The increasing demand for sustainable construction materials has raised concerns over the extensive use of cement and natural aggregates, prompting the need for alternative resources. This study explores the use of Aluminium Ash Dross (AAD) and Magnesium Oxide Dross (MOD) as partial cement replacements (5–20

Friction welding is an efficient and economical process of joining two similar or dissimilar metals among various welding processes. Now-a-days, the automobile and other industries are using dissimilar metals in a same working area to compensate the problems faced due to temperature and working atmosphere to enhance company's economy. The material AA6351 and EN353 alloy steel have wide applications in aerospace & automobile industries, are joined with different input parameters like Heating Time (HT), Heating ordered using L27 Taguchi Orthogonal Array (OA) to experiment the process. Friction welding is done in KUKA friction welding machine. After experimentation, the responses like temperature, hardness and axial shortening are measured. Using these responses, the optimization is carried out through Grey Relational Analysis (GRA) and the rankings are identified and tabulated to obtain the optimal solutions. Based on rankings, the optimal input parameters are concluded as 18 bar of Heating Pressure (HP), 7 sec of Heating Time (HT), 22 bar of Upset Pressure (UP) and 3 sec of Upset Time (UT). The Field Emission Scanning Electron Microscope (FESEM) analysis is also used to study the Inter-metallic compounds (IMCs).

Tool wear is a natural phenomenon in machining process and it leads to get damage to tool. According to more demand in the market, the selection of high speed, feed rate and depth of cut of machining process are latest trends in all industry. Such machining process creates high cutting temperature, which not only reduces tool life but also induces the product quality. Cutting fluids are used to maintain the tool life and to preserve the workpiece surface properties without damages. To avoid this imperfection, it is necessary to use standard coolants during machining operations. The temperature and surface finish play a vital role in a machining process. In this work, three different nano fluids, like aluminium oxide, copper oxide and titanium oxide,are introduced, and used as a coolant in CNC lathe for turning operation. The output responses of temperature and surface roughness of the workpieces are analyzed with the help of Design of Experiment (DOE) by using L9 orthogonal array of each nano coolant. The result of output responses like temperature and surface roughness are compared with three nano fluids. The copper oxide nano fluid gives a better surface finish as compared to aluminium oxides and titanium oxide.

Investigation of the optimization of machining processes for oil-hardened nitric steel material, aiming to understand the productivity and quality is carried out. Utilizing an orthogonal array design with three-level three-factor input parameters, the study assesses material removal rates (MRR) and surface finish quality. A regression model is developed using Taguchi design techniques and ANOVA for MRR with 0.059 P-value and for Surface roughness with 0.062 P-value validates the regression and the significant parameters. Further optimization is conducted using genetic algorithms. The optimization data are validated using scanning electron microscope (SEM) images for MRR and surface roughness individually. Leveraging the capabilities of MATLAB and LabVIEW, a user-friendly interface is designed and validated using the class function Object () [native code] node and core wrapper design of the Laboratory Virtual Instrument Engineering Workbench (LabVIEW). The objective is to create a software tool that enhances machining processes, addressing the needs of various industries. This research aims to develop a mathematical model incorporating statistical techniques to predict machining processes tailored to specific machine-material combinations. A framework for user interface to predict the best machining conditions for chosen outputs by the combination of machines and material is created. The experimental machining data were converted into regression equations and then into .m files using MATLAB. Based on the existing knowledge, a suitable method for optimizing (Genetic Algorithm) the machining process is chosen and the results obtained in a user friendly interface.

This research article presents the optimization of the hot wire gas-tungsten arc welding (HW-GTAW) process parameters for joining AISI super 304 H (SS304H) plates with experiments designed using historic data design methodology. HW-GTAW can overcome the low deposition efficiency of the conventional GTAW process. The current of hot wire, welding current, and wire feed rate are the input factors, and the weight of weld deposition (WWD) and bead width (BW) are the outputs measured for analysis. Micrographs of weldment show defect-free joints; a higher wire feed rate leads to the disturbance of the main arc, whereas a lower wire feed rate results in droplet transfer, interrupting the welding. The weld interface exhibits the presence of finer grains and partially deformed grains in the partially mixed zone (PMZ) and coarser grains in a heat-affected zone (HAZ). The presence of columnar dendrites leads to superior tensile properties compared to the base metal. Optimization shows that the joint fabricated with a welding current of 150 A, hot wire current of 40 A, and a wire feed rate of 1500 mm/min exhibits a higher WWD and BW of 23.97 g and 13 mm, respectively. Wire feed rate revealed a higher influence on WWD, and welding current has a higher effect on the BW of SS304H joints. The optimized SS304 H joint exhibits a maximum strength in tension (598 MPa) and a mean hardness of 188 HV at the fusion zone (FZ) and HAZ. Nature-inspired metaheuristic zebra optimization algorithm also produces identical results from desirability analysis of historical data.

