Proceedings of international conference on intelligent manufacturing and automation ICIMA 2018 ( TQL)

Lecture Notes in Mechanical Engineering

Hari Vasudevan
Vijaya Kumar N. Kottur
Amool A. Raina Editors

Proceedings of
International
Conference
on Intelligent
Manufacturing and
Automation
ICIMA 2018


Lecture Notes in Mechanical Engineering


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Hari Vasudevan Vijaya Kumar N. Kottur
Amool A. Raina
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Editors

Proceedings of International
Conference on Intelligent
Manufacturing
and Automation
ICIMA 2018

123


Editors
Hari Vasudevan
Department of Production Engineering
Dwarkadas J. Sanghvi College
of Engineering
Mumbai, Maharashtra, India

Amool A. Raina
Aerospace Group, Institute of Textile
Technology
RWTH Aachen University
Aachen, Germany

Vijaya Kumar N. Kottur

Department of Mechanical Engineering
Dwarkadas J. Sanghvi College
of Engineering
Mumbai, Maharashtra, India

ISSN 2195-4356
ISSN 2195-4364 (electronic)
Lecture Notes in Mechanical Engineering
ISBN 978-981-13-2489-5
ISBN 978-981-13-2490-1 (eBook)
/>Library of Congress Control Number: 2018954026
© Springer Nature Singapore Pte Ltd. 2019
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Preface

This is an exciting time for business and wealth creation in the fields of manufacturing and automation. It is the time when industries are looking up to manufacturing and automation engineers for their assistance in increasing the overall
productivity in their organisation. It is also the time when the governments across
the globe have started to focus more on the manufacturing sector. The International
Conference on Intelligent Manufacturing and Automation 2018 (ICIMA 2018) was
therefore designed to encourage discussions and research on advancements and
applications in the areas of manufacturing and automation. The primary focus of
this conference was to bring together academicians, researchers and scientists for
knowledge sharing in various areas of manufacturing, automation and other allied
domains. The conference covered topics encompassing automation, mechatronics,
robotics, manufacturing processes, management and other related areas such as
product design and development, green manufacturing and smart materials with the
objective of brainstorming and emphasising upon the applications in the field of
intelligent manufacturing and automation. The response to call for papers was
overwhelming with 109 full papers being submitted, covering a wide spectrum of
topics related to the theme of the conference. We express our sincere appreciation to
the authors for their contribution to this book. We would also like to express our
sincere gratitude to all the experts and referees for their valuable comments and
support extended during the review process.
Mumbai, India
Mumbai, India
Aachen, Germany

Hari Vasudevan
Vijaya Kumar N. Kottur
Amool A. Raina

v

ICIMA 2018

Patrons
Shri Amrish R. Patel, Chief Patron, President, SVKM
Shri Bhupesh R. Patel, Joint President, SVKM
Shri Bharat M. Sanghvi, Vice President and Trustee, SVKM, and Chairman,
Governing Council, DJSCE
Shri Sunandan R. Divatia, Hon. Secretary, SVKM
Shri Utpal H. Bhayani, Hon. Treasurer, SVKM
Shri Shalin S. Divatia, Hon. Joint Secretary, SVKM
Shri Jayant P. Gandhi, Hon. Joint Secretary, SVKM
Shri Harshad H. Shah, Hon. Joint Treasurer, SVKM
Shri Harit H. Chitalia, Hon. Joint Treasurer, SVKM

International Advisory Committee
Dr.
Dr.
Dr.
Dr.
Dr.
Dr.

