Sundar Singh Sivam S.P

SRM Institute of Science and Technology | SRM · Department of Mechanical Engineering

Simulation-assisted process development in metal forming is a valuable approach to bolstering sustainability by exploring alterations that can diminish the necessity for new metal production, thereby contributing to environmental preservation. Real-world industrial challenges often revolve around the quest for cost-effective and efficient manufactu...

In incremental sheet forming of conical microcups, intuitionistic fuzzy MABAC optimizes sustainability by efficiently handling uncertainty in material selection and process parameters, ensuring stable convergence for precise cluster assignments and informed decision-making in the fabrication process. It addresses conventional factors such as feed r...

The deep drawing process is considered environmentally friendly as it generates minimal waste. This paper introduces the multi-draw deep drawing method and identifies the optimal number and parameters for scaled cup quality. This approach extends from macro to micro-parts, making it suitable for miniaturized devices in high-quality electronic appli...

Simulation-assisted process development in metal forming is a great way to promote sustainability by looking for changes that would reduce the need for new metal production. Real-world problems often involve finding cheaper and more efficient ways to make things without lowering product quality. This is because companies need to stay competitive to...

Estimating the forming limit diagram (FLD) is tedious and cost-intensive. Methods driven by data and artificial intelligence are used to determine the relationship between scaled thickness and the forming rates of various cups drawn out of ETP copper sheets. Machine learning (ML) techniques have a good chance of predicting the FLD of copper alloys,...

Most sectors are moving towards downsizing products that retain high standards of quality and satisfy customer needs. Miniaturisation of components typically makes use of scaling rules. In this work, we use the idea of similarity theory to investigate the micro-and nano-scale thinning behaviours of multi-stage deep-drawn cups. Deep drawing with a l...

Predicting the results of multi-stage deep drawing in determining the thickness distribution and thinning of the workpiece are measures that will help reduce production costs by saving materials and production time. Machine Learning (ML) technique is a promising method for predicting the thickness distribution (TD) of drawn copper metal. Macro and...

Deep drawing is a method of producing sheet metal. It is extensively used in the automobile, packaging and home appliance industries. Incorrect parameter selection might induce defects in stamped components. Trial and error can improve product accuracy, but at the expense of execution and calculation. An optimisation approach and a response surface...

In recent years, the use of artificial neural networks (ANN) for modeling and optimizing metal forming processes has gained popularity. Numerous benefits are provided by ANNs, which can only be attained by constructing a high-performance ANN model. However, selecting an ANN’s appropriate training and architectural parameters remains challenging. Ty...

Deep drawing is one of the primary sheet metal forming processes that is used all over the world. The current study focused on using Analytical Hierarchy Process-Elimination and Choice Translating the Reality (AHP-ELECTRE I), Response Surface Methodology-Genetic Algorithm (RSM-GA), and Artificial Neural Network-Genetic Algorithm (ANN–GA) for determ...

Neural networks are algorithms in series, which is like a human brain to identify the relationships between data. It is utilized for implementing ANN and ML for better prediction techniques for self-reacting friction stir welding (FSW) in Aluminium 6061-T6. It has an input, which gathers the data from outer sources and hidden layers that runs the d...

Artificial neural networks can provide data in parallel, which means they can handle more than a single task simultaneously. ANN can store information on the network. ANN aids the better prediction technique on face milling on ZE41 magnesium alloy, which was used to understand the improvement made in our methodology compared with the existing model...

Our Project aims to demonstrate the softening process of annealing of copper in an appropriate furnace at an optimum temperature. Copper is soft at its initial state and needs to be bended for various applications and used to the desired shape. Upon bending, Copper tends to have voids development that results in crack formation and make the sheets...

Ultrasonic welding is a method of combining solid-state components that does not require the use of heat or flux and instead relies on vibration to hold the components together. When connecting copper wires to an equipment alternator in electrical and automotive applications, a solid-state joining method is utilized as the preferred connection meth...

The kinetics of microstructural changes plays a vital role in designing the material properties. There are various microstructural transformation phenomena such as recovery, recrystallization, and strain-induced boundary migration, which affect the properties of materials. This study aims to investigate the kinetics of low-strain deformed electroly...

