P. Sudhakar Rao

National Institute of Technical Teachers Training and Research

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Mohd. Yunus Khan

Aligarh Muslim University

B. S. Pabla

National Institute of Technical Teachers Training and Research

Rupinder Singh

National Institute of Technical Teachers Training and Research

Gurwinder Singh

University of Newcastle Australia

Dheerendra Kumar Dwivedi

Indian Institute of Technology Roorkee

Pramod Kumar Jain

Indian Institute of Technology Roorkee

Mumtaz Rizwee

National Institute of Technology Jamshedpur

Chandrakant Chaturvedi

National Institute of Technology Delhi

Akhilesh Sinha

National Institute of Technical Teachers’ Training and Research

Gurwinder Singh

National Institute of Technical Teachers Training and Research

Cooperative Institutions

National Institute of Technical Teachers Training and Research

National Institute of Technical Teachers’ Training and Research

Indian Institute of Technology Roorkee

Chandigarh University

Banaras Hindu University

Indian Institute of Technology Delhi

Indian Institute of Technology Mandi

Indian Institute of Technology Ropar

Sharda University

Central Research Institute

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On the use of Copper Tool developed by Atomic Diffusion Additive Manufacturing (ADAM) Process for Electrical Discharge Machining

E3S Web of Conferences (2023)

Mohd. Yunus Khan P. Sudhakar Rao B. S. Pabla

This paper highlights the review of work done in the area of 3D printed tools for the spark machining process. In recent times, additive manufacturing has gained wide popularity in different sectors. The additive manufacturing process or 3D printing, is a method for creating three-dimensional objects by layering material. Using the additive manufacturing technique of atomic diffusion, a tool for electrical discharge machining was developed. In this method, a mixture of metal and polymer that are formed into wire was employed and kept in a cartridge. The material mix is deposited in similar to extrusion process. A computer software does all the calculation, costing, weight analysis and printing time assessment. The procedure of the same is discussed. The scanning electron microscopic analysis of the same is done along with porosity measurement using ImageJ software. The surface characteristics of the printed tool was measured with Gwyddion software. Discussion on applicability of printed tool for electrical discharge machining process is done. words.

Electrical Discharge Machining

10.1051/e3sconf/202345502014

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Characterization and Experimental Investigation on Mechanical Behavior of B₄C and RHA reinforced Aluminium Alloy 7075 hybrid Composite using Stir Casting

Research Journal of Engineering and Technology (2017)

Nishant Verma P. Sudhakar Rao S.C. Vettivel

This paper is going to deal with the effect of Boron Carbide (B4C) and Rice Husk Ash (RHA) in AA7075 Hybrid Composite. To study the effect of the addition of reinforcement on AA 7075, the fabrication is done by using bottom pouring type stir casting machine. K2TiF6 isadded as filler to avoid the wettability problem of liquid molten aluminium alloy 7075 and B4C. The results shows that the hardness of the hybrid composite is increased with increase in the wt. % of reinforcements. Scanning Electron Microscopy is used to confirm the microstructure of composite and distribution of reinforcements. The results of Energy Dispersive Spectroscopy analysis is used to confirm the elements in Al 7075/B4C/RHA hybrid composite and some useful conclusions are made.

Boron carbide

Husk

Energy-dispersive X-ray spectroscopy

10.5958/2321-581x.2017.00029.0

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Citations (7)

3-D Printing Technology: Inclusive Study and Applicability in Different Sectors

Lecture notes in mechanical engineering (2021)

Mohd. Yunus Khan P. Sudhakar Rao B. S. Pabla

10.1007/978-981-16-0673-1_29

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On modes of electrochemical machining: a comprehensive review

Advances in Materials and Processing Technologies (2024)

Gurwinder Singh Rupinder Singh P. Sudhakar Rao

Conventional (C) electrochemical machining (ECM) is an established toolroom process to remove controlled materials from conductive materials, including composites that are otherwise difficult to machine. Several variants of ECM with different modes/mechanisms of material removal are commercially available. However, hitherto, little has been reported on the comprehensive review of the mechanisms for different modes (such as pulsed, hybrid, air/water jet, laser-assisted, mask, etc.) of the ECM process. In this work, an effort has been made to review the different ECM modes/mechanisms employed for mass transfer (from the bulk electrolyte solution to the electrode surface), electron transfer at the electrode surface, and chemical reactions preceding or following the electron transfer and other surface reactions, such as adsorption, desorption, or crystallisation in diverse procedures for machining various materials. Some investigations from the broad field of CECM and modified (M) ECM developed to improve the overall process for high-quality tool rooms are also reported. Finally, the advancements in MECM, its associated problems, and future research prospects have been presented. The study highlights significant research gaps in material reaction metrics, circularity, cylindricity, dimensional stability, and surface properties in various modes of ECM.

