Next Generation Materials and Processing Technologies: Select Proceedings of RDMPMC 2020 (Springer Proceedings in Materials, 9)

✍ Scribed by Swarup Bag (editor), Christ Prakash Paul (editor), Mayuri Baruah (editor)

• Publisher: Springer
• Year: 2021
• Tongue: English
• Leaves: 581
• Category: Library

✦ Synopsis

This book presents the select proceedings of Conference on Research and Developments in Material Processing, Modelling and Characterization (RDMPMC 2020). It highlights the new technologies developed in the generation of rational materials for various applications with tailored properties. It covers fundamental research in emerging materials which includes biomaterials, composites, ceramics, functionally graded materials, energy materials, thin film materials, nanomaterials, nuclear materials, intermetallic, high strength materials, structural materials, super alloys, shape memory alloys and thermally enhanced materials. It includes the numerical modeling and computer simulation to investigate the properties and structure of materials. Few of the most relevant manufacturing techniques highlighted in this book are welding, coating, additive manufacturing, laser-based manufacturing, advanced machining processes, casting, forming and micro and nanoscale manufacturing processes.Given its contents, this book is beneficial to students, researchers and industry professionals.

✦ Table of Contents

Preface
Contents
About the Editors
Materials
1 Development of High Strength Low Carbon Lean Micro-alloyed Steel with Optimized Toughness
1 Introduction
2 Experimental Procedure
3 Results and Discussion
3.1 Microstructural Evolution
4 Conclusions
Acknowledgements
References
2 The Pros and Cons of an Energy-Efficient Q&P Approach to Develop Advanced Steels
1 Introduction
2 Q&P and Related Approaches in Hot-Rolled Steels
3 Pros and Cons of Various Approaches Applied to Hot-Rolled Steels
4 Future Prospects and Outlook
5 Conclusions
References
3 Ductility Improvement in Commercially Pure Aluminium by Friction Stir Processing
1 Introduction
2 Materials and Methods
3 Results and Discussion
3.1 Mechanical Properties
3.2 Microstructure
3.3 Grey Relational Analysis and Regression Analysis
4 Conclusion
Acknowledgements
References
4 Development of Composites Using Bamboo Waste and Polymers for Industrial Application
1 Introduction
2 Experimental Methodology
3 Results and Discussion
3.1 Water Absorption and Thickness Swelling
3.2 Microstructure
3.3 Mechanical Performance Results
4 Conclusions
References
Technologies
5 Design and Analysis of Membrane-Based Parabolic Space Reflector
1 Introduction
1.1 Problem Statement
1.2 Scope of the Project
1.3 Objective of the Project
2 Membrane Theory
3 Methodology
3.1 Membrane Material Selection
3.2 Inflatable Design and Construction
3.3 Equation of a Parabola
3.4 Software Versions
4 Inflatable Membrane-Based Parabolic Reflector Model
5 Parametric Study
6 Results and Conclusion
7 Conclusion
7.1 Future Work
References
6 Development of Integrated Aerator combining Paddlewheel and Propeller Aspirator Aerators for Shrimp Farming
1 Introduction
2 Research Approach
2.1 Problem Identification
3 Materials and Methodology
3.1 Development of Integrated Aerator (IA)
3.2 Experimental Setup
3.3 Aeration Test
4 Result and Discussion
4.1 Dissolved Oxygen
4.2 Temperature
4.3 Standard Deviation
4.4 Water Current
5 Conclusion
References
7 Experimental Investigation of Al 2024 Aluminum Alloy Joints by Underwater Friction Stir Welding for Different Tool Pin Profile
1 Introduction
2 Experimental Procedure
2.1 Workpiece Material
2.2 Tool Design
2.3 Experimental Setup
2.4 Process Parameter
3 Results and Discussion