As steel continues to expand its current range with stronger, more ductile automotive brands, automakers are turning their attention to this. The future of vehicle weight reduction does not require a shift to alternative material systems and a complete overhaul of existing manufacturing infrastructure. When it comes to enhancing surface quality and...

Among the most commonly used tools in the industrial business, high-speed steel (HSS) tools rank first. A large web thickness and cryogenic treatment were used to obtain the most significant improvements in machining quality with the HSS tool. The results of this study are presented in this publication. Being stiffer in nature than normal drills, t...

Wire Arc Additive Manufacturing (WAAM) is used to produces small to large components because of its high accuracy in deposition rate and potentially unlimited build size. As online simulation has become an important tool nowadays, encouragement of using online tools for wire arc additive manufacturing has changed the wide picture. In this experimen...

It is a challenging task to achieve high strength without any loss in its electrical conductivity in pure copper because commonly used strengthening mechanisms such as alloying, grain boundary strengthening, and dislocation, result in an increase in strength but simultaneously reduce its electrical conductivity. However, if strengthening is achieve...

Composite materials are having high strength and are used in the aerospace and marine industry. Most of the wings and wind turbine blades have an aerofoil box structure with more internal components such as ribs, spars and stringers (stiffeners) for strength and stability compliance. So many industries prefer the I section, T section and C section...

The Utilization of natural fibers for various polymeric applications in increasing owing to its cost effectiveness and versatile applications. In this work four different Tri layer hybrid composites were developed by using hand lay up by varying the kenaf and ramie fibers in different stacking sequences. Fourdifferent hybrid composites with K1-Kena...

This research paper presents a unique biodiesel, Bael biodiesel, with diesel vehicles. Bael oil is produced from bael seeds, which are obtained from the fruits of the bael tree. Within that article, the performance, toxicity, and ignition properties of a diesel engine running on diesel, bael seed oil methyl ester (BSOME) and its blends (B20, B40, B...

In Electron backscatter diffraction (EBSD), kernel average misorientation (KAM), grain average misorientation (GAM), and grain orientation spread (GOS) are considered as the reflection of the extent of recrystallization. This work presents a comparative study of KAM, GAM, and GOS to bring out the bestsuited parameter to determine the extent of recr...

One of the challenging issues in the world today is waste management. Improper waste management could be the main source of environmental pollution. In this context, an attempt has been made to prevent the disposal of large quantities of Waste Cooking Oil (WCO) from hotels and restaurants and utilize them as a fuel in diesel engines. WCO is one of...

This paper examines a new application in the multi-criteria comparison of approximate boundary regions (MABAC). This method estimates the distance between the target performance of each of the observed options and the approximate area of the solution. An approximate cut-off area is specified for each standard and depends on all alternative values f...

Metal spinning is an advanced chip-free forming method, while energy components are mainly used in the aero and missile industries, where components require high specific strength. By using these systems in a block diagram, test time and materials can be significantly reduced. In addition, it also allows the creation of parts with improved mechanic...

This Research Paper Involves the study of Machining and improvement in the field of their Process Parameters of AM-60 magnesium alloy, which is obtained by gravity die casting with a hardness of 65 and using the orthogonal array L9 Taguchi as well as using the Approach for this study that is Multi-Attributive Bordering Approximation Comparison – MA...

In order to take advantage of the machining characteristics of magnesium, it is useful to consider recommended tool design and angles. The geometry of the tool can have a large influence on the machining process. Tool geometry can be used to aid with chip flow and clearance, reduce excessive heat generation, reduce tool build up, enable greater fee...

Amid the delivering of an item, any material or abundance vitality created moreover to a definitive item will be named as waste. The waste produced in light of machining could be a noteworthy ecological worry for creators. The shape and condition of waste streams created and their transportation components contrast with the strategy utilized and al...

The sheet metal forming processes in several industries like automobile and aerospace suppose the yielding of the sheet metals once strained. Yielding is categorized by the plastic flow of the materials once strained. The yield purpose just in case of uniaxial tension may be simply determined from the stress strain graph, however just in case of mu...

Aluminum alloys with silicon as the main alloying element constitute a class of materials and account for the most important part of all materials used in casting. These alloys are widely used in the automotive and aerospace industries due to their excellent casting and mechanical properties, as well as good corrosion and wear resistance. The addit...

