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A Case Study on Implementation of 5S in a Manufacturing Plant to Improve Operational Effectiveness

A Case Study on Implementation of 5S in a Manufacturing Plant to Improve Operational Effectiveness

A comprehensive investigation on development of lightweight aluminium miniature gears by thermoelectric erosion machining process

A review on solid lubricant based machining of difficult-to-machine materials

A review on the influence of process parameters on powder metallurgy parts

  • Authors: Edosa, Osarue Osaruene , Tekweme, Francis Kunzi , Gupta, Kapil
  • Date: 2021
  • Subjects: Composites , Mechanical properties , Microstructure
  • Language: English
  • Type: Journal artice
  • Identifier: http://hdl.handle.net/10210/490435 , uj:44751 , Citation: Edosa, O.O., Tekweme, F.K. and Gupta, K., 2022. A review on the influence of process parameters on powder metallurgy parts. Engineering and Applied Science Research, 49(3), pp.433-443. , DIO:10.14456/easr.2022.44
  • Description: Abstract: The capability of powder metallurgy (PM) process to produce high quality components/parts is largely dependent on the control of process parameters. To obtain the desirable quality characteristics or properties in the produced part, an appropriate combination of process parameters is required. This paper presents a detailed review of powder metallurgy process parameters and their effects on a wide range of properties while developing a wide range of metallic and composites products. Key process parameters in this study include compaction pressure, sintering temperature, sintering time, sintering atmosphere, lubrication and reinforcement percentage volume. Their influence on physical properties, mechanical properties and microstructure of PM parts are extensively discussed. An extensive literature study as reported in this paper reveals that compaction pressure, sintering temperature, time and sintering atmosphere highly influence part density and strength, whereas part hardness and wear are greatly affected by hard ceramic reinforcement addition, compaction pressure, sintering temperature and time. Die wall lubrication greatly improve the physical, mechanical properties and microstructure of PM components compared to powder mass lubrication. It is observed that the powder metallurgy process conducted at optimum parameters produce quality products. This paper aims to facilitate researchers and scholars by providing a detail knowledge of PM process parameters and their effects, for them to conduct research and development to establish the field further.
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A study on machinability of nickel based superalloy using micro-textured tungsten carbide cutting tools

  • Authors: Gupta, Kapil , Khan, M. Adam
  • Date: 2020
  • Subjects: Superalloy , Cutting tool , Laser texturing
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/411151 , uj:34539 , Citation: M Adam Khan and Kapil Gupta 2020 Mater. Res. Express 7 016537 , DOI: https://doi.org/10.1088/2053-1591/ab61bf
  • Description: Abstract: In this research, an investigation on machinability of nickel-based superalloy (Inconel 600) under the influence of textured tungsten carbide cutting tools is conducted. Two main machinability indicators, namely, wear and life, have been investigated. Three types of micro-texture patterns i.e. dimples, lines and splines are laser engraved on the flank face of the cutting tool. Experiments are done with different cutting velocities, feed rate and depth of cut considering the texture pattern one among the input parameters. Firstly, while machining Inconel 600 with plain (non-textured)tungsten carbide cutting tool, it is investigated that at low velocity, the cutting nose caused damage due to abrasion and friction between the tool-chip interface. Severity in tool edge has increased along with adhesive wear and built- up edge at the cutting radius with increase in velocity. Thereafter, using textured on the tools, it is observed that the cutting tool wear resistance has tremendously increased with different textured patterns due to significant reduction in friction and heat. At low velocity (50 m min−1 ) the tool wear measured is in the range of 100–150 μm and maximum of 394 μm at high cutting velocity of 150 m min−1 . The tool life was calculated using Taylor’s equation based on Gaussian method. Tool lives for dimple and line textures are found superior. It is concluded that textured tools have potential to machine hard materials like Inconel superalloys with longer tool life.
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A study on machinability of nickel based superalloy using microtextured tungsten carbide cutting tools