Amit S. Jariwala, Georgia Institute of Technology, USA
Huynh T. Luong, Asian Institute of Technology, Thailand
Raghu Echempati, Kettering University, USA
Amool Raina, RWTH Aachen University, Germany
Rohan A. Shirwaiker, North Carolina State University, USA
Iris V. Rivero, Iowa State University, USA

National Advisory Committee
Dr. S. K. Ukarande, Dean, Faculty of Science and Technology, University
of Mumbai
Dr. S. S. Mantha, Former Chairman, AICTE, New Delhi
Dr. S. K. Mahajan, Joint Director, DTE, Maharashtra
Dr. S. M. Khot, FCRIT, Navi Mumbai
Dr. L. Ganapathy, NITIE, Mumbai
Dr. S. G. Deshmukh, ABV-IIITM, Gwalior
Dr. K. P. Karunakaran, IIT Bombay
Dr. K. Maddulety, NITIE, Mumbai
vii


viii

ICIMA 2018

Dr. Suhas S. Joshi, IIT Bombay
Dr. Tushar Desai, NIT Surat
Dr. V. R. Kalamkar, VNIT Nagpur
Dr. P. Sakthivel, VIT Vellore
Mr. C. M. Venkateswaran, Aker Solutions

Organising Committee
Dr. Hari Vasudevan, General Chair, Convener and Principal, DJSCE
Dr. A. C. Daptardar, General Co-Chair, Vice Principal (Admin.), DJSCE
Dr. M. J. Godse, General Co-Chair, Vice Principal (Acad.), DJSCE
Dr. Vijaya Kumar N. Kottur, Joint Convener, Professor and Head, Department of
Mechanical Engineering, DJSCE
Mr. Rajendra S. Khavekar, Co-Convener, Training and Placement Officer, DJSCE

Members
Dr. Atul Dhale
Dr. Sanjeev Thool
Mr. E. Narayanan
Mr. Sandeep R. Vaity
Mr. Prasad S. Shirodkar
Mr. Vyankatesh U. Bagal
Mr. P. Frank Crasta
Mr. Prashant P. Patankar
Mr. Rajnarayan M. Yadav
Mr. Bronin Cyriac
Mr. Greegory Mathew
Mr. Dharam V. Ranka
Mrs. Meeta N. Gandhi
Mr. Amit Chaudhari
Mr. Ramesh Rajguru
Mrs. Trupti Markose
Mr. Rohit K. Chaurasia
Mr. Mehul S. Prajapati
Mr. Vinit R. Katira
Mr. Pavan R. Rayar
Mr. Kartik M. Ajugia
Mr. Dhaval J. Birajdar
Mr. Sandip H. Mane
Mr. Sanket D. Parab
Mr. Shashikant M. Auti
Mr. Dhananjay Shukla
Mr. Ravikant Hattale

About This Book

This volume comprises the best-selected papers presented at the International
Conference on Intelligent Manufacturing and Automation, which was organised by
the Departments of Mechanical Engineering and Production Engineering of
Dwarkadas J. Sanghvi College of Engineering. The volume focuses on narrowed
topics of automation, mechatronics, robotics, CAD/CAM/CAE/CIM/FMS in
manufacturing, product design and development, DFM/DFA/FMEA, MEMS and
nanotechnology, rapid prototyping, computational techniques, industrial engineering, manufacturing process management, modelling and optimisation techniques,
CRM, MRP and ERP, logistics and supply chain management, quality assurance
and environment protection, advanced materials processing and characterisation
and composites and smart materials. The papers are divided into four main domains
like design, advanced materials, manufacturing and automation. We expect the
articles, being published in the book, would contribute to and reinvigorate
the overall efforts in enhancing manufacturing productivity across various sectors.
The content of the book is also expected to be helpful for postgraduate and doctoral
students in their efforts to enhance the research outcome of their studies.

ix


Contents

Part I

Design

Mathematical Modeling and Optimization of Process Parameters
for Tensile Strength and Nugget Diameter in Resistance Spot Welding

of HR E-34 Steel Sheet Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B. S. Gawai, R. L. Karwande, Md. Irfan and Prafull S. Thakare
Numerical Simulation Over Conical Aerospike at Mach 6 . . . . . . . . . . .
Rahul S. Pawar, N. R. Gilke and Vivek P. Warade

3
15

Multi-characteristics Optimization in the Turning of GFRP
Composites Based on Grey-Taguchi Method . . . . . . . . . . . . . . . . . . . . .
Hari Vasudevan, Ramesh Rajguru and Kalpesh Tank

