international journal of manufacturing and materials processing vol 2 issue 1

Mechanical Engineering

Electronics and Telecommunication Chemical Engineering

Architecture

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¬ International Journal of Thermal Energy andApplications

¬ International Journal of Production Engineering¬ International Journal of Industrial Engineering

and Design¬ International Journal of Manufacturing and

Materials Processing¬ International Journal of Mechanical Handling and

Automation

« International Journal of Radio Frequency Design« International Journal of VLSI Design and Technology« International Journal of Embedded Systems and Emerging

Technologies« International Journal of Digital Electronics« International Journal of Digital Communication and Analog

Signals

« International Journal of Housing and Human SettlementPlanning

« International Journal of Architecture and InfrastructurePlanning

« International Journal of Rural and Regional PlanningDevelopment

« International Journal of Town Planning and Management

Applied Mechanics

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Computer Science and Engineering « International Journal of Wireless Network Security« International Journal of Algorithms Design and Analysis« International Journal of Mobile Computing Devices« International Journal of Software Computing and Testing« International Journal of Data Structures and Algorithms

Nanotechnology« International Journal of Applied Nanotechnology« International Journal of Nanomaterials and Nanostructures« International Journals of Nanobiotechnology

« International Journal of Solid State Materials« International Journal of Optical Sciences

Physics

« International Journal of Renewable Energy and itsCommercialization

« International Journal of Environmental Chemistry« International Journal of Agrochemistry« International Journal of Prevention and Control of Industrial

Pollution

Civil Engineering« International Journal of Water Resources Engineering« International Journal of Concrete Technology« International Journal of Structural Engineering and Analysis« International Journal of Construction Engineering and

Planning

Electrical Engineering« International Journal of Analog Integrated Circuits« International Journal of Automatic Control System« International Journal of Electrical Machines & Drives« International Journal of Electrical Communication

Engineering« International Journal of Integrated Electronics Systems and

Circuits

Material Sciences and Engineering « International Journal of Energetic Materials« International Journal of Bionics and Bio-Materials« International Journal of Ceramics and Ceramic Technology« International Journal of Bio-Materials and Biomedical

Engineering

Chemistry « International Journal of Photochemistry« International Journal of Analytical and Applied Chemistry« International Journal of Green Chemistry« International Journal of Chemical and Molecular

Engineering

« International Journal of Electro Mechanics andMechanical Behaviour

« International Journal of Machine Design andManufacturing

« International Journal of Mechanical Dynamicsand Analysis

« International Journal of Fracture and damageMechanics

« International Journal of Structural Mechanicsand Finite Elements

5 more...4 more...

3 more...

Biotechnology « International Journal of Industrial Biotechnology and

Biomaterials« International Journal of Plant Biotechnology« International Journal of Molecular Biotechnology« International Journal of Biochemistry and Biomolecules« International Journal of Animal Biotechnology and

Applications3 more...

Nursing « International Journal of Immunological Nursing« International Journal of Cardiovascular Nursing« International Journal of Neurological Nursing« International Journal of Orthopedic Nursing« International Journal of Oncological Nursing

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International Journal of

Manufacturing and

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Jan – June 2016 IJMMP

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Hidam Renubala

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Commissioning Editors

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Chhavi Goel

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EDITORIAL BOARD MEMBERS

Dr. D.S. Robinson SmartKarunya University, Coimbatore, (Tamil Nadu),

India

Dr. P. Narendra MohanUniversity College of Engineering and

Technology, Acharya Nagarjuna University, Nagarjuna Nagar Guntur, (Andhra Pradesh),

India

Dr. Muthuramalingam ThangarajSRM University, Chennai, (Tamil Nadu), India

Dr P. M. M. Subrahmanya Sarma VIZAG Institute of Technology, Dakamarri, Bheemunipatnam Mandal, Visakhapatnam,

India

Dr. S. John AlexisKumaraguru College of Technology,

Coimbatore, (Tamil Nadu), India

Dr. Sarang PandeFaculty of PG and Research, Marwadi Education Foundation, Rajkot, India

