in Fms & Force Analysis Using M...IJMERJOURNAL
ABSTRACT: This paper describes the development of a flexible and vibratory bowl feeding system which is suitable for use in a flexible manufacturing system. The vibratory bowl feeder for automatic assembly, presents a geometric model of the feeder, and develops force analysis, leading to dynamical modeling of the vibratory feeder. Based on the leaf-spring modeling of the three legs of the symmetrically arranged bowl of the feeder, and equating the vibratory feeder to a three-legged parallel mechanism, the paper reveals the geometric property of the feeder. The effects of the leaf-spring legs are transformed to forces and moments acting on the base and bowl of the feeder. Resultant forces are obtained based upon the coordinate transformation, and the moment analysis is produced based upon the orthogonality of the orientation matrix. This reveals the characteristics of the feeder, that the resultant force is along the z-axis and the resultant moment is about the z direction and further generates the closed-form motion equation.
Investigating The Performance of A Steam Power PlantIJMERJOURNAL
ABSTRACT: The performance analysis of Shobra El-Khima power plant in Cairo, Egypt is presented based on energy and exergy analysis to determine the causes , the sites with high exergy destruction , losses and the possibilities of improving the plant performance. The performance of the plant was evaluated at different loads (Full, 75% and, 50 %). The calculated thermal efficiency based on the heat added to the steam was found to be 41.9 %, 41.7 %, 43.9% , while the exergetic efficiency of the power cycle was found to be 44.8%, 45.5% and 48.8% at max, 75% and, 50 % load respectively. The condenser was found to have the largest energy losses where (54.3%, 55.1% and 56.3% at max, 75% and, 50 % load respectively) of the added energy to the steam is lost to the environment. The maximum exergy destruction was found to be in the turbine where the percentage of the exergy destruction was found to be (42%, 59% and 46.1% at max, 75% and, 50 % load respectively). The pump was found to have the minimum exergy destruction. It was also found that the exergy destruction in feed water heaters and in the condenser together represents the maximum exergy destruction in the plant (about 52%). This means that the irreversibilities in the heat transfer devices in the plant have a significant role on the exergy destruction. So, it is thought that the improvement in the power plant will be limited due to the heat transfer devices.
Study of Time Reduction in Manufacturing of Screws Used in Twin Screw PumpIJMERJOURNAL
ABSTRACT: This paper gives the characteristics of Time reduction in manufacturing of screws for Twin screw pumps. Screws are playing a vital role in the performance of pumps, because pumps give the fluids transfer rate with the help of screws. There is a gap in screws which shows its positiveness. This indicates that we are studying about positive displacements pumps. Positive displacements pumps having no point of contact between screws, because of that there will be no any friction formation. Automation is best for development of product to reduce time in manufacturing of any product. In this paper we also tried to explain this feature of Automation to help reduction of time to manufacture of product to increase productivity.
Mitigation of Voltage Imbalance in A Two Feeder Distribution System Using IupqcIJMERJOURNAL
ABSTRACT: Proliferation of electronic equipment in commercial and industrial processes has resulted in increasingly sensitive electrical loads to be fed from power distribution system which introduce contamination to voltage and current waveforms at the point of common coupling of industrial loads. The unified power quality conditioner (UPQC) is connected between two different feeders (lines), hence this method of connection of the UPQC is called as Interline UPQC (IUPQC).This paper proposes a new connection for a UPQC to improve the power quality of two feeders in a distribution system. Interline Unified Power Quality Conditioner (IUPQC), specifically aims at the integration of series VSC and Shunt VSC to provide high quality power supply by means of voltage sag/swell compensation, harmonic elimination in a power distribution network, so that improved power quality can be made available at the point of common coupling. The structure, control and capability of the IUPQC are discussed in this paper. The efficiency of the proposed configuration has been verified through simulation using MATLAB/ SIMULINK.
Adsorption of Methylene Blue From Aqueous Solution with Vermicompost Produced...IJMERJOURNAL
ABSTRACT: The removal of Methylene blue as a synthetic dye from aquatic system was investigated by using vermicompost. The dye concentration, contact time and pH of the solution carried out in the adsorption studies. Batch adsorption experimental data were suitable for the Langmuir isotherm and a very good fit to the second order kinetic model (pH=10). The maximum adsorption capacity calculated 256.66 mg g-1 . Vermicompost and the dye loaded vermicompost were characterized by SEM and FTIR. It was found that the vermicompost is stable without losing their activity.
Analytical Solutions of simultaneous Linear Differential Equations in Chemica...IJMERJOURNAL
ABSTRACT: Analytical method for solving homogeneous linear differential equations in chemical kinetics and pharmacokinetics using homotopy perturbation method has been proposed. The mathematical model that depicts the pharmacokinetics is solved. Herein, we report the closed form of an analytical expression for concentrations species for all values of kinetic parameters. These results are compared with numerical results and are found to be in satisfactory agreement. The obtained results are valid for the whole solution domain.
Experimental Investigation of the Effect of Injection of OxyHydrogen Gas on t...IJMERJOURNAL
ABSTRAC: Oxy-Hydrogen gas, H2O2, is a mixture of hydrogen and oxygen produced by water electrolysis. In this work, an experimental exploration was carried out in order to study the effect of the addition of oxy-hydrogen gas into inlet air manifold on speed performance characteristics of a diesel engine at different operating conditions. The experimental work was performed on a test rig comprising a four stroke 5.67 liters water-cooled diesel engine and a Heenan hydraulic dynamometer. Instrumentation included devices for measuring engine speed, load, fuel consumption and inlet air flow rate. The measurements were conducted at 1000, 1500, 2000 and 2500 rpm. At each speed, the engine load was adjusted to 20%, 40% and 80% from the engine full load which corresponds to engine brake mean effective pressures of 1.55, 3.11, and 6.22 bar, respectively, for Oxy-hydrogen generator supplied Currents of 26A and electrolyte concentration of 25 %. The fuel saving percentage and so the brake thermal efficiency for the H2O2 enriched CI engine is more evidently seen at low loads and high-speed conditions. the volumetric efficiency drop was about 5 % at small speeds and reaches to about 2% at higher engine speed.
