Chatter occurs in all metal cutting process and it is an important factor that causes uneven tool wear and reduced tool life resulting in poor surface finish of work piece. It even causes geometrical inconsistencies and poor surface finish. It can lead to higher costs, delayed deliveries and even loss of orders due to poor quality of the machined component. To reduce and control the tool vibration in metal cutting it is necessitating that to develop a clamping method to improve the vibration damping capability and improves the machining conditions. To cater this need design and development of Magnetorheological (MR) fluid assisted novel vibration damping fixture designed. The application of MR damper assisted fixture in milling machine is considered to be a solution for better vibration control and surface finish. From the experimental investigation it was evident that MR damper performance depends on parameters like suspended fluid, density, reaction time, particle size, maximum yield stress. The viscosity of the MR fluid depends on the intensity of magnetic field applied. Coil orientation, number of turns, current, gap between cylinder and piston are important parameters to be consider while designing a MR Damper. From the experimental results it was witnessed that the magnetorheological assisted fixture reduces the vibration during machining significantly and improves the surface roughness and machining performance.

Miniature products are requisite to make micro creation widely in electronics and micromechanical products. The microfabrication process is identified to satisfy the production of such miniature products rather than an ordinary manufacturing process. Microextrusion is one of the microforming processes in micromanufacturing. In this present work, an attempt has been made to investigate the influence of grain size and deformation behavior of Al6063 microstepped pin with annealed billets for the cold extrusion process. The methodology on the characterization of the microextrusion of Al6063 includes, annealing of the billet, extrusion testing, microhardness examination and surface roughness analysis. The billet with three different sizes of grains is extruded. The experimental result shows that the deformation load and average microhardness of the AA96 (annealed Al6063 with an obtained grain size of 96 μ m) are high compared to AA208 (annealed Al6063 with an obtained grain size of 208 μ m). The surface finish has improved using diamond-like carbon (DLC) coated die compared to uncoated and lubricated dies. DLC coating with AA208 billet achieved a maximum pin length of 13.1 mm, and uncoated die with AA96 billet achieved a minimum pin length of 5.5 mm. Thus, the findings of this study contribute to the fundamental understanding of cold microextrusion of aluminium 6063 alloy.

Micro/Meso fabrication has received worldwide acclaim for its manufacturing methods and procedures. Micro forming is one of the most popular micromanufacturing processes. While there have been efforts to comprehend micro extrusion for industrial applications, the technology is not mature enough. Unlike conventional methods, there is no in-depth expertise. Therefore, it has become critical to create a proper understanding, which can then be used to build sharp plans for producing metallic micro components. In this research, the numerical simulation of the micro-extrusion process is used to investigate the effect of die angle on the deformation behaviour of AA6063. Various die angles of 15 , 30 , 45 , and 60 are tested under friction conditions, and one of the die angle results obtained from the numerical investigation is compared to the experimental data. According to the results, the die angle is directly proportional to the load and inversely proportional to the punch displacement. Furthermore, friction plays a significant part in the micro-extrusion process. The experimental and modelling results for die angle 30 are compared. As a result, the study demonstrates a viable tool for finite element software to examine the micro-forming process in the industry.

Manufacturing of components for micro-systems is a key enabling technology for a new generation of miniaturized devices. The micro-forming is to manufacture the parts or part features with the dimensions in sub-millimeter scale. The process has great potential to become a promising micro-manufacturing method. Micro-forming technology poses much higher demands on accuracy, velocity and mass production, and the common forming machines cannot satisfy these requirements. Micro-forming equipment with high speed and high precision has become an important research field for industrial application. In this work, micro-extrusion ability of bio-absorbable AZ80 alloy is examined using a novel micro-extrusion equipment consisting of forward extrusion assembly and a loading setup. This work aims at discussing the size effect-related deformation behaviors which will help to understand the mechanisms and fundamentals of the size effects in micro-extrusion process. The realization of such a productive forward extrusion assembly poses significant advantages when compared to the conventional manufacturing technologies in the production of nano- and micro-parts.

