This study explores the effects of distinct cutting strategies (dry, flood, liquid nitrogen (LN2) and cryogenic carbon dioxide (CO2)) on the machinability of Inconel 625. Face milling (FCM) trials were conducted using PVD-TiAlN coated inserts at distinct feed-speed combinations. The cutting temperature (Tc), torque, surface roughness (Ra), and tool wear were measured to evaluate the performance of each cutting conditions. The LN2 coolant reduced the temperature by 72-83% compared to dry, 52-71% compared to flood, and 13-25% compared to CO2 condition. When it comes to surface finish, CO2 reduced the Ra by 48-62% compared to dry, 41-50% compared to flood, and 16-23% compared to LN2 condition. The Evaluation based on Distance from Average Solution (EDAS) optimization approach was utilized to establish the optimal cutting environment. In addition, a machine learning (ML) algorithm, multilayer perceptron (MLP) was used to predict the Appraisal Score (APS) values from EDAS.

The machining of titanium grade 5 is a big challenge for manufacturers due to its low thermal conductivity. Machining titanium with some cutting fluids and coated tools shows better performance in terms of surface quality and tool life from the literature. In this present study, Ti–6Al–4V was machined under emulsion and cryogenic environments with coated and uncoated cutting tools. The surface quality of machined part and cutting forces were observed. From the results, it is observed that the cryogenic environment with a coated tool shows better performance than the emulsion condition. The less cutting forces and the high-surface quality of machined work material were observed with the machining parameters being Vc = 90 m/min, d = 0.5 mm and f = 0.102 mm/rev. To reduce the cost of machining trials, the grey relation analysis was adopted to get better machining parameters.

A combined analytical and experimental study was carried out to investigate the effect of cryogenic cooling on temperature during turning of pure titanium grade-2. Cryogenic machining investigations were carried out by applying liquid nitrogen (LN2) to the cutting zone. The temperature distribution at the machined surface was predicted using a 3D finite element model. An average deviation of 7.42% was noted for the cutting temperature result, and there was good agreement between the simulated and experimental results. The experimental results reveal that LN2 machining improves cooling and lubrication by lowering the cutting zone temperature. Acceptable tool wear, surface roughness, and favourable chip formation are observed in LN2 machining at higher cutting speeds.

This research introduces a challenge in integrating and cleaning the data, which is a crucial task in object matching.While the object is detected and then measured, the vibration at different light intensities may influence the durability and reliability of mechanical systems or structures and cause problems such as damage, abnormal stopping, and disaster.Recent research failed to improve the accuracy rate and the computation time in tracking an object and in the vibration measurement.To solve all these problems, this proposed research simplifies the scaling factor determination by assigning a known real-world dimension to a predetermined portion of the image.A novel white color sticker of the known dimensions marked with a color dot is pasted on the surface of an object for the best result in the template matching using the Improved Up-Sampled Cross-Correlation (UCC) algorithm.The vibration measurement is calculated using the Finite-Difference Algorithm (FDA), a machine vision system fitted with a macro lens sensor that is capable of capturing the image at a closer range, which does not affect the quality of displacement measurement from the video frames.The field test was conducted on the TAFE (Tractors and Farm Equipment Limited) tractor parts, and the percentage of error was recorded between 30% and 50% at very low vibration values close to zero, whereas it was recorded between 5% and 10% error in most high-accelerations, the essential range for vibration analysis.Finally, the suggested system is more suitable for measuring the vibration of stationary machinery having low frequency ranges.The use of a macro lens enables to capture of image frames at very close-ups.A 30% to 50% error percentage has been reported when the vibration amplitude is very small.Therefore, this study is not suitable for Nano vibration analysis.

The most troublesome challenge in overcoming the threats of energy crises, an eco-friendly energy source to replace fossil fuels greatly hinders the development of PEM fuel cells (PEMFC) with their ability to convert hydrogen gas and oxygen gas into electrical energy and water which offers clean, reliable, no pollutant and efficient power source in the automobile industries. The bipolar plates (BPPs) are one of the influential components of PEMFC, where the BPPs account for 60 - 80% of total weight and 45 - 60% of total manufacturing cost of PEMFC. The potential surplus of metallic bipolar plates is optimistic for replacing conventional carbon-based (graphite) BPPs while its cost is still relatively high. Manufacturing these plates through Electromagnetic forming (EMF) is highly suitable for mass production at Uniform pressure actuators. EMF is a technology of forming a conductive sheet metal workpiece at high speed without physical contact by applying a high-impulse electromagnetic field to the workpiece and no working medium is required. The EMF technique forming of metallic bipolar plates micro-channel was investigated in the Copper sheet metal of 200 mu m. A large variant of serpentine-like flow field structures was constructed and evaluated by running 3D simulations of Ansys LS-DYNA.

