Faculty Publications

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    Modern manufacturing technology: Spotlight on future
    (CRC Press, 2021) Katiyar, J.K.; Sahu, R.K.
    Modern Manufacturing Technology: Spotlight on Future summarizes the emergence and development of modern manufacturing techniques (MMTs) with a focus on metallic and advanced material-based additive manufacturing technologies and their potential applications. Further, it explores advanced machining techniques for production of novel nanomaterials. The book also covers modern sophisticated techniques for the fabrication of ultrafine electronic devices such as micro-electromechanical systems (MEMS), nano-electromechanical systems (NEMS), semiconductors, and optical systems. A dedicated chapter on manufacturing technology for Industry 4.0 is included. Features: Describes the background of manufacturing techniques in brief including the advent of and introduction to MMTs Reviews various types of MMTs established in recent years and their accelerated growth and development innovation-driven applications Overviews the physical and chemical techniques used for nanomaterials production Explores the fabrication mechanisms of MEMS, NEMS, semiconductors and optical devices Provides a conceptual overview of additive manufacturing technologies This book is geared to undergraduate and postgraduate students and professionals in mechanical and manufacturing engineering, and the manufacturing industry. © 2022 Jitendra Kumar Katiyar and Ranjeet Kumar Sahu.
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    Microstructural and Size Accuracy Study of Electrochemical Machined Aluminium Alloy Features
    (Springer Nature, 2019) Sahu, R.K.; Pal, V.K.; Kumar, P.
    The present work focuses on the machining of aluminium 6061 alloy workpiece electrodes using Electro-Chemical Machining (ECM) by varying the control parameters like voltage, feed rate and machining time. Scanning electron microscopy study is carried out to examine the microstructure of the craters of definite morphology machined on the workpiece. Optimum parameter settings to maximize the length, width and depth of the obtained features were studied individually through a parametric experimental design layout of Taguchi. The results reveal that the optimal parameter settings are found to be different for each performance objective. As a result, the grey Taguchi method has been adopted to convert the three objectives into a single objective and by considering the performance objectives concurrently, the process parameters were optimized. The favourable parameters to maximize the responses are determined to be voltage—15 V, feed rate—0.3 mm/min and machining time—5 min. Further, the effect of process parameters on the microstructure and size accuracy of the Al alloy features is studied. © 2019, Springer Nature Singapore Pte Ltd.
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    DDoS Attack Detection on IoT Devices Using Machine Learning Techniques
    (Springer Science and Business Media Deutschland GmbH, 2022) Kumar, S.; Sahu, R.K.; Rudra, B.
    The Internet of Things made life easy and simple. It has become a part of life to control the devices and activate them for various applications using the Internet. Due to the drastic increase of its usage in day-to-day life, researchers are moving towards the concept of everything connected to the internet which can lead to penetration. To avoid malicious penetrations into the network, it is required to develop a reliable mechanism for secure communication over IoT devices. In order to find the best accurate algorithm, many Machine Learning (ML), as well as Deep Learning (DL) methods, need to be applied to the collected dataset for the detection of DDoS attacks. Hence in this paper, an effective model is selected by applying and comparing all the ML and DL models on a dataset. © 2022, The Author(s), under exclusive license to Springer Nature Switzerland AG.
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    MOJAYA Coupled with R-method for Optimization of Machining Parameters Used in the Generation of Micro Holes on GFRP Composite Using an In-House Developed µ-ECDM System
    (Springer Science and Business Media Deutschland GmbH, 2023) Bhargav, K.V.J.; Shanthan, P.; Balaji, P.S.; Sahu, R.K.
    Glass fiber reinforced plastic is a highly versatile composite with properties such as high strength, flexibility, durability, stability, lightweight, and resistance to heat, temperature, and moisture. It is commonly used in automobiles, aerospace, construction, power generation, and manufacturing. Owing to these numerous applications, machining holes in GFRP composite has become the need of the day. This paper focuses on machining microholes in GFPR composite using an in-house developed µ-ECDM system. The process parameters selected for machining are voltage (V), concentration (wt%), and duty factor (DF), and the machining characteristics chosen are material removal rate (MRR) and overcut (OC). The machining parameters are optimized using the multi-objective JAYA algorithm coupled with the multi-attributed decision-making technique R-method to find the most favorable responses for machining GFRP composites. © 2023, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
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    Effect of blending duration on physical, mechanical and tribological behavior of aluminum matrix composites: An experimental analysis
    (Elsevier Ltd, 2024) Veeranaath, V.; Sahu, R.K.; Priya, I.M.
