Journal of Modern Mechanical Systems and Machining ISSN: 3139-5066 (Online)

Auhtors:- Ganesh Singh Keshav, Lalit Singh

Abstract:- Systems for virtual manufacturing provide a practical way to produce goods "right the first time" without the requirement for actual shop floor testing. An earlier focus of study was creating a virtual manufacturing environment. Simple graphical modeling and prediction made way for complicated multi-science forecasts throughout time. To assist virtual manufacturing, virtual systems including virtual machine tools, virtual machining, virtual assembly, virtual tooling, and virtual prototypes have been created. Different methods and techniques have various intended uses. This paper seeks to offer a thorough analysis of current virtual systems. In order to improve the accuracy and productivity of part manufacture, actual machining processes can be examined and adjusted in virtual settings. Therefore, it is possible to obtain greater added value in component manufacturing by studying and then altering the real machining processes that are being used using virtual machining systems.

Keywords:- Virtual Machining, Accuracy Of The Parts Produced, Machine Tools.

Authors:- Purshotam Sharma, Vishal Saxsena

Abstract:- Automobiles are one of the finest inventions, however as technology advances, it also has some negative consequences on the environment. This work is based on a theoretical analysis of the influence of transportation on the environment. It will help us understand the environmental effect of automobiles. This will assist to comprehend the breadth of pollution done by automobiles and their harmful consequences on human and animal. This document discusses how to reduce automobile pollution and protect yourself against pollution. In this work, we attempt to investigate the numerous issues associated with automobile fuel combustion. Environmental contamination is highlighted in this article. This study discusses noise and air pollution.

Keywords:- Vibrations, particulate matters, GHG’s, air quality.

Authors:- Dr. Rakhi Prajapati, Sanjay Gehlot

Abstract:- Tungsten inert gas (TIG) welding is a metal joining procedure. This technique has been in use for over 25 years because of its advantages, such as less heat required, a small arc, efficient production, a small thermally affected area, and environmental friendliness. Tungsten inert gas welding is used to unite various ferrous and non-ferrous metals that cannot be welded using traditional welding methods. While joining metal, many welding procedures were employed, as well as readings such as current, voltage, wire feed rate, speed, nozzle distance, torch angle, and gas flow rate. Several strategies, including regression approaches, the Taguchi strategy, and statistical procedures, were used to improve welding readings, according to the findings. In this work, we investigated all aspects relating to progress in welding quality and strength.

Keywords:- mild steel, taguchi method, but joint, TIG welding, parameter, tensile test

Authors:- Dr. A. Harini, V. Gayathri

Abstract:- Using a sprocket and chain or gear system, power can be generated by a person cycling. Since many years ago, peddling by human power has been utilised frequently in bicycles. A few examples of applications for this idea include pedal-powered water wells, grinders, and electricity generation. Here, the fundamental idea is that pedalling is transformed into circular motion. In modern society, washing clothes is one of the most common routine tasks performed by the human population. Because it requires human labour, time, and expense in a water environment, this normal task is more painful. The goal of the current study is to create a nonelectric washing machine (NEWM) that can accommodate the needs of the majority of the population in any given nation. This machine's mechanism and its working principle are practically identical. The primary goal of the current Endeavour was to create inexpensive initial and operating cost machinery that could be used in places without access to electricity.

Keywords:- turbulent flow, gear system, electricity, Pedal power, washing machine, foot pedal, nonelectric mechanism,

Authors:- Atul Pandey , Ashutosh Merhra 

Abstract:- Technology's benefits have skyrocketed in recent years, and everything seen around us is a result of its contributions. As a result, staying current with technology is a requirement of modern science. The more automated the procedures, the more current the technology. This article describes the design and construction of a low-cost, flexible, and secure polythene bag sealer based on automation. This article will look at the automation function, sealing mechanism, and system integration of an automated filler, robotic hand, and conveyor. This system's aim is to provide polythene bags via vacuum grippers and mechanically seal these bags, therefore the name "automated sealer." The parts utilized in this system are functioning well, and the strength of the sealing has been verified by hanging a dead weight with the polythene bag. If enough resources and investment are put behind this procedure, it will be feasible to build the necessary equipment and make it suitable for usage in the industry.