For our study the main elements chosen are aluminium-silicon alloy, form a group of materials and plays a most vital part in the process of casting with other materials The alloys of aluminium and silicon have a desired liking in the field of Aero-space engineering and The Automotive Production industries due to the fact of increased and exceptiona...

This work compares conventional unidirectional rolling (UDR) and cross rolling (CR) based on mechanical properties, microstructure, and stored energy. Pure copper is subjected to UDR and CR to true strains of 0.69, 1.39, 2.08, and 2.77, respectively. The UDR samples show high strength and hardness compared to the CR. Investigation of microstructure...

Magnesium alloys are highly preferred for use in the automobile sector and aerospace industry because of their low density and superior strength. Due to the lightweight and high strength of magnesium alloys, they are continuously being used for engineering applications. The transport industry has benefitted a lot as weight reduction is of prime imp...

In this work, the effects of alloying elements in the as cast microstructures and mechanical properties of heavy section ductile cast iron were carrying out a systematic to build up press die material having high strength and high ductility the effect of the cooling rate and alloying elements in the microstructures response is particularly analyzed...

Deformation and deterioration of the electrode caused by chemical reaction is resistant to AISI 1020 with caps screw electrodes. In this study, squeeze, weld, hold time, current and pressure is evaluated for the nugget diameter. OP1is the surface waviness, OP2 is the force, OP3 is the nugget height and OP4 is welded by spot welding on steel plates....

Objectives – Since parts and components are manufactured of different sizes and geometries, the fabrication of such parts of various size could be predicted the process parameters that affect the performance based on scaling laws and could be verified through experimentation. The purpose of this study is to determine optimum thinning process parame...

Single point Incremental shaping (SPIF) is a metal forming process which rose to unambiguous quality toward the commencement of the 1990 s. ISF is an exceptionally limited twisting procedure in which a device, modified to take after in a specific direction, moves over a sheet metal and structures the coveted shape and a prosperous process to manufa...

Apparently, the drilling geometry and treatment influence the drill operation and its performance. Factually, the performance given by the drill bit is powerfully associative with efficiency, hence with economical fabrication. As a further matter, typical performance indicator, that is deviation from diameter, Cylindricity, tool wear, surface rough...

Metal spinning operation is one of the most seasoned techniques for chip less formation, the segments for the most part discover application in the airplane and aerospace industry which requires a high strength to low weight ratio for their component. By utilizing these systems in the process outline, the time and material wasted by utilizing the e...

Electrode deterioration by deformation and chemical reaction during resistance spot welding of steel sheets confirming to AISI1020 is an issue for class II electrode. In view of this, the present study carried out the impacts of squeeze, weld, current and pressure on the nugget diameter, height, force and waviness of welding joint in electrical res...

Super plastic forming is a manufacturing process utilized in the automotive industry like vehicle structures to produce complex geometries of aluminium or magnesium alloy components which cannot be fabricated at room temperature. The technique has proven to be an efficient cost-worthy process in forming various lightweight components for aerospace...

Today in industrialized nations, the machining cost adds up to over 15% of the estimation of every fabricated item.“ Reason why machined component have been proven as one most significant parts of manufacturing science and technology. Magnesium - Mg and its amalgams are widely used due to their remarkable properties such as low density, excellent m...

Designers of high pace advanced vehicles in aerospace industries particularly vehicle manufacturing types are placing more needs at the sheet metal forming enterprise by designing components from the high strength thermal resistance alloy. The principle goal of the observation is to test the mechanical, formability parameters and Erichsen cupping v...

Sheet metal forming forms in numerous industries like vehicle depend on the yielding of the sheet metals when strained. Yielding is portrayed by plastic flow of the materials when strained. The yield point if there should be an occurrence of uniaxial tension can be effectively decided from the pressure strain diagram, yet if there should arise an o...

This research work reports on the investigation on the suitability of prepared Al-Mg binary alloys of hypo-eutectic and eutectic compositions, for making metal matrix composites for light weight applications. Commercial pure aluminium, and magnesium blocks were used for the purpose of making binary alloys of Al-Mg, with the Mg in weight percentages...