Dr. V SugumaranSchool of Mechanical Engineering and Building

Sciences, VIT University, India

Dr. K R SivadasSree Narayana Gurukulam College of

Engineering, Kadayiruppu, India

Dr. Nataraj J.RR.V. College of Engineering, Mysore Road,

Bangalore, (Karnataka), India

Dr. D. Siva PrasadGITAM Institute of Technology,

Visakhapatnam, India

Dr. Sam PaulKarunya University Coimbatore, (Tamil Nadu),

India

Bo-Wun HuangChina

Dr. Siva Prasad KondapalliAnil Neerukonda Institute of Technology & Sciences, Visakhapatnam, (Andhra Pradesh),

India

Mr. Harish KumarNoida International University, Yamuna

Expressway, Greater Noida, (Uttar Pradesh), India

From the Editor's Desk

Dear Readers,

We would like to present, with great pleasure, the inaugural volume of a new scholarly

journal, International Journal of Manufacturing and Material Processing. This journal is

part of the Engineering Sciences, and is devoted to the scope of present Manufacturing and

Material Processing issues, from theoretical aspects to application-dependent studies and

the validation of emerging technologies.

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Material Processing as an emerging and increasingly vital field, now widely recognized as an integral part

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community, addressing researchers and practitioners in this area.

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International Journal of Manufacturing and Material Processing focuses on original high-quality research

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compliant mechanisms, Electro-mechanical systems, Computer-aided design.

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editorial staff of JournalsPub, who supported us at every stage of the project.

It is our hope that this fine collection of articles will be a valuable resource for Manufacturing and Material

Processing readers and will stimulate further research into the vibrant area of Manufacturing and Material

Processing.

Puneet Mehrotra

Managing Director

1. A Comprehensive Study on Optimization of Neural Networks and Global Minimization M. Aravindh, C. Velmurugan 1

2. Productivity Improvement in a Four Wheeler Seat Manufacturing Industry Using Lean Techniques B. Senthilnathan, M. Gomathi Prabha 9

3. Review of Optimization Process Parameters in Welding SystemN.H. Khan, R.P. Kori 18

4. Effect of Cutting Parameters in Hard Turning on Chip Formation and Machined SurfaceS. Choubisa, B.P. Nandawana, M.A. Saloda, M.S. Khidiya 25

5. Risk Assessment and Analysis in a Chemical IndustryM. Ananthu, A.P. Arun 45

Contents

IJMMP (2016) 1–8 © JournalsPub 2016. All Rights Reserved Page 1

International Journal of Manufacturing and Material Processing

Vol. 2: Issue 1

www.journalspub.com

A Comprehensive Study on Optimization of Neural Networks and

Global Minimization

M. Aravindh*, C. Velmurugan Department of Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India

Abstract

The neural network toolbox is one of the commonly used, commercially available and

powerful software tool for constructing new networks and it forms a inter linkage between

functionalities and their respective objective function. The software is user-friendly, permits

flexibility and convenience in interfacing with other toolboxes in the same environment to

develop a full application and has a wide range of scope in making models with linear and

non-linear functions, without any assumptions and applied in almost every field of science

and engineering. In addition, it underlies in one directional linear function with and without

hard limit, and possesses the responsibility of radial and triangular biasing and suitable for

competitive soft max functions. A wide variety of training and learning algorithms are

supported through neural networks. The functions used in the neural networks are as same as

model of brain and nervous system which are highly parallel and possess high speed

information resemble the brain and a super computer. The functionalities in neural networks

have very simple principles and possess very complex behaviors. In this paper, an attempt is

made to enhance effortless operation of neural networks in a systematic procedure through

MATLAB for optimizing and global minimizing.

Keywords: global minimization, MATLAB, neural networks, optimization, training

INTRODUCTION

An optimization function is defined as the

system which possesses a function for

getting objective values with a valid

constraint equation set and variables that

defines a function. The objective of any

optimization is that find the variables that

lead to an optimal value to find (either

minimum or maximum), while satisfying

all the constraints. [1–3]

Learning of problem domains for neural

network is considered by the factor when a

Input is highly-dimensional discrete or

real-valued (e.g. raw sensor input) and

output in the form of discrete or real

valued which has a vector of values and

considered as a target function, Humans

need not to interpret during the results.[4]

Neural networks can be trained using

local, gradient-based procedures. Such

methods frequently find suboptimal

solutions as local minima. Optimization of

neural network structures and global

minimization methods is applicable for

cost functions have strong influence on all

aspects of network performance. [5]

The structure of neurons is considered

with the input layers, output layers and

hidden layer. Neuron acts as an input

signal when it exceeds a certain amount in

a short time period. Synapses or

connection may vary in strength that


International Journal of Manufacturing and Material Processing Vol. 2: Issue 1

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Productivity Improvement in a Four Wheeler Seat Manufacturing

Industry Using Lean Techniques

B. Senthilnathan*, M. Gomathi Prabha

Department of Mechanical Engineering, PSG College of Technology, Coimbatore,

Tamil Nadu, India

Abstract

The industries along with the development of technology became competitive in nature.