Keywords:- Sealing, Automation Low cost, flexible and secure operation

Authors:- Suman Rai, Anu Pathak, Alka Singh

Abstract:- Embossing is traditionally done by hand in various manufacturing industries, employing a jig and fixture. Mechanical, pneumatic, or hydraulic machines are used for embossing. These machines are more expensive to manufacture, install, and maintain, and their operating costs are also higher. This machine is defeated by an electromagnetic embossing machine. To create forces, we propose an embossing machine with an electromagnetic coil coiled around a metal core. The goal of this endeavour is to create a machine that can aid in decreasing human effort. This machine will meet the fundamental demands of the industries at a low cost, with simple installation and better operator safety and precision.

Keywords:- Iron core, embossing, and electromagnet

Author :- Nemailal Tarafder

Abstract:- It is clear that clothing is the key to body comfort. Comfort is difficult to define since it covers both quantifiable data and subjective characteristics. The highly competitive world of sports have increased awareness among the professional sports persons who use to demand more specific functions to be performed  by sportswear in real time to increase their efficiency. Because of increasing interests and participation in sports and leisure activities, the consumption of sports goods and equipment and attendant, consumption of textiles in such goods and equipment has already shown steady growth. Non-woven textiles in the indoor environment can contribute to the amount of space and visual privacy being used as free standing constructions that divide the indoor space into smaller areas. Textile products contribute to the athletes in terms of safety and performance in many types of sports, especially in outdoor sports. The three different types of sportswear fabrics were tested to observe the influence on the physiological response and performance of volunteers in sports conditions was investigated. The use of high tech textile materials in sports is nothing new. In recent years, some fabrics and designs have been observed that can quickly remove moisture from the body meaning it absorbs sweat faster and dries the skin. Consumer spending has been restrained in many parts of the world, demand has buoyed by sharp increase in disposable income in key economics in the developing world, along with the major advances in fabric technology. Sports composites usage in India includes boxing equipment, inflatable balls and protective equipment for cricket. The sportswear and sports goods sector of the textile industry has seen market diversification for fibrous materials and has also contributed toward the elevation of textile science and technology to a level approaching that of other high-tech industrial sectors.

Keywords:-  Engineered fibres, Polymeric coating, Artificial Turf, Floor coverings, Professional athletes, Physiological response

Authors:- Sahil Sanjay Chougule, Aman Yakub Mundangur, Sudesh Dagadu Mane,Milind Sagar Kognole, R.R. Kapse

Abstract:- This study developed a compact front loading machine for slicing loaves of bread. The machine is fast, efficient, safe and easy to operate. It was designed to accommodate a normal loaf of bread per pass. It works on the principle of gravity loaf in-feed system and the up-and-down reciprocating motion of the blade frame that carries 22 parallel cutting blades spaced at a regular interval of 14.5 mm apart. It is driven by a 2 horsepower electric motor via a V-belt power transmission system. The moving components are born on self-lubricating bearings and specially designed vibration absorbers; it automatically stops to save running cost once the loaf is completely sliced. It also incorporates a crumb collection tray to enhance the hygiene of the process. Evaluation tests revealed that increasing the cutting speed above the standard commercial bakery speed of 420 r/min increased bread wastage and reduced uniformity of slice thickness.

Keywords:- Machine, Bread Slicer, Slicer, Electric motor

Abstract

Engineering design has traditionally relied on expert knowledge, heuristics, and trial-and-error approaches. However, the rapid growth of data from sensors, simulations, and design software has paved the way for data-driven decision support in engineering design. Data-driven methods leverage statistical models, machine learning, and computational intelligence to assist engineers in making informed decisions, improving product quality, reducing design cycles, and optimizing resources. This paper provides a comprehensive review of data-driven decision support in engineering design, discussing methodologies, tools, applications, and challenges. Emphasis is placed on predictive modeling, optimization, and integration with computer-aided design (CAD) and manufacturing systems. Case studies demonstrate practical implementations, and potential future directions are outlined.

