m.tech & b.tech project abstrat
- 1. M.TECH THISIS DEVELOPMENT & GENERATION OF MICRO-GEAR BY WIRE EDM PROCESS Under the Supervision of Dr.Dipankar Bose, Professor National Institute of Technical Teachers’ Training & Research, Kolkata. ABSTRACT Wire cut EDM is a high precision automatic machining process. Today, WEDM process is the most demandable industrial machining process in the field of gear manufacturing, preferred for its high dimensional accuracy, high precision, high surface finish and the relative ease of adapting the process to robotic automation. In WEDM process the machining is occurred by thermal erosion caused by spark. WEDM machining process requires a wire electrode, having chemical composition similar to that of the conductive material, is continuously machining through a wire electrode. The present study aims on investigating the effect of various WEDM process parameters on the gear micro-geometry and develop the process performance for achieving high production as well as high accurate and precision spur gear. The process parameters taken under consideration are wire feed rate, pulse on time, and pulse off time, gap voltage, group pulse, and peak current. The output considered are cutting speed, material removal rate, and spark time to develop the process performance and also gear micro-geometry error i.e. run out error, pitch error, addendum error, dedendum error, root error, average surface roughness and maximum surface roughness for studying the effect of process parameter on gear profile. The electrode wire used in the study is of 0.25 mm diameter of brass material. Experimental runs have been conducted on 4.57 mm thick work pieces i.e. aluminium-6061, as per Box-behnken approach of RSM methodology using three levels of each of the WEDM input parameters. Leica optical microscope has been used for measuring the micro-geometry error of gear profile at sub-micron level. Analysis of variance (ANOVA) has been done to identify the significant process parameters which influences the output variables and also validation of mathematical model obtained from RSM. Latin hypercube one factor at a time approaches have been carried out to observe the relative importance of each input parameter on the output variables individually. RSM has been applied on the experimental data to optimize the output variables as per maximize/minimize criteria for all the responses (i.e. cutting speed, material removal rate, and spark time, run out error, pitch error, addendum error, dedendum error, root error, average surface roughness, and
- 2. maximum surface roughness). DOE based on Box-behnken approach of RSM methodology, optimization of the response variables and ANOVA is performed with the help of DESIGN EXPERT, version 9 software. For getting the optimal response value, A model independence and multi- platform hydro particle swarm optimization have been carried out using R environment and software. OBJECTIVE OF INVESTIGATION Keeping these considerations in view, the objectives of the present research have aimed as follows: I. To study the fundamental characteristics of wire cut electrical discharge machining process for manufacturing of miniature spur gear as well as to identify the problematic area of miniature gear manufacturing. II. To study the feasibility of wire cut electrical discharge machining process for manufacturing of miniature gear on Al-6061. III. To carry out gear measurement technique based on gear geometry by metallurgical optical microscope. IV. To carry out experimental planning based on Box-Behnken approach of RSM design methodology to perform the experiments and analyse the result for regression modelling. VI. To carry out analysis of variance (ANOVA) test for validation of regression modelling. VII. To study the relative importance of the machining parameters with respect of each response using Latin hypercube one-factor-at-a-time approach. VIII. To optimize the machining performance and micro-geometry error using hydro particle swarm optimization.
- 3. B.TECH PROJECT DESIGN OF A TWO STAGE REDUCTION GEAR BOX Under the Supervision of Dr.Jhankar Basu, Professor ABSTRACT The project is to Design and Fabricate a spur gear speed reducer gear box for Rear wheel drive differential simulation rig. This will help the motor to running at optimal speed while output shaft will run at low required speed. This project requires significant number of machining processes such as welding, turning, milling, metal cutting and grinding. In this project, it needs lot of skills and information and also knowledge such as Computer Aided Design software (Auto Cad), Solid works software, using EDM wire cut machine, cnc milling machine, lathe machine, band saw, bench work and welding process.