In the current scenario, due to the high expectations and rapidly changing demands of the customers’, the majority of manufacturing sectors in developing nations now facing very tough to thrive. As ...this environment becomes more challenging, it is necessary to switch from conventional manufacturing systems to advanced manufacturing systems, such as CNC, FMS, HFMS, and CIM. This paper’s goal is to give researchers a foundation on which to choose proactive alternatives to CNC. This study’s objectives are to identify the elements that influence the manufacturing system and identify the most effective manufacturing system. For this purpose, different alternate technologies like flexible numerical control (FNC), The intelligent numerical control, open numerical control system, digital signal processor (DSP), and open-architecture CNC have been discussed in detail. The revised definition of an FMS, or FNC, proposed in this work gives room for the creation of more efficient systems and creates new avenues for research. Limitations of traditional FMS, design and working principle of DSP servo control technology, and other related alternate technologies to CNC in FMS have also been discussed in this research.
The MoS
2
nanoflakes can be a novel candidate as a solid lubricant in fabricating friction material for automotive brake-pad disc systems. In this paper, an investigation has been made to analyze the ...effect of MoS
2
nanoflakes on the mechanical and tribological behavior of the formulated copper-free low-metallic composite friction material. Three samples, namely S
1
, S
2,
and S
3,
have been fabricated containing different types of solid lubricant. Sample S
1
had a solid lubricant as graphite, while samples S
2
and S
3
had graphite mixed with solid lubricant MoS
2
with average flake sizes of 2 µm and 50 nm, respectively. Other components included steel, PAN, and aramid as reinforcing fibers; walnut powder, barium sulphate (BaSO
4
), and nitrile-butadiene rubber as fillers; phenolic resin as a binder; and FeO, Quartz, and MgO as abrasives. A pin-on-disc tribometer test (ASTM G-99) was conducted to carry out the wear test at a load of 60 N, sliding velocity of 2.09 m/s, and sliding distance of 6283 m at room temperature. A scanning electron microscope was used to study the micro-structural evolution of worn composite friction pin material. The results show that the nano-sized MoS
2
solid lubricant influences the structural integrity of the formulated composites, which governs the friction and wear behavior. The graphite and MoS
2
-based friction composites S
2
and S
3
perform better than the conventional friction material (S
1
) containing graphite in terms of physical–mechanical, thermal, and tribological properties. The specific wear rate of the S
1
sample is the highest (2.72 × 10
–5
mm
3
/Nm) followed by S
2
(1.84 × 10
–5
mm
3
/Nm) and S
3
(0.98 × 10
–5
mm
3
/Nm) respectively. The graphite and MoS
2
-based friction specimens S
2
and S
3
showed adequate coverage of friction plateaus, reducing wear and abrasion of the counter disc.
Graphical Abstract
This work reports thermo-mechanical, thermo-gravimetric, thermal conductivity, and fracture toughness behavior of Cobalt particulates (0–2wt% @ step of 0.5%) reinforced Al 7075 alloy composites ...fabricated via a high vacuum casting method for gear materials. The experimentally evaluated results show that thermo-mechanical and thermo-gravimetric magnitudes improve with reinforcing phase content. The fracture toughness measured experimentally at various crack lengths of 1, 3, and 5 mm was found to be in the range of 1.69–4.07 MPa.m
1/2
and shows a rising trend with particulate content, while thermal conductivity (range 130–120 W/m°K) shows the diminishing trend. A theoretical model of both characteristics was proposed and validated with an error of ~ 4%.
These research works investigate, the mechanical and dry sliding behaviour of AA7075-B4C-rice husk ash (RHA) hybrid alloy composite. The specimens of AA7075 with 0, 2, 4, 6, 8 wt% of B4C mixed with ...0, 2, 4, 6 and 8 wt% rice husk ash (RHA) are prepared using high vacuum casting machining to study the dry sliding wear behaviour at room temperature. The surface study is used to characterize the fabricated hybrid AA7075 composites. The mechanical behaviour, hardness, flexural tests are conducted using respective ASTM standards. The maximum hardness of 128 HV is obtained for AA7075-8 wt% B4C – 8 wt% rice husk ash (RHA) hybrid composite. The maximum tensile, compressive and flexural strength obtained to be 270 MPa, 570 MPa and 480 MPa respectively, at 8 wt% B4C – 8 wt% of RHA. RHA and B4C particles improved the wear resistance of hybrid composites and decreased the damage on the worn surface. The obtained results are also optimized and observed that addition of 8 wt% B4C – 8 wt% of RHA have reduced wear rate of composite greatly even with increasing sliding velocity and the applied load. Thus, the wear resistance of composite improves at 8 wt% B4C – 8 wt% of RHA.
