RSM: A Key to Optimize Machining: Multi-Response Optimization of CNC Turning with Al-7020 Alloy


Book Description

Parametric optimization, especially in machining of non-ferrous alloys seems to be quite rare and needs an immediate attention because of its associated downstream financial and non-financial losses. This book tries to fill the gap and presents an optimization problem of commonly used Al-7020 Alloy. Principles of Response Surface Methodology (RSM) have been implemented through Minitab software to bring necessary multi-response optimization, while turning on a CNC turner. The present study focuses on to enhance Material Removal Rate (MRR) while simultaneously reducing the Surface Roughness (Ra), during turning of Al-alloy. Such opposite natured response optimization is much difficult to achieve, particularly when uncoated carbide tip has been used as a cutting tool. Intensive literature survey helps to pin point parameters like; Cutting Speed, Feed Rate and Depth of Cut as a most critical to machining parameters, as far as effective and efficient optimization of selected responses are concerned. All these control-parameters are directly or inversely related to each other. If the depth of cut is increased MRR increases at the same time we get poor surface finish. Increase in the cutting speed has positive impact on both material removal rate and surface finish. Shortlisted parameters are conflicting, so we have to optimize these for further enhancement of the overall turning performance. At last, the optimized results are verified by using ANOVA as a statistical tool. This book provides quite rare Case-study of multi-response optimization (while non-ferrous CNC turning) to practioners, machinists and SME owners appropriately.




WRAP THE SCRAP WITH DMAIC: Strategic Deployment of Six Sigma in Indian Foundry SMEs


Book Description

Six Sigma approach is generally employed to improve the sigma level of manufacturing or service processes by reducing their deviations and defects. Six Sigma provides the opportunity to eliminate mistakes, improve morale and save money. Doing things right in first time and keeping them consistent is the only idea behind Six Sigma. Its fundamental objective is to achieve customer satisfaction with continuous improvement in quality and productivity. Mostly we are emphasizing on various tools or techniques being used during DMAIC projects and almost ignore the procedure to execute different phases of the Six Sigma project. This book provides unique step by step methodologies to perform Define, Measure, Analyse, Improve and Control phases of a Six Sigma project, respectively. An empirical investigation has been carried out in a make-to-order type (medium sized) foundry and Six Sigma is successfully implemented by decreasing the scrap of piston castings, appreciably. The book focuses on scrap reduction specifically in Indian foundries and tries to find out the reasons of low productivity index. It also tends to shatter the various phobias of SMEs in context of Six Sigma by validating the compatibility of proposed methodologies through a successful case study in Indian foundry environments.




Minerals in Africa


Book Description

Africa’s dire need to industrialize is universally acknowledged and it is evident that the continent’s vast mineral resources can catalyze that industrialization. This requires the promotion of local beneficiation and value addition of minerals to yield materials on which modern Africa’s industry and society can rely. This book is, therefore, about transforming Africa’s comparative advantages in minerals into the continent’s competitive edge regarding materials. Mineral beneficiation and value addition form the basis and provide opportunities for mineral-driven Africa’s industrialization. The scope of the book is three-fold with inter-connected relationships: Information, Technical, and Policy oriented. It will be a useful reference material for mining undergraduate students on beneficiation and value addition of each of the minerals found in Africa. The book, while presenting a broad overview of beneficiation and value addition of Africa’s minerals, provides crucial starting material for postgraduate research students and R&D institutions who wish to delve into more advanced methods of extraction and utilization of mineral-derived materials that are in Africa for the purpose of industrialization of the continent.




WRAP THE SCRAP WITH DMAIC. Strategic Deployment of Six Sigma in Indian Foundry SMEs


Book Description

Six Sigma approach is generally employed to improve the sigma level of manufacturing or service processes by reducing their deviations and defects. Six Sigma provides the opportunity to eliminate mistakes, improve morale and save money. Doing things right in first time and keeping them consistent is the only idea behind Six Sigma. Its fundamental objective is to achieve customer satisfaction with continuous improvement in quality and productivity. Mostly we are emphasizing on various tools or techniques being used during DMAIC projects and almost ignore the procedure to execute different phases of the Six Sigma project. This book provides unique step by step methodologies to perform Define, Measure, Analyse, Improve and Control phases of a Six Sigma project, respectively. An empirical investigation has been carried out in a make-to-order type (medium sized) foundry and Six Sigma is successfully implemented by decreasing the scrap of piston castings, appreciably. The book focuses on scrap reduction specifically in Indian foundries and tries to find out the reasons of low productivity index. It also tends to shatter the various phobias of SMEs in context of Six Sigma by validating the compatibility of proposed methodologies through a successful case study in Indian foundry environments.




