Faculty Publications
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Item Rheodynamic lubrication of a squeeze film bearing under sinusoidal squeeze motion(Springer Science and Business Media, LLC, 2007) Kandasamy, A.; Vishwanath, K.P.Lubricants with variable viscosity are assuming importance for their applications in polymer industry, thermal reactors and in biomechanics. With the bearing operations in machines being subjected to high speeds, loads, increasing mechanical shearing forces and continually increasing pressures, there has been an increasing interest to use non-Newtonian fluids characterized by an yield value. The most elementary constitutive equation in common use that describes a material which yields is that of Bingham fluid. In the present work, the problem of a circular squeeze film bearing lubricated with Bingham fluid under the sinusoidal squeeze motion has been analyzed. The shape and extent of the core for the case of sinusoidal squeeze motion has been determined numerically for various values of the Bingham number. Numerical solutions have been obtained for the bearing performances such as pressure distribution and load capacity for different values of Bingham number, Reynolds number and for various amplitudes of squeeze motion. The effects of fluid inertia, non-Newtonian characteristics, and the amplitudes of squeeze motion on the bearing performances have been discussed. Copyright © 2007 SBMAC.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 Inertia effects in circular squeeze film bearing using Herschel-Bulkley lubricants(2010) Vishwanath, K.P.; Kandasamy, A.Recent engineering trends in lubrication emphasize that in order to analyze the performance of bearings adequately, it is necessary to take into account the combined effects of fluid inertia forces and non-Newtonian characteristics of lubricants. In the present work, the effects of fluid inertia forces in the circular squeeze film bearing lubricated with Herschel-Bulkley fluids with constant squeeze motion have been investigated. Herschel-Bulkley fluids are characterized by an yield value which leads to the formation of a rigid core in the flow region. The shape and extent of the core formation along the radial direction is determined numerically for various values of Herschel-Bulkley number and power-law index. The bearing performances such as pressure distribution and load capacity for different values of Herschel-Bulkley number, Reynolds number, power-law index have been computed. The effects of fluid inertia and non-Newtonian characteristics on the bearing performances have been discussed. © 2009 Elsevier Inc. All rights reserved.Item Analysis of surface roughness and hardness in titanium alloy machining with polycrystalline diamond tool under different lubricating modes(Universidade Federal de Sao Carlos, 2014) Revankar, G.D.; Shetty, R.; Rao, S.S.; Gaitonde, V.N.The present work deals with the investigation on machining of difficult-to-machine material titanium alloy (Ti-6Al-4V) using poly crystalline diamond (PCD) tool under different coolant strategies, namely dry, flooded and MQL. Taguchi technique has been employed and the optimization results indicated that MQL lubricating mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.25 mm depth of cut is necessary to minimize surface roughness and dry mode with cutting speed of 150 m/min, feed rate of 0.15 mm/rev, nose radius of 0.6 mm and 0.75 mm depth of cut is necessary to maximize surface hardness. The results indicate the substantial benefit of the minimum quantity of lubrication (MQL) and justify PCD inserts to be the most functionally satisfactory commercially available cutting tool material for machining titanium alloys for better surface finish and hardness.Item Machinability studies on 17-4 PH stainless steel under cryogenic cooling environment(Taylor and Francis Inc. 325 Chestnut St, Suite 800 Philadelphia PA 19106, 2017) Sivaiah, P.; Dupadu, D.Under higher cutting conditions, machining of 17-4 precipitation hardenable stainless steel (PH SS) is a difficult task due to the high cutting temperatures as well as accumulation of chips at the machining zone, which causes tool damage and impairment of machined surface finish. Cryogenic machining is an efficient, eco-friendly manufacturing process. In the current work, cutting temperature, tool wear (flank wear (Vb) and rake wear), chip morphology, and surface integrity (surface topography, surface finish (Ra), white layer thickness (WLT)) were considered as investigative machinability characteristics under the cryogenic (liquid nitrogen), minimum quantity lubrication (MQL), wet and dry environments at varying cutting velocities while machining 17-4 PH SS. The results show that the maximum cutting temperature drop found in cryogenic machining was 72%, 62%, and 61%, respectively, in contrast to dry, wet, and MQL machining conditions. Similarly, the maximum tool wear reduction was found to be 60%, 55%, and 50% in cryogenic machining over the dry, wet, and MQL machining conditions, respectively. Among all the machining environments, better surface integrity was obtained by cryogenic machining, which could produce the functionally superior products. © 2017 Taylor & Francis.Item 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. © 2018Item Minimum Quantity Lubrication through the micro-hole textured PCD and PCBN inserts in the machining of the Ti–6Al–4V alloy(Elsevier Ltd, 2021) Rao, C.M.; Sachin, B.; Rao, S.S.; Herbert, M.A.A novel cutting tool development with the micro-hole textures on the flank and rake face of the cutting inserts helps in the reduction of tribological