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There is a long demand for light-weight, high-strength, and wear-resistance aluminium alloys, particularly in automotive and aerospace industries. This demand is somewhat fulfilled by aluminium metal matrix composites. However, aluminium... more
There is a long demand for light-weight, high-strength, and wear-resistance aluminium alloys, particularly in automotive and aerospace industries. This demand is somewhat fulfilled by aluminium metal matrix composites. However, aluminium nano-metal matrix composite because of its superior properties is increasingly popular to replace aluminium metal matrix composites. The SiC (grit size is <90 nm) with purity 99.9% nanoparticle can enhance the properties of the base material in terms of tensile strength, hardness, microhardness, and mechanical strength. Pure Al (99.9%) matrix composites reinforced with SiC (purity 99.9%) nanoparticles are fabricated by liquid-state method with 1 wt% Mg, and their microstructure, mechanical properties (wear resistance, tensile behaviour, hardness), XRD, SEM were investigated. Here pure SiC purity 99.9% added into molten Al with 1 wt% Mg using squeeze die casting with furnace temperature 850 °C and pathway temperature 700 °C and for uniform mixing of SiC nanoparticles into matrix use stir method with 400 rpm for 2 min and pressure was 31.3 mpa. Pure Al and 1 wt% SiC nanocomposites with 1 wt% Mg were developed; the Al-SiC nanocomposites were characterised using scanning electron microscope (SEM) and X-ray diffraction (XRD). Due to used higher pressure during solidification, there is very low porosity. Stir is used before mixing the nano-SiC particle and pouring the metal into mould, which gives the uniform distribution of nanoparticles into matrix.
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In continuous casting of steel, liquid steel is continuously solidified into a finished product. Bokaro Steel Limited have slab caster and during continuous casting, one of the major operational irregularities encountered is breakout. A... more
In continuous casting of steel, liquid steel is continuously solidified into a finished product. Bokaro Steel Limited have slab caster and during continuous casting, one of the major operational irregularities encountered is breakout. A breakout is a hazard whereby the thin shell of the strand breaks, allowing the still-molten metal inside the strand to leak out from the mould, thus necessitating an expensive machine shutdown. Hence the breakout has a profound influence on the caster availability; affecting the productivity, cost of production, damage of machinery, safety hazards, etc. Breakouts occur due to the presence of a primary crack before solidification of liquid steel. Controlling the primary cracks lead to reduce chances of breakouts. Breakout prediction system of Bokaro Steel Limited uses only thermocouples temperature as an input of logic based algorithm controlled by strand PLC to predict breakout and generate alarm. This system sometimes generates lots of false alarm and sometimes even fails to generate an alarm before breakout. In this paper, two back-propagation neural networks are developed to predict the presence of primary crack that might lead to breakout of liquid steel. One is neural network1 train only with one input parameter (temperatures of thermocouples attached to the mould) and the other is neural network2 train with three input parameters (temperatures of thermocouples, casting speed and mould level). Both the neural network1 and network2 have only one output. Output of neural networks is either 0 for no alarm (no primary crack) or 1 for alarm (presence of primary crack) in breakout conditions. Comparison of the network1 with network2 showed that network2 has less output error, better performance and identifies primary crack more accurately. Performance of neural networks are done using Levenberg–Marquardt training algorithm, and also log sigmoid transfer function is used for both the hidden and output layer. The neural networks model training, validation and testing is done by simulating in Mat-Lab/Simulink.
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Mold breakout is one of the significant problems in a continuous casting machine (caster). It represents one of the key areas within the steel production facilities of a steel plant. A breakout event on a caster will always cause safety... more
Mold breakout is one of the significant problems in a continuous casting machine (caster). It represents one of the key areas within the steel production facilities of a steel plant. A breakout event on a caster will always cause safety hazards, high repair costs, loss of production, and shutdown of the caster for a short while. In this paper, a logic-judgment-based mold breakout prediction system has been developed for a continuous casting machine. This system developed new algorithms to detect the different sticker behaviors. With more algorithms running, each algorithm is more specialized in the other behaviors of stickers. This new logic-based breakout prediction system (BOPS) not only detects sticker breakouts but also detects breakouts that takes place due to variations in casting speed, mold level fluctuation, and taper/mold problems. This system also finds the exact location of the breakout in the mold and reduces the number of false alarms. The task of the system is to reco...
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Metal foams are known to exhibit multifunctional behavior. It can offer a unique combination of several properties that cannot be achieved by one conventional material at the same time e.g. ultra-low density, high stiffness and capability... more
Metal foams are known to exhibit multifunctional behavior. It can offer a unique combination of several properties that cannot be achieved by one conventional material at the same time e.g. ultra-low density, high stiffness and capability to absorb crash energy, and excellent sound absorption properties. These unique combinations of properties indicate its various potential applications such as ultra light structures, in impact/blast absorption systems, and for sound absorption etc. Metal foam is a generic term for a class of material, which can be classified in terms of their structures, processing routes, and base metal. The main aim of this research work is to produce low cost, low-density aluminum foams by indigenously designed and fabricated equipment. This aluminum foam material possess all the positive attributes realized in current metal foam technology, such as high specific stiffness, low relative density, and high-energy absorption capacity. This material is designed to r...
