Journal of The Institution of Engineers : Series C 

About: Journal of The Institution of Engineers : Series C is an academic journal published by Springer Science+Business Media. The journal publishes majorly in the area(s): Materials science & Machining. It has an ISSN identifier of 2250-2122. Over the lifetime, 845 publications have been published receiving 4648 citations.

Post Processing Methods used to Improve Surface Finish of Products which are Manufactured by Additive Manufacturing Technologies: A Review

Abstract: The Additive Manufacturing (AM) processes open the possibility to go directly from Computer-Aided Design (CAD) to a physical prototype. These prototypes are used as test models before it is finalized as well as sometimes as a final product. Additive Manufacturing has many advantages over the traditional process used to develop a product such as allowing early customer involvement in product development, complex shape generation and also save time as well as money. Additive manufacturing also possess some special challenges that are usually worth overcoming such as Poor Surface quality, Physical Properties and use of specific raw material for manufacturing. To improve the surface quality several attempts had been made by controlling various process parameters of Additive manufacturing and also applying different post processing techniques on components manufactured by Additive manufacturing. The main objective of this work is to document an extensive literature review in the general area of post processing techniques which are used in Additive manufacturing.

Development of Nylon Based FDM Filament for Rapid Tooling Application

Abstract: There has been critical need for development of cost effective nylon based wire to be used as feed stock filament for fused deposition modelling (FDM) machine. But hitherto, very less work has been reported for development of alternate solution of acrylonitrile butadiene styrene (ABS) based wire which is presently used in most of FDM machines. The present research work is focused on development of nylon based wire as an alternative of ABS wire (which is to be used as feedstock filament on FDM) without changing any hardware or software of machine. For the present study aluminium oxide (Al2O3) as additive in different proportion has been used with nylon fibre. Single screw extruder was used for wire preparation and wire thus produced was tested on FDM. Mechanical properties i.e. tensile strength and percentage elongation of finally developed wire have been optimized by Taguchi L9 technique. The work represented major development in reducing cost and time in rapid tooling applications.

Sustainability of Recycled ABS and PA6 by Banana Fiber Reinforcement: Thermal, Mechanical and Morphological Properties

Abstract: In the present study efforts have been made to prepare functional prototypes with improved thermal, mechanical and morphological properties from polymeric waste for sustainability. The primary recycled acrylonitrile butadiene styrene (ABS) and polyamide 6 (PA6) has been selected as matrix material with bio-degradable and bio-compatible banana fibers (BF) as reinforcement. The blend (in form of feed stock filament wire) of ABS/PA6 and BF was prepared in house by conventional twin screw extrusion (TSE) process. Finally feed stock filament of ABS/PA6 reinforced with BF was put to run on open source fused deposition modelling based three dimensional printer (without any change in hardware/software of the system) for printing of functional prototypes with improved thermal/mechanical/morphological properties. The results are supported by photomicrographs, thermographs and mechanical testing.

Investigations on Surface Milling of Hardened AISI 4140 Steel with Pulse Jet MQL Applicator

Abstract: In this article, an experimental investigation was performed in milling hardened AISI 4140 steel of hardness 40 HRC. The machining was performed in both dry and minimal quantity lubricant (MQL) conditions, as part of neat machining, to make a strong comparison of the undertaken machining environments. The MQL was impinged int the form of pulse jet, by using the specially developed pulse-jet-attachment, to ensure that the cutting fluid can be applied in different timed pulses and quantities at critical zones. The tool wear, cutting force and surface roughness were taken as the quality responses while cutting speed, table feed rate and flow rate of the pulse were considered as influential factors. The depth of cut was kept constant at 1.50 mm because of its less significant effects and the straight oil was adopted as cutting fluid in pulse-jet-MQL. The effects of different factors, on the quality responses, are analyzed using ANOVA. It is observed that MQL applicator system exhibits overall better performance when compared to dry milling by reducing surface roughness, cutting force and prolonging tool life but a flow rate of 150 ml/h has tremendous effects on the responses. This investigation and afterward results are expected to aid the industrial practitioner and researcher to adopt the pulse-MQL in high speed milling to prolong tool life, reduce tool wear, diminish cutting force generation and promote better surface finish.

Process Parameters Optimization in Single Point Incremental Forming

Abstract: This work aims to optimize the formability and surface roughness of parts formed by the single-point incremental forming process for an Aluminium-6063 alloy. The tests are based on Taguchi’s L18 orthogonal array selected on the basis of DOF. The tests have been carried out on vertical machining center (DMC70V); using CAD/CAM software (SolidWorks V5/MasterCAM). Two levels of tool radius, three levels of sheet thickness, step size, tool rotational speed, feed rate and lubrication have been considered as the input process parameters. Wall angle and surface roughness have been considered process responses. The influential process parameters for the formability and surface roughness have been identified with the help of statistical tool (response table, main effect plot and ANOVA). The parameter that has the utmost influence on formability and surface roughness is lubrication. In the case of formability, lubrication followed by the tool rotational speed, feed rate, sheet thickness, step size and tool radius have the influence in descending order. Whereas in surface roughness, lubrication followed by feed rate, step size, tool radius, sheet thickness and tool rotational speed have the influence in descending order. The predicted optimal values for the wall angle and surface roughness are found to be 88.29° and 1.03225 µm. The confirmation experiments were conducted thrice and the value of wall angle and surface roughness were found to be 85.76° and 1.15 µm respectively.