Advances in Forming, Machining and Automation

M. S. ShunmugamM. Kanthababu Editors

Proceedings of AIMTDR 2018

Lecture Notes on Multidisciplinary Industrial EngineeringSeries Editor: J. Paulo Davim

Lecture Notes on Multidisciplinary IndustrialEngineering

Series Editor

J. Paulo Davim , Department of Mechanical Engineering, University of Aveiro,Aveiro, Portugal

“Lecture Notes on Multidisciplinary Industrial Engineering” publishes specialvolumes of conferences, workshops and symposia in interdisciplinary topics ofinterest. Disciplines such as materials science, nanosciences, sustainability science,management sciences, computational sciences, mechanical engineering, industrialengineering, manufacturing, mechatronics, electrical engineering, environmentaland civil engineering, chemical engineering, systems engineering and biomedicalengineering are covered. Selected and peer-reviewed papers from events in thesefields can be considered for publication in this series.

More information about this series at http://www.springer.com/series/15734

M. S. Shunmugam • M. KanthababuEditors

Advances in Forming,Machining and AutomationProceedings of AIMTDR 2018

123

EditorsM. S. ShunmugamManufacturing Engineering SectionDepartment of Mechanical EngineeringIndian Institute of Technology MadrasChennai, Tamil Nadu, India

M. KanthababuDepartment of Manufacturing EngineeringCollege of Engineering, GuindyAnna UniversityChennai, Tamil Nadu, India

ISSN 2522-5022 ISSN 2522-5030 (electronic)Lecture Notes on Multidisciplinary Industrial EngineeringISBN 978-981-32-9416-5 ISBN 978-981-32-9417-2 (eBook)https://doi.org/10.1007/978-981-32-9417-2

© Springer Nature Singapore Pte Ltd. 2019This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or partof the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations,recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmissionor information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilarmethodology now known or hereafter developed.The use of general descriptive names, registered names, trademarks, service marks, etc. in thispublication does not imply, even in the absence of a specific statement, that such names are exempt fromthe relevant protective laws and regulations and therefore free for general use.The publisher, the authors and the editors are safe to assume that the advice and information in thisbook are believed to be true and accurate at the date of publication. Neither the publisher nor theauthors or the editors give a warranty, expressed or implied, with respect to the material containedherein or for any errors or omissions that may have been made. The publisher remains neutral with regardto jurisdictional claims in published maps and institutional affiliations.

This Springer imprint is published by the registered company Springer Nature Singapore Pte Ltd.The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721,Singapore

AIMTDR 2018 Conference’s Core OrganizingCommittee

Patrons

Dr. M. K. Surappa, Vice Chancellor, Anna UniversityDr. J. Kumar, Registrar, Anna University

President (NAC-AIMTDR)

Mr. P. Kaniappan, Managing Director, WABCO India Ltd.

Vice-President (NAC-AIMTDR)

Dr. Uday Shanker Dixit, Professor, IIT Guwahati, India

Co-patrons

Dr. A. Rajadurai, Dean, MIT Campus, Anna UniversityDr. T. V. Geetha, Dean, CEG Campus, Anna UniversityDr. L. Karunamoorthy, Chairman, Faculty of Mechanical Engineering, AnnaUniversityDr. S. Rajendra Boopathy, Head, Department of Mechanical Engineering, AnnaUniversity

v

Chairman

Dr. S. Gowri, Honorary Professor, Department of Manufacturing Engineering,Anna University

Co-chairman

Dr. P. Hariharan, Professor, Department of Manufacturing Engineering, AnnaUniversity

Organizing Secretary

Dr. M. Kanthababu, Professor and Head, Department of ManufacturingEngineering, Anna University

Joint Organizing Secretaries

Dr. M. Pradeep Kumar, Professor, Department of Mechanical Engineering, AnnaUniversityDr. A. Siddharthan, Associate Professor, Department of Production Technology,Anna University

International Scientific Committee

Prof. Abhijit Chandra, Iowa State University, USAProf. Ajay P. Malshe, University of Arkansas, USAProf. Andrew Y. C. Nee, NUS, SingaporeProf. Chandrasekar S., Purdue University, USAProf. Dean T. A., University of Birmingham, UKProf. Hong Hocheng, National Tsing Hui University, TaiwanProf. John Sutherland, Purdue University, USAProf. Kamlakar P. Rajurkar, University of Nebraska, USAProf. Kornel Ehmann, Northwestern University, USAProf. Liao Y. S., National Taiwan University, TaiwanProf. McGeough J. A., University of Edinburgh, UKProf. Mustafizur Rahman, NUS, Singapore

vi AIMTDR 2018 Conference’s Core Organizing Committee

Prof. Philip Koshy, McMaster University, CanadaProf. Rakesh Nagi, University of Buffalo, USAProf. Shiv Gopal Kapoor, University of Illinois, USAProf. Srihari Krishnasami, Binghamton University, USAProf. Tae Jo Ko, Yeungnam University, South KoreaProf. Tugrul Ozel, State University of New Jersey, USA

