Recent developments in laser cutting of metallic materials
- Anghel, Cristina, Gupta, Kapil, Mashamba, Able, Tien-Chen, Jen
- Authors: Anghel, Cristina , Gupta, Kapil , Mashamba, Able , Tien-Chen, Jen
- Date: 2018
- Subjects: Heat affected zone , Kerf width , Laser cutting
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/288767 , uj:31314 , Citation: Anghel, C. et al. 2018. Recent developments in laser cutting of metallic materials.
- Description: Abstract: Laser cutting has become an extensively used method of material removal with cost effective solutions for complex manufacturing processes. Consequently, the process has become an area of intense research and development activity where researchers and industry experts are focusing on maximizing the productivity and reducing the cost while maintaining a high quality. Laser cutting, as the prevalent application of laser beam machining (LBM), offers a competitive advantage over conventional cutting processes in terms of material savings due to narrow kerf width, less heat affected zone and minimum distortions. The process offers high precision and good surface quality, with no tool wear and easy automation. The current paper aims to present an overview on the recent research on laser cutting of metallic materials, in terms of process monitoring and control as well as modeling and optimization, and to summarize the past five years of research on the topic.
- Full Text:
- Authors: Anghel, Cristina , Gupta, Kapil , Mashamba, Able , Tien-Chen, Jen
- Date: 2018
- Subjects: Heat affected zone , Kerf width , Laser cutting
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/288767 , uj:31314 , Citation: Anghel, C. et al. 2018. Recent developments in laser cutting of metallic materials.
- Description: Abstract: Laser cutting has become an extensively used method of material removal with cost effective solutions for complex manufacturing processes. Consequently, the process has become an area of intense research and development activity where researchers and industry experts are focusing on maximizing the productivity and reducing the cost while maintaining a high quality. Laser cutting, as the prevalent application of laser beam machining (LBM), offers a competitive advantage over conventional cutting processes in terms of material savings due to narrow kerf width, less heat affected zone and minimum distortions. The process offers high precision and good surface quality, with no tool wear and easy automation. The current paper aims to present an overview on the recent research on laser cutting of metallic materials, in terms of process monitoring and control as well as modeling and optimization, and to summarize the past five years of research on the topic.
- Full Text:
Analysis and optimization of surface quality of stainless steel miniature gears manufactured by CO2 laser cutting
- Anghel, Cristina, Gupta, Kapil, Jen, T.C.
- 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.
- Full Text:
- 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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Effect of laser beam cutting parameters on productivity and dimensional accuracy of miniature spur gears of stainless steel
- Anghel, Cristina, Gupta, Kapil, Jen, T. C.
- 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.
- Full Text:
- 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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A comprehensive investigation on development of lightweight aluminium miniature gears by thermoelectric erosion machining process
- Chaubey, Sujeet Kumar, Jain, Neelesh, Gupta, Kapil
- Authors: Chaubey, Sujeet Kumar , Jain, Neelesh , Gupta, Kapil
- Date: 2021
- Subjects: Thermoelectric erosion , Micromanufacturing , Microgeometry
- Language: English
- Type: Book chapter
- Identifier: http://hdl.handle.net/10210/485865 , uj:44177 , Citation: Chaubey, S.K.; Jain, N.K.; Gupta, K. A Comprehensive Investigation on Development of Lightweight Aluminium Miniature Gears by Thermoelectric Erosion Machining Process. Micromachines 2021, 12, 1230. https://doi.org/10.3390/mi12101230 , DOI: 10.3390/mi12101230
- Description: Abstract: Please refer to full text to view abstract.
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- Authors: Chaubey, Sujeet Kumar , Jain, Neelesh , Gupta, Kapil
- Date: 2021
- Subjects: Thermoelectric erosion , Micromanufacturing , Microgeometry
- Language: English
- Type: Book chapter
- Identifier: http://hdl.handle.net/10210/485865 , uj:44177 , Citation: Chaubey, S.K.; Jain, N.K.; Gupta, K. A Comprehensive Investigation on Development of Lightweight Aluminium Miniature Gears by Thermoelectric Erosion Machining Process. Micromachines 2021, 12, 1230. https://doi.org/10.3390/mi12101230 , DOI: 10.3390/mi12101230
- Description: Abstract: Please refer to full text to view abstract.
