RTMT 2015 Natonal Conference Abstract Proceedings

5. ANNA UNIVERSITY
Chennai – 600 025, INDIA
Phone : (O) 2235 2161, 2235 7003
Fax : 91-44-2235 1956
Gram : ANNATECH
Email : registrar@annauniv.edu
Dr. S. GANESAN
REGISTRAR
Dated : 10.04.2015
MESSAGE
I am immensely pleased to know that the Department of Manufacturing Engineering,
College of Engineering, Guindy Campus, Anna University, Chennai is organizing a
National Conference on “Recent Trends in Manufacturing Technology” during 16th and
17th April, 2015.
I have come to know that the objective of this conference is to enrich and strengthen
the knowledge in the field of Manufacturing Engineering through research findings and
input of the knowledge of the experts and I fully endorse this noble objective.
Engineers and Scientists work for betterment of society. Manufacturing Engineers
contribute immensely to the well being of the society by creating wealth, employment,
abundance and affluence. I am sure that the National Conference will provide a forum
for all committed teachers, technocrats and researchers to discuss the advancements
in the area of manufacturing technology.
S. GANESAN

7. COLLEGE OF ENGINEERING GUINDY
ANNA UNIVERSITY
Chennai – 600 025
DEAN Phone : 044 - 2235 8491
Telefax : 044 - 2230 1357
Email : deanceg@annauniv.edu
09th
April, 2015
MESSAGE
I am delighted to know that a National Conference on Recent Trends in Manufacturing
Technology is being organized by the Department of Manufacturing Engineering, College
of Engineering, Guindy campus, Anna University, Chennai during 16th and 17th April,
2015.
In today’s competitive world markets, the success strategy for the manufacturing
industry is the production of defect free, high quality products with low rejection rate.
Focused research and development is inevitable to implement this strategy. Therefore,
this conference, which brings the students, researchers, and experts from industry
together, is most relevant at this juncture.
The Faculty and Students of Department of Manufacturing Engineering deserve
appreciation and congratulations for organizing a grand event of this magnitude in our
Institution.
(Dr. P.NARAYANASAMY)

9. ANNA UNIVERSITY
Chennai – 600 025, INDIA
Dr. L. Karunamoorthy
MESSAGE
A nation’s economic development is directly related to the advancement in the
industrial scenario. This being the situation, enhancement of productivity and quality of
products and processes adopted for manufacturing products is mandatory. This feasible
only by continuous change in the manufacturing sectors by adopting latest technologies
on par with the developed countries. It is indeed right time to conduct conference titled
‘Recent Trends in Manufacturing Technology 2015’, organized by the Department of
Manufacturing Engineering, Anna University, Chennai, as this will provides a platform
for people from institutions, industries and R&D organizations to share their knowledge
and core strengths so that a win-win situation could exist between institutions and
industries. I wish all success for the conference.
Chairman
Faculty of Mechanical Engineering
09th
April, 2015

11. Dr. P. HARIHARAN
Head
ANNA UNIVERSITY
COLLEGE OF ENGINEERING GUINDY
Chennai – 600 025, INDIA
Department of Manufacturing Engineering (DoME)
Ph : +91-44-2235 7711 / 2235 7713 Fax : 2230 1357 email : hari@annauniv.edu
MESSAGE
Manufacturing Engineers who apply scientific principles to production of goods are
key team members in the production of extensive range of products-Automobiles, Railway
Equipment, Air planes, Tractors, Electronics, Surgical instruments, toys to name a few.
They design the processes and systems to make products with required functionality and
high quality available where customers prefer at the best possible price and in ways that
are environmentally friendly.
In this context the conference RTMT 2015 is being organized to enrich and strengthen
the knowledge in the field of Manufacturing Engineering and provides a platform for exchange
of information and generation of new ideas. The organizers have received overwhelming
response to the call of papers, out of which the reviewers have chosen around 40 quality
papers for presentation. We whole heartedly welcome and thank all the Guests, Resource
persons and Participants who have come from far and wide to attend this great conference.
The faculty and students of Department of Manufacturing Engineering who are the
organizers of this conference “Recent Trends in Manufacturing Technology” RTMT 2015
deserveappreciationandcongratulationsfororganizingsuchanimportantNationalConference
and I am sure that this conference will be a grand success to the satisfaction of one and all.
(Dr. P.HARIHARAN)
09th
April, 2015

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RTMT 2015
CHIEF PATRON
Dr.M.RAJARAM
Vice Chancellor, Anna University, Chennai-25
PATRONS
Dr.S.Ganesan
Registrar, Anna University
Dr.P.Narayanasamy
Dean, CEG, Anna University
CHAIRMAN
Dr.P.Hariharan,
Professor and Head, Dept of Manufacturing Engineering (DoME), Anna University
CO-CHAIRPERSONS
Dr.S.Gowri
Prof. and Director -EMMRC, Anna University
Dr.L.Karunamoorthy
Chairman, Faculty of Mech. Engg, Anna University
Dr.G.Arumaikkannu
Professor Dept of Manufacturing Engineering (DoME), Anna University
ADVISORY COMMITTEE
Dr.V.Radhakrishnan, Professor IIST-Trivandrum
Dr.P.V.Mohan Ram, Professor, Mech. Engg. PSG Tech, Coimbatore
Dr.B.Mohan, Prof and Head Mech. Engg, AU
Dr.A.NoorulHuq, Professor, Prod., Engg. NIT – Trichy
Dr.S.Rajendraboopathy, Professor Mech.Engg, AU
Dr.V.Balasubramanian, Professor, Prodn.Engg. Annamalai University, Chidambaram
Prof.A.Jothilingam,Head, Prod.Engg. MIT,AU
Dr. SivanandamAravindan, Professor ,MechEngg IIT – Delhi
Dr.A.Rajadurai,Professor, Prod., Engg MIT,AU
Dr.M.S.Shanmugam, Professor Mech. Engg, IIT-Madras
Dr.L.Vijayaraghavan, Professor Mech. Engg, IIT-Madras
Dr.Bijoy Bhattacharya,Professor, Prod. EnggJadavpur University, Kolkata
Dr. R. Balasubramaniam, Scientist ‘F’, BARC, Mumbai
Dr.A.Velayudham, Scientist 'F',CVRDE, Chennai

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ORGANISING COMMITTEE
Dr.M.Kanthababu, Prof., DoME, AU
Mr.S.Suthagar, Asst. Prof., DoME, AU
Mr.J.UdayaPrakash, TF, DoME, AU
Mr.J.Deepak, TF, DoME, AU
Mr.V.Mohankumar, TF, DoME, AU
COMMITTEE
1. Reception Committee
Convener : Dr.G.Arumaikkannu, Prof., DoME, AU
Members : Ms.G.Sathiya, Office Assistant
Ms.K.K.Megavarthini, PG Student
Ms.O.V.Mythreyi, PG Student
Mr.M.JacksonFenore, PG Student
Mr.M.Thomas Prince, PG Student
Mr.K.Shagul, PG Student
2. Registration Committee
Convener : Dr.M.KanthaBabu, Professor
Members : Mr.V.Mohankumar, Teaching Fellow
Mr.P.Thamizhvalavan, RS
Mr. C.S. Murali, Superintendent
Mr.N.Rajesh Kumar, Prof.Asst.
Mr.M.JacksonFenore, PG Student
Mr.M.Thomas Prince, PG Student
Mr.K.Shagul, PG Student
3. Hall Management Committee
Convener : Dr.A.SureshBabu, Asst. Professor &Mr.S.Suthagar, Asst. Professor
Members : Mr.J.Deepak, Teaching Fellow
Mr.S.V.Perianayagasamy, JTA
Mr.Y.Perumal, Lab Asst.
Mr.T.Raja, Prof.Asst.
Mr.P.Prasanna Kumar, PG Student
Mr.R.Hariharasudhavelan, PG Student

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4. Catering Committee
Convener : Mr.S.Suthagar, Asst. Professor &Mr.J.Udayaprakash, Teaching Fellow
Members : Mr.V.ArunPillai, RS
Mr.S.Sathyanarayanan, Foreman
Mr.A.Prasangam, MOG-B
Mr.S.Vetrivel, Prof.Asst.
Mr.C.Jaganathan, Office Assistant
Mr.V.Sakthi, PG Student
Mr.R.Nirmalkumar, PG Student
5. Sponsorship Committee
Convener : Dr.S.Gowri, Professor & Director, EMMRC
Members : Dr.P.Hariharan & Dr.A.SureshBabu
6. Souvenir/Conference Proceeding Committee
Convener : Dr.A.Azad, Professor
Members : Mr. K.Hariharan, RS
Mr.M.Sugavaneshwaran, RS
Mr.M.Tamizhanban, Prof.Asst.
Mr.D.Adhithyan, PG Student
Mr.R.Srinivasan, PG Student
7. Web/Press/Transport/Accommodation
Convener : Dr.M.Omkumar, Associate Professor
Members : Mr.J.Udayaprakash, Teaching Fellow
Mr.Gopikrishanan, RS
Mr.A.Vijayakumar, Prof. Asst.
Mr.R.Ciddharthan, PG Student
Mr.R.Purushothaman, PG Student

16. 16
About Department of Manufacturing Engineering
The Division of Production Engineering was found in 1968 and in the same year the division began
offering the M.sc.(Production Engineering)programme. The B.E (Production Engineering) programme
was started in 1978 when Anna University was established. In 2002, the Division of Manufacturing
Engineering was upgraded and renamed on as a Department of Manufacturing Engineering (DOME) with
a Department status.
Department of Manufacturing Engineering is currently offering B.E.( Manufacturing Engineering-full
time ), B.E. ( Manufacturing Engineering-Part Time ), M.E. ( Computer Integrated Manufacturing- Full
Time), M.E. ( Computer Integrated Manufacturing-Part Time), M.S.( by research), Ph.D.Programmes. The
faculty of the department specialize in such fields as Micro Machining, Electronics Manufactring, Digital
Manufacturing, Rapid Prototyping, Nano Technology, Composite Materials, Cellular Manufacturing,
Flexible Manufacturing Systems, Quality Management, etc.,
The faculty strength consists of 4 professors, 1 Associate Professors, 2 Assistant Professors, 3 TF, 1
UGC fellowship and 2ACR Fellowships. The Department has 380 UG students, 100 PG students, 40 PhD
scholars. The Department of Manufacturing Engineering is endowed with state of the art Laboratories such
as Advanced Machine Tools Lab, CAMLab, CADLab, Advanced Metrology Lab, Nano TechnologyLab,
Composite Lab, Metallurgy Lab, Machine Tools Lab, etc.,
DoME is well funded by the University (CPDE, Consortium, etc) and by Government of India
agencies. At present the Department is working on two funded projects worth 40 Lakhs. The Graduates of
the department have been well placed in leading industries and educational institutions both in India and
abroad, Government of India Labs, and agencies.
The Department is also strong in research activity and has produced 23 PhDs, 4 M.S.( byResearch)
and at present 40 PhDs are actively involved in research. Since the department has valuable Research
Equipment, Students and Research Scholars from other University Department and other colleges
frequently use these equipment for Project/Research work. Department of Manufacturing Engineering
has one of the best departmental libraries, a state of the art seminar hall. All the faculty members have
been provided wih computer and internet facility. The department is also provided with wi-fi facility. The
students ofthe department have formed the Association of Manufacturing Engineering (AME), which

17. 17
regularly organizes guest lectures, Carrier Guidance Programmes, Symposia and other Co- and Extra
Curricular activies.
The Faculty of the Department have published number of International & National Journals and
Conference Papers. The Department of Manufacturing Engineering is also supported by central facilities
such as Central Library, RCC, AU-FRG CAD/CAM Institute, Central Workshop and other laboratories of
various departments.
The Department of Manufacturing Engineering, with its highly qualified, talented and dedicated
faculty and staff, brilliant students, state of the art Laboratories with an excellent attitude for healthy
growth, is rapidly growing to become one of the best in its field. It aims to find solutionto great challenges
and prepare students for leadership in today’s competitive world.