In the present research work, organic hybrid friction composite materials based on synergistic binary and ternary fibrous combination of ceramic-organic fibers were designed and fabricated especially ...for automotive braking applications. It encompasses masterbatch of straight phenolic resin, barite, and graphite reinforced with aramid pulp, potassium titanate whiskers and aluminosilicate ceramic fiber amounting to 100% by weight. Fabrication was carried as per formulation design and as per standard industrial procedure using hot molding compression machine followed by post-curing and polishing of pad surface. Thereafter, specimens were characterized for their physical, thermal, mechanical and friction braking performance. The performance parameters (viz. frictional response, friction-fade, friction-recovery, wear, etc.) were evaluated on the Krauss friction testing machine following European Commission for Energy Regulation-90 (ECE R-90) regulations and (pulse velocity wave) PVW-3212 standard test protocol. In this work, thermal characteristics (i.e. DMA and TGA/DTG) of the investigated composites are discussed in details and an attempt has been made to correlate various thermophysical-mechanical characteristics and their possible influence on the braking tribology and wear performance.
This research work reports sliding wear performance of graphite reinforced AA6061 alloy composites for rotor drum/disk application in automobiles. The solid lubricant i.e. graphite-particulates of ...varying weight percentage (0–10 wt%) was used to reinforce AA6061 alloy, fabricated via high vacuum casting method. The sliding wear was simulated experimentally using Taguchi techniques on Pin-on-Disk tribo-tester, with operating conditions viz. applied load (15–55 N), sliding speed (0.5–2.5 m/s) and sliding distance (200–1000 m). Results show improvement in wear resistance of alloy due to the lubricating effect of graphite. Additionally, 7.5 wt% 6061/Gr alloy composite shows superior wear resistance performance under experimental conditions. Surface morphological studies of worn-out surfaces are carried using scanning electron microscope (SEM), in-order-to understand hidden surface wear mechanisms.
In this research article, ceramic particulate (SiO2/SiC) reinforced AA2024 alloy composite material formulation has been prepared via semi-automatic stir casting technique following industrial ...standard practice. The samples specimens have been prepared as per ASTM standard dimensions and the physical, mechanical and wear performance test were performed. The obtained test results have higher confidence level (95%) and the same has been used to rank the composite materials of the formulation using Preference Selection Index (PSI) method (a Multi-Criteria-Decision-Making (MCDM) tool) which is simple to compute and understand. This enables a practicing engineer to rank the designed materials via optimizing material properties like tensile strength, flexural strength, impact strength, wear resistance, density etc. It has been observed that the aluminium alloy composite incorporated with an equal presence of both ceramics shows best properties and also ranked highest by PSI method. Hence, such techniques may be used for decision making successfully in the selection of materials.
The frothers of alcohol family (MIBC and Alpha-terpineol) were compared with polyglycol ethers (DF-1012) in terms of two phase characterization parameters like foamability, foam stability, surface ...activity and bubble size distribution. In this research, fundamental two phase frother characterization parameters were linked with three phase coal flotation behavior.
The frothers are found to have a major impact on bubble size. It seems that frothers not only prevent bubble coalescence, but also, affect the bubble break-up process. DF-1012 is more efficient in preventing bubble coalescence and provides more stable and viscous foams compare to MIBC and Alpha-terpineol. The least surface-active frother, MIBC, produces the finest bubbles and the largest bubbles are observed when the most surface-active frother DF-1012 is used. DF-1012 is showing parallel (loop and coil) orientation at the air–water interface. DF-1012 is showing maximum frothing performance (max. retention time) and foam stability (max. collapse time) at all pH. DF-1012, Alpha-terpineol and MIBC are insensitive to solution pH. Two phase frother characterization indices and observations are well correlating with three phase flotation performance indices like selectivity, kinetics and size wise flotation efficiency.
In this work, AA7075 ˗ SiC (0–8 wt.% @ step of 2%) / marble dust (8–0 wt.% @ step of 2%) / graphite (3 wt.%) hybrid alloy composites have been designed and fabricated via high vacuum casting method ...as per standard procedure, leading to five samples namely SM-08, SM-26, SM-44, SM-62, SM-80 respectively. Thereafter, possible synergistic impact of the complementary combination of SiC/marble dust reinforcing particulates on physical, mechanical, and sliding wear performance of hybrid alloy composites were investigated followed by surface morphology studies. Taguchi approach has been used for sliding wear parametric optimization and hybrid ENTROPY-VIKOR decision-making technique is used for ranking of material based on performance measures. It is observed that with the reinforcing phase the properties like wear performance, coefficient of friction, density, voids content, compressive strength, and impact strength of composites increases considerably while flexural strength diminishes. Thus, SM-62 alloy composite (having 6 wt.% SiC, and 2 wt.% marble dust) shows better improved overall performance relative to others.
