The manufacturing of automobile moulds is itself a challenging job and very tedious task requiring high accuracy of component profiles. The required complicated and complex profiles are generated when the mould inserts are relinquished from several numbers of workstations, which run for a longer process time. As the accuracy needed for the component area is very high and it (insert) has to pass through several bottleneck workstations, the production time and increased buffer time are observed. This chapter focuses on providing economical methods for manufacturing hot die steel inserts. These techniques are implemented on a pressure die-casting insert component. The present solution is derived for manufacturing time reduction and minimisation of the die-casting inserts (moving and fixed die) at every stage. Implementing combined electrodes, assembly machining and cluster plate machining/sparking techniques are critical development advancements in the research. In the combined electrode concept, one electrode is designed in the same area to cover multiple areas that were initially covered by separate individual electrodes. Furthermore, this concept is outstretched by the cluster plate concept. Those electrodes that cannot be covered by a single electrode are machined together to act as a single electrode and later separated while individual sparking. Combined electrode design, assembly machining and cluster machining/sparking of the electrodes reduce the total machining time of the die and the machining centre. Reducing the machine run time will reduce the production cost and increase profit. The results achieved show that the combined electrode design setup shows 75% savings in the combined sparking setup, whereas the cluster plate machining setup shows 35% savings in the tool list generation (from software used) of the net savings. The proposed solution opens up new avenues for similar automobile components by setting benchmarks to decrease the rope length associated with manufacturing and increase profit.

The hardness testing is vital for metals for testing and production quality control. Hardness testing is a fine indicator to determine the mechanical characteristics of metals. The various types of hardness testing methods include Rockwell, Vicker, Brinell, and Knoop testing methods. The most prevalent manual method to determine hardness is indentation using dead weight technology. However, the said technology is quite ancient and it has its own limitations, like the kinetic effect applying excessive load at actual, man-to-man variations, variation over the period due to deterioration and friction effects of moving parts like lever, weight block hanger, etc. increases the uncertainty of this method and eventually demands for upgradation of the technology. Further, the methods currently in use are open-loop and manually operated testers. The main drawback of all these testers is that they provide zero feedback, and so the obtained result needs to be compared to the desired result. To overcome the above-stated problem, the paper presents some novel modifications for measuring hardness using existing methods of Rockwell, Vicker, and Brinell testing. Toward this objective, the paper proposes to modify existing testers and develop a semiautomatic hardness testing system. Firstly, for Rockwell testing, the work aims to design a closed-loop system for hardness testing. The proposed system comprises of Arduino as an open microcontroller, a load cell along with servo motor, and its driver to establish the desired closed loop. The need of obtaining a more accurate result, free from human interference gives rise to a closed-loop system for hardness testing. The key aspect of the closed-loop system lies in retaining the basic structure of the metal. Unlike traditional hardness tester, during testing, the weight increases gradually, due to which the basic structure of metal is not deformed. Secondly, the paper proposes a computational methodology that would estimate the Vickers and Brinell hardness value. The proposed system comprises of a camera for gathering hardness indentation images, thereby automating the system. Further, these images are analyzed based on image processing software, and the indentation depth is obtained. The proposed work thus replaces human intervention to calculate the hardness of the material. The results obtained based on the proposed systems provide a proof of concept to address the problems of traditional Rockwell, Vicker, and Brinell testing.

This review paper represents the analysis and optimization for the selection of input variable based on controlling casting regime in order. This review uses specific example of introduced advantage of concurring new products with modern software package comparing to conventional manner. It refers implementation of modern software packages reduces time necessary for concurring new product, reinstates better control over process, increases quality and reduces price of new product. This review paper facilitates not only numerical casting simulation but the optimization of the present casting process design can be done but also an entirely new casting process design for a new casting can be quickly and efficiently made.

Flexural cartridge/suspension is compliant mechanism that is used in nano precision engineering application due to its excellent advantages of providing no backlash, no friction and compact in size. These inbuilt qualities which are obtained help them to suit as a single one piece coupling that serves kinematic–mechanical behavior with small and very large deflection for variety of applications. The spiral shaped flexural cartridge is used in multiple number and multiple configurations to achieve the desired output for an application. To address the net deflection as the output (net deflection of the stack in assembled condition) it is very necessary to understand the changes which are brought in the geometrical parameters of the spiral shaped flexural cartridge/suspension. The importance geometrical parameters of spiral shape cartridge is been reported in this paper. The paper reviews the key concepts, technical advancements, identifying the most sensitive parameters of the spiral shaped flexural cartridge. This paper presents a guide to select the most appropriate parameter for the application engaged in flexural system.