Hybrid Methods of Some Evolutionary Computations AndKalman Filter on Option P...IJMERJOURNAL
ABSTRACT: The search for a better option price continues within the financial institution. In pricing a put option, holders of the underlying stock always want to make the best decision by maximizing profit. We present an optimal hybrid model among the following combinations: Kalman Filter-Genetic Programming(KF-GP), Kalman Filter-Evolutionary Strategy(KF-ES) and Evolutionary Strategy -Genetic Programming(ES- GP). Our results indicate that the hybrid method involving Kalman Filter-Evolutionary Strategy(KF-ES) is the best model for any investor. Sensitivity analysis was conducted on the model parameters to ascertain the rigidity of the model.
An Efficient Methodology To Develop A Secured E-Learning System Using Cloud C...IJMERJOURNAL
ABSTRACT: Now-a-days, each and every action involved in our life becomes computerized in order to reduce the time, complexity and manual power. The education systems are also being computerized, to train the students in a much efficient way. This system is termed as E-Learning. E-Learning is an Internet-based learning process, in which the Internet technology is used to design, implement, manage and extend learning, which will improve the efficiency of learning. Learning, Teaching and Training are intensely connected components, which are all included in the development of E-Learning system. Cloud Computing provides an efficient platform to support the E-Learning systems, as it can be dramatically changes over time .In this paper, an overview on the new emerging E-Learning system , utilization of the SAAS (Software as a Service) and the methodology to test the efficiency of the person in a secured way are described.
Nigerian Economy and the Impact of Alternative Energy.IJMERJOURNAL
ABSTRACT: Nigeria is endowed with natural resources which are aim at developing the country.The need for alternative energy resources to drive the nation economy cannot be over-emphasized. The incessant power failure has grossly affected the economy, seriously slowing down development in rural and sub-rural settlement. A robust solution must be found to end the crises. Alternative energy source has the potential of solving power problem in Nigeria as well as providing safer and cleaner environment than the fossil fuel. This paper also examines the socio–economic benefits of the alternative energy (solar, wind, biomass, hydro and geothermal) to the nation economy and the utilization of the resources to meet human needs and the generation yet unborn and to provide sustainable development, thereby improve the standard of living and mitigating climate change.
ABSTRACT: Many writers describe empowerment as a process as opposed to a condition or state of being which is being a key feature of empowerment emphasized by many researchers. As a process empowerment becomes difficult to be measured by standard tools available to social scientists. As case study helps in bringing us to understand a complex issue or object and can extend experience or add strength to what is already known through previous research. Case studies also emphasized on detailed contextual analysis of a limited number of events or conditions and their relationships. Researcher had made use of this qualitative research method to examine contemporary real-life situations.
Validation of Maintenance Policy of Steel Plant Machine Shop By Analytic Hier...IJMERJOURNAL
ABSTRACT: In this paper the maintenance activities of the Machine shop of Steel plant have been considered. As maintenance is a routine activity to keep a machine at its normal operating condition so that it can deliver its expected performance without causing any loose of time on account of accidental damage or breakdown and maintenance is a recurring activity. So for reduction of maintenance cost and safety of the operator as well as the residents of nearby area it is better to decide which machines should go for which type of maintenance. For this decision AHP is used and the Expert choice software is used for that calculations and this paper is for the validation of results.
li-fi: the future of wireless communicationIJMERJOURNAL
ABSTRACT: Nowadays people and their electronic devices access wireless internet. But, clogged airwaves are going to make it increasingly difficult to latch onto a reliable signal. So, Radio waves are just one part of the spectrum that can carry our data. We can use “Data through Illumination”. In this process, the data is sent through an LED source that varies in intensity faster than the human eye could follow. The future can be envisioned where the data for laptops, smart phones and all other smart applications is transmitted through the light in our living room. And security would be a snap—if you can’t see the light, you can’t access the data.
Null Bangalore | Pentesters Approach to AWS IAMDivyanshu
#Abstract:
- Learn more about the real-world methods for auditing AWS IAM (Identity and Access Management) as a pentester. So let us proceed with a brief discussion of IAM as well as some typical misconfigurations and their potential exploits in order to reinforce the understanding of IAM security best practices.
- Gain actionable insights into AWS IAM policies and roles, using hands on approach.
#Prerequisites:
- Basic understanding of AWS services and architecture
- Familiarity with cloud security concepts
- Experience using the AWS Management Console or AWS CLI.
- For hands on lab create account on [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
# Scenario Covered:
- Basics of IAM in AWS
- Implementing IAM Policies with Least Privilege to Manage S3 Bucket
- Objective: Create an S3 bucket with least privilege IAM policy and validate access.
- Steps:
- Create S3 bucket.
- Attach least privilege policy to IAM user.
- Validate access.
- Exploiting IAM PassRole Misconfiguration
-Allows a user to pass a specific IAM role to an AWS service (ec2), typically used for service access delegation. Then exploit PassRole Misconfiguration granting unauthorized access to sensitive resources.
- Objective: Demonstrate how a PassRole misconfiguration can grant unauthorized access.
- Steps:
- Allow user to pass IAM role to EC2.
- Exploit misconfiguration for unauthorized access.
- Access sensitive resources.
- Exploiting IAM AssumeRole Misconfiguration with Overly Permissive Role
- An overly permissive IAM role configuration can lead to privilege escalation by creating a role with administrative privileges and allow a user to assume this role.
- Objective: Show how overly permissive IAM roles can lead to privilege escalation.
- Steps:
- Create role with administrative privileges.
- Allow user to assume the role.
- Perform administrative actions.