Keywords: Data-driven design, decision support system, engineering design, predictive modeling, optimization, machine learning, CAD integration

Author: Juhi Rawat, Babita Singh

Abstract: The sun drier has been carefully designed and tested for its efficacy in drying tomato slices. The dryer's loading capacity was around 10 kg slices each batch. The dryer's drying qualities were investigated and compared to the open sun drying technique. The maximum temperature reached in the dryer's drying chamber was 52.63°C. The drying time for tomato slices in stated solar dryer was 12.5 h from beginning moisture content of 94 percent (wb) to final moisture content of 8.97 percent (wb), whereas 15 h was observed in open sun drying. The powder made from tomato slices dried in the solar panel drier exhibited a dark red colour when compared to the powder made from open sun-dried tomato slices. The gravel with iron scrap heat storage system was seen to provide heat to the drying chamber for an additional three hours after dark. As a result, the prolonged 3 hours after the sun set made it possible to finish drying in a single day.

Keywords: Solar cabinet dryer, heat storage system, flat plate solar air heater

Author: Srishti Sharma, Parul Saxena

Abstract: A beach dust collector is a machine that collects waste items from beach sand so that it may be cleaned. These devices are tracked or wheeled manual vehicles that are hauled by a quad bike or tractor. Beach cleaning devices are employed by seaside communities to combat pollution at the beach. One of the most significant things that should be focused on for future cleaning is dust cleaning on beaches. As a result of the effort, a gadget that collects dust from the beach was developed, and it has a basic design. Cleaning of beach sand is done here with the use of mechanical machinery such as a chain conveyor and gears, which produce superior results.

Keywords: Dust Collector, Waste, Machine, Conveyor, Gears

Author: Sunil Chauhan, Vijay Pratap, Dr. Sudeep Bhonsle

Abstract: The current study proposed a comparison of different parameters such as dry bulb temperature (DBT), turbine power (TP), generator power (GP), and specific fuel consumption (SFC). The current work also includes a detailed comparison of the variation of characteristic parameters for a simple cycle gas turbine and an absorption cooling technique. Transient simulation is used to analyse the performance characteristics for the above comparison for a typical metrological year (TMY).

Keywords: Turbine Inlet Cooling, Transient Assessment, Absorption Chiller

Author: Pratiksha Nagtode, Mahesh Gharde

Abstract: Faults in machinery due to vibration are of great concern in the engineering sector. Due to the nonlinear features of damping and mass of composite patching under dynamic settings, the repairing efficiencies cannot be determined directly from a frequency standpoint. Cracks can form as a result of manufacturing process flaws or mechanical flaws. A mechanical structural crack is caused by mechanical accidents, fatigue, and environmental impacts. Composite materials are harmed as a result of mechanical loads and environmental conditions. For this reason bonded composite repair are often preferred. They offer improved stress transfer mechanisms, as well as increased joint efficiency and aerodynamic performance. The use of advanced composites in primary and secondary aerospace structural components is on the rise these days. To recover damaged composite components, it is critical to have dependable, strong, and reproducible structural bonded repair techniques. But this procedure has significant scientific hurdles with the present existent repair methods. The dimensions of the composite patch were selectively stretched along the platform dimensions (x and y) in order to optimise the patching shape.