National Advisory Committee

Prof. Ahuja B. B., Government College of Engineering, PuneProf. Amitabha Ghosh, BESUProf. Bijoy Bhattacharyya, Jadavpur University, KolkataProf. Biswanath Doloi, Jadavpur University, KolkataProf. Chattopadhyay A. K., IIT KharagpurProf. Deshmukh S. G., IIT GwaliorShri. Dhand N. K., MD, ACE Micromatic, BangaloreProf. Dixit U. S., IIT Guwahati, GuwahatiProf. Jain P. K., IIT Roorkee, RoorkeeProf. Jain V. K., IIT KanpurProf. Jose Mathew, NIT CalicutShri. Lakshminarayan M., WABCO India Pvt. Ltd.Prof. Lal G. K., IIT KanpurProf. Mehta N. K., IIT RoorkeeProf. Mohanram P. V., PSG Institute of Technology and Applied ResearchShri. Mohanram P., IMTMA, BangaloreDr. Mukherjee T., Tata Steel Ltd., JamshedpurShri. Muralidharan P., Lucas TVS Ltd., VelloreProf. Narayanan S., VIT University, VelloreMr. Niraj Sinha, Scientist ‘G’, PSA, GOIProf. Pande S. S., IIT Bombay, MumbaiDr. Prasad Raju D. R., MVGRECProf. Radhakrishnan P., PSG Institute of Advanced Studies, CoimbatoreProf. Radhakrishnan V., IIST, TrivandrumProf. Ramaswamy N., IIT Bombay (Former), ChennaiProf. Ramesh Babu N., IIT MadrasShri. Rangachar C. P., Yuken India Ltd., BangaloreProf. Rao P. V., IIT DelhiDr. Santhosh Kumar, IIT BHUDr. Sathyan B. R., CMTI, BangaloreProf. Satyanarayan B., Andhra University (Former), VisakhapatnamProf. Selvaraj T., NIT TrichyProf. Shan H. S., IIT Roorkee (Former), ChandigarhProf. Shunmugam M. S., IIT Madras

AIMTDR 2018 Conference’s Core Organizing Committee vii

Shri. Shirgurkar S. G., Ace Designers Ltd., BangaloreDr. Sumantran V., Celeris TechnologiesDr. Suri V. K., BARC, MumbaiShri. Venu Gopalan P., DRDL, HyderabadProf. Vinod Yadav, Motilal Nehru National Institute of Technology, Allahabad

viii AIMTDR 2018 Conference’s Core Organizing Committee

Foreword

It gives us immense pleasure to present the Advances in Manufacturing Technologyand Design—Proceedings of All India Manufacturing Technology, Design andResearch (AIMTDR) Conference 2018.

We would like to express our deep gratitude to all the members of OrganizingCommittee of AIMTDR 2018 Conference and also to authors, reviewers, sponsors,volunteers, etc., for their wholehearted support and active participation. Our specialthanks to Mr. P. Kaniappan, Managing Director, WABCO India Ltd, Chennai, whokindly agreed to act as President of National Advisory Committee (NAC) of theAIMTDR 2018 Conference. We also express our sincere thanks to ChairmanDr. S. Gowri, Honorary Professor, and Co-chairman Dr. P. Hariharan, Professor,Department of Manufacturing Engineering, Anna University, Chennai, for theirwholehearted support. We would like to express our sincere thanks to ResearchScholars Mr. K. R. Sunilkumar, Mr. U. Goutham, Mr. V. Mohankumar andMr. R. Prabhu and also UG/PG students of the Department of ManufacturingEngineering, Anna University, for their contributions in the preparation of thisvolume.

High-quality papers have been selected after peer review by technical experts.We hope you find the papers included in the Proceedings of AIMTDR 2018Conference are interesting and thought-provoking.

We also like to express our gratitude for the support provided by WABCO IndiaLtd., Chennai; Kistler Instruments India Pvt. Ltd., Chennai; AMETEK InstrumentsIndia Pvt. Ltd., Bengaluru; Central Manufacturing Technology Institute,Government of India, Bengaluru; Defence Research and Development Organisation,Government of India, New Delhi; and Ceeyes Engineering Industries Pvt Ltd.,Trichy.

ix

Finally, we would like to express our gratitude to the National AdvisoryCommittee (NAC) members of AIMTDR 2018 Conference for providing thenecessary guidance and support.

Uday Shanker DixitVice-President, National Advisory Committee

AIMTDR, Guwahati, India

x Foreword

Preface

All India Manufacturing Technology, Design and Research (AIMTDR) Conferenceis considered globally as one of the most prestigious conferences held once in twoyears. It was started in 1967 at national level at Jadavpur University, Kolkata, India,and achieved the international status in the year 2006. It was organized by variousprestigious institutions such as Jadavpur University, IIT Bombay, IIT Madras,CMTI Bangalore, PSG iTech, IIT Kanpur, CMERI, IIT Delhi, NIT Warangal, IITKharagpur, BITS Ranchi, VIT Vellore, IIT Roorkee, Andhra University, IITGuwahati and College of Engineering Pune.

The recent edition of the AIMTDR Conference, 7th International and 28th AllIndia Manufacturing Technology, Design and Research (AIMTDR) Conference2018, was jointly organized by the Departments of Manufacturing Engineering,Mechanical Engineering and Production Technology during 13–15 December 2018at College of Engineering Guindy, Anna University, Chennai, India, with the theme‘Make in India—Global Vision’. A major focus was given on recent developmentsand innovations in the field of manufacturing technology and design throughkeynote lectures. About 550 participants registered for the conference. During theconference, researchers from academia and industries presented their findings andexchanged ideas related to manufacturing technology and design.

Of the 750 papers received initially, 330 papers were finally selected after rig-orous review process for publication. Selected papers from the conference are beingpublished by Springer in the series Lecture Notes on Multidisciplinary IndustrialEngineering in five volumes, namely Volume 1—Additive Manufacturing and Joining,Volume 2—Forming, Machining and Automation, Volume 3—UnconventionalMachining and Composites, Volume 4—Micro and Nano Manufacturing and SurfaceEngineering and Volume 5—Simulation and Product Design and Development.