- Differentiation between PassRole vs AssumeRole
Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
Advanced control scheme of doubly fed induction generator for wind turbine us...IJECEIAES
This paper describes a speed control device for generating electrical energy on an electricity network based on the doubly fed induction generator (DFIG) used for wind power conversion systems. At first, a double-fed induction generator model was constructed. A control law is formulated to govern the flow of energy between the stator of a DFIG and the energy network using three types of controllers: proportional integral (PI), sliding mode controller (SMC) and second order sliding mode controller (SOSMC). Their different results in terms of power reference tracking, reaction to unexpected speed fluctuations, sensitivity to perturbations, and resilience against machine parameter alterations are compared. MATLAB/Simulink was used to conduct the simulations for the preceding study. Multiple simulations have shown very satisfying results, and the investigations demonstrate the efficacy and power-enhancing capabilities of the suggested control system.
Redefining brain tumor segmentation: a cutting-edge convolutional neural netw...IJECEIAES
Medical image analysis has witnessed significant advancements with deep learning techniques. In the domain of brain tumor segmentation, the ability to
precisely delineate tumor boundaries from magnetic resonance imaging (MRI)
scans holds profound implications for diagnosis. This study presents an ensemble convolutional neural network (CNN) with transfer learning, integrating
the state-of-the-art Deeplabv3+ architecture with the ResNet18 backbone. The
model is rigorously trained and evaluated, exhibiting remarkable performance
metrics, including an impressive global accuracy of 99.286%, a high-class accuracy of 82.191%, a mean intersection over union (IoU) of 79.900%, a weighted
IoU of 98.620%, and a Boundary F1 (BF) score of 83.303%. Notably, a detailed comparative analysis with existing methods showcases the superiority of
our proposed model. These findings underscore the model’s competence in precise brain tumor localization, underscoring its potential to revolutionize medical
image analysis and enhance healthcare outcomes. This research paves the way
for future exploration and optimization of advanced CNN models in medical
imaging, emphasizing addressing false positives and resource efficiency.
Applications of artificial Intelligence in Mechanical Engineering.pdfAtif Razi
Historically, mechanical engineering has relied heavily on human expertise and empirical methods to solve complex problems. With the introduction of computer-aided design (CAD) and finite element analysis (FEA), the field took its first steps towards digitization. These tools allowed engineers to simulate and analyze mechanical systems with greater accuracy and efficiency. However, the sheer volume of data generated by modern engineering systems and the increasing complexity of these systems have necessitated more advanced analytical tools, paving the way for AI.
AI offers the capability to process vast amounts of data, identify patterns, and make predictions with a level of speed and accuracy unattainable by traditional methods. This has profound implications for mechanical engineering, enabling more efficient design processes, predictive maintenance strategies, and optimized manufacturing operations. AI-driven tools can learn from historical data, adapt to new information, and continuously improve their performance, making them invaluable in tackling the multifaceted challenges of modern mechanical engineering.
Introduction- e - waste – definition - sources of e-waste– hazardous substances in e-waste - effects of e-waste on environment and human health- need for e-waste management– e-waste handling rules - waste minimization techniques for managing e-waste – recycling of e-waste - disposal treatment methods of e- waste – mechanism of extraction of precious metal from leaching solution-global Scenario of E-waste – E-waste in India- case studies.
An improved modulation technique suitable for a three level flying capacitor ...IJECEIAES
This research paper introduces an innovative modulation technique for controlling a 3-level flying capacitor multilevel inverter (FCMLI), aiming to streamline the modulation process in contrast to conventional methods. The proposed
simplified modulation technique paves the way for more straightforward and
efficient control of multilevel inverters, enabling their widespread adoption and
integration into modern power electronic systems. Through the amalgamation of
sinusoidal pulse width modulation (SPWM) with a high-frequency square wave
pulse, this controlling technique attains energy equilibrium across the coupling
capacitor. The modulation scheme incorporates a simplified switching pattern
and a decreased count of voltage references, thereby simplifying the control
algorithm.
An improved modulation technique suitable for a three level flying capacitor ...
Fabrication of Cutting And Polishing Machine
1. International
OPEN ACCESS Journal
Of Modern Engineering Research (IJMER)
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 3 |
Fabrication of Cutting And Polishing Machine
Koteswaran.P.J
Student, Department of Mechanical Engineering R.M.K College of Engineering & Technology, Thiruvallur,
India
I. INTRODUTION
1.1-Types Of Cutting Operation:
Sawing
Flame cutting
Laser cutting
Water jet cutting
Plasma cutting
Shear cutting
Cutting metal with a saw is similar to cutting wood with a saw. The main difference is that the cutting blade is
thinner and the teeth are smaller. The
Fig. no 1.1 sawing operation
blade also moves at a faster rate. Large industrial saws can cut thick blocks of steel and are limited only by the
size of the machine.
There are different types of saws such as coping saws, band saws and circular saws. Non-industrial
steel saws are designed for thin metals used for such things as shelves and duct work. Metals thicker than 1/8
inch should be cut using other methods.
1.1.2 Flame-Cutting Operation:
Flame from a welding torch melts the metal and pushes it along in the direction of the flame, leaving a
cut in the metal. With the flame adjusted to the right temperature, cutting is fast, but the cut edges need grinding
down to make a smooth edge.
ABSTRACT: The first step in machining most working jobs is to cut the stock to the desired length. This
cutting operation should be done in the shortest time possible consistent with the desired quality. Similarly
the polishing operation in a metal working job should give the desired surface finish in the quickest time
possible. There are many methods by which the cutting operation and the polishing operation can be done.
The various methods can be explained below.
2. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 4 |
Fig.no 1.2 Flame cutting operation
Flame-cutting equipment consists of a nozzle connected to hoses that connect to tanks of gas. Most
often the gasses are oxygen and acetylene. Regulating the pressure of the gasses using the pressure gauges
attached to the tanks adjusts the temperature of the flame. Thicker steel needs a more intense flame to make the
cut.
1.1.3 Plasma Cutting Operation:
Plasma cutting starts by clamping a ground cable onto the sheet of metal. Compressed air or a gas such
as nitrogen or argon is blown at extreme high speed out of the nozzle of the plasma torch, which contains an
electrode. Moving the nozzle close to the metal creates a high-frequency electrical arc that travels through the
compressed air, superheating it. The compressed air turns to plasma, a gas that has been energized to the point
that some electrons break free. Adding more electricity makes the plasma hotter.