18. 18
INVITED LECTURES
DAY-1
16-04-2015
Key Note Address:
Lecture 1 Time:10.45am to 11.30am
Precision Machining of Novel Materials For Space & Strategic Applications
Dr.S.V.Ramagopal,
Chief Scientist,
CSIO-CSIR, Chandigarh
Lecture 2 Time:11.30am to 12.15 pm
Recent Trends & New Applications in Ultra Precision Machining
Mr. MurugeshThimmanna
National Sales Manager -Precitech
Precitech / Sterling /TMC
Lecture 3 Time :12.15pm to 1 pm
Optical Metrology based on Multi wavelength Interferometer Technology
J Gabriel Suresh Kumar
Business Development - India & SE Asia
DAY-2
17-04-2015
Key Note Address:
Lecture 1 Time:10.45 am to 11.30am
Recent Trends and new applications in ultra precision machining
Mr.Mike Tanniru
Business Director , Ametek Precitech

19. 19
Session Details
SESSION 1A. DESIGN 16.04.2015 2 pm to 3.30pm
Session Chair : Dr. K Shanmugasundaram Associate Professor, Mechanical Engg.
Mrs.R.Rashia Begum Assistant Professor, Mechanical Engg.
1. Optimal Design of Rotavator Structure
Anbarasu. M, Shanmugasundaram. K
2. Design of Intelligent Electric Vehicle for physically challenged people
Ilakkiya. M, Vaishnavi. S, Kalaiarasi. P
3. Optimisation of Air Chamber Mounting Bracket for Heavy Commercial Vehicle
Ayyanar T., Shanmugasundaram K.
4. Parameter estimation in Surface Radiation Heat Transfer using Optimization Method in Vertical
Plate
Anu Nair.P ,Balakrishnan.P , Karuppasamy K.
5. Design, Fabrication and Analysis of Copper Honey Comb Sandwich Panels
Babu K, Kalaichelvan K, Jothilingam A, Kumaresan G
6. Design and Fabrication of automatic tri-axial winding machine
Vasanth Bharath S. *, Omkumar M.
SESSION 1B.MANUFACTURING PROCESS-OPTIMIZATION 16.04.2015 2 pm to 3.30pm
Session Chair : Dr.M.Rajmohan Associate Professor, Industrial Engg
Dr.M.Omkumar,Associate Professor, Manufacturing Engg.
1. Optimization of Tribological Properties of HybridAluminium Matrix Composites using Taguchi
Technique
Perumal S, Udayaprakash J
2. Experimental analysis and optimization of composition of Al-fly ash composite material to
enhance its wear resistance
Rajesh Babu J.C. , Omkumar M., Jaisingh Durai M.
3. Optimization of Cryogenic Grinding Process Parameters using the application of Grey Relation
analysis
Selva Raja A., Elanchezhian J., Pradeep Kumar M.
4. Parameter Optimization for WEDM of HCHCr- D2 Steel using Box-Behnken Design
Suresh Babu A, Elumalai S

20. 20
SESSION 2A.INDUSTRIAL ENGINEERING 16.04.2015 3.45 pm to 5.15 pm
Session Chair : Dr.T.Paul Robert, Professor, Industrial Engg.
Dr.R.Baskaran, Assistant Professor, Industrial Engg.
1. Estimation of Machine Rates –Pre Engineered Building Components using Activity Based
Costing
Sagotharani K
2. Multi Stage Flow Shop Scheduling using Aco Cuckoo Algorithm to minimize Makespan
Ravianandan M, Omkumar M
3. Shainin Doe Approach for Identifying the Critical Success Factors in Railway Products
Manufacturing Industry
Kokila M, Paul Robert T
4. Improving Defect Removal Efficiency using LSS
Jayalakshmi S, Dillibabu R
5. Application of Lean Six Sigma in Manufacturing of Demu Coaches
Saravanan M., Dillibabu R.
6. Work Flow Management in Construction and Implementation
Vasumathi A.M., Venkateswaran M.
SESSION 2B. MATERIALS JOINING 16.04.2015 3.45 pm to 5.15 pm
Session Chair : Dr.V.S.Senthilkumar, Associate Professor, Mechanical Engg.
Dr.A.Suresh babu, Assistant Professor, Manufacturing Engg.
1. Magnetic Pulse Welding of Dissimilar Materials for Automotive Applications
Kudiyarsan S , Arungalai Vendan S
2. Review of Friction Stir Welding Tools
Balasubramaniyan C., Vijaya Ranjan V. , Saravanaganesh M.
3. Friction Stir Welding of AA6061 Aluminium Alloys with Hollow Cylindrical Sections
Navukkarasan A., Jothilingam A.
4. Effect of Heat Treatment on Micro Structure and Mechanical properties of MIG and TIG welded
304 Stainless Steel
Vinay Prakash K, Radha R
5. Experimental Investigation of Mechanical Properties in Frictional Stir Welding of Dissimilar
Material Joints
Ranjith Kumar L. , Omkumar M.

21. 21
SESSION 3.MATERIAL CHARACTERIZATION 17.04.2015 9.30am to 10.30 am
/SURFACE ENGINEERING
Session Chair : Dr.S.Balasivanandha Prabhu Associate Professor, Mechanical Engg
Mr.S.Suthagar Assistant Professor, Manufacturing Engg.
1. Experimental Analysis on Anti-Corrosion Properties of Mild Steel
Veerapriya.C, Subramanian. N
2. Corrosion andAbrasive Wear behaviour of Detonation Gun Sprayed Coatings of Cr3C2-25NiCr
and WC-(10Co)-4Cr ON 316L Stainless Steel Substrate
Usharani.R, Kanthashoba.M
3. Comparison of Wear Resistance of Plasma Sprayed Ceramic Coating on a Coated and Uncoated
Ti6al4v Grade 5 Substrate
Steve Augustine S., Jeshwanth B., Manivel S., Bragadeeshwaran M., Azad A.
4. Abrasive Water Jet Polishing of D2 Steel and Ti (grade2)
Pradeep N., Hariharan P., Jothilingam A
5. Wear Characterisation of the Solution Treatment of Al-Cu-Ni-Sn-Mg Alloy
Darshan G, Radha.R
SESSION 4.MATERIALS AND PROCESSING-I 17.04.2015 11.30am to 1.00 pm
Session Chair : Dr.K.Kalaiselvan Professor, Ceramic Technology
Mr.S.Suthagar, Assistant Professor, Manufacturing Engg.
1. Comparison of Mechanical Properties of Aluminum Based Metal Matrix Composites
Ramachandran V., Mohankumar V., Thamizhvalavan P., Kanthababu M.
2. Study on the influence of Silicon Carbide Filler on Impact Behaviour of Jute - Glass Fibre
Reinforced Epoxy Hybrid Composites
Sathya Narayanan S., Kumaresan G.
3. Study of Mechanical behavior of Natural based Composite using Coir and Aloe Vera
Yamini S, Shanmugasundaram K
4. Comparison of Mechanical Properties of Al-Si-B4c and Al-Si-Sic Metal Matrix Composites
Sunil Kumar.K, Sriraman.N, Edward Kennedy .Z, Jaii Hareesh.K
5. Micro-Structural and Corrosion behaviour of Co-Extruded Al-Cu Macro Composite
Jaii Hareesh.K., Rajesh Kumar.B , Edward Kennedy.Z , Sriraman.N ,Alphin M.S
6. Material Characteristics of fabricated Reinforced Polymers Composites
Dinagar S., Prem Kumar V.

22. 22
7. Investigation of mechanical properties on Jute fiber-Epoxy reinforced composites
Rajesh babu.J.C ,Jaisingh durai.M
SESSION 5A.MATERIALS AND PROCESSING-II 17.04.2015 2 pm to 3.30pm
Session Chair : Dr.S.Senthil Kumaran Associate Professor, Mechanical Engg
Dr.M.Omkumar Associate Professor, Manufacturing Engg.
1. Estimate and evaluation of mechanical properties of Boron Carbide and titanium dioxide
reinforced Aluminum alloy metal matrix composites
Selva Ganesan C., Stalin B., Arivukkarasan S.
2. Analysis of mechanical properties of Aluminium matrix reinforced with Silicon Carbide and
Titanium Dioxide
Balaji R., Stalin B., Arivukkarasan S.
3. Analysis of Mechanical Properties of Matrix Aluminium Reinforced With Tungsten Carbide
and Silicon Carbide
Ashwin Prabhu G., Stalin B. , Arivukkarasan S.
4. Fabrication of Al ADC12 MMC by using stir casting method
Raja T., Muthukumar V. , Venkatasamy R., Suresh babu .A
5. Processing of Al LM6 MMC by using stir casting method
Ramki D., Muthukumar V. , Venkatasamy R. Suresh babu .A
6. Preparation of sisal fiber composite by compression moulding
Jeeva rathinam M., Muthukumar V. , Venkatasamy R. Antony George Fernando A.
5B.ADVANCED MANUFACTURING TECHNIQUES 17.04.2015 2 pm to 3.30pm
Session Chair : Dr.M.Pradeepkumar Associate Professor, Mechanical Engg
Dr.A.Suresh babu Assistant Professor, Manufacturing Engg.
1. Investigation the Effect of Process Parameters on Electrochemical Micromachining using α--
Titanium
Madhana gopal G., Geetha priyan T., Kalaichelvan K.
2. Review on Pocket Milling using Abrasive Water Jet Machining
Gokul R., Thomas George, Naveenkumar M., Manojanandha V., Rajesh Kumar N., Kanthababu M.
3. Experimental investigations on Pocket Milling of Aluminium Alloy 6061 Using Abrasive Water
Jet Machining
Rajes Ram M, Peter Nithin Emmanuel, Gokul R., Vaddi Seshagiri Rao, Kanthababu M.

23. 23
4. Influence of Corrugated Structure and its Geometrical Parameters on Flexural Properties of
Mulitimaterial 3D Printed Structures
Indarajith J.S.,Nizam Mydeen, Sai Prasaanth, Thangaraj.N., Arumaikkannu G.
5. AStudy on the white layer formation during Hard Turning by CBN, using protecting atmosphere
to improve fatigue life
Abdul Kalam.S , Azad.A , Giri Sankar.S
6. MRR improvement in Micro EDM Drilling using Variable Magnetic Field
Siva Prakash. N, Mythreyi.O.V , Hariharan P.

