Abstract
Manufacturing processes are the means to convert raw material into a final product. Manufacturing processes can be classified into two classes: macro/meso manufacturing and micro/nano manufacturing. In this Special Issue, the research papers dealing with both macro- and micro-manufacturing are included. This Special Issue consists of the expanded and peer re-reviewed papers that were presented in the “4th International and 25th All India Manufacturing Technology Design and Research” (AIMTDR) conference held at Jadavpur University (JU), Kolkata, India. This Special Issue consists of two review papers on micromanufacturing, followed by five papers on forming, five papers on machining and grinding, three papers on joining/welding, one paper on casting and the last paper on minimum quantity lubrication (MQL).
First paper is on “Micromanufacturing: A review—Part 1” written by Jain, Sidpara, Balasubramaniam, et al. This paper gives an overview of micromachining, nanofinishing, microturning and high aspect ratio X-ray lithography. It enumerates latest developments in these fields that have taken place in the recent past. It also reviews R&D activities in detail that are taking place in the field of high aspect ratio X-ray lithography. At the end of different sections/sub-sections, some research areas have been identified, which would hopefully fill the gap between the theoretical analysis, reported experimental work and applications. The second paper deals with “Micromanufacturing: A review—Part 2” authored by Jain, Dixit, Paul and Kumar. This paper covers overall developments in the area of microforming, microwelding and microcasting. It deals with many microforming processes, namely, micro deep drawing, microextrusion, microstamping and similar others. Here, the application of lasers in microbending and micropunching has been enumerated. Furthermore, it also discusses permanent mold and investment microcasting processes along with some potential research areas in this field. The last part of this paper deals with interesting applications and theory of laser microwelding and summary of developments in other microwelding processes. Both these papers (Part 1 and Part 2) present technological and scientific developments in different micromanufacturing fields. Both these papers also enumerate research areas for each micromanufacturing process, which need to be explored in near future.
Next five papers deal with recent advances in forming processes. The first paper of this category written by Maji, Pratihar and Nath of Indian Institute of Technology (IIT) Kharagpur, is on the analysis of pulsed laser bending of metallic sheets using artificial neural network. The proposed model would be helpful in automating the pulsed laser forming processes. Second paper is by Reddy, Asghar, Lingam and Shibin of IIT Kanpur, on the accuracy enhancement in single point incremental forming (SPIF) of sheet metals. The authors claim that significant improvement in accuracy is achieved by using the deflection compensated tool path. This is achieved by minimizing the dimensional deviation in the wall and base regions of components formed by SPIF. The third paper is written by Kant and Joshi of IIT Guwahati, on the application of laser in bending of magnesium alloy sheets. An attempt has been made to obtain the required bend-angle and curvature by means of laser irradiation. It is reported that the results will be useful in adjustment and alignment processes, and production of complex shapes using laser. The fourth paper of this series is by Bandyopadhayay, Panda and Saha from IIT Kharagpur, on prediction of formability of laser welded dual phase steel. This is basically a theoretical work based on finite element analysis. The last paper on forming proposes a computational approach to evaluate temperature distribution in roll and strip during forming process. The theoretical results are compared with the experimental results available in the literature, and a good agreement between the two is found. In this analysis, heat partition between rolls and strip is obtained by matching the interface temperature.
Third group of the papers of this Special Issue deals with some recent developments in the field of grinding and machining. The first paper in this group is by Dinesh, Yadav and Ghosh from IIT Delhi. In this paper, they have attempted to improve the grindability of Titanium alloy, difficult-to-machine material, using cryogenic cooling. Cryogenic cooling is proposed as a sustainable alternative cooling in place of use of cutting fluids. Second paper authored by Bartarya and Choudhury of IIT Kanpur, is related to the study of hard turning of EN31 steel. The authors have proposed a favorable range of machining parameters, which are claimed to give better machining performance. Empirical models based on regression analysis have been proposed. Third paper is on self propelled rotary face milling (SPRFM) titanium alloy by Jegarj, Raju and Kumar from Defence Research and Development Laboratory (DRDL) Hyderabad and Rao from National Institute of Technology (NIT) Warangal. This paper describes the experimental investigations and regression models for SPRFM operation. Cutting forces in X, Y and Z directions are evaluated at different cutting conditions and then compared with the model values. Next paper by Pawar (Bharat Forge, Pune), Joshi, Tewari and Joshi (IIT Bombay), describes the tool wear mechanism during turning of titanium alloys. The experimentally observed chip-tool contact length has been compared with the predicted values. Abrasion, abrasion with built up edge and plastic deformation of cutting edge have been proposed as the dominant tool wear mechanisms. The last paper of the grinding and machining group authored by Chinchanikar and Choudhury of IIT Kanpur is related to machining performance of different coated carbide inserts. They have conducted parametric analysis, and determined optimum cutting conditions using response surface methodology.
Next paper by Singh (Sant Longowal Institute of Engineering and Technology (SLIET), Longowal), Madan (Sri Guru Granth Sahib World (SGGSW) University) and Kumar (National Institute of Standards and Technology (NIST), Gaithersburg) discusses the side-core design for die casting parts. The paper claims to bridge the gap between the design and manufacturing practices of die casting process. Next three papers deal with the developments in the area of joining/welding processes. Chakarvarthy, Ramanaiah and Rao from Andhra University, Visakhapatnam, discuss the applications of laser beam welding and its effects on mechanical and metallurgical properties of Cu-Ni alloy weldment. The following paper authored by Vasudevan, Bandyopadhay and Panda of IIT Kharagpur, deals with the drawability (or formability) of Tailor welded blanks (TWB) of low carbon steel. It is concluded that Lankford anisotropy parameter, R-value influences the thickness distribution, weldline movement and failure location in TWBs. Friction stir welding window (FSWW) is discussed by Gadakh and Kumar from NIT Warangal. Authors have attempted to optimize the welding parameters to give defect free joints having better mechanical properties.
The last paper of the Special Issue describes some findings about MQL during turning with multilayered TiN top-coated inserts as cutting tools. It is authored by Ghosh and Roy from IIT Madras. An advanced nanofluid coolant was also used for MQL. Multi-walled carbon nanotubes based nanofluid was found to perform very well.
As per above outlines of different papers of this Special Issue, I am sure that the readers will find them very interesting and useful for their R&D activities and industrial growth.
I am thankful to Prof. Paul Maropoulos, Editor-in-chief, Journal of Engineering Manufacture (JEM) who kindly agreed to bring out this Special Issue on “Advances in Manufacturing Technologies” from the expanded and re-reviewed papers presented in the AIMTDR conference held at JU Kolkata. I am also thankful to the organizers of the conference who shouldered this responsibility of Special Issue on me. I highly appreciate the efforts made by the authors in improving their papers presented in the conference, and the referees for thorough evaluation of these papers by providing useful and critical comments to improve the quality of papers. Last but not least, I would like to record the help and cooperation extended by Katrina Newitt, Associate Editor—Peer Review Management, SAGE Publication Ltd.