Advances in Additive Manufacturing and Metal Joining: Proceedings of AIMTDR 2021

Description

This book presents select proceedings of the 8th International and 29th All India Manufacturing Technology, Design and Research Conference (AIMTDR 2021). It discusses the latest advances in miniature manufacturing, machining of miniature components, surface engineering, nanomaterials, nanotechnology, Industry 4.0, optimization techniques, micro-electric discharge machining, electrochemical micro-machining, thin films, optimization of micro-machining process parameters, machining of nano-composites, characterization using atomic force microscopy, micro-tool fabrications, characterization of nano-composites, surface roughness analysis, tribological performance of surface coated materials and sustainability in manufacturing. The contents of this book are useful for students, researchers and as well as industry professionals in the various fields of mechanical engineering. Foreword Preface Contents About the Editors Additive Manufacturing A Review on Fused Deposition Modeling of Thermoplastics 1 Introduction 1.1 Process Chain of Additive Manufacturing 1.2 Classification of Additive Manufacturing 1.3 Advantages of Additive Manufacturing [18] 1.4 Issue Related to AM 2 Fused Deposition Modeling 2.1 History 2.2 Filament Manufacturing 2.3 FDM Process Parameter 3 Materials for FDM 4 Advantages and Limitation 5 Major Challenges and Future Prospective—Conclusion References Analysis of Density of Laser Powder Bed Fusion Fabricated Part Using Decision Tree Algorithm 1 Introduction 2 Methodology 3 Machine Learning 4 Results and Discussion 4.1 Process Parameters and Their Relation with Density 4.2 Model Testing and Prediction 5 Conclusion References ANP–MOORA-Based Approach for Selection of FDM 3D Printer Filament 1 Introduction 2 Methodology 2.1 Overview of MCDA/MCDM 2.2 Overview of ANP Method 2.3 Overview of MOORA Method 3 Result and Discussion 3.1 Calculation of ANP Method 3.2 Result and Discussion of ANP Method 3.3 Calculation of MOORA Method 3.4 Result and Discussion of MOORA Method 3.5 Comparison of ANP and MOORA Results 4 Conclusions References Applications of Laser Beam Welding in Automotive Sector-A Review 1 Introduction 2 Laser Beam Welding 2.1 Experimental Setup 2.2 Process Parameter 2.3 Shielding Gas 2.4 Types of Materials 3 Applications of LBW in Automotive Sector 3.1 Tailor Blank Applications 3.2 Body in White Applications 3.3 Manufacture of Lightweight Structure 3.4 Fastening of Plastic Components 3.5 Mechanical Fastenings 4 Conclusions 5 Future Scope References Application of S-LCA Principles to Additive Manufacturing 1 Introduction 2 Literature Review 3 Methodology 4 Case Study 4.1 Social Life Cycle Assessment 5 Result 6 Conclusions References Areal Surface Texture Characterization Methods for Selective Laser-Sintered Parts 1 Introduction 2 Methodology 2.1 Sample Manufacturing and Measurement 2.2 Form Removal, Filtering, and Parameterization 3 Result and Discussion 3.1 Areal Roughness Parameter 3.2 Abbott-Firestone Curve Parameters 4 Conclusion 5 Future Scope References Controlling Waviness in Additive Manufacturing of Thin Walls by Laser-Directed Energy Deposition Process 1 Introduction 2 Experimental Setup 3 Results and Discussions 3.1 Effect of Heat Accumulation in Thin Wall Depositions 3.2 Effect of Varying Laser Scan Speed and Introducing Dwell Time 3.3 Controlling Waviness Through Adjustment of Stand-Off Distance 4 Conclusions References Development of a Clay 3D Printing Pen 1 Introduction 2 Experimentation 2.1 Fabrication of