  • Authors: Khan, M. Adam , Gupta, Kapil
  • Date: 2020
  • Subjects: Superalloy , Cutting tool , Tool, laser texturing
  • Language: English
  • Type: Aricle
  • Identifier: http://hdl.handle.net/10210/459479 , uj:40850 , Citation: M Adam Khan and Kapil Gupta 2020 Mater. Res. Express 7 016537 , DOI: https://doi.org/10.1088/2053-1591/ab61bf
  • Description: Abstract: In this research, an investigation on machinability of nickel-based superalloy (Inconel 600) under the influence of textured tungsten carbide cutting tools is conducted. Two main machinability indicators, namely, wear and life, have been investigated. Three types of micro-texture patterns i.e. dimples, lines and splines are laser engraved on the flank face of the cutting tool. Experiments are done with different cutting velocities, feed rate and depth of cut considering the texture pattern one among the input parameters. Firstly, while machining Inconel 600 with plain (non-textured) tungsten carbide cutting tool, it is investigated that at low velocity, the cutting nose caused damage due to abrasion and friction between the tool-chip interface. Severity in tool edge has increased along with adhesive wear and builtup edge at the cutting radius with increase in velocity. Thereafter, using textured on the tools, it is observed that the cutting tool wear resistance has tremendously increased with different textured patterns due to significant reduction in friction and heat. At low velocity (50mmin−1) the tool wear measured is in the range of 100–150 μmand maximum of 394 μmat high cutting velocity of 150mmin−1. The tool life was calculated using Taylor’s equation based on Gaussian method. Tool lives for dimple and line textures are found superior. It is concluded that textured tools have potential to machine hard materials like Inconel superalloys with longer tool life.
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An experimental study on MQL assisted high speed machining of NiTi shape memory alloy

  • Authors: Miller, Terence , Gupta, Kapil , Laubscher, Rudolph
  • Date: 2018
  • Subjects: Machinability , MQL , Shape memory alloy Sustainability
  • Language: English
  • Type: Conference proceedings
  • Identifier: http://hdl.handle.net/10210/279964 , uj:30075 , Citation: Miller, T., Gupta, K. & Laubscher, R. 2018. An experimental study on MQL assisted high speed machining of NiTi shape memory alloy.
  • Description: Abstract: Nickel Titanium (NiTi) shape memory alloy is a prominent material for biomedical implants. Machining of shape memory alloy is challenging and requires intervention of sustainable techniques to produce quality products with minimum environmental footprints. This paper details the results of experimental investigation conducted on MQL assisted high speed machining of shape memory alloys. It reports the effect of MQL parameters on surface roughness and tool wear during turning (at speed 90 m/min) of NiTi shape memory alloy. Experiments are conducted based on Taguchi’s robust design of experiment technique with L9 orthogonal array. Rhomboid shaped simple carbide tool is selected for experimentation. Green lubricant which is a blend of natural, synthetic and sulphurized esters is used as MQL fluid. Three important MQL parameters such as flow rate, air pressure, and nozzle distance are varied at 3 levels each. Parameters are optimized to secure the optimum combination producing best surface finish (Ra~1.39μm) and tool flank wear 1.6 mm.
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Analysis and optimization of surface quality of stainless steel miniature gears manufactured by CO2 laser cutting

  • Authors: Anghel, Cristina , Gupta, Kapil , Jen, T.C.
  • Date: 2020
  • Subjects: Gear , Laser , Machining
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/411159 , uj:34540 , Citation: Anghel, C., Gupta, K. & Jen. T.C. 2020. Analysis and optimization of surface quality of stainless steel miniature gears manufactured by CO2 laser cutting.
  • Description: Abstract: This paper reports the results of investigation conducted on CO2 laser cutting of miniature gears of stainless steel 304. In this work, analysis of the effects of important laser parameters such as power, cutting speed, focal position, and gas pressure on average surface roughness (Ra) has been investigated. Stainless steel spur gears having 9.04 mm outside diameter and 4.5 mm face width have been cut using a CO2 laser system with nitrogen as assisted gas. A total of twenty nine experiments have been conducted based on BBD (Box-Behnken Design) technique of response surface methodology where aforementioned laser parameters varied at three levels each. ANOVA study found focal position as the most significant parameter. Further, the Desirability based optimization of laser parameters obtained best values of Ra- 0.43 µm at laser power- 2407 W, cutting speed- 1.25 m/min, focal position- (-) 2.4 mm, gas pressure- 12.5 bar. A scanned electron microscopy study also revealed the good surface morphology of the miniature gear machined at optimum parameters.
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Analysis and optimization of surface quality while machining high strength aluminium alloy

