Sri Ramakrishna Engineering College (An Autonomous Institute Affiliated to Anna University of Technology, Coimbatore)

Department of Manufacturing Engineering

In Sponsored with

Council of Scientific and Industrial Research, New Delhi

Technical Co-Sponsored

Proceedings of the National Conference on

Recent Trends in Metal Joining

Techniques

March 30, 2012

Proceedings of the National Conference on Recent Trends in Metal Joining Techniques (NCRTMJT-2012)

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Coimbatore-641 012

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i

Proceedings of the

National Conference on Recent Trends in Metal Joining

Techniques

NCRTMJT-2012

Coimbatore, Tamilnadu, India

Organizing Committee

NCRTMJT-2012, Department of Manufacturing Engineering

Sri Ramakrishna Engineering College

Coimbatore, Tamilnadu, India

Editor

Dr.J. David Rathnaraj

Prof.C. Bhagyanathan

Prof.S. Sathish

Published by

Bonfring

292/2, 5th Street Extension, Gandhipuram

Coimbatore-641 012

Tamilnadu, India

E-mail: info@bonfring.org

Website: www.bonfring.org

ii

About the College

Sri Ramakrishna Engineering College was established in the year 1994 by SNR Sons

Charitable Trust, which runs 16 other reputed educational and medical institutions in the city.

The trust is currently spearheaded by the Managing Trustee Thiru.C. Soundararaj and Joint

Managing Trustee Sri.R. Vijayakumhar. The college is empowered by Dr. Ebenezer

Jeyakumar, Director (Academic) and Dr.R. Radhakrishnan, Principal. This institution is the

first self-financing autonomous institution in the south zone to get autonomous status granted by

the University Grants Commission in 2007. The institution is accredited by NBA (National

Board of Accreditation) and approved by AICTE. The College offers 9 UG, 8 PG along with 3

Ph.D Programmes. The college has entered into a Memorandum of Understanding with Rutgers,

The state university of New Jersey USA and South Dakota school of Mines and technology,

Rapid City, USA for student and staff Exchange programs. The college has also signed MOU

with Salzer Electronics Ltd, Infosys, Wipro, Suguna Industries and CODISSIA to enable the

students to undergo training for practical knowledge.

Department of Manufacturing Engineering (PG)

The Manufacturing Engineering department was started in the year of 2003. The department

has adequate infrastructure with well established laboratories and research centers. The core

members of the faculty have rich academic experience and research exposure. The latest

advancements in the fields of technology and current affairs have been brought in to implant in-

depth knowledge and to cater the needs of the core industries. The department strives to provide

students with concept oriented teaching to ensure excellence as a professional. The department

has set up a Metal Joining Research Centre (MJRC) in the campus jointly along with Sri

Ramakrishna Advanced Training Institute (SRATI), which is furnished with state of the art

equipments to carry out the research in the field of metal joining.

iii

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Bonfring Conveys its Hearty Wishes to NCRTMJT-2012

iv

Thiru.C. Soundararaj D.Text(Boston)

SNR Sons Charitable Trust

The Trustee’s Message

I am extremely happy to know that Sri Ramakrishna Engineering College is

conducting a National Conference on Recent Trends in Metal joining Techniques

on 30th March 2012.

The management is proud to acknowledge that the students have endeavor with

enthusiasm in organizing this mega function. It is a moment of pride for every soul

associated with the conference, who has dedicated their whole self in its making.

I wish to congratulate the Principal, HODs, Staff and Students of Sri

Ramakrishna Engineering College on this precious occasion.

Managing Trustee

v

Thiru.R. Vijayakumhar B.E.,M.S.,M.B.A

SNR Sons Charitable Trust

The Joint Managing Trustee’s Message

It is indeed heartening to know that Sri Ramakrishna Engineering College is

conducting a National Conference on Recent Trends in Metal joining Techniques

on 30th March 2012.

The management is glad to encourage the students who have strived hard in

making this event a grand success.

I wish to congratulate the Principal, HODs, Staffs and Students of Sri

Ramakrishna Engineering College on this momentous occasion.

Joint Managing Trustee

vi

Dr.A. Ebenezer Jeyakumar., M.E., Ph.D.

Director

Message

It is gladdening that the Department of Manufacturing Engineering (PG) is

organizing a National Conference on Recent Trends in Metal Joining Techniques

(NCRTMJT2012) on 30 March 2012.

A national conference of this type is a pressing need of the day in the sense that

the emerging knowledge and new trends in the field of Manufacturing Engineering

can be brought together in one place by experts for meaningful discussion and

deliberation for the use of learning students and empowering teachers.