Prosthetics are made with solid, biocompatible materials. Though the materials have a very good strength-to-weight ratio, they are not aesthetic or customized. Most of the time, it is made standard and is not lightweight for the user. Presently Metal 3D printing develops lightweight structures with the highest strength-to-weight ratio. In countries like India, the people have limited access to a good prostheses, as the prostheses is not affordable. The prosthetic limbs, to a certain degree, help amputees get back to their basic functional movement systems and help amputees develop better mobility and operate freely without depending on others. The design and fabrication of an improved and affordable prosthetic leg for people with below-knee amputation which will mimic the function of the natural leg using additive manufacturing technology. The additive manufacturing allows design freedom and customisation advantage. Autodesk Fusion 360 and Solid Works software was used for solid modelling and simulation and topology optimization was done using Autodesk Fusion 360. After measurement of the leg parameters, the measured data are fed into editable 3D software. The best design is chosen from the available designs based on ESAR foot (Energy storage and return foot). The present work based on topologically optimized design and ESAR foot was able to withstand the given loads and can be easily moved and thus chosen for further manufacturing and testing. This pave the way to develop a customer-oriented design and use 3D printing to make prosthetic legs that would look more personal and aesthetic.

In this investigation, commercially pure titanium (grade2) was machined under cryogenic conditions at high cutting speeds with varying feed rates and depths of cuts. A Taguchi orthogonal array is used to choose the cutting parameters. The output responses include experimentally confirmed cutting forces (Vc), surface roughness (Ra), tool wears, chip production, and chip shape. In order to obtain the final significant machinability, an excellent parametric combination for the work section was obtained by GRA. ANOVA was used to estimate the percentage contributions of the control components. Finally, the cryogenic liquid significantly lowers the cutting temperatures even at high cutting speeds, producing chips with favorable serrations.

This research work presents a novel method for evaluating the wire feed rate for Fused Deposition Modelling (FDM) 3D printers within the framework of Industry 4.0. The method measures the pace at which 3D printers deposit layers of material. It has been decided to design and calibrate an automatic wire detection and measuring (AWDM) wire feed rate device. The data is then sent by WIFI to the ThingSpeak cloud platform, allowing users to remotely monitor the wire feed rate using their mobile phones as well. The signal that is created by the AWDM device is fed to NodeMCU, which is then fed to ThingSpeak. In addition to this, it is possible to incorporate it without any problems into the existing industrial configuration of FDM printers, and it offers a solution that is inexpensive, nonintrusive, and portable.

The investigation focuses on the validation of nano-coated tool insert with various controlled cutting parameters under different coolants in the turning Ti-alloy. A cutting of aerospace grade-5 alloy has the inherent ability to produce an elevated cutting temperature. During turning operation, it not only damages a tool insert but also damages the surface finish of the workpiece. The regular commercial cutting fluid is inadequate for controlling the wear mechanism and cutting temperature. The wet and cryogenic coolants were used in turning Ti-alloy. The effect of cutting parameters on machining temperature, main cutting force, and surface roughness was identified using optimization of multi-response TOPSIS method. From TOPSIS, the optimized cutting parameter was at cutting velocity (135 m/min), at depth of cut (0.5 mm), and at feed rate (0.102 mm/rev). The tool wear and surface roughness also were analyzed. The results show the AlCrN nano-coated insert under cryogenic (LN2) coolant was better compared to other conditions.

