Faculty Publications

Now showing 1 - 3 of 3

Eco-friendly lightweight filament synthesis and mechanical characterization of additively manufactured closed cell foams
(Elsevier Ltd, 2019) Patil, B.; Bharath Kumar, B.R.; Bontha, S.; Balla, V.K.; Powar, S.; Hemanth Kumar, V.H.; Suresha, S.N.; Doddamani, M.
Environmentally pollutant fly ash cenospheres (hollow microballoons) are utilized with most widely consumed, relatively expensive high density polyethylene (HDPE) for developing lightweight eco-friendly filament for 3D printing of closed cell foams. Cenospheres (20, 40 and 60 by volume %) are blended with HDPE and subsequently extruded in filament to be used for 3D printing. Cenosphere/HDPE blends are studied for melt flow index (MFI) and rheological properties. MFI decreases with cenospheres addition. Complex viscosity, storage and loss modulus increase with filler loading. DSC results on the filament and printed samples reveal increasing crystallization temperature and decreasing crystallinity % with no appreciable change in peak melting temperature. Cooling rate variations exhibit crystallinity differences between the filament and the prints. CTE decreases with increasing cenosphere content resulting in lower thermal stresses and under diffusion of raster leading to non-warped prints. Micrography on freeze fractured filament and prints show cenospheres uniform distribution in HDPE. Intact cenospheres lower the foam density making it lightweight. Tensile tests are carried out on filaments and printed samples while flexural properties are investigated for 3D prints. Cenospheres addition resulted in improved tensile modulus and decreased filament strength. Tensile and flexural modulus of printed foams increases with filler content. Results are also compared with injection molded samples. Printed foams registered comparable tensile strength. Specific tensile modulus is noted to be increased with cenospheres loading implying weight saving potential of 3D printed foams. Property map reveals printed foams advantage over other fillers and HDPE composites synthesized through injection and compression molding. © 2019 Elsevier Ltd
Drilling parameter optimization of cenosphere/HDPE syntactic foam using CO2 laser
(Elsevier Ltd, 2022) Singh, S.; Yaragatti, N.; Doddamani, M.; Powar, S.; Zafar, S.
High-density polyethylene is a high-strength, and low-weight material system. Besides numerous applications in a variety of fields and products, its machining for generation of holes is rather difficult with traditional methods such as drilling as the process is not very conducive for composites due to associated damage. Hence, a non-contact material removal process such as laser machining provides an appealing, cost-effective, accurate, and fast alternative. For this study, the effect of the laser process controls key parameters such as laser power and laser speed on the cut surface integrity defined by surface roughness, kerf taper angle, and heat-affected zone of neat HDPE and HDPE with 60 wt% cenosphere was investigated and optimized using response surface methodology. Also, the machining operation was visualized using a Photron FASTCAM SA 1.1 high-speed camera to observe the effects of the high-intensity laser beam on specimens and to investigate the mechanism of laser machining. The optimum values for a defect-free cut surface (minimum surface roughness and low kerf taper angle) in neat HDPE comes out to be as laser power of 97.5 W and laser speed of 5 mm/s, with corresponding surface roughness and kerf taper angle of 54.304 μm and 0.152 degrees respectively and the optimum input values for HDPE with 60 wt% cenosphere are 102.126 W laser power and 5 mm/s laser speed, with corresponding surface roughness and kerf taper angle of 26.574 μm and 0.253 degrees. This study finds importance for the industrial and medical application to creates small size holes for mechanical joints such as rivets, bolts, and screws in assembly as low surface roughness and kerf width are always preferred as quality parameters in creating holes for industrial applications. © 2022
Buckling and free vibrations behaviour through differential quadrature method for foamed composites
(Elsevier B.V., 2023) Duryodhana, D.; Waddar, S.; Bonthu, D.; Jeyaraj, P.; Powar, S.; Doddamani, M.
The current work focuses on predicting the buckling and free vibration frequencies (fn) of cenosphere reinforced epoxy based syntactic foam beam under varying loads. Critical buckling loads (Ncr) and fn are predicted using the differential quadrature method (DQM). Ncr and fn have been calculated for beams of varying cenosphere volume fractions subjected to axial load under clamped-clamped (CC), clamped-simply (CS), simply-simply (SS), and clamped-free (CF) boundary conditions (BC′s). Upon increasing the cenosphere volume fraction, Ncr and fn of syntactic foam composites increases. These numerical outcomes are compared with the theoretical values evaluated through the Euler-Bernoulli hypothesis and further compared with experimental outcomes. Results are observed to be in precise agreement. The results of the DQM numerical analysis are given out for the different BC′s, aspect ratios, cenosphere volume fractions, and varying loads. It is perceived that depending on the BC′s, the type of axial varying loads and aspect ratios has a substantial effect on the Ncr and fn behaviour of the syntactic foam beams. A comparative study of the obtained results showed that the beam subjected to parabolic load under CC boundary conditions exhibited a higher buckling load. © 2023 The Authors

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