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Structural analysis on mild-steel and aluminium brake disk for application on belt conveyor
- Chelopo, Daniel, Gupta, Kapil
- Authors: Chelopo, Daniel , Gupta, Kapil
- Date: 2020
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/460211 , uj:40946 , Citation: Daniel Chelopo and Kapil Gupta 2020 IOP Conf. Ser.: Mater. Sci. Eng. 971 042056
- Description: Abstract: A disk brake system has three essential functions, namely, reducing the moving conveyor speed, preserving its steady downhill speed and stopping the conveyor fully during normal or emergency operation. There has been a persistent demand in recent years for light weight disks with highly efficient energy-absorbing structures and materials in the overall conveyor system. This aspiration has led to experimental work in attempt to use various materials for engineering designs. In this article, a rotating annular disc subjected to in-plane frictional loads is analytically modelled on the brake system. In order to obtain modal properties of breaking for inputs into the finite element model, the experimental modal test of disc brake device free under free boundary conditions is performed. The goal of this research is to recognize various properties that may in future enable us to optimize working parameters and increase braking system efficiency. The findings will enable us to achieve the optimal functionality of this structure to improve the operational disc life or performance. The aim of this document is to examine stress concentration, structural deformation and brake disk contact pressure during a single braking stop event using ANSYS 19.2 academic finite element software. This research therefore provides an important guide to the design and engineering of the brake disk and the brake pad. Structural and stress analysis are therefore preferred to pick the lightweight material for improved performance. Consequently, the lightweight material may be recommended to reduce the conveyor working load and preserve operational energy consumption, provided that light weight will satisfy working duty requirements. Comparing the results achieved with those of the technical literature, the simulation is satisfactory.
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- Authors: Chelopo, Daniel , Gupta, Kapil
- Date: 2020
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/460211 , uj:40946 , Citation: Daniel Chelopo and Kapil Gupta 2020 IOP Conf. Ser.: Mater. Sci. Eng. 971 042056
- Description: Abstract: A disk brake system has three essential functions, namely, reducing the moving conveyor speed, preserving its steady downhill speed and stopping the conveyor fully during normal or emergency operation. There has been a persistent demand in recent years for light weight disks with highly efficient energy-absorbing structures and materials in the overall conveyor system. This aspiration has led to experimental work in attempt to use various materials for engineering designs. In this article, a rotating annular disc subjected to in-plane frictional loads is analytically modelled on the brake system. In order to obtain modal properties of breaking for inputs into the finite element model, the experimental modal test of disc brake device free under free boundary conditions is performed. The goal of this research is to recognize various properties that may in future enable us to optimize working parameters and increase braking system efficiency. The findings will enable us to achieve the optimal functionality of this structure to improve the operational disc life or performance. The aim of this document is to examine stress concentration, structural deformation and brake disk contact pressure during a single braking stop event using ANSYS 19.2 academic finite element software. This research therefore provides an important guide to the design and engineering of the brake disk and the brake pad. Structural and stress analysis are therefore preferred to pick the lightweight material for improved performance. Consequently, the lightweight material may be recommended to reduce the conveyor working load and preserve operational energy consumption, provided that light weight will satisfy working duty requirements. Comparing the results achieved with those of the technical literature, the simulation is satisfactory.
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A review on the influence of process parameters on powder metallurgy parts
- Edosa, Osarue Osaruene, Tekweme, Francis Kunzi, Gupta, Kapil
- 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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- 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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Minimum quantity lubrication (MQL) assisted machining of grade-4 titanium
- Gupta, Kapil, Laubscher, R.F.
- Authors: Gupta, Kapil , Laubscher, R.F.
- Date: 2016
- Subjects: Minimum quantity lubrication , Green machining , Taguchi robust design
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/123579 , uj:20814 , Citation: Gupta, K & Laubscher, R.F. 2016. Minimum quantity lubrication (MQL) assisted machining of grade-4 titanium.
- Description: Abstract: This paper presents the results of an experimental investigation for turning of Grade-4 titanium with carbide cutting tool inserts with minimum quantity lubrication (MQL). Experiments were designed based on Taguchi’s L9 orthogonal array. The MQL parameters of flow rate (50-70-90 mL/hr); nozzle distance (20-30-40 mm) and air pressure (4-5-6 bar) were varied for three different levels each. Cutting speed, feed and depth of cut were fixed at 125 m/min; 0.2 mm/rev and 1 mm respectively. The grey relational method in conjunction with the Taguchi technique was used for optimizing the MQL parameters. The nozzle distance was recognized as the most significant parameter. The data further indicated that the optimum MQL parameters were a flow rate of 70 mL/hr, nozzle distance of 30 mm and air pressure of 6 bar. When compared to dry and wet cutting conditions MQL was shown to have significant advantages.
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- Authors: Gupta, Kapil , Laubscher, R.F.
- Date: 2016
- Subjects: Minimum quantity lubrication , Green machining , Taguchi robust design
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/123579 , uj:20814 , Citation: Gupta, K & Laubscher, R.F. 2016. Minimum quantity lubrication (MQL) assisted machining of grade-4 titanium.