I wish the national conference a grand success and commend all the faculty

members, scholars and researchers for making this intellectual exercise a great

event.

vii

Dr.R. Radhakrishnan., M.E., Ph.D.

Principal

Message

I am very much delighted to have the National Conference on Recent Trends in

Metal Joining Techniques (NCRTMJT 2012) organized by Department of

Manufacturing Engineering (PG) at our institution on 30 March 2012.

The conference, I am sure will provide a forum for discussion on the

contemporary developments in the field of Manufacturing Engineering and would

further deepen and sharpen the young minds. At this juncture, I express my warm

welcome to all the participants of NCRTMJT 2012.

The Head of the Department, the faculty members and all the students deserver a

special appreciation for all their hard work.

I wish the conference a great success and my heartiest wishes to the participants.

viii

Organizing Committee

Chief Patrons

Sri C. Soundararaj, Managing Trustee, SNR Sons Charitable Trust, Coimbatore

Sri R. Vijayakumhar, Joint Managing Trustee, SNR Sons Charitable Trust, Coimbatore

Patrons

Dr.A. Ebenezer Jeyakumar, Director (Academic), SNR Sons Charitable Trust, Coimbatore

Dr.R. Radhakrishnan, Principal, Sri Ramakrishna Engineering College, Coimbatore

Convenor

Dr.J. David Rathnaraj, Head of the Department/ Mfg-PG

Co-Convenor

Prof.C. Bhagyanathan, Assistant Professor/ Mfg-PG

Co-ordinators

Prof.S. Sathish, Assistant Professor/ Mfg-PG

Advisory Committee

Dr.R. Rudramoorthy, Principal, PSG Tech, Coimbatore

Dr.P. V. Mohanram, Dean, PSG Tech, Coimbatore

Dr.D. R. Yadav, Director – Engineering, DRDL, Hyderabad

Dr.M. Ravi, Scientist E2, NIIST, Trivandram

Dr.R. Sundararajan, Principal, GCT, Coimbatore

Dr.M. Sakthivel, COE, Anna University of Technology, Coimbatore

Dr.P.S.S. Prasad, Professor, PSG Tech, Coimbatore

Dr.G. Sundarajan, Professor, PSG Tech, Coimbatore

Dr.K.S. Amirthagadeswaran, Professor, GCT, Coimbatore

Dr.G.L. Samuel, Assistant Professor, IIT Madras

Dr. M. Karthikeyan, Principal, KEC, Trichy

Dr. Darius Gnanaraj, Dean (AA), Karunya University, Coimbatore

Dr. Varadarajan, Professor, Cochin University, Cochin

Dr.T.P. Lukose, Professor, SNGCET, Kannur

Mr.K. Ilango, Managing Director, Auto Cast, Coimbatore

Mr.P. Raghul Raj, Director, Athi Parasakthi Alloy Steel, Coimbatore

Mr. Viswanthan, Pisshey Industries, Bangalore

ix

CONTENT

S.No. Paper ID Title/Author Page No.