27

Vibrational Analysis of Single-Point Cutting Tool for Different Tool
Material and Nose Radius Using Design of Experiment . . . . . . . . . . . . .
C. M. Choudhari, I. A. Bhisti, M. G. Choudhary and A. H. Mistry

35

Design of Automated Two-Wheeled Forklift with Retracting
Third Wheel and Dynamic Counterbalance Mechanism . . . . . . . . . . . .
Abhinav Kshirsagar, Neha Kesarkar and N. S. Chandrashekhar

47

Design and Analysis of Piercing and Extrusion Tool . . . . . . . . . . . . . . .
Gopal B. Mudholkar, Girish M. Lonare and Sadhana R. Hivre

55

Design and Analysis of Coaxial Rotor Wind Turbine . . . . . . . . . . . . . .
Sachin Manohar Shinde, Mohit Chaudhari, Tejas Jeurkar, Sanket Kadam
and Kiran B. Salunkhe

69

Parametric Optimization of MIG Welding on IS 1079
HR 2 by Taguchi Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mayur D. Jagtap and Niyati Raut

81

xi


xii

Contents

Design and Prototype of Wireless Robot for Condition Monitoring
of Coal Conveyor Roller Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vikesh P. Kumawat, Nikhil S. Divate, Sangeeta Bansode,
Amit Kumar Patel and Kailas S. Jagtap
Design, Analysis and Modification of 3 Stage Helical Gearbox Casing
Using Finite Element Method Considering Different Materials . . . . . . .
Ronak D. Gandhi and Nimeshchandra S. Patel

89

99

Analysis of Cyclone Separator Used for Liquid-Gas Mixing . . . . . . . . . 115
Gayatri Malekar and Niyati Raut
Development of Mathematical Model for Top Roller Displacement
of Three-Roller Bending Machine Using Dimensional Analysis . . . . . . . 125
Prafull S. Thakare, Sandip M. Salodkar and C. C. Handa
Design and Analysis of Vertical Vacuum Fryer . . . . . . . . . . . . . . . . . . . 133
Abhishek Gupta, Amit Choudhari, Taha Kadaka and Pavan Rayar
Design, Manufacture and Testing of an Impact Attenuator
for a FSAE Car . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Parth Thakar, Suyash Ail, Jayraj Ranade and Parshva Mehta
Application of Steady State and Transient Modeling
for Characterization of Vortex in Vertical Pump Intake
for Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Rahul Paliwal, Bhola Nagelia, Hrishikesh Pangarkar, Anant Jhaveri
and Channamallikarjun S. Mathpati
Design of Feedstock and Liquefier for Printing Aluminium
Parts by Fused Deposition Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Pravin S. Misal and N. S. Chandrashekhar
Static Structural Analysis of Car Rim by Finite Element
Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Suraj L. Gondhali, Atul D. Dhale and Sunil Pagare
Comparative Thermal Analysis of Fins . . . . . . . . . . . . . . . . . . . . . . . . . 195
H. A. Patel, V. S. Kale, S. U. Joshi, S. D. Jadhav and S. N. Teli
Design and Development of Small-Capacity Mango
Process Plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Nandu Durge, Shankar Mantha and Vikas Phalle
Analysis of Curve Fitting for Case Studies: An Appropriate
or Non-appropriate Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Rajkumar P. Narkhede and Prabha Rastogi
Posture Assessment Among Waste Loading Workers in India . . . . . . . . 229
Francis J. Emmatty and Vinay V. Panicker


Contents

xiii

Evaluation of Performance Characteristics and Bite Condition
of Single Ferrule Bite Fitting by Finite Element Analysis (FEA) . . . . . . 239
Akshay Kusneniwar, Prathamesh Potdar and Santosh Rane
Optimization of the Chest Geometry for the Storage
and Transportation of Fruits and Vegetables . . . . . . . . . . . . . . . . . . . . . 253
Ajinkya Netake, Rushabh Mutha, Akash Mishra, Aditya Sawant,
Prathamesh Potdar and Nitin Panaskar
Part II