- Description: Abstract: This paper presents the results of an experimental investigation for turning of Grade-4 titanium with carbide cutting tool inserts with minimum quantity lubrication (MQL). Experiments were designed based on Taguchi’s L9 orthogonal array. The MQL parameters of flow rate (50-70-90 mL/hr); nozzle distance (20-30-40 mm) and air pressure (4-5-6 bar) were varied for three different levels each. Cutting speed, feed and depth of cut were fixed at 125 m/min; 0.2 mm/rev and 1 mm respectively. The grey relational method in conjunction with the Taguchi technique was used for optimizing the MQL parameters. The nozzle distance was recognized as the most significant parameter. The data further indicated that the optimum MQL parameters were a flow rate of 70 mL/hr, nozzle distance of 30 mm and air pressure of 6 bar. When compared to dry and wet cutting conditions MQL was shown to have significant advantages.
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Recent developments in sustainable manufacturing of gears: a review
- Gupta, Kapil, Laubscher, R.F., Davim, J. Paulo, Jain, N.K.
- Authors: Gupta, Kapil , Laubscher, R.F. , Davim, J. Paulo , Jain, N.K.
- Date: 2016
- Subjects: Sustainable manufacturing , Gear machining , Minimum quantity lubrication
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/123571 , uj:20813 , Citation: Gupta, K. 2016. Recent developments in sustainable manufacturing of gears: a review.
- Description: Abstract: Environment awareness is of the utmost importance to all socially responsible manufacturers. To be competitive on a global scale manufacturing needs to be aligned with various strict environmental regulations. The manufacturing industry at large is striving to improve productivity and product quality while maintaining a clean and sustainable environment. This can only be achieved by adopting sustainable techniques of manufacturing which include minimizing the number of manufacturing steps by employing advanced and alternative methods, environment-friendly lubricants and lubrication techniques while machining, reducing wastage, active waste management and minimizing energy consumption etc. Gear manufacturing industries, the major service providers to all other industrial and manufacturing segments are also focusing on to implement the techniques targeting overall sustainability. Some of the recent developments to achieve sustainability in gear manufacturing can be summarized as reducing the use of mineral-based cutting fluids by employing alternative lubrication techniques i.e. minimum quantity lubrication (MQL) and dry machining, material saving, waste reduction, minimizing energy consumption and maintaining economic efficiency by reducing the number of gear manufacturing stages (eliminating the necessity of finishing processes) by utilizing advanced methods such as gear rolling and wire electric-discharge machining (WEDM), and finally increasing productivity by minimizing tool wear at high gear cutting speeds through the use of alternative tool materials and coatings. This paper reviews and amasses the current state of technology for sustainable manufacturing of gears and also recommends ways to improve the productivity and quality while simultaneously ensuring environmental sustainability.
- Full Text:
- Authors: Gupta, Kapil , Laubscher, R.F. , Davim, J. Paulo , Jain, N.K.
- Date: 2016
- Subjects: Sustainable manufacturing , Gear machining , Minimum quantity lubrication
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/123571 , uj:20813 , Citation: Gupta, K. 2016. Recent developments in sustainable manufacturing of gears: a review.
- Description: Abstract: Environment awareness is of the utmost importance to all socially responsible manufacturers. To be competitive on a global scale manufacturing needs to be aligned with various strict environmental regulations. The manufacturing industry at large is striving to improve productivity and product quality while maintaining a clean and sustainable environment. This can only be achieved by adopting sustainable techniques of manufacturing which include minimizing the number of manufacturing steps by employing advanced and alternative methods, environment-friendly lubricants and lubrication techniques while machining, reducing wastage, active waste management and minimizing energy consumption etc. Gear manufacturing industries, the major service providers to all other industrial and manufacturing segments are also focusing on to implement the techniques targeting overall sustainability. Some of the recent developments to achieve sustainability in gear manufacturing can be summarized as reducing the use of mineral-based cutting fluids by employing alternative lubrication techniques i.e. minimum quantity lubrication (MQL) and dry machining, material saving, waste reduction, minimizing energy consumption and maintaining economic efficiency by reducing the number of gear manufacturing stages (eliminating the necessity of finishing processes) by utilizing advanced methods such as gear rolling and wire electric-discharge machining (WEDM), and finally increasing productivity by minimizing tool wear at high gear cutting speeds through the use of alternative tool materials and coatings. This paper reviews and amasses the current state of technology for sustainable manufacturing of gears and also recommends ways to improve the productivity and quality while simultaneously ensuring environmental sustainability.
