Green Materials and Advanced Manufacturing Technology: Concepts and Applications

Description

This book includes recent theoretical and practical advancements in green composite materials and advanced manufacturing technology. It provides important original and theoretical experimental results which use nonroutine technologies often unfamiliar to some readers and covers novel applications of more familiar experimental techniques and analyses of composite problems. Green Materials and Advanced Manufacturing Technology: Concepts and Applications provides insight and a better understanding into the development of green composite materials and advanced manufacturing technology used in various manufacturing sectors. It highlights recent trends in the fields of green composites, metal matrix composites, ceramic matrix composites, surface modification using laser cladding, types of dust collectors in waste management and recycling in industries, machinability studies of metals and composites using surface grinding, drilling, electrical discharge machining, joining of metals using friction stir welding, shielded metal arc welding, and linear friction welding. This book is written for engineering students, postgraduate students, research scholars, faculty members, and industry professionals who are engaged in green composite materials and development of advanced manufacturing technology. Cover Half Title Series Page Title Page Copyright Page Table of Contents Preface Editors Contributors Chapter 1 Parametric Optimization of Surface Roughness and Surface Temperature during Minimum Quantity Lubrication (MQL) and Conventional Flood Lubrication Techniques in Surface Grinding of Mild Steel: A Performance Comparison and Analysis 1.1 Introduction 1.2 Materials and Experimental Setup 1.2.1 Dry Grinding Operation 1.2.2 Flood Grinding Operation 1.2.3 MQL Grinding Operation 1.2.3.1 MQL Grinding with Both Nozzles Same Side [MQL(BNSS)] 1.2.3.2 MQL Grinding with Both Nozzles on Opposite Sides [MQL(BNOS)] 1.3 Results and Discussion 1.3.1 Surface Temperature in Dry Grinding Operation 1.3.1.1 Dry Grinding Operations with Maximum Temperature per Pass 1.3.2 Surface Temperature during Flood Grinding Operation 1.3.2.1 Flood Grinding Operations with Maximum Temperature per Pass 1.3.3 Surface Temperature in MQL Grinding Operation 1.3.4 Temperature Comparison in Various Grinding Operations 1.3.5 Temperature Comparison in Various MQL Grinding Operations 1.3.6 Measurement of Surface Roughness 1.3.6.1 Surface Roughness in Dry Grinding Operation 1.3.6.2 Surface Roughness in Flood Grinding Operation 1.3.6.3 Surface Roughness in Various MQL Grinding Operations 1.3.7 Surface Roughness Comparison in Various Grinding Operations 1.4 Conclusion Declaration of Conflict of Interest Funding Ethical Approval Acknowledgements References Chapter 2 Importance of Dust Collectors in Waste Management and Recycling in Industries 2.1 Introduction to Dust Collectors 2.2 Electrostatic Precipitator 2.3 Fabric Filters 2.4 Unit Collectors 2.5 Wet Scrubbers 2.6 Inertial Separators 2.6.1 Baffle Chambers 2.6.2 Settling Chamber and Centrifugal Collectors 2.7 Cyclone Separator 2.7.1 Cyclone Separator Working Principle 2.7.2 Tangential Inlet Cyclone Separator 2.7.3 Axial-Flow Cyclone Separator 2.7.4 Bottom Inlet Cyclone Separator 2.7.5 Cut-Off Diameter and Pressure Drop 2.7.6 Applications 2.7.7 Advantages of the Cyclone Separator 2.7.8 Disadvantages of the Cyclone Separator References Chapter 3 Influence of Nickel-Based Cladding on the Hardness and Wear Behaviour of Hard-Faced Mild Steel Using E-7014 Electrode Using Shielded Metal Arc Welding 3.1 Introduction 3.2 Material and Methodology 3.2.1 Selection of Electrode 3.2.2 Selection of Metal Powders 3.2.3 Selection of Welding Process 3.2.3.1 Welding Equipment 3.3 Results and Discussion 3.4 Conclusion Declaration of Conflict of Interest Funding Ethical Approval Acknowledgements References Chapter 4 Erosion Response of Martensitic Stainless Steel Subjected to Slurry Flow 4.1 Introduction 4.2 Materials and Methods 4.3 Experimental Analysis 4.4 Results and Discussions 4.5 Conclusion References Chapter 5 Optimization of Machining Parameters during the Drilling of Natural Fibre-Reinforced Polymer Composites: A Critical Review 5.1 Introduction 5.2 Drilling of Hybrid Polymer Composites 5.3 Input and Output Parameters 