Advanced Materials

Experimental Investigations of Mechanical Properties
and Microstructural Characterization of Aluminum–Silicon Alloy
Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
D. M. Wankhede, B. E Narkhede, S. K. Mahajan and C. M. Choudhari
Multiobjective Optimization in Drilling of Composites . . . . . . . . . . . . . . 279
Paramjit Thakur, S. N. Teli and Siddhesh Lad
Evaluation of the Mechanical Properties of Recycled
Jute Fiber–Reinforced Polymer Matrix Composites . . . . . . . . . . . . . . . . 287
Pullareddy Mekala, Manohar Reddy Kunuthur
and B. Chandramohana Reddy

Predictive Modelling of Delamination Factor and Cutting
Forces in the Machining of GFRP Composite Material
Using ANN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Hari Vasudevan, Ramesh Rajguru and Rajnarayan Yadav
Review of Application of Nitinol in the Manufacture
of Bone Staples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Neel Sanghvi, Frank Crasta and Vijaya Kumar N. Kottur
A Review on Graphene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Farhan Sayed, Mitesh Parmar and Shashikant Auti
Comparative Wear Analysis of (3 Â 3) PTFE Composite
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
A. D. Diwate and S. B. Thakre
Synthesis of Polyaniline-Vanadium Pentoxide Nanocomposites:
A High-Performance Conducting Material for Energy Storage . . . . . . . 345
Sugam Shivhare, Praveen Kumar Loharkar, Supriya Vyas,
Vivekanand Bagal and Malvika Sharma
Effect of Benzoxazine on Epoxy Based Carbon Fabric
Reinforced Composites for High Strength Applications . . . . . . . . . . . . . 353
C. Venkateshwar Reddy, Ch. Joseph S. Raju, P. Ramesh Babu
and R. Ramnarayanan


xiv

Contents

Microwave Assisted Synthesis of Palladium Doped Zinc Oxide
Nanostructures and Their Gas Sensing Applications . . . . . . . . . . . . . . . 369
Yogita S. Patil, Sushil Charpe, F. C. Raghuvanshi
and Ramzan Muhammad

Investigation of Moisture Absorption in Jute Fiber
Polymer Matrix Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
Manohar Reddy Kunuthur and B. Chandramohan Reddy
Experimental Performance and Analysis of Domestic
Refrigeration System Using Nano-Refrigerants . . . . . . . . . . . . . . . . . . . 389
Deepak Bondre, Apurav Joshi, Tejas Shinde, Apurv Deshmukh
and Kavita Dhanawade
Experimental Investigation and Optimization of End-Milling
Parameters in the Machining of Inconel 825 Using
Carbide-Coated Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Hari Vasudevan, Ramesh Rajguru, Geet Dave, Arun Alva, Vinil Punjani
and Devdatt Bhurke
Optimization of Machining Parameters in the Turning Operation
of Inconel 825 Using Grey Relation Analysis . . . . . . . . . . . . . . . . . . . . . 413
Hari Vasudevan, Ramesh Rajguru, Shreyans Jain, Milan Kaklotar,
Jaineel Desai and Sanidhya Mathur
A Review and Analysis of the Machining Process Involving
Nickel-Based Super Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
Ramesh Rajguru and Hari Vasudevan
Part III

Manufacturing

Minimization of Shrinkage Porosity in HPDC Process
with Local Squeeze Pin Using Flow Simulation . . . . . . . . . . . . . . . . . . . 435
Shivkumar Biradar and Prashant T. Borlepwar
Optimization of Injection Moulding Process Parameters
Using Response Surface Methodology . . . . . . . . . . . . . . . . . . . . . . . . . . 445
Khavekar Rajendra, Hari Vasudevan and Gosar Vimal
Optimization of Cutting Parameters in Dry Turning of AISI 4140