Chennai, India M. S. ShunmugamMay 2018 M. Kanthababu

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Contents

Part I Forming

1 Effect of Heat Treatment on Formability of AA6082 by SinglePoint Incremental Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3S. Maharajan, D. Ravindran and S. Rajakarunakaran

2 Forming Behavior of AA5052-H32 and AA6061-T6 DuringSingle Point Incremental Forming . . . . . . . . . . . . . . . . . . . . . . . . . 17M. M. Ghadmode, R. R. Pawar and B. U. Sonawane

3 Pull-Out Forming: Experiments and Process Simulation . . . . . . . . 29S. Kumar

4 Failure Prediction and Forming Behavior of AA5754 Sheetsat Warm Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Sudhy S. Panicker, Kaushik Bandyopadhyayand Sushanta Kumar Panda

5 Magnetic Pulse Forming and Punching of Al Tubes—A NovelTechnique for Forming and Perforation of Tubes . . . . . . . . . . . . . . 67Sagar Pawar, Sachin D. Kore and Arup Nandy

6 Experimental Investigation on the Forming of AA 5052-H32Sheet Using a Rigid-Body-Based Impact in a Shock Tube . . . . . . . 79S. K. Barik, R. Ganesh Narayanan and N. Sahoo

7 An Experimental Study on Single-Point Incremental Formingof AA5083 Sheet Using Response Surface Methodology . . . . . . . . . 91Gautam Kumar, Saurabh, Maharshi Roshan, Kumar Nandanand Kuntal Maji

8 Study and Establishment of Manufacturing Processof Molybdenum Liners Using Warm Flow Forming Process . . . . . . 105P. S. S. R. K. Prasad, Navneet Verma, Narendra Kumarand K. M. Rajan

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Part II Machining

9 Influence of Surgical Drill Geometry on Drilling Performanceof Cortical and Trabecular Bone . . . . . . . . . . . . . . . . . . . . . . . . . . 119Ramesh Kuppuswamy and Brett Christie-Taylor

10 Study of Cutting Temperature and Chip Formation in Drillingof AA6351–B4C Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133S. Thirumalai Kumaran, G. S. Samy, M. Uthayakumar and Tae Jo Ko

11 A Study of Parameters Affecting Cutting Forces in MinimumQuantity Lubrication-Assisted Cross-Peripheral Grindingof Alumina Ceramic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143A. V. Manu, V. G. Ladeesh and R. Manu

12 Condition Monitoring of Abrasive Waterjet MillingUsing Acoustic Emission and Cutting Force Signals . . . . . . . . . . . . 153U. Goutham, M. Kanthababu, S. Gowri, K. R. Sunilkumar,M. Mathanraj, J. John Rozario Jegaraj and R. Balasubramanian

13 A Novel Small Quantity Lubrication Method to AssessGrindability of Inconel 718 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Sirsendu Mahata, Manas Bhattacharyya, Bijoy Mandaland Santanu Das

14 Performance of Carbon Nanotubes Based Cutting Oilon Turning of AISI 1040 Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177M. Amrita, P. Yogesh Chandra, P. Venkata Ramana, U. Shyam Saiand Chatti Sreeram

15 Investigations on the Influence of Serration Parameterson Cutting Forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189P. Bari, P. Wahi and M. Law

16 Effect of Minimum Quantity Lubrication on Tool Wearand Surface Integrity During Hard Turning of EN31 Steel . . . . . . 205Jitendra Kumar Verma, Gaurav Bartarya and Jitendra Bhaskar

17 Temperature Profiling of Microwave–Metal Discharge PlasmaChannel Using Image Processing Technique . . . . . . . . . . . . . . . . . . 219Anurag Singh and Apurbba Kumar Sharma

18 Applicability of CaF2 Solid Lubricant-Assisted MinimumQuantity Lubrication in Turning for SustainableManufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229Mayur A. Makhesana, K. M. Patel and Anand S. Patel

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19 Cryogenic Machining of AZ31B Magnesium Alloyfor Bio-implant Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239Vaibhav Tibrewal, Kalpit Dak, Aundhe Himanshu, Hema Kumar,P. Kuppan and A. S. S. Balan

20 Experimental Investigation on Machining Parametersof Hastelloy C276 Under Different Cryogenic Environment . . . . . . 253S. Vignesh and U. Mohammed Iqbal

21 Machining of EN-31 Steel and Experimental Analysis of VariousProcess Parameters Using Minimum Quantity Lubrication . . . . . . 269Ashutosh Saini and S. K. S. Yadav

22 Effect of Tool Material on Trepanning of CFRP Composites . . . . . 283B. R. Jayasuriya, A. Harsha Vardhan and V. Krishnaraj

23 Effect of Air Delivery Pressure and Flow Rate on SurfaceIntegrity in Minimum Quantity Cooling Lubrication Grindingof Inconel 718 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Anirban Naskar, Amit Choudhary, Biddu Bhushan Singh and S. Paul

24 Effect of Different Geometric Texture Shapes on Wettabilityand Machining Performance Evaluation Under Dry and MQLEnvironments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305Sarvesh Kumar Mishra, Sudarsan Ghosh and Sivanandam Aravindan

25 Evaluation of Surface Morphology of Yttria-Stabilized Zirconiawith the Progress of Wheel Wear in High-Speed Grinding . . . . . . . 315Amit Choudhary, Anirban Naskar and S. Paul

26 Grindability and Surface Integrity of Nickel-Based CastSuperalloy IN-738 by Vitrified Alumina Wheel . . . . . . . . . . . . . . . . 325Srinivasa Rao Nandam, A. Venugopal Rao, Amol A. Gokhaleand Suhas S. Joshi

