Faculty Publications

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    A new approach for estimation of properties of metamorphic rocks
    (Inderscience Publishers, 2011) Rajesh Kumar, B.R.; Vardhan, H.; Govindaraj, M.
    Rock properties play an important role in the preliminary design of structures. This research focuses on developing empirical models using multiple regression technique for prediction of physical properties of metamorphic rocks. The model considers the following parameters: drill bit diameter, bit speed, penetration rate and equivalent sound level produced during drilling. The F-test was used to check the validity of the developed models. The experimentally measured rock property values and the values calculated from the developed regression model were fairly close which indicates that the developed models could be efficiently used in prediction of intact metamorphic rock properties. Copyright © 2011 Inderscience Enterprises Ltd.
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    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.
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    Hole Quality Assessment in Drilling of Glass Microballoon/Epoxy Syntactic Foams
    (Minerals, Metals and Materials Society 184 Thorn Hill Road Warrendale PA 15086, 2018) Ashrith, H.S.; Doddamani, M.; Gaitonde, V.; Gupta, N.
    Syntactic foams reinforced with glass microballoons are used as alternatives for conventional materials in structural application of aircrafts and automobiles due to their unique properties such as light weight, high compressive strength, and low moisture absorption. Drilling is the most commonly used process of making holes for assembling structural components. In the present investigation, grey relation analysis (GRA) is used to optimize cutting speed, feed, drill diameter, and filler content to minimize cylindricity, circularity error, and damage factor. Experiments based on full factorial design are conducted using a vertical computer numerical control machine and tungsten carbide twist drills. GRA reveals that a combination of lower cutting speed, filler content, and drill diameter produces a good quality hole at optimum intermediate feed in drilling syntactic foams composites. GRA also shows that the drill diameter has a significant effect on the hole quality. Furthermore, damage on the hole exit side is analyzed using a scanning electron microscope. © 2018, The Minerals, Metals & Materials Society.
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    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
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    Development of novel cutting tool with a micro-hole pattern on PCD insert in machining of titanium alloy
    (Elsevier Ltd, 2018) Rao, C.M.; Rao, S.S.; Herbert, M.A.
    The development of a novel cutting tool that had a micro-hole pattern on their rake and flank face of cutting tool surface has found wider potential in the field of manufacturing. Micro-hole pattern features on a tool rake face help in controlling the tribological characteristics of the cutting tool. Micro-holes with the different number of holes orientation, diameter and depth were fabricated using the advanced application of the electrical discharge super drilling machine with the view to assist lubricant penetration and retention. A comparative study has been conducted between micro-hole patterned Polycrystalline Diamond (PCD) cutting insert and the commercially available PCD cutting insert. The effect of micro-hole pattern on the machining of Titanium alloy (Ti-6Al-4 V) is investigated with the application of the Minimum Quantity Lubrication (MQL) method in turning operation. Vibration signals were captured in feed force direction and measured using the tri-axial accelerometer. The cutting temperature, tool-wear, and chip-morphology were measured with an infrared thermometer and Scanning Electron Microscope (SEM). It was found that micro-hole textured inserts reduced the friction on the rake face resulting in the decrease of vibration up to 30–50%. The cutting temperature, tool wear and surface roughness were reduced to 30%, 50% and 40%, respectively. The conical and helical chips were produced in micro pool lubrication system. The friction coefficient can be minimized at the tool-chip interface by using liquid lubrication method. There is no unfavourable effect on the performance of cutting tools having holes on the cutting tool surface. All these parameters led to the improvement in the tool life. © 2018
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    Experimental investigation and statistical analysis of operational parameters on temperature rise in rock drilling
    (International Information and Engineering Technology Association info@iieta.org, 2018) Vijay Kumar, V.K.; Kunar, B.M.; Murthy, C.S.
    Heat generated during rock drilling, due to friction at the bit-rock interface. Due to which temperature increases, which can influence the thermal stress and subsequent rock failure. In this paper, an attempt is made to present results related to the temperature assessment during rotary drilling of rocks on medium-grained sandstone under controlled laboratory conditions. The experiments were conducted by using embedded thermocouple technique, the thermocouple was placed at a distance of 0.5mm (horizontal) from the bit-rock interface. The influence of operational parameters, i.e., the diameter of the drill bit, spindle speed and rate of penetration of rise in temperature was studied using multiple regression and data analysis was carried out using analysis of variance (ANOVA). The temperature was measured by using embedded thermocouple technique at a depth of 6mm, 14mm, 22mm and 30mm respectively. Regression models were developed for the prediction of temperature at the bit-rock interface. It was observed that the increase in temperature for medium-grained sandstone was from 49 0 C to 74 0 C (51.08%) with an increase in the diameter of the drill bit, spindle speed and rate of penetration. © 2018 International Information and Engineering Technology Association.
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    Performance evaluation of mechanical micro-drilling, electrical discharge machining and laser beam machining on nimonic 80A alloy
    (National Institute of Science Communication and Information Resources (NISCAIR) ijact.editor@gmail.com Dr. K. S. Krishnan Marg (Near Pusa Gate) New Delhi 110-012, 2018) Sudhakar, S.; Kumar, P.; Srinivas, G.; Ravishankar, S.; Dupadu, D.; Barshilia, H.C.