Causes and impact of human error in maintenance of mechanical systems

  • Authors: Nkosi, Mfundo , Gupta, Kapil , Mashinini, Madindwa
  • Date: 2020
  • Subjects: Failure , Human error , Human factor
  • Language: English
  • Type: Conference proceedings
  • Identifier: http://hdl.handle.net/10210/411127 , uj:34536 , Citation: Nkosi, M., Gupta, K. & Mashinini, M. 2020. Causes and impact of human error in maintenance of mechanical systems.
  • Description: Abstract: The concept of minimizing human error in maintenance is progressively gaining attention in various industries. The incorporation of human factors when solving engineering problems, particularly in maintenance, can no longer be ignored where high standards of performance are expected. The journey of improving maintenance performance through the reduction of human error begins with the understanding of causes and impact of human error in maintenance. This paper evaluates previous scholarly writings on human errors, to specifically establish the causes and impact of human error in maintenance. This study relies predominantly on the existing literature on human error in maintenance derived from published and unpublished research. The primary findings emerging from the research exhibit a number of key factors that cause a human error in maintenance such as poor management and supervision, organizational culture, incompetence, poorly written procedures, poor communication, time pressure, plant and environmental conditions, poor work design and many more. The literature review also revealed that human errors have a negative impact on safety, reliability, productivity and efficiency of the equipment. It was further discovered that equipment failures leading to accidents, incidents, loss of life and economic losses are the major effects of human error. Human error in mechanical systems’ maintenance is a serious problem which needs adequate attention in order to develop corrective and preventive measures. This review paper serves as a basis for maintenance practitioners and interested parties to develop corrective and preventive measures for minimizing human error in the maintenance of mechanical systems.
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Developments in non-conventional machining for sustainable production - a state of art review

Effect of laser beam cutting parameters on productivity and dimensional accuracy of miniature spur gears of stainless steel

  • Authors: Anghel, Cristina , Gupta, Kapil , Jen, T. C.
  • Date: 2020
  • Language: English
  • Type: Conference proceedings
  • Identifier: http://hdl.handle.net/10210/460212 , uj:40945 , Citation: Cristina Anghel et al 2020 IOP Conf. Ser.: Mater. Sci. Eng. 971 022081
  • Description: Abstract: Product quality and process productivity are one of the major indicators to evaluate the performance of any manufacturing process. The quality of any product covers its appearance, geometric and dimensional accuracy, and surface finish and integrity that majorly include microstructure, micro-hardness type of parameters. Whereas, the productivity can be determined using material removal rate. Laser beam cutting is an important advanced machining process and has been scarcely explored for miniature gears. This paper reports, the effect of laser beam cutting parameters on one of the quality parameters i.e. dimensional deviation of miniature spur gears of stainless steel and material removal rate. Box Behnken design of experiments methodology has been adopted to conduct a total of twenty nine experiments where four important laser parameters i.e. power, cutting speed, focal position, and gas pressure have been varied at three levels each. The manufactured external spur gear of stainless steel consists of ten teeth, 0.750 module, 9.04 mm outside diameter, and 4.5 mm face width or thickness. The investigation found that cutting speed significantly affected material removal rate and laser power affected dimensional deviation. Individual effects of laser parameters on both material removal rate and dimensional deviation are discussed in detail in the chapter. The investigation identifies laser beam cutting as a viable substitute of conventional manufacturing processes for fabrication of quality miniature gears with high productivity.
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Experimental evaluation of surface quality characteristics in laser machining of nickel-based superalloy

  • Authors: Khan, Adam M. , Gupta, Kapil
  • Date: 2019
  • Subjects: Kerf , Laser , Microstructure
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/404309 , uj:33902 , Citation: Khan, A.M. & Gupta, K. 2019. Experimental evaluation of surface quality characteristics in laser machining of nickel-based superalloy.
  • Description: Abstract: This paper reports the investigation results of CO2 laser cutting of Inconel 718 superalloy. Investigation on the effects of the two important laser parameters power and travel speed on machinability i.e. material removal rate, kerf wall inclination, and average surface roughness of Inconel 718 has been conducted. Increased kerf wall inclination has been found with slow travel speed and increasing power. Low power and high travel speed produced maximum material removal rate and minimum surface roughness. Premature state of fusion has advanced dross regime at a slow cutting speed of 3.3 m/min and leading to a surface roughness of 9.3 microns maximum. Dendrite structures were formed and changes in surface hardness were observed due to high travel speed. Therefore, based on the investigation, slow travel speed with appropriate laser power is recommended for the improved machinability and surface quality of Inconel 718 superalloys.
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Experimental investigation of nozzle clogging using vibration signal-based condition monitoring for fused deposition modeling