24. 24
PRECISION MACHINING OF NOVEL MATERIALS FOR SPACE &
STRATEGIC APPLICATIONS
RAMAGOPAL V SAREPAKA
Chief Scientist, CSIR-Central Scientific Instruments Organisation, Chandigarh
sarepaka.vrg@gmail.com
Most of the space and military and commercial applications require lightweight and extremely stable
mirrors, substrates, precision modules and mechanical modules to function under adverse environments. Main
challenges of these systems include very tight budgets in the system development in terms of weight, volume
and foot print while delivering near theoretical performances. Beryllium, titanium and silicon carbide are
commonly used materials, albeit at severe cost penalties in such applications. In view of these severe limitations
on feasibility, development and performance, new materials are explored for meeting the application-specific
development requirements, while meeting stringent performance specifications.
A detailed development study is conducted with extensive design and cost trade-off exercises on high-
performance materials for use as, metal mirror substrates, precision components and other housing sub-systems.
During these studies, it is found that the Aluminium-Silicon (Al-Si) alloy offers a viable and an economical
candidate material for use in these applications. In this discussion, the feasibility of using the Al-Si alloy fir
making light weight and stable systems for space and strategic applications. This material is extensively used
in automotive industry. The very same characteristics exhibited in automotive industry applications make this
alloy an attractive alternative candidate for space and military and commercial applications.
To verify the usability of this material, two mirrors are developed for a space camera system. The figure
and finish of these mirrors are monitored by profilometry, under repeated thermal cycles for dimension
stability. Despite a successful and long record of this material in automobile industry, this alloy is never used
in space systems, and hence offers significant cost and weight advantages in space, strategic and commercial
applications.
The discussion introduces the various aspects of the precision machining, mirror development and the
verification of the dimensional stability and surface quality through a series of thermal loading and unloading
cycles as per the simulated environmental conditions of performance.

25. 25
Fast non-contact high accuracy 3D form measurement of aspheres
including determination decenter and wedge errors
Gernot Berger (1), Jürgen Petter (1), Junji Kumasa (2)
1 : Luphos GmbH, Germany, Business Unit of Taylor Hobson Ltd., UK
2 : Taylor Hobson Ltd, Japan.
Abstract: A method for non-contact 3D form testing of aspheric surfaces is presented including determination
of decenter and wedge errors and lens thickness. The principle is based on the absolute measurement capability
of multi wavelength interferometry (MWLI). The method produces high density 3D data at high accuracies in
short measurement times. The system allows inspection of aspheres without restrictions in terms of spherical
departures, of segmented, ground, or discontinuous optics. The instrument is robust against external vibrations
and can be used on the shop floor.
Keywords: Asphere, metrology, optical testing, profilometer, absolute testing, wedge error, decenter error.
1. Introduction
In order to match special functionalities today’s optics designers tend to create increasingly complex lens
shapes. While production machines can already produce such shapes at accuracies in the range of a few
nanometers, suitable measurement systems are rare. The demands on the employed measurement technology
are manifold: In addition to the absolute form measurement accuracy, which must be significantly better than
±100 nm, high flexibility in terms of the asphericity (i.e. large spherical departures), the base form (e.g.
segmented optics, annular lenses, or asphero-diffractives), and the surface texture (different materials, material
mixes, ground, polished) are required. On top of this, measurement times need to be short and users desire to
assess all form errors including especially wedge and decenter errors. Established instruments are only partly or
not applicable for measuring contemporary optics, either because they are not flexible enough or since the
systems use tactile scanning probes. While parallel measuring interferometers are geometrically limited [1],
tactile probes are slow and often harm the test surface despite very little contact forces [2], especially when
measuring sensitive optics made of e.g. aluminum, germanium, or plastics.
In this contribution a unique and highly flexible approach is presented that enables non-contact profiling of
rotational symmetric optics with diameters from 4 mm up to 420 mm that can exhibit almost unlimited spheric
departures. The specific arrangement of four precision stages in conjunction with a unique reference concept
enables even measuring of objects with steep and fast changing slopes such as “pancake” and “gull wing”
objects without any deterioration in terms of the achievable accuracy. Furthermore, the utilized sensor
technology facilitates measurement of segmented objects, objects with ground surfaces and surfaces that exhibit
steps or discontinuities such as asphero-diffractive lenses. In the following the basic functional principle of the
MWLI sensor technology and the reference concept of the metrology system are introduced. Subsequently,
measurements of various optics are presented and limits of the utilized metrology concept are discussed.

26. 26
2. Sensor technology
2.1 Multi wavelength interferometry
Sophisticated single laser interferometers can provide accuracies of a few nanometers and resolve distance
changes down to the picometer range. However, when using only a single wavelength, one has to count
interference fringes as soon as a distance change is larger than half of the employed wavelength (e.g. approx.
190…390 nm when employing visible light). If continuous signal tracking is not possible the distance
information very easily becomes ambiguous. This serious constraint can be overcome by multi wavelength
interferomtry. In an MWLI several discrete wavelengths are used simultaneously, i.e. several independent
measuring interferometers share a light path. If two different wavelengths, 1 and 2, are used to measure the
same distance, each of the two measurements provides an individual interference signal. These signals exhibit
the characteristics of single wavelength interferometers in terms of high accuracy (approx. /2000) and small
unambiguity intervals (1/2 and 2/2). However, in an MWLI the range of unambiguousness can drastically be
increased by means of calculating the mutual beating frequency of the utilized wavelengths. Its size is given by
half of the artificial wavelength  generated by the beat of 1 and 2:
Λ/2 = (λ2· λ1)/(λ2-λ1) .
In this range a distance variation can be determined absolutely, even when tracking of the distance change is
not possible. The size  is defined by the spectral position of the laser lines. It gets larger for more closely
spaced wavelengths. In real systems the size of the interval allowing absolute measurements can range up to a
few millimeters. Obvious advantage of the purely mathematical analysis of the beat signal is that the precision
of the single wavelength interferometers is maintained while the unambiguous range of the distance
measurement is increased by a thousand times.
The use of MWLI probe technology in an optical metrology system bears a couple of essential benefits. Due to
the enlarged range of unambiguousness the system masters interruptions of the beam during measurements
without the necessity for referencing. This feature opens up the possibility for measuring objects with
discontinuous surfaces, such as segmented lenses or lenses with diffractive structures. In gereral, the system
provides an absolute distance signal for each measurement point on the surface without any deterioration in
terms of accuracy. Furthermore, this capability can also be exploited for implementation of a sophisticated
solution to wedge and decenter error determination of lenses.
2.2 Implemented MWLI technology
In a scanning metrology system capable of measuring the 3D shapes of surfaces either the object or the probe
head or both need to be moved. In order to enable movements of the optical probe it suggests itself that the
employed MWLI systems is to be implemented completely fiber optics based. Actually, in the realized
configuration the light of four independent, highly stabilized lasers operating in the region 1530 nm up to
1610 nm is coupled into an optical fiber and guided to a probe head. The object surface is then illuminated by a
small light spot and reflected or scattered light is recollected by the probe head. These signal waves interfere
with internally generated reference waves, giving rise to independent interference signals, one for each
employed wavelength. After spectral separation and independent detection, the signals are digitized and their

27. 27
information is combined in order to determine the position of the object within the range of half of the artificial
wavelength.
Fig. 1: Schematic setup of a fiber-based multi wavelength interferometer (MWLI) that operates four probes
simultaneously.
The introduced metrology system is designed to achieve its accuracy through a clever reference concept
including 3 reference probes measuring exactly simultaneous with the object probe. Based on the single probe
MWLI system building a multi probe system can be accomplished by utilizing standard fiber components and
additional detector units. As shown in the schematic diagram Fig. 1, first the light of the four lasers is coupled
into one fiber, and then the light is divided into multiple fibers to attach several probes to the system. The
interference signals recorded by each of these probes are evaluated separately. In this way several high
precision distance measurements can be performed truly simultaneously.
3. Optical metrology concept
Fig. 2. Motion axes employed to perform 3D scanning of rotational symmetric optics: probe stages (R, Z, T)
and object stage (C).

28. 28
The MWLI scanning metrology instrument is based on an arrangement of motion stages as shown in Fig. 2.
The MWLI point probe continuously measures the distance to the object surface under test. Objects are rotated
by means of a 360 degree rotary stage (C) while the probe position and orientation are controlled by 2 linear
stages (enabling horizontal (R) and vertical (Z) movements) and 1 rotary stage (T). In standard operation mode
the sensor is presented normal and equidistant to the surface. It is controlled to follow the profile of an ideal
counterpart of the specimen. During a measurement the C stage rotates the object and the other stages move the
probe so as to perform a spiral scan over the whole surface. The resultant point cloud reveals shape deviations
and defects of the object surface. However, when moving the object probe errors of the stages R, Z, and T mix
up with the actually desired form deviation of the object surface. That is, in order to allow reliable assessment
of the object errors, the stage errors need to be compensated. This can be accomplished by the reference
concept that is introduced in the following.
3.1 Reference concept
In order to ensure a high and constant accuracy throughout the whole measurement volume a reference frame
and 3 reference probes are introduced (Fig. 3). In accordance with the Abbe principle, this concept enables
compensation of all first order errors related to the mechanical motion stages of the probes (stage errors that
have direct impact on the distance measured towards the object surface). The highly reproducible errors of the
air-bearing object rotary stage (C) are not actively recorded during the measurement, but can be determined by
calibration. Statistical errors of this stage are not considered. Because the C stage errors are not actively
monitored, the whole concept can be considered as an open loop metrology frame.
Fig. 3. Reference frame and layout of the four motion stages (C, R, T, Z) including the object probe (obj) and 3
reference probes (ref).
3.2 Measurement accuracy
In conjunction with protective elements against air turbulences the concept guarantees an overall form
measurement accuracy in the range of 30..50 nm (3σ). Various experiments performed over several weeks

29. 29
reveal that the reproducibility of results is better than 20 nm (3σ) independent of the actual object shape.
4. Measuring form errors of aspheric objects
In order to conduct measurements, the measurement instrument needs to know the design shape of the optics
under test. The corresponding surface description can be provided, for instance, by means of the radius of
curvature (Roc), the conic constant and the aspheric coefficients. As an example a simple convex asphere is
investigated with a Roc = 20.097 and a diameter of 26 mm. The actual design profile is plotted in Fig. 4. Fig. 5
shows the 3D deviation of this lens from its design shape. In this case the measurement, which was
accomplished in 2:44 min (200 points/mm2
), yields a Roc deviation of 0.54 µm, a Power of -60 nm, a PV of
313 nm, an RMS of 13 nm, and an astigmatism of 174 nm.
Fig. 4. Profile of an aspheric lens sample
Fig. 5. Deviation of the asphere from its design shape
4.1 Alignment requirements
In order to generate reliable, highly accurate measurement results it is obvious that lenses have to be well
aligned in the system. The majority of lenses that have to be measured are either still stuck on an expansion
arbor from the production process or completely unmounted. For lenses still stuck on expansion arbors a
corresponding expansion chuck in the measurement instrument is most desirable, since the set-up process
would be fast and straightforward. On the other hand, unmounted lenses could be aligned by means of 3-jaw
chucks. Although the solution of an expansion arbor in combination with an expansion chuck is easier to use
and provides better alignment accuracies, in both cases lenses will not be perfectly aligned in terms of tilt and
decenter. The questions that crops is “What is the impact of misalignment on the measurement result?”.