Keywords: Composite material, Repair, Machinery, Crack, Cantilever beam

Abstract

Artificial Intelligence (AI) is increasingly transforming the product design and manufacturing landscape. Integrating AI into product design enables enhanced innovation, faster prototyping, and reduced development cycles, while quality optimization ensures that the final product meets customer expectations and industrial standards. This paper reviews current trends, tools, and methodologies in AI-assisted product design, including generative design, machine learning-based material selection, and simulation-driven optimization. Additionally, it highlights quality optimization techniques such as predictive maintenance, defect detection, and process parameter tuning. Case studies, conceptual tables, and figures illustrate practical applications. The paper aims to provide insights into how AI can be leveraged for efficient product design and quality enhancement in small-to-medium manufacturing setups.

Keywords: Artificial Intelligence, Product Design, Quality Optimization, Generative Design, Machine Learning, Predictive Maintenance, Process Optimization

Abstract

Centrifugal pumps are widely utilised in a variety of sectors for a variety of applications. Because the blade intake or outlet angle affects the pump's performance, vibrations are a factor. By changing the geometric features of the impeller of the pumps, the performance of centrifugal pumps may be enhanced. The blade exit angle has a significant impact on centrifugal pump performance. The blade exit angle is the primary source of vibration. The blade rotates according to its inherent frequency and mode shapes. A single entry impeller with radial vanes was chosen for the research. Modeling and simulation of the impeller were carried out using Creo 4.0 and ANSYS Workbench software. Using eigenvalues and eigenvectors, the relative frequencies and associated mode forms of the impeller were determined. The results revealed that changing the impeller blade exit angle had a substantial impact on the impeller's natural frequency.

Keywords: Ansys, Workbench software, Impeller, Centrifugal force, Vibration

Authors:-Harish Kumar, Akshat Jain , K.B. Anand

Abstract:-As the name indicates the idea of this paper is that the Fan will be shift from one location to another location as per the user’s need. In short we can say that Fan is travelling on ceiling as per the user’s expectation. The working principle of the mechanism is to convert rotary motion into linear motion by using rack and pinion. It provides the air at all the locations of the room. There is no need to sitting in room according to fan. The person who is sitting away from the fan & wants the air without moving from there can easily do it. It also replaces the quantity of fans which are not necessary in a room. It provides the air at all the locations of the room. There is no need to sitting in room according to fan. The person who is sitting away from the fan & wants the air without moving from there can easily do it. It also replaces the quantity of fans which are not necessary in a room.

Keywords:-Ceiling Fan, rotary motion, sliding

Authors: Anil Kaushal, Prof. Bhupendra Kumar Pandey

Abstract: In India there are several rituals river where India’s people clean their cloths and bath daily and leave some waste. On the festivals like Durga pooja, Ganesh Chathurthi, Chatthpooja, their statues and discharge waste is immersed in these rivers or lakes by which plastic waste floats on the surface of water. This polluted water destroys the lives of aquatic insects and nearby resident people. Human lives suffer by such type of diseases like Cholera, Diarrhoea, Dysentery, hepatitis etc. As there are also conventional machines available in the market have high cost and not so much effective cleaning water is our main purpose. The conventional machine which can be operated through mobile phone from a long distance and can easily remove waste material from the surface of water is made up of DC motors, PVC pipes, propeller, conveyor, NODE MCU, Battery. Conveyor attach to DC motors for collecting garbage waste from water.

Keywords: Waste Removal Machine, DC motors, clean water, Conveyor

 

Authors: Bhushan S. More, Pravin Mane, Niraj Sarda, Suyog Mahajan

Abstract:A way to increase the efficiency of a non-positive air compressor is to spray the lubrication oil to use it not only as a lubricant and roofing agent but also as a performance enhancer. The importance of economic exploitation of resources has brought about the need for integrated and efficient systems. In this paper to use Optimum oil used for compressor, thin wear and tear between contacts, improve compressor efficiency by increasing oil quality (according to NAS Theory) by using different filters.