AMST'05 Advanced Manufacturing Systems and Technology


Book Description

Manufacturing a product is not difficult, the difficulty consists in manufacturing a product of high quality, at a low cost and rapidly. Drastic technological advances are changing global markets very rapidly. In such conditions the ability to compete successfully must be based on innovative ideas and new products which has to be of high quality yet low in price. One way to achieve these objecti ves would be through massive investments in research of computer based technology and by applying the approaches presented in this book. The First International Conference on Advanced Manufacturing Systems and Technology AMST87 was held in Opatija (Croatia) in October 1987. The Second International Conference on Advanced Manufacturing Systems and Technology AMSV90 was held in Trento (Italy) in lune 1990. The Third, Fourth, Fifth and Sixth Conferences on Advanced Manufacturing Systems and Technology were all held in Udine (Italy) as follows: AMST93 in April 1993, AMST96 in September 1996, AMST99 in June 1999 and AMST02 in June 2002.




Machining of Hard Materials


Book Description

Hard machining is a relatively recent technology that can be defined as a machining operation, using tools with geometrically defined cutting edges, of a work piece that has hardness values typically in the 45-70HRc range. This operation always presents the challenge of selecting a cutting tool insert that facilitates high-precision machining of the component, but it presents several advantages when compared with the traditional methodology based in finish grinding operations after heat treatment of work pieces. Machining of Hard Materials aims to provide the reader with the fundamentals and recent advances in the field of hard machining of materials. All the chapters are written by international experts in this important field of research. They cover topics such as: • advanced cutting tools for the machining of hard materials; • the mechanics of cutting and chip formation; • surface integrity; • modelling and simulation; and • computational methods and optimization. Machining of Hard Materials can serve as a useful reference for academics, manufacturing and materials researchers, manufacturing and mechanical engineers, and professionals in machining and related industries. It can also be used as a text for advanced undergraduate or postgraduate students studying mechanical engineering, manufacturing, or materials.







Six Sigma Quality Improvement with Minitab


Book Description

This book aims to enable readers to understand and implement, via the widely used statistical software package Minitab (Release 16), statistical methods fundamental to the Six Sigma approach to the continuous improvement of products, processes and services. The second edition includes the following new material: Pareto charts and Cause-and-Effect diagrams Time-weighted control charts cumulative sum (CUSUM) and exponentially weighted moving average (EWMA) Multivariate control charts Acceptance sampling by attributes and variables (not provided in Release 14) Tests of association using the chi-square distribution Logistic regression Taguchi experimental designs




Build Your Own CNC Machine


Book Description

Do you like to build things? Are you ever frustrated at having to compromise your designs to fit whatever parts happen to be available? Would you like to fabricate your own parts? Build Your Own CNC Machine is the book to get you started. CNC expert Patrick Hood-Daniel and best-selling author James Kelly team up to show you how to construct your very own CNC machine. Then they go on to show you how to use it, how to document your designs in computer-aided design (CAD) programs, and how to output your designs as specifications and tool paths that feed into the CNC machine, controlling it as it builds whatever parts your imagination can dream up. Don't be intimidated by abbreviations like CNC and terms like computer-aided design. Patrick and James have chosen a CNC-machine design that is simple to fabricate. You need only basic woodworking skills and a budget of perhaps $500 to $1,000 to spend on the wood, a router, and various other parts that you'll need. With some patience and some follow-through, you'll soon be up and running with a really fun machine that'll unleash your creativity and turn your imagination into physical reality. The authors go on to show you how to test your machine, including configuring the software. Provides links for learning how to design and mill whatever you can dream up The perfect parent/child project that is also suitable for scouting groups, clubs, school shop classes, and other organizations that benefit from projects that foster skills development and teamwork No unusual tools needed beyond a circular saw and what you likely already have in your home toolbox Teaches you to design and mill your very own wooden and aluminum parts, toys, gadgets—whatever you can dream up




UGC and Higher Education System in India


Book Description

The development of Indian higher education since independence has, in many respects, been impressive. UGC played a great role in higher education by assistance and grants for development of colleges, universities and institutions. Despite the criticism of the over expansion of higher education, the provision of postsecondary education to more than five million students and the expansion of postsecondary education from the cities to a much wider geographical area in a developing society is a significant achievementand one which has had considerabel socieal support over the years.