Hardened Alloy Steel with Coated Carbide Tool . . . . . . . . . . . . . . . . . . 455
Sandip Mane and Sanjay Kumar
A Perspective of Integrated Machine Vision Based-Multivariate
Statistical Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Ketaki N. Joshi and Bhushan T. Patil


Contents

xv

Development of Facility Layout for Medium-Scale Industry
Using Systematic Layout Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
Onkar V. Potadar and Ganesh S. Kadam
Intelligent Unmanned Aerial Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . 485
Parth Thakkar, Anand Balaji and Vaibhav S. Narwane
Study on Power Consumption of Split Air Conditioner Depending
on Distance Between Condenser and Evaporator Units . . . . . . . . . . . . . 495
Bysani Malakondaiah
Monte Carlo Simulation of Arrival of Materials
on Assembly Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503
Jimit Shelat
Recent Developments in the Field of Rapid Prototyping:
An Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511
Umesh Sable and Prashant T. Borlepwar
Performance Study of Stamping Process Using Condition
Monitoring: A Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521
Tushar Y. Badgujar and Vijay P. Wani
Application of Discrete-Event Simulation to Increase
Throughput of Manufacturing System—A Case Study . . . . . . . . . . . . . 531

Prasad V. Thete and Ramesh R. Lekurwale
Enhancement in Productivity by Integration of 5S Methodology
and Time and Motion Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541
Rushank Sangani and Vijaya Kumar N. Kottur
Decision Support System for Failure and Down Time Reporting:
A Tool for Achieving Production Targets from Remote Mining
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 551
V. M. Kalra, Thakur Tilak and B. S. Pabla
Reviewing the Problem of ELVs in India and Checking
Possibilities of Pyrolysis as a Solution . . . . . . . . . . . . . . . . . . . . . . . . . . 565
Kaival Rajesh Nayak and Shashikant Auti
Effect of Process Parameters While Machining Using
Abrasive Jet Machine (AJM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575
Shaishav M. Jadav and Ramesh R. Lekurwale
Identifying Key Success Factors of Sustainability in Supply
Chain Management for Industry 4.0 Using DEMATEL Method . . . . . . 583
Malleshappa T. Bhagawati, E. Manavalan, K. Jayakrishna
and P. Venkumar


xvi

Contents

Supplier Selection in Plastic Products Manufacturing MSMEs
Using a Combined Traditional and Green Criteria Based
on AHP and Fuzzy AHP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
Ashish J. Deshmukh and Hari Vasudevan
Green Supply Chain Management Practices and Its Impact
on Business Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601

Meeta Gandhi and Hari Vasudevan
Part IV

Automation

Reliability Assessment of Seals Used in Propulsion Module
of an Autonomous Unmanned Vehicle Using Markov Chains . . . . . . . . 615
Prathamesh Mohite, Elroy Rodrigues and Shivani Vartak
Elitist Non-dominated Sorting Genetic Algorithm-Based Heuristic
for Optimizing Rail Freight Transportation . . . . . . . . . . . . . . . . . . . . . . 623
Vinay V. Panicker, C. S. Aryadutt and K. P. Anoop
Vibration Control of 6 Dof Three-Wheeler Using Pid
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 631
Routh Rajesh and S. Srinivasa Rao
Automation of Stone Feeding on T8 Honing Machine . . . . . . . . . . . . . . 651
S. J. Patil, A. S. Suryawanshi, O. R. Choukar and C. R. Deokate
Performance Optimization of Bias Bar-Type Brake System
Using Data Acquisition System (DAQ) . . . . . . . . . . . . . . . . . . . . . . . . . . 661
Megh Doshi, Suhrid Subramaniam, Sachin Patel and Meet Shah
Simulation for Variable Transmission Using Mono
Level Genetic Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 669
Ritwik Dhar and Niti Doshi
Fuzzy Analytic Hierarchy Process (FAHP) for Green
Supplier Selection in Indian Industries . . . . . . . . . . . . . . . . . . . . . . . . . . 679
Samadhan Deshmukh and Vivek Sunnapwar
Crash Simulation of an Automotive Body to Explore
Performance of Different Metallic Materials Using ANSYS . . . . . . . . . . 689
C. M. Choudhari, Jaineel Desai, Shlok Bhavsar
and Dharmendra Choudhary
Condition Monitoring of Rolling Element Bearing by Acoustic