This manuscript focuses on providing optimized transfer rate of heat produced in the fins that are provided on the cylinder head present on the compressor. In this paper three different cross sections are taken in to consideration, which are straight (rectangular), trapezoidal and parabolic cross section. The parabolic cross section stands to be the optimized cross section at level one. Then further rectangular and triangular profiles are analyzed at the tip periphery and at the base of the parabolic fin. Investigation results declare that parabolic fin body having rectangular slot at the base provides the most optimized heat transfer rate in the profile. The last stage optimization is done by providing circular holes at the tip and at the base of the fin geometry. The final results that are laid in the paper depicts that parabolic fin body having rectangular profile cut at the base along with cylindrical profile slots is the most optimized geometry that provides highest heat transfer rate.

Drilling Electro Chemical Discharge Machining (D-ECDM) Process is a new thermal based non-conventional machining process, having potential to machine electrically non-conductive hard and brittle materials by using a rotating tool electrode. In D-ECDM process the repeated piercing of rotating tool the terminal having ECD (electro Chemical discharge) spark across the work piece perform the machining operation. The corresponding motion between work piece and tool controls the energy piercing rate and as a result improve the output response so the impact of input process parameters plays an vital role. In present study Buckingham’s Pi-theorem was used to found relation between input process parameter and response parameters. MRR (material removal rate) and overcut were taken as performance characteristics. During predictive modeling, the constant terms and coefficients were estimated from the non-linear experimental data. The outcomes manifested by the predictive models are in good agreement with the experimental results and the error in overall results for output performance are in 8–9%

The application of a gate valve is to make a straight-inline flow of fluid with less restriction as the turbulence is created through the aperture provided in the valve body. The change in direction of the fluid creates change on the operating stress of the vale body. The paper is targeted for designing the valve body for reduction in the overall weight of the body and making it light in weight. The optimized design keeps the operating stress with operating stress within change of 5% which thereby ensures that the original stress value is not altered much. In the current manuscript the ribs of various thicknesses are proposed those are to be welded across the outer periphery of the body. The ribs provided on the periphery are substitutes for the reduction in the weight. The sensitivity analysis along with the change in the materials is analyzed in the manuscript. The complete optimization is valve body is done by topology optimization tool in ANSYS. This paper help and give an aim for researchers on optimizing the gate valve body with help of finite element analysis (FEA) and optimized design by adding ribs to the gate valve body to reduce the stress and deformation.

Efficient energy utilization becomes the concentrative point among research group.Among this agriculture field is most popular.Direct injection diesel engine GF 50I MP is considered as reference model for analysis.Here work is concentrated on homogeneous combustion considering controlling parameters as nozzle angle and piston bowl geometry.Further reduction in emission parameters like NOx, CO2, HC is also a prime aim.Key parameters velocity and turbulence kinetic energy (TKE) is analyzed for same using CFD tool ANSYS.Different geometry and nozzle angle analysis leads to improved TKE and velocity at an angle of 60 0 and geometry with shallow depth of 19 mm at throat section and edge radius of 41 mm.Result shows that on the aspect of velocity and NOx emission Modified geometry-1 and improved nozzle angle-2 (60°) is better among all the cases.Leads to form optimum geometry of piston and nozzle angle and reduction in NOx and increase in HC.

Efficient energy utilization becomes the concentrative point among research group.Among this agriculture field is most popular.Direct injection diesel engine GF 50I MP is considered as reference model for analysis.Here work is concentrated on homogeneous combustion considering controlling parameters as nozzle angle and piston bowl geometry.Further reduction in emission parameters like NOx, CO2, HC is also a prime aim.Key parameters velocity and turbulence kinetic energy (TKE) is analyzed for same using CFD tool ANSYS.Different geometry and nozzle angle analysis leads to improved TKE and velocity at an angle of 60 0 and geometry with shallow depth of 19 mm at throat section and edge radius of 41 mm.Result shows that on the aspect of velocity and NOx emission Modified geometry-1 and improved nozzle angle-2 (60°) is better among all the cases.Leads to form optimum geometry of piston and nozzle angle and reduction in NOx and increase in HC.