Fig.no 1.3 Plasma cutting operation
Portable plasma torches are used for smaller jobs. The bulk of plasma cutting is left to industrial mass
production applied to large plates of steel. A programmed robotic arm moves the nozzle over the steel, making
cuts at predetermined points. The edges of a plasma cut need grinding to take off the burrs, which are solidified
drops of melted steel.
1.1.4 water-Jet Cutting:
Water jet cutting machines are used in industry for mass production. Water is forced through a pinhole
in the end of a diamond or sapphire nozzle at pressures up to 60,000 pounds per square inch. The stream that
comes out of the nozzle can cut through materials such as plastic, rubber and fiberglass. Adding a fine abrasive
like garnet in the water stream adds more force. which will cut through aluminum, stainless steel and titanium.
3. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 5 |
Fig.no 1.4 water jet cutting
Cuts are clean and accurate using a waterjet process. The cutting produces no heat to affect the metal,
eliminating the need for grinding. Water from the cut is collected underneath, filtered and reused in the cutting
process.
1.1.5laser-Cutting Process:
Laser cuts hit the metal with a tightly focused laser beam that heats the metal and forms a melt
capillary (a tube with a very small diameter) through the metal. A jet of gas ejects molten metal from the back of
the steel during the cuts. Cuts are accurate, with no need for finishing off the edges before welding is done.
Fig.no 1.5 laser cutting operation
Cutting the steel with a laser is accomplished in one of two ways: moving the laser beam over the steel
or moving the steel under a fixed-position laser beam. Computer programs control the movement during the
cutting process, creating accurate cuts.
1.1.6shear-Cutting:
Shearing is a process of brute force that exceeds the strength of the steel, causing it to separate at the
cutting location. A sheet of steel is placed on a table with a blade on the edge. A blade above the steel is thrust
down, cutting the steel in a straight line the way a pair of scissors cuts material. There is a small gap between the
upper and lower blades to allow for stress on the steel.
4. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 6 |
Thin sheets of steel like duct work metal can be cut using a foot press shear. Thicker metals need the
force of hydraulics. Before the metal separates, it gets bent a little over the bottom die, which leaves a sharp
edge that needs
Fig.no 1.6 shear cutting
grinding. Fabrication shops use shears to cut steel down to size before forming it into parts used for products.
1.2 TYPES OF POLISHING OPERATIONS:
Hand polishing
Mechanical polishing
Electro polishing
Using special cleansers
1.2.1HAND-POLISHING OPERATION:
Those who wish to polish steel at home with household products have several options. First, for mildly
stained steel, water may be all that is needed to restore the metal to a natural shine. Soak a clean cloth in warm
water and wipe down the fixture that needs polishing. It is important to wipe the water with another clean, dry
cloth before the water has time to dry. Microfiber cloths are best for this method.
Fig.no 1.7 hand polishing
Household cleaners such as glass cleaners or ammonia can also help to clean steel. Newspapers or
clean cloths are acceptable for wiping the product onto and off the steel. It may be necessary to wipe the
chemicals off with warm water and another dry cloth.
5. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 7 |
A mix of apple cider and vinegar or olive oil and club soda are steel cleaning options for those looking
for a more eco-friendly solution. Mixing baking soda and water into a paste, coating the steel, rinsing with warm
water and drying with a clean cloth is another effective home polishing method.
1.2.2 Mechanical-Polishing Operation:
For moderately tarnished steel, consider mechanical polishing. A rag wheel or a power buffer gets
quick results. Put a coat of special polish on the item, then use the power buffer to lightly apply pressure. When
using such equipment, make sure all hair, jewelry, etc., are out of the way. Wearing eye protection is a good
idea.
Fig.no 1.8 mechanical polishing
1.2.3 Electro-Polishing:
For products in need of serious attention, electropolishing is a viable option. Electropolishing smooths
the surface of a metal object. A surface layer of metal is removed delicately from the object; it is not cleansed or
wiped down. The object is immersed in an electrolyte and subjected to an electrical current. The product does
not only come out shiny and polished, but smooth.
1.2.4 Using Special Cleansers:
Most commercial products for steel polishing are made for stainless steel. Look for products without chlorine,
and avoid using brushes or scrubbing pads, as this could damage steel instead of restore it.
Thus these are the different types of cutting and polishing operations used generally.
II. COMPONENTS USED
2.1motor:
Motor is a device that creates motion. It usually refers to an engine of some kind. The generally used type of
motors and its general use is given as follows:
o Electric motor is a machine that converts electricity into a mechanical motion.
o Ac motor is an electric motor that is driven by alternating current
Synchronous motor is analternating current motor distinguished by a rotor spinning with coils passing
magnets at the same rate as the alternating current and resulting magnetic field which drives it.
Induction motor, also called a squirrel-cage motor, a type of asynchronous alternating current motor where
power is supplied to the rotating device by means of electromagnetic induction.
Dc motor is an electric motor that runs on direct current electricity
Brushed DC electric motor is an internally commutated electric motor designed to be run from a direct current
power source. Brushless DC electric motor is a synchronous electric motor which is powered by direct current
electricity and has an electronically controlled commutation system, instead of a mechanical commutation
system based on brushes. Electrostatic motor is a type of electric motor based on the attraction and repulsion of
electric charge.
6. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 8 |
Engines which are very commonly called "motors.
Starter motor is for starting an internal-combustion engine of a vehicle. Stepper motor is a type of electric
motor capable of rotating its output shaft in equally spaced fractions of a full rotation, known as steps.
Internal fan-cooled electric motor is an electric motor that is self cooled by a fan, typically used for motors with
a high energy density.
Actuator is a mechanical device for moving or controlling a mechanism or system
Hydraulic motor is a machine that converts the energy of pressurized liquid flow into mechanical motion
Rocket motor usually refers to solid rocket engines.
Molecular motor the agents of movement in living organisms.