The DOE methodology was applied to identify the best combination of variables-Recycled Aggregate (RA), Aluminium Ash dross (AAD), and Magnesium oxide dross (MOD)-to enhance concrete's mechanical properties. Utilising the Response Surface Methodology's Central Composite Design (CCD), the study examined four variables: the concrete's split tensile and compressive strengths at 14 and 28 days. ANOVA was used to test regression models for these factors, with the results displayed in a Pareto chart for visualization. The impact of each independent variable was evaluated, and second-order polynomial equations were devised to represent the models obtained. The findings suggested a positive contribution from the inclusion of RA, AAD, and MOD to improve mechanical properties, though higher levels of their inclusion led to reduced strength. Through surface plots, Pareto charts, and regression analysis, it was revealed that Recycled Aggregate and AAD were the most significant factors distressing compressive strength (CS) and split tensile strength (STS) at both 14 and 28 days. Validation tests were similar to predicted results for both compressive strength and split tensile strength, signifying the consistency of these models in predicting strength properties based on the selected variables.

The modern world is unthinkable without the advent of aluminium alloys and their allied composites. Being the most abundantly available material in our mother Earth, aluminium finds its usage dating back to several centuries ago. Owing to their attractive attributes such as low weight, affordable cost of raw materials, high strength-to-weight ratio and excellent workability, aluminium alloys and their relative composites are enjoying immense popularity and omnipresence almost in every field such as automobile, aircraft and marine vehicle construction materials, multi-purpose containers, structural components, house building, etc. This research work concentrates on an analytical study-cum-evaluation of machinability behaviour of gravity die-casted aluminium matrix composites (GDC-AMCs) during the milling process, in which chill cast aluminium alloy LM25 is reinforced with boron carbide ceramic particles. Material removal rate (MRR) and resultant cutting forces are calculated during the process. Finally, the best specimen with optimal material properties is selected from a series of composite combinations using a specialized subsect in response surface methodology (RSM)–based optimization called historical data design (HDD).

Consuming various TIG welding settings, the impact of mechanical properties on the butt joint of 410-Martensitic Stainless Steel Plate is explored. Mechanical properties such as tensile strength and hardness are evaluated on the welded butt junction plates using three levels of 200 A, 220 A and 240 A welding currents and the electrode diameters of 1.5, 2 and 2.5 mm and four factor parameters of inputs. Welding current, wire feed rate, electrode diameter, and gas flow rate are set as input parameters. The optimal input responses of welding current, electrode diameter, wire feed rate, and gas flow rate are employed over the 27 sample specimens based on array L27 Design of Experiment tool. The input parameters 240 A of welding current have improved significantly over the structural changes on martensitic form which is evidenced by their multiple SEM Micrographs, as it can be seen in the Hardness up to maximum of 512 BHN and the Tensile strength of 1090 N/mm2 outcomes.

Sand casting is one of the best processes to produce a product to satisfy the customer requirements. The prime advantages of choosing the sand casting technique are perfect dimensional geometry, development of pattern is easy, production rate is high, and solidification time is low when compared to other casting techniques. The main purpose of sand casting is to produce a product with better quality in low cost. The properties of the green sand are based on the sand composition and the most important parameters in the preparation of moulding sand are green strength, moisture content and clay content. In this work, the silica oxide is blended in green sand with various compositions for cope box. The various compositions of sand parameters are experimentally investigated by using Response Surface Methodology (RSM). The results of sand parameters are compared with Artificial Neural Network (ANN) analysis. The blending of 9.2% SiO2 with green sand is very suitable for this casting process. The blending of 9.2% SiO2 with green sand is very suitable for this casting process. The effect of SiO2 blending with green sand, the initial raw material is reduced up to 25% of volume without casting defects. The hardness value increased up to 22% and the surface roughness decreased up to 12% by varying the percentage of SiO2 in green sand.

Primary manufacturing processes like casting, forming, and shaping (forging, rolling, drawing, extrusion, sheet forming, and molding) further need any of the secondary manufacturing processes like turning, drilling, boring, planing, milling, grinding, etc. In order to produce superior quality products, and to enhance productivity, the selection of desirable process parameters is significant. The selection of suitable process parameters is essential for accomplishing the desired component. Based on the existing literature, this study examines the causes, effects, and variances regarding chip formation, tool geometry, thrust force, torque, surface roughness, drilling time, and other drilling quality characteristics in the most typical machining operations such as drilling. Developing a repository on these process parameters will guide the process planning engineer for ready reckon. Therefore, this work aims at the development of a detailed repository with the study of characteristics. Further, this literature review comprehends the characteristics of a behavior with its reasoning, which was detailed in the past decade. It reveals the beneficial process parameters for achieving better production rate and superior quality.

