Faculty Publications
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Item Experimental evaluation of diamond burnishing for sustainable manufacturing(Institute of Physics Publishing helen.craven@iop.org, 2018) Sachin, B.; Narendranath, S.; Dupadu, D.Diamond burnishing is one of the most popular surface finishing technique used to achieve an excellent surface finish. The aim of the present study is to investigate the effect of process parameters in diamond burnishing of 17-4 PH stainless steel (PH SS) under cryogenic environment. The requirement of a sustainable environment for various machining processes urged to explore the importance of cryogenic burnishing over other cooling techniques. Surface modification was achieved by the application of liquid nitrogen (LN2) during diamond burnishing. The process parameters considered to reduce the surface roughness (Ra) and increase the surface hardness (H) are burnishing speed, burnishing feed and burnishing force. The diamond burnishing experiments were conducted based on the L9 orthogonal array. The significant parameters and the optimal level of each parameters were determined by using analysis of variance (ANOVA) and main effect plots respectively. Multi-response optimization has been carried out for cryogenic diamond burnishing of 17-4 PH stainless steel by using Taguchi's grey relation analysis (TGRA). From the TGRA, it was observed that at burnishing speed 73 m min-1, burnishing feed 0.048 mm/rev and burnishing force 150 N, improved diamond burnishing performance characteristics were obtained. An improvement in grey relation grade (GRG) was found to be 38.47%. Cryogenic diamond burnishing has led to modifications in the microstructure and also an improvement in the subsurface hardness of the material. © 2018 IOP Publishing Ltd.Item Sustainable diamond burnishing of 17-4 PH stainless steel for enhanced surface integrity and product performance by using a novel modified tool(Institute of Physics Publishing helen.craven@iop.org, 2019) Sachin, B.; Narendranath, S.; Dupadu, D.Amajor sustainability concern of manufacturing industries is indiscriminate use of lubrication, energy consumption, and allied cost. To avoid such kind of situation and to improve the product quality, sustainable manufacturing concept has been widely used. One of the popular technique is the use of Minimum Quantity Lubrication (MQL) as a working fluid to improve the product performance. Diamond burnishing underMQLenvironment is an exceptional technique to obtain the improved surface integrity of the material without affecting operator health and environmental aspects. In this work, the impact of control factors on the surface integrity characteristics namely surface roughness, surface topography, surface hardness, surface morphology, residual stress and subsurface hardness of 17-4PHstainless steel have been studied underMQLenvironment by using a novel modified tool. It was ensured that minimum surface roughness of 0.05 ?mand maximum surface hardness of 405HV had been achieved. Improved surface finish and surface hardness were obtained for a diamond sphere radius of 4mmand 3mmrespectively under optimal diamond burnishing conditions. The obtained investigational results confirm that a novel modified tool was successfully implemented to enhance the surface integrity characteristics under theMQLenvironment. © 2019 IOP Publishing Ltd.Item Effect of working parameters on the surface integrity in cryogenic diamond burnishing of 17-4 PH stainless steel with a novel diamond burnishing tool(Elsevier Ltd, 2019) Sachin, B.; S, N.; Dupadu, D.The productivity of the components is adversely affected by the poor surface integrity characteristics as a consequence of the generation of high temperature in the burnishing zone. The abundant use of conventional lubricants causes environmental pollution and health problems. To overcome these issues, cryogenic cooling has been used across the world to reduce the temperature generated in the burnishing zone. It is well known that most of the accidents which involve aero engines have revealed that the reason for this may be due to the failure of the first stage of compressor blades. Hence aerospace material, 17-4 precipitation hardenable (PH) stainless steel can be used in aero engines to minimize the failure occurring due to foreign object damage. In the present study, the effect of cryogenic diamond burnishing on the surface integrity characteristics such as surface roughness, surface hardness, surface morphology, surface topography, subsurface microhardness, and residual stress of 17-4 pH stainless steel have been investigated with a novel diamond burnishing tool and also it has been related to dry and minimum quantity lubrication (MQL) environments. From the experimental results of diamond burnishing process, surface roughness was observed to be reduced by 33%–50%, 34%–51% and 25%–40% in the cryogenic cooling environment in contrast with MQL and dry environments. Similarly, the surface hardness improvement in a cryogenic cooling environment was found to be 5%–7%, 6%–10%, and 6%–9%, in comparison with MQL and dry environments respectively. © 2019 The Society of Manufacturing EngineersItem Selection of optimal process parameters in sustainable