5.4 Conclusions Declaration of Conflict of Interest Funding Ethical Approval References Chapter 6 Mechanical Properties of the Palmyra Fibre Epoxy Composites 6.1 Introduction 6.2 Materials and Methods 6.3 Influence of Fibre Loading on Composite Tensile Strength 6.4 Influence of Fibre Loading on Composite Impact Strength 6.5 Influence of Fibre Loading on Composite Flexural Strength 6.6 Conclusions References Chapter 7 ANFIS-Based Prediction of MRR and Surface Roughness in Electrical Discharge Machining of HAMMC 7.1 Introduction 7.2 Materials Selection and Methodology 7.2.1 Selection of Base Materials 7.2.2 Powder Metallurgy 7.2.3 Electrical Discharge Machining 7.2.4 Taguchi’s Technique for Experimental Design 7.2.5 Adaptive Neuro-Fuzzy Inference System (ANFIS) 7.3 Results and Discussions 7.4 Conclusions References Chapter 8 Experimental Investigation and Optimization of EDM Process Parameters on Ti-6Al-4V Alloy Using Taguchi-Based GRA and Modelling by RSM 8.1 Introduction 8.2 Materials and Methods 8.3 Results and Discussions 8.3.1 Optimization of Process Parameters by Taguchi Method and GRA 8.3.2 Examination of EDM Process Parameters on the EWR 8.3.3 Examination of EDM Process Parameters on the MRR 8.3.4 Examination of EDM Process Parameters on Ra 8.3.5 Response Surface Methodology (RSM) 8.3.6 Analysis of Variance (ANOVA) 8.3.7 Confirmation Experiment 8.4 Conclusions Declaration of Conflict of Interest Funding Ethical Approval References Chapter 9 High-Temperature Tribological Behaviour of Surface-Coated Tool Steel 9.1 Introduction 9.2 Experimental Materials 9.3 Configuration and Sliding Contact 9.4 Test Setting and Procedures 9.5 Results and Discussion 9.5.1 Characterization of Surface Topography 9.5.2 Friction Results 9.5.2.1 Friction of Coating Initially 9.5.2.2 Friction of Coatings during 10 Minutes 9.5.3 Wear Resistances 9.5.3.1 Wear Resistance at 40°C 9.5.3.2 Wear Resistance at 800°C 9.5.4 Surface Damages 9.5.4.1 Surface Damage at 40°C 9.5.4.2 Surface Damage at 800°C 9.5.5 Oxidation of Sliding Surfaces 9.6 Conclusion References Chapter 10 Process Modelling and Optimization of Hardness in Laser Cladding of Inconel® 625 Powder on AISI 304 Stainless Steel 10.1 Introduction 10.2 Experimental Methods 10.3 Process Model Development by Curve Fitting Method 10.4 ANN for Model Development 10.5 Parametric Optimization by First Derivative Test 10.6 Generalized Reduced Gradient for Process Optimization 10.7 Grey Relational Analysis for Parametric Optimization References Chapter 11 Effect of Wire Electric Discharge Machining Process Parameters on Surface Roughness of Monel 400 Alloy 11.1 Introduction 11.2 Experimental Method 11.2.1 Wire Electrical Discharge Machining 11.2.2 Material Used: Monel 400 11.2.3 Tool Electrode Material: Brass 11.2.4 Dielectric Fluid: Deionized Water 11.2.5 Measuring Apparatus 11.2.6 Parameters and Its Range 11.2.7 Design of Experiments 11.3 Results and Discussion 11.3.1 Effect of Pulse On Time 11.3.2 Effect of Pulse Off Time 11.3.3 Effect of Wire Tension 11.3.4 Effect of Wire Feed 11.3.5 Effect of Surface Roughness on Machining Parameters 11.4 Conclusion References Chapter 12 Experimental Investigation of the Effect of Various Chemical Treatments on Agave angustifolia Marginata Fibre 12.1 Introduction 12.2 Materials and Experiments 12.2.1 Natural Fibre Material 12.2.2 Extraction of Fibre From Plants 12.3 Chemical Treatment of Fibre 12.3.1 NaOH Treatment 12.3.2 NaClO Treatment 12.3.3 H2O2 Treated 12.4 Physical Properties of Fibre 12.4.1 Fibre Density 12.4.2 Fibre Diameter 12.4.3 Chemical Properties of Fibre 12.4.4 Wax Content 12.4.5 Moisture Content 12.4.6 Cellulose Content 12.4.7 Lignin Content 12.4.8 Hemicellulose Content 12.4.9 Fourier-Transform Infrared Spectrometry (FTIR) 12.4.10 Tensile Strength of Agave Angustifolia ‘Marginata’ Fibre 12.4.11 Thermal Analysis 12.5 Results and Discussion 12.5.1 Physical Properties of AAM Fibre 12.5.1.1 Fibre Density 12.5.1.2 Fibre Diameter 12.5.1.3 Chemical Properties of Fibre 12.5.1.4 Fourier-Transform Infrared Spectrometry (FTIR) 12.6 Tensile Properties of AAM Fibre 12.7 Thermal Analysis 12.8 Conclusions References Chapter 13 Defect Identification in Casting Surface Using Image Processing Techniques 13.1 Introduction to Surface Inspection 13.2 Challenges and Issues in Defect Detection 13.3 Proposed Method 13.4 Contrast Enhancement 13.5 Image Segmentation 13.6 Feature Extraction 13.7 Classification of Defects 13.8 Conclusion 13.9 Applications Bibliography Chapter 14 Effect of Y2O3 Doping on Mechanical Properties and Microstructure of Al2O3/10wt.