Environmental concerns become increasingly evident as technology progresses and the world's population expands. Kitchen ventilation is a subdivision of ventilation that deals with the treatment of air from kitchens. Grease, fumes, and odours are all problems that kitchen ventilation solves. As a result, a cost-effective chimney was chosen to assist civilians. The primary components for venting the kitchen air are the filter, fan, flue, and duct. In this work, the new geometry duct design is improved and analysed by ANSYS. The volume of hot flue gas and discharge of hot flue gas are calculated theoretically and also recommended standard dimensions and geometry to the industry. Academic contributions to chimney advancements are recognised in this study endeavour, and a research deficit is identified based on these objectives.

Aluminum silicon carbide (AlSiC) composite, weight-sensitive characteristic material having wide applications in electric vehicles and semiconductor industries usually made by stir casting of aluminum metal with SiC (7.5%) and Mg (2.5%) powders. The microstructure study followed by machining parameters optimization was done by particle swarm optimization (PSO) on the fabricated AlSiC composite. Initially, energy-dispersive spectroscopy (EDS) in combination with scanning electron microscopy (SEM) provided the investigation of near-surface elements and their quality of spread at various positions in order to develop a map of the AlSiC composite. From the results of EDS, the AlSiC composite is verified with Al-46.23%, Si-5%, Mg-3.3% (wt %). Finally, optimization study on machining parameters states that the feed rate influences reduction of both the surface roughness (SR) and machining time (MT) while the depth of cut increases the material removal rate (MRR) and spindle speed is causing a rise in temperature. This work delivers a mathematical model for each output response with its interactions. Significant process parameters for machining were identified, validated, and proposed.

Magnesium（Mg） alloys are extensively used in the automotive and aircraft industries due to their prominent properties. The selection of appropriate process parameters is an important decision to be made because of the cost reduction and quality improvement. This decision entails the selection of suitable process parameters concerning various conflicting factors, so it has to be addressed with the Multiple Criteria Decision Making（MCDM） method. Therefore, this work addresses the MCDM problem through the TOPSIS（Technique for Order Preference by Similarity to Ideal Solution） and COPRAS（COmplex PRoportional ASsessment） methods. The assessment carried out in the material Mg AZ91 with the Solid Carbide（SC） drill bit. The dependent parameters like drilling time, burr height, burr thickness, and roughness are considered with the independent parameters like spindle speed and feed rate. Drilling alternatives are ranked using the above said two methods and the results are evaluated. The optimum combination was found on the basis of TOPSIS and COPRAS for simultaneous minimization of all the responses which is found with a spindle speed of 4540 rpm and a feed rate of 0.076 mm/rev. The identical sequencing order was observed in TOPSIS and COPRAS method. The empirical model was developed through Box-Behnken design for each response. Superior empirical model developed for drilling time which is 3.959 times accurate than the conventional equation. The trends of various dependents based on the heterogeneity of various independents are not identical, these complex mechanisms are identified and reported. The optimized results of the Desirability Function Approach are greater accordance with the TOPSIS and COPRAS top rank. The confirmation results are observed with lesser deviation suggesting the selection of the above independent parameters.

Joining of similar materials by varying the input factors on a continuous drive friction welding process is done in this study. The intention is to find the optimal solution in friction welding input process parameters. Among several types of welding processes, friction welding forms good metal joints. The process factors considered for this material joining practice are Upset Time (UT), Heating Time (HT), Heating Pressure (HP), Upset Pressure (UP), chemical composition and measurements of the materials. Frictional joints provide better mechanical properties, hence it is attracted by researchers. Here, EN353 is used as the specimen, for its extensive usage in the automobile and manufacturing sectors. Axial shortening, hardness testing and the temperature during welding are evaluated, compared and optimized using Taguchi Design of Experiments (DoE) scheme using L27 orthogonal array and Grey Relational Analysis (GRA).

In this work, the integration of surface texturing and extended self-lubrication for machining grey cast iron materials is made for a hassle-free and toxic-free working environment for industrial workers. The Cross-chevron and line textures were fabricated on the tool's rake, and flank faces using Nd: YAG laser texturing machine. Turning experiments are made using an untextured ceramic tool (UT), cross-chevron and line textured tool (TT), semi-solid lubricants MoS2, Graphite, and SAE 40 oil solutions filled texture tool (STL) under dry conditions. The investigational results showed reduced main cutting force, feed force, average friction co-efficient for semi-solid lubricant filled texture tool than other considered tools. Due to the lesser adherability of grey cast iron (workpiece material) with the surface textured tool and texture gaps filled with semi-solid lubricants, a significant reduction in cutting forces were observed at higher cutting speeds. The authors found that the texture surfaces and the texture gaps filled with lubricant at a far distance away from the cutting edge were not helpful during the trial experiments.