Analysis Using LabVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 697
Anish Nadar and Rajanarasimha Sangam


Contents

xvii

Computational Modeling and Analysis of Artificial Flood
Using Automata . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 711
Nabamita Deb and Ashiya Noorie
Author Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 721


About the Editors

Dr. Hari Vasudevan has his master’s degree in production engineering and postgraduate diploma in
industrial engineering from VJTI (University of
Mumbai) and Ph.D. from IIT Bombay. He has also
done a 3-month full-time certificate programme
(ERP-BaaN) from S.P. Jain Institute of Management
and Research, Mumbai, under the University Synergy
Programme of the BaaN Institute, Netherlands. His
areas of interest include manufacturing engineering,
manufacturing systems and strategy, market orientation
of manufacturing firms and world-class manufacturing.
He is an approved Ph.D. guide at the University of
Mumbai and NMIMS (Deemed to be University) and
has so far guided three Ph.D. students. He is the president of Indian Society of Manufacturing Engineering
(ISME); life member of ISTE, New Delhi; fellow of the

Institution of Engineers (India); fellow of ISME and
senior member of IEDRC. He has 26 years of experience in teaching and 2 years of experience in the
industry. Presently, he is working as the principal of
Dwarkadas J. Sanghvi College of Engineering,
Mumbai. He has published over 82 papers in international and national conferences and journals.

xix


xx

About the Editors

Dr. Vijaya Kumar N. Kottur heads the Department
of Mechanical Engineering at Dwarkadas J. Sanghvi
College of Engineering, Mumbai. He completed his
master’s degree in engineering management from SJCE
Mysore, master’s degree in mechanical engineering
with machine design as specialisation from SPCE
Mumbai and Ph.D. from the University of Mumbai. He
has 28 years of teaching experience and published 48
papers in national and international journals and
conferences. He is an approved Ph.D. guide at the
University of Mumbai, Pune University and JJTU
University and has so far guided two Ph.D. students. He
worked as a guest faculty at NITIE Mumbai. His areas
of interest are quality engineering, world-class manufacturing, supply chain management and system
dynamics. He is the life member of professional bodies
like ISNDT, IIIE, ISTE and ISME.
Dr. Amool A. Raina currently coordinates and heads

the aerospace programme at the Institut für Textiltechnik
(ITA) of RWTH Aachen University. His doctoral thesis
(highest distinction received) majoring in aerospace
engineering at the University of Kansas presented
solutions for the improvement in wind turbine design
and manufacturing. He is considered as an expert in wind
turbine design and engineering and has a work experience of over 6 years in the aerospace and renewable
industry prior to joining ITA. He has designed and
engineered over 35 wind turbine blades ranging from 2 to
105 m in length with over 16,000 blades successfully
flying worldwide. He has also been involved in projects
relating to design and optimisation of aircraft engines
and other components. He is currently developing and
promoting textile-based solutions for several sectors
including aerospace, automotive, traditional textiles and
digital solutions as per Industry 4.0 norms for the above
industries. Apart from his technical responsibilities, he
also heads all affairs and activities pertaining to the
European Union and European Space Agency at ITA.


