Faculty Publications

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Multi-response optimization of the turn-assisted deep cold rolling process parameters for enhanced surface characteristics and residual stress of AISI 4140 steel shafts
(Elsevier Editora Ltda, 2020) Prabhu, P.R.; Kulkarni, S.M.; Sharma, S.
Surface and near-surface areas play an important role as far as safety and dependability ofengineering components particularly when it is subjected to fatigue loading. By applyingdiverse mechanical surface enhancement (MSE) strategies, close to surface layers can becustom-made bringing about enhanced fatigue strength. MSE methods are used to gener-ate surface hardened components without the time and energy-consuming heat treatment.Deep cold rolling (DCR) is one such method that can be employed where the mechanicalenergy induced enables surface-hardening of steels and thereby the combination of hard-ening and finishing in one single step. The objective of this work is to enhance residualstress and near-surface properties of AISI 4140 steel which is the most commonly usedmaterial in the automobile and aerospace industry. The samples were first turned and thendeep cold rolled with various process parameters. Microstructure, surface hardness, sur-face finish, fatigue life, and residual compressive stress after the treatment were examined.Response surface methodology (RSM) and desirability function approach (DFA) was used torelate the empirical relationship between the various process variables and responses andalso to determine the optimum parameter settings for better responses. Further, numericalsimulation of turn-assisted deep cold rolling (TADCR) process was done by utilizing ANSYS-LS-DYNA software to understand the state of residual stress under various treating settings.Confirmation experiments conducted with the optimum parameter setting to validate theimprovements in response and it is found that the deviation between optimum predictedand confirmatory experimental values is about 5%. © 2020 The Authors.
Surface Properties and Corrosion Behavior of Turn-Assisted Deep-Cold-Rolled AISI 4140 Steel
(Springer, 2020) Prabhu, P.R.; Prabhu, D.; Sharma, S.; Kulkarni, S.M.
In this research, the effect of various turn-assisted deep-cold-rolling process parameters on the residual stress, microstructure, surface hardness, surface finish, and corrosion behavior of AISI 4140 steel has been investigated. The examination of the surface morphology of the turned and processed samples was performed by using a scanning electron microscope, energy-dispersive spectroscopy, and atomic force microscopy. Response surface methodology and desirability function approach were used for reducing the number of experiments and finding local optimized conditions for parameters under the study. The results from the residual stress measurements indicate that the rolling force has the highest effect by generating a deeper layer of residual compressive stress. The outcomes of surface hardness and surface finish emphasize that rolling force and number of tool passes are the most significant parameters affecting the responses. Surface studies confirmed the corrosion and its intensity onto the metal surface, and according to atomic force microscopy studies, the surface had become remarkably rough after exposure to the corrosive medium. Improvements in surface microhardness from 225 to 305.8 HV, the surface finish from 4.84 down to 0.261 ?m, and corrosion rate from 6.672 down to 3.516 mpy are observed for a specific set of parameters by turn-assisted deep-cold-rolling process. The multiresponse optimization for surface finish and corrosion rate together shows that a ball diameter of 10 mm, a rolling force of 325.75 N, initial roughness of 4.84 µm, and number of tool passes of 3 give better values for the two responses under consideration with composite desirability of 0.9939. Based on the experimental work at the optimum parameter setting, the absolute average error between the experimental and predicted values for the corrosion rate is calculated as 3.2%. © 2020, The Author(s).
Formability behaviour of ferritic and austenitic rolled Nb–Ti stabilized IF grade steel
(Springer, 2023) Satish Kumar, D.; Sambandam, S.; Udaya Bhat, K.
Recently, soft hot strip and hard hot strip produced through ferritic rolling are projected as a direct replacement to austenitic cold-rolled sheets for many forming applications. However, industrial hot-rolling mills, with final rolling thickness limitations cannot produce these thinner products and have to be subsequently cold-rolled to the desired application thickness and further annealed. Under ferritic rolling conditions, the hot-rolling temperature of these coils governs the final properties. The temperature difference in hot-rolled sheets generates the difference in the microstructure and texture of these coils after cold-rolling and annealing and variation in their formability behaviour. In the present work, an Nb–Ti stabilized IF grade steel was hot-rolled at two different temperatures in the ferritic regime and subsequently cold-rolled and annealed for structure-property comparison. As formability is an application-specific requirement, the annealed sheets were tested for different formability characteristics. Industrially rolled samples were tested for fracture criterion, stretch-flangeability, deep drawability and stretch formability through the formability limit diagram, hole expansion ratio, earing test and Erichsen cupping test respectively. These parameters were compared with those of the austenitic regime rolled sheets. High temperature ferritic rolled sheets show improved formability in all tests due to better r ˙ , higher n-value, low Δr and stronger gamma fibre maxima at 111<121>. Low temperature ferritic rolled sheets show the lowest Δr and improved n-value, but has reduced r ˙ and higher alpha fibre texture. High temperature ferritic rolled sheets show higher formability limits in uniaxial tension and low temperature ferritic rolled sheets in biaxial tension of the FLD curve. Various tests established that high temperature ferritic rolled sheets are best suited for deep drawing and stretching applications whereas low temperature ferritic rolled sheets should be preferred for stretch forming applications. © 2022, Indian Academy of Sciences.

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