Moreover globalization made this scenario even worst. The productivity becomes vital

element with product variety. The four wheeler seat manufacturing industries are badly

affected by productivity issues due to high cycle time, unbalanced workload and improper

layout. Our ultimate aim of this paper is to use lean methodology to improve productivity

without affecting current working pressure in industry. The problems in the current layout

are identified and analyzed through value stream mapping. Then the layout is modified in

sub-assembly and workload is balanced in conveyor line. The results are compared with the

current layout. The results revealed an improvement of 14% in productivity.

Keywords: line balancing and layout optimization, value stream mapping

INTRODUCTION

One of the most important characteristics

of manufacturing is cycle time. The

customers expect their manufacturers to

be responsive in delivering products on

time. So, they are constantly leaning

towards cycle time reduction of all the

processes. Cycle time is an interval of

time, during which a set of consecutive

actions takes place repeatedly which in

turn is defined as the time of longest

operation in a sub-assembly and assembly

line. If the line is balanced properly and

sub-assembly layout is optimized it will

reduce the cycle time. Value stream

mapping is used to identify the NVA

activities.

The four wheeler manufacturing industry

finds problem in assembly section as

cycle time taken by process is irregular

and unbalanced. The scope of this paper

is to use different lean tools such as line

balancing, VSM, layout optimization and

kaizen for improving the productivity by

eliminating NVA activities and reducing

production time.

LITERATURE SURVEY

Line Balancing

Assembly line balancing is the process of

dividing the workloads between stations.

So that workstations have equal time

allotted and less time is wasted.

Santhosh [1]

gave an idea about line

balancing in truck assembly line, which

helps to reduce cycle time of the process.

Shamuvel [2]

found that with help of line

balancing it is possible to improve

productivity and better utilization of

resources.

Johan [3]

identified that there is a less

accuracy of standard time and a poor

work arrangement. In order to overcome

root causes, line balancing is suitable

method.



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Review of Optimization Process Parameters in Welding System

N.H. Khan*, R.P. Kori Department of Mechanical Engineering MITS, Gwalior, MP, India

Abstract

This study was based on design of experiment (DOE) using Taguchi method with four

welding parameters namely welding current, welding speed, root gap and electrode angle

considered for experimentation. An orthogonal array of L9 experimental design was adopted

and ultimate tensile strength was investigated for each experimental run. The tensile test was

carried out on extracted welded and unwelded specimens using universal testing machine

(UTM). Microstructures of the welded specimens were carried out and analyzed. Statistical

analysis (ANOVA) and signal to noise ratio were used to study the significant effect of input

parameters on ultimate tensile strength and optimized conditions for the process performance

respectively. The results showed that experiment number 7 has the highest ultimate tensile

strength (UTS) of 487MPa and S/N ratio of 53.74 dB. The S/N ratio of higher value indicates

better characteristic of optimum MMAW process performance. The study shows that the

optimum condition is A3B1C3D2 at welding current 100A, electrode angle of 700, root gap

of 3.3 mm and a welding speed of 3.6 mm/s.

Keywords: optimized conditions, welding parameters, welding processes, work piece

INTRODUCTION

Welding process is very critical to the

development of a nation because it is the

hub on which modern industries revolve.

Gasser et al. [1]

stated that no secondary

process has been and continues to be more

important to the survival, comfort and

advancement of mankind than welding.

According to him, welding has made it

possible to build our world. It is in view of

this that many researchers have employed

various optimization techniques to

improve different welding process

parameters on both semi and full

automated welding processes. Although,

the semi and full automatic welding

processes are more productive, experience

has shown that due to complexity and

economic cost of the equipment and their

operations, the choice of manual metal arc

welding (MMAW) process is very popular

in developing countries. This is so because

of its several advantages such as low cost

and simple operation. The MMAW

process is portable and it can easily be

used in places where other welding

methods are not possible. Manual metal

arc welding is also known as shielded

metal arc welding (SMAW), or stick

welding process. It is one of the oldest and

most widely used arc welding processes.

