Green Materials and Advanced Manufacturing Technology: Concepts and Applications

✍ Scribed by Samson Jerold Samuel Chelladurai, Suresh Mayilswamy, Arun Seeralan Balakrishnan, S. Gnanasekaran

• Publisher: CRC Press
• Year: 2021
• Tongue: English
• Leaves: 339
• Series: Green Engineering and Technology
• Category: Library

✦ Synopsis

This book includes recent theoretical and practical advancements in green composite materials and advanced manufacturing technology. It provides important original and theoretical experimental results which use nonroutine technologies often unfamiliar to some readers and covers novel applications of more familiar experimental techniques and analyses of composite problems.

Green Materials and Advanced Manufacturing Technology: Concepts and Applications provides insight and a better understanding into the development of green composite materials and advanced manufacturing technology used in various manufacturing sectors. It highlights recent trends in the fields of green composites, metal matrix composites, ceramic matrix composites, surface modification using laser cladding, types of dust collectors in waste management and recycling in industries, machinability studies of metals and composites using surface grinding, drilling, electrical discharge machining, joining of metals using friction stir welding, shielded metal arc welding, and linear friction welding.

This book is written for engineering students, postgraduate students, research scholars, faculty members, and industry professionals who are engaged in green composite materials and development of advanced manufacturing technology.

