International Journal of Machine Design and Manufacturing vol 2 issue 2

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

From the Editor's Desk
Dear Readers,
We would like to present, with great pleasure, the inaugural volume of a new scholarly
journal, International Journal of Machine Design and Manufacturing. This journal is part
of the Engineering Sciences, and is devoted to the scope of present Machine Design issues,
from theoreticalaspectstoapplication-dependentstudiesand thevalidationofemergingtechnologies.
This new journal was planned and established to represent the growing needs of Machine Design and
Manufacturing as an emerging and increasingly vital field, now widely recognized as an integral part of
scientific and technical investigations. Its mission is to become a voice of the Engineering Science
community,addressing researchersandpractitionersinthisarea.
The core vision of International Journal of Machine Design and Manufacturing in JournalsPub is to
propagate novel awareness and know-how for the profit of mankind ranging from the academic and
professional research societies to industry practitioners in a range of topics in Machine Design in general.
JournalsPub acts as a pathfinder for the scientific community to published their papers at excellently, well-
time&successfully.
International Journal of Machine Design and Manufacturing focuses on original high-quality research in
the realm of Turbomachines, Intelligent machines, Shaft design and bearing selection, Power transmitting
shafts,Advancedvibrations,Tribologyand bearingdesign,etc.
The Journal is intended as a forum for practitioners and researchers to share the techniques of Machine
Design and Manufacturingandsolutionsinthearea.
Many scientists and researchers have contributed to the creation and the success of the Mechanical
Engineering community. We are very thankful to everybody within that community who supported the idea of
creating an innovative platform. We are certain that this issue will be followed by many others, reporting
newdevelopmentsinthefieldofMachineDesignandManufacturing.
This issue would not have been possible without the great support of the Editorial Board members, and we
would like to express our sincere thanks to all of them. We would also like to express our gratitude to the
editorialstaffofJournalsPub,who supported us ateverystageoftheproject.
It is our hope that this fine collection of articles will be a valuable resource for engineering readers and will
stimulatefurtherresearchintothevibrantareaofMachineDesignandManufacturing.
PuneetMehrotra
ManagingDirector

1. Speculative Study of Ball Bearings and Its Related Parts
C. Chinglenthoiba, V. Balaji, B. Abbas, A. Madhan Kumar 1
2. Nontraditional Material Removal Processes for a Variety of Machining Materials
Priyanka Garg 5
3. MEMS and Failures Caused by Tribological Issues in Them
S. Sharmila 9
4. Review on Methodologies Used For Compliant Mechanism
Deepika Bhadauria 13
5. Development of an Effective Uncemented Femoral Stem Implant With CNC Ball End Milling
Sadananda Chakraborty, Bidhan Chandra Biswas, Nirmal Kumar Mandal 18
Contents

IJMDM (2016) 1–4 © JournalsPub 2016. All Rights Reserved Page 1
International Journal of Machine Design and Manufacturing
Vol. 2: Issue 2
www.journalspub.com
Speculative Study of Ball Bearings and Its Related Parts
C. Chinglenthoiba*, V. Balaji, B. Abbas, A. Madhan Kumar
Department of Mechanical Engineering, Mahendra Engineering College, Affiliated to Anna University,
Namakkal, Chennai, India
ABSTRACT
A bearing is a mechanical device used to enable rotational or linear movement, while
reducing friction and handling stress. A bearing is easier to move both in rotary and linear,
and it has a simple structure with internal and external smooth metal surfaces.
Keywords: angular contact, ball bearing, cap
INTRODUCTION
Although the concept of the ball bearing
dates back at least to Leonardo da Vinci,
their design and manufacture has become
remarkably sophisticated. This technology
was brought to its present state of
perfection only after a long period of
research and development. The benefits of
such specialized research can be obtained
when it is possible to use a standardized
bearing of the proper size and type.
However, such bearings cannot be used
indiscriminately without a careful study of
the loads and operating conditions.[1–10]
BEARING WITH BEARING CAP
The bearings are pressed smoothly to fit
into the shafts because if hammered the
bearing may develop cracks. Bearing is
made upon steel material and bearing cap
is mild steel. Ball and roller bearings are
used widely in instruments and machines
in order to minimize friction and power
loss. In addition, the bearing must be
provided with adequate mounting,
lubrication and sealing.[11–17]
Design engineers have usually two
possible sources for obtaining information
which they can use to select a bearing for
their particular application:
a) Textbooks
b) Manufacturers
Catalogs textbooks are excellent sources;
however, they tend to be overly detailed
and aimed at the student of the subject
matter rather than the practicing designer.
They, in most cases, contain information
on how to design rather than how to select
a bearing for a particular application.
Manufacturers’ catalogs, in turn, are also
excellent and contain a wealth of
information which relates to the products
of the particular manufacturer. These
catalogs, however, fail to provide
alternatives – which may divert the
designer’s interest to products not
manufactured by them. Our Company,
however, provides the broadest selection
of many types of bearings made by
different manufacturers.
For this reason, we are interested in
providing a condensed overview of the
subject matter in an objective manner,
using data obtained from different texts,
handbooks and manufacturers’ literature.
This information will enable the reader to
select the proper bearing in an expeditious
manner. If the designer’s interest exceeds
the scope of the presented material, a list

