Faculty Publications
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Item Modern manufacturing technology: Spotlight on future(CRC Press, 2021) Katiyar, J.K.; Sahu, R.K.Modern Manufacturing Technology: Spotlight on Future summarizes the emergence and development of modern manufacturing techniques (MMTs) with a focus on metallic and advanced material-based additive manufacturing technologies and their potential applications. Further, it explores advanced machining techniques for production of novel nanomaterials. The book also covers modern sophisticated techniques for the fabrication of ultrafine electronic devices such as micro-electromechanical systems (MEMS), nano-electromechanical systems (NEMS), semiconductors, and optical systems. A dedicated chapter on manufacturing technology for Industry 4.0 is included. Features: Describes the background of manufacturing techniques in brief including the advent of and introduction to MMTs Reviews various types of MMTs established in recent years and their accelerated growth and development innovation-driven applications Overviews the physical and chemical techniques used for nanomaterials production Explores the fabrication mechanisms of MEMS, NEMS, semiconductors and optical devices Provides a conceptual overview of additive manufacturing technologies This book is geared to undergraduate and postgraduate students and professionals in mechanical and manufacturing engineering, and the manufacturing industry. © 2022 Jitendra Kumar Katiyar and Ranjeet Kumar Sahu.Item State of the art on sustainable manufacturing using mono/hybrid nano-cutting fluids with minimum quantity lubrication(Taylor and Francis Ltd., 2022) Singh, V.; Sharma, A.K.; Sahu, R.K.; Katiyar, J.K.In machining operations, the application of cutting fluids has been of prime importance for the extraction of heat from rake surfaces, ease of removal of the chips and reduction of friction at the chip–tool interface. These three objectives are achieved by the supply of suitable conventional cutting fluid at the machining zone using different techniques. However, the misuse of these fluids and their wrong disposal methods were found to have an adverse effect on the environment and health of human. To reduce the usage of conventional cutting fluid, minimum quantity lubrication (MQL) technique has been emerged as an alternative means in the last few years, leading to better eco-friendly. Further, to increase the sustainability of MQL technique, it becomes necessary to use an appropriate exceptional nanostructured material with MQL that could be an effective cutting fluid (i.e. nanocutting fluids) with better tribological and thermophysical properties, and might be helpful in addressing the eco-friendly problem to a great extent. Therefore, the present paper focuses on the review of important published works related to the use of mono/hybrid nanocutting fluids with MQL technique at various processing parameters in different metal cutting operations. Most of the studies have shown a significant reduction in cutting forces, temperature at cutting zone, tool wear, and friction coefficient, and considerable improvement in surface quality by the addition of mono/hybrid nanoparticles enriched cutting fluid in MQL technique as compared to dry as well as wet machining processes. Further, the paper discusses the future scope in the area of hybrid nano-cutting fluids in different machining processes. © 2022 Taylor & Francis.Item Novel application of graphite-talc hybrid nanoparticle enriched cutting fluid in turning operation(Elsevier Ltd, 2021) Singh, V.; Sharma, A.K.; Sahu, R.K.; Katiyar, J.K.In this study, the influence of hybrid nanocutting fluid (both graphite and talc nanoparticles dispersed in a base fluid) in turning of Titanium alloy grade 5. The hybrid nanocutting fluid was developed by the blending of graphite and talc nanoparticles in a constant volumetric proportion (50:50) in pure coconut oil as a base fluid. The prepared hybrid nanocutting fluid has been investigated for its tribological behaviour using a pin-on-disc machine. The Gray relational analysis (GRA) is applied as a conservative approach in the optimization of process variables of Titanium alloy with multiple performance characteristics. The turning performance of the hybrid nanocutting fluid is compared with that of pure coconut oil in terms of cutting force and surface roughness. From the Gray relational grade analysis, it is obtained that the feed rate has a larger influence on responses as compared to cutting speed and nanoparticle concentration as well. By the application of hybrid nanocutting fluid, it is obtained a significant reduction in cutting force and surface roughness compared to pure coconut oil by 21.19 % and 18.9 %, respectively. © 2020 The Society of Manufacturing EngineersItem Mechanical properties of MWCNTs and graphene nanoparticles modified glass fibre-reinforced polymer nanocomposite(Springer, 2021) Seshaiah, S.; Reddy, K.V.K.; Sahu, R.K.; Katiyar, J.K.In the present study, the multi-walled carbon nanotubes (MWCNTs) and graphene nanoparticles were used as a reinforcement to fabricate glass fibre polymer composite at different orientations (unidirectional glass fibres 0° and 90°; woven glass fibres 0°/90° and 45°/45°). The composites were developed using hand lay-up-assisted vacuum bagging method at 1 torr pressure. The concentrations of nanoparticles (~diameter 5–20 nm) were varied in the range of 0.1–0.3 wt% in the matrix. The mechanical properties like impact strength, tensile strength and fatigue strength were carried out on Izod and Charpy machine, universal testing machine and computer-controlled machine under sinusoidal wave, respectively. It is observed that the glass fibre/epoxy composite blended with MWCNTs/graphene by 0.2 wt% has shown higher fatigue life by 56%, higher tensile strength by 36% and higher capability of energy absorption by 927.7% in notched type and lower capability of energy absorption by 155.43% in un-notched type, as compared to pure composite. The increment in properties is due to the better bonding