✦ Table of Contents

Cover
Half Title
Series Page
Title Page
Copyright Page
Table of Contents
Preface
Editors
Contributors
Chapter 1 Parametric Optimization of Surface Roughness and Surface Temperature during Minimum Quantity Lubrication (MQL) and Conventional Flood Lubrication Techniques in Surface Grinding of Mild Steel: A Performance Comparison and Analysis
1.1 Introduction
1.2 Materials and Experimental Setup
1.2.1 Dry Grinding Operation
1.2.2 Flood Grinding Operation
1.2.3 MQL Grinding Operation
1.2.3.1 MQL Grinding with Both Nozzles Same Side [MQL(BNSS)]
1.2.3.2 MQL Grinding with Both Nozzles on Opposite Sides [MQL(BNOS)]
1.3 Results and Discussion
1.3.1 Surface Temperature in Dry Grinding Operation
1.3.1.1 Dry Grinding Operations with Maximum Temperature per Pass
1.3.2 Surface Temperature during Flood Grinding Operation
1.3.2.1 Flood Grinding Operations with Maximum Temperature per Pass
1.3.3 Surface Temperature in MQL Grinding Operation
1.3.4 Temperature Comparison in Various Grinding Operations
1.3.5 Temperature Comparison in Various MQL Grinding Operations
1.3.6 Measurement of Surface Roughness
1.3.6.1 Surface Roughness in Dry Grinding Operation
1.3.6.2 Surface Roughness in Flood Grinding Operation
1.3.6.3 Surface Roughness in Various MQL Grinding Operations
1.3.7 Surface Roughness Comparison in Various Grinding Operations
1.4 Conclusion
Declaration of Conflict of Interest
Funding
Ethical Approval
Acknowledgements
References
Chapter 2 Importance of Dust Collectors in Waste Management and Recycling in Industries
2.1 Introduction to Dust Collectors
2.2 Electrostatic Precipitator
2.3 Fabric Filters
2.4 Unit Collectors
2.5 Wet Scrubbers
2.6 Inertial Separators
2.6.1 Baffle Chambers
2.6.2 Settling Chamber and Centrifugal Collectors
2.7 Cyclone Separator
2.7.1 Cyclone Separator Working Principle
2.7.2 Tangential Inlet Cyclone Separator
2.7.3 Axial-Flow Cyclone Separator
2.7.4 Bottom Inlet Cyclone Separator
2.7.5 Cut-Off Diameter and Pressure Drop
2.7.6 Applications
2.7.7 Advantages of the Cyclone Separator
2.7.8 Disadvantages of the Cyclone Separator
References
Chapter 3 Influence of Nickel-Based Cladding on the Hardness and Wear Behaviour of Hard-Faced Mild Steel Using E-7014 Electrode Using Shielded Metal Arc Welding
3.1 Introduction
3.2 Material and Methodology
3.2.1 Selection of Electrode
3.2.2 Selection of Metal Powders
3.2.3 Selection of Welding Process
3.2.3.1 Welding Equipment
3.3 Results and Discussion
3.4 Conclusion
Declaration of Conflict of Interest
Funding
Ethical Approval
Acknowledgements
References
Chapter 4 Erosion Response of Martensitic Stainless Steel Subjected to Slurry Flow
4.1 Introduction
4.2 Materials and Methods
4.3 Experimental Analysis
4.4 Results and Discussions
4.5 Conclusion
References
Chapter 5 Optimization of Machining Parameters during the Drilling of Natural Fibre-Reinforced Polymer Composites: A Critical Review
5.1 Introduction
5.2 Drilling of Hybrid Polymer Composites
5.3 Input and Output Parameters
5.4 Conclusions
Declaration of Conflict of Interest
Funding
Ethical Approval
References
Chapter 6 Mechanical Properties of the Palmyra Fibre Epoxy Composites
6.1 Introduction
6.2 Materials and Methods
6.3 Influence of Fibre Loading on Composite Tensile Strength
6.4 Influence of Fibre Loading on Composite Impact Strength
6.5 Influence of Fibre Loading on Composite Flexural Strength
6.6 Conclusions
References
Chapter 7 ANFIS-Based Prediction of MRR and Surface Roughness in Electrical Discharge Machining of HAMMC
7.1 Introduction
7.2 Materials Selection and Methodology
7.2.1 Selection of Base Materials
7.2.2 Powder Metallurgy
7.2.3 Electrical Discharge Machining
7.2.4 Taguchi’s Technique for Experimental Design
7.2.5 Adaptive Neuro-Fuzzy Inference System (ANFIS)
7.3 Results and Discussions
7.4 Conclusions
References
Chapter 8 Experimental Investigation and Optimization of EDM Process Parameters on Ti-6Al-4V Alloy Using Taguchi-Based GRA and Modelling by RSM