27 Simulating the Effect of Microstructure in Metal Slidingand Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339A. S. Vandana and Narayan K. Sundaram

28 What Do Chip Morphologies Tell Us About the CuttingProcess? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Koushik Viswanathan, Anirudh Udupa, Dinakar Sagapuramand James B. Mann

29 Simultaneous Optimization of Milling Process Responsesfor Nano-Finishing of AISI-4340 Steel Through SustainableProduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361Muhammed Muaz and Sounak Kumar Choudhury

Contents xv

30 Assessment of Cutting Tool Reliability During TurningConsidering Effects of Cutting Parametersand Machining Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375Gaddafee Mohamad and Satish Chinchanikar

31 An Experimental Investigation on Productivity and ProductQuality During Thin-Wall Machining of AluminumAlloy 2024-T351 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385G. Bolar and S. N. Joshi

32 An Approach of Minimizing Energy Consumptionin the Machining System Using Job Sequences VaryingTechnique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Md. Shahzar Jawaid, S. C. Srivastava and S. Datta

33 Comparative Study on the Performance of Different Drill Bitsfor Drilling CFRP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407N. S. Sowjanya, V. G. Ladeesh, R. Manu and Jose Mathew

34 A Cyber-Physical System Improves the Quality of Machiningin CNC Milling Machine—A Case Study . . . . . . . . . . . . . . . . . . . . 421Ganesh Kumar Nithyanandam, Saravana Kumar Sellappanand Selvaraj Ponnumuthu

35 Challenges in Machining of Silica–Silica Cone for AerospaceApplication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431Ashish Tewari, T. Srinivasulu, B. Hari Prasad and A. P. Dash

36 Optimization of Cutting Parameters for Hard Turningof WC–Co–Ni–Cr (15% Binder) Mill Rolls on CNC Lathewith Polycrystalline Diamond . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441Mahesh J. Hunakunti, Vaishali Jagannath, Ramesh S. Rao,S. Srinivas, S. Shyamsundar and D. Ashokkumar

37 Multi-response Optimization of End Milling on Al6061–SicpMetal Matrix Composite–Hybrid GRA-PCA Approach . . . . . . . . . 451B. Ravi Sankar and P. Umamaheswarrao

38 Experimental Investigation on Dewaxed TungstenCarbide-Based Self-lubricant Cutting Tool Material . . . . . . . . . . . . 461A. Muthuraja

39 An Experimental Investigation on Horizontal Surface Grindingof Mild Steel Using Different Lubricating Oils . . . . . . . . . . . . . . . . 471Soutrik Bose and Nabankur Mandal

40 Comparison Between Advanced Cutting Tools to Achievea Better Cutting Condition for the Machining of Aluminium . . . . . 481S. K. Pattnaik, M. Behera, S. Padhi and S. K. Sarangi

xvi Contents

41 Investigation on Machining Responses during Hard Turningof AISI D2 Steel under Dry, Wet and Nano-based MQLConditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495Vaibhav Chandra, Sudarsan Ghosh and P. Venkateshwara Rao

42 Effect of Machining Parameters on Surface Integrity in EndMilling of Inconel 625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505Ramesh Rajguru and Hari Vasudevan

43 Tool Wear Behavior in Milling of Hardened Custom465 Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517V. Prasath, V. Krishnaraj, J. Kanchana and B. Geetha Priyadharshini

44 Experimental Study on Machining of EN24 Using MinimumQuantity Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527Gaurav Tyagi, J. Bhaskar, S. K. Singhal and G. Bartarya

45 Investigative Study of Temperature Produced During TurningOperation Using MQL and Solid Lubricants . . . . . . . . . . . . . . . . . 539Anand S. Patel, Mayur A. Makhesana and K. M. Patel

46 Effect of Dressing Infeed on Alumina Wheel During GrindingTi–6Al–4V Under Varying Depth of Cut . . . . . . . . . . . . . . . . . . . . 551Manish Mukhopadhyay, Souvik Chatterjee, Pranab Kumar Kunduand Santanu Das

47 Experimental Evaluation of Surface Roughness, DimensionalAccuracy, and MRR in Cylindrical Grinding of EN 24 Steel . . . . . 561Pankaj V. Mohire and Raju S. Pawade

Part III Automation

48 Bio-inspired Knowledge Representation Framework for DecisionMaking in Product Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573Varun Tiwari, Prashant Kumar Jain and Puneet Tandon

49 Heuristic Algorithmic Approach for Automatic Generationof Pin Layout for Robotic Unloading of Sheet Metal Parts . . . . . . . 587A. Ramesh Babu

50 Voxel-Based Strategy for Efficient CNC Machining . . . . . . . . . . . . 601A. Kukreja, H. D. Mane, M. Dhanda and S. S. Pande

51 Effect of Geometrical and Process Parameters on Utilizationof Sheet Material in Plasma and Laser Cutting Processes . . . . . . . 613N. Venkatesh, S. Sabari Sriram, V. Satish Chandranand A. Ramesh Babu

Contents xvii

52 Development of Manufacturability Indices for Prismatic Parts . . . . 625Manish Kumar Gupta, Pramod Kumar Jainand Abinash Kumar Swain

53 A Cyber-Physical System Architecture for SmartManufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637Jitin Malhotra, Faiz Iqbal, Ashish Kumar Sahu and Sunil Jha

54 Measurement of Bores Using Scanning Mode of Articulated ArmCoordinate Measuring Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . 649Ashik Suresh and P. B. Dhanish

