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LASERS IN GREEN MANUFACTURING PROCESS

LASERS IN GREEN MANUFACTURING PROCESS. S.BALASUBRAMANIAN Department of mechanical Engineering SNSCE. INTRODUCTION. Heat treatment is one of the manufacturing processes Enhance strength of metal components Hard or Soft Selective hardening Ex: Teeth Engine cylinder

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LASERS IN GREEN MANUFACTURING PROCESS

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  1. LASERS IN GREEN MANUFACTURING PROCESS S.BALASUBRAMANIAN Department of mechanical Engineering SNSCE

  2. INTRODUCTION • Heat treatment is one of the manufacturing processes • Enhance strength of metal components • Hard or Soft • Selective hardening Ex: Teeth • Engine cylinder • Types of heat treatment processes • Flame,Case,Electronbeam,Induction,laser

  3. . CASE HARDENING FLAME HARDENING ELECTRON BEAM HARDENING CARBURIZING

  4. . INDUCTION HARDENING LASER SURFACE HARDENING

  5. . • Safe and healthy work piece is important in sustainable manufacturing process. • Laser surface hardening process-on major part of its applications, not using quenching oil or water, is less detrimental to the environment. • Not affecting the sorroundings,less distortion, time save, no heating up, accurate case depth, no need of specific tools,flexible,no additional machining, power saving and very less air polluted process. • With these qualities of laser surface hardening (real time problem)- the bottom rollers on textile machine are taken for experimental analysis.

  6. BOTTOM ROLLER • The bottom rollers - medium carbon steel (En9) (AISI 1055) • continuous running • radial, thrust, torsion, and compressive stresses • eccentric running affects the yarn quality. • The present heat treatment process is induction hardening, which partially fulfill the requirements.

  7. . • The complicated contour surface of the roller was hardened with Nd-YAG laser at RRCAT-Indore. • The samples and specimen were tested for micro hardness, depth of hardness, grain structure, temperature distribution, wear and trial running on the textile ring spinning machine at mills. The comparative results shows improved hardness at critical contours and samples produced better yarns on the machine. • The yarns produced from laser treated bottom rollers tested at SITRA shows lesser hairiness, thin and thick places than the yarn produced by the adjacent by induction hardened rollers. Also improved production rate. • The return on investment is short by reducing manufacturing operations when compared to the traditional heat treatment processes. • The laser surface hardening gives better quality on work piece and less polluted manufacturing process.

  8. Objective • Experimental analysis of bottom rollers. • Indentify the suitable laser parameters. • Compare the results with existing process. • Highlight the advantages of laser hardening towards quality and green manufacturing. • Reveal the return on investment of laser source.

  9. PARAMETERS for LASER HARDENING and INDUCTION HARDENING Developed mathematical model for 3 factor 5 levels

  10. . • Optical microscopy, micro hardness test, depth of hardness at PSG and RRCAT • Wear test at KARUNYA University lab • FEA analysis made for temperature distribution with ANSYS software Ducom-TR20 Wear Tester LEITZ MINI-2 Hardness Tester Olympus Microscope

  11. DIRECT EFFECT OF POWER ON HARDNESS

  12. HAIRINESS IN YARN EXISTING IMPROVED

  13. Comparison Induction Vs Laser

  14. .

  15. Conclusion • The important objective in the surface hardening process are to get quality components, low production cost and foremost healthy environment to human being. • Laser surface hardening highlights its uniqueness towards green manufacturing. • The increasing health awareness in global market adopt this technology as an update.

  16. References • [1].P. DineshBabu, K.R. Balasubramanian, G. Buvanashekaran, Laser Surface Hardening – A Review, International Journal Surface Science and Engineering,Vol.5,N.2-3, (2011),pp.131-151. • [2].CITGO-Quenching Oil 22,Product:Metal Working Fluid,(2005),Chronic health hazard notes. • [3].Friedrich Bachmann, Industrial applications of high power diode lasers in materials processing, Applied Surface Science Vol.208-209, (2003),pp.125-136. • [4].Tomáš ,Laser surface treatment not only for automobiles, Industrial Laser solutions for manufacturing,(2010)www.industrial lasers.com. • [5].JohnHyunMoon,Melting characteristics of metals by combined laser beams with different wavelengths, Journal of Laser Applications,Vol.15,(2003),pp.37-42. • [6].J. Lawrence and L Li,Wettability characteristics of a modified mild steel with CO2,Nd-YAG,excimer and high power diode lasers, Journal of Physics,Vol.32.(1999). • [7].M.Nogueiras,j.Penide,R.Comesana,J.delVal,Feasibility Study of wide band laser surface treatment, SciVerse Science Direct, 41, (2013), pp. 356-361. • [8].Air Pollution May Speed Hardening of Arteries, By Health Day - April 23,(2013).

  17. . THANK YOU

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