% SiC Ceramic Composites Synthesized by Microwave Sintering 14.1 Introduction 14.2 Microwave Sintering 14.2.1 Basics of Microwave Heating 14.2.2 Interaction of Microwaves with Materials 14.2.2.1 Transparent 14.2.2.2 Opaque 14.2.2.3 Absorbent 14.2.3 Heating Pattern 14.2.4 Microwave Heating Mechanisms 14.2.4.1 Resistive Heating 14.2.4.2 Bipolar Rotation 14.2.4.3 Electromagnetic Heating 14.2.4.4 Dielectric Heating 14.2.5 Microwave Heating Methods 14.2.5.1 Microwave-Assisted Heating 14.2.5.2 Direct Microwave Heating 14.2.6 Advantages of Microwave Sintering 14.3 Synthesis of Al2O3/10 wt.% SiC with Y2O3 Ceramic Composite Samples Using Microwave Sintering 14.3.1 Materials 14.3.2 Weighing and Milling 14.3.3 Powder Compaction and Green Pellet Fabrication 14.3.4 Sintering 14.4 Mechanical Testing and Characterization 14.4.1 Relative Density 14.4.2 Average Matrix Grain Size 14.4.3 Vickers Hardness 14.4.4 Fracture Toughness 14.4.5 X-Ray Diffraction (XRD) 14.4.6 Microscopy Using Scanning Electron Microscope (SEM) 14.5 Results and Discussion 14.6 Conclusion References Chapter 15 Multiobjective Optimization of BSL 165 Aluminium Composite For Aeronautical Applications 15.1 Introduction 15.2 Optimization by Using Genetic Algorithm 15.3 Surface Roughness 15.4 Material Removal Rate (MRR) 15.5 Experimental Outline 15.6 Selection of Controllable Parameters 15.6.1 Selection of Tool 15.6.2 Limits of Process Parameters 15.7 Design Matrix 15.8 Experimentation 15.9 Response Surface Model for the Prediction of Surface Roughness 15.9.1 Surface Roughness 15.10 Results and Discussion on Surface Roughness 15.10.1 Parameter Interaction Effects 15.11 Response Surface Model for the Prediction of MRR 15.11.1 Material Removal Rate (MRR) 15.12 Results and Discussion on MRR 15.12.1 Parameter Interaction Effects 15.12.2 An Optimized Set of Parameters 15.13 Genetic Algorithm Optimization 15.13.1 Validation of the Model 15.14 Conclusion References Chapter 16 Abrasive Wear Behaviour of Titanium and Ceramic-Coated Titanium 16.1 Introduction 16.2 Abrasive Wear Behaviour of Titanium 16.3 Abrasive Wear Behaviour of Titania (TiO2) 16.4 Abrasive Wear Behaviour of TiO2 + 5 SiC Coating 16.5 Abrasive Wear of TiO2 + 10 SiC Coating 16.6 Abrasive Wear of TiO2 + 15 SiC Coating 16.7 Summary References Chapter 17 Impact of Friction Stir Welding Process on Mechanical and Microstructural Behaviour of Aluminium Alloy Joint – A Review 17.1 Introduction 17.2 Literature Survey 17.2.1 Effect of Friction Stir Welding Parameters 17.2.2 Postweld Heat Treatment of FSW Joints 17.2.3 Friction Stir Welding of Dissimilar Joint 17.2.4 Friction Stir Welding of Metal Matrix Composite 17.2.5 Under Water Friction Stir Welding Process 17.3 Conclusion References Chapter 18 Effect of Solution Treatment and Artificial Ageing on Strength Properties of Friction Stir Welded AA2014-T6 Aluminium Alloy 18.1 Introduction to Effect of Solution Treatment and Artificial Ageing on Friction Stir Welding Joints 18.2 Method of Manufacturing Advance Material 18.3 Strength and Microstructural Properties of Joint 18.4 Analysis of Precipitate Morphology of FSW Joints 18.5 Summary of Effect of Solution Treatment and Artificial Ageing on FSW Joints References Chapter 19 Effect of Oscillation Frequency on Microstructure and Tensile Properties of Linear Friction Welded Ti-6Al-4V Alloy Joints 19.1 Introduction 19.2 Experimental Details 19.3 Results 19.3.1 Macrostructure Analysis 19.3.2 Tensile Properties 19.3.3 Microhardness Variations across the Joints 19.3.4 Microstructural Features of the LFW Joint 19.3.5 Analysis of SEM Microstructure 19.3.6 Fracture Surface Analysis 19.4 Discussion 19.5 Conclusions References Chapter 20 Linear Friction Welding of Ni-Co-Cr Superalloy for Blisk Assembly 20.1 Introduction 20.1.1 Friction Welding 20.1.1.1 Linear Friction Welding Process 20.2 Experimental Conditions 20.3 Results and Discussion 20.3.1 Transverse Tensile Properties 20.3.2 Microhardness Measurement 20.3.3 Impact Testing 20.3.4 Macrostructural and Microstructural Features of Inconel-100 Weld Joint 20.3.5 Elemental Analysis (EDS) of Welded Joints 20.4 Conclusion References Index