Faculty Publications
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Item Parametric Analysis and Response Surface Optimization of Surface Roughness and Cutting Rate in the Machining Using WEDM(Springer Science and Business Media Deutschland GmbH, 2022) Manoj, I.V.; Narendranath, S.Nickelvac HX is an amalgamation of nickel, chromium, iron, molybdenum etc. As nickel-based alloys have high-temperature strength they can be used in many applications like afterburners, blades of turbines, turbocharges, submarines parts etc. Wire electric discharge machining a non-contact spark machining was found to be the most precise machining process. Among the WEDM parameters, different process parameters like servo voltage, pulse on time, cutting speed override and pulse off time were employed for the examination. It was noticed that both response characteristics increased with the increase in cutting speed override and pulse on-time. In the case of servo voltage and pulse off time, as it was increased the cutting rate and surface roughness diminished. The effects of cutting rate on surface roughness and microhardness were analyzed. The response surface optimization was employed for optimizing surface roughness and cutting rate as it controls product quality. © 2022, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.Item Variation and artificial neural network prediction of profile areas during slant type taper profiling of triangle at different machining parameters on Hastelloy X by wire electric discharge machining(SAGE Publications Ltd, 2020) Manoj, I.V.; Narendranath, S.In the present research work, an in-house developed fixture is used to achieve taper profiles which avoids the disadvantages in convention tapering operation in wire electric discharge machining like wire bend, inaccuracies in taper, insufficient flushing, guide wear etc. A simple triangular profile was machined at 0°, 15° and 30° slant/taper angles. These taper profile areas are investigated for various machining parameters like wire guide distance, corner dwell time, wire offset and cutting speed override. It is observed that as the wire guide distance and cutting speed override increases, the profile area decreases. Whereas in case of wire offset, as offset increases the profile areas also increase. The corner dwell time parameter do not effect on the profile area. The taper profile areas measured highest at 30° followed by 15° and 0° slant angles. This is due to the workpiece placed at different angles during machining with the aid of fixture to obtain taper profile. The taper angle represents the angularity of slant triangular profiles. As the slant angle increases the variation in taper error also increases due to higher wire vibration. An artificial neural network model is developed for the prediction of these areas at a different slant angle. The model is validated experimentally where the errors in prediction ranged from 1% to 9%. In conclusion, it can be noticed that the machining parameters and slant angle influence on profiles irrespective of their dimensions. © IMechE 2020.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 Artificial neural network-based prediction assessment of wire electric discharge machining parameters for smart manufacturing(De Gruyter Open Ltd, 2023) Manoj, I.V.; Narendranath, S.; Mashinini, P.M.; Soni, H.; Rab, S.; Ahmad, S.; Hayat, A.Artificial intelligence (AI), robotics, cybersecurity, the Industrial Internet of Things, and blockchain are some of the technologies and solutions that are combined to produce "smart manufacturing,"which is used to optimize manufacturing processes by creating and/or accepting data. In manufacturing, spark erosion technique such as wire electric discharge machining (WEDM) is a process that machines different hard-to-cut alloys. It is regarded as the solution for cutting intricate parts and materials that are resistant to conventional machining techniques or are required by design. In the present study, holes of different radii, i.e. 1, 3, and 5 mm, have been cut on Nickelvac-HX. Tapering in WEDM is a delicate process to avoid disadvantages such as wire break, wire bend, wire friction, guide wear, and insufficient flushing. Taper angles viz. 0°, 15°, and 30° were obtained from a unique fixture to get holes at different angles. The study also shows the influence of taper angles on the part geometry and area of the holes. Next, the artificial neural network (ANN) technique is implemented for the parametric result prediction. The findings were in good agreement with the experimental data, supporting the viability of the ANN approach for the evaluation of the manufacturing process. The findings in this research provide as a reference to the potential of AI-based assessment in smart manufacturing processes and as a design tool in many manufacturing-related fields. © 2023 the author(s), published by De Gruyter.