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Optimization of laser machining parameters and surface integrity analysis of the fabricated miniature gears

- Anghel, C., Gupta, K., Jen, T. C.

An Investigation on Achieving Sustainability in Fused Deposition Modeling via Topology Optimization

- Espach, A., Gupta, K.

A review on green machining techniques

- Gupta, K.

  • Authors: Gupta, K.
  • Date: 2020
  • Subjects: Environment , Green , Machining
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/457922 , uj:40654 , Citation: Gupta, K. 2020. A review on green machining techniques.
  • Description: Abstract: Industrial revolutions from Industry 1.0 to Industry 4.0 have drastically transformed human life. Industrialization with high productivity, zerodefect quality, improved efficiency, significant time saving and much better connectivity are some major benefits, but on the cost of environmental degradation. To overcome this challenge, globally sustainable manufacturing interventions are being given considerable importance. The term Sustainability is the ability of the processes, systems, products, or services to perform efficiently without affecting environment. From raw material processing to supplying final products, sustainability interventions are in place. Sustainability interventions incorporate various strategies and techniques to conserve natural resources and protect environment. Machining is an important segment in manufacturing sector to produce engineered parts and components for capital and consumer goods with the help of typical processes. These processes eventually result out in high environmental-footprints. It necessitated the development of green machining techniques such as hybrid machining, green lubrication methods, dry-cutting, energy-efficient and assisted machining processes etc. This paper discusses some of the green machining techniques developed in conventional and non-conventional machining domain for clean, green and safe environment. It is hoped that green machining techniques would greatly assist towards the success of industrial revolutions. The main objective of this paper is to facilitate researchers and academics by providing useful information in order to establish the field further.
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On machinability of titanium grade 4 under minimum quantity lubrication assisted high speed machining

- Mathonsi, T. N., Laubscher, R. F., Gupta, K.

  • Authors: Mathonsi, T. N. , Laubscher, R. F. , Gupta, K.
  • Date: 2018
  • Language: English
  • Type: Conference proceedings
  • Identifier: http://hdl.handle.net/10210/279947 , uj:30074 , Citation: Mathonsi, T.N., Laubscher, R.F. & Gupta, K. 2018. On machinability of titanium grade 4 under minimum quantity lubrication assisted high speed machining.
  • Description: Abstract: The wonder metal Titanium and its alloys are prime candidate for various automotive, biomedical and aerospace applications due to their good strength-to-weight ratio, biocompatibility and corrosion resistance. Titanium and its alloys are known as difficult-to-machine materials i.e. their machining is challenging. The experimental work reported in the present paper attempts to enhance the machinability of Titanium Grade 4 under the influence of minimum quantity lubrication at high speed conditions. In this work a total of twenty seven experiments has been conducted based on full factorial design of experiment technique. Cutting speed, feed rate, and depth of cut are varied at three levels each and the values of important MQL parameters are fixed. The effects of machining parameters on surface roughness are discussed. Machining at optimum combination of parameters resulted in precision finish with maximum roughness value 2.16 μm and maximum tool flank wear value 0.201 mm. The research results reveal the superiority of MQL over conventional wet cooling to successfully machine Titanium Grade 4 at high speed conditions with sustainability.
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On abrasive water jet machining of miniature brass gears

- Phokane, T. C., Gupta, K., Popa, C.

  • Authors: Phokane, T. C. , Gupta, K. , Popa, C.
  • Date: 2018
  • Subjects: Abrasive water jet machining , Miniature gear , Precision
  • Language: English
  • Type: Conference proceedings
  • Identifier: http://hdl.handle.net/10210/279329 , uj:29996 , Citation: Phokane, T.C., Gupta, K. & Popa, C. 2018. On abrasive water jet machining of miniature brass gears.
  • Description: Abstract: Miniature gears are the key components of various miniaturized devices. Manufacturing quality, surface finish, and surface integrity of miniature gears are of prime importance to determine their functional performance and service life. This article presents the results of some experimental investigations conducted to machine precision miniature brass gears by abrasive water jet machining process. The fabricated gears are external spur type and have 8.4 mm pitch diameter, 12 teeth, and 5 mm thickness. It reports important results i.e. micro‐geometry and surface roughness of miniature gears machined by abrasive water jet process. The manufacturing quality DIN 8 and surface finish 1.03 μm have been obtained in the present research. It also discusses important aspects of various stages of this research along with the discussion on the effects of machining parameters on surface quality of gears, and a detailed surface integrity analysis. The present research identifies AWJM as a sustainable alternate to the conventional processes of miniature gear manufacturing that needs further exploration with other gear types and materials.
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Investigation on laser beam machining of miniature gears

- Popa, C., Gupta, K., Mashamba, A., Jen, T. C.