30. 30
Fig. 6. BFR, Power and Coma versus decenter when measurement a hemisphere (D = 25 mm) up to 90 degree
(worst case scenario).
In the following the alignment demands in the introduced metrology instrument are assessed in the worst case
scenario of a decentered hemisphere. A calibrated ball is repeatedly measured up to 90 degree while
intentionally increasing the decenter with respect to the C axis. The ball exhibits a form accuracy of λ/20 and
has a diameter of 25 mm. Fig. 6 shows the effect of increasing decenter on the parameters best-fit-radius (BFR),
Power and Coma. It is clearly discernible that misalignment has almost no impact on the determined BFR. Also
the variation of the Power value remains small. Expectedly in this scenario the misalignment has an impact on
the Coma, which slightly downgrades as the decenter increases.
Further investigations indicate that typical aspheres that exhibit smaller slopes, e.g. the one shown in Fig. 4, can
reliably measured up to a decenter of even more than 50 µm without any degradation. That is, the adjustment
accuracy of the above mentioned mounting solutions (either expansion arbor and expansion chuck or 3-jaw
chucks) which are usually in the range of 10 to 30 µm, would be more than sufficient for most measurement
situations.
4.2 Deteremination of wedge and decenter errors
Due to the absolute measurement capability of the employed sensor, it is possible to correlate data obtained on
different surfaces that were measured successively. Based on this basic characteristic a concept is introduced
that enables absolute correlation of the results measured on both sides of optics. In this way it is possible to
determine the object thickness as well as their wedge and decenter errors. In addition, also the lens–mount

31. 31
positioning can be assessed.
Measurement principle
The lens under test is mounted in a special holder comprising reference rings (see Fig. 7). The actual
measurement of the first surface is started as usual. Subsequently the lens with the holder is turned over as
shown in the Fig. 8 and the second surface is measured as usual. In addition to the standard scanning procedure,
the object probe is automatically controlled in a way to measure the exact orientation of each lens surface with
respect to the calibrated reference surfaces of the holder. The measurement steps are depicted in Fig. 8. After
measuring the two reference rings it is straightforward to calculate the exact positioning of the lens surfaces
with respect to the reference surfaces. Tilt and decenter, as well as the elevation of each lens surface are
determined. Hence, after measuring and correlation of the data all geometric errors of the part are accessible.
Fig. 7. Positions of the object probe when measuring one of the object sides: Pos. 1: Object surface; Pos. 2:
Annular reference surface from the same side; Pos. 3: Lateral cylindrical reference surface (runout).
Fig. 8. The turning of the object in the holder with reference surfaces.
Measurement example
Fig. 9 shows the profile of a sample with two aspheric sides that was measured by means of this procedure. The
radii of curvature of the test lens are Roc1 ≈ −28 mm and Roc2 ≈ 30 mm. The deviations of each side from the
corresponding aspheric design shape are described by P2V1 = 182 nm (RMS1 = 60 nm), Power1 = 262 nm and
P2V2 = 162 nm (RMS2 = 37 nm), Power2 = 56 nm, respectively. Based on the measured positioning within the
calibrated holder, the total wedge and decenter errors could be determined to 1.76” and 1.55 µm. The lens
thickness is 6.557 mm. Systematic investigations emphasize that the accuracy of the wedge and decenter
determination mainly depends on the asphericity of the measured surfaces, where stronger asphericity supports
higher accuracies. For most of the contemporary aspheres as well as for the above test sample the accuracy of
wedge and decenter determination is better than ± 0.5” (2σ) and ± 0.5 µm (2σ), respectively.

32. 32
Fig. 9: Lens sample with two aspheric sides used here for testing wedge and decenter determination.
6. Conclusions
This article presents unique concepts for non-contact 3D form testing of aspheric optics. The measurement
principle is based on an optical point probe featuring scanning multi wavelength interferometry (MWLI). The
employed motion stages are optimized for measuring any rotational symmetric optics including aspheres with
steep or drastically changing slopes, or points of inflection, and objects with discontinuities and annular optics.
Furthermore, a the absolute measurement capability of the MWLI sensor in conjunction with a sophisticated
holder enables complete form characterization of optics comprising surface deviation of both sides, wedge error
decenter error, and thickness. The concept can be applied to transparent as well as opaque or specular objects.
Due to a unique reference frame concept the measurement instrument provides high accuracies better than 50
nm also under productions conditions on the shop floor. Measurement times (including object set-up) are
usually short and lay in the range of a few minutes.
References
[1] M. F. Kuechel: Interferometric measurement of rotationally symmetric aspheric surfaces.– In: Proc. SPIE 7389, Optical
Measurement Systems for Industrial Inspection VI, 2009.
[2] F. Meli, A. Küng: AFM investigation on surface damage caused by mechanical probing with small ruby spheres.– In: Meas.
Sci. Technol., Vol. 18, No. 2, pp. 496, 2007.

33. ABSTRACT

35. 35
Optimal Design of Rotavator Structure
Anbarasu. M, ShanmugaSundaram. K
Department of Mechanical Engg., College of Engg., Guindy, Chennai
In the agricultural field Soil preparation is the first and most important operation. One of the best soil
preparing equipment is rotavator. Rotavator has three different major assemblies such as structure, transmission
system and blade assembly. The function of the structure is to accommodate all the parts and to with stand the
different field loads. For the mass production of rotavator structure we should confirm the optimized structure
design with easy manufacturability, less weight and high strength. The present work involves preparing the
various conceptual designs of rotavator structure by applying the standard design principles, DFMA principles
and by applying the stability concepts, selecting the best solution from the various conceptual designs, finding
the geometric dimensions of the each and every component of the structure for the required loading condition
and verifying the design with finite element analysis. The design optimization of rotary tillage tool on the basis
of finite element method and simulation method is done by using CAD-software for the Structural analysis.
The three different types of the rotary tillage tool designs were modeled in the CAD software Pro-E, The static
structural analysis and model analysis were performed in the ANSYS Workbench, The maximum stress and
displacement values in the different parts for the three designs are found and tabulated.All the three designs gave
better results and stress values within the yield limits. The design based on DFMA Principles has less weight
compare to other designs and has the components that can be easily manufacturable. The parts of the stabilized
design of the rotavator by corrected centre of gravity position has reduced stress and displacement values.
Keywords: Rotavator, Rotary Tiller, 3D Modelling, Finite Element Analysis, Von-miss stress, DFMA
Principles, Conceptual Redesigns, Optimization.
Design of Intelligent Electric Vehicle for
physically challenged people
Ilakkiya. M*, Vaishnavi. S, Kalaiarasi. P
Department of Electrical and Electronics Engineering, Dhanalakshmi College of Engg, Chennai.
*ilakkiya05081993@gmail.com
Recent improvement in technology can solve many problems of physically challenged people. There are
lot of person who cannot walk very easily due to illness. For them travelling with safety is a major problem. An
intelligent electric vehicle is thus required to solve their problem. The vehicle is made with lot of technologies
such as obstacle detection, Sonar based obstacle avoidance, traffic signal analysis and semi-automatic control
system for vehicle. This paper proposes a design of completely intelligent electric vehicle for physically
challenged people. The vehicle works based on the voice commands. The vehicle is designed to obey all traffic
signals so that the design is apt for real world.We propose a design of completely intelligent electric vehicle for
blind which can be implemented successfully.
Keywords: Digital Image Processing, Obstacle Avoidance, Sonar, Voice Command.

36. 36
Optimisation of Air Chamber Mounting Bracket
for Heavy Commercial Vehicle
Ayyanar T., Shanmugasundaram K.
Engineering Design Division, Department of Mechanical Engineering,
College of Engineering, Guindy, Anna University, Chennai
sree.ayyan@yahoo.co.in
The competitions in the vehicle manufacturers are very high due to which the overall vehicle cost cannot
be increased but the raw material and the manufacturing costs are increasing day by day. These situations
are to be handled in an appropriate way by the vehicle manufacturer as well as supplier.We are supposed to
design and develop a product without sacrificing the function and performance of the product. The function
and performance of the product are to be verified by doing the validation test. Cost reduction can be done by
many ways for example, product optimisation, material change, manufacturing method change, process change,
etc. Optimisation is found to be one of the best way to reduce the product cost. Optimisation of air chamber
mounting bracket in the Diameter 410 x Lining width 160 S’cam Brake assy is going to be carried out. This
Brake assy is being used for TML LPT2518 vehicle.
Keywords: Chamber bracket, Brake design and safety, IS11852 & ECER13
Parameter estimation in Surface
Radiation Heat Transfer using Optimization
Method in Vertical Plate
Anu Nair.P ,Balakrishnan.P , Karuppasamy K.
Department of Mechanical Engineering,Regional Centre Anna University: Tirunelveli -627 007
kkssurabu2001@yahoo.co.in
Emissivity is a parameter which helps to determine emissive power of a Surface. Much experimental
work in radiation has been done to find out the value of emissivity for different surfaces. The paper
reports the ability of Bayesian Approach and least square method in parameter estimation when radiation
heat transfer is encountered. The aim is to estimate the value of Emissivity of material using Bayesian
optimization method and least square residual method where air is used as a working medium. The steady
temperature time history is mainly used to estimate Emissivity of material in Bayesian and least square
optimization method. The experimental setup has been designed and fabricated. Finally, Estimated Parameter
is compared with Actual benchmark.
Keywords: Radiation Heat transfer, Vertical Plate, Least square residual method,Bayesian

37. 37
Design, Fabrication and Analysis of Copper Honey Comb
Sandwich Panels
Babu K1*
, Kalaichelvan K2
, Jothilingam A3
, Kumaresan G4
Department of Production Technology, Madras institute of Technology, Anna University, Chennai-44.
*babumech83@gmail.com
A honeycomb structure has a wide variety of application and it is often used in aerodynamics to reduce or
to create wind turbulence. It is also used to obtain a standard profile in a wind tunnel and many industries like
transportation rails and ships manufacturing. The project titled “Design, Fabrication and Analysis of Copper
honey comb sandwich panels” In this study a copper as a core material to make a honey comb structure with
different core dimensions and face sheet using as a Copper. Honeycombs are most often an array of hollow
hexagonal cells with thin vertical walls Copper Honeycomb is low density permeable material with numerous
applications. The defining characteristic of these Honeycombs is a very high porosity; typically 75 -95% of
the volume consists of void spaces. The structure is formed in pressing with various tonnage capacities and
it is to be welded by using brazing operation. The honey comb structure is designed and modeled with Catia
software and analyzed with Ansys to find the deflection using different bending test. The theoretical load and
deflections of copper honey comb sandwich panel values are adapted and compared with simulation results.
Metallic Honeycombs have found a wide variety of applications in heat exchangers, energy absorption, flow
diffusion and lightweight optics. Copper honeycomb is used in numerous engineering and scientific applications
in industry for good damping, Heat transfer rate, Flexural stiffness, porosity and strength.
Keywords: Copper sandwich panel; Honeycomb core; FEA; 3-Point bending test, Thermal conductivity
Design and Fabrication of automatic tri-axial winding
machine
Vasanth Bharath S. *, Omkumar M.
Department of Manufacturing Engineering,College of Engineering, Guindy,Chennai
*svbpsk@gmail.com
Recent fire accidents in fireworks industries have resulted in the loss of many life and property which has
increased the necessity to automate most of the manufacturing processes in these industries. This automation
should replace human workers and most important is that they should remain safe and fire proof, as most of
the raw materials used in this industry are highly inflammable. One of the popular products of this industry
nicknamed as atom bomb is made by winding thread in three axes around a small box containing the chemical.
The size of the box is 1X1X0.5 inch, hence holding the work piece and winding the thread around it in all three
axes continuously is a very tricky process. To imitate this highly human dependent process with a fully automated
machine with higher rate of production is a huge challenge. Hence none of the current fireworks automation
companies are not producing this kind of machine.Adetailed study was done and an automatic winding machine
to solve the purpose was designed with pneumatic actuation system controlled by an electronic micro controller.