Synthetic molecular motor, molecular machines capable of rotation under energy input.
Nanomotor, a molecular device capable of converting energy into movement.
Pneumatic motor, a machine that converts the energy of compressed air into mechanical motion.
A brief description of the most commonly used type of motors is given as follows:
Dc motors:
A simple DC motor has a coil of wire that can rotate in a magnetic field. The current in the coil is
supplied via two brushes that make moving contact with a split ring. The coil lies in a steady magnetic field. The
forces exerted on the current-carrying wires create a torque on the coil.
Fig.no 2.1 dc motor
The force F on a wire of length L carrying a current i in a magnetic field B is iLB times the sine of the
angle between B and i, which would be 90° if the field were uniformly vertical. The direction of F comes from
the right hand rule. The two forces shown here are equal and opposite, but they are displaced vertically, so they
exert a torque. The coil can also be considered as a magnetic dipole, or a little electromagnet, as indicated by the
arrow SN: curl the fingers of your right hand in the direction of the current, and your thumb is the North pole. In
the sketch at right, the electromagnet formed by the coil of the rotor is represented as a permanent magnet, and
the same torque (North attracts South) is seen to be that acting to align the central magnet. The angular
momentum of the coil carries it past this break point and the current then flows in the opposite direction, which
reverses the magnetic dipole. So, after passing the break point, the rotor continues to turn anticlockwise and
starts to align in the opposite direction. In the following text, I shall largely use the 'torque on a magnet' picture,
but be aware that the use of brushes or of AC current can cause the poles of the electromagnet in question to
swap position when the current changes direction.
The torque generated over a cycle varies with the vertical separation of the two forces. It therefore
depends on the sine of the angle between the axis of the coil and field. However, because of the split ring, it is
always in the same sense. The animation below shows its variation in time, and you can stop it at any stage and
check the direction by applying the right hand rule.
Ac Motor:
With AC currents, we can reverse field directions without having to use brushes. This is good news,
because we can avoid the arcing, the ozone production and the ohmic loss of energy that brushes can entail.
Further, because brushes make contact between moving surfaces, they wear out.
7. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 9 |
The first thing to do in an AC motor is to create a rotating field. 'Ordinary' AC from a 2 or 3 pin socket
is single phase AC--it has a single sinusoidal potential difference generated between only two wires--the active
and neutral. With single phase AC, one can produce a rotating field by generating two currents that are out of
phase using for example a capacitor. In the example shown, the two currents are 90° out of phase, so the vertical
component of the magnetic field is sinusoidal, while the horizontal is cosusoidal, as shown. This gives a field
rotating counterclockwise. In this animation, the graphs show the variation in time of the currents in the vertical
and horizontal coils. The plot of the field components Bx and By shows that the vector sum of these two fields is
a rotating field. The main picture shows the rotating field. It also shows the polarity of the magnets: as above,
blue represents a North pole and red a South pole.
Fig.no 2.2 ac motor
If we put a permanent magnet in this area of rotating field, or if we put in a coil whose current always
runs in the same direction, then this becomes a synchronous motor. Under a wide range of conditions, the motor
will turn at the speed of the magnetic field. If we have a lot of stators, instead of just the two pairs shown here,
then we could consider it as a stepper motor: each pulse moves the rotor on to the next pair of actuated poles.
Please remember my warning about the idealised geometry: real stepper motors have dozens of poles and quite
complicated geometries.
Induction Motor:
An induction or asynchronous motor is an AC electric motor in which the electric current in
the rotor needed to produce torque is induced by electromagnetic induction from the magnetic field of
the stator winding. An induction motor therefore does not require mechanical commutation, separate-excitation
or self-excitation for all or part of the energy transferred from stator to rotor, as in universal, DC and
large synchronous motors. An induction motor's rotor can be either wound type or squirrel-cage type.
Fig.no 2.3 induction motor
8. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 10 |
Three phase squirrel cage induction motors are widely used in industrial drives because they are
rugged, reliable and economical. Single-phase induction motors are used extensively for smaller loads, such as
household appliances like fans. Although traditionally used in fixed-speed service, induction motors are
increasingly being used with variable-frequency drives (VFDs) in variable-speed service. VFDs offer especially
important energy savings opportunities for existing and prospective induction motors in variable-
torque centrifugal fan, pump and compressor load applications. Squirrel cage induction motors are very widely
used in both fixed-speed and VFD applications.
2.2bevel Gear:
Two important concepts in gearing are pitch surface and pitch angle. The pitch surface of a gear is the
imaginary toothless surface that you would have by averaging out the peaks and valleys of the individual teeth.
The pitch surface of an ordinary gear is the shape of a cylinder. The pitch angle of a gear is the angle between
the face of the pitch surface and the axis.
The most familiar kinds of bevel gears have pitch angles of less than 90 degrees and therefore are cone-
shaped. This type of bevel gear is called external because the gear teeth point outward. The pitch surfaces of
meshed external bevel gears are coaxial with the gear shafts; the apexes of the two surfaces are at the point of
intersection of the shaft axes.
Fig.no 2.4 bevel gear
Bevel gears that have pitch angles of greater than ninety degrees have teeth that point inward and are called
internal bevel gears.
Bevel gears that have pitch angles of exactly 90 degrees have teeth that point outward parallel with the
axis and resemble the points on a crown. That's why this type of bevel gear is called a crown gear. Bevel gears
are classified in different types according to geometry:
Straight bevel gears have conical pitch surface and teeth are straight and tapering towards apex.
Spiral bevel gears have curved teeth at an angle allowing tooth contact to be gradual and smooth.
Zero bevel gears are very similar to a bevel gear only exception is the teeth are curved: the ends of each
tooth are coplanar with the axis, but the middle of each tooth is swept circumferentially around the gear.
Zero bevel gears can be thought of as spiral bevel gears (which also have curved teeth) but with a spiral
angle of zero (so the ends of the teeth align with the axis).