AISI 1050 Alloy has a Wide Range of Applications and were Subjected to Machining Operations. the Purpose of the Study is to Find the Optimum Input Plain Turning Process Parameters at Three Levels, Using L18 Orthogonal Array and Grey Relation Analysis; and to Investigate the Mechanical and Microscopic Properties of the AISI 1050 Alloy before (untrea...

This is a major problem with Friction Stir Welding (FSW) when different alloys such as Ti and Mg alloys are used. In this article, we will investigate the effects of spindle speed (rpm), feed rate, various shapes, on the welding tools used to ignite No Sparks, Sparks, Flares - Major Sparks and Fire- continuous sparks, Ring of fire Ti and Mg alloys....

Single point Incremental shaping (SPIF) is a metal forming process which rose to unmistakable quality toward the start of the 1990s. ISF is an exceedingly limited twisting procedure in which a device, modified to take after a specific direction, moves over a sheet metal and structures the coveted shape. During the SPIF, process parameters such as t...

Industrial enterprises increasingly demand optimum quality of products keeping in consideration a strict adherence where forming parameters are concerned. As far as incorporating the vital forming process upon an assortment of materials is concerned, it has grown excruciatingly challenging for industrial enterprises for laying out the adequately pr...

Heat treatment of metal alloys is one of the most widely used techniques for achieving the desired mechanical properties by modifying the microstructure namely the grain and or by altering the second phases present in heat treat able alloys. At times heat treated materials undergo further process like forming, machining, welding etc. Thus the prese...

This paper details the failure analysis of deformed passenger car door lock case and presents a solution to avoid the part deformation during caulking process. This failure was observed during the assembly of case and its cover by caulking process. Mechanical properties and chemical composition of case (Zn Al4 material) has been checked by universa...

This study presents the optimization of machining parameters on ZE41 Mg alloy fabricated by gravity die casting and Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). Focus on the optimization of machining parameters using the technique to get minimum surface roughness, cutting force, thermal stress, residual stress, chip thic...

Automotive side impacts are particularly dangerous as location of impact is very close to the passenger, who can be immediately reached by the impacting vehicle. FMVSS 214 static is a US safety regulation for occupant safety during side impacts, in which the vehicle is tested at static loading conditions to measure its load baring capacity and inte...

In the present work Drilling parameters has been advanced for EN-8 combination steel utilizing GRA (Grey Relational Examination). The parameters advanced are axle speed (SS-3000, 3500 and 4000 rpm), feed rate (FR-0.18, 0.20 and 0.22 mm/rev) and cemented Carbide twist drill of 14.5 mm width with Three flutes point angle (PA-118,127 and 1350) And Lub...

In the primary days of Titanium Nitride tools, before coatings, tool manufacturers appreciated the tools would last elongate and scuffle cratering if they put a little bit of Titanium Nitride (TiN) in the combination when making the tool. This had the anticipated consequence, but the more TiN that was added, the feebler and more brittle the tool be...

This investigation shows the improvement of Drilling parameters on AM-60 Mg alloy made with the help of Gravity Die Casting and with reactions upheld symmetrical cluster with Grey relational analysis-GRA. Which Focuses on the streamlining of Drilling constraints utilizing the system to get least surface Roughness (Ra), Tool Wear, Cutting Time, Powe...

AISI 1050 is utilized in the creation of landing Gear, actuators and other aviation parts yet their application is constrained because of erosion protection from the high quality. In any metal cutting task the highlights of Tools, input work materials, machine parameter settings will impact the procedure proficiency and yield quality attributes. A...

It may be more expensive on some system, as manufacturers frequently obtain and spread over new producing materials that are brighter and stouter—and thus a lot of fuel-effectual—it follows that cutting tool manufacturers should mature tools which will machine the new specimens and Geometry at the best attainable levels of productivity. Feasibly th...

The aluminium and its alloys welding has continually shown a good task for designers and technologists. Specifically heat-treatable aluminium alloys, are tough to merge by fusion fastening methods. The method was established primarily for aluminium alloys, meanwhile Friction Stir Welding (FSW) was established which is appropriate for merging huge n...

