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1

Solid state friction stir welding using square groove butt joint

Thamizhmanii S., Mohideen R., Mujahid A., Zaidi A., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2015

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Vol. 73, nr 2

118--123

EN

Purpose: of this paper is to high light the application of Friction Stir Welding (FSW) process using square butt joint. Design/methodology/approach: The design adopted was tool spindle speed, tool plunge depth and transverse movement of the work piece. Findings: The findings are encouraging. It is possible to increase the strength of the joint by 22.45% from the basic tensile strength. The optimum tensile stress obtained was at spindle speed of transverse speed of 700 RPM at transverse speed 325 mm/min taking into consideration the fracture of the materials. The optimum travel speed for the spindle speed 700 RPM is 325 mm/min, this is because the heat generation and the time for the material to joint was increased. But the 200 mm/min is not optimum for the spindle speed 700 rpm because, there is too much heat generation and the welded part become soft by the welding. When there is not enough heat generated, the stir between materials or part will not occur or not properly welded. Research limitations/implications: The limitations in this research were proper fixture. Machine should have variable tool rotation instead of fixed machine spindle speed. Practical implications: It is possible to weld by FSW process and not tested in any application. Originality/value: The research on FSW The limitations in this research were proper fixture. Machine should have variable tool rotation instead of fixed machine spindle speed. is upcoming project and not much work done in this field. Using square shaped joint unique and no references so far using this square groove. Many of the research were by straight butt joint.

2

Performance of cryogenically treated CBN inserts on difficult to cut materials during turning

Thamizhmanii S., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2012

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Vol. 55, nr 2

829--834

EN

Machining of materials is recognized as removing unwanted materials by using different cutting inserts. In this research, cutting inserts used are CBN inserts and treated cryogenically at -196°C in liquid nitrogen chamber. The inserts are subjected to 30 hours of treatment in controlled atmosphere. The materials used are Titanium and AISI 440 C hard Martensitic Stainless steel. The cutting parameters are cutting velocity 30, 40 and 50 m/min with feed rate of 0.05, 0.10 and 0.15 mm/rev and depth of cut of 0.05, 0.75 and 1.00 mm. The performance evaluated was tool wear, surface roughness. Cryogenically treated CBN inserts produced less tool wear on titanium than AISI 440 C Martensitic stainless steel. The roughness produced was low at high cutting speed with low feed rate. Flank wear was not progressive and varied. In turning AISI 440 C stainless steel, built up edge formed in all cutting speed which is a common phenomena and lead to crater wear formation. The chips produced were saw tooth chips by both materials.

3

Machinability of hard stainless steel and alloy steel using PCBN tools

Thamizhmanii S., Sulaiman H.

Journal of Achievements in Materials and Manufacturing Engineering

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2011

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Vol. 46, nr 2

169--174

EN

Purpose: of this paper was to find out the machinability of two hard materials - AISI 440 C martensitic stainless steel and SCM 400 alloy steel. It was analysed by measuring surface roughness, tool wear, cutting force and specific cutting pressure. Design/methodology/approach: The approach was adopted using various operating parameters like cutting velocity, feed rate and a constant depth of cut. The results were obtained using various measuring instruments like surface roughness tester, dynamometer, scanning electron microscope. Findings: Machinability of materials was easy in machining SCM 440 alloy steel than AISI 440 C stainless steel. Analysis was done by having low specific cutting pressure, low tool wear and low surface roughness. Research limitations/implications: The research limitations on research was due to fast wear of tools while machining stainless steel than alloy steel even the same hardness was maintained. Practical implications: More number of experiments could not conduct due to fast tool wear. Originality/value: The materials used in this experiment were not used by most of the researcher. The results obtained can be used by the other researcher and may be references.

4

A review on an employee empowerment in TQM practice

Thamizhmanii S., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2010

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Vol. 39, nr 2

204-210

EN

Purpose: This paper discusses the issues of employee’s empowerment, their training needs, suggestions and other issues related to it. Total quality management (TQM) is a management technique adopted by the most manufacturing organizations. TQM in general is viewed as organization set up which will help to manufacture products at lowest cost by the following various management techniques through continuous improvement. Employee empowerment is providing decision making powers to a team or an individual. Design/methodology/approach: Employee empowerment is providing decision making powers for a team or individual. Findings: Employee empowerment is good for an organization and employee is empowered to make specific decision for the interest of the organization. Empowerment helps to play a wider role in an organization as a process owner. Research limitations/implications: This is a conceptual study, and hence, there is no hypothesis tested as an empirical study. It does provide a good foundation for future research. Originality/value: The paper is a conceptual design and more elaborative requirements can be done. This is an input to create awareness among the organizations.

5

A study of minimum quantity lubrication on Inconel 718 steel

Thamizhmanii S., Rosli, Hasan S.