Electrochemical Machining

10.1080/2374068x.2024.2439703

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Performance of Capillary Fed Wick Stove Fuelled with Blends of Butanol and Kerosene

Lecture notes in mechanical engineering (2021)

Mohd. Yunus Khan P. Sudhakar Rao Md. Imran Sandip Kumar

Kerosene

Stove

n-Butanol

Liquid fuel

10.1007/978-981-15-9678-0_15

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WITHDRAWN: Powder mixed electrical discharge machining (PM-EDM): A methodological review

Materials Today Proceedings (2020)

Mohd. Yunus Khan P. Sudhakar Rao B. S. Pabla

10.1016/j.matpr.2020.10.122

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Precision Finishing of External Cylindrical Surfaces of EN8 Steel by Electro Chemical Honing (ECH) Process using OFAT Technique

Materials Today Proceedings (2015)

P. Sudhakar Rao Pramod Kumar Jain Dheerendra Kumar Dwivedi

Honing

Inconel

Surface finishing

10.1016/j.matpr.2015.07.117

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Citations (15)

Feasibility of used cooking oil-based biodiesel (UCOB) as a dielectric for electrical discharge machining

Journal of King Saud University - Science (2022)

Mohd. Yunus Khan P. Sudhakar Rao B. S. Pabla Ashok Kumar K

This study is centered on the practicality of used cooking oil-based biodiesel (UCOB) as the dielectric for electrical discharge machining (EDM). To establish the usefulness of used cooking oil-based biodiesel as a dielectric for EDM, the essential properties of UCOB were determined and compared with ST EDM oil. Used cooking oil is an important source that can be employed for biodiesel production. Biodiesel was extracted by the process of transesterification. EDM performance was evaluated by applying a "one factor at a time" approach while machining Inconel-625 using EDM oil and bio-dielectric fluids. For both dielectric fluids, the material removal rate was observed to increase with discharge current. The lowest value of TWR was observed at 50 µs while the highest value was observed at 1000 µs. Thus, the performance trend for both fluids was similar. However, the performance of UCOB was slightly better than that of EDM oil. This variation is due to the difference in chemical composition of both dielectric fluids. The highest material removal rate 20.333 mm3/min was observed for UCOB operation at a discharge current of 12.48 A and the lowest material removal rate (0.123 mm3/min) was obtained with a discharge current of 1.56 A for EDM oil. It has been established that UCOB can be suitably utilized as dielectric fluid to increase the sustainability of the EDM process.

Liquid dielectric

Electrical Discharge Machining

10.1016/j.jksus.2022.102305

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On electrochemical machining with an interelectrode slit for a partially insulating cathode

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering (2024)

Gurwinder Singh Rupinder Singh P. Sudhakar Rao

Electrochemical machining is an established non-conventional machining process in which material removal during electrolysis relies on the quantity of electricity passed through the electrolyte. The amount of electricity passed further depends on several factors, such as electrochemical reactivity/dissolution, penetration rate, tool properties (profile, surface area, and material), electrical conductivity, chemical composition, temperature sensitivity, crystal structure, and initial surface roughness (Ra) of workpiece material, voltage, feed rate, electrolyte selection/concentration, etc. As per reported studies, a thermoplastic inter-electrode slit of rectangular/square profile between the tool and workpiece in modified electrochemical machining helps to generate the cavity with a better aspect (h/d) ratio without changing the tool profile. However, little has been reported on the effect of variation in interelectrode slit thickness on material removal rate/penetration rate. In this study, the results of experimental investigations for material removal rate/penetration rate with modified electrochemical machining using a square inter-electrode slit of variable thickness between the cathode (circular tool) and anode (workpiece) with 03 different materials (Al, Cu, and Ti) have been presented. Taguchi L 18 , orthogonal array-based design of experiments, has been used in parametric optimization of the modified electrochemical machining process. Overall, the best settings for material removal rate in modified electrochemical machining are electrolyte concentration 150 g/L, voltage 21 V, tool material Cu, workpiece Al, interelectrode slit thickness 1.5 mm, and tool feed rate 132 µm/min. The outcomes have been braced by scanning electron microscopy, energy dispersive spectroscopy, and Ra analysis.

Electrochemical Machining

Horizontal scan rate

10.1177/09544089241264186

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Processing, tool wear measurement using machine vision system and optimization of machining parameters of boron carbide and rice husk ash reinforced AA 7075 hybrid composite

Materials Research Express (2019)

Nishant Verma S.C. Vettivel P. Sudhakar Rao Sunny Zafar

This work is focused on the fabrication and machining of Aluminium Alloy (AA) 7075, AA 7075/B4C composite and AA 7075/B4C/RHA hybrid composite. The composites were fabricated using stir casting technique. The highest hardness value was reported on AA 7075-5 B4C-5 RHA hybrid composite. It was 72% higher than pure AA 7075. Scanning electron microscopy (SEM) was used to study the surfaces of fabricated and machined surfaces of the composites. The theoretical density was calculated by the rule of mixture and actual density was calculated by the Archimedes principle. Energy dispersive spectroscopy (EDS) analysis was used to confirm the distribution of reinforcements in AA7075. Turning of AA 7075, AA 7075/B4C composite and AA 7075/B4C/RHA hybrid composites were done by using plain carbide inserts. The various responses studied were Surface Roughness (SR), Material Removal Rate (MRR) and Tool Wear (TW). The analysis and optimization of the experimental results were carried out using response surface methodology. The feed rate was considered as the most influencing parameter for SR and MRR. Speed was considered as the most influencing factor for tool wear and the wt% of reinforcement is considered as least influencing factor for MRR.

Boron carbide

Husk

10.1088/2053-1591/ab2509

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Citations (25)