55 A Method for Evaluation of Simple Torus Surfaces . . . . . . . . . . . . 659T. S. R. Murthy

56 An Artefact-Based Continues Performance Verificationof Coordinate Measuring Machine . . . . . . . . . . . . . . . . . . . . . . . . . 671Goitom Tesfay and Rega Rajendra

57 Development of Welding Fixture for Rocket Motor CasingAssembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 679Venkateswarlu Chepuru, P. Kiran and B. Hari Prasad

58 Generation of Sequence of Machining Operations ThroughVisualization of End Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 689G. V. S. S. Sharma, P. Srinivasa Rao and B. Surendra Babu

59 Monitoring the Dynamics and Tracking of a Vehicle UsingInternet of Things (IoT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699Sri Harsha Dorapudi, Vivek Varma Buddharaju, V. V. Vimal Varmaand R. Ramesh

60 Automated Production of Medical Screws Using Titanium Baron Indigenous Sliding Headstock Automat . . . . . . . . . . . . . . . . . . . 709Manohar Bulbule, Naveen Hosamani and S. R. Chandramouli

61 Process Mechanization and Automation for Hybrid TIG MAGArc Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 723Onkar S. Sahasrabudhe and D. N. Raut

62 Two-Sided Assembly Line Balancing—A Company Case StudySolved by Exact Solution Approach . . . . . . . . . . . . . . . . . . . . . . . . 733Ashish Yadav and Sunil Agrawal

xviii Contents

About the Editors

M. S. Shunmugam is a Professor (Emeritus) in the Manufacturing EngineeringSection in the Department of Mechanical Engineering, Indian Institute ofTechnology (IIT) Madras. After receiving his PhD in Mechanical Engineering fromIIT Madras in 1976, he has worked in IIT Bombay (from 1977 to 1980) and in IITMadras from 1980 onwards. He was a visiting faculty member at MichiganTechnological University during 1989-1991 and was a member in the board ofgovernors of IIT Madras during 2012-2013. Dr. Shunmugam’s research interestsinclude metrology, machine tools, manufacturing, gears, micro-machining andcomputer applications in manufacturing. He has published about 130 peer-reviewedinternational journal papers, 15 peer-reviewed national journal papers, 75 interna-tional conferences and about 80 national conferences.

M. Kanthababu is a Professor in the Department of Manufacturing Engineering inAnna University, Chennai, India and the Director of the Centre for IntellectualProperty Right and Trade Marks in Anna University. He has completed his MS inMechanical engineering and PhD in Advanced Manufacturing Technology from IITMadras. Prof. Kanthababu’s research interests include manufacturing technology,composite materials and machining, and automation in manufacturing. He haspublished more than 30 peer reviewed international journal papers and 2 books, andholds one patent.

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Part IForming

Chapter 1Effect of Heat Treatment on Formabilityof AA6082 by Single Point IncrementalForming

S. Maharajan , D. Ravindran and S. Rajakarunakaran

Abstract This paper investigates the formability of annealed and un-annealedAA6082 sheets by using single point incremental forming (SPIF) process.Lightweight alloys represent key materials for the future of the manufacturing indus-try, and their use in the emerging fields, such as automobile and aerospace engineer-ing, is a continual topic for researchers of all over the world. It is a reliable areawhere huge opportunities available for rapid prototyping. In this experimental work,the sheet metal is deformed into the required shape by a hemispherical tool in thevertical CNC milling machine. The straight groove tests are carried out by varyingthe forming process parameters like feed, speed and step depth. Four experiments areconducted with two sets of different forming process parameters for annealed andun-annealed sheet metals. The formability, forming time and maximum step depthare examined for each experiment. It is found that better formability is achieved inannealed AA6082 aluminium sheet than un-annealed AA6082 aluminium sheet andalso observed that step depth plays a major role in forming time and formability.

Keywords Single point incremental forming · AA6082 aluminium alloy ·Formability · Coordinate measuring machine

1.1 Introduction

Incremental forming is a forefront sheet metal forming technology enabling the for-mation of the desired shape by passing a sheet metal through a series of small incre-mental plastic deformation. A CNC vertical milling machine traces the movement offorming tool path. A special die is not required for this process. A fixture is enoughto hold the sheet metal in all the four sides, and highly sophisticated machines arenot required to carry out the forming operation. In this machining operation, forming

S. Maharajan (B) · S. RajakarunakaranDepartment of Mechanical Engineering, Ramco Institute of Technology, Rajapalayam, Indiae-mail: maharajan@ritrjpm.ac.in

D. RavindranDepartment of Mechanical Engineering, National Engineering College, Kovilpatti, India

© Springer Nature Singapore Pte Ltd. 2019M. S. Shunmugam and M. Kanthababu (eds.), Advances in Forming, Machiningand Automation, Lecture Notes on Multidisciplinary Industrial Engineering,https://doi.org/10.1007/978-981-32-9417-2_1

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4 S. Maharajan et al.

