Faculty Publications
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Item Experimental investigations on performance characteristics in wire electro discharge machining of Ti50Ni42.4Cu7.6 shape memory alloy(2013) Narendranath, S.; Manjaiah, M.; Basavarajappa, S.; Gaitonde, V.N.This article investigates the effect of pulse on time, peak current and pulse off time on wire electro discharge machining characteristics of Ti 50Ni42.4Cu7.6 shape memory alloy. A Ti 50Ni42.4Cu7.6 alloy was prepared by conventional tungsten arc melting. The machining experiments were performed as per Box-Behnken design on computer control wire electro discharge machining machine using molybdenum wire electrode. The relationships between the process parameters (pulse on time, peak current and pulse off time) and wire electro discharge machining responses (surface roughness and material removal rate) have been established using response surface methodology-based quadratic models. The analysis of variance has been employed to test the significance of the developed second-order mathematical models. The parametric analysis-based results reveal that low peak current with prolonged pulse on duration leads to reduced surface roughness. However, combination of low peak current with low pulse on time is beneficial for achieving better material removal rate for machining of shape memory alloy. © IMechE 2013.Item Wire electric discharge machining characteristics of titanium nickel shape memory alloy(Nonferrous Metals Society of China B12 Fuxing Road Beijing 100814, 2014) Manjaiah, M.; Narendranath, S.; Basavarajappa, S.; Gaitonde, V.N.TiNi shape memory alloys (SMAs) have been normally used as the competent elements in large part of the industries due to outstanding properties, such as super elasticity and shape memory effects. However, traditional machining of SMAs is quite complex due to these properties. Hence, the wire electric discharge machining (WEDM) characteristics of TiNi SMA was studied. The experiments were planned as per L27 orthogonal array to minimize the experiments, each experiment was performed under different conditions of pulse duration, pulse off time, servo voltage, flushing pressure and wire speed. A multi-response optimization method using Taguchi design with utility concept has been proposed for simultaneous optimization. The analysis of means (ANOM) and analysis of variance (ANOVA) on signal to noise (S/N) ratio were performed for determining the optimal parameter levels. Taguchi analysis reveals that a combination of 1 ?s pulse duration, 3.8 ?s pulse off time, 40 V servo voltage, 1.8×105 Pa flushing pressure and 8 m/min wire speed is beneficial for simultaneously maximizing the material removal rate (MRR) and minimizing the surface roughness. The optimization results of WEDM of TiNi SMA also indicate that pulse duration significantly affects the material removal rate and surface roughness. The discharged craters, micro cracks and recast layer were observed on the machined surface at large pulse duration.Item Evaluation of WEDM performance characteristics of Inconel 706 for turbine disk application(Elsevier Ltd, 2015) Sharma, P.; Dupadu, D.; Narendranath, S.Inconel 706 is a newly developed superalloy, which offers high mechanical strength alongwith easy fabricability thus making it suitable for turbine disk applications. Although Inconel 706 exhibits a substantial increase in stress rupture and tensile yield strength compared to other superalloys, its conventional machining yields poor surface finish and low dimensional accuracy of the machined components. Hence, wire electrical discharge machining (WEDM) of Inconel 706 has been performed and various performance attributes such as material removal rate (MRR), surface roughness (SR), recast surface, topography, microhardness, microstructural and metallurgical changes of the machined components have been evaluated. The experimental results revealed that servo voltage, pulse on time, and pulse off time greatly influence the MRR and SR. Due to high toughness of Inconel 706, no micro cracks were observed on the machined surface. Micro voids and micro globules are significantly reduced at low pulse on time and high servo voltage. But, there is a propensity of thick recast layer formation at high pulse on time and low servo voltage. EDAX analysis of recast surface exposed the existence of Cu and Zn which have migrated from the brass wire. The subsurface microhardness was changed to 80. ?m due to significant thermal degradation. © 2015 Elsevier Ltd.Item Influence of process parameters on material removal rate and surface roughness in WED-machining of Ti50Ni40Cu10 shape memory alloy(Inderscience Publishers, 2016) Manjaiah, M.; Narendranath, S.; Basavarajappa, S.; Gaitonde, V.N.Among the shape memory alloys (SMAs), TiNi SMAs have been typically used as the functional elements in the larger part of the industries due