Archives of Materials Science and Engineering

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2009

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Vol. 39, nr 1

38-44

EN

Purpose: Maching of difficult to cut materials like Inconel 718 is a difficult task. The purpose of the research was to machine Inconel 718 nickel based material by milling process applying vegetabled oil by minimum quantity lubrication (MQL). MQL helps to use limited supply of coolant in order to minimise waste and it is environmental free. Design/methodology/approach: The experiments was carried in a vertical milling machine with super hard cobalt tool. The experiments were carried by various cutting parameters like cutitng speed, feed rate and constant depth of cut. The MQL considered was 12.5, 25 and 37.5 milli litre per hour (ml/hr). The MQL was vegetable oil used for cooking purpose. The experiments were with on MQL and dry milling. Findings: The supply of 37.5 ml / hour produced low surface roughness than 12.5 and 25 ml/hr. As the length of time was increased, the surface roughness increased due to tool wear. The surface roughness was affected by 32.65 % and tool wear affected by 29.2 % between low and high supply of MQL. The super cobalt tool has given more life by MQL than dry milling. The cutting speed of 20 and 30 m/min produced more flank wear than by 10 m/min for the same feed rate and given depth of cut. Research limitations/implications: There was no formation of built up edge at tool due to reduction in the heat and flushing of the chips away from the tool edge. The MQL can able to subsidize the heat generataed. Originality/value: The originality of this paper lies with conducting experiments and finding optimum operating parameters. The other researches can have this as reference

6

Surface roughness analyses on hard martensitic stainless steel by turning

Thamizhmanii S., Bin Omar B., Saparudin S., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 26, nr 2

139-142

EN

Purpose: The purpose of this research paper was to analyze the surface roughness produced by turning process on hard martensitic stainless steel by Cubic Boron Nitride cutting tool. The work piece material was hard AISI 440C martensitic stainless steel. Design/methodology/approach: The experiments were designed using various operating parameters like cutting speed, feed rate and depth of cut. These operating parameters are predominantly used in carrying out the experiments. Findings: Low surface roughness was produced at cutting speed of 225 m/min with feed rate of 0.125 mm/rev and 0.50 mm depth of cut (doc). However, moderate cutting speed of 175 m/min under above feed rate and doc is an ideal operating parameters taking flank wear in to account. Research limitations/implications: While searching for references in turning of martensitic stainless steel, very limited journals are available, but very few literatures are available on turning of AISI 440C hard martensitic stainless steel which was a constraint. Practical implications: The turning of hard martensitic stainless steel brings interesting information on surface roughness, tool wear etc. and further can be extended to turn with different cutting tools. Originality/value: The value of the research work lies in using the results by other researches. The result will upgrade the knowledge about the influence parameters on surface roughness especially on martensitic stainless steel especially on martensitic stainless steels.

7

Analyses of surface roughness by turning process using Taguchi method

Thamizhmanii S., Saparudin S., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2007

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Vol. 20, nr 1-2

503-506

EN

Purpose: The purpose of this research paper is focused on the analysis of optimum cutting conditions to get lowest surface roughness in turning SCM 440 alloy steel by Taguchi method. Design/methodology/approach: Experiment was designed using Taguchi method and 18 experiments were designed by this process and experiments conducted. The results are analyzed using analysis of variance (ANOVA) method. Findings: Taguchi method has shown that the depth of cut has significant role to play in producing lower surface roughness followed by feed. The cutting speed has lesser role on surface roughness from the tests. Research limitations/implications: The vibrations of the machine tool, tool chattering are the other factors which may contribute poor surface roughness to the results and such factors ignored for analyses. Originality/value: The results obtained by this method will be useful to other researches for similar type of study and may be eye opening for further research on tool vibrations, cutting forces etc.

8

A study of multi-roller burnishing on non-ferrous metals

Thamizhmanii S., Saparudin B., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2007

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Vol. 22, nr 2

95-98

EN

Purpose: The burnishing is chip less machining which can be used to improve the surface roughness and surface hardness on any metal workpiece. The purpose of the research was to demonstrate the multi roller burnishing process on non ferrous metals namely Aluminum, Brass and Copper to improve surface roughness and surface hardness. Design/methodology/approach: The experiments were carried on non-ferrous metals in a vertical milling machine with various spindle rotations, feed rate and depth of penetration. Findings: The surface roughness on various no-ferrous metals improved by high spindle rotations with high feed rate and depth of penetration. Research limitations/implications: Due to high spindle rotations with multi roller in action, the vibration of the equipment could not be controlled. Some mechanisms have to be devised to reduce the vibrations. However, it is not in the scope of this research. Practical implications: The experiments were conducted with out coolant and this is added advantages for the environment and pollution free. Originality/value: The burnishing process can be carried in a lathe and vertical/horizontal milling machines with suitable fixtures to hold the workpiece. The research can be continued on hard metals with varying hardness to find the surface roughness improvement. It is an eye opening for researches to continue.

9

Analyses of roughness, forces and wear in turning gray cast iron

Thamizhmanii S., Hasan S.

Journal of Achievements in Materials and Manufacturing Engineering

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2006

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Vol. 17, nr 1-2

401--404

EN

Purpose: Purpose of this research was to analyze the surface roughness, cutting tool forces and tool wear in machining casted gray iron. Design/methodology/approach: The methodology adopted was turning process from other machining process. The turning is the widely employed manufacturing process. The tests were conducted by designing various cutting speed, feed and a constant depth of cut. In turning casted gray iron, flank wear, crater wear and built up edge are the common phenomenon. Findings: from the tests were the formation of flank wear, crater wear while machining the casted gray iron. Further research is possible in the direction measuring the residual stresses and the vibration of the cutting tool. Research limitations/implications: There are some limitations in carrying the tests namely vibration of the tool, tool wear and length of work piece. The constraint in measuring depth of crater wear was due to non availability of technology devices and equipments. However, the length of crater wear was measured for analyzes. Originality/value: The value of the work lies in the utility of the results obtained to researchers and users of the casted gray iron material for their components.