Faculty Publications

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    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 Engineers
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    Measurement of WEDM performance characteristics of aero-engine alloy using RSM-based TLBO algorithm
    (Elsevier B.V., 2021) Sharma, P.; Dupadu, D.; Narendranath, N.
    Alloy-706 is a newly introduced exceptional class of turbine wheel alloy for high-performance aero-engine. To precisely measure the WEDM performance of complex aero-engine parts, the RSM-based TLBO algorithm is proposed in the current study. Morphology, topography, recast layer thickness, and roughness parameters of machined surface are studied to examine the surface integrity of aero-engine components. Better surface morphology, smoother topography, low roughness value, and minimum recast layer are observed at low pulse duration, high pulse-off period, and high servo voltage. RSM is used for statistical modeling of removal rate and average roughness. Then, these models are used in TLBO algorithm for individual and multiple performance optimizations. The Pareto optimal solutions are obtained for lower roughness value and highest removal rate. The microscopic investigation represents a considerable number of melted droplets, micro-holes, and craters on the WEDM-cut surface due to high energy discharge pulses followed by improper flushing of molten material. © 2021 Elsevier Ltd