3.1 Tensile Testing of the Joints
3.2 Optical Macrograph of Weld Joints
3.3 Microhardness Test of Weld Joint
4 Conclusions
References
8 Performance Evaluation of Spiral Separator for Coal Cleaning Using Mixture Model
1 Introduction
2 Theory
2.1 Geometry
3 CFD Modeling
3.1 Geometry and Mesh
3.2 Governing Equations
3.3 Boundary Conditions
4 Results and Discussion
4.1 Primary Velocity
4.2 Water Depth
5 Conclusions
Acknowledgements
References
9 Mixing Performance Analysis of Serpentine Microchannels with Straight and Curved Bends
1 Introduction
2 Methodology—Numerical Simulations
2.1 Microchannel Geometry
2.2 Boundary Conditions
2.3 Meshing
3 Results and Discussion
3.1 Effect on the Pressure Drop (Pa)
3.2 Effect on the Mixing Length
4 Conclusions
References
10 Comparison of Certain Models to Estimate the Best Solar Global Radiation for Jamshedpur, Jharkhand, India
1 Introduction
2 Climatic Factors of Jamshedpur, Jharkhand
2.1 Sunshine Hours Data for Jamshedpur, Jharkhand
2.2 Monthly Mean Daily Global Solar Radiation on Horizontal Surface
3 Methodology
3.1 Comparison and Validation of Models with Statistical Error
3.2 Models Analysis
4 Results and Discussion
5 Conclusions
References
Processing and Characterization
11 A Study of Microstructure and Mechanical Properties of Wire Arc Additive Manufactured Component with ER70S6 Alloy Wire Using CMT Process
1 Introduction
2 Experimental Procedure
2.1 Methods and Materials
2.2 Parameter Optimization
2.3 Deposition Process
2.4 Testing and Characterization
3 Results and Discussion
3.1 Tensile Properties
3.2 Hardness
3.3 Impact Property
3.4 Microstructure and Metallography
3.5 Macroscopic Morphology and Defects
4 Conclusions
Acknowledgements
References
12 Effect of MoS2 and CeO2 Powder Addition by Friction Stir Processing on Wear and Corrosion Properties of Al7075 Alloy
1 Introduction
2 Materials and Methods
3 Results and Discussion
4 Conclusions
References
13 Effect of Current Pulsation on Weld Microstructure During Micro-Plasma Arc Welding of Inconel 718
1 Introduction
2 Experimental Details
3 Results and Discussion
3.1 Microstructure
3.2 XRD Analysis
3.3 Mechanical Properties
4 Conclusion
Acknowledgements
References
14 Effect on Microstructure and Mechanical Property of 4043 Wire Arc Additively Manufactured Aluminum Alloy with Different Process Parameters
1 Introduction
2 Experimental Details
3 Result and Discussion
3.1 Deposit Profile
3.2 Microstructure and Microhardness
4 Conclusion
References
15 Influence of WEDM Parameters for Estimating the Surface Integrity of Laser Additive Manufactured Hybrid Material
1 Introduction
1.1 Materials for Aerospace Industries
1.1.1 Steel Alloy
1.1.2 Aluminium Alloy
1.1.3 Titanium Alloy
1.1.4 Magnesium Alloy
1.1.5 Superalloys
1.1.6 Composites
1.1.7 Functionally Graded Materials (FGM)
1.1.8 Others
1.2 Background
1.2.1 Optimization of Parameters
1.2.2 Survey on Process Parameters Effects
2 Experimental Investigation
2.1 Design of Experiment
2.2 Materials and Methodology
3 Results and Discussion
3.1 Analysis of Surface Roughness
3.2 Analysis of Kerf Width
3.3 Analysis of Material Removal Rate (MRR)
3.4 Analysis of Heat Affected Zone (HAZ) Thickness
3.5 Analysis of Cutting Speed
4 Future Research Directions
5 Conclusions
Acknowledgements
References
16 Effect of Vibrations on Solidification Behavior and Mechanical Properties of Shielded Metal Arc Weld
1 Introduction
2 Methodology
2.1 Design of Vibratory Setup
3 Result and Discussion
3.1 Microhardness Testing
3.2 Microstructural Study
3.3 Tensile Testing
4 Conclusion
References
17 Investigating Laser Surface Texturing on SS 304 for Self-cleaning Applications
1 Introduction