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Recent developments in additive manufacturing of gears : a review
- Authors: Gupta, Kapil
- Date: 2018
- Subjects: Additive manufacturing , Gear , Miniaturization
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/279985 , uj:30079 , Citation: Gupta, K. 2018. Recent developments in additive manufacturing of gears : a review.
- Description: Abstract: Additive Layer Manufacturing (ALM) is an advanced technology to produce quality gears of metals and plastics. Some significant benefits such as capability to handle complex gear shapes and design, and produce near net-shaped gears; resource efficiency; and rapid product development etc. make this process a sustainable alternate to the other processes of gear manufacturing. This paper sheds light on the development of some of the important additive layer manufacturing processes such as Stereolithography, Fused Deposition Modeling, and 3D Printing to manufacture gears. The article aims to facilitate researchers and encourages them to do further research and development for improved gear quality, process productivity, and sustainability.
- Full Text:
- Authors: Gupta, Kapil
- Date: 2018
- Subjects: Additive manufacturing , Gear , Miniaturization
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/279985 , uj:30079 , Citation: Gupta, K. 2018. Recent developments in additive manufacturing of gears : a review.
- Description: Abstract: Additive Layer Manufacturing (ALM) is an advanced technology to produce quality gears of metals and plastics. Some significant benefits such as capability to handle complex gear shapes and design, and produce near net-shaped gears; resource efficiency; and rapid product development etc. make this process a sustainable alternate to the other processes of gear manufacturing. This paper sheds light on the development of some of the important additive layer manufacturing processes such as Stereolithography, Fused Deposition Modeling, and 3D Printing to manufacture gears. The article aims to facilitate researchers and encourages them to do further research and development for improved gear quality, process productivity, and sustainability.
- Full Text:
Recent developments in sustainable manufacturing of gears : a review
- Gupta, Kapil, Laubscher, R.F., Davim, J. Paulo, Jain, N.K.
- Authors: Gupta, Kapil , Laubscher, R.F. , Davim, J. Paulo , Jain, N.K.
- Date: 2015
- Subjects: Sustainable manufacturing , Gear machining , Minimum quantity lubrication
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/72392 , uj:18273 , Citation: Gupta, K. et al. 2015. Recent developments in sustainable manufacturing of gears : a review.
- Description: Abstract: Environment awareness is of the utmost importance to all socially responsible manufacturers. To be competitive on a global scale manufacturing needs to be aligned with various strict environmental regulations. The manufacturing industry at large is striving to improve productivity and product quality while maintaining a clean and sustainable environment. This can only be achieved by adopting sustainable techniques of manufacturing which include minimizing the number of manufacturing steps by employing advanced and alternative methods, environment-friendly lubricants and lubrication techniques while machining, reducing wastage, active waste management and minimizing energy consumption etc. Gear manufacturing industries, the major service providers to all other industrial and manufacturing segments are also focusing on to implement the techniques targeting overall sustainability. Some of the recent developments to achieve sustainability in gear manufacturing can be summarized as reducing the use of mineral-based cutting fluids by employing alternative lubrication techniques i.e. minimum quantity lubrication (MQL) and dry machining; material saving, waste reduction, minimizing energy consumption and maintaining economic efficiency by reducing the number of gear manufacturing stages (eliminating the necessity of finishing processes) by utilizing advanced methods such as gear rolling and wire electric-discharge machining (WEDM) and finally increasing productivity by minimizing tool wear at high gear cutting speeds through the use of alternative tool materials and coatings. This paper reviews and amasses the current state of technology for sustainable manufacturing of gears and also recommends ways to improve the productivity and quality while simultaneously ensuring environmental sustainability.
- Full Text:
- Authors: Gupta, Kapil , Laubscher, R.F. , Davim, J. Paulo , Jain, N.K.
- Date: 2015
- Subjects: Sustainable manufacturing , Gear machining , Minimum quantity lubrication
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/72392 , uj:18273 , Citation: Gupta, K. et al. 2015. Recent developments in sustainable manufacturing of gears : a review.