38. 38
The initial prototype is fabricated with electric motors performing the same functions as intended and designed
with the pneumatic system. The electronic control system is designed with relay controls supported by signal
transmitted by limit switches to precisely control the process. Adequate fire hazard safety systems are designed
to be integrated with the machine, hence the machine will be intelligent enough to avoid any potential fire
accident during production process. The implementation of this automation to replace the current highly labor
intense fireworks production process can ensure the safety of human life and environment.
Keywords: Winding; Tri-axial; Fireworks; Automation
Optimization of Tribological Properties of Hybrid
Aluminium Matrix Composites using Taguchi Technique
Perumal S1*, Udayaprakash J2
Department of Manufacturing Engg., College of Engg guindy, Anna University,Chennai
* perumalpearl@gmail.com
This paper presents an effective approach for the optimization of the tribological properties of Hybrid
Aluminium Matrix Composites (356-B4Cp- MoS2) fabricated by stir casting technique. In this study B4C was
kept constant at 6% for all three composites (356-6% B4C, 356-6%B4C-2%MoS2 and 356-6%B4C-4% MoS2)
and MoS2 was varied from 0 to 4 % with an increment of 2 wt%. Dry sliding wear tests were conducted using a
standard pin on disc test setup following a well-planned experimental schedule based on Taguchi’s orthogonal
arrays. The input parameters such as sliding speed, sliding distance, load and reinforcement percentages are
optimized for wear rate using Signal to Noise ratio (S/N). The optimal levels of input parameters were selected
from response table and response graph from the S/N ratio analysis. ANOVA was used to find the significance
of the wear parameters.
Keywords:HybridAluminiummatrixcomposites,Stircasting,TaguchiDesignofExperiments,S/NRatio,ANOVA.
Experimentalanalysis and optimization of composition of
Al-Fly ash composite material to enhance its wear resistance
Rajesh Babu J.C.* 1
, Omkumar M. 2
, Jaisingh Durai M. 3
3
Department of Mechanical Engineering, Sri venkateswara college of Engineering and Technology, Tiruvallur
1,2
Department of Manufacturing Engg., College of Engg. Guindy., Anna University, Chennai
* rajeshdj2013@gmail.com.
Composite materials are widely used in automotive industry due to their enhancing mechanical properties
such as wear resistance, hardness and tensile strength. Grey cast iron castings cause residual stress, brittle, high
density and low shock resistance. In the present study they are replaced with Aluminum matrix material and
various weight percentage of fly ash to increase wear resistance. The mechanical behavior and microstructure
of Al-Fly ash composites are investigated. The dry sliding wear behavior of unreinforced alloy and composites

39. 39
are studied using Pin-On-Disc machine. In this experiment the Al-Fly ash composites have proved that are best
suitable for automobile Disk brake due to its high coefficient of friction. The results showed that the Aluminum
fly ash composite at the precise composition has shown increase in wear resistance. In addition Taguchi analysis
is performed for optimization of single response problem.
Keywords: Aluminum Fly ash composite, Pin On Disc test, Taguchi Method.
Optimization of Cryogenic Grinding Process Parameters
using the application of Grey Relation analysis
Selva Raja A., Elanchezhian J., Pradeep Kumar M.
Department of Mechanical Engineering, College of Engg. Guindy, Anna University, Chennai
selvaraj08992@gmail.coma, elanmec@gmail.comb, pradeep@annauniv.educ
In this paper presents the optimization studies on grinding of titanium (Ti–6Al–4V) alloy under wet and
cryogenic coolants using the application of grey relational analysis. The input process parameters such as
table speed and depth of cut were considered for the wet and cryogenic environment conditions. The output
response parameters were considered such as material removal rate, tangential force, temperature, and surface
roughness. In this experimental study, Taguchi method was used to design the experiments under three different
level of combination of process parameters. The experimental result indicates that the grinding process has
been improved at cryogenic coolant condition over than wet coolant condition and their results were achieved
through the grey relational analysis.
Keywords: Grinding, Cryogenic, Ti–6Al–4V alloy, Grey relational analysis
Parameter Optimization for WEDM of HCHCr- D2 Steel
using Box-Behnken Design
Suresh Babu A1*, Elumalai S2
Department of Manufacturing Engg., College of Engg guindy, Anna University,Chennai
* subaceg@annauniv.edu
Wire Electrical Discharge Machining is a controlled machining process used to manufacture geometrically
intricate shapes with higher accuracy and good surface finish. WEDM is now growing as an important process
in various fields. In this paper, an attempt has been made to machine HCHCr D2 steel using wire electric
discharge machining. The objective is to investigate the influence of various process parameters namely pulse
on time, pulse off time, Gap Voltage and servo feed on material removal rate and surface finish.ABox-Behnken
design approach of response surface methodology (RSM) is used to plan and analyze the experiments. The
relationships between WEDM input process parameters and response parameters are established to determine
optimal values of material removal rate and surface finish mathematically. Analysis of variance (ANOVA) and
F-test were performed to identify statistically significant process parameters. The optimal process parameters
have been verified by confirmation experiments .Experimental process results shows good agreement between

40. 40
actual and predicted values.
Keywords: WEDM, RSM, ANOVA, HCHCr-D2 steel.
Estimation of Machine Rates –Pre Engineered Building
Components using Activity Based Costing
Sagotharani K *
Post Graduate Student in Quality Engg and Mgmt, Department of Industrial Engg., Anna University,
Chennai
*sagotharani@gmail.com
Utilizing theActivity Based Costing in order to optimize the Component cost to enrich the business thereby
to makes Customers delight& powerful decision making skill in well advance during the bidding stage itself by
way of computing each component cost using ABC , since xyz Company lacks in business development due
to fair decision making skills during bidding and negotiating. Here we discuss about the Pre-Engineered Metal
Building Systems (PEB) components unit cost for Anchor Bolt, Column, Rafter, Purlin, Girt, Flange brace,
Sagrod, Connection plate and other structural accessories .We deal with Computing machine Rates (ie., Fixed
cost, Operating Cost and Labour cost based on their each component activity. Components are charged for
the costs of capacity they use – not for the costs of capacity they don’t use. ABC helps managers make better
decisions about product design, pricing, marketing, and mix and encourages continual improvement. ABC
concepts guide managers in seeking the best pricing strategies to pursue in the future. Compare this proposed
ABC pricing strategies with Traditional strategy. It enables Top Management to have a holistic view of cost
management. It leads the organization to more competent level, strategic working condition and very helpful
for future development projects too.
Keywords: Activity Based Costing,, Homogeneous Cost Pool, Pool Rate and Activity Driver.
Multi Stage Flow Shop Scheduling using Aco Cuckoo
Algorithm to minimize Makespan
Ravianandan M*, Omkumar M
Dept. of Manufacturing Engineering,College of Engineering,Anna University, Chennai.
*mravianandan@gmail.com
Job Scheduling in manufacturing is often an NP-hard problem due to multiple solutions possible for a
problem at the hand and the computation required to arrive at the best possible solution. A hybrid flow shop
is a flow shop having parallel machines arranged in stages where each can be processed on any machine in a
given set of machines in each stage. Job Scheduling problems provide with multiple solutions for a problem
at hand. The possibility of arriving at the near optimal solution at faster rate for a given problem makes the
problem NP-hard. Evolutionary algorithms like GA,ACO and PSO have been successfully used in solving many

41. 41
NP-hard problems. Hybrid flow shop flow optimization with Ant Colony Optimization (ACO) Algorithm is an
emerging trend in flow optimization simulations. A 4 -stage hybrid flow job simulation problem with objective
function to minimize the Makespan of a job and hence minimize cost attached to it. A recent evolutionary
algorithm called cuckoo search optimization (CSO) algorithm that adopts the strategy used in a brood parasitic
behaviour exhibited by cuckoo bird species for successful breeding, has been found more efficient and faster. A
Hybrid algorithm combining the effectiveness of Cuckoo search andAnt Colony search is used to arrive at near
optimal solution to minimize make span in a job scheduling problem. The final result from the hybrid algorithm
is compared with metaheuristic algorithm like GS, Cuckoo, and Ant colony algorithm on various parameters
like make span, standard deviation of solution. Etc. In this work, an effort has been made to use an improved
hybrid ACO-Cuckoo algorithm in scheduling jobs in a hybrid flow shop and the performance of the hybrid
algorithm has been compared with that of the other hybrid Metaheuristic algorithms. A multistage hybrid flow
shop problem is solved and compared with other hybrid algorithm to show its effectiveness.
Keywords: Flexible flowshop, ANT Colony algorithm, CUCKOO search
Shainin Doe Approach for Identifying the Critical Success
Factors in Railway Products Manufacturing Industry
Kokila M *, Paul Robert T
Department of Industrial Engineering, Anna University, Chennai
*kokila.m.10@gmail.com
Quality is of atmost importance in Railway products manufacturing industries. The percentage of products
rejected as well as requiring rework during the manufacturing of railway coach doors needs to be addressed.
Timely implementation of the Shainin techniques based on the quality control research is a must to avoid defects
in such railway products. In this paper, quality management tools and techniques such as Pareto chart, Cause
and effect diagram and Shainin tool have been employed to provide remedies for rejection. The objective of the
study is to identify and evaluate various factors affecting the quality of products that would reduce the percentage
of rejection, material wastage and rework in railway coach doors. The aim is to control the rejection percentage
so as to maximize the profit with reducing scrap and increasing the production output.
Keywords : Shainin DOE, Pareto , Root Cause Analysis
Improving Defect Removal Efficiency using LSS
Jayalakshmi S, Dillibabu R
Department of Industrial Engineering, Anna University, Chennai
d.s.jayam@gmail.com, dillibabu@annauniv.edu
Nowadays software industries are booming and changing the current era into software era in all aspects, so there
are many brain are targeting software field, to improve the human comfort. Like manufacturing industries, quality