2 Theory and Analytical Model
3 Experimental Work
4 Results and Analysis
5 Conclusion
Acknowledgements
References
18 Critical Assessment of Metallurgical and Mechanical Characteristics of Pulse Laser Welded α + β Phase Ti-Alloy
1 Introduction
2 Materials and Methodology
3 Theoretical Background
4 Results and Discussions
4.1 Laser Welding and Bead Analysis
4.2 Comparison Between Experimental and Numerical Bead Profile
4.3 Interrelation Between Thermal Cycle and Phase Constituents
4.4 Compositional Analysis
4.5 Microstructural Evolution
4.6 Mechanical Performance
5 Conclusions
Acknowledgements
References
19 Characterization as a Tool for Failure Investigation: Tata Steel Experience
1 Introduction
2 Methodology for Failure Investigations
3 Results and Discussion (Case Studies)
3.1 Failure Analysis of 2 Ton Electric Fork Lift in a Cold Rolling Mill
3.2 Failure Analysis of Bend Pulley Shaft of INBA Slag Granulation System of a Blast Furnace
3.3 Failure Analysis of Heat Exchanger of a Batch Annealing Furnace
4 Concluding Remarks
References
20 Assessment of Bio-dielectric Calophyllum inophyllum (Polanga) Oil in Electro-discharge Machining: A Step Toward Sustainable Machining
1 Introduction
2 Preparation of Bio-dielectric
3 Experimental Methods
4 Result and Discussion
4.1 Material Removal Rate
4.2 Surface Roughness
5 Summary
References
21 Analysis of Tensile and Microstructural Properties of Al–Ni Joints by Ultrasonic Spot Welding
1 Introduction
2 Experimental Details
3 Results and Discussion
3.1 Tensile Shear Failure Load Analysis
3.2 Microstructural Analysis of Weld Interface
4 Conclusions
References
22 Cutting Force Analysis in Micro-milling of Al6061-SiCp Composite
1 Introduction
2 Experimental Procedure
2.1 Preparation of Al6061-SiCp MMCs
2.2 Setup for Micro-milling Experiment
3 Results and Discussion
3.1 Effect of Feed on Cutting Forces
3.2 Effect of Spindle Speed on Cutting Forces
3.3 Effect of Reinforcement (Change in SiCp wt%) on Cutting Forces
4 Conclusions
References
Simulation
23 A Hybrid Slicing Method to Eliminate the Need of Support Structures in Direct Energy Deposition and Material Extrusion-Based Processes
1 Introduction
2 Methodology
2.1 Horizontal Planar Slicing Strategy
2.2 Nonplanar Conformal Slicing
2.3 Horizontal—Conformal Hybrid Slicing
3 Illustration
3.1 Slicing
3.2 Offsetting for Machining Allowance
3.3 Deposition
3.4 Finish Milling
4 Conclusion
References
24 Discrete Element Analysis of Gravity-Driven Powder Flow in Coaxial Nozzles for Directed Energy Deposition
1 Introduction
1.1 Powder Feedstock Handling in DED
1.2 Powder Delivery Nozzles
2 Methodology
2.1 Effect of Nozzle’s Cone Angle
2.2 Effect of Head Tilt
2.3 Continuous and Discrete Coaxial Nozzle: A Comparative Study
3 Discrete Element Method
3.1 Theoretical Background
3.2 Particle Contact Model
3.3 Modeling Setup
4 Results and Discussion
4.1 Effect of the Cone Angle
4.2 Effect of Nozzle Inclination
4.3 Discrete and Continuous Coaxial Nozzle
5 Conclusion
References
25 Computational Modelling of In-Process Mitigation Technique to Control Residual Stress in Thick Plate Welding
1 Introduction
2 Methodology
2.1 Mathematical Formulation
2.2 FE Modelling and Meshing
3 Results and Discussion
4 Conclusions
References
26 Phenomenological Modelling of Surface Morphology in Friction Stir Welding of Aluminium Alloy
1 Introduction
2 Theoretical Formulation
2.1 Material Model
2.2 Mass Scaling and Stability of the Model
2.3 Boundary Condition and Contact Interaction
3 Results and Discussion
4 Conclusions
Acknowledgements
References
27 A Numerical Model for Piezoelectric Beam with Graded Properties
1 Introduction
2 Literature Survey
3 Modeling of FGPM Beam