the Clay 3D Printing Attachment 2.2 Slip Formation 2.3 CNC Machines with Their Preparatory Codes 2.4 3D Printing Parameters for Different Models 3 Results and Discussion 3.1 3D Printed Models 3.2 Optimization of Printing Parameters 4 Conclusions References Modeling of Inconel Powder Flow and Thermal Distribution During the Direct Energy Deposition Process 1 Introduction 2 Simulation Methodology 3 Results and Discussions 4 Conclusions References Experimental Study on Chemical Polishing of Laser Powder Bed Fusion-Based Inconel 718 Features 1 Introduction 2 Chemical Polishing 3 Materials and Methods 4 Results and Discussion 4.1 Microstructural Studies 4.2 Chemical Polishing Experiments on Inconel 718 5 Conclusions References Effect of Input Parameters on Strength-to-Weight Ratio in Fused Deposition Modeling for ABS P430 Material 1 Introduction 2 Process Parameters 2.1 Build Orientation 2.2 Layer Thickness 2.3 Speed of Deposition 2.4 Percentage Infill 3 Experimentation 4 Selection of Orthogonal Array for Experimentation 5 Result and Discussion 6 Conclusion References Finishing of Laser Powder Bed Fusion-Based Turbine Blade Sample Using Polymer Rheological Abrasive Fluids 1 Introduction 2 Experimentation 2.1 Viscoelastic Polymer Media 2.2 Blade Sample and Work Holding Fixture 2.3 Abrasive Flow Finishing Machine 3 Results and Discussion 3.1 Rheological Analysis 3.2 Surface Roughness Improvement 4 Conclusions References Geometrical Form Deviation and Defect Analysis of SLM Processed Slender Parts Using Computer Vision Methodology 1 Introduction 2 Experiment Design 2.1 CAD Model 2.2 SLM Layer Simulation 3 Results and Discussions 3.1 Grayscale Pixel Value Analysis 3.2 Deviation Analysis 4 Conclusions References Hybrid Additive Manufacturing of Knee Joint Implant: Possibilities and Challenges 1 Introduction 2 Methods of Additive Manufacturing of Knee Joint Implant 2.1 Powder-Based Fusion Techniques (PBF) of Additive Manufacturing 2.2 Directed Energy Deposition (DED) Techniques of Additive Manufacturing 3 Subtractive Manufacturing Methods of Knee Joint Implant 3.1 Research Studies on Implant Development 3.2 Modeling and Tool Path Generation for Multi-axis CNC Machining 4 Challenges of Hybrid Additive Manufacturing of Knee Joint Implant 5 Conclusions References Influence of Build Orientation on Tensile and Flexural Strength of FDM Fabricated ABS Component 1 Introduction 2 Materials and Methodology 2.1 Materials and Part Fabrication 2.2 Mechanical Characterization 3 Results and Discussion 3.1 Uniaxial Testing 3.2 Flexural Testing 3.3 Fractography 4 Conclusion References Leaf Vein Structure in Additively Manufactured Aluminium Components for Stiffness 1 Introduction 2 Design and Simulation 2.1 Fabrication of Standard Sample 2.2 Three-Point Bending Test 2.3 Mesh Independency Checking 3 Results and Discussion 3.1 Simulation of Aluminium 6061-T6 Parts 4 Conclusions References Laser Induced Forward Transfer-Based Micro-3D Printing of NiTi Alloy 1 Introduction 2 Transfer Mechanism 3 Experimental Setup 4 Results and Discussion 5 Conclusion References Machine Learning Module for Predicting Tensile Response of SLMed Ti-6Al-4V 1 Introduction 2 Methodology 2.1 Database Development 2.2 ML Model Architecture 3 Results and Discussions 3.1 Yield Strength Predictive Model Training 3.2 Ultimate Strength Predictive Model Training 3.3 Ductility Predictive Model Training 3.4 Validation of Trained Models 3.5 Discussions 4 Conclusions and Future Perspectives References Multi-objective Optimization of Laser Beam Drilling in Carbon Fiber-Reinforced Plastics Using