This paper aims to investigate the formability of difficult to form stainless steel material by the application of heat in the single-point incremental forming [SPIF] process. The forming tool is made up of EN36 case hardening steel and it is coated with the magnetron sputtering method. A modular fixture was developed with a heating setup, and in this work, stainless steel SS316 grade 1 mm thick sheet was used for forming. Suitable work geometry was selected and the tool path was generated by using MATLAB software. The experiments are carried out with suitable process parameters in LV45 LMW make vertical machining centre (VMC). The output parameters such as forming depth, thickness distribution, surface roughness, and forming limit diagram (FLD) are compared between room temperature forming and with the hot forming condition. The results show that hot forming in the SPIF process will make a constructive influence on the results this could infer from the forming limit diagram (FLD). FLD shows that heating the sheet has made it bear the more longitudinal strain, which allows for smooth forming of the sheets along with postponing the failure to an extended depth, in comparison with that of the room temperature formed sheets. It is found that heating of SS sheet while forming itself gives better results. The coating of the tool does not make any difference in these experiments. The microstructural study has also proved that hot-formed stainless steel parts retained the austenite structure, whereas the room temperature formed parts converted to tempered martensite.

Microgears are critical components in the field of manufacturing complicated micro-devices for precise motion control that require lightweight, high-dimensional accuracy, and optimum performance under variable environments. Continuous demand of microcomponents has speeded up the need of producing microgears with high quality and economically from different materials. Microforming process offers a good quality of formed parts with low cost and high productivity. In this work, the deformation behavior of copper microgear is investigated under two different forming conditions. The results show that microgears extruded with high temperature resulted in good formability and improved dimensional accuracy. Microhardness measurements exhibit an inhomogeneous deformation pattern as the hardness at the center is higher when compared with the tooth. Significant reduction in microhardness and coefficient of variation were observed in the specimens formed with temperature assistance. The outcome of the current research will definitely contribute to the fundamental understanding of microextrusion of copper and enhance development microgears in a larger scale.

Friction stir incremental forming is a dieless forming process achieved through the severe plastic deformation of sheet metals by localized heat through tool friction with sheet metal. Tool rotation contributes significantly to determining the local heat generation and deformation of the sheets. In this study, a novel attempt was made to improve the desired surface quality with minimum tool wear using three different tool coatings. To identify the optimal parameters, process factors such as spindle speed, step size, and table feed were considered with two response parameters forming force and surface roughness. A total of 27 experiments based on a full factorial design were performed. During this optimization using TOPSIS, parameters are selected based on which FSIF parts should attain the minimum forming force and surface roughness. Based on the results obtained, the titanium nitride coating in the tool enhanced the surface roughness and increased the maximum formability. This study provides an optimal parameter setting for AA8011 and an understanding of the friction stir effect during the incremental forming process.

Prior research has reported that new product development can integrate product design, marketing inputs, and supplier performance. Yet, our knowledge of the startup stabilization process is minimal. Hence, the present study empirically investigates how an Indian tech giant attempts a new product development in the market penetration category. In this context, the current investigation proposes an implementation strategy using lean-six sigma philosophy, i.e., Define-Measure-Analyze-Design-Validate (DMADV) methodology. The new product considered for the current study belongs to the existing market - existing product, i.e., mobile surveillance devices in the Indian market. The lean tools used in the present investigation are Project charter, brainstorming, voice of customer, market analysis, benchmarking, quality function deployment, and system diagram. Our study reveals critical implementation insights about the market penetration model for lean startups and underscores its significance. Furthermore, a cost gap of 94 US$ of the product manufacturing cost with the lowest available model price is reported. The findings inferred from the present study help entrepreneurs to stabilize their startups effectively using lean philosophy. The potential readership for this study is entrepreneurs, management graduates, and industrial management teams.

The extensive list of elements and procedures for enhancing public trust in public-funded events was largely overlooked. In this background, the authors proposed an empirical framework to increase public trust by incorporating DMAIC methodology. Here, the organizational transparency rate is utilized as a quantitative parameter of measuring public trust. The present investigation's objective is approached by democratic and knowledge-based power division, fund transparency, and transparent leadership. The study revealed that the lean philosophy increases the precepted trust level and enhances the experience-based trust and accountability among colleagues by 0.19 in terms of organizational transparency rate. The proposed framework can improve the public trust and, therefore, a higher coherence atmosphere and higher member participation in public-funded events during the pandemic crisis of COVID-19. The present investigation underlines the higher resource utilization that can range from human resources to materials used in the process. With higher organization transparency, movement of the materials can be streamlined and thus achieve lean philosophy goals.

