Faculty Publications
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Publications by NITK Faculty
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Item Slant type taper profiling and prediction of profiling speed for a circular profile during in wire electric discharge machining using Hastelloy-X(SAGE Publications Ltd, 2021) Manoj, I.V.; Narendranath, S.Hastelloy-X a nickel-based alloy used in nozzles, flame holders, turbine blades, turbocharges, jet engine tailpipes, afterburner components etc. having complex tapering profiles. Wire electric discharge machining proves to be the most beneficial machining technique as it provides required accuracy for the components. In the present research, a slant type taper fixture is employed for achieving taper angles as convention tapering have many hindrances like wire bend, angular inaccuracy, guide wear, insufficient flushing and wire breakage etc. and machining a simple circular profile on Hastelloy-X. The behaviour of different output parameters like profiling speed, surface roughness, profile areas, microhardness and recast layer were investigated for various input parameters for machined taper components at 0°, 15° and 30°. The cutting speed override parameter influenced most on the profiling speed and surface roughness. The wire offset parameter was found to be the most significant factor in the case of circular profile areas that were machined. The variation of different output parameters to profiling/cutting speed and taper angle was also highlighted. It is found the recast layer decreased which indicated lesser thermal degradation at higher taper angles at different profiling parameters. This is also validated by the microhardness where the machined surface hardness of taper angular profiles was found to be greater than the 0° profiles. The artificial neural networks and adaptive neuro-fuzzy interference system were used for the prediction of profiling speed. The adaptive neuro-fuzzy interference system was found better in prediction as the percentage error varies between 0–5 per cent. In conclusion, the profiling speed influences both on the accuracy and surface of machined taper circular profiles. © IMechE 2021.Item Wire Electric Discharge Machining at Different Slant Angles during Slant Type Taper Profiling of Microfer 4722 Superalloy(Springer, 2022) Manoj, I.V.; Narendranath, S.Wire electric discharge machining (WEDM) is nonconventional machining that provides machining solutions irrespective of the material hardness. In the present study, a simple profile was machined on Microfer 4722 at different slant angles using to know the effect of machining parameters. A unique method of obtaining taper components was employed by slant type taper fixture to avoid the disadvantages of the conventional method. The profiling speed, profile roughness, profiling error (Corner error), recast layer thickness, micro-hardness, microstructural and metallurgical changes of the machined component were investigated. As the taper of the component increases the profile roughness, corner error increases although profiling speed decreases. It is observed that recast layer thickness decreases as the taper of the component increases. A contrasting phenomenon is observed in the case of hardness at the WEDM surface. The metallurgical changes like the addition of Cu, Zn and O in the nickel-based alloy after machining from WEDM at different slant angles are highlighted. It is observed that residual stress decreased as the slant angles increased from 0° to 30° during slant type profiling. © 2021, ASM International.Item Examination of Machining Parameters and Prediction of Cutting Velocity and Surface Roughness Using RSM and ANN Using WEDM of Altemp HX(Hindawi Limited, 2022) Manoj, I.V.; Soni, H.; Narendranath, S.; Mashinini, P.M.; Kara, F.The Altemp HX is a nickel-based superalloy having many applications in chemical, nuclear, aerospace, and marine industries. Machining such superalloys is challenging as it may cause both tool and surface damage. WEDM, a non-contact machining technique, can be employed in the machining of such alloys. In the present study, different input parameters which include pulse on time, wire span, and servo gap voltage were investigated. The cutting velocity, surface roughness, recast layer, and microhardness variations were examined on the WEDMed surface. The genetic algorithm was used to optimize the cutting velocity and surface roughness, thereby improving the overall quality of the product. The highest recast layer values were recorded as 25.8 μm, and the lowest microhardness was 170 HV. Response surface methodology and artificial neural network were employed for the prediction of cutting velocity and surface roughness. Artificial neural network prediction technique was the most efficient method for the prediction of response parameters as it predicted an error percentage lesser than 6%. © 2022 I. V. Manoj et al.Item Evaluation of WEDM performance characteristics and prediction of machining speed during taper square profiling on Hastelloy-X(Taylor and Francis Ltd., 2023) Manoj, I.V.; Narendranath, S.Hastelloy-X is one of the wrought nickel-base superalloy comprising of oxidation resistance and high-temperature strength. Wire electric discharge machining process is the favoured technique for precise component fabrication of such materials. Apart from precision the most essential aspect with surface integrity and cutting velocity in manufacturing. This investigation deals with the effects of cutting speed override, corner dwell time, wire guide distance and wire offset on taper profile response characteristics. The variation of these parameters is studied by machining a simple square profile at 0°, 15° and 30° taper angles. It is observed that as the taper angle gets increased, both the machined errors at corners and machined roughness increased although the machining speed gets reduced. The recast layer and micro-hardness are explored for the taper square profile components. It is observed that the recast layer thickness was least for 30° taper profiles indicating least thermal degradation which was validated by micro-hardness. It was established that in a machined profile, that corners possessed lower hardness than the edges. The micro-hardness of inner profile corners was found to be lower than outer profile corners. Adaptive neuro-fuzzy interference system is better prediction computing method having least error ranging from 0–4.89%. In conclusion, the machining speed and taper angle also contribute to the output characteristics in wire electric discharge taper profiling. © 2021 Engineers Australia.Item Performance of profile characteristics at different machining parameters during wire electric discharge slant type taper profiling on Nicrofer 4722(Inderscience Publishers, 2024) Manoj, I.V.; SannaYellappa, N.In the present study, a slant type taper fixture is employed to achieve taper machining by wire electric discharge machining. Machining parameters like wire distance between the guides (WD), wire offset (WO), corner-dwell time (CT) and cutting-speed override (CO) is used to produce tapered components at 0°, 15°, and 30° angles. It is observed that as the WD, CO and WO increases the profile roughness also increases. The profiling error (PE) increases with increasing WD and CO parameters due to the increase in wire lag phenomenon. However, the WO and CT parameters showed a decreasing effect on PE. There is a reduction observed in the recast layer thickness, as the taper angle increased. The apex of the triangular profile always tends to be shifted opposite to the wire direction of travel at 15° and 30° tapered components due to the electromagnetic force and decreased strength of the tapered corners. © © 2024 Inderscience Enterprises Ltd.