8.1 Introduction
8.2 Materials and Methods
8.3 Results and Discussions
8.3.1 Optimization of Process Parameters by Taguchi Method and GRA
8.3.2 Examination of EDM Process Parameters on the EWR
8.3.3 Examination of EDM Process Parameters on the MRR
8.3.4 Examination of EDM Process Parameters on Ra
8.3.5 Response Surface Methodology (RSM)
8.3.6 Analysis of Variance (ANOVA)
8.3.7 Confirmation Experiment
8.4 Conclusions
Declaration of Conflict of Interest
Funding
Ethical Approval
References
Chapter 9 High-Temperature Tribological Behaviour of Surface-Coated Tool Steel
9.1 Introduction
9.2 Experimental Materials
9.3 Configuration and Sliding Contact
9.4 Test Setting and Procedures
9.5 Results and Discussion
9.5.1 Characterization of Surface Topography
9.5.2 Friction Results
9.5.2.1 Friction of Coating Initially
9.5.2.2 Friction of Coatings during 10 Minutes
9.5.3 Wear Resistances
9.5.3.1 Wear Resistance at 40°C
9.5.3.2 Wear Resistance at 800°C
9.5.4 Surface Damages
9.5.4.1 Surface Damage at 40°C
9.5.4.2 Surface Damage at 800°C
9.5.5 Oxidation of Sliding Surfaces
9.6 Conclusion
References
Chapter 10 Process Modelling and Optimization of Hardness in Laser Cladding of Inconel® 625 Powder on AISI 304 Stainless Steel
10.1 Introduction
10.2 Experimental Methods
10.3 Process Model Development by Curve Fitting Method
10.4 ANN for Model Development
10.5 Parametric Optimization by First Derivative Test
10.6 Generalized Reduced Gradient for Process Optimization
10.7 Grey Relational Analysis for Parametric Optimization
References
Chapter 11 Effect of Wire Electric Discharge Machining Process Parameters on Surface Roughness of Monel 400 Alloy
11.1 Introduction
11.2 Experimental Method
11.2.1 Wire Electrical Discharge Machining
11.2.2 Material Used: Monel 400
11.2.3 Tool Electrode Material: Brass
11.2.4 Dielectric Fluid: Deionized Water
11.2.5 Measuring Apparatus
11.2.6 Parameters and Its Range
11.2.7 Design of Experiments
11.3 Results and Discussion
11.3.1 Effect of Pulse On Time
11.3.2 Effect of Pulse Off Time
11.3.3 Effect of Wire Tension
11.3.4 Effect of Wire Feed
11.3.5 Effect of Surface Roughness on Machining Parameters
11.4 Conclusion
References
Chapter 12 Experimental Investigation of the Effect of Various Chemical Treatments on Agave angustifolia Marginata Fibre
12.1 Introduction
12.2 Materials and Experiments
12.2.1 Natural Fibre Material
12.2.2 Extraction of Fibre From Plants
12.3 Chemical Treatment of Fibre
12.3.1 NaOH Treatment
12.3.2 NaClO Treatment
12.3.3 H2O2 Treated
12.4 Physical Properties of Fibre
12.4.1 Fibre Density
12.4.2 Fibre Diameter
12.4.3 Chemical Properties of Fibre
12.4.4 Wax Content
12.4.5 Moisture Content
12.4.6 Cellulose Content
12.4.7 Lignin Content
12.4.8 Hemicellulose Content
12.4.9 Fourier-Transform Infrared Spectrometry (FTIR)
12.4.10 Tensile Strength of Agave Angustifolia ‘Marginata’ Fibre
12.4.11 Thermal Analysis
12.5 Results and Discussion
12.5.1 Physical Properties of AAM Fibre
12.5.1.1 Fibre Density
12.5.1.2 Fibre Diameter
12.5.1.3 Chemical Properties of Fibre
12.5.1.4 Fourier-Transform Infrared Spectrometry (FTIR)
12.6 Tensile Properties of AAM Fibre
12.7 Thermal Analysis
12.8 Conclusions
References
Chapter 13 Defect Identification in Casting Surface Using Image Processing Techniques
13.1 Introduction to Surface Inspection
13.2 Challenges and Issues in Defect Detection
13.3 Proposed Method
13.4 Contrast Enhancement
13.5 Image Segmentation
13.6 Feature Extraction
13.7 Classification of Defects
13.8 Conclusion
13.9 Applications
Bibliography
Chapter 14 Effect of Y2O3 Doping on Mechanical Properties and Microstructure of Al2O3/10wt.% SiC Ceramic Composites Synthesized by Microwave Sintering
14.1 Introduction
14.2 Microwave Sintering
14.2.1 Basics of Microwave Heating
14.2.2 Interaction of Microwaves with Materials
14.2.2.1 Transparent
14.2.2.2 Opaque
14.2.2.3 Absorbent