In today's world, shorter lead times and greater customer satisfaction necessitate our preemptive duty of responsiveness. Almost everything is being done faster and just in time, where manufacturers must produce faster without sacrificing quality and deliver to customers on time in order to compete in this globalized world. Manufacturers must find ways to minimize lead-time and costs in order to increase operating efficiency while maintaining the highest level of product quality. To achieve this product diversification, manufacturers must concentrate more on making setup quicker to keep machines running with less idle time and converging to minimize nonadded value activities. Adopting lean tools Single Minute digit Exchange of Die (SMED) and Kaizen can help reduce setup time when transitioning from one product to another. The main goal of this paper is to use SMED method to minimize idle time of machine during setup operation. This study is carried out in a gearbox manufacturing industry. This research work demonstrate the need to overcome most of bottleneck of equipment’s unavailability for resource utilization to run production more efficiently. The projects objective were met, and the change over time was decreased from 80-24 mins (70%), result in improved efficiency and lesser machine idle time. A comparative analysis of the results is then performed using charts and tables to supplement the improvement achieved through the SMED and kaizen approaches. As a result product diversification and production output has increased.

Micro scale deformational behavior of metals is improved upon increasing the room temperature. Further, the drawbacks of micro forming caused by size effects are reduced significantly. In the current work, investigation on the material behavior of copper at elevated temperature ranging from room temperature to 200 ℃ is conducted. On the experimental part, a novel micro extrusion die set assembly has been developed along with temperature assistance, where the specimen is heated within the die assembly to study deformation behavior. When the forming temperature is raised, an enlargement of the forming limits is achieved along with a significant reduction in extrusion force. Further, the flow of material inside the die orifice was more uniform, and the micro pin showed a good replication of the die dimensions with homogeneous material deformation. During the increase of extrusion temperature and lubrication conditions (diamond-like carbon coating), the micro pin is more complete with higher dimensional accuracy and surface finish. The investigation on the influence of temperature showed that there is a reduction in microhardness of samples compared to the hardness of samples extruded at room temperature. However, there is a significant reduction of scattering due to homogenizing effect.

The interfacial friction between tool and workpiece is unpredictable in the micromanufacturing process. It has a major influence on process workability, which determines product formability. In this study, the microtribological behavior of MgO–ZnO mixed metal oxide nanoadditive lubricant with dry friction is investigated in the microextrusion process. In the microextrusion of aluminum 6063 gear, the extrusion force reduced significantly upon using the nanoadditive lubricant. The surface roughness result shows the improved surface quality due to the existence of nanoadditives in the micromanufacturing process. The quantitative deviation due to interfacial friction is resolved with different coefficients by performing the numerical evaluation. This research contributes to the fundamental understanding about the tribological and mechanical behavior of nanoadditive lubricant in the microextrusion process and facilitates in minimizing the interfacial friction.

Microgears are the crucial parts in the manufacturing of complex microdevices for motion control requiring ultra-light weight, tiny and compact, operational characteristics and dimensional accuracy. During the microforming of gears, the material behavior and grain size effect influence on the formability, yield strength, microhardness and surface roughness of the microgear. In this work, the combined effect of grain size and temperature on flow stress and microstructure of the microgear is investigated during the microplastic deformation of 6063 aluminum alloy. The material with three different grain sizes of aluminum 6063 alloy is considered for its good formability and its strength. The results show the grain size, orientation and boundary have a significant effect on the microplastic deformation process. Microhardness values at the middle and at tooth are controversy and exhibit the inhomogeneous deformation due to the occurrences of the size effect. The grain size dependence on temperature is determined with their difference in microstructure and mechanical properties. This research outcomes thus contribute the basic considerate about the hot microextrusion of aluminum 6063 alloy and enable the development of microgears.

Miniaturization drives the need for developing appropriate technology for microproducts of extremely small geometric features with high tolerances. In this work, the authors have investigated the material behavior and size effect in microextrusion of pure copper and aluminum with different grain sizes. A forward microextrusion assembly has been developed in the first phase of work to investigate the grain size effects. The experimental results are then compared to finite element simulation to quantify force displacement response. It has been found that the simulated deformation load is comparable with experimental results. The influence of size effect in both copper and aluminum showed that the extrusion load and average microhardness of 38 μm and 34 μm are higher when compared to 204 μm and 124 μm. In the second phase of work, an attempt has been made to fabricate the copper microgear (m = 0.416 mm) by the developed extrusion setup. The findings of this work are essential for further development of micro-formed parts and will facilitate in introducing microextrusion for mass production of industrial components.