    Aluminum matrix composites exhibit a vibrant role in the present research and scientific world due to their astonishing features compared to other conventional materials. Among the various techniques available for processing these composites, powder metallurgy (P/M) is considered one of the prominent techniques. This is because of its identical dispersal of the fillers, near net shape samples, etc. wherein blending is the most imperative step of the process. To accomplish efficient blending of the phases for composite preparation, ball milling is found to be suitable. In this paper, aluminum matrix composites filled with 20 wt% novel reinforcement (extracted from Aegle marmelos) is synthesized via the P/M technique by varying the blending duration from 60 to 240 min to study its effect on the behavior of composites. The mixing of the constituents is carried out at 300 rpm with a ball-to-powder ratio of 10:1 in ball milling. The blended powders were then compacted and sintered in an inert gas atmosphere for consolidation. The hardness, density, and wear tests were conducted to characterize the developed composite specimens. The microstructural characterization was carried out using an optical microscope and SEM, and the elemental composition of the synthesized composite was studied using EDS techniques. The hardness and density were found to have a growing influence up to a ball milling duration of 180 min and beyond this time there is found to be a decrement in the characteristics of the composites. This is due to the damage of the reinforcements observed during lengthier ball milling duration. The wear behavior of the fabricated specimens followed the same trend. Further, grey relational analysis was adopted in this study to determine the degree of relationship between the blending duration and the composites' behavioral performance. © © 2024 Elsevier Ltd. All rights reserved.
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    State of the art on sustainable manufacturing using mono/hybrid nano-cutting fluids with minimum quantity lubrication
    (Taylor and Francis Ltd., 2022) Singh, V.; Sharma, A.K.; Sahu, R.K.; Katiyar, J.K.
    In machining operations, the application of cutting fluids has been of prime importance for the extraction of heat from rake surfaces, ease of removal of the chips and reduction of friction at the chip–tool interface. These three objectives are achieved by the supply of suitable conventional cutting fluid at the machining zone using different techniques. However, the misuse of these fluids and their wrong disposal methods were found to have an adverse effect on the environment and health of human. To reduce the usage of conventional cutting fluid, minimum quantity lubrication (MQL) technique has been emerged as an alternative means in the last few years, leading to better eco-friendly. Further, to increase the sustainability of MQL technique, it becomes necessary to use an appropriate exceptional nanostructured material with MQL that could be an effective cutting fluid (i.e. nanocutting fluids) with better tribological and thermophysical properties, and might be helpful in addressing the eco-friendly problem to a great extent. Therefore, the present paper focuses on the review of important published works related to the use of mono/hybrid nanocutting fluids with MQL technique at various processing parameters in different metal cutting operations. Most of the studies have shown a significant reduction in cutting forces, temperature at cutting zone, tool wear, and friction coefficient, and considerable improvement in surface quality by the addition of mono/hybrid nanoparticles enriched cutting fluid in MQL technique as compared to dry as well as wet machining processes. Further, the paper discusses the future scope in the area of hybrid nano-cutting fluids in different machining processes. © 2022 Taylor & Francis.
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    Experimental and Digimat-FE based representative volume element analysis of exceptional graphene flakes/aluminium alloy nanocomposite characteristics
    (Institute of Physics Publishing helen.craven@iop.org, 2019) Nayak, B.; Sahu, R.K.
    The present article is focused on the in-house synthesis of graphene nano-flakes (size range: 3-8 nm) reinforced Al-alloy (AA6005 series) nanocomposites using stir casting process. The microstructure of the obtained Al nanocomposites at different concentration of flake shaped graphene nanoparticles (GRNPs) show that the particles at 2 wt% and 4 wt% found to be distributed extensively on the surfaces of Al alloy matrix but observed negligible across the grain boundary whereas in the case of 6 wt% concentrated developed composite specimen, the GRNPs were observed to be well dispersed both on the surfaces and grain boundary of the matrix. With the addition of the particles, there found to be the formation of more voids in the nanocomposite specimens. The experimental characterization results reveal that with the increase in graphene content to 6 wt%, the tensile strength, compressive strength, impact energy, hardness and wear resistance of the nanocomposites were increased by 9% to 36%, 30% to 44%, 9.8 J, 36.03 HRB and 33% respectively as compared to unreinforced alloy. It was observed that the composites with increased concentration of reinforcement exhibits brittle behaviour and at 6 wt% GRNPs, the elongation is almost found to be 50% lower than the unreinforced one. Further, a 3D microstructure representative volume element (RVE) model of aluminium nanocomposite is generated using Digimat-FE software. Then, microstructural deformation behaviour of the nanocomposite is realized by RVE model. The simulation results reveal that the tensile property of the aluminium nanocomposites predicted using RVE model is in well agreement with the experimental values. © 2019 IOP Publishing Ltd.
