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! Computer-Aided Manufacturing
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Karunya University, Coimbatore, (Tamil Nadu),
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Dr. P. Narendra Mohan
University College of Engineering and
Technology, Acharya Nagarjuna University,
Nagarjuna Nagar Guntur, (Andhra Pradesh),
India
Dr. Muthuramalingam Thangaraj
SRM University, Chennai, (Tamil Nadu), India
Dr P. M. M. Subrahmanya Sarma
VIZAG Institute of Technology, Dakamarri,
Bheemunipatnam Mandal, Visakhapatnam,
India
Dr. S. John Alexis
Kumaraguru College of Technology,
Coimbatore, (Tamil Nadu), India
Dr. Sarang Pande
Faculty of PG and Research, Marwadi
Education Foundation, Rajkot, India
Dr. V Sugumaran
School of Mechanical Engineering and Building
Sciences, VIT University, India
Dr. K R Sivadas
Sree Narayana Gurukulam College of
Engineering, Kadayiruppu, India
Dr. Nataraj J.R
R.V. College of Engineering, Mysore Road,
Bangalore, (Karnataka), India
Dr. D. Siva Prasad
GITAM Institute of Technology,
Visakhapatnam, India
Dr. Sam Paul
Karunya University Coimbatore, (Tamil Nadu),
India
Bo-Wun Huang
China
Dr. Siva Prasad Kondapalli
Anil Neerukonda Institute of Technology &
Sciences, Visakhapatnam, (Andhra Pradesh),
India
Mr. Harish Kumar
Noida International University, Yamuna
Expressway, Greater Noida, (Uttar Pradesh),
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 Manufacturing and Material Processing. This journal is
part of the Engineering Sciences, and is devoted to the scope of present Manufacturing and
Material Processing issues, from theoretical aspects to application-dependent studies and
thevalidationofemergingtechnologies.
This new journal was planned and established to represent the growing needs of Manufacturing and
Material Processing 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 Manufacturing and Material Processing 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 Manufacturing and Material
Processing in general. JournalsPub acts as a pathfinder for the scientific community to published their
papers atexcellently,well-time&successfully.
International Journal of Manufacturing and Material Processing focuses on original high-quality research
in the realm of Computer-aided manufacturing, Medical device design and manufacturing, manufacturing
processes in dental and medical practices, Multi body system dynamics, Control systems, kinematics, and
compliantmechanisms, Electro-mechanicalsystems, Computer-aideddesign.
The Journal is intended as a forum for practitioners and researchers to share the techniques of
Manufacturingand MaterialProcessingand solutionsinthearea.
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
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It is our hope that this fine collection of articles will be a valuable resource for Manufacturing and Material
Processing readers and will stimulate further research into the vibrant area of Manufacturing and Material
Processing.
PuneetMehrotra
ManagingDirector

1. A Comprehensive Study on Optimization of Neural Networks and Global Minimization
M. Aravindh, C. Velmurugan 1
2. Productivity Improvement in a Four Wheeler Seat Manufacturing Industry Using Lean Techniques
B. Senthilnathan, M. Gomathi Prabha 9
3. Review of Optimization Process Parameters in Welding System
N.H. Khan, R.P. Kori 18
4. Effect of Cutting Parameters in Hard Turning on Chip Formation and Machined Surface
S. Choubisa, B.P. Nandawana, M.A. Saloda, M.S. Khidiya 25
5. Risk Assessment and Analysis in a Chemical Industry
M. Ananthu, A.P. Arun 45
Contents

IJMMP (2016) 1–8 © JournalsPub 2016. All Rights Reserved Page 1
International Journal of Manufacturing and Material Processing
Vol. 2: Issue 1
www.journalspub.com
A Comprehensive Study on Optimization of Neural Networks and
Global Minimization
M. Aravindh*, C. Velmurugan
Department of Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India
Abstract
The neural network toolbox is one of the commonly used, commercially available and
powerful software tool for constructing new networks and it forms a inter linkage between
functionalities and their respective objective function. The software is user-friendly, permits
flexibility and convenience in interfacing with other toolboxes in the same environment to
develop a full application and has a wide range of scope in making models with linear and
non-linear functions, without any assumptions and applied in almost every field of science
and engineering. In addition, it underlies in one directional linear function with and without
hard limit, and possesses the responsibility of radial and triangular biasing and suitable for
competitive soft max functions. A wide variety of training and learning algorithms are
supported through neural networks. The functions used in the neural networks are as same as
model of brain and nervous system which are highly parallel and possess high speed
information resemble the brain and a super computer. The functionalities in neural networks
have very simple principles and possess very complex behaviors. In this paper, an attempt is
made to enhance effortless operation of neural networks in a systematic procedure through
MATLAB for optimizing and global minimizing.
Keywords: global minimization, MATLAB, neural networks, optimization, training
INTRODUCTION
An optimization function is defined as the
system which possesses a function for
getting objective values with a valid
constraint equation set and variables that
defines a function. The objective of any
optimization is that find the variables that
lead to an optimal value to find (either
minimum or maximum), while satisfying
all the constraints. [1–3]
Learning of problem domains for neural
network is considered by the factor when a
Input is highly-dimensional discrete or
real-valued (e.g. raw sensor input) and
output in the form of discrete or real
valued which has a vector of values and
considered as a target function, Humans
need not to interpret during the results.[4]
Neural networks can be trained using
local, gradient-based procedures. Such
methods frequently find suboptimal
solutions as local minima. Optimization of
neural network structures and global
minimization methods is applicable for
cost functions have strong influence on all
aspects of network performance. [5]
The structure of neurons is considered
with the input layers, output layers and
hidden layer. Neuron acts as an input
signal when it exceeds a certain amount in
a short time period. Synapses or
connection may vary in strength that