Hypoid bevel gears are similar to spiral bevel but the pitch surfaces are hyperbolic and not conical. Pinion
can be offset above or below the gear centre, thus allowing larger pinion diameter, and longer life and
smoother mesh, with additional ratios e.g., 6:1, 8:1, 10:1. In a limiting case of making the "bevel" surface
parallel with the axis of rotation, this configuration resembles a worm drive.
Two bevel gears in mesh is known as bevel gearing. In bevel gearing, the pitch cone angles of the
pinion and gear are to be determined from the shaft angle, i.e., the angle between the intersecting shafts. The
9. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 11 |
bevel gear has many diverse applications such as locomotives, marine applications, automobiles, printing
presses, steel plants, railway track inspection machines, etc.
For examples, see the following articles on:
Bevel gears are used in differential drives, which can transmit power to two axles spinning at different
speeds, such as those on a cornering automobile.
Bevel gears are used as the main mechanism for a hand drill. As the handle of the drill is turned in a
vertical direction, the bevel gears change the rotation of the chuck to a horizontal rotation. The bevel gears
in a hand drill have the added advantage of increasing the speed of rotation of the chuck and this makes it
possible to drill a range of materials.
Fig 2.5 bevel gear
The gears in a bevel gear planner permit minor adjustment during assembly and allow for some
displacement due to deflection under operating loads without concentrating the load on the end of the tooth.
Spiral bevel gears are important components on rotocrafts drive systems. In this application, spiral bevel
gears are used to redirect the shaft from the horizontal gas turbine engine to the vertical rotor.
The Following Are The Advantages Of A Bevel Gear:
This gear makes it possible to change the operating angle.
Differing of the number of teeth (effectively diameter) on each wheel allows mechanical advantage to be
changed. By increasing or decreasing the ratio of teeth between the drive and driven wheels one may
change the ratio of rotations between the two, meaning that the rotational drive and torque of the second
wheel can be changed in relation to the first, with speed increasing and torque decreasing, or speed
decreasing and torque increasing.
The following are the disadvantages of using a bevel gear:
One wheel of such gear is designed to work with its complementary wheel and no other.
Must be precisely mounted.
The shaft‟s bearings must be capable of supporting significant forces
2.3ball Bearing:
The purpose of a ball bearing is to reduce rotational friction and support radial and axial loads. It
achieves this by using at least two races to contain the balls and transmit the loads through the balls. In most
applications, one race is stationary and the other is attached to the rotating assembly (e.g., a hub or shaft). As
one of the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling they have a
much lower coefficient of friction than if two flat surfaces were sliding against each other.
Ball bearings tend to have lower load capacity for their size than other kinds of rolling-element
bearings due to the smaller contact area between the balls and races. However, they can tolerate some
misalignment of the inner and outer races.
Although roller bearings had been developed since ancient times, the first modern recorded patent on
ball bearings was awarded to Philip Vaughan, aWelsh inventor and ironmaster who created the first design for a
ball bearing in Carmarthen in 1794. His was the first modern ball-bearing design, with the ball running along a
groove in the axle assembly.
10. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 12 |
Jules Suriray, a Parisian bicycle mechanic, designed the first radial style ball bearing in 1869, which
was then fitted to the winning bicycle ridden byJames Moore in the world's first bicycle road race, Paris-Rouen,
in November 1869.
Fig.no 2.5 ball bearing
There are several common designs of ball bearing, each offering various trade-offs. They can be made
from many different materials, including: stainless steel, chrome steel, and ceramic (silicon nitride (Si3N4)). A
hybrid ball bearing is a bearing with ceramic balls and races of metal.
Applications:
In general, ball bearings are used in most applications that involve moving parts. Some of these applications
have specific features and requirements:
Hard drive bearings used to be highly spherical, and were said to be the best spherical manufactured shapes,
but this is no longer true, and more and more are being replaced with fluid bearings.
German ball bearing factories were often a target of allied aerial bombing during World War II such was
the importance of the ball bearing to the German war industry.
In horology, the company Jean Lassale designed a watch movement that used ball bearings to reduce the
thickness of the movement. Using 0.20 mm balls, the Calibre 1200 was only 1.2 mm thick, which still is the
thinnest mechanical watch movement.
Aerospace bearings are used in many applications on commercial, private and military aircraft including
pulleys, gearboxes and jet engine shafts. Materials include M50 tool steel (AMS6491), Carbon chrome steel
(AMS6444), the corrosion resistant AMS5930, 440C stainless steel, silicon nitride (ceramic) and titanium
carbide coated 440C.
Skateboard wheels each contain two bearings, which are subject to both axial and radial time-varying loads.
Most commonly bearing 608-2Z is used (a deep groove ball bearing from series 60 with 8 mm bore
diameter)
Yo-Yos there are ball bearings in the center of many new, ranging .
2.4cutting Blade:
Circular saw blades put the power of the saw where it's needed, so the right blade is a key to the
success of the project. Just as there are different saws and different project materials, there are different circular
saw blades – each suited to a tool and a task.
11. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 13 |
Fig.no 2.6 blade parts
There are four important parts on standard circular saw blades:
Tips bite into the work piece.
Shoulders support the tips
Gullets remove material from the work piece. Deeper gullets remove more material with each pass, while
more shallow gullets create a finer cut.
Expansion slots help prevent the blade from warping as it expands and contracts during use. The end result
is less vibration and a straighter cut.
Other features you might see on a circular saw blade include heat vents which aid in reducing vibration
and an antifriction coating, which decreases buildup on the blade. A blade may also have a diamond
knockout you can remove to allow you to use the blade on a saw with a corresponding shaft.
In addition to the standard toothed blades, there are also continuous rim blades that do not have the
typical tip / gullet configuration. Blades that cut materials such as concrete, brick and tile often have a
continuous rim.
More teeth on a toothed circular saw blade produce a smoother cut, while fewer teeth allow a blade to quickly
cut through material
Circular Saw Blade Materials
The materials from which saw blades are manufactured play a significant role in the life and performance of the
blade. There are several material types you will commonly see:
Steel blades are inexpensive and work well for cutting softwood, but they dull quickly in hardwood.