01 NC12101 An Overview of Friction Stir Welding of Dissimilar Aluminium

Alloys

K. Anganan, M. Muthu Krishna, V.M. Ganesh and K. Marimuthu

01

02 NC12102 Development of Supply Chain Management Process for Cast Iron

Foundry

C. Narayanaswamy and K. Natarajan

07

03 NC12103 Experimental Analysis Heat Transfer in Solar Pond

K. Arulselvan and S. Sivakumar

13

04 NC12104 Green Supply Chain Management for New Product Development

M. Muni Prabaharan

16

05 NC12109 Sensorless Vector Control of Permanent Magnet Synchronous Motor

Using Robust Hysteresis Current Controller with Rotor Position

Tracking PI Controller

Merin Antony and B. Adhavan

21

06 NC12110 Torque Ripple Minimization in Brushless Direct Current Motor by

Commutation Time Extension

S. Gowdham Kumar and B. Adhavan

26

07 NC12111 Finite Element Modeling of a Piezofan Using Ansys Software

Shamon K Shamsudheen

32

08 NC12112 Design and Analysis of Six Way Valve

S. Sajan

38

09 NC12113 Analysis of Hydrodynamic Lubrication of Surfaces with Micro Grooves Using CFD

Nedheesh Eldho Baby

43

10 NC12114 Value Engineering of Slew Mechanism in Electric Cranes

K. Logesh, K. Muruganantham and V. Babu

48

11 NC12115 A Review of Fatigue and Impact Studies on Various Composites

K. Logesh, V. Babu and K. Muruganantham

53

12 NC12116 Effect of Zirconium Additions on the Tensile Properties of Cast Al-

6Mg Alloys

S. Kanagaraj, M. Ravi and P.G. Venkatakrishnan

59

13 NC12117 Generation of an Empirical Model to Describe the Experimental

Evolution of Drag Ratio for a Two Phase Horizontal Pipe Flow of

Non-Newtonian Liquid (Carbopol)/Air Mixture

Febin Cyriac, J.M. Franco and Mª Carmen Sánchez

62

14 NC12118 Design and Fabrication of Kadak - A Pipe Inspection Robot

S. Arun Kumar, S. Dhinesha, M. Kailashnath and K. Kaja Shareef

70

x

15 NC12119 Resudial Stress and Angular Distorsion of GMAW in FEA

Simulation – A Review

S. Ramani and V. Vel Murugan

73

16 NC12201 Optimization of Parameters by Reducing Set-Up Time and Costs

Using DGCAPP

S. Santhosh and C. Bhagyanathan

78

17 NC12202 Prediction of Surface Roughness Characteristics on 50cr30mo Alloy

by CNC Turning Operation

N. Dinesh and C. Bhagyanathan

82

18 NC12203 Failure Mode Effective Analysis in Spur Gear N. Karthick and Dr.J. David Rathnaraj

87

19 NC12204 Scheduling of Fan Pulley Mixed Model Assembly Line Using POM

Software S. Sathish and S. Premkumar

93

20 NC12205 Optimize Design and Analysis of Blanking Punch Tool to Increase

its Strength and Life

P. Naveenkumar and C. Bhagyanathan

99

21 NC12207 Microstructural and Mechanical Studies of Semi-Solid Metal

Processed A356 Aluminum Alloy

T. Karthikeyan, Dr.M. Ravi and C. Bhagyanathan

103

22 NC12208 Studying the Properties of Newly Developed Aluminium Alloy for Automotive Piston by Using Squeeze Casting

M. Pradeep Kumar, C. Bhagyanathan and Dr.M. Ravi

108

23 NC12209 Optimization of Friction Welding Parameters for Joining Aluminium

and Mild Steel Using RSM

S. Sundaraselvan and C. Bhagyanathan

113

24 NC12210 Effects of Process Variables on Metal Loss Due to Corrosion for

Metal Inert Gas (MIG) Welded Structures

MS. Saravanakumar and C. Bhagyanathan

117

25 NC20320 A Survey on Feasibility and Effectiveness of Heat Pipe Cooling in

End Milling Operations: Thermal, Structural Static, and Dynamic

Analyses: A New Approach

R. Rangaraju and C. Bhagyanathan

121

26 NC20321 A Survey on Mathematical Modelling of Metal Removal Rate and

Hardness in Electric Discharge Machining Using DOE Approach and

Regression Analysis

V. Rajkumar and C. Bhagyanathan

127

27 NC20322 A Survey on Impact of External Magnetic Field on Weld Quality of

Resistance Spot Welding

S. Anand and C. Bhagyanathan

133

28 NC20323 A Review on Investigations on Deformation Behavior of AA5754

Sheet Alloy Under Warm Hydroforming Conditions

J. Baskaran and C. Bhagyanathan

137

xi

29 NC20324 A Survey on Condensation Analysis of Exhaust Gas Recirculation

System for Heavy-Duty Trucks

Kevin Sunny and C. Bhagyanathan

144

30 NC20325 A Survey on Minimizing Contamination in Commercial Mass

Production of Metal Injection Molded Pure Titanium

Shijo Thomas and C. Bhagyanathan

150

31 NC20326 A Survey on Physical Limitations for the Bandwidth Frequency of a

Pressure Controlled, Axial-Piston Pump

V. Rajkumar and S. Sathish

157

32 NC20327 A Review on Dynamic Process Modeling for Rotary Ultrasonic

Machining of Alumina

U.C. Vivek and C. Bhagyanathan

164

33 NC20328 A Survey on Analysis and Modeling of a Pneumatic Servo System

Based on Backstepping Design

Y. Amaladasan and S. Sathish

169

34 NC20329 A Review on “Toward Automation of Friction Stir Welding Through

Temperature Measurement and Closed-Loop Control”

M. Suganthy and C. Bhagyanathan

175

35 NC20330 A Review on Load and Stress Analysis for the Swash Plate of an

Axial Piston Pump/Motor

Suraj and C. Bhagyanathan

179

36 NC20331 A Review on Fuzzy Neuron Adaptive Modeling to Predict the

Surface Roughness under Process Variations in CNC Turning

J. Sujithkumar and C. Bhagyanathan

186

37 NC20332 Metallographic Analysis of Low Carbon Alloy Steel with High

Corrosion Resistance Material

S. Sreedhar, K. Sudhakar, T.S. Vignesh Kumar and M. Vinoth Kumar

190