Vol. 2: Issue 1
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Productivity Improvement in a Four Wheeler Seat Manufacturing
Industry Using Lean Techniques
B. Senthilnathan*
, M. Gomathi Prabha
Department of Mechanical Engineering, PSG College of Technology, Coimbatore,
Tamil Nadu, India
Abstract
The industries along with the development of technology became competitive in nature.
Moreover globalization made this scenario even worst. The productivity becomes vital
element with product variety. The four wheeler seat manufacturing industries are badly
affected by productivity issues due to high cycle time, unbalanced workload and improper
layout. Our ultimate aim of this paper is to use lean methodology to improve productivity
without affecting current working pressure in industry. The problems in the current layout
are identified and analyzed through value stream mapping. Then the layout is modified in
sub-assembly and workload is balanced in conveyor line. The results are compared with the
current layout. The results revealed an improvement of 14% in productivity.
Keywords: line balancing and layout optimization, value stream mapping
INTRODUCTION
One of the most important characteristics
of manufacturing is cycle time. The
customers expect their manufacturers to
be responsive in delivering products on
time. So, they are constantly leaning
towards cycle time reduction of all the
processes. Cycle time is an interval of
time, during which a set of consecutive
actions takes place repeatedly which in
turn is defined as the time of longest
operation in a sub-assembly and assembly
line. If the line is balanced properly and
sub-assembly layout is optimized it will
reduce the cycle time. Value stream
mapping is used to identify the NVA
activities.
The four wheeler manufacturing industry
finds problem in assembly section as
cycle time taken by process is irregular
and unbalanced. The scope of this paper
is to use different lean tools such as line
balancing, VSM, layout optimization and
kaizen for improving the productivity by
eliminating NVA activities and reducing
production time.
LITERATURE SURVEY
Line Balancing
Assembly line balancing is the process of
dividing the workloads between stations.
So that workstations have equal time
allotted and less time is wasted.
Santhosh [1]
gave an idea about line
balancing in truck assembly line, which
helps to reduce cycle time of the process.
Shamuvel [2]
found that with help of line
balancing it is possible to improve
productivity and better utilization of
resources.
Johan [3]
identified that there is a less
accuracy of standard time and a poor
work arrangement. In order to overcome
root causes, line balancing is suitable
method.

Vol. 2: Issue 1
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Review of Optimization Process Parameters in Welding System
N.H. Khan*, R.P. Kori
Department of Mechanical Engineering MITS, Gwalior, MP, India
Abstract
This study was based on design of experiment (DOE) using Taguchi method with four
welding parameters namely welding current, welding speed, root gap and electrode angle
considered for experimentation. An orthogonal array of L9 experimental design was adopted
and ultimate tensile strength was investigated for each experimental run. The tensile test was
carried out on extracted welded and unwelded specimens using universal testing machine
(UTM). Microstructures of the welded specimens were carried out and analyzed. Statistical
analysis (ANOVA) and signal to noise ratio were used to study the significant effect of input
parameters on ultimate tensile strength and optimized conditions for the process performance
respectively. The results showed that experiment number 7 has the highest ultimate tensile
strength (UTS) of 487MPa and S/N ratio of 53.74 dB. The S/N ratio of higher value indicates
better characteristic of optimum MMAW process performance. The study shows that the
optimum condition is A3B1C3D2 at welding current 100A, electrode angle of 700, root gap
of 3.3 mm and a welding speed of 3.6 mm/s.
Keywords: optimized conditions, welding parameters, welding processes, work piece
INTRODUCTION
Welding process is very critical to the
development of a nation because it is the
hub on which modern industries revolve.
Gasser et al. [1]
stated that no secondary
process has been and continues to be more
important to the survival, comfort and
advancement of mankind than welding.
According to him, welding has made it
possible to build our world. It is in view of
this that many researchers have employed
various optimization techniques to
improve different welding process
parameters on both semi and full
automated welding processes. Although,
the semi and full automatic welding
processes are more productive, experience
has shown that due to complexity and
economic cost of the equipment and their
operations, the choice of manual metal arc
welding (MMAW) process is very popular
in developing countries. This is so because
of its several advantages such as low cost
and simple operation. The MMAW
process is portable and it can easily be
used in places where other welding
methods are not possible. Manual metal
arc welding is also known as shielded
metal arc welding (SMAW), or stick
welding process. It is one of the oldest and
most widely used arc welding processes.
The process involves the use of arc current
to strike an arc between the base material
and a consumable electrode rod. The
electrode rod is made of a metal that is
compatible with the base material being
welded and it is covered with a flux. The
heat generated melts a portion of the tip of
the electrode, its coating and the base
metal just below the arc. As the coating on
the electrode melts, the flux gives off
vapors that serve as a shielding gas and