High-speed steel blades (HSS) are harder than steel blades and stay sharper longer.
Carbide blades have carbide tips attached to their teeth. They‟re more expensive than other blades but stay
sharp much longer than steel or high-speed steel.
Diamond blades use diamond-tipped teeth designed for cutting ceramic tile, glass and concrete.
Abrasive blades are made of rough material and are for cutting concrete, brick, cinder block and other
masonry materials and metals.
Circular Saw Blade Types
Some circular saw blades are suited for stationary tools like table saws and compound miter saws,
while others are suited for handheld circular saws. Know which blade your cutting tool will accept and make
sure the blade you are considering is correct for the tool you'll be using.
It's also important to know what kind of material you'll be cutting and to match the material to the
capability of the blade. In addition, some blades are suitable for dry cutting only while some are suitable only
for wet cutting. Others are appropriate for either wet or dry applications.
Some examples of blade types and uses are below. Always follow the saw and blade manufacturers' instructions
for use, safety, compatible blade diameter for the saw and materials you can cut with a blade.
Thin Kerf:
This types of blades are used for cutting dimensional or engineered lumber. It has a thin profile for easy
cutting and less material waste. This types of blades are used to cut the wooden materials. The blade has a kerf
12. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 14 |
which is sharp and it cuts the materials.the kerf is placed on the tooth at certain angle which facilitates the
cutting.
Fig.no 2.7 thin kerf
Abrasive cut-off blades:
Allied's Abrasive Cut-Off Blades are specially formulated for metallurgical sectioning. Aluminum
oxide, silicon carbide, diamond or CBN (cubic boron nitride) abrasives are offered in various bond types for
sectioning a wide varietyof materials. Choosing the right blade for the right material is crucial inreducing
thermal and structural deformation.
Protective arbor inserts are supplied on resin and rubber/resin blades. All blade arbor holes fit BOTH
32 mm and 1-1/4" spindle arbors. All blades are precision ground to slightly less than the stated diameter to
universally fit all makes and models of cutting machines. Blotters are supplied to shield vibration from the metal
flange and help protect the blade from breaking during use.
Fig.no 2.8 abrasive cut-off blade
Resin bonded blades cut cooler with less resistance and friction and do not emit a burned rubber odor
as with the rubber bonded blades. Rubber bonded blades are ideal for production environments where durability
and longer life are desired.
Concrete cutting blades:
13. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 15 |
Circular saw blades are made from all kinds of materials and have different types of teeth and blades.
Each combination of material and style yields a blade that is ideal for a certain purpose. For instance, steel
circular saw blades are great for slicing through softwood, but they wear our quickly if you try to cut hardwood
with them. And the more teeth on the blade, the easier it'll slice through certain materials. To cut plywood,
you're better off with 100 or more teeth, but to cut across the grain of regular wood, you can make a smooth cut
starting out with just 48 teeth [source: Lowe‟s]. Plus, your saw may be better for certain tasks depending on
where the handle, motor and blade are in relation to each other.
Fig.no 2.9 concrete cutting blade
To cut through concrete, you need a circular saw blade with diamond tips or some other kind of
abrasive blade. As with any replacement blade, when you attach an abrasive blade to your saw, you have to
make sure that it's the right diameter for your tool. A worm-drive style saw where the motor and blade line up
and the handle is toward the back is probably best for a big job like cutting concrete. You also need to make sure
your saw is strong enough. The amp rating on a saw tells you how much power the saw uses, but not how much
it yields. Oddly enough, the price of a saw may be the best indication of its quality and strength When using a
circular saw to cut through concrete, safety should be your first concern. Like in any dangerous task, protective
gear for your eyes and ears is a must. Make sure you're using the right type of blade for the task, and only use an
abrasive blade if your saw has an aluminum or magnesium guard on the material.
Alumina Powder:
EMS's Alumina Powders are accurately controlled for all specs and particle size distribution, assuring
you the best polishing results. The following micron sizes are available: 0.05, 0.3, and 1.0.
Some of the typical applications are
Precision Optics
Metallographic Sections
Electro-Optical Crystals
Silicone Wafers
Ferrite Components
Gem Stones
Acrylic lenses
Type DX Alumina Powder is specially treated to reduce the number of agglomerates (group of particles in each
grade of manufactured alumina). The result is fast polishing and improved quality of the finished products.
III. CONSTRUCTION AND WORKING
3.1construction:
The apparatus is designed to perform the cutting and polishing operation on wood, metal and
composites for square and rectangular components. The construction of this apparatus is too simple. The main
components used for the construction of this apparatus is:
14. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 16 |
Double shaft ac motor
Welded base
Shafts
cutting blades (to cut wood, metal ,tiles and composites)
Polishing disc
Bevel gear
Ball bearings
The whole apparatus is supported by a welded base plate. The double shaft ac motor is placed atop the
base plate along its centre to provide enough space for all the components to be placed on the base plate. The
shaft to the right side of the motor is fitted to a cutting disc and L angled plate to support the feed to be given to
the cutting disc. The cutting disc is fitted to the shaft with the help of a key such that the discs can be changed
according to the convenience of the user. The shaft to the right side of the motor is fitted with a bevel gear. The
bevel gear is used to aid in upward transmission and so another shaft is connected to the bevel gear in the
longitudinal direction. Ball bearings are placed between the longitudinal shaft and the bevel gear in order to
prevent wear and tear of the shaft and gear due to friction and also to provide support to the shaft. A polishing
disc is attached to the longitudinal shaft that arises from the bevel gear. All the components of the apparatus are
welded or bolted to the base metal. The base metal is chosen in such a way as to withstand all the vibrations of
the apparatus and also to support the whole apparatus.
3.2working:
The cutting and polishing apparatus uses a motor for the performance of the cutting and polishing
operation. The two shafts of the motor aid in performing the cutting and polishing operation of the components.
A base metal supports the whole apparatus and the double shaft ac motor is placed along the centre of the base
metal. The motor runs at a speed of 1440 rpm. The shaft to the right side of the motor performs the cutting
operation and the shaft to the left side of the motor performs the polishing operation.