Nd: YAG Laser 1 Introduction 2 Fabrication and Experimental Details 3 Results and Discussion 3.1 Selection of Input Parameters, Their Levels, and Responses Factors 3.2 Orthogonal Array Selection Based on Balancing Property 3.3 Calculation of Quality Losses for Every Quality Feature 3.4 Normalized Quality Loss Calculation for Each Quality Characteristic 3.5 Total Normalized Quality Loss Calculation (TNQL) 3.6 Calculation of Multiple S/N Ratios (MSNR) 3.7 The Variance Analysis (ANOVA) 3.8 Factor Effects and Optimal Settings Determination 3.9 Confirmatory Experiment 4 A Comparison of the Outcomes of Multi-objective at the Initial Level 5 Conclusions References On Surface Features of Canine Strategic Teeth by Metal Additive Manufacturing and Investment Casting—A Comparative Study 1 Introduction 2 Selected Methodology 3 Experimentation 3.1 Development of Die Stone Model for 3D Scanning 3.2 FDM-Based Thermoplastic Printing of CAD Files 3.3 3D Printing Assisted IC of Metallic Crowns 3.4 Direct Metal Printing of DC 4 Result and Discussion 4.1 Porosity and Grain Size Analysis at Each Stage of Fabrication 4.2 Surface Roughness, Amplitude Distribution Function, Peak Count, and Bearing Ratio Curve 4.3 Verifying Dimensions as Per IT Grade 5 Conclusions References Part Quality Improvement of Fused Filament Fabrication-Based Additive Manufacturing by Means of Slicing Software Modifications 1 Introduction 2 Methodology 2.1 Collision Model of the Print Head 2.2 Surface Angle 2.3 Toolpath Generation 2.4 Collision Checks and Avoidance 3 Evaluation 4 Results and Discussion 5 Conclusions References Development and Characterization of Zn–Mg Biodegradable Materials Using Powder Metallurgy 1 Introduction 2 Materials and Methodology 2.1 Sample Preparation 2.2 Density and Porosity Calculation 2.3 Micro Hardness 3 Results and Discussion 4 Conclusions References Radial Slicing Methods for Rotary Substrate Wire Arc Additive Manufacturing 1 Introduction 2 Experimental Details 3 Result and Discussion 3.1 Path Planning for the Deposition 3.2 Validation of Code 3.3 Part Deposition 4 Conclusions References Topology Optimization as an Enabler of Additive Manufacturing: A Case Study 1 Introduction 1.1 Topology Optimization 1.2 Literature Review 1.3 Problem Statement 1.4 Applications 2 Research Methodology 3 Case Study 4 Conclusion References Metal Joining A Study on Friction Stir Lap Welding of Dissimilar Al 6061 to Polycarbonate 1 Introduction 2 Experimental Procedure 3 Results and Discussions 3.1 Effect of Process Parameters on Weld Bead Profile 3.2 Effect of Process Parameters on Joint Strength 3.3 Sensitivity Analysis 4 Concluding Remarks References Characterization of Dissimilar Welding of AISI 409 Ferritic to AISI 316l Austenitic Stainless Steel Using AISI 308 Filler Wire Under Different Temperature Conditions 1 Introduction 2 Parameters and Experimental Apparatus 2.1 Process Parameters and Methods 3 Result and Discussion 3.1 Visual Observations 3.2 Tensile Tests 3.3 Microhardness 3.4 Surface Residual Stress 3.5 Metallurgical Test 4 Selection of Optimum Parameters 5 Conclusions References Experimental Investigation and Optimization to Maximize Ultimate Tensile Strength and Elongation of Weld Joint During GMAW of AISI 201LN 1 Introduction 2 Materials and Methods 2.1 Experimental Work 2.2 Tensile Testing 2.3 Development of Predictive Modeling of Weld Strength 2.4 RSM Modeling of UTS and E 3 Results and Discussion 3.1 ANOVA Analysis 3.2 Model Analysis 3.3 Parametric Optimization 3.4 Microstructural Analysis 4 Conclusions References Experimental Investigations