Keywords: - Screw compressor, NAS Theory, Filters

Abstract

The increasing demand for high-precision manufacturing of complex freeform surfaces in aerospace, automotive, and biomedical industries has necessitated the development of advanced toolpath optimization methods. Traditional toolpath generation often compromises surface quality and machining efficiency due to topological inconsistencies and redundant tool motions. This paper presents a comprehensive review of topology preserving toolpath optimization techniques, which maintain the geometric and topological integrity of freeform surfaces while minimizing machining time, tool wear, and errors. The study discusses key algorithms, including iso-parametric, iso planar, and adaptive slicing strategies, along with topology-aware path planning methods. Case studies and simulation results demonstrate significant improvements in machining accuracy and efficiency. Challenges in implementation and future research directions are also highlighted.

Keywords: Toolpath optimization, freeform surfaces, topology preservation, CNC machining, adaptive slicing, surface integrity, path planning.

Abstract

Tool wear and unexpected tool failure are major issues in modern machining industries because they directly affect product quality, machining cost, and machine downtime. Traditional tool inspection methods depend mostly on manual checking or scheduled tool replacement which is not always efficient and can lead to unnecessary cost. Tool Condition Monitoring (TCM) has emerged as an important solution for predicting tool wear and detecting tool failure during machining operations. With the advancement of sensors, data acquisition systems and artificial intelligence, machine learning based monitoring methods are widely used. Sensor fusion further improves monitoring accuracy by combining signals from multiple sensors such as vibration, acoustic emission, cutting force and temperature. This paper reviews the concept of Tool Condition Monitoring using Machine Learning and Sensor Fusion techniques. It discusses the working principle, different sensors used for monitoring, data processing techniques and machine learning algorithms applied in TCM systems. The paper also highlights benefits, challenges and future research directions in this field. The study shows that integrating multiple sensors with machine learning models can significantly improve tool wear prediction accuracy and machining process reliability. However, challenges such as data quality, sensor noise, and model generalization still exist and require further research. 

Keywords: Tool Condition Monitoring, Machine Learning, Sensor Fusion, Tool Wear Prediction, Smart Manufacturing, CNC Machining

Abstract In modern manufacturing industries, sustainability has become an important concern due to increasing environmental regulations and the need to reduce resource consumption. Conventional machining processes generally use large amount of cutting fluids for cooling and lubrication. These fluids help to improve tool life and surface finish but they also create environmental pollution, health hazards for workers and high disposal cost. Therefore industries are looking for alternative machining techniques that can reduce or eliminate the use of conventional cutting fluids. Sustainable machining is an approach that aims to minimize environmental impact while maintaining machining performance and productivity. One of the most promising techniques is Minimum Quantity Lubrication (MQL), where only a small amount of lubricant is supplied directly to the cutting zone in the form of mist or aerosol. Another approach is the use of eco-friendly coolants such as biodegradable oils, vegetable based lubricants and water-based solutions that are less harmful to environment. This paper presents a detailed review of sustainable machining practices with focus on Minimum Quantity Lubrication and eco-friendly coolants. The principles, working mechanism, advantages, limitations and applications of these technologies are discussed. The effect of MQL and green coolants on tool wear, surface finish, cutting temperature and machining efficiency is also analysed. Various research studies indicate that MQL combined with biodegradable lubricants can significantly reduce cutting fluid consumption while maintaining good machining performance. Sustainable machining techniques are expected to play a major role in future manufacturing systems where environmental protection and resource efficiency will become more important.

Keywords: Sustainable machining, Minimum Quantity Lubrication, Eco friendly coolants, Green manufacturing, Cutting fluids, Environmentally conscious machining.