IJMMP (2016) 25-44 © JournalsPub 2016. All Rights Reserved Page 25
Vol. 2: Issue 1
www.journalspub.com
Effect of Cutting Parameters in Hard Turning on Chip
Formation and Machined Surface
S. Choubisa*, B.P. Nandawana, M.A. Saloda, M.S. Khidiya
Department of Mechanical Engineering, College of Technology and Engineering, Udaipur, Rajasthan, India
Abstract
Cost effectiveness, increasing demand, high production rates and reliability of the product
have increased the potential of industrial application of hard turning technology during the
past few years. Grinding operation for hard steel component reduces the machining
sequence, the machining time and the specific cutting energy. Hard turning also shows effects
like generation of high temperature, the formation of saw toothed chips. In this thesis,
experimental investigation is conducted in order to study the chip transition using Scanning
Electron Microscopy and chip micro-hardness were conducted to correlate the chip
morphology, cutting forces using micro-hardness tester. The surface integrity of machines
part is also investigated. This study focuses on surface and sub-surface defects and white
layer formation. The machined surfaces are examined using SEM to study effect of different
process parameters on the quality of the machined surface. Cutting forces were measured by
lathe tool dynamometer and ANOVA test were performed to observe the effect of cutting
parameters on cutting forces.
Keywords: AISI D2 steel, chip formation, cutting forces, hard turning, microstructure of
machined surface ANOVA
INTRODUCTION
For aerospace industries high precision
hardened steel is required therefore hard
turning technology has been increased and
now a dayshard turning has been replaced
the grinding processes of hardened steel
components in practice. Improved ceramic
tool and CBN tool have been emerged as
very important cutting for machining of
hardened steel without any coolant. If we
talk economically then it also provides less
–effective time, less cost and most
importantly high precision parts. When
compared to grinding process the
machining time is comparatively 50%
lesser. If the right combination of nose
radii, feed rate, cutting speed, depth of cut
is used then a better surface finish can be
obtained as compare to grinding
operations. Here, it is confirmed that these
tool offers less machining time, higher
surface finish during hard turning but its
mechanism is need to be studied.[1]
During hard turning the designing of
cutting tool is to be considered and these
can be studied by observance of cutting
force at various cutting conditions. In the
current environment, the performance
variables are determined experimentally
using a trial and error method. To obtain
this design plan, it is necessary to estimate
the cutting forces from a basic approach so
that the performance of the cutting tools
and machine tools can be calculated. An
analytical model can also be obtained to
the predicted values. In the process of
hardened machining such as hard turning

Vol. 2: Issue 1
www.journalspub.com
Risk Assessment and Analysis in a Chemical Industry
M. Ananthu1*
, A.P. Arun2
1
Industrial Engineering, Kumaraguru College of Technology, Coimbatore, India
2
Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India
Abstract
Chemical manufacturing sector in India is well established and has recorded a steady
growth in the overall industrial scenario. The chemical and the allied industries are among
the faster growing segments of Indian industry. The risks associated with the chemical
industry are commensurate with their growth. Apart from their utility, chemicals have their
own inherent properties and hazards like flammable, explosive, toxic or corrosive etc.
Several major accidents had occurred in India and around the world killing many lives of
people. Thus safety in a chemical industry is of prime concern and this project deals with
safety in a chemical company (TCC LTD).There are several methods to improve the safety
and minimize the risks like risk assessment, safety models, safety management systems.
Several methods are implemented in the industries with safety standards like OSHA, HSE,
etc. Even though many industries are implementing safety systems with these standards still
injuries and accidents tend to happen due to many reasons. In this project these reasons are
searched and necessary actions are taken by implementing a loss prevention programme so
that the potential risks are detected and eliminated. The objective is to improve safety and
working conditions by carrying out risk assessment in the chemical industry which is
TRAVANCORE COCHIN CHEMICALS Ltd, ERNAKULAM.
Keywords: failure, loss management, occurrence, risk assessment, safety, severity
INTRODUCTION
Organizations often adopt safety
management system or behavior based
system approaches to manage their safety
functions in an attempt to achieve
performance excellence. Safety is a
critical issue in the chemical industry
because chemical plants store and use
large volumes of hazardous materials that
can cause major incidents such as fires,
explosions, and the release of toxic
chemicals.
An effective safety management system is
vital to improve the overall safety of the
industry. In this project a chemical
industry is selected and a loss
management program is implementing to
improve the safety in the firm.
In the past several accidents have taken
place in the plant and generally in all the
chemical industries there is always a risk
of major hazard due to various reasons.[1,2]
A loss management program integrates the
concepts of safety as well as
identification, assessment and control of
both hazards and risks for the express
purpose of reducing harmful risks to
people, environment, assets and
production. In this project one of the
elements in loss management has been
taken and applied in the industry which is
hazard identification and risk assessment

International Journal of Manufacturing and Materials Processing vol 2 issue 1

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