- Description: Abstract: Environment awareness is of the utmost importance to all socially responsible manufacturers. To be competitive on a global scale manufacturing needs to be aligned with various strict environmental regulations. The manufacturing industry at large is striving to improve productivity and product quality while maintaining a clean and sustainable environment. This can only be achieved by adopting sustainable techniques of manufacturing which include minimizing the number of manufacturing steps by employing advanced and alternative methods, environment-friendly lubricants and lubrication techniques while machining, reducing wastage, active waste management and minimizing energy consumption etc. Gear manufacturing industries, the major service providers to all other industrial and manufacturing segments are also focusing on to implement the techniques targeting overall sustainability. Some of the recent developments to achieve sustainability in gear manufacturing can be summarized as reducing the use of mineral-based cutting fluids by employing alternative lubrication techniques i.e. minimum quantity lubrication (MQL) and dry machining; material saving, waste reduction, minimizing energy consumption and maintaining economic efficiency by reducing the number of gear manufacturing stages (eliminating the necessity of finishing processes) by utilizing advanced methods such as gear rolling and wire electric-discharge machining (WEDM) and finally increasing productivity by minimizing tool wear at high gear cutting speeds through the use of alternative tool materials and coatings. This paper reviews and amasses the current state of technology for sustainable manufacturing of gears and also recommends ways to improve the productivity and quality while simultaneously ensuring environmental sustainability.
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Developments in non-conventional machining for sustainable production - a state of art review
- Gupta, Kapil, Gupta, Munish Kumar
- Authors: Gupta, Kapil , Gupta, Munish Kumar
- Date: 2019
- Subjects: Abrasive water jet machining , Electric discharge machining , Electrochemical machining
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/406733 , uj:34208 , Citation: Gupta, K., Gupta, M.K. 2019 : Developments in non-conventional machining for sustainable production- a state of art review.
- Description: Abstract :
- Full Text:
- Authors: Gupta, Kapil , Gupta, Munish Kumar
- Date: 2019
- Subjects: Abrasive water jet machining , Electric discharge machining , Electrochemical machining
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/406733 , uj:34208 , Citation: Gupta, K., Gupta, M.K. 2019 : Developments in non-conventional machining for sustainable production- a state of art review.
- Description: Abstract :
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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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- 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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On productivity of abrasive water jet machining for miniature gear manufacturing
- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Quality , Productivity , Sustainability
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/411272 , uj:34554 , Citation: Kapil Gupta 2020 IOP Conf. Ser.: Mater. Sci. Eng. 709 044100 , DOI:10.1088/1757-899X/709/4/044100
- Description: Abstract: Quality, productivity, and sustainability are three major indicators to evaluate the performance of any manufacturing process. Abrasive water jet machining (AWJM), which is an advanced or nonconventional machining process possess numerous benefits over conventional and other advanced processes for manufacturing of precision engineering components. Material removal rate directly indicates about the process productivity, and often finds contradictory to quality and sustainability. This paper reports the productivity of AWJM process while manufacturing miniature gears of brass. It is a part of experimental investigation conducted to manufacture high quality miniature brass gears using AWJM process. Taguchi L9 orthogonal array based experimental study where a total of nine experiments with two replicates each was conducted to evaluate the effect of AWJM parameters on miniature gear quality, process productivity and sustainability. AWJM parameters were optimized to enhance material removal rate and an optimum value of 18.80 mm3 /min was obtained. Furthermore, AWJM was identified as a superior to conventional machining processes for manufacturing of miniature gears.
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- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Quality , Productivity , Sustainability
- Language: English
- Type: Conference proceedings
- Identifier: http://hdl.handle.net/10210/411272 , uj:34554 , Citation: Kapil Gupta 2020 IOP Conf. Ser.: Mater. Sci. Eng. 709 044100 , DOI:10.1088/1757-899X/709/4/044100
- Description: Abstract: Quality, productivity, and sustainability are three major indicators to evaluate the performance of any manufacturing process. Abrasive water jet machining (AWJM), which is an advanced or nonconventional machining process possess numerous benefits over conventional and other advanced processes for manufacturing of precision engineering components. Material removal rate directly indicates about the process productivity, and often finds contradictory to quality and sustainability. This paper reports the productivity of AWJM process while manufacturing miniature gears of brass. It is a part of experimental investigation conducted to manufacture high quality miniature brass gears using AWJM process. Taguchi L9 orthogonal array based experimental study where a total of nine experiments with two replicates each was conducted to evaluate the effect of AWJM parameters on miniature gear quality, process productivity and sustainability. AWJM parameters were optimized to enhance material removal rate and an optimum value of 18.80 mm3 /min was obtained. Furthermore, AWJM was identified as a superior to conventional machining processes for manufacturing of miniature gears.