of CO2 Laser Beam Welded Joints of AISI 304 and AISI 4130 Steels 1 Introduction 2 Literature Survey 2.1 Objective of the Research Paper 3 Experimental Process 3.1 Metals Selections 4 Weld Joint Testing 5 Results and Discussions 5.1 ANOVA Results and Discussions 5.2 Effect of Process Parameters on Output Responses 6 Optimization 6.1 Whale Optimization Algorithm 7 Conclusions References Identification of Optimized Process Parameters for Solid State Joining of AA6063 with AISI 4130 Using Friction Welding Technique 1 Introduction 2 Literature Survey 3 Material Selection 3.1 Aluminum Alloy 3.2 Aluminum Alloy Series 3.3 Steel Dissimilar Metal for Joining with Aluminum Alloy 4 Process Parameters Selection 4.1 Levels of Process Parameters and DOE 5 Experimental Setup 5.1 Joining of AA6063 with AISI 4130 6 Tensile Testing of Specimen 7 Result and Discussion 8 Conclusions References Investigation and Optimization of Weld Bead Geometry of AISI 1023 with Varying Plate Width Using Taguchi and Multiple Regression Analysis 1 Introduction 2 Materials and Methods 2.1 Taguchi 2.2 Multiple Regression Analysis 3 Results and Discussion 3.1 Effect of Input Variables on Penetration 3.2 Effect of Input Variables on Weld Bead Width 3.3 Effect of Input Variables on Reinforcement Height 3.4 Effect of Input Variables on Percentage Dilution 3.5 Effect of Input Variables on HAZ 4 Conclusion References Joining of Dissimilar Galvanized Steel Sheets by Resistance Spot Welding and Self-piercing Riveting 1 Introduction 2 RSW and SPR of Thin Sheets 2.1 Methodology of RSW 2.2 Methodology of SPR 2.3 Material Properties 3 Welding and Characterization 3.1 RSW 3.2 SPR 3.3 Macrostructure and Hardness Evaluation 3.4 Lap Shear Test 4 Results and Discussion 4.1 Lap Shear Test Results 4.2 Macrostructure and Microstructure 4.3 Microhardness 4.4 Comparison of Lap Shear Test Performance of RSW and SPR Joints 5 Conclusions References Optimization of Weld Parameters on Bead Characteristics During EBW of Inconel 825 1 Introduction 2 Experimental Investigation 3 Response Surface Modeling (RSM) 3.1 Predictive Performance of the RSM Models 4 Parametric Study 5 Optimization of EBW Parameters 5.1 Indufstry Need-Based Multi Optimization Using GA 5.2 Desirability Optimization Approach 5.3 Comparison of Results 6 Conclusions References Fuzzy Logic-Based Prediction of Mechanical Characteristics of Friction Welded AISI 430 Joint 1 Introduction 2 Materials and Methods 3 Fuzzy Modeling of Parameters 4 Results and Discussion 5 Confirmation Test 6 Conclusions References Productivity Benefits in Employing SiO2 Flux-Based Activated TIG Welding for Joining Thicker Components 1 Introduction 2 Experimental Details 3 Results and Discussion 4 Productivity Assessment in Employing A-TIG Welding 4.1 Productivity Assessment When Welding from Both Faces is Allowed 4.2 Productivity Assessment When Welding from Only One Face is Allowed 4.3 Comparison with Respect to Time and Heating Cycles 5 Conclusion References Experimental Investigation on Joining of DP590–DP980 Automotive Steels by Resistance Spot Welding 1 Introduction 2 Materials and Experimental Procedure 3 Design of Experiments 4 Analysis of Variance 5 Conclusions References Review on Friction Stir Welding of Titanium Alloys—A Fracture Mechanics Perspective 1 Introduction 2 Objectives of the Present Paper 3 Processed Material Characteristics 4 Selection of Tool Materials, Pin Profiles, and Process Parameters 5 Microstructural Evolution and Characterization of the Mechanical Properties 6 Fracture Mechanics 7 Conclusions and Future Outlook References