tool is fitted in the tool holder instead of milling cutter. The CNC vertical machinecan carry out the entire operation with its CNC programming. This process is onlysuitable for low-series production. Manufacturing of a large variety of complicatedshapes, which are difficult to form using other forming technology, can be easilyformed using incremental forming method. Formability can be enhanced by heattreatment process in the incremental forming technology which in turn will be usedfor prototyping process. Incremental forming plays a vital role in automotive indus-try and biomedical applications where flexibility is needed to manufacture the sheetmetal with high accuracy and dimensions [1]. By increasing feed rate, formabilityand surface roughness are increased which simultaneously reduces the forming time.The friction between the tool and sheet can be reduced by freely rotating the ball endtool which is supported with proper lubrication in all the directions [2]. The straightgroove test is a suitable method for finding formability. The ball ended forming toolis used for increasing formability with less feed rate by lowering the friction betweentool ball end and sheet metal [3]. Feed rate, vertical step down, rotating speed of thetool and lubrication are the major process parameters. Lubrication plays a major rolein enhancing the formability. Feed rate is the least factor for maximizing formabil-ity and minimizing the surface roughness [4]. An increasing trend in temperatureand a reducing trend in surface roughness are observed when tool rotates in bothclockwise and anticlockwise directions. Surface roughness reduces insignificantlyas the rotating speed of the tool is increased. Simultaneously, the forming forcesdecrease significantly as the rotating speed of the tool is increased [5]. Formabilitywill increase as the temperature varies from 100 to 250 °C. Progressive formingprovides high inclination angle and exceeds forming limits in the incremental form-ing technology [6]. Heat generation between sheet and tool increases as the rotatingspeed of the tool increases. Sometimes, such heat is beneficial in enhancing theformability, and at the same time, the surface damage should be assessed due to thefriction between tool and surface of the sheet. Formability can be improved withnon-hemispherical tool. Step depth plays a major role in enhancing formability. Byreducing step depth, formability can be increased [7]. Tool diameter is the significantfactor in increasing wall angle, formability and surface roughness. Formability canbe increased by reducing the tool diameter and feed rate. By properly controlling thetool diameter, surface roughness can be reduced [8]. Surface finish is significantlygood in curved path when compared to straight path of the tool. Hence, higher thecontact between tool and workpiece, greater will be the surface roughness. Smoothcurve tool path enhances formability which, in turn, increases the flow of material[9]. Forming forces are reduced by reducing vertical step depth. Surface roughnessis reduced by controlling the step depth. Thickness distribution is uniform when wallangle is greater than 65° [10]. Forming force could be reduced by increasing thegrain size of the sheet. Suitable heat treatment temperature should be maintained tocontrol the grain size [11]. In the hybrid optimization technique, it was found thatfeed rate is themost important factor, followed by vertical depth and the tool diameter[12]. Appropriate heat treatment process provides sheet material with homogeneousand fine microstructure. Heat treatment process increases the strength of the compo-nent. Various experiments conducted reveal that the formability can be significantly

1 Effect of Heat Treatment on Formability of AA6082 … 5

increased for heat-treated sheet material in the tube hydroforming of Cu alloy andAl alloy materials [13]. On comparing stretch bending with single point incrementalforming, it was found that SPIF formability enhancement is more than stretch bend-ing operation. Forming force increases as the tool diameter increases. This is becausecontact area is more in large tool diameter. At the same time, higher step down ispossible with higher tool diameter which reduces the forming time [14]. Since thelocalization of strain can be inhibited in incremental forming technique, forming limitis similar for both flattened sheet metal and uniform sheet metal. So, this processis suitable for cold recycling process of sheet metal waste [15]. The microstructurestudy is important in understanding the formable behaviour of Al sheet material inany forming technology. The necking ductility can be improved with the combina-tion of coarse and fine grain microstructure. Aluminium alloy microstructure can berefined due to the presence of Mg [16]. The expressions used to determine majorstrains and minor strains are given as follows, as developed by Narayanasamy andSathiya Narayanan [17]:

Major strain (e1) = ln(Major diameter of the ellipse/Original diameter of the circle)

Minor strain (e2) = ln(Minor diameter of the ellipse/Original diameter of the circle)

Fully recrystallized microstructure with good formability can be obtained at350 °C annealing temperature for Al 1145 alloy sheet. Heat treatment of aluminiumalloy enhances the formability of sheet metal [18]. The forming limit curve in incre-mental forming is quite different from that in conventional forming. It appears to bea straight line with a negative slope in the positive regions of the minor strains in theforming limit diagram [19]. Most of the researchers have carried out experimentsfor un-annealed sheet metal by varying process parameters like feed, speed and stepdepth and found the formability. From the literature survey, it is evident that annealedsheet metal formability work in the SPIF has not been carried out so far.

In this work, a new aluminium alloy AA6082 is used for which annealing pro-cess has been carried out. Response parameters such as formability, forming timeand maximum step depth are experimentally determined and discussed. From theexperimental work, it is clear that the forming time had substantially reduced inthe annealed sheet metal when compared to un-annealed sheet metal. Generally, theannealing process is carried out to refine crystal structure, improve ductility andrelieve internal stresses. In addition to this, it is found that the annealing heat treat-ment process also helps to improve the formability of the sheet metal and achievemaximum step depth at the time of fracture of the sheet metals.

