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Shunmugam M S
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Shunmugam M S
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Shunmugam M S
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Shunmugam, M. S.
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6 results
Now showing 1 - 6 of 6
- PublicationMagnetic field analysis and roughness prediction in magnetorheological abrasive honing (MRAH)(01-04-2009)
;Sadiq, A.Magnetorheological Abrasive Honing (MRAH) is a recently developed process to finish engineering surfaces. The process makes use of a magnetically stiffened abrasive-mixed magnetorheological fluid as the flexible tool and rotation-cum-reciprocation movements between the finishing medium and the work piece surface for providing finishing action. In the present work, a finite element analysis with Mechanical/Emag module of ANSYS is performed to understand the nature of magnetic field developed in the process and verification is done with actual measurements. Considering the simulated magnetic field, a model to predict final roughness value (Ra) is developed. The model, when applied for different work materials and various process parameters, such as magnetic flux density, process duration and work piece rotation, yields results that are in good agreement with experimental results. - PublicationTool condition monitoring in honing process using acoustic emission signals(01-01-2008)
;Kanthababu, M.; Singaperumal, M.Sensing Acoustic Emission (AE) signals from a machining process is one of the most promising methods suitable for tool condition monitoring because of its sensitivity combined with quick and high frequency response. In this work, AE signals are monitored during rough, finish and plateau honing of cylinder liner using fresh and completely worn out honing tools. AE parameters such as Root Mean Square (RMS), peak to peak, skewness and kurtosis and dominant frequency in the power spectrum are analysed. The results show that the dominant frequency in the power spectrum is very sensitive to honing tool conditions and a good correlation exists with honed surface quality. Therefore, AE signals can be used for ascertaining the honing tool performance and establishing the end of tool life. Copyright © 2008, Inderscience Publishers. - PublicationMulti-sensors-based condition monitoring for honing of cylinder liners(01-01-2012)
;Kanthababu, M.; Singaperumal, M.Development of cylinder liner for internal combustion engines is a challenging task and it involves a thorough understanding of interaction between functional requirements of liners, performance of honing process and desired surface characteristics. In the present work, an attempt is made to bring out the relation between performance of honing process and surface characteristics with the condition of the honing tools. Signals from multiple sensors during rough, finish and plateau operations with fresh or worn out tools show a good correlation between honing tool condition and performance measures such as material removal and surface topography. A strange phenomenon of reduced amplitude in power spectrum of vibration signals occurring with worn out tools is explained. On comparing the acoustic emission (AE) signals and the signals obtained from piezoelectric cutting force dynamometer and accelerometer, it is found that the signals obtained from AE sensor show higher sensitivity in terms of performance measures. A tool condition monitoring strategy which considers all three sensors including AE sensor is proposed in this paper. Such a strategy would help in the timely replacement of the honing tools, thereby enhancing the productivity. Copyright © 2012 Inderscience Enterprises Ltd. - PublicationA novel method to improve finish on non-magnetic surfaces in magneto-rheological abrasive honing process(01-05-2010)
;Sadiq, A.Magneto-Rheological Abrasive Honing (MRAH) is a recently developed process that makes use of magnetically stiffened abrasive-mixed magneto-rheological fluid and combined rotary and reciprocating motions to finish engineering surfaces. Effect of magnetic field has been investigated on specimens mounted in a holder and subjected to MRAH. It is observed that the change in the surface finish on magnetic specimens is insignificant, while the surface finish on non-magnetic specimens improves appreciably. By a novel method of introducing magnetic specimens along with non-magnetic specimens, the magnetic field near the non-magnetic specimens is enhanced. The results obtained on the non-magnetic specimens by this approach for different magnetic field and process duration confirm that the finishing capability of the process is greatly improved, and yields a maximum improvement in finish of 41.7% and 43.5%, respectively while the previously reported results are 6.7% and 24.2%. © 2010 Elsevier Ltd. All rights reserved. - PublicationIdentification of significant parameters and appropriate levels in honing of cylinder liners(01-01-2009)
;Kanthababu, M.; Singaperumal, M.Surface topography of cylinder liners influences the functional behaviour of internal combustion engines. The cylinder liners after boring operation are subjected to rough, finish and plateau honing operations in which parameters such as rotary speed, reciprocating speed, pressure and honing time are selected on the basis of operator's experience. The present work is a comprehensive investigation carried out to identify the significant honing parameters and their values for different honing operations. The honing trials are carried out according to design of experiments. Before each operation, all cylinder liners are processed identically under conditions identified from the previous operation. Parameters considered for characterising the surface topography are roughness average (Ra) and all five bearing area parameters (Rpk, Rk, Rvk, Mr1 and Mr2). It is established in the present work that Ra can be replaced effectively by Rk in finish and plateau honing operations to control the final surface topography and these parameters (Ra, Rk) are influenced by honing pressure. For the most important bearing area parameter Mr2, the significant process parameters are medium honing time in finish honing and high reciprocating speed in plateau honing. These results are useful for controlling the honing operations during the manufacture of the cylinder liners. Copyright © 2009, Inderscience Publishers. - PublicationInvestigation into magnetorheological abrasive honing (MRAH)(01-06-2009)
;Sadiq, A.A scheme to finish external curved surfaces, by imparting rotation while the abrasive-mixed magnetorheological fluid (or abrasive-mixed MR fluid) is pushed up and down, is presented in this paper. Since the relative motions resemble those present in conventional honing, the proposed method is named as 'Magnetorheological Abrasive Honing' (MRAH). This paper outlines the design and development of magnetorheological abrasive honing setup. A DC electromagnet with cylindrical pole faces is used and measurement for magnetic flux density is done. Experiments are conducted with aluminum and austenitic stainless steel workpieces to understand the effect of magnetic field. Effect of initial roughness, workpiece rotation and process duration on finishing was investigated with ground austenitic stainless steel workpieces. It is observed that the improvement in finish is better for rougher surface and higher rotation speed of workpiece and a reduction in roughness is consistent with process duration. © 2009 Elsevier Ltd. All rights reserved.