Deep-sea mineral resources are the replacement of land-based minerals on future demands of modern civilization. Polymetallic nodules are in abundant quantity on the ocean floor and technology is developed to recover them from a remote place. This research aims to develop efficient nodule picking through a mechanical pick-up device by optimizing the input parameters with the help of response surface methodology (RSM). We studied the effect of three independent variables such as soil depths of cut (50 to 100 mm), picking device angle (28 to 30), and haulage velocity (0.15 to 0.3 m/s) for the various dependent responses of haulage force, nodule picking efficiency, peak power drawn, and specific energy consumption of nodule mining. The statistical models describe the experimental sets and analysis of variance used to assess the model fit with the experimental results. A second-order quadratic model has been proposed correlating the input variables to maximize the nodule picking efficiency at optimum operating conditions using the RSM-based Box-Behnken design technique. Based on the higher desirability approach, the achieved optimum parameter sets were 50 mm soil depth of cut, 30 pick-up device angle and 0.15 m/s haulage velocity for maximum nodule picking efficiency of pick-up device.

This study presents a detailed experimental investigation on the effects incorporating non-metallic fibers in hybrid form in self-compacting concrete (SCC). In this regard SCC was prepared with Alccofine and Metakaolin as partial replacement for cement in 15% and 20% respectively along with the hybrid fibre combinations namely abaca fibres (0.25%, 0.5% & 0.75%), polypropylene fibres (0.5%, 1%, 1.5% & 2%) and glass fibres (0.5%, 1%, 1.5%, & 2%). The fresh properties of SCC with and without hybrid fibre combinations were assessed through the standard tests such as slump flow, J ring and V-funnel tests. The conventional mechanical tests such as compressive strength test, split tensile strength test and flexural strength test were performed at 7 and 28 days. The experimental results reveal that the fresh properties of SCC were highly influenced by alccofine and Metakaolin adopted in this research. Furthermore, that the hybrid combination of abaca with polypropylene and glass fibres improved the mechanical properties of SCC and in particular the mix with 1% glass fibre and 0.25% Abaca fibre had shown better flexural and tensile strength behaviour. Microstructure analyses were also done to confirm the improvement in mechanical properties. The Scanning Electron Microscope images of the mix with 1% glass fibre and 0.25% abaca fibre showed less voids presence and presence of more hydrated components conveying that the usage of hybrid fibres had restricted the propagation of cracks there by reducing the percentage of voids and the use of metakaolin and alcofine helping in forming hydrated components at earlier stage leading to better strength.

The structure of an agricultural tractor is a structure without a suspension system to limit the vibrations generated by its engine.It exposed the entire body of an agricultural tractor operator to vibration.Thus, the body of the driver, constantly exposed to the vibration, becomes fatigued.This fatigue becomes a factor in the driver's inattention.The driver's body has transmitted to vibration through the tractor's seat, accelerator pedal, brake pedal, and steering wheel.Quantifying seat, accelerator pedal, brake pedal, and steering wheel vibrations is one of the most important factors in determining the cause of vibration and correcting it.The ISO 5349 standard lays down a guideline for the measurement and assessment of vibrations transmitted by the human hand.To meet the ISO 5349 standard, assess human exposure to hand-transmitted vibration and meet the human subjective comfort level.It must keep the vibration within a specified range.This study attempts to measure steering wheel vibrations through a new machine vision system using up-sampled cross correlation and a Discrete Finite Transform algorithm.In this study, it was impossible to calculate vibration in three axes from the video images recorded by the camera.According to ISO 5349-2, the vibration obtained on two axes multiplied by 1 to 1.7 to calculate the equivalent measurement for the vibration on the third axis.The results show that when the vibration is high; the errors are less and when the vibration is low, near zero, the errors range from 30 % to 50 %.But this study suggests that very low-level vibrations are unnecessary for vibration analysis.This study is not suitable for Nano-vibration measurement methods that measure fine vibrations.

Despite the recent developments in non-conventional manufacturing approaches, machining is still a prominent technique for the mass production of metallic components. However, given the difficult-to-machine nature and high heat generation during machining of Hastelloy-X, there is a lack of comparative investigations that can provide basics for sustainable process management in machining of Hastelloy-X. Different sustainable cooling approaches (dry, minimum quantity lubrication (MQL), cryogenic) and their impact on Hastelloy-X machining process behavior have been investigated in this study. Machining parameters such as constant cutting speed of 124 mm/min, feed rate of 0.15 mm/min, and cutting depth of 0.1 mm and cutting force, cutting temperature, and surface roughness were consider as output responses. It was observed that with the adaptation of cryogenic conditions, cutting forces can be reduced 5 to 14% in comparison with MQL and dry conditions. Cutting temperature and surface roughness values were however observed to be largely reduced with cryogenic cooling. The chipping and adhesion were found to be reduced with cryogenic cooling due to the reduction in workpiece softening behavior and increase in hardness to cutting tool.