42. 42
standards are very crucial in software industry as well. So I have selected my project is to improve the software life
cycle process efficiency by improving defect removal efficiency. To achieve my goal, I have chosen lean six sigma
methodologies. In particularly DMAIC (Define, Measure, Analyze, Improve and Control), as I am implementing it
in the maintenance phase of software life cycle project. I would like to apply DMAIC methodology in my project
to identify the appropriate process to follow and improve the quality in-terms of avoiding different level of waiting
time, redundant task, risk etc.As an outcome of this project will bring us an efficient process management method in
our software maintenance project to improve the quality and I have referred defects per feature, man working hours,
availability of lab resources, delivery time, etc. as a quality metrics.
Keywords : LSS, DMAIC, Improving Efficiency, Software Maintenance
Application of Lean Six Sigma in
Manufacturing of Demu Coaches
Saravanan M.1
*, Dillibabu R.2
Dept.of Industrial Engineering, College of Engineering Guindy, Anna University, Chennai.
msritesicf@gmail.com, b dillibabu@annauniv.edu,
Indian Railways is one of the largest railway systems spread over a network of 63,028 route kilometers.
It runs about 12,500 trains which carry nearly 13 million passengers and more than one million tons of freight
traffic daily from and to 6853 stations dotting the country. During the last five decades, the volume of freight
transport has increased nearly six folds, while there has been a four-fold increase in the volume of passenger
transport. To move such a large volume of passenger and freight traffic, Indian Railways operate a fleet of about
7566 Locomotives, 37,840 Passenger coaching vehicles, 4730 other coaching vehicles and 2,22,147 Wagons (in
units) with a work force of 15.7 million. Rolling stocks are manufactured and furnished in production units in
railways. Timely supply to various railways to cater passenger services is utmost need in Indian railways. There
is a undue delay in dispatches of coaches which leads to shortages of trains to open railways. There is a need
for the reduction of lead time of the furnishing of coaches by eliminating the waiting time and by removing the
non-value-added activities in production line.
Keywords: Lean production, value stream mapping (VSM), Diesel Electric Multiple Unit (DEMU).
Work Flow Management in Construction and
Implementation
Vasumathi A.M., Venkateswaran M.
Dept of Civil Engineering, K.L.N.College of Information Technology,Potapalayam,Sivagangai Dt,
This paper on workflow management in construction is based on the combination of location based
scheduling and 3d cad models. Project designer’s has to carefully design the construction process that ensures
the continuous and reliable flow of resources through different location in project. The flow of resources through
locations, termed work-flow, and mainly used in the brief step by step description of project. The focus of this

43. 43
project is based on the planning of transformation in short term management of task and low cost estimation
model. The process is defined by comparing various workflow literature papers in which this project produces a
model with less time and at low cost. In my project the first step provides a 3D CAD model of the building with
AutoCAD software and it is cost is estimated with construction estimation software and its scheduling method
are done by project management software. The work flow process in this project is proposed for residential
building for minimising the cost and to determine the proper scheduling process by integration of various
software to perform the various tasks.
Magnetic Pulse Welding of Dissimilar
Materials for Automotive Applications
Kudiyarsan S 1
*, Arungalai Vendan S 2
1
Technical Group, Bharatiya Nabhikiya Vidyut Nigam Limited (BHAVINI), Kalpakkam.
2
Industrial Automation and Instrumentation Division, School of Electrical Engineering, VIT University, Vellore
*kudiyarasan@rediffmail.com
Severalintricaciesareencounteredduringweldingofdissimilarmetalssuchasaluminumandcoppertogether.The
joining of copper to aluminum is inevitable for certain application in the electrical industry due to good conductivity
and response offered by copper, aluminum for weight reduction.Whilst in the majority of cases, aluminum and copper
can be joined by adhesive bonding, mechanical fastening, fusion welding and solid-phase welding techniques. Several
intricacies are encountered during welding of dissimilar metals such as aluminum and copper together. Parts made
of aluminum and copper joints are suggested for reducing the weight of automobiles to enhance fuel efficiency. This
promotes greater demand for joining these two dissimilar materials in different shapes. Magnetic pulse welding has
technically sound phenomenon that enables its applicability in joining dissimilar conductive materials. In this process,
a high intensity current flowing through a coil near an electrically conductive material generates an intense magnetic
field that induces eddy currents in the flyer.The electromotive force developed gives rise to a current whose magnetic
field opposes the original change in magnetic flux. Through this study the feasibility of MPW for joining dissimilar
conductive materials are well established.
Keywords:MagneticPulseWelding(MPW),MagneticFlux,Eddycurrent,Weldingofaluminum,Electromagnetic
force.
Review of Friction Stir Welding Tools
Balasubramaniyan C1
., Vijaya Ranjan V.2
, Saravanaganesh M.3
Dept. of Mechanical Engineering, Sri Venkateswaraa College of Technology, Vadakal,
Sriperumbudur-602105
Friction stir welding is one of the advance trends using in welding technology. It is a solid state joining
process. Weld is created by frictional heating and mechanical deformation only. This process has a process
parameter of tool geometry, welding parameter (tool rotation speed in rpm, tool traverse speed in mm/min and
tool tilt angle in degree) and joint design. From this parameter the tool geometry is one of the major parameter.

44. 44
In current stages different types of tool are using for join the materials in friction stir welding operation. The
aluminum alloys, titanium alloys, copper alloys are more suitable for friction stir welding. So only tool geometry
is consider a major parameter in FSW. In this paper deals with only tool geometry of the friction stir welding
process. Different tool materials are used like HSS, HCHCR etc., working tool is a main factor to decide a
quality of the weld and operation efficiency
Keywords: Tool geometry, Tool design, Tool specification.
Friction Stir Welding of AA6061 Aluminium Alloys
with Hollow Cylindrical Sections
Navukkarasan A., Jothilingam A.
Department of Production Technology, Madras Institute of Technology, MIT, Chromepet, Chennai
navukkaras@gmail.com.
Friction stir welding, a solid state joining process, is energy efficient, environment friendly and versatile.
Though this process is a proven technique for producing efficient joints in aluminium alloys with flat geometry,
it has limitations with circular cross sections. To overcome this limitation, a novel approach has been made by
developing a fixture to facilitate joining of materials with hollow cylindrical section. In order to demonstrate the
feasibility,AA6061 alloy is welded by friction stir welding and efficiency of the joint is evaluated by performing
tensile tests, hardness survey and microstructural analysis.
Keywords: Friction stir welding, AA 6061, tensile test, microstructural analysis.
Effect of Heat Treatment on
Micro Structure and Mechanical properties of
MIG and TIG welded 304 Stainless Steel
Vinay Prakash K, Radha R
School of mechanical and building science, VIT University, Chennai Campus,Chennai.
Kvinay.prakash2014@vit.ac.in, radha.r@vit.ac.in
Stainless steel has many excellent properties. Based on these properties it is used in many engineering fields.
In this paper, it is compared the results of TIG and MIG welding of 304 stainless steel. The study is taken on
welding similar metals. The microstructural study and mechanical properties are tested for weld of 5mm thick
304 stainless steel of TIG and MIG welding. Tensile test shows the strength of welded joints and hardness of
joint were examined by Rockwell hardness test. In this paper it is observed that the heat treatment shows the
effect on tensile strength of welded plates 304 SS at welded joint.
Keywords: stainless steel, TIG welding, MIG welding

45. 45
Experimental Investigation of Mechanical Properties in
Frictional Stir Welding of Dissimilar Material Joints
Ranjith Kumar L. 1*
, Omkumar M.2
Department of manufacturing Engg. College of Engg., Guindy, Anna University, Chennai,
* ranjithkumar@yahoo.com.
This project is used to Investigation the mechanical properties of friction stir welded dissimilar metal joint.
Design of Experiment methodology based on the Taguchi Method experiments with three parameters, from
these three factors and nine runs for metal was used to conduct the experiment and to develop the mathematical
regression model by using of Minitab 14 software. The three welding parameters considered were rotational
speed, welding speed, and axial force. Analysis of variance was applied to validate the predicted models.
Micro structural characterization and fractography of joints were examined using optical and scanning electron
microscopes. Also the effects of the welding parameters on mechanical properties of friction stir welded joints
were analyzed in detail. The results showed that the developed models were reasonably accurate. The increase
in welding parameters resulted in increasing of tensile strength, Hardness, Yield Strength, Impact Strength and
Percentage of Elongation of the joints up to a maximum value. Elongation percentage of the joint increased
with increase of rotational speed and axial force, but decreased by increasing of welding speed, continuously.
In addition, hardness of the joints decreased with increase of rotational speed and axial force, but increased
by increasing of welding speed. The Yield Strength of the joints increase of increase the weld speed and axial
force. The joints welded at higher heat input conditions revealed more ductility fracture mode. Final take the
conformation test and prove the 95% of weld joint applicable by NDT method.
Key words: Friction Stir Welding, Taguchi Methods, ANOVA
Experimental Analysis on Anti-Corrosion
Properties of Mild Steel
Veerapriya.C*, Subramanian. N
Dr.Pauls Engineering College, Villupuram.
* priya.met.gce@gmail.com
In this paper, Cupper nano particles (CuO) are newly incorporated in the binary (Ni-P) and ternary (Ni-
Cu-P) alloy coatings that results the composite coatings of Ni-CuO-P and Ni-Cu-CuO-P. Deposited surfaces
were characterized by x-ray diffraction and corrosion test was done by using potentio-dynamic polarization
test. Deposition rate, grain size and crystalline structure of the deposition were investigated. High deposition
rate was obtained in Ni-P coating than the other three types of coatings. In XRD pattern, Composite coatings
(Ni-CuO-P and Ni-Cu-CuO-P) have smaller grain size and broadened peak that influences the crystallinity.
Smaller grain sizes, Peak broadening of deposit and crystallinity are favorable conditions for better corrosion
resistance. Finally, significant range of improvement in corrosion resistance was obtained in the composite
coatings while compared to the binary and ternary alloy coatings.

46. 46
Corrosion and Abrasive Wear behaviour of
Detonation Gun Sprayed Coatings of Cr3C2-25NiCr and
WC-(10Co)-4Cr ON 316L Stainless Steel Substrate
Usharani.R1
*, Kanthashoba.M2
Department of Mechanical Engineering,
Thanthai Periyar Government Institute of Technology, Vellore-632002.
* universalkalai677875@gmail.com
Functionally graded materials serve a chief position owing to its continuous variation of properties with
position in today’s hasty material science research areas. The foremost crisis that comes into view with the
316L Stainless Steel was squat hardness, friction, creep strength and wear resistance even though it acquires
vast variety of applications. In this paper Cr3C2-25NiCr and WC-(10Co)-4Cr coatings were deposited onto the
316L stainless steel substrates using Detonation Gun thermal spray process with Coating thickness of 205μm
and 250μm respectively. Micro hardness, corrosion and abrasion wear properties were tested as per IS 1501/12,
ASTMA-262-10,ASTM D5963 standards respectively and the results were compared with stainless steel substrate
and both Cr3C2-25NiCr coating and WC-(10Co)-4Cr coatings under as sprayed condition. Experimental results
showed that the resistance on 316L stainless steel substrate due to WC-(10Co)-4Cr coating was increased as
compare to both substrate and Chromium carbide based coating.
Keywords: FGM, Cr3
C2
-25NiCr, WC-(10Co)-4Cr, D-Gun spray, Micro hardness, Corrosion and
Abrasion.
Comparison of Wear Resistance of Plasma
Sprayed Ceramic Coating on a Coated and Uncoated
Ti6al4v Grade 5 Substrate
Steve Augustine S., Jeshwanth B., Manivel S., Bragadeeshwaran M., Azad A.
Department of Manufacturing Engineering, CEG, Anna University, Chennai.
Surface treatments and coatings are the practical approaches used to extend the lifetime of componentsand
structures.Plasma Sprayed coatings are one of the most wear resistance coating widely used in manypractical
mechanical applications.Ti-6Al-4V, and Titanium alloys in general, have a tendency to gall and are not
recommended for wear applications. So in-order to improve its wear performance, Titanium alloys are
surface coated. In this study, we investigate the wear behavior of Ti6Al4V samples coated with (87%
Alumina – 13% Titanium Oxide) by Plasma spray method for a thickness of 100 µm and uncoated Ti6Al4V
specimens for less Wear rate and high Co-efficient of Friction for Aircraft Brake Pads. Results have shown
that the coated Ti6Al4V specimens have significantly minimum wear rate and high friction Co-efficient
when compared to its counterpart.