Part I

Design


Mathematical Modeling
and Optimization of Process Parameters
for Tensile Strength and Nugget
Diameter in Resistance Spot Welding

of HR E-34 Steel Sheet Joint
B. S. Gawai, R. L. Karwande, Md. Irfan and Prafull S. Thakare
Abstract In the present investigation, HR E-34 steel sheets are welded by resistance
spot welding. The welding current, welding cycle, and pressure are the principal
variables that are controlled in order to provide the necessary combination of heat and
pressure to form the weld. The effect of various parameters on weld strength of Hot
Rolled E-34 material is determined by using Minitab 16 software and using design
of experiment. Response surface methodology (Box-Behnken Design) is chosen to
design the experiments. The highly significant factor was determined by analysis of
variance. In the analysis, it was observed that predicted and experimental results were
in good agreement and the coefficient of determination was found to be 0.967 and
0.955 for tensile strength and nugget diameter implies adequacy of derived model.
The aim of the research is to find out improvement in welds strength and also reduces
various welding defects.
Keywords Response surface method (RSM) · Tensile strength · Nugget diameter
Analysis of variance (ANOVA) · Resistance spot welding (RSW)

B. S. Gawai
MSS’S, College of Engineering and Technology, Jalna,
Maharashtra, India
e-mail:
R. L. Karwande (B) · Md. Irfan · P. S. Thakare
Department of Mechanical Engineering, MSS’S,
College of Engineering and Technology, Jalna, Maharashtra, India
e-mail:
Md. Irfan
e-mail:
P. S. Thakare
e-mail:
© Springer Nature Singapore Pte Ltd. 2019

H. Vasudevan et al. (eds.), Proceedings of International Conference on Intelligent
Manufacturing and Automation, Lecture Notes in Mechanical Engineering,
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3


4

B. S. Gawai et al.

1 Introduction
Resistance welding is one of the oldest of the electric welding processes in use
by industry today. Resistance welding is group of welding processes which produce
coalescence of metals with the heat obtained from resistance offered by the workpiece
to the flow of electrical current through the parts being joined. In this process, heavy
electric current is passed through the metals to be joined. This causes local heating to
increase temperature to plastic state over limited area of contact. Mechanical pressure
is applied to join them completely. No additional filler metal is required. The current
is passed through the electrodes which incorporate very low resistance in the circuit
and the resistance at the joints of metals is very high. Thus, maximum heating is
produced at the point of contact where weld is to be made. Resistance welding is
use to weld sheet metals of all engineering metals in Steel cabinets, boxes, cans and
furniture automobile industry, air craft industry, and pipe and tubing production. It is
an efficient joining process widely used for the fabrication of sheet metal assemblies.

2 Literature Review
The review present in this section is related to mathematical modeling and optimization of process parameters of resistance spot welding machine. The present literature
review investigates various techniques and methods for improvement in parameters
like nugget diameter and tensile Strength. The survey is given as:
Kahraman [1] has carried out outcome of experimental investigations to assess

the performance of commercially pure (CP) titanium sheets (ASTM Grade 2) were
welded by resistance spot welding at different welding parameters and under different
welding environments. Aslanlar [2] has experimentally studied the change in Nucleus
size ratio for tensile peel strength and Tensile shear strength were investigate and
optimum welding condition for parameters like weld current and time were find out.
Vural et al. [3] have aimed to analyze the effect of welding nugget diameter on the
fatigue strength of the resistance spot welded joints of different steel sheets. Han et al.
[4] concluded experimental correlation study of mechanical strength of resistance
spot welding of AA5754 aluminium alloy.
Hamidinejad et al. [5] carried out the modeling and process analysis of resistance
spot welding on galvanized steel sheets used in car body manufacturing. Zhao et al.
[6] investigated and optimized process parameter like welding time, welding current,
and electrode force for improvement in failure energy and spot weld quality of spot
welded titanium alloy. Mathematical model of input parameter and output parameter
was prepared by using response surface methodology.


Mathematical Modeling and Optimization of Process Parameters …

5

2.1 Material
Material used in this study is Hot rolled E-34 steel sheet. Material is cut in samples
of dimensions 100 × 20 × 2 mm (Table 1).