  • Authors: Jhodkar, Durwesh , Nayak, Ankit , Gupta, Kapil
  • Date: 2021
  • Subjects: Condition monitoring , Nozzle clogging , FDM
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/477097 , uj:43095 , Citation: Jhodkar, D., Nayak, A. & Gupta, K. 2021. Experimental investigation of nozzle clogging using vibration signal-based condition monitoring for fused deposition modeling.
  • Description: Abstract: Fused deposition modeling (FDM) or 3D printing is one of the promising techniques widely preferred to fabricate complex and customized 3D objects or prototypes for various engineering and non-engineering applications. With the growing demands of customized prototypes, researchers are facing a major challenge for maintaining effective part quality with adequate surface finish and strength; and minimizing the cost, defects, and waste in 3D printing. Condition monitoring is one of the strategies to achieve the aforementioned. It has a huge potential to minimize defects and print failures in 3D printing. The main objective of this research work is to perform online condition monitoring of the nozzle status with the help of vibration signals in fused deposition modelling process. The effect of nozzle clogging on the consistency of material deposition and its effect on surface finish has experimentally investigated in this work. The set of experiments were performed by artificially creating the condition of nozzle clogging to investigate the effect of nozzle clogging on print quality (surface finish). Nozzle clogging condition was created by increasing the feed rate of polylactic acid (PLA) filament at a low heat supply rate to the nozzle by modifying the commands of 3D printer. The layer thickness was varied throughout the experiments to observe the nozzle clogging. The vibrations signals were acquired by using an accelerometer that was mounted near the nozzle. The data acquisition frequency of the accelerometer was 12500Hz. Further, the acquired vibration signals were analyzed using the Fast Fourier transformation (FFT) signal processing technique. Results revealed that nozzle clogging severely affects surface quality and geometrical accuracy of the fabricated 3D part due to nozzle vibration and non-uniform material deposition. Moreover, nozzle clogging and its relevant consequences like non uniform material deposition can be monitored using vibration signal-based condition monitoring during part fabrication and based upon that appropriate measures can be taken for defects and waste elimination.
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FUZZY-MOORA based optimization of machining parameters for machinability enhancement of titanium

  • Authors: Jhodkar, Durwesh , Khan, Akhtar , Gupta, Kapil
  • Date: 2021
  • Subjects: Fuzzy , Machining , Hybrid optimization
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/477089 , uj:43094 , Citation: Jhodkar, D., Khan, A. & Gupta, K. 2021. FUZZY-MOORA based optimization of machining parameters for machinability enhancement of titanium. DOI:
  • Description: Abstract: The aim of this study is to determine the optimal combination of process parameters when machining commercially pure titanium grade 2. The unification of Multi objective optimization based on ratio analysis (MOORA) and fuzzy approach has applied to optimize the process parameters. Three process parameters i.e. cutting speed, tool overhang, and microhardness have been varied at three levels each and a total of twenty seven experiments have been conducted based on Taguchi’s L27 design of experiment technique. Cutting force, tool flank wear, and average surface roughness have been considered a machinability indicators to measure the process performance. Feed rate and depth of cut have been kept constant. Successful optimization is done and results show that machining titanium at higher cutting speed (140 m/min) and higher tool overhang length (65 mm) with medium hardness (1934 HV) results in lower cutting force, tool flank wear, and surface roughness. Outcomes of the present work reveal that the hybrid fuzzy-MOORA method is convincing enough to obtain the best process parameter combination for the best machinability while machining titanium type difficult-to-machine materials.
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Influence of coated and uncoated carbide tools on tool wear and surface quality during dry machining of stainless steel 304