  • Authors: Popa, C. , Gupta, K. , Mashamba, A. , Jen, T. C.
  • Date: 2018
  • Subjects: Laser , Miniature gear , Precision
  • Language: English
  • Type: Conference proceedings
  • Identifier: http://hdl.handle.net/10210/279304 , uj:29994 , Citation: Popa, C. et al. 2018. Investigation on laser beam machining of miniature gears.
  • Description: Abstract: Micro‐machining has become a fast growing field in the global manufacturing sector due to increasing demand of miniature machines and devices. The trend involves the fabrication of precision miniature parts that have widespread applications in many areas such as, electronics, biomedical, aerospace, robotics, automobiles and consumer products. Miniature gears are essential components of miniaturised devices such as miniature motors and pumps, scientific instruments, medical equipment, timing devices, and robots etc. These gears are generally fine‐pitched gears running at very high speed, mainly used for transmission of motion and/or torque. Therefore, minimum running noise, accurate motion transfer and long service life are the required qualities of these gears. Considering that a laser beam is capable of cutting complex shapes with great precision and little waste, motivates its use to machine small sized parts including miniature gears. This article reports on the fabrication of stainless steel miniature gears by laser beam machining (LBM) process. A total of twenty experiments have been conducted following one factor at a time design of experiment strategy on CO2 laser machine. The fabricated gears have 9 mm pitch diameter, 10 teeth, and 4.5 mm thickness. The effects of laser machining parameters on surface roughness (mainly average roughness ‘Ra’ and mean roughness depth ‘Rz’) of gears have been analysed. The best quality miniature gear fabricated by LBM possesses 1.04 μm average roughness and 5.797 μm mean roughness depth at par with that obtained by conventional and other advanced processes of miniature gear manufacturing. Investigation reveals that LBM is capable to produce miniature gears of good surface finish and integrity ensuring their high functional performance and long service life. The outputs of this preliminary work encourage further exploration of LBM to establish it as an alternative process for fabrication of precision miniature gears.
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On wire spark erosion machining induced surface Integrity of Ni55.8Ti shape memory alloys

- Sharma, N., Gupta, K.

  • Authors: Sharma, N. , Gupta, K.
  • Date: 2019
  • Subjects: Wire spark erosion machining , Shape memory alloy , Surface integrity
  • Language: English
  • Type: Article
  • Identifier: http://hdl.handle.net/10210/407448 , uj:34297 , Citation: Sharma, K., Gupta, K. 2019: On wire spark erosion machining induced surface Integrity of Ni55.8Ti shape memory alloys.
  • Description: Abstract: Ni55.8Ti shape memory alloys (SMAs) find applications in different fields of medical and engineering. In every field, surface integrity greatly affects the functional performance of shape memory alloy parts. In the present work, wire spark erosion machining of Ni55.8Ti shape memory alloys has been conducted and surface integrity parameters of the machined specimens have been evaluated. Experiments are designed using Taguchi L16 robust design of experiment technique. Effect of important process parameters i.e. voltage, pulse-on time and pulse-off time on maximum surface roughness has been studied. Deterioration in surface integrity at various combinations of pulse-on and pulse-of time which produced high discharge energy has been observed. Scanned electron microscopic investigation, energy dispersive spectroscopy and XRD analyses, roughness measurement, and micro-hardness testing results are presented, analyzed and discussed. Optimization of process parameters resulted in surface integrity enhancement with low roughness (Rt - 7.78 µm and Ra - 1.45 µm) and very thin recast layer (4-6 µm) along with minimum subsurface defects.
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