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TOPSIS-Fuzzy-PSO Integrated Modelling and Computation of Wire-EDM Parameters for Productivity and Surface Quality while Machining Ni55.8Ti Shape Memory Alloy
- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Computation , Optimization , PSO
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/411327 , uj:34561
- Description: Abstract: Modelling and optimization of manufacturing processes for better quality engineered parts has always been a requirement. Numerous statistical and soft computing techniques have been used for this purpose. This paper reports on modelling and computation of Wire-EDM process parameters for optimum productivity and surface quality when machining Ni55.8Ti shape memory alloys using a TOPSIS-Fuzzy-PSO integrated hybrid technique. Ni55.8Ti is an important biomaterial and its appropriate machining at optimum set of parameters is essential to achieve high process productivity and to simultaneously maintain high product quality. Productivity in terms of material removal rate ‘MRR’ and surface quality in the form of maximum roughness ‘Rt’ and recast layer thickness ‘RCL’ have been considered. Four wire-EDM parameters namely servo voltage ‘SV’, pulse-on time ‘Pon’, pulse-off time ‘Poff’, and wire feed rate ‘WF’ have been varied at four levels each to machine Ni55.8Ti alloy based on Taguchi L16 robust design of experiment technique and the aforementioned conflicting responses have been measured corresponding to each experiment. To establish the relationship between wire-EDM parameters and the responses, all the response characteristics were converted into a single response of TOPSIS-fuzzy performance index (TFPi). PSO coupled with TOPSIS and Fuzzy logic has been employed for computation of optimum wire-EDM parameters for the best values of all responses considered. Analysis of variance (ANOVA) of TOPSIS-fuzzy performance index (TFPi) exhibited the effectiveness of the integrated hybrid technique. The optimum values of wire-EDM parameters obtained by hybrid technique are SV-50V; Pon-1µs; Poff-17 µs; WF-4 m/min for MRR-0.049 g/min, Rt- 11.45 µm, and RCL- 22.10 µm. Validation experiments conducted to confirm the reproducibility of the response characteristics predicted by hybrid technique.
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- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Computation , Optimization , PSO
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/411327 , uj:34561
- Description: Abstract: Modelling and optimization of manufacturing processes for better quality engineered parts has always been a requirement. Numerous statistical and soft computing techniques have been used for this purpose. This paper reports on modelling and computation of Wire-EDM process parameters for optimum productivity and surface quality when machining Ni55.8Ti shape memory alloys using a TOPSIS-Fuzzy-PSO integrated hybrid technique. Ni55.8Ti is an important biomaterial and its appropriate machining at optimum set of parameters is essential to achieve high process productivity and to simultaneously maintain high product quality. Productivity in terms of material removal rate ‘MRR’ and surface quality in the form of maximum roughness ‘Rt’ and recast layer thickness ‘RCL’ have been considered. Four wire-EDM parameters namely servo voltage ‘SV’, pulse-on time ‘Pon’, pulse-off time ‘Poff’, and wire feed rate ‘WF’ have been varied at four levels each to machine Ni55.8Ti alloy based on Taguchi L16 robust design of experiment technique and the aforementioned conflicting responses have been measured corresponding to each experiment. To establish the relationship between wire-EDM parameters and the responses, all the response characteristics were converted into a single response of TOPSIS-fuzzy performance index (TFPi). PSO coupled with TOPSIS and Fuzzy logic has been employed for computation of optimum wire-EDM parameters for the best values of all responses considered. Analysis of variance (ANOVA) of TOPSIS-fuzzy performance index (TFPi) exhibited the effectiveness of the integrated hybrid technique. The optimum values of wire-EDM parameters obtained by hybrid technique are SV-50V; Pon-1µs; Poff-17 µs; WF-4 m/min for MRR-0.049 g/min, Rt- 11.45 µm, and RCL- 22.10 µm. Validation experiments conducted to confirm the reproducibility of the response characteristics predicted by hybrid technique.
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MOORA-Fuzzy-Regression based Hybrid Approach for Machinability Optimization of SS304
- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Dry machining , Fuzzy , MCDM
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/411335 , uj:34562
- Description: Abstract: Stainless steel has various scientific, engineering, medical, and industrial applications. It undergoes extensive machining operations to make products for the aforementioned applications. Stainless steel is a difficult-to-machine material and requires novel ways and optimum parameter combinations for better machinability. In view of this, the present work investigates the machinability of SS304 using coated and uncoated carbide tools under dry environment. The machinability indicators studied in the present work are material removal rate (MRR), chip reduction coefficient (CRC), maximum surface roughness (Rt) and tool flank wear. Fuzzy logic integrated with multi objective optimization by ratio analysis (MOORA) has been used for the prediction of performance index (PI). The PI solved by fuzzy logic and MOORA is termed as MOORA-Fuzzy performance index (MFPI). This MFPI has been solved by regression analysis to predict the optimal parametric setting for multi-criteria decision making (MCDM) approach. The parametric combination i.e. cutting speed: 170 m/min; feed rate: 0.2 mm/rev; and depth of cut: 1.5mm has obtained as the optimal setting. The ANOVA results and confirmation experiments verify the superiority of the proposed model. The experimental results at the predicted setting represent excellent results regeneration.