  • Authors: Sharma, Neeraj , Gupta, Kapil
  • Date: 2019
  • Subjects: Coating , Friction , Surface roughness
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/407456 , uj:34298 , Citation: Sharma, N., Gupta, K. 2019: Influence of coated and uncoated carbide tools on tool wear and surface quality during dry machining of stainless steel 304.
  • Description: Abstract: Machining of difficult-to-machine materials has always been a prime area of investigation for researchers. With regard to that tool wear and surface roughness are some of the most important machinability indicators to evaluate the performance of machining processes. This paper reports a part of investigation conducted on dry turning of SS 304 using uncoated and multilayer coated carbide tools. In this work, the influence of machining parameters on tool wear and surface roughness is studied. The mechanisms of both crater wear and flank wear have been analyzed through scanned electron microscopy and energy dispersive spectroscopy. Moreover, surface roughness (mean roughness depth) profiles have been investigated. Carbide tools coated with TiAlN/TiN alternate layers outperformed uncoated tools with a significant reduction in tool flank wear and mean roughness depth (Rz). The percentage reductions in tool flank wear and Rz were investigated at different levels of input machining parameters. On average approximately 25% reduction in tool wear and 15% reduction in Rz was observed using coated tool than uncoated tool. Furthermore, the tool life has been improved by approximately 200 % after using coated tools. Comparatively less irregular surface while machining with coated tools has been found than uncoated tools. The research is also complemented with a short chip morphology study. The present work recommends the use of multilayer TiAlN/TiN coating on carbide tools for machining of SS 304 under dry conditions.
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Influence of MQL and hobbing parameters on microgeometry deviations and flank roughness of spur gears manufactured by MQL assisted hobbing

  • Authors: Kharka, Vishal , Jain, Neelesh Kumar , Gupta, Kapil
  • Date: 2020
  • Subjects: Gear hobbing , MQL , MQLAH
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/453119 , uj:39992 , Citation: Kharka, V., Jain, N.K. & Gupta, K. 2020. Influence of MQL and hobbing parameters on microgeometry deviations and flank roughness of spur gears manufactured by MQL assisted hobbing.
  • Description: Abstract: Abstract Conventional cutting fluids used in gear hobbing have negative impacts on the environment and health of the machine operators thereby adversely affecting the sustainability of the gear hobbing process. This paper reports on MQL assisted hobbing (MQLAH) using environment friendly fatty alcohol-based lubricants to manufacture superior quality spur gears. Experimental investigation was conducted to study of influence of six parameters of MQLAH namely hob cutter speed, axial feed, depth of cut, lube flow rate, air pressure, and nozzle angle on microgeometry deviations, avg. and max. values of flank surface roughness, and material removal rate to identify their optimum ranges to manufacture better quality spur gears with maximum productivity. Deviations in total profile, lead, cumulative pitch and radial runout were used to evaluate microgeometry of the spur gears. It revealed that depth of cut has no considerable effect on the spur gear quality. It identified that higher value of hob cutter speed, lower value of axial feed, optimum values of lube flow rate as 100 ml/hr, nozzle angle as 30o, and air pressure in a range from 3-5 bar yield superior quality of spur gears by MQLAH.
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Intelligent machining of shape memory alloys

  • Authors: Gupta, Kapil
  • Date: 2021
  • Subjects: Optimization , Shape memory alloy , TOPSIS-Fuzzy
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/482647 , uj:43774 , Citation: Gupta, K. 2021. Intelligent machining of shape memory alloys.
  • Description: Abstract: Shape memory alloys are important biomaterials but difficult-to-machine (DTM). Their machining needs to be done using intelligent techniques to obtain a better machinability. Hybrid optimization is one of such techniques which can perform modeling and optimization of machining parameters for the best values of machinability indicators. Wire electric discharge machining (WEDM) of shape memory alloy has been found as a prominent alternate to the conventional machining techniques; however it needs the assistance of intelligent techniques to machine such materials to obtain the optimum values of machinability indicators. In this paper, WEDM of shape memory alloy Ni55.8Ti was reported. WEDM was carried out by varying four process parameters i.e. servo voltage SV, pulse-on time Pon, pulse-off time Poff, and wire feed rate WF using Taguchi L16 robust design of experiment technique. A hybrid optimization technique TOPSIS-Fuzzy-PSO has been successfully used to optimize these parameters (SV-50V; Pon-1µs; Poff-17 µs; WF-4 m/min) for the best possible values of material removal rate (MRR) – 0.049 g/min, maximum roughness – 11.45 µm, and recast layer – 22.10 µm simultaneously.
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Intelligent optimization of Wire-EDM parameters for surface roughness and material removal rate while machining WC-Co composite

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