to exceptional properties like super elasticity and shape memory effect. However, traditional machining of these alloys is fairly complex due to these properties. The non-traditional machining process like electric discharge machining (EDM) exhibits outstanding capability in machining of these alloys. The poor selection of machining parameters may cause increased roughness of workpiece and lesser material removal rate. Hence, an effort has been made in the present work to explore the effects of three process parameters, such as pulse on time, pulse off time and servo voltage in wire electric discharge machining (WEDM) of Ti50Ni40Cu10 shape memory alloy (SMA) using zinc coated brass wire electrode on material removal rate and surface roughness using response surface methodology (RSM)-based mathematical models. The experiments were planned as per central composite design (CCD). The investigations revealed that pulse on time and servo voltage have predominant effects in maximising material removal rate and minimising surface roughness. The best combination of the process parameters for multi-response optimisation was obtained through desirability function. ©2016 Inderscience Enterprises Ltd.Item Wire Electro Discharge Machining Performance of TiNiCu Shape Memory Alloy(Springer Netherlands, 2016) Manjaiah, M.; Narendranath, S.; Basavarajappa, S.The study presents the effect of Wire Electro Discharge Machining (WEDM) system parameters on the Material Removal Rate (MRR), surface roughness and surface morphology of Ti 50Ni 45Cu 5 SMA developed using vacuum arc melting. The WEDM parameters such as pulse on time, peak current, pulse off time and table feed were selected as control factors over MRR and surface roughness. The results reveal that the surface roughness and MRR increases with increased peak current, pulse on time and table feed but decreases slightly with pulse off time. Higher MRR was attained at 5Amps peak current and 70 ?m/s table feed. Better surface roughness was obtained for a combination of lower pulse on time, peak current and table feed with high pulse off time. Surface defects such as recast layer, craters, micro–cracks, pockmarks and voids were found on the machined surface. The globule of appendages formed around the craters and the intensity of the crater was evident for the higher surface roughness with an increase in peak current and pulse-on time during WEDM. © 2015, Springer Science+Business Media Dordrecht.Item Evaluation of wire electro discharge machining characteristics of Ti50Ni50-xCux shape memory alloys(Cambridge University Press, 2016) Manjaiah, M.; Laubscher, R.F.; Narendranath, S.; Basavarajappa, S.; Gaitonde, V.N.The machining of shape memory alloys (SMAs) is fairly essential and integral part in the manufacture of components for utilizing in engineering applications. An effort has been made in the present work to study the effect of wire electro discharge machining process parameters such as pulse on time (T on), pulse off time (T off) and servo voltage (SV) have been analyzed on material removal rate and surface roughness. The investigation clearly reveals that an increased pulse on time with decrease in pulse off time as well as SV increases the amount of material removed in machining of SMAs. On the other hand, the surface roughness increases with increased pulse on time and decreases with increased pulse off time as well as SV. The surface topography of the machined surface was analyzed using scanning electron microscope (SEM) and confocal micrographs. Phase changes on the machined surface with respect to pulse on time and SV were evaluated from X-ray diffractometer (XRD) analysis. © Materials Research Society 2016.Item Experimental investigation on variation of output responses of as cast TiNiCu shape memory alloys using wire EDM(ModTech Publishing House office@hotelfloramamaia.ro, 2017) Roy, A.; Narendra Nath, S.; Nedelcu, D.The present research study is emphasized on investigation of machining characteristics of TiNiCu shape memory alloys using Wire EDM and analyzes the effect of input process parameters on the quality of the machined surfaces. Complications associated with the machining process results in degradation of surface quality which notably is not avoidable. But proper optimization of the process parameters may help to achieve the desired or near-perfect quality of these machined products. Experiments were conducted as per Taguchi’s L16 orthogonal array considering four input parameters at four levels of operation for Ti50Ni40Cu10, Ti45Ni45Cu10 and Ti40Ni50Cu10 shape memory alloys. Zinc coated brass wire is used as the wire electrode in this study. Material removal rate (MRR) and surface roughness (SR) of the machined samples are considered as the output responses of these alloys. Optimum MRR and SR achieved while machining these alloys are 6.9431 mm3/min and 1.060 µm respectively for Ti50Ni40Cu10. Keeping