    Micromachining techniques such as mechanical micro-drilling, electrical discharge machining (EDM) and laser beam machining (LBM) play an important role in the manufacturing of micro-devices used in mechanical, electronics, aerospace and medical applications. In this paper, an effort has been made to compare the performance of these micromachining techniques with regard to tool wear, burr formation and surface integrity. This is done by producing 20 micro-holes of approximately 800 ?m diameter on a rectangular block (90×30×3 mm3) of Nimonic 80A superalloy. TiAlN coated WC micro-drills, Cu electrodes and CO2 laser beam are used to produce these holes in conventional micro-drilling, EDM and LBM, respectively. The quality of the drilled hole (diameter, surface roughness and micro-burr formation), tool diameter analysis, taper angle and material removal rate (MRR) are compared and reported. A comprehensive analysis is also carried out on overcut, which leads to hole inaccuracy. Results show that mechanical micro-drilling produces better results in the above mentioned characteristics in comparison to LBM and EDM techniques. The relatively better performance of mechanical micro-drilling is attributed to the usage of TiAlN coating on WC tool. © 2018, National Institute of Science Communication and Information Resources (NISCAIR). All rights reserved.
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    Effect of wall thickness and cutting parameters on drilling of glass microballoon/epoxy syntactic foam composites
    (Elsevier Ltd, 2019) Ashrith, H.S.; Doddamani, M.; Gaitonde, V.
    Effect of glass microballoon (GMB) wall thickness and cutting parameters (cutting speed, feed and drill diameter) on thrust force (Ft), surface roughness (Ra), specific cutting coefficient (Kf), cylindricity (CYL), circularity error (Ce-Exit) and damage factor (Fd-Exit) in drilling of GMB/epoxy syntactic foam is presented. CNC vertical machining centre is utilised for conducting experiments based on full factorial design. Significant process parameters are identified through response surface methodology. Wall thickness significantly affects the Ce-Exit and CYL of the drilled hole. Increasing wall thickness significantly reduces the Ra (30%), CYL (41%) and Ce-Exit (56%) due to the increased thermal stability of syntactic foams. This observation is very crucial for the syntactic foams used in structural applications pertaining to structural stability. Drill diameter is observed to be significant for Ft, Ra, CYL and Fd-Exit; while Kf is governed by feed. Furthermore, grey relation analysis (GRA) is used to identify the specific combination of process parameters to obtain good quality drilled hole. Combination of higher particle wall thickness and feed, lower cutting speed and drill diameter produces a sound hole quality as observed from GRA. Hole quality is highly influenced by drill diameter followed by cutting speed and GMB wall thickness. The present study offers guidelines for the industries (structural applications) to produce quality holes in GMB reinforced epoxy matrix. © 2018 Elsevier Ltd
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    Quantification of Rock Properties Using Frequency Analysis During Diamond Core Drilling Operations
    (Springer, 2019) Vijaya Kumar, C.; Vardhan, H.; Murthy, C.S.N.
    Rock drilling is one of the most essential operations in mining and allied industries. This study focuses on the quantification of physico-mechanical rock properties using dominant frequencies from the sound signal generated through diamond core drilling operations. The rock drilling experiments were performed on five different types of rock samples using a computer numerical control drilling machine. Using simple linear regression analysis, satisfactory mathematical equations were developed between various physico-mechanical rock properties, namely, uniaxial compressive strength, Brazilian tensile strength, density and dominant frequencies of sound level were generated during diamond core drilling operations. The developed models can be utilised for quantification of rock properties with an acceptable degree of accuracy in realistic applications. © 2019, The Institution of Engineers (India).
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    Estimation of Rock Strength Properties Using Selected Mechanical Parameters Obtained During the Rotary Drilling
    (Springer, 2019) Lakshminarayana, C.R.; Tripathi, A.K.; Pal, S.K.
    During the preliminary stage of rock engineering projects, the estimation of mechanical properties of rocks is most often required. The requirement of a large number of high-quality rock core samples is the major drawback when the mechanical rock properties are to be determined in a well-established rock mechanics laboratory. In this study, an attempt is made to estimate the uniaxial compressive strength and Brazilian tensile strength of sedimentary rocks using the selected mechanical drilling operating parameters obtained during the rotary drilling. The operating measured parameters such as the weight on bit or thrust and the vibration frequency induced at machine or drill head were acquired using the drill tool dynamometer and sound/vibration data acquisition system, respectively. The mathematical models were developed considering the drilling operational parameters (drill bit diameter, drill bit speed and penetration rate) and measured mechanical parameters (thrust and vibration frequency). The prediction potential of the developed models was assessed by the prediction performance indices. The outcome results revealed that the developed mathematical model using the approached method is significant and can be conveniently used for the estimation of mechanical properties of rocks during the rotary drilling. © 2019, The Institution of Engineers (India).