4 Numerical Technique
5 Numerical Results and Discussions
5.1 Convergence Study
5.2 Validation Study
5.3 Parametric Study
6 Summary and Conclusion
References
28 Design and Analysis of Microgripper Using COMSOL for Drug Delivery Applications
1 Introduction
2 Gripper Modelling
3 Simulation
3.1 Base Material Analysis
3.2 Piezoelectric Material Analysis
3.3 Contact Pressure Analysis
3.4 Gap Distance Analysis
3.5 Stress Distribution Analysis
4 Conclusion
References
29 Automated Modeling of Swaged Reissner–Mindlin Plates Using FEniCS
1 Introduction
2 Formulation for Thin Swaged Reissner–Mindlin Plate
2.1 Finite Element Formulation of the Reissner–Mindlin Plate [5, 6]
2.2 Boundary Condition for the Swaged Reissner–Mindlin Plate
3 Introduction FEniCS Implementation
4 Results and Discussion
5 Conclusion
References
30 Theoretical Analysis of Composite Blade in Static Condition to Find Material Uncertainty and Validation with COMSOL Software
1 Introduction
2 Theoretical Analysis of Composite Blade
2.1 Moment of Inertia for Composite Box Beam
2.2 Free End Deflection Calculation
3 Numerical Analysis of Composite Blade
3.1 Numerical or Simulation Result
4 Conclusion
References
31 Free Vibration Analysis of FGM Structures Using FEM Technique
1 Introduction
2 Modelling of FGM Structures
2.1 Boundary Conditions
3 Validation Study
3.1 Validation Study for Isotropic Skew Plate
3.2 Validation Study for Laminate Composite Skew Plate
4 Parametric Study
4.1 Parametric Study for Triangular Plate
4.2 Parametric Study for Trapezoidal Plate
5 Summary and Conclusion
References
32 Numerical Behaviour of Al 6063 Under Varying Striker Velocity and Length of Split Hopkinson Pressure Bar at Large Strain Rates
1 Introduction
2 Methodology
2.1 Split Hopkinson Pressure Bar
2.2 Finite Element Analysis
2.3 Validation of Numerical Approach
3 Results and Discussion
3.1 Effect of Striker Bar Velocity
3.2 Effect of Length of Striker Bar
3.3 Effect of Diameter of Specimen
4 Conclusions
References
33 Mathematical Modelling-Based Solar PV Module and Its Simulation in Comparison with Datasheet of JAPG-72-320/4BB Solar Module
1 Introduction
2 India’s Sources of Power Production
3 Methodology
4 Mathematical Model Form of Photovoltaic Cell
5 Modelling of an Ideal PV Cell
6 Steps Associated for Making Simulation
7 Simulated Model
8 Results and Discussion
9 Conclusion
References
34 Computational Analysis of Efficiency for Non-toxic Perovskite Solar Cell with Inorganic HTMs
1 Introduction
2 Analysis of the Device
2.1 Method
2.2 Modeling of the Device
2.3 Simulation Procedure
3 Results and Discussion
3.1 Best Suitable Configuration
3.2 J-V Characteristics
3.3 Effect of Absorber Layer on Various Parameters
3.3.1 Effect of Absorber Thickness on PCE for All the Cell Configurations
3.3.2 Effect of Absorber Defect Density on the PCE
3.3.3 Effect of Perovskite Thickness on Various Parameters
4 Conclusion
References
Optimization
35 Optimization of Process Variables of Twin-Screw Extruder Using Response Surface Methodology for the Production of Fish Added Extruded Snack Product
1 Introduction
2 Materials and Methods
2.1 Raw Material Preparation
2.2 Twin-Screw Extruder
2.3 Proximate Evaluation
2.4 Design of the Experiment
2.5 Response Surface Methodology
2.6 Box-Behnken Mechanism
3 Results and Discussion
3.1 Proximate Analysis
3.2 Optimization
4 Conclusion
Acknowledgements
References
36 MCDM Optimization of Characteristics in Resistance Spot Welding for Dissimilar Materials Utilizing Advanced Hybrid Taguchi Method-Coupled CoCoSo, EDAS and WASPAS Method
1 Introduction
2 Experimental Analysis and Methodology
3 Optimization Methods
3.1 Combined Compromise Solution Method (CoCoSo)
