Faculty Publications
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Item Experimental Investigation and Parametric Optimization on Hole Quality Assessment During Drilling of CFRP/GFRP/Al Stacks(Springer, 2020) Janakiraman, A.; Pemmasani, S.; Sheth, S.; Kannan, C.; Balan, A.S.S.Carbon fiber/glass fiber-reinforced aluminum (Al) stacks are becoming predominant in the aerospace industries owing to their synergistic effect on numerous properties obtained by the combination of metal and composite material. This necessitates an investigation work to be performed on the machining characteristics of this special category of Al stacks. This research work focuses on studying the influence of cutting speed, feed rate and machining environment on thrust force, delamination and roughness of the finished surface of hybrid Al stacks. Dry, minimum quantity lubrication (MQL), and cryogenic environments are considered in this work. The impact of cutting speed on the responses is observed to be negligible in contrast to the feed rate. Moreover, the drilling under cryogenic environment is found to improve the surface finish and mitigated the delamination, while drilling under MQL environment minimized the thrust force. Regression models are also developed to determine the output responses. High-quality holes in aluminum stacks can be obtained under cryogenic conditions over other machining environments as revealed by multi-objective optimization. © 2020, The Institution of Engineers (India).Item Effect of Cryogenics-Assisted Low-Plasticity Burnishing on Laser-Clad Stellite 6 over SS420 Substrate(Springer, 2020) Anirudh, P.V.; Kumar, B.; Girish, G.; Shailesh, S.; Oyyaravelu, R.; Kannan, C.; Balan, A.S.S.The influence of modern additive manufacturing methods, especially from the direct energy deposition (DED) processes to the coat-like finished components, is crucial under present industrial circumstances. DED induces several traits like enhanced mechanical, thermal properties in shorter lead time, which extend their adaptation for diverse applications including aerospace and automobile industries. Among the several DED processes, laser cladding has been a prospect that explores various capabilities of improving the wear resistance of cobalt-chromium (Co-Cr)-based alloys. Rather than fabricating the complete component using expensive alloys, laser cladding has paved an approach to deposit particles possessing superior qualities over the conventional material. This research work attempts to evaluate the surface integrity of SS420 when cladded with Stellite 6. The vertical face milling is executed on the cladded component surface to facilitate either low-plasticity burnishing (LPB) or cryogenic burnishing (CB) as sequential post-treatment processes. The effects of these post-treatments on the surface and subsurface microhardness, surface topography and residual stress profiles are elaborated. Increased surface and subsurface microhardness, as well as improved residual stress profiles, are observed with CB over LPB-processed specimen samples. © 2020, ASM International.Item Effect of cryogenic grinding on fatigue life of additively manufactured maraging steel(MDPI AG, 2021) Balan, A.S.S.; Kannan, C.; Kumar, A.V.; Hariharan, H.; Pimenov, D.Y.; Giasin, K.; Nadolny, K.Additive manufacturing (AM) is replacing conventional manufacturing techniques due to its ability to manufacture complex structures with near?net shape and reduced material wastage. However, the poor surface integrity of the AM parts deteriorates the service life of the components. The AM parts should be subjected to post?processing treatment for improving surface integrity and fatigue life. In this research, maraging steel is printed using direct metal laser sintering (DMLS) process and the influence of grinding on the fatigue life of this additively manufactured material was investigated. For this purpose, the grinding experiments were performed under two different grinding environments such as dry and cryogenic conditions using a cubic boron nitride (CBN) grinding wheel. The results revealed that surface roughness could be reduced by about 87% under cryogenic condition over dry grinding. The fatigue tests carried out on the additive manufactured materials exposed a substantial increase of about 170% in their fatigue life when subjected to cryogenic grinding. © 2021 by the authors. Licensee MDPI, Basel, Switzerland.Item Numerical modelling and analytical comparison of delamination during cryogenic drilling of cfrp(MDPI, 2021) Balan, A.S.S.; Kannan, C.; Jain, K.; Chakraborty, S.; Joshi, S.; Rawat, K.; F Alsanie, W.F.; Thakur, V.K.Carbon-Fibre-Reinforced Polymers (CFRPs) have seen a steady rise in modern industrial applications due to their high strength-to-weight ratio and corrosion resistance. However, their potential is being hindered by delamination which is induced on them during machining operations. This has led to the adoption of new and innovative techniques like cryogenic-assisted machining which could potentially help reduce delamination. This study is aimed at investigating the effect of cryogenic conditions on achieving better hole quality with reduced delamination. In this paper, the numerical analysis of the drilling of CFRP composites is presented. Drilling tests were performed experimentally for validation purposes. The effects of cooling conditions and their subsequent effect on the thrust force and delamination were evaluated using ABAQUS/CAE. The numerical models and experimental results both demonstrated a significant reduction in the delamination factor in CFRP under cryogenic drilling conditions. © 2021 by the authors. Licensee MDPI, Basel, Switzerland.