The process involves the use of arc current

to strike an arc between the base material

and a consumable electrode rod. The

electrode rod is made of a metal that is

compatible with the base material being

welded and it is covered with a flux. The

heat generated melts a portion of the tip of

the electrode, its coating and the base

metal just below the arc. As the coating on

the electrode melts, the flux gives off

vapors that serve as a shielding gas and

IJMMP (2016) 25-44 © JournalsPub 2016. All Rights Reserved Page 25


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Effect of Cutting Parameters in Hard Turning on Chip

Formation and Machined Surface

S. Choubisa*, B.P. Nandawana, M.A. Saloda, M.S. Khidiya Department of Mechanical Engineering, College of Technology and Engineering, Udaipur, Rajasthan, India

Abstract

Cost effectiveness, increasing demand, high production rates and reliability of the product

have increased the potential of industrial application of hard turning technology during the

past few years. Grinding operation for hard steel component reduces the machining

sequence, the machining time and the specific cutting energy. Hard turning also shows effects

like generation of high temperature, the formation of saw toothed chips. In this thesis,

experimental investigation is conducted in order to study the chip transition using Scanning

Electron Microscopy and chip micro-hardness were conducted to correlate the chip

morphology, cutting forces using micro-hardness tester. The surface integrity of machines

part is also investigated. This study focuses on surface and sub-surface defects and white

layer formation. The machined surfaces are examined using SEM to study effect of different

process parameters on the quality of the machined surface. Cutting forces were measured by

lathe tool dynamometer and ANOVA test were performed to observe the effect of cutting

parameters on cutting forces.

Keywords: AISI D2 steel, chip formation, cutting forces, hard turning, microstructure of

machined surface ANOVA

INTRODUCTION

For aerospace industries high precision

hardened steel is required therefore hard

turning technology has been increased and

now a dayshard turning has been replaced

the grinding processes of hardened steel

components in practice. Improved ceramic

tool and CBN tool have been emerged as

very important cutting for machining of

hardened steel without any coolant. If we

talk economically then it also provides less

–effective time, less cost and most

importantly high precision parts. When

compared to grinding process the

machining time is comparatively 50%

lesser. If the right combination of nose

radii, feed rate, cutting speed, depth of cut

is used then a better surface finish can be

obtained as compare to grinding

operations. Here, it is confirmed that these

tool offers less machining time, higher

surface finish during hard turning but its

mechanism is need to be studied.[1]

During hard turning the designing of

cutting tool is to be considered and these

can be studied by observance of cutting

force at various cutting conditions. In the

current environment, the performance

variables are determined experimentally

using a trial and error method. To obtain

this design plan, it is necessary to estimate

the cutting forces from a basic approach so

that the performance of the cutting tools

and machine tools can be calculated. An

analytical model can also be obtained to

the predicted values. In the process of

hardened machining such as hard turning



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Risk Assessment and Analysis in a Chemical Industry

M. Ananthu1*

, A.P. Arun2

1Industrial Engineering, Kumaraguru College of Technology, Coimbatore, India

2Mechanical Engineering, Kumaraguru College of Technology, Coimbatore, India

Abstract

Chemical manufacturing sector in India is well established and has recorded a steady

growth in the overall industrial scenario. The chemical and the allied industries are among

the faster growing segments of Indian industry. The risks associated with the chemical

industry are commensurate with their growth. Apart from their utility, chemicals have their

own inherent properties and hazards like flammable, explosive, toxic or corrosive etc.

Several major accidents had occurred in India and around the world killing many lives of

people. Thus safety in a chemical industry is of prime concern and this project deals with

safety in a chemical company (TCC LTD).There are several methods to improve the safety

and minimize the risks like risk assessment, safety models, safety management systems.

Several methods are implemented in the industries with safety standards like OSHA, HSE,

etc. Even though many industries are implementing safety systems with these standards still

injuries and accidents tend to happen due to many reasons. In this project these reasons are

searched and necessary actions are taken by implementing a loss prevention programme so

that the potential risks are detected and eliminated. The objective is to improve safety and

working conditions by carrying out risk assessment in the chemical industry which is

TRAVANCORE COCHIN CHEMICALS Ltd, ERNAKULAM.