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    Novel application of graphite-talc hybrid nanoparticle enriched cutting fluid in turning operation
    (Elsevier Ltd, 2021) Singh, V.; Sharma, A.K.; Sahu, R.K.; Katiyar, J.K.
    In this study, the influence of hybrid nanocutting fluid (both graphite and talc nanoparticles dispersed in a base fluid) in turning of Titanium alloy grade 5. The hybrid nanocutting fluid was developed by the blending of graphite and talc nanoparticles in a constant volumetric proportion (50:50) in pure coconut oil as a base fluid. The prepared hybrid nanocutting fluid has been investigated for its tribological behaviour using a pin-on-disc machine. The Gray relational analysis (GRA) is applied as a conservative approach in the optimization of process variables of Titanium alloy with multiple performance characteristics. The turning performance of the hybrid nanocutting fluid is compared with that of pure coconut oil in terms of cutting force and surface roughness. From the Gray relational grade analysis, it is obtained that the feed rate has a larger influence on responses as compared to cutting speed and nanoparticle concentration as well. By the application of hybrid nanocutting fluid, it is obtained a significant reduction in cutting force and surface roughness compared to pure coconut oil by 21.19 % and 18.9 %, respectively. © 2020 The Society of Manufacturing Engineers
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    Artificial Intelligence System Approach for Optimization of Drilling Parameters of Glass-Carbon Fiber/Polymer Composites
    (Springer Science and Business Media B.V., 2021) Upputuri, U.H.; Vijaya Sai, N.V.; Sahu, R.K.
    In recent times, the study on machining characteristics of combined (hybrid) fiber polymer composites has drawn a remarkable research attention because of its emerging industrial applications. The present study focuses on the drilling of hybrid glass-carbon fiber reinforced (GCFR) epoxy composites fabricated using hand layup technique. The machining characteristics were considered in the drilling of GCFR composites which include thrust force, torque, delamination factor and surface roughness. The influence of the drilling process parameters such as spindle speed, drill diameter and feed rate on the characteristics are studied. To avoid the confounding effect of the individual optimized characteristics, an artificial intelligence system i.e. fuzzy inference system approach is adopted. The fuzzy inference system transformed all the performance characteristics of drilled hybrid composites into a multi response performance index (MPI) and optimized the MPI at the common factor level setting. The optimal combination of process parameters for minimum thrust force, torque, delamination factor and surface roughness found to be: speed 3000 RPM, drill diameter 5 mm and the feed rate 50 mm/min. The analysis of variance results show that drill diameter is the most significant parameter followed by feed rate and speed. Further, a theoretical model was proposed for the estimation of MPI and found that an average absolute error of 14.8% with respect to the experimental MPI data is obtained. © 2020, Springer Nature B.V.
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    Mechanical properties of MWCNTs and graphene nanoparticles modified glass fibre-reinforced polymer nanocomposite
    (Springer, 2021) Seshaiah, S.; Reddy, K.V.K.; Sahu, R.K.; Katiyar, J.K.
    In the present study, the multi-walled carbon nanotubes (MWCNTs) and graphene nanoparticles were used as a reinforcement to fabricate glass fibre polymer composite at different orientations (unidirectional glass fibres 0° and 90°; woven glass fibres 0°/90° and 45°/45°). The composites were developed using hand lay-up-assisted vacuum bagging method at 1 torr pressure. The concentrations of nanoparticles (~diameter 5–20 nm) were varied in the range of 0.1–0.3 wt% in the matrix. The mechanical properties like impact strength, tensile strength and fatigue strength were carried out on Izod and Charpy machine, universal testing machine and computer-controlled machine under sinusoidal wave, respectively. It is observed that the glass fibre/epoxy composite blended with MWCNTs/graphene by 0.2 wt% has shown higher fatigue life by 56%, higher tensile strength by 36% and higher capability of energy absorption by 927.7% in notched type and lower capability of energy absorption by 155.43% in un-notched type, as compared to pure composite. The increment in properties is due to the better bonding between fillers and matrix. However, the increase of MWCNTs and graphene nanoparticles by wt% in composite laminates have shown lower fatigue strength because of the agglomeration of MWCNTs particles in matrix that caused the propagation of fatigue cracks under cyclic loading. Further, the damage behaviour of composite materials was analysed using scanning electron microscopy. It is found that a different damage behaviour in each composite is observed which is attributed to the matrix cracking, fibre rupture, fibre pullout, fibre split and fibre de-bonding. © 2021, Indian Academy of Sciences.