The present work deals with a critical fractographic analysis into low carbon (0.18%-C) steel samples which were used for three different mechanical tests: tensile test; shear test; and toughness test. These mechanical tests were performed in standard sized specimens as recommended by ASTM. In each category of test, there were two different specimens with different physical states according to heat treated conditions. First specimen was in ‘as received’ condition and another was annealed. For annealing, sample was first heated up to austenitic temperature and inserted inside the sand for slow rate of cooling. As these two categories of samples were undergone through destructive tests, the variation in fracture behaviour of the samples was analysed by FESEM, XRD. A significant variation in fractographic images could be observed in different heat-treated samples. Micro-pores, dimples, cleavage facet, peaks, valleys, and cave formation were observed in the samples.

Personal body armor has surfaced in a variety of different forms throughout the centuries. Today, bulletproof vests serve as a lightweight armor technology designed to protect the wearer from critical internal injuries caused by firearm projectiles. These bulletproof vests are predominantly manufactured by using Kevlar. Though Kevlar has adequate absorption capacity, its strength to withstand bullet comes with the addition of Kevlar layers, which adds up to the body armor's weight. Carbon Nanotubes (CNTs) are of great area of interest nowadays due to their exceptional mechanical properties. It is much lighter and possesses higher strength when compared to Kevlar. This study focuses on the Finite Element Analysis (FEA) of bulletproof vest made up of CNTs. Furthermore, it also gives a comparative study of Carbon nanotubes and Kevlar 29 in ballistic applications.

In electrochemical micromachining process (ECMM), cathodes are the microfeature creators yet, the deposition of sludge particles on the cathode surface is expected in ECMM while machining with neutral electrolytes which have a negative influence on the generated micro profile. In this research, the feasibility of reducing insoluble reactant products/sludges adhering onto the cathodic surface of the Pencil Graphite Electrode (PGE) of two variants namely the non-treated PGE (NPGE) and the LN2-treated PGE (CPGE) aided by the NaNO3 electrolyte and their influence on producing burr-free micro-holes with better surface roughness (Ra) on SS304 are investigated. The XRD report confirms the presence of graphite in both the PGEs and the spectral peaks from the EDS data of the adhered sludge particles on the cathode surface reported in traces of the element Fe and O that possibly forms iron oxides (Fe2O3) on the pencil graphite cathodes. Further, findings from the SEM images and the Brunauer–Emmett–Teller models shows the lucid results of CPGE exhibiting reduced pore-size and pore volume of 8.12 nm and 0.23 cm3/g, respectively that resulted in less sludge/reactant product adherence on the cathodic surface up to 75% owing to better surface finish with no burrs and no micro sparks effect.

In this experimental work, the micro structure and the micro hardness of the surfaces machined under the dry EDM process is analyzed for AISI D2 tool steel and LM13 aluminum alloy. The experiments were conducted using copper tool electrode. Few modifications were made in the tool for conducting the experiments under dry EDM process. Discharge current, pulse on time, voltage, pressure, tool rotational speed and the duty factor were used as the various process parameters and their influence over the micro structure and micro hardness of the machined surfaces were analyzed. Better results were observed in the dry EDM process for AISI D2 tool steel, whereas dry EDM process did not reveal appreciable results for LM13 aluminum alloy.

Inconel 625 is a nickel-based super alloy especially used in aeronautical industries, due to its high mechanical strength, exceptional weldability and good corrosion resistance properties. However, machinability of Inconel 625 is quite challenging because of high-level heat generation in the cutting zone. In this work, to improve sustainable machining of Inconel 625; cryogenic CO2 and LN2 have been used as lubricants. Face milling was performed at two feed rates (f) of 0.2 and 0.6 mm/rev and spindle speeds (n) of 509 and 764 rpm with cryogenic (CO2 and LN2) cooling environments. The resulting surface characteristics, such as morphology, topography, micro-hardness and residual stress, along with chip morphology and tool wear, were investigated. Both cryogenic lubricants offered relatively better results at lower feed rate (f) and spindle speed (n). While cryogenic CO2 provided better surface morphology and topography, LN2 provided lower residual stress and higher surface micro-hardness.