6 S. Maharajan et al.

1.2 Experimental

In this work, AA6082 aluminium alloy sheet (Cu—0.06%,Mg—0.97%, Si—1.09%,Fe—0.22%, Mn—0.46%, Cr—0.21%, Al—remaining) was deformed to the desiredshapebyusing incremental forming for straight groove test.AA6061 aluminiumalloysheet has been replaced with AA6082 aluminium alloy sheet in many applications,since AA6082 gives higher strength. The addition of a large amount of manganesecontrols the grain structure which in turn results in a stronger alloy. The sheet metalthickness was 0.5 mm and was cut into dimensions of 200 × 200 mm. The lasermarked 5-mm grid circle was printed on the two sheet metals, and another twosheet metals were printed with 2-mm grid circle to facilitate strain measurementafter and before deformation. High-carbon and high-chromium steel tool is used. Ithas high wear and abrasion resistant properties. It is heat treatable and will offerhardness in the range 55–62 HRC and is machinable in the annealed condition. TheD2 tool was used for this research. This tool was made with hemispherical end.Cold-work tool steels include the high-carbon, high-chromium steels or group Dsteels. These steels are designated as group D steels and consist of D2, D3, D4,D5 and D7 steels. These steels contain 1.5–2.35% of carbon and 12% of chromiumwith elastic modulus of 210 GPa. Tool dip diameter is 5 mm, and the length ofthe tool is 100 mm. The D2 tool steel picture is shown in Fig. 1.1. AA6082 sheetmetal with 5-mm grid circle forming is shown in Fig. 1.2. Grid circle diameter anddeformed grid circle dimensions after forming process were measured in coordinatemeasuringmachine (CMM) in Ramco Institute of Technology, Rajapalayam. ACNCvertical milling machine specification is Travel, x-axis: 810 mm, y-axis: 510 mmand z-axis: 510 mm; Maximum Spindle speed, 6000 rpm; and Maximum Feed,1000 mm/min. The incremental forming operation is carried out in CNC verticalmilling machine at Precision Automation in Trichy as shown in Fig. 1.3. The inputforming process parameters were spindle speed, feed and step depth. Favourableoutputs were formability, forming time andmaximum step depth achieved at the timeof fracture. Four experiments were carried out for two different conditions with threeinput process parameters for annealed and un-annealed sheets. Response parameters

Fig. 1.1 High-carbon andhigh-chromium tool steel(D2 tool steel)

Fig. 1.2 AA6082 sheetmetal with 5-mm grid circle

1 Effect of Heat Treatment on Formability of AA6082 … 7

Fig. 1.3 Incremental forming process in CNC vertical milling machine set-up

Table 1.1 Experiments carried out for two different conditions with three input process parameters(annealing and un-annealing AA6082 aluminium sheets)

Exp. No. AA6082 alloy sheetcondition

Spindle speed (rpm) Feed (mm/min) Step depth (mm)

1 Un-annealing 1200 100 0.2

2 Un-annealing 1400 150 0.4

3 Annealing 1200 100 0.2

4 Annealing 1400 150 0.4

were found through experiments and compared between annealed and un-annealedsheet metal. Most importantly, formability was calculated for each experiment andcompared annealed sheet with un-annealed sheet. The results were discussed. Fourexperiments details are given in Table 1.1.

1.3 Results and Discussions

1.3.1 Analysis of Formability of the Un-annealed AA6082Sheet Metal

Un-annealed Aluminium Alloy 6082 Sheet 1 (First Experiment). First experimentwas carried out for un-annealed sheetmetalwith the input formingprocess parameterssuch as spindle speed of 1200 rpm, feed of 100 mm/min and step depth of 0.2 mm.The time taken for forming operation was 23 min 10 s. Maximum depth of formingwas achieved with 11.4 mm at the time of fracture. The deformed sheet metal isshown in Fig. 1.4.

The original grid circle diameter is 5 mm. After incremental forming operation,the elliptical shape grid major axis length and minor axis length were measured byusing CMM. The coordinate Measuring Machine (CMM) is shown in Fig. 1.5.

8 S. Maharajan et al.

Fig. 1.4 AA6082 deformedsheet metal after formingoperation

Fig. 1.5 Measuring enlargedgrid circle major and minoraxis length using CMM

After forming operation, the experimental values were tabulated. The formabilitywas calculated by using the formula as developed by Narayanasamy and SathiyaNarayanan [17]:

Major strain (e1) = ln(Major diameter of the ellipse/Original diameter of the circle)(1.1)

Minor strain (e2) = ln(Minor diameter of the ellipse/Original diameter of the circle)(1.2)

As per modified Cockroft–Latham criterion [20],

Formability = Major strain (e1)+Minor strain (e2) (1.3)

The formability values are calculated and tabulated in the below-mentionedTable 1.2.

The formability limit curve (FLC) was plotted for major strain versus minor strainfor the un-annealed AA6082 sheet 1 for the first experiment. The FLC is shown inFig. 1.6.

Un-annealed Aluminium Alloy 6082 Sheet 2 (Second Experiment). Secondexperiment was carried out for un-annealed sheet metal with the input forming pro-cess parameters such as spindle speed of 1400 rpm, feed of 150 mm/min and stepdepth of 0.4 mm. The time taken for forming operation was 7 min 36 s. Maximumdepth of formingwas achieved with 10.8mm at the time of fracture. The original gridcircle diameter is 5 mm. After incremental forming operation, the elliptical shapegrid major axis length and minor axis length were measured by using CMM. Theformability values are calculated and tabulated in Table 1.3.

1 Effect of Heat Treatment on Formability of AA6082 … 9

Table 1.2 Formability analysis for un-annealed sheet 1 with step depth of 0.2 mm

Major circle dia (mm) Minor circle dia (mm) Major strain Minor strain Formability

12.0422 4.3427 0.878979 −0.1409 0.738037

12.0242 4.0731 0.877483 −0.2050 0.672449

12.0015 4.2314 0.875594 −0.1669 0.708689

12.0059 4.3481 0.87596 −0.1397 0.736261

11.9978 4.0527 0.875285 −0.2100 0.66523

11.9084 4.0735 0.867806 −0.2049 0.662871

12.0042 4.0308 0.875819 −0.2154 0.660346

5.2053 4.9846 0.040239 −0.0030 0.037154

Average value 0.610129

Fig. 1.6 Formability limit curve for un-annealed sheet 1 (experiment 1)

