Faculty Publications
Permanent URI for this communityhttps://idr.nitk.ac.in/handle/123456789/18736
Publications by NITK Faculty
Browse
13 results
Search Results
Item Effect of thermal response on physical properties during drilling operations-A case study(Elsevier Ltd, 2018) Vijay Kumar, S.; Murthy, Ch.S.N.; Kunar, B.M.The temperature induced or generated during deep hole drilling operations is due to the heat generated between the interface of work piece surface and the tool surface. Several research study have been conducted to predict the temperature involved while drilling process as a predominant functions of many parameters like feed rate, torque, depth of cut etc. Similarly many experimental procedures have been conducted by several researchers to measure temperature directly by using thermocouples, infrared measurement, pyrometer, and thermisters etc. There is no precise experimental method is available to measure analytical value of energy, power, heat flux etc, while drilling process. The temperature rigma depends on material compositions and physical properties. This paper presents the influence of temperature on physical properties of some study samples during drilling operations. © 2017 Elsevier Ltd.Item Effect of drilling parameters on Neem wood veneer epoxy composites using grey relational analysis(Elsevier Ltd, 2019) Jaiprakash, M.; Nagamadhu, M.; Karthikeyan, K.; Kiran; Shariff, M.; Kumar, G.C.In recent trend the composites based wood are replacing the normal wood and other materials in various fields. The wood composites have cosmic properties like cheaper in cost, denser, free from defect, they can be machined in any way to make desired output product. This paper is all about investigation of wood properties and its behavior for drilling process. Drilling is one of the universal machining process that being carried out in the world.The purpose of drilling is to remove the excess of material from the work piece (specimen) to produce a hole and drilling is the primary process that need to be carried on the specimen to perform other machining operation (boring, reaming and tapping) as drilling got various level of importance in different applications, studying about drilling process and its parameter on different materials is important. This paper is all about the analysis of different drilling parameters such as feed rate (mm/min), spindle speed (rpm), Drill diameter on the quality of drilled hole. To study these factors Grey relation technique and Taguchi analysis is implemented. The result shows that feed rate is the major influencing parameter when compared to other cutting parameter and by selecting the optimal value,the quality of the drilled hole can be improved. © 2019 Elsevier Ltd.Item Experimental investigations on hole quality in drilling of cenosphere reinforced epoxy composite(Institute of Physics Publishing helen.craven@iop.org, 2019) Angadi, S.B.; Ashrith, H.S.; Gaitonde, V.N.; Karnik, S.R.; Doddamani, M.Cenosphere reinforced epoxy composites are steadily replacing the conventional materials in marine, aerospace and automobile structuresowing to their lightweight properties.Drilling is an important conventional machining process essential for assemblyof polymer composites using rivets and bolts. Drilling induces damage around the hole which significantly deteriorates composite performance. In the present study, hole quality characteristicssuch as cylindricity and delamination in drilling of fly ash cenosphere filled epoxy composites are investigated using coated tungsten carbide drill bits.Feed, cutting speed, filler content and drill diameter are considered as the drilling process variables.Samples are fabricated by varying cenosphere content from 10to 60by volume %inepoxy resin.Full factorial design (FFD) based experiments are conducted on CNC vertical machining center. Response surface methodology (RSM) based mathematical models are proposed to estimate the characteristics of the hole quality in developed composites. Analysis of variance is used to validate the developed mathematical models.Present study reveals that the cylindricity and delamination decreases with increasing feed. Increasing cutting speed decreases the cylindricity, however delamination is found to be increasing.Results also shows the importance of using high cenosphere content for producing sound quality holes, which is also beneficial from weight savingperspective. © 2019 IOP Publishing Ltd. All rights reserved.Item Temperature Measurement During Rotary Drilling of Rocks - A Statistical Approach(Springer Nature, 2020) Vijay Kumar, S.; Kunar, B.M.; Murthy, C.S.N.This paper discusses a statistical analysis to measure the temperature during rotary drilling of fine-grained sandstone (pink) using embedded thermocouple method. The regression models consist of three input variables such as diameter of the bit, rpm and rate of penetration for different depth of thermocouples. Experimental test were conducted in computer numerical control (CNC) vertical machining centre. The measured temperature has been applied to study the influencing parameter using statistical technique. Analysis of variance (ANOVA) shows that the percentage contribution ratio of each operational parameters on temperature (output response). The most influencing parameter for temperature is rate of penetration with a percentage contribution of 71.32%, followed by drill bit diameter and spindle speed which contribute 19.27% and 2.99% respectively. The ANOVA and regression models for temperature give p-values of less than 0.05. Hence the predicted regression models are statistically significant and good predictive capabilities with acceptable accuracy. © 2020, Springer Nature Switzerland AG.