Precision machining of an aluminum alloy piston reinforced with a cast iron insert |
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Authors: | Marimuthu Uthayakumar Gopalakrishnan Prabhakaran Sivanandham Aravindan and Jonna Venkata Sivaprasad |
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Affiliation: | (1) Department of Mechanical Engineering, Kalasalingam University, Krishnan Koil, Tamil Nadu, India, 626-190;(2) Department of Mechanical and Industrial Engineering, Caledonian College of Engineering, C.P.O Seeb - 111, Sultanate of Oman;(3) Department of Mechanical Engineering, Indian Institute of Technology, New Delhi, 110-016, India;(4) Engineering Department, India Pistons Ltd, Maraimalai Nagar, Chennai, India, 603-209 |
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Abstract: | Bimetallic pistons consisting of aluminum alloy reinforced with a cast iron (CI) insert are used to reduce the weight and
improve the wear resistance of pistons. A major problem with machining such bimetallic pistons is producing the desired shape
with minimal cutting forces and without damaging the bonding registry. The objective of this paper is to determine the optimal
cutting parameters (cutting speed, feed, and depth of cut) for turning bimetallic pistons. When machining, we wish to obtain
optimal values of the cutting forces and a better surface integrity while maintaining the required surface finish. Experiments
were conducted following Taguchi’s parameter design approach using a cubic boron nitride tool for the machining. The results
indicate that the process parameters affected the mean and variance of the cutting force at the Al-CI interface of the piston.
The Al-CI interface was examined using an ultrasonic piston bond tester after machining to assure the bond quality. The surface
roughness of the components was measured with a surface roughness tester. A mathematical model was developed using the Systat
12.0 software package to establish the relationship between the input quantities (speed, feed, and depth of cut) and the output
data (cutting force). The output data of the mathematical model were compared with the experimental results. The results from
the Taguchi robust design concept were compared with the results obtained from a nonconventional Genetic Algorithm optimization
technique. |
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Keywords: | 3D shape morphing Template mesh Implicit function Mesh smoothing Modified Laplacian coordinate |
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