Vol. 2: Issue 2
www.journalspub.com
Nontraditional Material Removal Processes for a Variety of
Machining Materials
Priyanka Garg*
University of Madras, Tamil Nadu, India
ABSTRACT
Some non-conventional machining methods which are widely accepted in material processing
are ultrasonic machining and laser-beam machining. Since these technologies are
implemented for machining of variety of materials, they are extensively used to meet extra
required machining conditions. When these processes are employed properly, they offer
many advantages over non-traditional machining processes. The present paper gives a
precise description about the two machining technologies and their uses.
Keywords: composite material, microstructures, milling, laser-beam machining, non-
traditional machining process
INTRODUCTION
USM is mechanical material removal
process or an abrasive process used to
erode holes or cavities on hard or brittle
workpiece by using shaped tools, high
frequency mechanical motion and an
abrasive slurry. USM offers a solution to
the expanding need for machining brittle
materials such as single crystals, glasses
and polycrystalline ceramics, and
increasing complex operations to provide
intricate shapes and workpiece profiles. It
is therefore used extensively in machining
hard and brittle materials that are difficult
to machine by traditional manufacturing
processes. The hard particles in slurry are
accelerated toward the surface of the
workpiece by a tool oscillating at a
frequency up to 100 KHz – through
repeated abrasions, the tool machines a
cavity of a cross section identical to its
own. A schematic representation of USM
is shown in Figure 1.[1–4]

Vol. 2: Issue 2
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MEMS and Failures Caused by Tribological Issues in Them
S. Sharmila*
University of Madras, Chennai, India
ABSTRACT
Because of large surface-to-volume ratios and low restoring forces, unwanted adhesion and
friction can dominate the performance of microelectromechanical systems (MEMS) devices.
To guarantee the function and reliability of MEMS devices, tribologists must understand the
origins of adhesion, friction, and wear over a broad range of length scales from the
macroscopic to the molecular. In this article, we present an overview of challenges,
successes, and initial steps toward a fundamental understanding of MEMS
microelectromechanical systems.
Keywords: adhesion, device fabrication, microelectromechanical systems, macroscale,
tribological issues
INTRODUCTION
The manufacture of many types of
extremely small devices and structures,
such as microelectromechanical systems
(MEMS) is possible due to recent
developments in micro-fabrication
technology.
A development of microtribology is
presented by investigating surface and
interfacial forces. Adhesion and friction
will be discussed with not only an
emphasis on theory, but also a look at
experimental tools used to measure these
properties in the laboratory, and an
explanation of wear in MEMS actuators
will follow.
Because these devices must react to
mechanical signals, many of these use
construction topologies that require
physical motion. For example, an
accelerometer-type device translates the
motion of a suspended proof mass into
capacitance which is later converted to a
voltage output.[1]
Similarly, micromechanical mirrors must
be able to deflect a light beam in a
particular direction. Suspended
micromachined structures such as plates
and beams are commonly used in the
manufacturing of pressure and acceleration
sensors. These structures are typically
made by forming a layer of the plate or
beam material on top of a sacrificial layer
of another material and etching the
sacrificial layer. These microstructures
have relatively large areas, but a very
small stiffness.
At the same time these elements are
fabricated a few microns from their
supporting substrate. The combination of
these three characteristics makes MEMS
devices highly susceptible to surface
forces which can cause the suspended
members to deflect toward the substrate.
Under certain conditions, the elastic
member can collapse and permanently