properties. The machining of Ti–6Al–4V alloy leads to some challenges during machining namely higher cutting temperature, and rapid tool wear. In this research, a comparison study has been performed with the new cutting tool inserts with surface modification such as Polycrystalline Cubic Boron Nitride (PCBN) and Polycrystalline Diamond (PCD) inserts for high-speed machining of Ti–6Al–4V alloy. The influence of the micro-hole textured insert on the machining of the Ti–6Al–4V alloy was investigated with the Minimum Quantity Lubrication (MQL) method. Compared to modified PCBN inserts, modified PCD inserts showed better results in all the performance characteristics. © 2020 Elsevier LtdItem Development of Self-lubricating Nickel Based Composite Clad using Microwave Heating in Improving Resistance to Wear at Elevated Temperatures(Korean Institute of Metals and Materials, 2022) Gudala, S.; Ramesh, M.R.; Srinath, M.S.This paper reports on a study of the high-temperature tribological performance of self-lubricating nickel-based composite clad. A porous and crack free clad containing matrix, reinforcement, and lubricant phase is developed on titanium 31 alloy using microwave irradiation. The microstructure of both NiCrSiB/WC and NiCrSiB/WC/Ag/BaF2 clad revealed very good metallurgical bonding with the substrate. The average microhardness of NiCrSiB/WC and NiCrSiB/WC/Ag/BaF2 clad is 710.58 HV and 650.25 HV respectively, is comparatively higher than the titanium 31 substrate (320 HV). The addition of Ag and BaF2 solid lubricants in the clad endowing clad to operate at a broad temperature range. Compared with the NiCrSiB/WC clad, solid lubricant encapsulate clad has shown very low friction coefficient and wear rates. The sliding wear characteristics of the clad were investigated by varying load and temperatures. The results revealed that oxide phases (NiO and Cr3O) and lubricant phases (Ag and BaWO4) formed at low and high temperatures are adequate to reduce delamination and material loss. Graphical abstract: [Figure not available: see fulltext.] © 2021, The Korean Institute of Metals and Materials.Item Transformation of refinery cracked naphtha stream into efficient lubricity improvers for ULSD(Springer, 2022) Sruthi, H.; Udayakumar, D.U.; Hegde, P.; Manjunatha, M.G.; Karthick, R.; Nandakumar, V.A new route for the conversion of refinery light cracked naphtha (LCN) stream into lubricity improvers for ultra-low sulphur diesel (ULSD) was developed through a simple chemical process involving olefin epoxidation and esterification reactions. Two different methods viz., H2O2/glacial acetic acid and m-chloroperbenzoic acid (m-CPBA), were found to be suitable for the epoxidation of LCN. The LCN epoxide was subjected to an esterification reaction via epoxide ring opening using different long chain (C4 - C18 alkyl groups) organic acids to get the hydroxy ester derivatives of LCN. The lubricating property of the newly synthesized hydroxy esters was studied by dosing them with ULSD at 300 and 150 ppm (wt/vol) concentrations. Amongst them, LCN hydroxy ester derived from stearic acid showed the best lubrication-enhancing property at both dosage levels. The scanning electron microscope (SEM) image and energy dispersive spectra (EDS) of the high-frequency reciprocating rig (HFRR) specimen support the lubricating action of the LCN esters through the formation of a protective layer between the metallic surfaces. The synergy of simple chemical processes and efficient lubricity action makes these LCN esters as promising materials for low-cost and scalable additives for ULSD. Graphical abstract: The olefin-rich light cracked naphtha obtained from the fluidized catalytic cracker unit of the oil refinery was converted into hydroxy esters through an epoxidation reaction followed by the esterification with different carboxylic acids. The hydroxy esters at low dosage levels (150/300 ppm) enhance the lubricating property of ultra-low sulfur diesel. [Figure not available: see fulltext.]. © 2022, Indian Academy of Sciences.Item Enhancing mechanical properties of Ti-64 alloy through ECAE: lubricant optimization, microstructural evolution and optimal process parameters(Springer-Verlag Italia s.r.l., 2025) Castelino, M.R.; Mallikappa, N.; Karinka, S.; Vijayan, V.; Shivananda Nayaka, H.S.; Valder, J.This study explores the application of Equal Channel Angular Extrusion (ECAE) in enhancing the microstructural and mechanical properties of Ti-64 alloy. Finite Element (FE) analysis validates experimental outcomes, revealing a significant reduction in grain size, improved strength, and hardness. Microstructural analysis indicates dynamic recrystallization, transforming larger alpha (?) grains into smaller ones. Tensile testing demonstrates increased yield and ultimate strength in ECAE-treated specimens due to decreased grain size and heightened dislocation density. Lubricant optimization achieves low friction coefficients (0.02 and 0.04), reinforcing ECAE effectiveness. FE simulations and ANOVA analysis identify influential factors, leading to optimal parameter combinations. Isothermal ECAE successfully reduces grain size, resulting in substantial improvements in yield strength, ultimate strength, and hardness. These findings highlight ECAE's efficacy in enhancing the mechanical properties of Ti-64 alloy, with specific applications in biomaterials, particularly dental implants and bone support, as well as aerospace fasteners, where Ti-64 contributes to increased fuel efficiency, reduced emissions, and enhanced structural integrity. © The Author(s), under exclusive licence to Springer-Verlag France SAS, part of Springer Nature 2024.