Microforming is a promising technology in manufacturing micro parts through plastic deformation. In manufacturing of micro part, grain size and material behavior plays a very important role in material flow, yield strength, surface roughness, and microhardness of the micro part. In this work, a generic microextrusion tooling system is developed and biodegradable AZ80 magnesium with four different grain sizes is experimented to analyze the material behavior and grain size effect based on the punch force, microhardness, and interfacial friction. It is attempted to minimize the interfacial friction using two different die coatings. It is found that size, boundary, and distribution of grains have severe effect in the microextrusion process. Microhardness values at the surface layer and radial location show an adverse effect on overall hardness distribution of the micro part due to inhomogeneous deformation. The quantitative variation in interfacial friction is determined with different friction coefficient by numerical evaluation. This research provides the fundamental understanding about the microextrusion process on AZ80 magnesium and facilitates the development of microimplant.

The characteristics of grains during the micro forming process are unpredictable. It reflects in the material behavior, interfacial friction and surface finish due to size effects. This paper describes the numerical analysis of size effects and frictional effects during the plastic deformation of magnesium AZ80 alloy in the micro extrusion process. On the basis of true stress–strain curve, the material model is used for numerical investigation. The results reveal that the flow stress increases with decreasing grain size due to increasing interfacial friction. The results are then validated with the micro extrusion experiments conducted. Further, the friction generation and load prediction can be achieved through numerical simulation is the primary criteria.

Micromanufacturing has received good attention globally in terms of its manufacturing methods and processes. One of the most popular micromanufacturing processes is microforming. Although there were efforts made to realize microextrusion for industrial application, the technology itself was seen as being insufficiently mature and unlike conventional methods, there is no in-depth knowledge. It has become essential to develop a proper understanding which in turn could be used to develop dedicated processes for the manufacturing of metallic microcomponents. In this work, an attempt has been made to realize this special application of metal forming. A novel experimental setup consisting of forward extrusion assembly and a loading setup has been developed to obtain the force-displacement response. The effects of miniaturization on microcomponents and the material behavior during forward extrusion are investigated using a computerized universal testing machine (UTM). As per industrial requirement and application of micropart in micromanufacturing process, grain size is an important factor. By using a forming assembly in conjunction with a loading setup, the authors are able to investigate the force-displacement response for microextrusion with material of different grain sizes. Extrusion tests performed on the samples of different grain sizes demonstrated that decreasing grain size caused an increase of flow stress. The realization of such a productive forward extrusion assembly poses significant advantages when compared to the conventional manufacturing technologies in the production of microparts.

In the competitive market scenario, the companies are facing difficulties in making profit. The lean concepts are like solution tools for them. It mainly focuses on eliminating wastes from the process followed in the industries and creating valuable product to the customer with less capital investment. The Just in time (JIT) is an ideology originated in Toyota as like other lean concepts but it focuses on providing a pathway for the industries to reach a state where inventories requirement on the shop floor will be fulfilled by the suppliers at real time. The case study conducted in valve manufacturing industry where the raw material inventories have a larger pie of investment. The Sole purpose of this paper is to identify gaps present in supply chain process and replace it with JIT Approach. For identify the supply chain, understanding of procurement cycle is important. So, The Pathway starts with identification of key customer along with its key product. The key product is thoroughly analysed with ABC Analysis to determine the targeted part. The part suppliers are compared with their delivery date and quality produced by them in current process. The supplier development strategy generates different proposals, among which best four are selected. Among these four, supplier ranking need to be reformulated with increased number of factors for evaluating suppliers than Continuous inventory removal (CIR) Plan has formulated based on Continuous sampling plan used in sampling inspection and data's are analysed on cost aspect for this method. As the conclusion, the JIT implementation brings several favourable factors like reduction in inventory level, less investment required for running business.

In current competitive market every day a new design and manufacturing concept is evolved in polymer processing technology. The industries to cater the need of customers, apart from conventional polymer part manufacturing processes they are in need to develop new manufacturing techniques. This necessitates the need for new flexible polymer processing method that reduces design and manufacturing lead time. Research is on to develop new innovative process strategies and methods in the area of polymer processing. Such one technology is incremental forming (IF) of polymers. In this incremental polymer sheet forming process there is no need to develop dedicated dies and moulds. As a result high investment on moulds and dies was totally eliminated. It is a very much flexible part forming process and is enabled with the help of Computer Numerical Control (CNC) technology. In this paper, numerical and experimental investigations are carried out for the applicability of Incremental forming in polymer part manufacturing. A Finite Element (FE) model is developed for the 3-D numerical simulation of incremental forming process of polymers using commercial software HYPERFORM. The developed model can predict the thickness distribution and percentage thinning of the blank. The FEA results and experimental results are compared for validation with the part design parameters (geometrical and physical parameters). Furthermore, this numerical simulation predicts the failure of polymers in IF process and it is verified with experimental results. By this numerical simulation, failure prediction can be done without expensive shop trials.