Abstract

Modern manufacturing industries are facing continuous changes in product design, demand variation and shorter product life cycles. Traditional machine tools are usually designed for specific tasks and they do not easily adapt to these changes. Because of this limitation, manufacturers are looking for more flexible solutions in production systems. Reconfigurable Machine Tools (RMTs) are one of the important technologies developed to support flexible manufacturing lines. These machines can be rapidly adjusted in structure, functionality and capacity according to the production requirements. The concept of reconfigurable machine tools focuses on modular design, scalability and convertibility which allow machines to change their configuration for different machining operations. This approach reduces production cost, increases productivity and improves manufacturing efficiency. RMTs are widely used in industries where product variety and demand fluctuations are common, such as automotive, aerospace and electronics manufacturing. This paper reviews the concept, design principles and architecture of reconfigurable machine tools used in flexible manufacturing lines. It also discusses important components such as modular structures, control systems, tooling arrangements and machine configurations. Advantages, challenges and industrial applications of RMTs are also presented. The study shows that reconfigurable machine tools can significantly improve manufacturing flexibility and help industries respond quickly to changing market demands.

Keywords: Reconfigurable Machine Tools, Flexible Manufacturing Systems, Modular Design, Manufacturing Flexibility, Smart Manufacturing

Abstract

Predictive maintenance has become an important strategy in modern manufacturing systems. Traditional maintenance practices such as corrective maintenance and preventive maintenance often lead to unnecessary downtime or unexpected machine failures. With the development of machine learning and industrial data collection systems, predictive maintenance algorithms are now widely used to predict equipment failures before they occur. These algorithms analyze historical and real time data obtained from sensors, machines and production systems to estimate the health condition of equipment. Machine learning techniques such as regression models, neural networks, decision trees and support vector machines help in identifying patterns related to machine degradation. This paper presents a review of predictive maintenance algorithms using machine learning techniques. The study discusses data acquisition methods, data preprocessing, different machine learning algorithms used for failure prediction and their applications in industrial environments. Advantages and limitations of these algorithms are also analyzed. Some examples of industrial implementations are discussed to show how predictive maintenance improves equipment reliability, reduces operational cost and increases production efficiency. The paper also includes tables summarizing different algorithms and their characteristics. Finally, future research directions are presented for improving predictive maintenance systems in smart manufacturing environments.

Keywords: Predictive maintenance, Machine learning, Industrial data analytics, Failure prediction, Smart manufacturing

Abstract

Machining automation is evolving rapidly, driven by the need for higher precision, flexibility, and efficiency in modern manufacturing. The integration of Robot Operating System (ROS) with real-time control systems presents a promising approach to enhance automation in machining processes. ROS provides a flexible software framework for robot programming and communication, while real-time control ensures deterministic execution of machining operations. This paper reviews the current state of research on integrating ROS with real-time controls, discusses various architectures and approaches, and highlights challenges and future directions. Experimental results and case studies indicate that the combination of ROS and real-time controllers improves accuracy, responsiveness, and system modularity in machining automation.

Keywords: Machining Automation, Robot Operating System, Real-Time Control, CNC, ROS Integration, Industrial Robotics, Mechatronics

Abstract

Manufacturing industries are continuously evolving to meet the demands of complex geometries, high precision, and reduced production time. Traditional manufacturing processes are mainly categorized into additive manufacturing (AM) and subtractive manufacturing (SM). Additive manufacturing builds components layer by layer, while subtractive manufacturing removes material from a solid workpiece using cutting tools. Each process has its own advantages and limitations. Hybrid manufacturing processes that combine additive and subtractive machining have emerged as an effective solution to overcome these limitations. Hybrid systems integrate the flexibility of additive manufacturing with the accuracy and surface quality of subtractive machining. This paper reviews the concept, technologies, advantages, challenges, and applications of hybrid subtractive additive machining processes. Different hybrid manufacturing systems such as Directed Energy Deposition (DED) combined with CNC machining, Laser Metal Deposition with milling, and hybrid additive-subtractive machines are discussed. The review also highlights the role of digital technologies and Industry 4.0 in enabling these integrated processes. Although hybrid manufacturing has great potential, challenges such as process control, cost, and machine complexity still exist. Future developments in automation, artificial intelligence, and digital twin technologies are expected to further enhance the capability of hybrid manufacturing systems.

Keywords: Hybrid Manufacturing, Additive Manufacturing, Subtractive Machining, CNC Machining, Directed Energy Deposition, Industry 4.0