between fillers and matrix. However, the increase of MWCNTs and graphene nanoparticles by wt% in composite laminates have shown lower fatigue strength because of the agglomeration of MWCNTs particles in matrix that caused the propagation of fatigue cracks under cyclic loading. Further, the damage behaviour of composite materials was analysed using scanning electron microscopy. It is found that a different damage behaviour in each composite is observed which is attributed to the matrix cracking, fibre rupture, fibre pullout, fibre split and fibre de-bonding. © 2021, Indian Academy of Sciences.Item Multi-response optimization and effect of tool rotation on micromachining of PMMA using an in-house developed µ-ECDM system(Elsevier Ltd, 2022) Bhargav, K.V.J.; Balaji, P.S.; Sahu, R.K.; Katiyar, J.K.Poly-methyl methacrylate (PMMA) is a lightweight and transparent thermoplastic material which is commonly used as an alternative for high-cost and resilient glass. PMMA has potential applications in the fields of microfluidics because of its high strength, low weight, optical transparency, and biocompatibility. Therefore, in this study, in-depth experimentation was carried out to generate microchannels on PMMA using an in-house developed micro Electrochemical Discharge Machining (µ-ECDM) system. The µ-ECDM process parameters used for the experimentation include voltage (V), electrolyte concentration (wt%), and duty factor (DF) (%). Experiments were designed at three levels of process parameters for the parametric study. The microchannels were machined on a 2.5 mm thick PMMA workpiece using a titanium tool of diameter 0.7 mm. The optical microscope images, along with SEM images, are used to characterize the machined channels. The machining characteristics such as material removal rate (MRR), tool wear rate (TWR), channel width, surface roughness (SR), and depth of the channel were studied using the process parameters. Individual response optimization is carried out using S/N ratios, but confounding of factors at different factor level settings is observed for each response. Therefore, to overcome this problem, multi-response optimization using the JAYA algorithm coupled with the multi-attributed decision-making (MADM) R-method has been adopted for maximizing MRR and depth of the channel and minimizing TWR, channel width, and surface roughness at single factor level settings. The optimal process parameters are obtained by multi-response optimization are 51 V, 24 wt%, and 55% DF, and the MRR, TWR, channel width, surface roughness, and depth of the channel are found to be 21.5 µg/min, 5.5 µg/min and 804.33 µm, 5.2412 µm, and 238.22 µm, respectively that are in close pact with the predicted observations. Further, the optimal machining parameters have been used along with tool rotation (in RPM) to observe the effect on machining features. The findings show that with increment in tool rotation rate improved the MRR, TWR, and depth of the channel decreased the channel width and surface roughness. © 2022 CIRPItem Exemplary approach using tool rotation-assisted µ-ECDM for CFRP composites machining(Taylor and Francis Ltd., 2023) Bhargav, K.V.J.; Balaji, P.S.; Sahu, R.K.; Katiyar, J.K.Carbon fiber-reinforced polymer (CFRP) composites are an advanced composite material class due to their remarkable properties such as high load-carrying capacity and low density. CFRP composites have enormous applications in aerospace, biomedical, automobile, etc. Machining the CFRP composite is need of the day, but issues like delamination, fiber pullouts, workpiece damage, etc. have made it difficult. These limitations can be surpassed by the micro-electrochemical corona discharge machining (µ-ECDM) process. Although the process has showcased high process capability and great versatility in machining conducting and non-conducting materials, the process has limitations in machining holes deeper than 300 µm because of insufficient electrolyte supply at the machining zone. Aiding assistance to the process can overcome the limitation by enhancing electrolyte availability. Therefore, an experimental analysis is carried out by generating through holes on the CFRP composite using a tailor-made rotating tool-assisted micro-electrochemical corona discharge machining (RT-µ-ECDM) system. The process parameters, voltage, concentration, duty factor, and tool rotation rate are taken at three levels. The materials removal rate and overcut as machining characteristics were analyzed. The multi-response optimization using JAYA algorithm and R-method is used to obtain the optimal process parameters. The experimental investigation suggests RT-µ-ECDM system can machine through holes on CFRP composite. © 2022 Taylor & Francis.Item Optimisation of process parameters for dimensional stability in FDM(SAGE Publications Ltd, 2023) Sahu, J.K.; Sahu, R.K.; Katiyar, J.K.; Kiran, P.S.The fused deposition modelling (FDM) technique has been adopted in the present work to fabricate Acrylonitrile Butadiene Styrene (ABS) plastic components using input variables like layer thickness, orientation, infill rate and the number of shells. The dimensional geometrical changes of FDM printed built parts, that is, length, width and thickness variation, are optimised individually. Still, a confounding effect is found in the optimisation of individual responses. To overcome this issue, this study uses a fuzzy inference system as an artificially intelligent system. A fuzzy inference system transformed all the responses into one response, known as a multi-response performance index (MPI), and optimised the MPI coupled with Taguchi philosophy. The optimal parameter combination of FDM-printed ABS components for the slightest variation in length, width, and thickness was found to be layer thickness: 200 µm, orientation: 0°, infill rate: 20%,and the number of shells: 3. The significant parametric effect on the responses of FDM components was studied using analysis of variance, and the results reveal that orientation is the most influential parameter trailed by infill rate and the number of shells. © IMechE 2023.