diamond burnishing of 17-4 PH stainless steel(Springer Verlag service@springer.de, 2019) Sachin, B.; Narendranath, S.; Dupadu, D.Secondary finishing operations are the primary requirement of the manufacturing industries to achieve dimensional tolerance of the components. Burnishing is essentially a surface finishing operation usually performed after machining to achieve superfinishing. Diamond burnishing is one of the finest finishing technologies which has been conducted on any surface to attain mirror surface finish. The present work focuses on the development of a correlation model between the process parameters and the output responses while burnishing of 17-4 precipitation hardenable stainless steel using response surface methodology. A novel diamond burnishing tool has been used to analyze the influence of process parameters on output responses in the MQL environment. The control factors considered for the present study include burnishing speed, burnishing feed and burnishing force, and the corresponding output responses considered were surface roughness and surface hardness. The influence of process parameters on output responses has been determined by analysis of variance. Optimization was performed by a multi-objective genetic algorithm. The proposed methodology has been validated by performing experiments at the optimal process parameters, and the achieved results indicate the effectiveness of the diamond burnishing process. © 2019, The Brazilian Society of Mechanical Sciences and Engineering.Item Enhancement of surface integrity by cryogenic diamond burnishing toward the improved functional performance of the components(Springer Verlag service@springer.de, 2019) Sachin, B.; Narendranath, S.; Dupadu, D.17-4 precipitation-hardenable (PH) stainless steel is one of the widely used materials in various applications of engineering practices owing to their excellent corrosion resistance and high strength. The components such as automotive body, aerospace compressor blades, turbine blades and molds demand higher load carrying capacity and improved fatigue strength, which is possible to achieve by surface severe plastic deformation. Diamond burnishing process is an appropriate technique to produce such components which improves the surface integrity characteristics of the material. This article presents a comprehensive examination of the surface integrity of cryogenic diamond burnished 17-4 PH stainless steel using a novel diamond burnishing tool. The impact of diamond burnishing control factors on subsurface microhardness, surface roughness, surface hardness, surface topography, residual stress and surface morphology has been analyzed. The optimal control factor setting ensures the least surface roughness of 0.03 µm by the application of one factor at a time approach. Cryogenic diamond burnished surface achieves the exceptional surface finish and the surface hardness in tool-tip of 8 mm and 6 mm, respectively. The maximum surface hardness of 413 HV was attained using 6-mm tool-tip diameter. The subsurface microhardness improvement of 2% and 4% has been observed while using a tool-tip diameter of 6 mm in contrast to 8 mm and 10 mm. Compressive residual stresses have been generated at the top surface layer of the specimen. The attained experimental results prove that cryogenic diamond burnishing can be successfully applied to 17-4 PH stainless steel to enhance its surface integrity characteristics. © 2019, The Brazilian Society of Mechanical Sciences and Engineering.Item Application of Desirability Approach to Optimize the Control Factors in Cryogenic Diamond Burnishing(Springer, 2020) Sachin, B.; Narendranath, S.; Dupadu, D.Cryogenic diamond burnishing is an impactful method to enhance the functional performance of the product. In this article, an experimental study on the diamond burnishing of 17-4 precipitation hardenable stainless steel in a cryogenic cooling condition has been presented. This material has excellent corrosion resistance, high strength and enormous applications in the manufacturing industries. The control variables were namely burnishing force, burnishing feed and burnishing force have been studied and modeled for the output responses explicitly surface hardness and surface roughness. The influence of control variables on performance features has been analyzed using response surface graphs. The significant influence of burnishing conditions on the output responses was established by analysis of variance. Desirability function approach has been employed to optimize the multi-performance characteristics. At the corresponding highest desirability, the optimal process parameter combination was found to be burnishing feed = 0.053 mm/rev, burnishing speed = 31.29 m/min and burnishing force = 200 N which yields a minimum surface roughness = 0.199 µm and maximum surface hardness = 397.48 HV. The maximum percentage of error among the predicted and experimental results was found to be 10% and 2%, respectively, for surface roughness and surface hardness. The investigational findings were observed to be in agreement with the predicted value with permissible deviation. © 2020, King Fahd University of Petroleum & Minerals.Item 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).