3 DOE
DOE (Design of experiment) is used to know the nature of any system. Experiments
were carried out with the help of DOE method. By using DOE, it can predict the result
of output maximum or output minimum. In DOE, response surface methodology is
used for mathematical modeling. Box–Behnken design was used to set experimental runs. The input process parameters were weld current, weld time, pressure for

research work. Nugget diameter and tensile strength were output parameters. For
each experimental run the parameter were fit and alter with respect to the design
table. Parameter ranges are decided on the basis of literature review recommended
and machine feasibility and specifications given by BAJAJ Materials department
Bajaj auto Ltd, Akrudi.

3.1 Resistance Spot Welding Machine Specifications
75 KVA spot welding machine is employed for experimentation. Weld, current, and
pressure are used for responses like nugget diameter and strength of weld. Following
Fig. 1 shows setup of resistance spot welding.

Fig. 1 Resistance spot welding machine setup


%C

Composition 0.1
(wt%)

Element

0.7

%Mn

0.03

%S

Table 1 Chemical composition of HR E-34

0.03

%P
0.2

%Si
0.02–0.06

%Al
0.055

%Nb

0.045

%Ti

0.095

%V

Balance

Iron

6
B. S. Gawai et al.


Mathematical Modeling and Optimization of Process Parameters …

7

3.2 Experimentation
Welding is carried out with resistance spot welding machine with supply 415 V,
frequency 50 Hz with water-cooled chromium copper electrodes. Specimens are
prepared of size 100 × 20 × 2 mm and trial taken by spot welding process with abovementioned parameters. Later on same specimens are tested for tensile strength on
UTM machine.
Weld strength

Breaking Load/Nugget shearing Area

where D is Nugget diameter and t

Thickness of specimen, P

P/2π Dt
Breaking Load

4 Results and Discussion
4.1 Regression Analysis of Nugget Diameter
The mathematical model depicted by equation x is obtained by performing regression
analysis on generated data during experimentation. The regression equation is
Nugget diameter

2.56 + 0.0075 Weld Cycle + 0.330 Current − 0.390 Pressure

4.2 Model Adequacy Test for Nugget Diameter
(See Tables 2 and 3).
S

0.0983377 R − Sq

95.5% R − Sq(adj)

94.3% R − Sq(pred)

Table 2 Pre ANOVA model summary statics of nugget diameter
Predictor
Coef
SE coef
T

P

Constant
Weld cycle

2.5603
0.0075

0.4761
0.01738

5.38
0.43

0.000*
0.674*

Current
Pressure

0.33
−0.39

0.02318
0.06954

14.24
−5.61

0.000*
0.000*

* Denotes

significant terms

92.98%


8

B. S. Gawai et al.

Table 3 ANOVA model summary statics of nugget diameter
Source
DF
Contribution

Adj SS
Adj MS
F-value
(%)

P-value Remark

Model
Linear
Weld
cycle

3
3
1

95.52
95.52
0.08

2.2662
2.2662
0.0018

0.7554
0.7554
0.0018

78.12
78.12

0.19

0
0
0.674

Current

1

82.62

1.9602

1.9602

202.7

0

Most
significant

Pressure

1

12.82

0.3042

0.3042

31.46

0

More
significant

4.48
2.54

0.10637
0.06031

0.00967
0.0067

0.29

0.922

1.94
100.00

0.04607

0.02303

Error
11
Lack-of9
fit
Pure error 2
Total
14

Less
significant

Residual Plots for Nugget Diameter
Normal Probability Plot of the Residuals

Residuals Versus the Fitted Values

99

0.1

Residual

Percent

90
50
10
1

0.0

-0.1
-0.2

-0.2

-0.1

0.0

0.1

4.5

0.2

5.0

0.1

Residual

Frequency

4.5
3.0
1.5

0.0
-0.1
-0.2

-0.25

-0.20

-0.15

-0.10

-0.05

0.00

0.05

0.10

Residual

Graph 1 Residual plots for nugget diameter

4.2.1

6.0

Residuals Versus the Order of the Data

Histogram of the Residuals
6.0

0.0

5.5
Fitted Value

Residual

Interpretation of Residual Graph

(See Graph 1).

1

2

3

4

5

6

7

8

9

10 11

Observation Order

12 13

14 15