Faculty Publications
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Item A pressured steam JET approach to tool wear minimization in cutting of metal matrix composites(Trans Tech Publications Ltd, 2007) Anjaiah, D.; Shetty, R.; Pai B, R.; Vijaya, M.V.; Rao, S.S.Metal matrix composites (MMCs) have been found to possess tremendous prospective engineering applications that require materials offering a combination of lightweight with considerably enhanced mechanical and physical properties. However, the applications of MMCs are limited by their poor machinability which is a result of their highly abrasive nature that causes excessive wear to the cutting tools. In this study, an investigation into the mechanism of the tool wear in cutting of MMCs is carried out. It is found that during cutting of an MMC, the tool cutting edge will impact on the reinforcement particles. The impacted particles will then either be dislodged from the matrix, doing no harm to the tool, or be embedded into the matrix, ploughing on the tool flank and causing excessive tool flank wear. According to this tool wear mechanism, a pressured steam jet approach is developed for the minimization of the tool wear by preventing the impacted reinforcement particles from being embedded in the workpiece matrix. Experimental tests for cutting of SiC-aluminum MMC using cubic boron nitride (KB-90) and polycrystalline diamond (KP-300) tool inserts with the aid of the pressured steam jet are conducted. The results show that from full factorial design of experiments the effect of the pressured steam jet plays a significant role on the tool wear followed by tool inserts and depth of cut. The working mechanism of the pressured steam jet method and the experimental testing results are discussed in detail.Item Optimal Design of Rotary Magneto-Rheological Drum Brake for Transfemoral Prosthesis(Springer Science and Business Media Deutschland GmbH, 2021) Saini, R.S.T.; Kumar, H.; Chandramohan, S.; Sujatha, S.Semi-active technology offers good advantages in terms of controllability and adaptability. Magneto-rheological (MR) fluid is a class of smart fluids which display significant changes in its rheological properties under the influence of a magnetic field. Previous studies carried out using MR brake for the transfemoral prosthetic device were of multi-plate models which are complex in design and also to manufacture. Therefore, in the present study, a multi-coil rotary inverted drum brake is optimized with braking torque as the objective function. One of the advantages of the multi-coil design from multi-plate is that the former has fewer components and leads to a simpler design. The outermost geometric constraints are decided based on the knee cross-sections in anterior-posterior and mediolateral directions. Four design geometric variables are selected which are: coil depth, coil height, casing axial thickness, and casing radial thickness. A design of experiments technique is used to obtain 27 combinations of design variables. Magnetostatic analysis at each design point is performed and average flux densities in the annular and the radial gaps are determined. Regression analysis is conducted on the design data to obtain braking torque as a function of four design variables. Later, genetic algorithm is used to obtain the optimum geometric dimensions. A total maximum braking torque of 13.4 Nm is obtained using the optimum dimensions for a design current of 2 A. © 2021, The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.Item Delamination analysis in drilling process of glass fiber reinforced plastic (GFRP) composite materials(2007) Mohan, N.S.; Kulkarni, S.M.; Ramachandra, A.Machining processes are generally used to cut; drill, or contour composite laminates for building products. In fact, drilling is one of the most commonly used manufacturing processes to install fasteners for assembly of laminate composites. The material anisotropy resulting from fiber reinforcement heavily influences the machinability during machining. Machining of fiber reinforced plastic (FRP) components is often needed in spite of the fact that most FRP structures can be made to near-net shape and drilling is the most frequently employed secondary machining process for fiber reinforced materials. Therefore, the precise machining needs to perform to ensure dimensional stability and to obtain a better productivity of the component. The drilling parameters and specimen parameters evaluated were speed, feed rate, drill size and specimen thickness. A series of experiments were conducted using TRIAC VMC CNC machining center to machine the composite laminate specimens at various cutting parameters and material parameters. The measured results of delamination at the entry and exit side of the specimen were measured and analyzed using commercial statistical software MINITAB14. The experimental results indicated that the specimen thickness, feed rate and cutting speed are reckoned to be the most significant factors contributing to the delamination. A signal-to-noise ratio is employed