The present work reports a comparative study on the mechanical properties, and the formability of dual-phase DP 600 steel against the conventional SPFH 590 steel which are widely used in automobile industry for its high specific strength properties. In the present study, grain refinement is proposed as an alternative solution to improve the mechani...

The dawn of globalization of business and competitiveness in manufacturing has forced firms to enhance their manufacturing facilities to reply to plug necessities. One of the crucial factors for this is often machine evaluation that involves a crucial decision using general and obscure information. The Primarily mass production aims high productivi...

The study aims to provide an Automatic Feeder Machine to inspect the Ball diameter to eliminate any parallax error and to reduce the measuring time significantly also to create an ergonomic environment for the operator. The measurement of Steel Ball diameter which is very much important needs to measure 100% before assembly. The inspection is done...

The welding of Magnesium and Titanium and its alloys has continuously depicted a good challenge for designers and technologists. Ti and Mg alloys, particularly heat-treatable alloys, are difficult to join by fusion fastening techniques. The welding of dissimilar alloy such as Ti (Grade 2) and Mg (AZ91D) Alloy is an important problem during Friction...

The use of Magnesium alloy ZE41 nowadays has increased exponentially in the aeronautical industries for the manufacturing of certain high grade and complicated components. The reason for its perpetual usage is the fact that it has a very low mass to volume ratio and has very high hardness value, due to which it is used in aeronautical industries in...

This study presents the optimization of Machining parameters on AM60 Mg alloy manufactured by Gravity Die Casting and with responses supported orthogonal array with Grey relation analysis. Focuses on the optimization of Machining input parameters using the technique to get minimum surface roughness, Minimum Tool Wear, Cutting Time, Power Requiremen...

Super plastic Forming (SPF) is a close net-shape Forming process which gives numerous points of interest over ordinary shaping tasks including low Forming pressure because of low Flow Stress, low Die cost, more prominent Design flexibility, and the capacity to shape hard metals and shape complex shapes. The present work is going to focus on forming...

Super plastic forming (SPF) is a manufacturing process utilized in the automotive industry to produce complex geometry aluminium or magnesium alloy components which cannot be fabricated at room temperature. During the SPF, the process parameters such as die entry radius, pressure, temperature and Material Thickness at the sheet die interface greatl...

Objectives: To study the yield behavior and plastic flow of an anisotropic sheet metal during forming operations, various mathematical formulations of the plastic state of the sheet metals have been proposed, known as yield functions. Different yield functions pertain to different criteria and have different characteristics. Methods/Statistical Ana...

Objectives: This review presents a short communication of cold orbital forging process, its characteristics and compare with classical forging. Methods/Statistical Analysis: Orbital forging have special progressive motion permits the contact space between tool and workpiece to be smaller and thus, lowers forming load and friction. Therefore orbital...

Objectives: To increase the efficiency and the power output of the Energy recovery system. Methods/Statistical Analysis: A nozzle of suitable material is installed above a cooling tower of a certain height. The nozzle is used to improve the speed of the exhaust air coming out of the cooling tower exhaust. A horizontal axis wind turbine is placed ov...

Objectives: This study investigates the variation of heat transfer parameters using wavy fin located in the plate heat exchanger. Methods/Statistical Analysis: Velocity and temperature relations, fanning friction factor for iso-temperature and Colburn factor are evaluated for different flow rates of Reynolds Number from 200 to 2000 and its various...

Lean manufacturing is one of the most powerful systems in the world. The idea of lean manufacturing has continued to get use and visibility on a figure of fronts. Lean is frequently heralded as manufacturers' best hope for critical cost and retrieval their original edge. Implementation a lean manufacturing works is vital in the ceramic industry man...

Aluminum alloy 5083 is commonly used in the ship building application in marine environment and susceptible to corrosion when they are run at high speed velocity, high flow rate condition and stagnate condition. Therefore, solution heat treatment was carried out to prevent corrosion. The optimal heat treatment involved heating specimens for 90 min...

Sheet metal forming is a vital operation in the manufacturing of a number of automobile components. The quality of the formed component depends largely on the formability of the sheet metal. In the present study, the formability of SPRC440E steel sheets by deep drawing have been characterized and the forming limit diagram (FLD's) have been experime...