Table 1.3 Formability analysis for un-annealed sheet 2 with step depth of 0.4 mm

Major circle dia (mm) Minor circle dia (mm) Major strain Minor strain Formability

8.1247 4.9716 0.485471 −0.0057 0.479775

8.1103 4.9732 0.483697 −0.00537 0.478323

8.1468 4.8999 0.488187 −0.02022 0.467964

8.2001 4.8536 0.494708 −0.02972 0.464991

8.0108 4.9756 0.471353 −0.00489 0.466461

8.3096 4.9782 0.507974 −0.00437 0.503604

8.4132 4.9756 0.520364 −0.00489 0.515472

8.2132 4.9816 0.496305 −0.00369 0.492618

Average value 0.483651

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Fig. 1.7 Formability limitcurve for un-annealed sheet2 (experiment 2)

The FLC was plotted for major strain versus minor strain for the un-annealedAA6082 sheet 2 for the second experiment. The FLC is shown in Fig. 1.7.

From the above results, it was confirmed that the formability was decreased withincreasing step depth from 0.2 to 0.4 mm. At the same time, forming time wasdecreased with increasing the step depth 0.4 mm from 0.2 mm, spindle speed of1400 rpm from 1000 rpm and feed rate of 150mm/min from 100mm/min.Maximumamount of depth could be achieved in 0.2mmstep depthwith feed rate of 100mm/minand spindle speed of 1000 rpm in the first experiment when compared to secondexperiment process parameters, such as 0.4 mm step depth, 150 mm/min and spindlespeed of 1400 rpm.

1.4 Analysis of Formability of the Annealed AA6082 SheetMetal

Annealed Aluminium Alloy 6082 Sheet 3 (Third Experiment). AA6082 alu-minium alloy sheet metal was heated to 400 °C for 2 hours in electric arc furnace andthe AA6082 sheet was subsequently cooled to room temperature in the furnace itselffor 2 hours. Thus, AA6082 was annealed. Annealing process increased the ductil-ity. Third experiment was carried out for annealed sheet with input forming processparameters such as spindle speed of 1200 rpm, feed rate of 100 mm/min and stepdepth of 0.2 mm. The time taken for forming operation was 9 min 35 s. Maximumdepth of forming was achieved with 14 mm at the time of fracture. The original cir-cle diameter was 2 mm for annealed sheet. After incremental forming operation, the

1 Effect of Heat Treatment on Formability of AA6082 … 11

Table 1.4 Formability analysis for annealed sheet 3 with step depth of 0.2 mm

Major circle dia (mm) Minor circle dia (mm) Major strain Minor strain Formability

4.8333 2.1344 0.882382 0.065038 0.947421

4.8786 2.1098 0.891711 0.053446 0.945157

4.8361 2.1567 0.882961 0.075432 0.958393

4.8685 2.1309 0.889639 0.063397 0.953036

4.8982 2.1873 0.895721 0.089521 0.985242

4.8594 2.1897 0.887768 0.090617 0.978385

4.8051 2.1389 0.876531 0.067144 0.943675

4.8754 2.1534 0.891055 0.073901 0.964956

Average value 0.959533

elliptical shape grid major axis length and minor axis length was measured by usingCMM. The formability values are calculated and tabulated in the below-mentionedTable 1.4.

The FLCwas plotted for major versusminor strain for the annealed AA6082 sheet3 for the third experiment. The FLC is shown in Fig. 1.8.

From the above results, the forming timewas reduced to 9min to 35 s for annealedsheet when compared to un-annealed sheet whose forming time was 23 min 10 sfor the same input forming process parameter. Maximum depth of forming wasincreased up to 14mmfor annealed sheetwhen compared to un-annealed sheetwhosemaximum depth of formingwas recorded as 11.4mm. The formability was increasedto 0.959533 for annealed sheet when compared to un-annealed sheet formability,recorded as 0.61013.

Fig. 1.8 Formability limitcurve for annealed sheet 3(experiment 3)

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Table 1.5 Formability analysis for annealed sheet 4 with step depth of 0.4 mm

Major circle dia (mm) Minor circle dia (mm) Major strain Minor strain Formability

4.1237 2.1005 0.723604 0.049028 0.772632

4.1678 2.1045 0.734241 0.050931 0.785172

4.1136 2.1056 0.721151 0.051453 0.772604

4.1568 2.1567 0.731598 0.075432 0.807031

4.1983 2.1344 0.741533 0.065038 0.806571

4.1459 2.1098 0.728973 0.053446 0.782419

4.1005 2.1567 0.717962 0.075432 0.793394

4.1547 2.1309 0.731093 0.063397 0.794491

Average value 0.789289

Annealed Aluminium Alloy 6082 Sheet 4 (Fourth Experiment). Fourth experi-ment was carried out for annealed sheet metal with the input forming process param-eters such as spindle speed of 1400 rpm, feed of 150 mm/min and step depth of0.4 mm. The time taken for forming operation was 7 min 35 s. Maximum depth offorming was achieved with 13.4 mm at the time of fracture. The formability valuesare calculated and tabulated in the below-mentioned Table 1.5.

The FLCwas plotted for major versusminor strain for the annealed AA6082 sheet4 for the fourth experiment. The FLC is shown in Fig. 1.9.

The results shown in Table 1.6 reveal that annealing is applied to AA6082 sheetto stimulate softening, refine its crystal structure, strengthen its bending propertiesand consistency in the plastic deformation and reduce the chances of cracking duringthe forming process. Annealing process also improves the ductility and toughnessof the sheet metal. Ductility is the extent to which a material can undergo plastic

Fig. 1.9 Formability limitcurve for annealed sheet 4(experiment 4)