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- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Dry machining , Fuzzy , MCDM
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/411335 , uj:34562
- Description: Abstract: Stainless steel has various scientific, engineering, medical, and industrial applications. It undergoes extensive machining operations to make products for the aforementioned applications. Stainless steel is a difficult-to-machine material and requires novel ways and optimum parameter combinations for better machinability. In view of this, the present work investigates the machinability of SS304 using coated and uncoated carbide tools under dry environment. The machinability indicators studied in the present work are material removal rate (MRR), chip reduction coefficient (CRC), maximum surface roughness (Rt) and tool flank wear. Fuzzy logic integrated with multi objective optimization by ratio analysis (MOORA) has been used for the prediction of performance index (PI). The PI solved by fuzzy logic and MOORA is termed as MOORA-Fuzzy performance index (MFPI). This MFPI has been solved by regression analysis to predict the optimal parametric setting for multi-criteria decision making (MCDM) approach. The parametric combination i.e. cutting speed: 170 m/min; feed rate: 0.2 mm/rev; and depth of cut: 1.5mm has obtained as the optimal setting. The ANOVA results and confirmation experiments verify the superiority of the proposed model. The experimental results at the predicted setting represent excellent results regeneration.
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On Surface Morphology of Miniature Gears of Stainless Steel Manufactured by CO2 Laser Cutting
- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Gear , Laser , Miniature
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/411343 , uj:34563
- Description: Abstract: In this research, CO2 laser cutting process is used to manufacturing miniature gears of stainless steel 304. The aim of this research is to study the influence of laser process parameters i.e. laser power, gas flow pressure, laser scan rate and focal position on surface quality of the laser machined miniature gears. The field emission scan electron microscope (FESEM) is used to analyse the different regimes of machined surface and white light spectroscope for 3D surface profile mapping. The laser power is the predominant input factor for surface wear and it was in the form of surface oxides at high voltage of 2500W. In addition to surface analysis, the effect of laser heat source over the gear profile is also studied. The transformation in the microstructure of the gears is observed with metallurgical microscope following standards. The effect of heat source has produced twin in grain structure and lead to surface hardness. Optimal laser power of 2000 W with a scan rate of 2mm/min has produced best gear profile than other combinations.
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- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Gear , Laser , Miniature
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/411343 , uj:34563
- Description: Abstract: In this research, CO2 laser cutting process is used to manufacturing miniature gears of stainless steel 304. The aim of this research is to study the influence of laser process parameters i.e. laser power, gas flow pressure, laser scan rate and focal position on surface quality of the laser machined miniature gears. The field emission scan electron microscope (FESEM) is used to analyse the different regimes of machined surface and white light spectroscope for 3D surface profile mapping. The laser power is the predominant input factor for surface wear and it was in the form of surface oxides at high voltage of 2500W. In addition to surface analysis, the effect of laser heat source over the gear profile is also studied. The transformation in the microstructure of the gears is observed with metallurgical microscope following standards. The effect of heat source has produced twin in grain structure and lead to surface hardness. Optimal laser power of 2000 W with a scan rate of 2mm/min has produced best gear profile than other combinations.
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VIKOR-Regression-PSO based hybrid approach for optimization and analysis of green machining of SS304
- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Green machining , Hybrid optimization , PSO
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/411319 , uj:34560
- Description: Abstract: The selection of machining to process SS304 in an economical and eco-friendly way is the challenging task for the manufacturing engineers. The complication becomes at its peak due to the categorization of SS304 as difficult to machine material. In the current research, an attempt has been made to machine SS304 material using synthetic oil based cutting fluid. The machining variable selected as input process parameter are cutting speed (CS), feed (F) and depth of cut (DoC). The response characteristics measured and analyzed corresponding to L9 orthogonal array (Taguchi based) are tool wear, maximum surface roughness (Rt), mean roughness depth (Rz) and chip reduction coefficient (CRC). The optimization of the input process parameters was also attempted using hybrid approach of Vise Kriterijumska Optimizacija Kompromisno Resenje-Regression- Particle Swarm Optimization (VIKOR-Regression-PSO). The process parameters were optimized for each response individual and after that comparison was made with the responses obtained at the optimized setting suggested by hybrid approach for all responses simultaneously. The suggested optimized setting by hybrid approach was CS: 70m/min; F: 0.2mm/rev; DoC: 1.5mm. The response characteristics were validated after performing validation experiments as suggested optimal setting. The ±5% difference between predicted and experimental values reveals the authenticity of the hybrid optimization approach. During the machining of SS304, synthetic oil with synthetic ester (with appropriate mixture with water) was used as a cutting fluid to make the process as environment-friendly. Finally, the response characteristics after green machining at randomly selected experiments were compared to the results of dry machining and the outperformance of synthetic oil was measured in terms of response characteristics.
