Faculty Publications
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Item Development of novel cutting tool with a micro-hole pattern on PCD insert in machining of titanium alloy(Elsevier Ltd, 2018) Rao, C.M.; Rao, S.S.; Herbert, M.A.The development of a novel cutting tool that had a micro-hole pattern on their rake and flank face of cutting tool surface has found wider potential in the field of manufacturing. Micro-hole pattern features on a tool rake face help in controlling the tribological characteristics of the cutting tool. Micro-holes with the different number of holes orientation, diameter and depth were fabricated using the advanced application of the electrical discharge super drilling machine with the view to assist lubricant penetration and retention. A comparative study has been conducted between micro-hole patterned Polycrystalline Diamond (PCD) cutting insert and the commercially available PCD cutting insert. The effect of micro-hole pattern on the machining of Titanium alloy (Ti-6Al-4 V) is investigated with the application of the Minimum Quantity Lubrication (MQL) method in turning operation. Vibration signals were captured in feed force direction and measured using the tri-axial accelerometer. The cutting temperature, tool-wear, and chip-morphology were measured with an infrared thermometer and Scanning Electron Microscope (SEM). It was found that micro-hole textured inserts reduced the friction on the rake face resulting in the decrease of vibration up to 30–50%. The cutting temperature, tool wear and surface roughness were reduced to 30%, 50% and 40%, respectively. The conical and helical chips were produced in micro pool lubrication system. The friction coefficient can be minimized at the tool-chip interface by using liquid lubrication method. There is no unfavourable effect on the performance of cutting tools having holes on the cutting tool surface. All these parameters led to the improvement in the tool life. © 2018Item Influence of slide burnishing process on the surface characteristics of precipitation hardenable steel(Springer Nature, 2021) Sachin, B.; Rao, C.M.; Naik, G.M.; Puneet, N.P.The surface integrity of the material is the predominant necessity of a component to perform efficiently in varying working conditions. To improve the surface integrity of the workpiece secondary finishing processes are being performed. This work attempts to propose a realistic cryogenic slide burnishing condition for improvement of the surface integrity. The slide burnishing was performed by a novel slide burnishing tool on 17–4 precipitation hardenable stainless steel. The experiment was designed based on a central composite design. Initially, the effect of control parameters on the output response was examined by experimental analysis based on the design of experiment. Analysis of variance was used to analyze the influence of the variables on the performance indices. The regression technique was used to develop an empirical model. Optimization of process parameters for finding minimum surface roughness and maximum surface hardness was achieved by a multi-objective genetic algorithm. The optimized solutions were validated by performing confirmation experiments. © 2021, The Author(s).