3.2 Weighted Aggregated Sum Product Assessment Method (WASPAS)
3.3 Evaluation Based on Distance from Average Solution Method (EDAS)
4 Results and Considerations
4.1 Optimization Using Combined Compromised Solution (CoCoSo)
4.2 Optimization Using WASPAS
4.3 Optimization Using EDAS
4.4 Confirmation Experiment
5 Conclusions
Acknowledgements
References
37 MCDM Optimization of Karanja Biodiesel Powered CI Engine to Improve Performance Characteristics Using Super Hybrid Taguchi-Coupled WASPAS-GA, SA, PSO Method
1 Introduction
2 Preparation of Karanja Biodiesel
3 Experimental System
4 Optimization Methods
4.1 WASPAS Method (Weighted Aggregated Sum Product Assessment)
4.2 Genetic Algorithm
4.3 Simulated Annealing
4.4 Particle Swarm Optimization
5 Results and Considerations
5.1 Optimization Using Nature-Based Algorithm
5.2 Maximum Effective Factor
5.3 Confirmation Experiment
6 Conclusions
References
38 Characterization of Electrically Hybridized Friction Stir Welding of Mild Steel and Optimization of Process Parameters
1 Introduction
2 Principal of Friction Stir Joining
3 Experimental Setup
4 Taguchi Optimization
5 Result and Discussion
6 Microstructure Analysis
7 Conclusion
8 Future Scope of Study
References
39 Optimized Design and Performance Testing of a 1.5 MW Wind Turbine Blade
1 Introduction
2 Airfoil Parameterization
3 Objectives and Geometry Constraints
4 Design of Wind Turbine Blade
5 Results and Discussions
5.1 Control Variables of Base Airfoils and Optimized Airfoil
5.2 Comparison of Base Airfoil and Optimized Airfoil
5.3 Comparison of Aerodynamic Coefficients
5.4 Aerodynamic Analysis
5.5 Structural Analysis
6 Conclusions
References
40 A Fuzzy Set-Based Energy Consumption Model of Selective Laser Sintering
1 Introduction
2 Deterministic Model for Energy Estimation of Selective Laser Sintering
2.1 Energy Consumed by Laser System
2.2 Energy Consumed by Heater System
2.3 Energy Consumed by Roller
2.4 Energy Consumed by the Movable Platform
3 Implementation of Fuzzy Set Theory in the Energy Estimation
4 Case Studies
4.1 Estimation of Energy Considering Multiple Quantities of a Part in the Machine Chamber
4.2 Implementation of Fuzzy Arithmetic
5 Conclusion
References
41 Improving the Performance Analysis of MPPT Controller Unit of a PV Generation System Using Optimization Technique Based on Spider Monkey Principle (SMO)
1 Introduction
2 Modeling of PV Cell
3 Boost Converter Unit
4 MPPT Method
5 Spider Monkey Optimization Technique (SMO)
6 Simulation Results
7 Conclusion
References
Industry 4.0
42 The Blueprint of Managing Manpower in the Framework of Industry 4.0
1 Introduction
2 Review of Literature
3 Research Gap
4 Objectives
5 Research Methodology
6 Findings
6.1 Smart Human Resources (SHR4.0)
6.1.1 Changes in Organizational Structure
6.1.2 Changes in Manpower Management Activities
6.1.3 Changes in the Role of Manpower Management
6.1.4 Change in Skills and Competencies of Manpower
6.2 Benefits of SHR 4.0
6.3 Challenges of SHR 4.0
7 Conclusion
8 Future Research Directions
References
43 3D and 4D Printing in Industry 4.0: Trends, Challenges, and Opportunities
1 Introduction
2 Additive Manufacturing Applications in Industry 4.0
3 4D Printing
3.1 Emergence of 4D Printing
3.2 4D Printing Materials and Technologies
3.3 Applications of 4D Printing
4 Conclusions
Acknowledgements
References
44 Challenges in Implementation of Industry 4.0 in Manufacturing Sector
1 Introduction
2 Industry 4.0 Concept
3 Methodology
4 Discussion
4.1 Security and Privacy
4.2 Human Resources
4.3 Finance
4.4 Operations Management
4.5 Education and Training
4.6 Government Policies
5 Conclusion and Future Research Prospects
References