Purpose The purpose of this paper is to investigate the prominence of mechanical excitations at the time of welding. In the past years, the process of welding technology has expanded its influence in manufacturing. The crucial drawback of conventional welding is prompted by internal stresses and distortions, which is the focal reason for weld defects. These weld defects can be diminished by the process called post-weld heat treatment (PWHT), which consumes more working hours and needs skilled workers. To replace these PWHT processes, mechanical vibrations are introduced during the process of welding to diminish these weld defects. Design/methodology/approach In the current research, the mechanical vibrations are transferred to weld-pool through vibro-motor and DC motor connected to the electrode. As per standards, the tensile test specimens were prepared for welding with different voltages of vibro-motor and DC motor respectively. The weld joints were tested for tensile strength and analyzed the microstructure at the fusion zone. Findings Melt-ability at fusion zone of 1018 mild steel was investigated by the single-stroke intense heat process of fusion welding. It is observed that the mechanical vibrations technique has a profound influence on the enhancement of the fusion zone characteristics and grain structure. The peak value of the tensile strength is observed at 100 s of vibration, 190 V of vibro-motor voltage and 18 V of electrode voltage. The tensile strength of the welded joints with vibrations is increased up to 22.64% when it is compared with conventional welding. The enhancement of the tensile strength of the weld bead was obtained because of the formation of fine grain structure. So, mechanical vibrations are identified as the most convenient method for improving the mild steel alloys weld quality. Originality/value A novel approach called mechanical vibrations during the process of welding is implemented for fusion zone refinement.
Machining with conventional process of lubrication is a general industrial practice for diminishing cutting forces, high temperature, and friction. During the machining process, cutting fluid characteristics plays a crucial role in enhancing machining performance when it is properly chosen. The harmful gases during machining process are often hazardous to individuals and the environment. It is also economically unviable if the cutting fluid cost, method of application, and flow rate is underestimated. Due to chip obstruction and poor absorption, a high amount of heat is liberated and as a result high quantity and high quality of lubricant or coolant are need to be supplied between the chip-tool interfaces consistently. This process becomes costly and degrades the environment. In the current work, nano powder of boric acid is chosen as solid type lubricant in turning process, which is blended with bio-diesel consisting of coconut oil as base oil. The outcomes of nano powder mixed bio-diesel cutting fluids exhibited significant enhancement in machining characteristics when it is compared with wet and dry machining. And also, Taguchi method of orthogonal representation is considered to determine the optimum weight percentage of the bio-diesel blends at different conditions of the machining process. The optimum machining conditions were obtained at high machining operation with a feed of 0.04 mm/min, speed of 600 rpm, and toll diameter of 0.5 mm.
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