to analyze the influence of various parameters on peel up and push down delamination factor in drilling of glass fibre reinforced plastic (GFRP) composite laminates. The main objective of this study is to determine factors and combination of factors that influence the delamination using Taguchi and response surface methodology and to achieve the optimization machining conditions that would result in minimum delamination. From the analysis it is evident that among the all significant parameters, specimen thickness and cutting speed have significant influence on peel up delamination and the specimen thickness and feed have more significant influence on push down delamination. Confirmation experiments were conducted to verify the predicted optimal parameters with the experimental results, good agreement between the predicted and experimental results obtained to be of the order of 99%. © 2007 Elsevier B.V. All rights reserved.Item Statistical modeling of a magneto-rheological fluid damper using the design of experiments approach(2007) Shivaram, A.C.; Gangadharan, K.V.In this work, a through-rod-type magneto-rheological (MR) test damper has been designed and fabricated for experimental study. Various factors, such as the magnetic field strength, volume fraction of particles in the MR fluid, shearing gap between piston and cylinder, vibration frequency and amplitude, have been considered as input factors, and the root-mean-square (RMS) damping force as the output factor (response variable). These input factors are varied in two levels (low and high) during the initial phase of experimentation using 25 factorial design; the motivation is to identify the most influential factors. In the second phase of experimentation, the response surface method has been used to identify the modeling equation and to plot the response surfaces. Further, force versus displacement diagrams have been plotted at these factor levels; these give an insight into the damping behaviour of the MR damper. © IOP Publishing Ltd.Item Hydrogen Sulfide Removal in Biofilter: Evaluation of a new filter material by immobilization of thiobacillus sp(Walter de Gruyter GmbH peter.golla@degruyter.com, 2009) Potumarthi, R.; Anupoju, G.R.; Mugeraya, G.; Jetty, A.Different agricultural residue was evaluated as a biofilter material for the removal of Hydrogen sulfide (H2S) using Thiobacillus sp. A Combination of four different agricultural residues, viz., sugarcane bagasse, coconut coir pith, rice husk and saw dust were evaluated as biofilter material. From results, it was observed that filter material having composition of 2:4:2:2, 4:4:2:2 and 4:2:2:4 has resulted in retaining 70% moisture content at the end of 10 days. The biofilter was operated for 128 days in three phases by varying inlet H2S concentration from 321 to 2020 ppmv. Biofilter exhibited 100% removal efficiency (RE) at an inlet concentration of 570 ppmv, 99% RE at an inlet concentration of 1416 ppmv and 66% RE at a maximum inlet concentration of 2020 ppmv. The filter performance in terms of RE, dropped to 48% when the air was not humidified before sending to the filter, which has direct relation with the MC of the filter material. The RE recovered to 66% with recovery of moisture content (MC) to 57% upon subsequent re-introduction of the humidifier in to the circuit. The pH has dropped from 7.8 to 4.8 during the course of operation of the filter. H2S was effectively removed under different operating conditions using mixed agricultural residue as filter material. However humidification was most essential to maintain the required moisture content in the biofilter. SEM analysis has shown the good growth of Thiobacillus sp. in the filter bed and hence the new material proved to be good support for the immobilization of Thiobacillus sp. Copyright © 2009 The Berkeley Electronic Press. All rights reserved.Item Experimental studies on turning of discontinuously reinforced aluminium composites under dry, oil water emulsion and steam lubricated conditions using TAGUCHI's technique(Gazi University Eti Mahallesi, 2009) Shetty, R.; Pai B, R.B.; Rao, S.S.This paper reports on the experimental investigations carried out under dry, oil water emulsion and steam lubricated conditions in turning of DRACs. The measured results were then collected and analyzed with the help of the commercial software package MINITAB15. The experiments were planned on orthogonal arrays, made with prefixed cutting parameters and different lubricated conditions. An analysis of variance (ANOVA) was carried out to check tho validity of the proposed parameters and also their percentage contributions. The results of the tests show that with proper selection of the range of cutting parameters, it is possible to obtain better performance under steam lubricated condition.Item Taguchi's technique in machining of metal matrix composites(Brazilian Society of Mechanical Sciences and Engineering, 2009) Shetty, R.; Pai B, R.B.; Rao, S.S.; Nayak, R.This paper presents the study on Taguchi's optimization methodology, which is applied to