Abstract: In this study, a 50-W CO2 laser was used for the clad of 304L powders on the stainless steel substrate with a temperature sensor and image monitoring system. The laser power and cladding speed and focal position were modified to achieve the requirement of the workpiece flatness and mechanical properties. The numerical calculation is based on ANSYS to analyze the temperature change of the moving heat source at different surface positions when coating the workpiece, and the effect of the process parameters on the bath size was discussed. The temperature of stainless steel powder in the nozzle outlet reacting with the laser was simulated as a process parameter. In the experiment, the difference of the thermal conductivity in three-dimensional space is compared with single-layer cladding and multi-layer cladding. The heat dissipation pattern of the single-layer cladding is the steel plate and the multi-layer coating is the workpiece itself. The relationship between the multi-clad temperature and the profile was analyzed by the temperature signal from an IR pyrometer.
Abstract: Wire Electric Discharge Machining (WEDM) is
thermal machining process capable of machining very hard
electrically conductive material irrespective of their hardness.
WEDM is being widely used to machine micro scale parts with the
high dimensional accuracy and surface finish. The objective of this
paper is to optimize the process parameters of wire EDM to fabricate
the micro channels and to calculate the surface finish and material
removal rate of micro channels fabricated using wire EDM. The
material used is aluminum 6061 alloy. The experiments were
performed using CNC wire cut electric discharge machine. The effect
of various parameters of WEDM like pulse on time (TON) with the
levels (100, 150, 200), pulse off time (TOFF) with the levels (25, 35,
45) and current (IP) with the levels (105, 110, 115) were investigated
to study the effect on output parameter i.e. Surface Roughness and
Material Removal Rate (MRR). Each experiment was conducted
under different conditions of pulse on time, pulse off time and peak
current. For material removal rate, TON and Ip
were the most significant process parameter. MRR increases with the increase in
TON and Ip and decreases with the increase in TOFF. For surface
roughness, TON and Ip have the maximum effect and TOFF was found
out to be less effective.
Abstract: This paper presents a methodical approach for designing and optimizing process parameters in oil blending industries. Twenty seven replicated experiments were conducted for production of A-Z crown super oil (SAE20W/50) employing L9 orthogonal array to establish process response parameters. Power law model was fitted to experimental data and the obtained model was optimized applying the central composite design (CCD) of response surface methodology (RSM). Quadratic model was found to be significant for production of A-Z crown supper oil. The study recognized and specified four new lubricant formulations that conform to ISO oil standard in the course of analyzing the batch productions of A-Z crown supper oil as: L1: KV = 21.8293Cst, BS200 = 9430.00Litres, Ad102=11024.00Litres, PVI = 2520 Litres, L2: KV = 22.513Cst, BS200 = 12430.00 Litres, Ad102 = 11024.00 Litres, PVI = 2520 Litres, L3: KV = 22.1671Cst, BS200 = 9430.00 Litres, Ad102 = 10481.00 Litres, PVI= 2520 Litres, L4: KV = 22.8605Cst, BS200 = 12430.00 Litres, Ad102 = 10481.00 Litres, PVI = 2520 Litres. The analysis of variance showed that quadratic model is significant for kinematic viscosity production while the R-sq value statistic of 0.99936 showed that the variation of kinematic viscosity is due to its relationship with the control factors. This study therefore resulted to appropriate blending proportions of lubricants base oil and additives and recommends the optimal kinematic viscosity of A-Z crown super oil (SAE20W/50) to be 22.86Cst.