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 An experimental investigation of jack hammer drill noise with special emphasis on drilling in rocks of different compressive strengths(2007) Vardhan, H.; Murthy, Ch.S.N.An attempt has been made in this paper to investigate the influence on sound level due to drilling in rocks of varying physical properties i.e. compressive strength and abrasivity using jackhammer drill. For this purpose, a jackhammer drill setup was fabricated wherein the thrust applied can be varied while drilling vertical holes. The compressive strength and the abrasivity of various rock samples collected from the field were determined in the laboratory. A set of test conditions were defined for measurement of sound level of the jackhammer drill. Also, with the help of the experimental setup, vertical drilling was carried out on the rock samples for varying thrust and air pressure values and the corresponding A-weighted equivalent continuous sound levels were measured. The results of this study indicate that, increase in thrust increases the sound level at higher midband frequencies in the noise spectrum. The study indicated the sound level near the drill rod to be 0.5 to 1.5 dB, 2.0 to 3.0 dB and 4.0 to 6.0 dB higher relative to that at the drill bit, the exhaust and the operator's position respectively at an air pressure of 5 kg/cm2 and 160 N thrust for all the rock samples tested. Both the thrust and air pressure were found to have a significant effect on the sound level produced by jackhammer drill at all the measurement locations. The study further shows that an increase in sound level of the order of 1.5 to 2.5 dB at the operator's position can occur with an increase in air pressure by 2 kg/cm2 at 160 N thrust and with an increase in compressive strength and decrease in abrasivity of rocks. Also, the increase in sound level at the operator's position with increase in compressive strength and decrease in abrasivity of rock is of the order of 1.0 to 2.0 dB. In order to maintain a constant penetration rate in the rocks, both the thrust and air pressure need to be increased with an increase in compressive strength and decrease in rock abrasivity. Therefore, increased compressive strength and lower abrasivity of rocks will require higher air pressure and thrusts to be applied to achieve an optimum penetration rate and therefore will result in higher sound level at the operator's position and at other measurement locations. © 2007 Institute of Noise Control Engineering.Item Acoustic fingerprinting for rock identification during drilling(Inderscience Publishers, 2014) Shreedharan, S.; Hegde, C.; Sharma, S.; Vardhan, H.During the process of mining, it is imperative to know the type and properties of the rocks being handled. The current technology for this involves core drilling, and subsequently subjecting the drilled cores to various tests in the laboratory, to identify the rocks and establish their properties. In many cases, obtaining a sample may be cumbersome and/or non-profitable. This paper presents a novel method to monitor and evaluate the sounds produced as undesirable by-products, at the drill-bit and rock interface, to predict the type of rock being drilled. A rotary drill was fabricated in the laboratory and vertical drilling was carried out on cubical rock samples, keeping various drilling parameters constant. The results obtained are promising and reinforce that it may be possible to extend the proposed methodology in the field as well, with appropriate modifications. This method may be extrapolated further in the estimation of rock properties as well. Copyright © 2014 Inderscience Enterprises Ltd.Item Soft computing techniques during drilling of bi-directional carbon fiber reinforced composite(Elsevier Ltd, 2016) Shetty, N.; Herbert, M.A.; Shetty, R.; Shetty, D.S.; Vijay, G.S.Due to the intricacy of machining processes and inconsistency in material properties, analytical models are often unable to describe the mechanics of machining of carbon fiber reinforced polymer (CFRP) composites. Recently, soft computing techniques are used as alternate modeling and analyzing methods, which are usually robust and capable of yielding comprehensive, precise, and unswerving solutions. In this paper, drilling experiments as per the Taguchi L27 experimental layout are carried out on bi-directional carbon fiber reinforced polymer (BD CFRP) composite laminates using three types of drilling tools: high speed steel (HSS), uncoated solid carbide (USC) and titanium nitride coated SC (TiN-SC). The focus of this work is to determine the best drilling tool that produces good quality drilled holes in BD CFRP composite laminates. This paper proposes a novel prediction model 'genetic algorithm optimised multi-layer perceptron neural network' (GA-MLPNN) in which genetic algorithm (GA) is integrated with Multi-Layer Perceptron Neural Network. The performance capability of response surface methodology (RSM) and GA-MLPNN in prediction of thrust force is investigated. RSM is also used to evaluate the influence of process parameters (spindle speed, feed rate, point angle and drill diameter) on thrust force. GA is used to optimize the thrust force and its optimization performance is compared with that of RSM. It is observed that the GA-MLPNN is better predicting tool than the RSM model. The investigation in this paper demonstrates that TiN-SC is the best tool for drilling BD CFRP composite laminates as minimum thrust force is developed during its use. © 2016 Elsevier B.V. All rights reserved.Item Influence of materials and machining parameters on drilling performance of syntactic foams(ASTM International, 2018) Ashrith, H.S.; Doddamani, M.; Gaitonde, V.N.; Gupta, N.The effects of drilling parameters and material properties are investigated on epoxy matrix syntactic foams reinforced with 20, 40, and 60 volume percent glass microballoon. The influences of cutting speed, feed, drill diameter, and filler content on drilling performance are studied based on the full factorial design of experiments using tungsten carbide twist drills. Based on experimental results, machinability aspects within the range of the chosen input parameters are predicted using response surface methodology-based models, which can guide industrial practitioners for choosing the appropriate process parameters. Microscopy is conducted on the drilled specimens to understand crack initiation and propagation mechanisms. The thrust force and specific cutting coefficient of syntactic foam are 40 % lower as compared to those of neat epoxy. The surface roughness of syntactic foams is higher than that of neat epoxy. The micrographs of drill bits show negligible tool wear. These results show the possibility of using syntactic foams in industrial applications in which the drilling of material is required for reasons such as joining using bolts. © © 2018 by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959