14.2.3 Heating Pattern
14.2.4 Microwave Heating Mechanisms
14.2.4.1 Resistive Heating
14.2.4.2 Bipolar Rotation
14.2.4.3 Electromagnetic Heating
14.2.4.4 Dielectric Heating
14.2.5 Microwave Heating Methods
14.2.5.1 Microwave-Assisted Heating
14.2.5.2 Direct Microwave Heating
14.2.6 Advantages of Microwave Sintering
14.3 Synthesis of Al2O3/10 wt.% SiC with Y2O3 Ceramic Composite Samples Using Microwave Sintering
14.3.1 Materials
14.3.2 Weighing and Milling
14.3.3 Powder Compaction and Green Pellet Fabrication
14.3.4 Sintering
14.4 Mechanical Testing and Characterization
14.4.1 Relative Density
14.4.2 Average Matrix Grain Size
14.4.3 Vickers Hardness
14.4.4 Fracture Toughness
14.4.5 X-Ray Diffraction (XRD)
14.4.6 Microscopy Using Scanning Electron Microscope (SEM)
14.5 Results and Discussion
14.6 Conclusion
References
Chapter 15 Multiobjective Optimization of BSL 165 Aluminium Composite For Aeronautical Applications
15.1 Introduction
15.2 Optimization by Using Genetic Algorithm
15.3 Surface Roughness
15.4 Material Removal Rate (MRR)
15.5 Experimental Outline
15.6 Selection of Controllable Parameters
15.6.1 Selection of Tool
15.6.2 Limits of Process Parameters
15.7 Design Matrix
15.8 Experimentation
15.9 Response Surface Model for the Prediction of Surface Roughness
15.9.1 Surface Roughness
15.10 Results and Discussion on Surface Roughness
15.10.1 Parameter Interaction Effects
15.11 Response Surface Model for the Prediction of MRR
15.11.1 Material Removal Rate (MRR)
15.12 Results and Discussion on MRR
15.12.1 Parameter Interaction Effects
15.12.2 An Optimized Set of Parameters
15.13 Genetic Algorithm Optimization
15.13.1 Validation of the Model
15.14 Conclusion
References
Chapter 16 Abrasive Wear Behaviour of Titanium and Ceramic-Coated Titanium
16.1 Introduction
16.2 Abrasive Wear Behaviour of Titanium
16.3 Abrasive Wear Behaviour of Titania (TiO2)
16.4 Abrasive Wear Behaviour of TiO2 + 5 SiC Coating
16.5 Abrasive Wear of TiO2 + 10 SiC Coating
16.6 Abrasive Wear of TiO2 + 15 SiC Coating
16.7 Summary
References
Chapter 17 Impact of Friction Stir Welding Process on Mechanical and Microstructural Behaviour of Aluminium Alloy Joint – A Review
17.1 Introduction
17.2 Literature Survey
17.2.1 Effect of Friction Stir Welding Parameters
17.2.2 Postweld Heat Treatment of FSW Joints
17.2.3 Friction Stir Welding of Dissimilar Joint
17.2.4 Friction Stir Welding of Metal Matrix Composite
17.2.5 Under Water Friction Stir Welding Process
17.3 Conclusion
References
Chapter 18 Effect of Solution Treatment and Artificial Ageing on Strength Properties of Friction Stir Welded AA2014-T6 Aluminium Alloy
18.1 Introduction to Effect of Solution Treatment and Artificial Ageing on Friction Stir Welding Joints
18.2 Method of Manufacturing Advance Material
18.3 Strength and Microstructural Properties of Joint
18.4 Analysis of Precipitate Morphology of FSW Joints
18.5 Summary of Effect of Solution Treatment and Artificial Ageing on FSW Joints
References
Chapter 19 Effect of Oscillation Frequency on Microstructure and Tensile Properties of Linear Friction Welded Ti-6Al-4V Alloy Joints
19.1 Introduction
19.2 Experimental Details
19.3 Results
19.3.1 Macrostructure Analysis
19.3.2 Tensile Properties
19.3.3 Microhardness Variations across the Joints
19.3.4 Microstructural Features of the LFW Joint
19.3.5 Analysis of SEM Microstructure
19.3.6 Fracture Surface Analysis
19.4 Discussion
19.5 Conclusions
References
Chapter 20 Linear Friction Welding of Ni-Co-Cr Superalloy for Blisk Assembly
20.1 Introduction
20.1.1 Friction Welding
20.1.1.1 Linear Friction Welding Process
20.2 Experimental Conditions
20.3 Results and Discussion
20.3.1 Transverse Tensile Properties
20.3.2 Microhardness Measurement
20.3.3 Impact Testing
20.3.4 Macrostructural and Microstructural Features of Inconel-100 Weld Joint
20.3.5 Elemental Analysis (EDS) of Welded Joints
20.4 Conclusion
References
Index