Vol. 2: Issue 2
www.journalspub.com
Review on Methodologies Used For Compliant Mechanism
Deepika Bhadauria*
I.P.University, New Delhi, India
ABSTRACT
This paper gives a brief overview and comparison of the methods applied in the design of
compliant mechanisms. Since the first research works on the subject appeared in the 1980s,
several methods have being conceived to analyze and design these mechanisms that gain part
of their motion from the deflection of flexible members rather than from movable joints only.
The scope and limitations of the most widely used design tools in the field are also presented
in the article.
Keywords: compliant mechanism, flexible structure, structural optimization, joints
INTRODUCTION
A mechanism is a mechanical device used
to transfer or transform motion, force, or
energy. Traditional rigid-body
mechanisms consist of rigid links
connected at movable joints. The linear
input is transformed to an output rotation,
and the input force is transformed to an
output torque. This mechanism transfers
energy from the input to the output
(neglecting friction losses) due to which,
the output force may be much larger than
the input force, but the output
displacement is much smaller than the
input displacement. Structures may also
consist of rigid links connected at joints,
but relative motion is not allowed between
the links. Since a structure does not have
mobility, it does not perform work
(Figures 1, 2).[1]
Mechanisms in nature customize their
shape, their mechanical geometry, to
maintain optimal performance under
changing conditions in a dynamic
environment. This is possible since natural
bodies are essentially single-piece
compliant mechanisms in that their various
components grow out of one another or are
bonded with self-renewing transitional
surfaces. Such compliant designs are
inherently robust since fatigue stresses are
distributed throughout the entire form and
thus strains are disbursed or absorbed
during normal operation.
Fig. 1. The portion of a reciprocating
engine. Source:
https://compliantmechanisms.byu.edu/cont
ent/intro-compliant-mechanisms.
Fig. 2. Vice grips. Source:
https://compliantmechanisms.byu.edu/cont
ent/intro-compliant-mechanisms.

IJMDM (2016) 18-33 © JournalsPub 2016. All Rights Reserved Page 18
Vol. 2: Issue 2
www.journalspub.com
Development of an Effective Uncemented Femoral Stem Implant
With CNC Ball End Milling
Sadananda Chakraborty*, Bidhan Chandra Biswas, Nirmal Kumar Mandal
Mechanical Engineering Department, National Institute of Technical Teachers’ Training and Research,
Salt Lake City, Kolkata, India
ABSTRACT
Now a days uncemented total hip replacement (THR) is mostly used in surgery of hip joint.
Quality and reliability of an uncemented femoral stem depends on many factors. The effect of
roughness of the implant on the stress distribution, Von Mises Stress of the implanted femur
with varying frictional co-efficient ranges from 0.2 to 0.4 have been studied through finite
element analysis using commercial finite element analysis package ANSYS. Machining of the
implant is very important because there are so many factors likes, quality of the product,
combination of tool-work piece material, machinability of the work material, productivity etc
that depends on performance. The aim of the present study is to find out the optimum
significant parameters of the machining operation of femoral stem implant for optimum
surface roughness. SS316L has been taken as the work material as it is widely used as hip
implant. Ball end milling cutter of coated carbide has been chosen as the cutting tool as it is
used in the finish cut of complex shapes. Speed, feed rate and Step over are taken as the
cutting parameters. MINITAB 16 commercial software package is used to determine the
number of experiment through Design of Experiment (DOE). Total 20 no. of experiments are
conducted and the collected data are analyzed to predict the surface roughness through
regression analysis. Significance of input process parameters are tested by Analysis of
Variance (ANOVA). A model equation is formed using coefficients obtained from Analysis of
Variance (ANOVA) and this equation is used to find out optimum process parameters using
Genetic Algorithms.
Keywords: CATIA model, CNC ball end milling, femoral stem implant, GA, secondary
fixation
INTRODUCTION
In hip replacement surgery it has been
found that mainly some bone marrow top
section and head of femur can be replaced.
The total arrangement of these sections
must be secured and comfortable John
Charnley has introduced the use of
polymetacrylate bone cement to secure the
components to original living bone and
high-density polyethylene is used as a
bearing material in THA. This concept of
cemented THA shows very good results
even today. In the first generation of
cemented hips early failure has been
reported mostly of the cemented stem.
These failures has been associated with
localized areas of osteolysis mostly in the
femur caused by the systemic
inflammatory response believed to be a
process by cement particles, a
phenomenon called “cement disease”.
Several investigators therefore proposed
that the future of THA should be the
development of prostheses that are
implanted avoiding the use of cement. This
triggered the development of uncemented

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