Cutting Operation:
The shaft to the right side of the motor performs the cutting operation. The shaft is connected to the
cutting blades with the help of a key in such a way that the cutting discs can be constantly changed according to
the type of component that has to be cut. A L angle plate is welded to the base plate longitudinally to support the
shaft and also to support the user give the feed to the cutting discs. The cutting action is performed by
introducing the component to the cutting discs manually. Thus the cutting action is performed.
Polishing Action:
The shaft to the left side of the motor performs the polishing action. The shaft is connected to a bevel
gear which allows upward transmission. Another shaft is connected to the bevel gear in the upward direction. A
polishing disc is fitted to the longitudinal shaft. Between the shaft and the bevel gear, ball bearings are placed
which reduce friction between the bevel gear and the shaft and also to support the arrangement. The polishing
action is performed by introducing the component to the polishing disc. The constant rubbing of the polishing
disc to the components will bring a polished appearance to the components. Thus the polishing action has been
performed.
The speciality of this apparatus is that both the cutting and polishing action of the components can be done at
the same time. So the time of action is reduced. Thus, this is the working of cutting and polishing apparatus.
3.3cutting Speed And Feed Rate:
Cutting Speed:
Cutting speed may be defined as the rate (or speed) that the material moves past the cutting edge of the
tool, irrespective of the machining operation used. Cutting speeds are calculated on the assumption that
optimum cutting conditions exist, these include:
Metal removal rate (finishing cuts that remove a small amount of material may be run at increased speeds).
Full and constant flow of cutting fluid (adequate cooling and chip flushing).
Rigidity of the machine and tooling setup (reduction in vibration or chatter).
Continuity of cut (as compared to an interrupted cut, such as machining square section material in a lathe).
Condition of material (mill scale, hard spots due o white cast iron forming in castings).
Feed Rate:
15. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 17 |
Feed rate is the velocity at which the cutter is fed, that is, advanced against the work piece. It is
expressed in units of distance per revolution for turning and boring (typically inches per revolution or
millimetres per revolution). Feed rate is dependant on the:
Surface finish desired.
Power available at the spindle (to prevent stalling of the cutter or work piece).
Rigidity of the machine and tooling setup (ability to withstand vibration or chatter).
Strength of the work piece (high feed rates will collapse thin wall tubing).
Characteristics of the material being cut, chip flow depends on material type and feed rate. The ideal chip
shape is small and breaks free early, carrying heat away from the tool and the work.
3.4advantages & Limitations
Advantages:
Very simple in construction.
Easy to machine materials.
Reduce the usage of large conventional machines.
Can cut hard materials easily.
It can cut up to very smaller allowance as compared to conventional machines.
The machining process is simple.
It is portable and economically cheap
Limitations:
Very skilled labour is required.
It does„nt have any workholding devices.
High concentration is necessary.
There is possibilities of damaging of blade in case of improper feeding.
Only small materials can be machined.
IV. DESIGN CALCULATION
Maximum load = 300kg
Step-1:
Gear ratio =
z2
𝑧1
=
16
10
= 1.6
Step-2:
Tan
𝑡𝑎𝑛−1
(1.6)
Step-3:
Mild steel u =630 N/m𝑚2
Assume life (N) =20000 hrs
No of cycles =60nT
= 240 x 107
cycles
Step-4:
[Mt] = Mt.k.kd
[Mt] = 17.66 x 103
=
60∗3.7∗103
2∗𝜋∗2000
[Mt] = 22.96 x 103
N.mm Mt = 17.66 x 103
N.mm
Step-5:
From P.S.G data book
Eeq = 2.15 x 105
N/m𝑚2
Step-6:
[b] =1.4
kbl
nk
17. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 19 |
Checking
b =
𝑅 𝑖2+1
(𝑅−0.5𝑏)2∗𝑏∗𝑦 𝑣1∗𝑚 𝑡
=
75.47 𝑖 2+1
(75.47−(0.5∗29.93))2∗29.93∗8∗0.355
b =10.89 N/m𝑚2
b < [b]
The design is safe.
Step-13:
Checking
c =
0.72
(𝑅−0.5𝑏)
𝑖2+1
𝑖𝑏
∗ 𝐸𝑒𝑞 ∗ [𝑀𝑡]
1
2
=
0.72
(75.47−(0.5∗27.93))
1.62+1
1.6∗27.73
∗ 2.15 ∗ 105
∗ 22.96 ∗ 103
1
2
c = 169 N/m𝑚2
c < [c ]
Hence the bevel gear has been designed safely
V. COST ESTIMATION
Two shaft motor 3,500
Bevel gear 750
Cutting blades 550
Grinding wheel 80
Poloishing wheels 75
Mild steel base 1,191
L channel 574
Ball bearing 150
Machining cost 1,200
Welding cost 1,150
Transportation cost 1,300
Other allowances 1,500
Total 12,020
Assembled View
18. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 20 |
VI. CONCLUSION
VII.
Thus we have developed a project on “FABRICATION OF CUTTING AND POLISHING
MACHINE” which helps to know how to achieve low cost automation. The capacity of our cutting machine is
to cut all the materials by changing the blades. This machine also facilitates for polishing the materials which
had been cut. The polishing operation is very simple as compared to other conventional machines.
This machine would boom the mass reduction in industries having large conventional machines for cutting
heavy materials. The commercial production of this project is feasible economically.
REFERENCE AND BIBLIOGRAPHY
[1]. Fundamentals of metal cutting and machine tools by B.L.Juneja , Nitin Seth & G.S.Sekhon
19. Fabrication of Cutting and Polishing Machine
| IJMER | ISSN: 2249–6645 www.ijmer.com | Vol. 7 | Iss. 6 | June. 2017 | 21 |
[2]. Metal cutting theory and practice by Stephenson David
[3]. P.S.G data book
[4]. Research report on cutting fluid management by Eva kucharikova &Jozef Peterka
[5]. Design of transmission system by v.Jayakumar