optimize cutting parameters in turning of age hardened Al6061-15% vol. SiC 25 ?m particle size metal matrix composites with Cubic boron nitride inserts (CBN) KB-90 grade using steam as cutting fluid. Analysis of variance (ANOVA) is used to study the effect of process parameters on the machining process. This procedure eliminates the need for repeated experiments, time and conserves the material by the conventional procedure. The turning parameters evaluated are speed, feed, depth of cut, nozzle diameter and steam pressure. A series of experiments are conducted using PSG A141 lathe (2.2 KW) to relate the cutting parameters on surface roughness, tool wear, cutting force, feed force, and thrust force. The measured results were collected and analyzed with the help of the commercial software package MINITAB15. As well, an orthogonal array, signal-to-noise ratio is employed to analyze the influence of these parameters. The method could be useful in predicting surface roughness, tool wear, cutting force, feed force and thrust force as a function of cutting parameters. From the analysis using Taguchi's method, results indicate that among the all-significant parameters, steam pressure is the most significant parameter. © 2009 by ABCM.Item Optimization of two step karanja biodiesel synthesis under microwave irradiation(2011) Venkatesh Kamath, H.; Iyyaswami, I.; Saidutta, M.B.The free fatty acid of crude karanja oil (Pongamia pinnata) was reduced and biodiesel was synthesized from pretreated oil under microwave irradiation. The process variables such as irradiation time, methanol-oil ratio and sulfuric acid concentration for pretreatment step; irradiation time, methanol-oil ratio and KOH concentration were optimized through the Box-Behnken experimental design. The free fatty acid of crude karanja oil was reduced to 1.11 ± 0.07% with an optimal combination of 190 s irradiation time (180 W), 33.83 (w/w)% methanol-oil ratio and 3.73 (w/w)% sulfuric acid concentration. An optimal combination of 150 s irradiation time, 33.4 (w/w)% methanol-oil ratio and 1.33 (w/w)% KOH concentration yielded 89.9 ± 0.3% biodiesel. The model was validated by conducting experiments at optimal design conditions. The present work confirmed that the microwave energy has a significant effect on esterification and transesterification reaction. © 2010 Elsevier B.V. All rights reserved.Item Abrasive wear behavior of granite-filled glass-epoxy composites by SiC particles using statistical analysis(2011) Basavarajappa, .S.; Manjunath Yadav, S.M.; Kumar, S.; Arun, K.V.; Narendranath, S.This experimental investigation deals with the evaluation of abrasive wear behavior of Glass Epoxy (G-E) composites on pin-ondisc test rig. A plan of experiments, based on the Taguchi Design of Experiments, was performed to acquire data in controlled way. An orthogonal array and the analysis of variance were employed to investigate the percentage of contribution of various process parameters like sliding speed, applied load, sliding distance and their interactions affecting the abrasive wear volume loss of composites. The correlations between the various factors affecting the abrasive wear behavior of composites were obtained by using multiple linear regression equations. The obtained results indicate that applied load and sliding distance were the wear factors that have the highest physical as well as statistical influence on the abrasive wear behavior of both filled and unfilled G-E composites. A good agreement between the predicted and actual wear resistance was observed within±12%. © Taylor & Francis Group, LLC.Item The use of Dimensional Analysis and Optimization of Pneumatic Drilling Operations and Operating Parameters(Springer India sanjiv.goswami@springer.co.in, 2012) Kivade, S.B.; Murthy, C.S.N.; Vardhan, H.Dimensional analysis was used to demonstrate the significance of these important parameters, grouped together in dimensionless numbers which will then allow for optimum use of limited laboratory data to produce better results. It allows for reduction of total effort in designing laboratory experiments, reducing total load and cost, permitting variation of the important dimensional groups rather than individual drilling operating parameters, hence a more efficient design of experiments can be realized. Drilling operations are very expensive endeavors and efforts are continuous by engineers and researchers to achieve the optimum penetration rate. To enhance bit life and penetration rate, optimization of bit design and drilling operations must be realized. To measure the penetration rate of the pneumatic drill, a fabricated pneumatic drill set up available was used. Laboratory tests were carried out to obtain the physical and mechanical properties of the rock samples. Penetration rate has been derived by means of regression statistics method. In order to overcome this drawback, dimensional analysis was used to derive relevant dimensional groups leading to the development of empirical equation of penetration rate. © 2012, The Institution of Engineers (India).