47. 47
Abrasive Water Jet Polishing of D2 Steel and Ti (grade2)
Pradeep N.1
*, Hariharan P2
., Jothilingam A3
1,2
Department of Manufacturing Engineering, College of Engg., Guindy, Anna University, Chennai
3
Department of Production Technology, MIT Campus, Anna University, Chennai,
natarajanpradeep11@gmail.com
Abrasive water jet machining has been used for many years in machining of hard-brittle materials, where
the material is removed by the micro erosion processes. These technologies were employed to polish the hard-
brittle materials that are difficult to polish by conventional polishing method which results in induced residual
stress and the HAZ (heat affected zone) over the polished surface. This paper is focused on employing abrasive
water jet polishing (AWJP) process for polishing D2 steel and Titanium grade2 (commercially pure). In this
study, Taguchi method was used for the experimental design. The main objective of this study is to investigate
the surface roughness (Ra), material removal rate (MRR) and the residual stress which was obtained by abrasive
water jet polishing (AWJP) process. Finally, the experimental results indicates that Ra and MRR were strongly
depends on the abrasive water jet process parameters, such as abrasive mesh size, water jet pressure, impingement
angle, stand-off distance.
Key words: abrasive water jet polishing, surface roughness, material removal rate. Design of Experiments
Wear Characterisation of the Solution
Treatment of Al-Cu-Ni-Sn-Mg Alloy
Darshan G, Radha.R
School of Mechanical and Building Science, VIT University, Chennai Campus, Chennai 600127
darshan.g2014@vit.ac.in, radha.r@vit.ac.in
Now a days Nonferrous materials are widely used especially because of its corrosion resistance property
and ease of Machinability. The solidification environment and the type of casting method effects on all the
properties of materials. Especially it effects more on the Mechanical properties and Tribological Properties.In
this paper, we selected DIE-Casting method where metal molds are used. The base material for our casting is
Aluminium and the main alloying elements are copper, magnesium etc.
Keywords :Die-casting, Al-Cu-Sn, Chemical and Mechanical Properties.

48. 48
Comparison of Mechanical Properties of
Aluminum Based Metal Matrix Composites
Ramachandran V., Mohankumar V., Thamizhvalavan P., Kanthababu M.*
Department of Manufacturing Engg, College of Engg Guindy, Anna University, Chennai.,
* kb@annauniv.edu
Recently, metal matrix composites (MMCs) play an important role in various industrial applications
such as automobile, aerospace, defense, etc due to their excellent mechanical properties such as light
weight, good specific stiffness, low density, high strength, high hardness, etc. In this work, MMCs consist
of Aluminum alloy 6063 (Al 6063) and Aluminum alloy 7075 (Al 7075) are reinforced with boron carbide
(B4C) in various proportions such as 8 %, 16 % and 24 % by stir casting process and mechanical properties
such as tensile strength, hardness and density are evaluated and compared. The results are also compared
with unreinforced aluminum alloys. It is observed that the increase in percentage of B4C in the MMCs
leads to increase the tensile strength, hardness and density of the composites. Among the MMCs studied,
it is observed the Al 7075 MMC reinforced with B4C of 24 % is found to be having higher mechanical
strength than that of the other composites.
Keywords: Metal Matrix Composites, Boron Carbide, Stir Casting, Mechanical Properties, Aluminum
Alloy 6063, Aluminum Alloy 7075.
Study on the influence of Silicon Carbide Filler on
Impact Behaviour of Jute - Glass Fibre Reinforced
Epoxy Hybrid Composites
Sathya Narayanan S. *, Kumaresan G.
Department of Production Technology, Madras Institute of Technology, Anna University, Chennai
*sathieyan333@gmail.com
The aim of the present study is to investigate the influence of silicon carbide filler on impact behaviour of
Jute-Glass fibre reinforced epoxy hybrid composites. Silicon carbide filler is added 5% and 10% to the weight
of resin and their influence on the fibre reinforcement is studied.Alkaline treatment (5% NaOH) and acetylating
treatment (acetic acid) is carried out to improve the properties of jute fibre by modifying the cellulosic molecular
structure. Composites were fabricated using hand lay-up technique. The composite was allowed to cure at room
temperature for 24 hours. Drop-impact test was carried out on the composite samples. Specimens were prepared
as per ASTM standards. The results show that treatment with NaOH influences the behaviour of jute fibre and
presence of SiC (5 %) improves the stress transferability during 3 m/s compared to 5 m/s.
Keywords: Jute, Glass fibre, SiC, Impact test

49. 49
Study of Mechanical behavior of Natural based
Composite using Coir and Aloe Vera
Yamini S* Shanmugasundaram K
Engg. Design Division, Department of Mechanical Engg.
College of Engineering Guindy, Anna University, Chennai
This study explores the possibility of the use of Coir & Aloe vera fiber based composites in automotive
applications. Samples contained pure Coir and pureAloe vera, both in randomly oriented mats and bi-directional
mats. Before composite fabrication, the fibers were subjected to chemical modification using NaOH and a mixture
of alcohol and benzene to decrease water absorption and achieve better wettability with the matrix. Contact Hand
lay – up technique was used to fabricate the composite mats. The fabricated natural fiber composite samples
were subject to impact testing by un-notched Charpy Impact test and moisture absorption test. SEM analysis
was carried out on the fracture surfaces of impact specimens. The Coir composite consist the bi-directional
mat with un-treated fiber exhibited the maximum performance, but the impact value of the Aloe vera fiber was
comparatively lesser due to the fact that it has higher bond strength at the interface between the fiber and the
matrix.
Keywords : Aloe vera, Bidirectional composite, Coir, Natural composite
Comparison of Mechanical Properties of
Al-Si-B4c and Al-Si-Sic Metal Matrix Composites
Sunil Kumar.K, Sriraman.N, Edward Kennedy .Z, Jaii Hareesh.K
KCG College of Technology, Chennai 600097
zac.edwin@gmail.com
This paper deals with fabrication and mechanical investigation of Aluminium Alloy –Boron carbide with
Aluminium Alloy-Silicon carbide metal matrix composite. The Boron carbide and silicon carbide are used
as reinforcements which posses excellent hardness and high impact strength. Aluminium is the matrix metal
having high strength, light weight and high corrosive properties. The fabrication was done by using stir casting
and after solidification, the samples are prepared and mechanical testing like tensile, hardness, and impact was
done. The structure was characterized by using optical microscope.
Keywords: Aluminium Alloy, Boron carbide, Silicon carbide, Stir casting, Hardness, Tensile, Impact .

50. 50
Micro-Structural and Corrosion behaviour of Co-Extruded
Al-Cu Macro Composite
Jaii Hareesh.K.1
, Rajesh Kumar.B2
, Edward Kennedy.Z3
, Sriraman.N4
,Alphin M.S5
1-4 KCG College of Technology, Chennai 600097
5 SSN College of Engineering, Chennai 603110
zac.edwin@gmail.com
Aluminium 6061 is taken as the matrix material. It is known for its light weight and high corrosion resistant
properties. Pure Electrolytic copper powder is taken as the reinforcement. Electrolytic copper powder has fine
particle sizes, low apparent density and high strength. With these properties, it is particularly suited for use in wide
applications. Extrusion process is used to produce the macro composites. Holes are drilled in the aluminium billet
and copper powder is inserted into the holes. The billet is then extruded below its recrystallization temperature.
The extrusion process provides void free and good integrity surfaces. Aluminium and copper is extruded in
the ratio of 2:1. The composite is tested for its hardness at various places. Corrosion tests are conducted on the
composite in 3.5%NaCl.
Keywords: Aluminium 6061, Copper powder, Macro composite, Extrusion, Hardness, Corrosion.
Material Characteristics of fabricated Reinforced
Polymers Composites
Dinagar. S. r1
*, Prem KumarV.2 *
1 T. J. Institute of Technology, Chennai, India
2 Thangavelu Engineering College, Chennai, India
* dinagar91@gmail.com,*Premzikumar147@gmail.com
To enhance the performance of polymer composite materials, carbon nanotubes (CNTs) are being considered
as nanoscale fibres because of their high mechanical strength. Composite reinforced polymers are classified into
two different types which are fabricated for their better efficiency with correct proportions with CNTs. Resin
carbon nanotube reinforced and resin glass fiber carbon nanotube reinforced are the two types of CNT-based
composites. The reinforced CNT composite polymers are SEM analysed for unified structural stability.
Investigation of mechanical properties on Jute fiber-Epoxy
reinforced composites
Rajesh Babu J.C.1*
, Jaisingh Durai M.2
Department of Mechanical Engg, Sri Venkateswara College of Engg and Technology, Tiruvallur
*rajeshdj2013@gmail.com.
Natural fibers are low cost, light weight and it seems that environmentally superior to the synthetic fibers
in composites. In this present investigation focus on mechanical properties of natural jute fiber composites.

51. 51
Jute fiber composites are used as natural fiber reinforcement and epoxy resin as matrix. In order to get better
interfacial bonding between fiber and matrix by the extracted jute fibers from jute husk are chemically treated.
The prepared composites are randomly orientated fibers with different proportions of fibers and matrix ratio. The
impact and hardness tests are performed and the results are reported. The results showed that the fiber volume
fraction and composite post curing time increases with the mechanical properties of the composite increased.
In addition Taguchi analysis is performed for optimization of single response problem.
Keywords: Natural jute fibers, Impact test, Hardness test, Taguchi Method.
Estimate and evaluation of mechanical properties of Boron
Carbide and titanium dioxide reinforced Aluminum alloy
metal matrix composites
Selva Ganesan C.1
, Stalin B.2
, Arivukkarasan S.3
1,2
Department of Mechanical Engineering, Anna University Regional Office, Madurai
3
Department of Mechanical Engineering, SACS MAVMM Engineering College, Madurai
This paper deals with the fabrication and mechanical investigation of aluminium alloy (AA) lm6, B4C (boron
carbide) and TiO2 metal matrix composites. Aluminium is the matrix metal having properties like light weight,
high strength and ease of machinability. Boron carbide which has excellent hardness and fracture toughness
is added as reinforcements with TiO2. Here, the fabrication is done by stir casting which involves mixing the
required quantities of additives into stirred moltenAluminium alloy.Aluminium alloy (AA) lm6 was reinforced
with 5 wt.% of boron carbide (B4C) and 3 wt.% of TiO2 through liquid casting technique. After solidification,
the samples are prepared and tested to find the various mechanical properties like tensile, flexural, impact and
hardness. And the test reports were compared with the al lm6 mechanical properties. These reports were used
for the characterization of composites.
Key words: Aluminium alloy LM6, Boron carbide,TiO2, Stir casting, Mechanical properties
Analysis of mechanical properties of Aluminium matrix
reinforced with Silicon Carbide and Titanium Dioxide
Balaji R.1
, Stalin B.2
, Arivukkarasan S.3
1,2
Department of Mechanical Engineering, Anna University Regional Office, Madurai
3
Department of Mechanical Engineering, SACS MAVMM Engineering College, Madurai
Ceramic composite materials are found to be the best alternative to replace the conventional materials like
steel, Brass,Aluminum etc. Main Objective of metal matrix composites is to develop a material with a judicious
combination of toughness and stiffness. It decreases the sensitivity to cracks and flaws and at the same time
increases the static and dynamic properties. In this paper, hardness test, compression test and flexural test have
been conducted by varying mass fraction of Silicon carbide ceramic powder and Tungsten carbide ceramic powder