Keywords: failure, loss management, occurrence, risk assessment, safety, severity

INTRODUCTION

Organizations often adopt safety

management system or behavior based

system approaches to manage their safety

functions in an attempt to achieve

performance excellence. Safety is a

critical issue in the chemical industry

because chemical plants store and use

large volumes of hazardous materials that

can cause major incidents such as fires,

explosions, and the release of toxic

chemicals.

An effective safety management system is

vital to improve the overall safety of the

industry. In this project a chemical

industry is selected and a loss

management program is implementing to

improve the safety in the firm.

In the past several accidents have taken

place in the plant and generally in all the

chemical industries there is always a risk

of major hazard due to various reasons.[1,2]

A loss management program integrates the

concepts of safety as well as

identification, assessment and control of

both hazards and risks for the express

purpose of reducing harmful risks to

people, environment, assets and

production. In this project one of the

elements in loss management has been

taken and applied in the industry which is

hazard identification and risk assessment

Mechanical Engineering

Electronics and Telecommunication Chemical Engineering

Architecture

Office No-4, 1 Floor, CSC, Pocket-E,Mayur Vihar, Phase-2, New Delhi-110091, India

E-mail: [email protected]

¬ International Journal of Thermal Energy andApplications

¬ International Journal of Production Engineering¬ International Journal of Industrial Engineering

and Design¬ International Journal of Manufacturing and

Materials Processing¬ International Journal of Mechanical Handling and

Automation

« International Journal of Radio Frequency Design« International Journal of VLSI Design and Technology« International Journal of Embedded Systems and Emerging

Technologies« International Journal of Digital Electronics« International Journal of Digital Communication and Analog

Signals

« International Journal of Housing and Human SettlementPlanning

« International Journal of Architecture and InfrastructurePlanning

« International Journal of Rural and Regional PlanningDevelopment

« International Journal of Town Planning and Management

Applied Mechanics

5 more...

1 more...

2 more...2 more...

5 more...

Computer Science and Engineering « International Journal of Wireless Network Security« International Journal of Algorithms Design and Analysis« International Journal of Mobile Computing Devices« International Journal of Software Computing and Testing« International Journal of Data Structures and Algorithms

Nanotechnology« International Journal of Applied Nanotechnology« International Journal of Nanomaterials and Nanostructures« International Journals of Nanobiotechnology

« International Journal of Solid State Materials« International Journal of Optical Sciences

Physics

« International Journal of Renewable Energy and itsCommercialization

« International Journal of Environmental Chemistry« International Journal of Agrochemistry« International Journal of Prevention and Control of Industrial

Pollution

Civil Engineering« International Journal of Water Resources Engineering« International Journal of Concrete Technology« International Journal of Structural Engineering and Analysis« International Journal of Construction Engineering and

Planning

Electrical Engineering« International Journal of Analog Integrated Circuits« International Journal of Automatic Control System« International Journal of Electrical Machines & Drives« International Journal of Electrical Communication

Engineering« International Journal of Integrated Electronics Systems and

Circuits

Material Sciences and Engineering « International Journal of Energetic Materials« International Journal of Bionics and Bio-Materials« International Journal of Ceramics and Ceramic Technology« International Journal of Bio-Materials and Biomedical

Engineering

Chemistry « International Journal of Photochemistry« International Journal of Analytical and Applied Chemistry« International Journal of Green Chemistry« International Journal of Chemical and Molecular

Engineering

« International Journal of Electro Mechanics andMechanical Behaviour

« International Journal of Machine Design andManufacturing

« International Journal of Mechanical Dynamicsand Analysis

« International Journal of Fracture and damageMechanics

« International Journal of Structural Mechanicsand Finite Elements

5 more...4 more...

3 more...

Biotechnology « International Journal of Industrial Biotechnology and

Biomaterials« International Journal of Plant Biotechnology« International Journal of Molecular Biotechnology« International Journal of Biochemistry and Biomolecules« International Journal of Animal Biotechnology and

Applications3 more...

Nursing « International Journal of Immunological Nursing« International Journal of Cardiovascular Nursing« International Journal of Neurological Nursing« International Journal of Orthopedic Nursing« International Journal of Oncological Nursing

5 more... 4 more...

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Manufacturing and

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Jan – June 2016 IJMMP

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