in mind the productivity of the machining process, formation of recast layer of these alloys are also studied for optimum material removal rate, which led us to the conclusion that Ti45Ni45Cu10 alloy exhibits a surprising aversion towards formation of recast layer as compared to its counterparts. Also, Ti45Ni45Cu10 displayed least average recast layer thickness (RLT) of 9.16 µm compared to 23.93 µm and 21.65 µm for Ti50Ni40Cu10 and Ti40Ni50Cu10 respectively. Pulse on time (120 µs) and wire feed (10 m/min) are found as the most influential Wire EDM process parameters against pulse off time and wire feed for an optimum material removal rate and for a better surface finish, pulse on time (100 µs) and pulse off time (30 µs) against servo voltage and wire feed respectively. © 2017, ModTech Publishing House. All rights reserved.Item Multi-objective optimisation of cryogenic turning process using Taguchi-based grey relational analysis(Inderscience Publishers, 2017) Sivaiah, P.; Dupadu, D.Cryogenic machining is a sustainable manufacturing approach; it eliminates coolant disposal cost, health problems compared to the conventional flood cooling. The present study investigates the multiple response optimisation of turning process while machining AISI 17-4 PH stainless steel under the cryogenic environment (jetting of liquid nitrogen at -196°C at the rake face of the tool) by using Taguchi-based grey relational analysis. The optimum levels of the machining parameters are cutting speed at 120.89 m/min, feed rate at 0.048 mm/rev, depth of cut 0.4 mm and physical vapour deposition (PVD) AlTiN coated tungsten carbide (WC). Taguchi-based grey relational analysis method reduced the cutting forces by 7.75%, improved the surface finish by 55.87%, and increased the material removal rate (MRR) by 154.76% and 25% increased the tool flank wear in cryogenic turning process. From the analysis of variance, it was identified that feed rate is the most influenced process parameter on turning performance characteristics. © © 2017 Inderscience Enterprises Ltd.Item An experimental study of influence of wire electro discharge machining parameters on surface integrity of TiNiCo shape memory alloy(Cambridge University Press, 2017) Soni, H.; SannaYellappa, N.; Ramesh, M.R.Shape memory alloys (SMAs) are unique class of smart materials with excellent physical, mechanical and biomedical properties, which have wide applications in several fields such as aerospace, robotics, biomedical, and dental etc. These alloys are well known for exhibiting shape memory effect (SME) and pseudoelasticity (PE), it is a well-established fact that they are required to be processed into functioning parts. The conventional machining affects the internal properties of shape memory alloys and hence, it is reported that nonconventional machining techniques are more suitable. Wire electro discharge machining (WEDM) is one of the nonconventional machining processes for machining complicated shapes without hampering the internal properties of such type of materials. In the present experimental investigation, wire electro discharge machining of Ti50Ni40Co10 shape memory alloy (SMA) has been carried out and machining performances such as surface roughness (SR), and material removal rate (MRR) have been evaluated. Experimental results exposed that pulse on time, pulse off time and servo voltages are most influential process parameters on the responses. The machined surface has been characterised with respect to microstructure, microhardness, and phases formed. © Materials Research Society 2017.Item ANN and RSM modeling methods for predicting material removal rate and surface roughness during WEDM of Ti50Ni40Co10 shape memory alloy(AMSE Press 16 Avenue Grauge Blanche Tassin-la-Demi-Lune 69160, 2017) Soni, H.; Narendranath, S.; Ramesh, M.R.Present study exhibits the comparison between experimental and predicted values. Where response surface method (RSM) and artificial neural network (ANN) were used as predictor for the prediction of wire electro discharge machining (WEDM) responses such as the material removal rate (MRR) and surface roughness (SR) during the machining of Ti50Ni40Co10 shape memory alloy. It has been noticed from the literature survey that pulse on time and servo voltage are most important process parameters for the machining of TiNiCo shape memory alloy, hence there are five levels of these process parameters were chosen for the present study. For the present study selected alloy has been developed through vacuum arc melting and L-25 orthogonal array has been created by using Taguchi design of experiment (DOE) for experimental plan. During the present study ANN predicted values have been found to very close to experimental values compare to RSM predicted values, hence it can be say that ANN predictor gives more accurate values compare to RSM predicted values. © 2017 AMSE Press. All rights reserved.