52. 52
in the following proportions i.e.Aluminum 89%, Silicon Carbide 7%, Tungsten carbide 4% andAluminium 89%,
Silicon Carbide 4%, Tungsten carbide 7%. This paper deals with the fabrication and mechanical investigation of
aluminium alloy (LM6) with tungsten carbide and silicon carbide metal matrix composites. Here, the fabrication
is done by stir casting which is a simple and cost effective method for manufacturing of the composites by
mixing the required quantities of additives into stirred molten Aluminium. After solidification, the samples are
prepared and tested to find the various mechanical properties like compression, flexural and hardness. Mechanical
behavior of these ceramic composites are found individually and compared with aluminium.
Keywords : Aluminum(LM6) , Silicon Carbide, Tungsten carbide, Stir Casting, mechanical properities .
Analysis of Mechanical Properties of Matrix Aluminium
Reinforced With Tungsten Carbide and Silicon Carbide
Ashwin Prabhu G.1
, Stalin B.2
, Arivukkarasan S.3
1,2
Department of Mechanical Engineering, Anna University Regional Office, Madurai
3
Department of Mechanical Engineering, SACS MAVMM Engineering College, Madurai
Ceramic composite materials are found to be the best alternative to replace the conventional materials like
steel, Brass,Aluminum etc. Main Objective of metal matrix composites is to develop a material with a judicious
combination of toughness and stiffness. It decreases the sensitivity to cracks and flaws and at the same time
increases the static and dynamic properties. In this paper, hardness test, compression test and flexural test have
been conducted by varying mass fraction of Silicon carbide ceramic powder and Tungsten carbide ceramic powder
in the following proportions i.e.Aluminum 89%, Silicon Carbide 7%, Tungsten carbide 4% andAluminium 89%,
Silicon Carbide 4%, Tungsten carbide 7%. This paper deals with the fabrication and mechanical investigation of
aluminium alloy (LM6) with tungsten carbide and silicon carbide metal matrix composites. Here, the fabrication
is done by stir casting which is a simple and cost effective method for manufacturing of the composites by
mixing the required quantities of additives into stirred molten Aluminium. After solidification, the samples are
prepared and tested to find the various mechanical properties like compression, flexural and hardness. Mechanical
behavior of these ceramic composites are found individually and compared with aluminium.
Keywords : Aluminum(LM6) , Silicon Carbide, Tungsten carbide, Stir Casting, mechanical properities .
Fabrication of Al ADC12 MMC by using stir casting method
Raja T.1
, Muthukumar V. 2*
, Venkatasamy R. 3
,Suresh babu .A4
1-3
Saveetha Engineering College, Thandalam, Chennai
4
Department of Manufacturing Engineering,College of Engineering Guindy, Anna University Chennai
* profmuthukumarmech@gmail.com
Aluminum MMCs have the properties like high strength to weight ratio, good wear resistance and thermal
conductivity are preferred to other conventional materials in the fields of aerospace, automotive and marine
applications. In the present work an attempt has been made to synthesize metal matrix composite using ADC12

53. 53
Al as matrix material reinforced with three various reinforced particles using liquid metallurgy route in stir
casting technique. The reinforcement particle is being varied in 0 to 15 wt % in steps of 5 wt %. The reinforced
particles were preheated to improve the wettability and uniform distribution of particle inADC12Al alloy matrix.
Keywords: Aluminium alloy, Stir casting; Reinforcement particles.
Processing of Al LM6 MMC by using stir casting method
Ramki D.1
, Muthukumar V. 2*
, Venkatasamy R. 3
,Suresh babu .A4
1-3
Saveetha Engineering College, Thandalam, Chennai
4
Department of Manufacturing Engineering,College of Engineering Guindy, Anna University Chennai
* profmuthukumarmech@gmail.com
Aluminum MMCs are preferred to other conventional materials in the fields of aerospace, automotive and
marine applications due to the properties like high strength to weight ratio, good wear resistance and thermal
conductivity etc., The three various reinforced particles were used to synthesize metal matrix composite using
LM6 Al as a matrix alloy using liquid metallurgy route in stir casting technique. The reinforcement particle is
being varied in 0 to 15 wt % in steps of 5 wt %. To improve the wettability and uniform distribution of particle
in LM6 Al alloy matrix by the preheating of reinforced particles.
Keywords: Aluminium alloy, Stir casting, Reinforcement particles.
Preparation of sisal fiber composite by
compression moulding
Jeeva rathinam M., Muthukumar V. *
, Venkatasamy R. Antony George Fernando A.
Saveetha Engineering College, Thandalam, Chennai
* profmuthukumarmech@gmail.com
In recent years, there has been a increasing attention in utilizing natural fibres as reinforcement in polymer
composite for manufacture low cost structural and construction materials. Natural fibres are prospective reinforcing
materials and their use until now has been more traditional than technical Natural fiber industries employ
millions of people all over the world, especially in the developing countries. Natural fiber is generally used in
more automobile application because renewable sustainable, low cost, light weight and biodegradable instead
of synthetic fiber.Among the various natural fibres, sisal is of particular interest in that its composites have high
impact strength besides having moderate tensile and flexural properties compared to other lignocellulosic fibres.
The present paper surveys the research work published in the field of sisal fibre reinforced polymer composites
with special reference to the structure and properties of sisal fibre, processing techniques, and the physical and
mechanical properties of the composites. Epoxy polymer based composites reinforced with Raw sisal fiber at
different loading of 1, 2, 3, 4, 5, 6, 7 and 8 wt. % were prepared by compression moulding. Microstructures of
natural fibers after fiber surface treatments and moisture absorption were revealed
Keywords: Natural fiber, Compression Moulding , sisal fiber

54. 54
Investigation the Effect of Process Parameters on
Electrochemical Micromachining using α-Titanium
Madhana gopal G.1*
, Geetha priyan T.2
, Kalaichelvan K.3
1,2
Department of Production Technology, MIT campus, Anna university Chennai.
3
Department of Ceramic Technology, A.C.Tech campus, Anna university Chennai.
*madhan.auto@gmail.com
Electrochemical micro-machining is one of the non-traditional machining processes to machine micro-
complicated shapes for electrically conducting and difficult-to-machine materials such as super alloys, Titanium-
alloys, alloy steel, tool steel and stainless steel. EMM can be effectively used for high precision machining
operations, for accuracies of the order of ±1 µm on 50 µm. This paper investigates the effect of process parameters
such as voltage, duty cycle, electrolyte concentration and tool feed rate on material removal rate and surface
roughness characteristics and overcut.
Keywords: Electrochemical micro-machining, material removal rate, Surface roughness, Overcut, Titanium-
alloys
Review on Pocket Milling using Abrasive
Water Jet Machining
Gokul, Thomas George R., Naveenkumar M., Manojanandha V., Rajesh Kumar N., Kanthababu
M. *
Department of Manufacturing Engg., College of Engg. Guindy,Anna University, Chennai.
*kb@annauniv.edu
Abrasive water jet machining (AWJM) process is used for machining difficult-to-machine materials.Apart
from regular cutting,AWJM is also used for various machining operations like drilling, cutting, turning, milling,
etc. This work reviews the literature on abrasive water jet pocket milling (AWJPM). Most of the researchers
conducted experimental works in AWJPM in different materials like aluminium, glass, titanium, alloy steels,
etc. to understand the effect of input parameters like water jet pressure, standoff distance, traverse rate, abrasive
mass flow rate, jet impact angle, step-over distance, abrasive mesh size, machining time, etc. on the output
parameters such as depth of cut, undercut, material removal rate (MRR), surface roughness (Ra), kerf geometry,
etc. It is observed that the milling depth and surface quality of the machined surface can be controlled through
the proper selection of input process parameters. Future work involves AWJPM by tilting the workpiece using
a suitable work holding fixture at appropriate angles rather than conventional way of tilting the nozzle head in
order to achieve desired kerf geometry with accuracy.
Keywords: Abrasive Water Jet, Abrasive Water Jet Pocket Milling, GarnetAbrasive, Depth of Cut, Step-
over Distance, Jet Impact Angle.

55. 55
Experimental investigations on Pocket Milling of
Aluminium Alloy 6061 Using Abrasive Water Jet Machining
Rajes Ram M1
, Peter Nithin Emmanuel2
, Gokul R.3
, Vaddi Seshagiri Rao4
Kanthababu M.5
,
Department of Mechanical Engineering, St. Joseph’s College of Engineering, Chennai-600 119,
3, 5 Department of Manufacturing Engineering, College of Engineering Guindy
Anna University, Chennai-600 025
1
rajesram94@gmail.com, 2
peternitsemm@gmail.com,
3
gokul7252@gmail.com,5
kb@annauniv.edu, 4
principal@stjosephs.ac.in
Abrasive Water Jet Machining (AWJM) is one of the most popular unconventional machining processes
used to machine difficult-to-machine materials.Apart from regular cutting, it is also used for turning, threading,
slotting, milling etc. This paper details the experimental investigations on Abrasive Water Jet Pocket Milling
(AWJPM) on Aluminium alloy (Al 6061) using garnet abrasive. The influence of stand-off-distance, step-over,
traverse rate and abrasive mass flow rate were studied on the output responses such as depth of cut and surface
roughness (Ra). The experiments were designed using L9 Orthogonal Array and ANOVA analysis helped in
determination of significant process. ANOVA analysis on depth of cut indicated that step-over and traverse
rate are the most significant process parameters for aluminium alloy. However, ANOVA analysis for surface
roughness (Ra) was inconclusive and the significant process parameters could not be determined. Higher order
of experimentation is required for further analysis.
Keywords: Abrasive Water Jet Machining (AWJM), Abrasive Water Jet Pocket Milling (AWJPM), Garnet
abrasives, Orthogonal array, ANOVA, Response graph
Influence of Corrugated Structure and its Geometrical
Parameters on Flexural Properties of Mulitimaterial 3D
Printed Structures
Indarajith J.S.*,Nizam Mydeen, Sai Prasaanth, Thangaraj.N., Arumaikkannu G.
Department of Manufacturing Engg, College of Engg Guindy, Anna University, Chennai
*indarajithjs@gmail.com
Additive manufacturing (AM) is defined by ASTM as the ‘process of joining materials to make objects,
usually layer by layer, from 3D CAD data’. The technique has revolutionized manufacturing industry, but as
always it has its own disadvantages. The components manufactured by additive manufacturing method are not
structurally strong in terms of impact strength, flexural strength, tensile strength etc. So this paper concentrates
on improving the flexural strength of a component by inducing a second material or high strength material. The
two changes carried out are using of multi material and also using a reinforcement in corrugated shape thereby
increasing flexural strength without compromising on rigidity. The materials used are, acrylo butadiene styrene
and polypropylene one of high strength and other of large flexibility. The other change is use of reinforcement
material in corrugated shape in the direction of neutral axis of bending, as it increases the moment of inertia in