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VIKOR-Regression-PSO based hybrid approach for optimization and analysis of green machining of SS304
- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Green machining , Hybrid optimization , PSO
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/411319 , uj:34560
- Description: Abstract: The selection of machining to process SS304 in an economical and eco-friendly way is the challenging task for the manufacturing engineers. The complication becomes at its peak due to the categorization of SS304 as difficult to machine material. In the current research, an attempt has been made to machine SS304 material using synthetic oil based cutting fluid. The machining variable selected as input process parameter are cutting speed (CS), feed (F) and depth of cut (DoC). The response characteristics measured and analyzed corresponding to L9 orthogonal array (Taguchi based) are tool wear, maximum surface roughness (Rt), mean roughness depth (Rz) and chip reduction coefficient (CRC). The optimization of the input process parameters was also attempted using hybrid approach of Vise Kriterijumska Optimizacija Kompromisno Resenje-Regression- Particle Swarm Optimization (VIKOR-Regression-PSO). The process parameters were optimized for each response individual and after that comparison was made with the responses obtained at the optimized setting suggested by hybrid approach for all responses simultaneously. The suggested optimized setting by hybrid approach was CS: 70m/min; F: 0.2mm/rev; DoC: 1.5mm. The response characteristics were validated after performing validation experiments as suggested optimal setting. The ±5% difference between predicted and experimental values reveals the authenticity of the hybrid optimization approach. During the machining of SS304, synthetic oil with synthetic ester (with appropriate mixture with water) was used as a cutting fluid to make the process as environment-friendly. Finally, the response characteristics after green machining at randomly selected experiments were compared to the results of dry machining and the outperformance of synthetic oil was measured in terms of response characteristics.
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Surface morphology investigation of miniature gears manufactured by abrasive water jet machining
- Gupta, Kapil, Khan, Adam, Pathak, Sunil
- Authors: Gupta, Kapil , Khan, Adam , Pathak, Sunil
- Date: 2020
- Subjects: Abrasive , Gear , Machining
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/425958 , uj:36489
- Description: Abstract: In this paper, surface morphology investigation of miniature spur gears manufactured by abrasive water jet machining is discussed. Water jet pressure, abrasive flow rate and standoff-distance are the varying input parameters to study the surface morphology (surface roughness and topography) of the machined gears. From the investigation, the water jet pressure has highly influenced (with 47% contribution) the surface quality and found as a predominant process parameter. SEM micrograph study found that wear scars and clinging effects are the major surface defects found over the machined surfaces of the gear teeth. Maximum and minimum peaks of the wear tracks are observed with white light spectroscope. The best surface morphology with average surface roughness value 1.08 µm was achieved at 350MPa water jet pressure, 225 g/min abrasive mass flow rate, and 1mm stand-off distance. The present work identifies the potential of AWJM process for manufacturing of high quality miniature gears.
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- Authors: Gupta, Kapil , Khan, Adam , Pathak, Sunil
- Date: 2020
- Subjects: Abrasive , Gear , Machining
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/425958 , uj:36489
- Description: Abstract: In this paper, surface morphology investigation of miniature spur gears manufactured by abrasive water jet machining is discussed. Water jet pressure, abrasive flow rate and standoff-distance are the varying input parameters to study the surface morphology (surface roughness and topography) of the machined gears. From the investigation, the water jet pressure has highly influenced (with 47% contribution) the surface quality and found as a predominant process parameter. SEM micrograph study found that wear scars and clinging effects are the major surface defects found over the machined surfaces of the gear teeth. Maximum and minimum peaks of the wear tracks are observed with white light spectroscope. The best surface morphology with average surface roughness value 1.08 µm was achieved at 350MPa water jet pressure, 225 g/min abrasive mass flow rate, and 1mm stand-off distance. The present work identifies the potential of AWJM process for manufacturing of high quality miniature gears.
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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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- 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
- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Composite , Optimization , Surface roughness
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/481576 , uj:43640 , Citation: Gupta, K. 2020. Intelligent optimization of Wire-EDM parameters for surface roughness and material removal rate while machining WC-Co composite.
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- Authors: Gupta, Kapil
- Date: 2020
- Subjects: Composite , Optimization , Surface roughness
- Language: English
- Type: Article
- Identifier: http://hdl.handle.net/10210/481576 , uj:43640 , Citation: Gupta, K. 2020. Intelligent optimization of Wire-EDM parameters for surface roughness and material removal rate while machining WC-Co composite.
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