The standard western music notation for the major and minor chords is avail- able in the world. But the understanding of major and minor chords is very difficult for learning peoples particularly children’s. It is very complicated to memory of all major and minor chords and also roots of all chords. This inven- tion is easily understand by children and easily captured in standard piano and other instruments. The new method of conveying chords by numerical tech- niques is used in this invention. The octave notes are derived in to two different heads of major and minor chords by numerical method. There are two main equations are implemented and it is very easy to understanding of all major and minor chords.

Production improvement is a key to stay in the competitive market for most industries. In most of the scenarios, quality gets compensated while going for productivity improvement. Using proper optimization techniques with multi-objective solution tools we might be able to achieve it. Aluminum 7075 material having wide application in lightweight fields such as aviation especially because of its workability nature is taken for experimentation. Milling is one of the significant machining operations in such applications. Here we have attempted to optimize the milling of Al 7075 with two objectives like improving Material Removal Rate and minimizing Surface Roughness. Experimental machining is designed using Taguchi’s design of experiments. The machined data are used to create and analyze the machining operation using the statistical method of calculations. The multi-objective optimization is carried out by Grey relational Analysis and the investigation results are further discussed.

Incremental Sheet metal Forming (ISF) is a reliable process of converting a blank to work piece with better outputs compared to conventional forming process. The flexibility of ISF in producing the rapid prototype based on the customer needs is increased which is also desirable in the industry. But Single Point Incremental Forming (SPIF) process takes more time to form a product and hence the longer time is a barrier in implementing this process in industries. In this research work, the ISF process was made on sheet metal SS 202 using a newly designed multi-point tool and the obtained outputs were compared with the same material of sheet metal formed by traditionally available single point tool. This Multi Point Incremental Forming (MPIF) process takes lesser process time to give better formability, improved wall angle and good surface roughness. The input process parameters selected for the process are type of tool, speed, feed, Vertical Step Depth (VSD), and lubrication. They are arranged by using the taguchi Design of Experiments (DOE) approach. The responses considered are wall angle, formability, surface roughness, spring back and forming time. The multiple outputs obtained were optimized by Grey Relational Analysis (GRA) to predict the superior parameter. Confirmation test was also made to validate the output result. Fractography analysis was carried out to predict the fracture mechanism obtained during the forming process. The surface topography was also made on the surface of the formed area of the sheet metal. This research work concludes that newly designed MPIF outperforms SPIF.

Owing to the advancement in the field of materials, different range of grades have been developed. The machinability examination of these newer grades must be carried out for future applications. One such newer grade of magnesium with AZ31 is deemed for study during the drilling process. The independent parameters considered are spindle speed (SS), feed rate (FR) and drill bit diameter (DBD). The dependent parameters considered are burr height (BH), burr thickness (BT), drilling time (DT) and surface roughness (SR). Improving hole accuracy is essential for manufacturing superior products, which is discussed in this work. At the same time, the machining time has also to be minimized to increase the production rate. With these objectives, the experimental investigation is made. Further, an analytical model for predicting the responses is developed; later, optimization is carried out to obtain the desired responses through the desirability function approach. The multi-objective optimization suggests the SS of 1100[Formula: see text]rpm, the FR of 0.198[Formula: see text]mm/rev., and the DBD of 6[Formula: see text]mm for reducing the entire dependent is reckoned.

Development in the field of materials brings numerous newer grades, but the machinability studies over those materials have to be done. Drilling is the major manufacturing process which covers around 25% of machining processes. Magnesium AZ31 is considered for the present investigation to perform the drilling operation. Control over the responses like circularity, perpendicularity and cylindricity will improve the life of fastening element due the reduction of compressive and shear stress. The deviation of above responses will increase compressive and shear stress leads to fatigue and also increases the assembling time. This work concentrates on the reduction of such distinctive properties. Empirical model was developed to find the responses for the usage of process planning engineer, later optimization carried out through Desirability Function Approach (DFA). The multi objective optimization suggesting the spindle speed of 1100.02 rpm, the feed rate of 0.038 mm/rev. and the drill diameter of 6 mm for minimizing all the responses considered. Similarly Grey Relational Analysis (GRA) applied to reduce the responses. Evaluation made between DFA and GRA which highlights the superiority of GRA for circularity and cylindricity. The DFA be the superior technique for minimizing the perpendicularity.