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Aluminium foams, which may replace all the energy absorbing materials in near future, are produced by melting Aluminium alloy (LM6) containing blowing agent(s) and with continuous stirring of the melt. TiH2 is a known blowing agent for... more
Aluminium foams, which may replace all the energy absorbing materials in near future, are produced by melting Aluminium alloy (LM6) containing blowing agent(s) and with continuous stirring of the melt. TiH2 is a known blowing agent for this. As TiH2 begins to decompose into Ti and gaseous H2 when heated above about 738K (465°C), large volumes of hydrogen gas are rapidly produced, creating bubbles that leads to manufacture of closed cell foam. Cellular materials like this produced foams has to be machined into pieces with desired shape for further investigation. In order to define the Compressive and impact properties of this material, LS-DYNA modeling and crashing simulation, which uniquely defines the mechanical behavior of this modified Al-MMC foam has been discussed in details.
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Additive manufacturing (AM) has developed and gained popularity across the globe into a multi-billion-dollar industry that involves many materials and techniques. AM has created itself as a technology for the manufacturing of metallic... more
Additive manufacturing (AM) has developed and gained popularity across the globe into a multi-billion-dollar industry that involves many materials and techniques. AM has created itself as a technology for the manufacturing of metallic parts with enhanced mechanical characteristics that are scientifically sound and commercially feasible. However, there are various challenges, from business point of view, like high machine and material costs. Considering the complexities involved, sustainable manufacturing, optimization tools, and simulation models are necessary in order to save time and costly trial and errors. Topology optimization and simulation of AM processes are commercially available and are receiving attention from scientists and industry. Thus, this chapter is designed to provide readers with a brief introduction to AM technologies with typical applications. The main objective of this chapter is to provide the current trends and innovations in the field of design for additive...
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Abstract Semisolid metal processing (SSMP) is a novel metal forming technology which offers near net-shaped metal components of complex geometries. The present work aims to classify the currently available SSMP technologies and presents a... more
Abstract Semisolid metal processing (SSMP) is a novel metal forming technology which offers near net-shaped metal components of complex geometries. The present work aims to classify the currently available SSMP technologies and presents a comprehensive review of the potential mechanisms that lead to microstructural alterations during the production of feedstock material. Keeping in mind the current needs of the automobile and allied industries, the review of state-of-art research work was focused on thixoforming with an emphasis on aluminum-based alloys and composites. Focus was drawn on the two major SSMP routes: “rheo-casting” and “thixoforming.” The potential benefits and industrial applications were highlighted. Nondendritic microstructural evolution in the semisolid range and its beneficial effects is also emphasized. Considering the complexities involved in the areas of thixoforming for sustainable manufacturing, optimized solutions, are necessary. This chapter presents an overview of recent trends, and new challenges, for achieving sustainability at the product by taking Aluminum-based composites as the materials and thixoforming as the process focusing on the technology and system levels for achieving sustainability. Further, the mechanical properties of the thixoformed Al-based alloys and composites were presented and compared with gravity cast and rheo-cast conditions. Thus a critical assessment aimed at understanding the processing and structure–property relationships in the thixoformed alloys and composites in meeting the needs of the industry.
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Aluminum alloys have been extensively used as structural material due to its high strength and damage-tolerance. Alloy 6061, 2024 and 7075 are engineered to be lightweight and strong,and their ease of formability allows complex shapes and... more
Aluminum alloys have been extensively used as structural material due to its high strength and damage-tolerance. Alloy 6061, 2024 and 7075 are engineered to be lightweight and strong,and their ease of formability allows complex shapes and drawn parts,which can then be further enhanced with heat treating. In this study is aimed to improve the mechanical properties of aluminum alloys by heat treatment.AA2024 and AA7075 were selected and each alone at T3 and T6 temper conditions has been studied respectively.For the mechanical properties of AA2024 and AA7075 alloyshardness, fatigue behavior, tensile test and charpy impact test with standard V notched specimens at RTand-5 °C were analysed in the present study. Microstructural characterization has been done using standard metallography.
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In continuous casting of steel, liquid steel is continuously solidified into a finished product. Bokaro Steel Limited have slab caster and during continuous casting, one of the major operational irregularities encountered is breakout. A... more
In continuous casting of steel, liquid steel is continuously solidified into a finished product. Bokaro Steel Limited have slab caster and during continuous casting, one of the major operational irregularities encountered is breakout. A breakout is a hazard whereby the thin shell of the strand breaks, allowing the still-molten metal inside the strand to leak out from the mould, thus necessitating an expensive machine shutdown. Hence the breakout has a profound influence on the caster availability; affecting the productivity, cost of production, damage of machinery, safety hazards, etc. Breakouts occur due to the presence of a primary crack before solidification of liquid steel. Controlling the primary cracks lead to reduce chances of breakouts. Breakout prediction system of Bokaro Steel Limited uses only thermocouples temperature as an input of logic based algorithm controlled by strand PLC to predict breakout and generate alarm. This system sometimes generates lots of false alarm and sometimes even fails to generate an alarm before breakout. In this paper, two back-propagation neural networks are developed to predict the presence of primary crack that might lead to breakout of liquid steel. One is neural network1 train only with one input parameter (temperatures of thermocouples attached to the mould) and the other is neural network2 train with three input parameters (temperatures of thermocouples, casting speed and mould level). Both the neural network1 and network2 have only one output. Output of neural networks is either 0 for no alarm (no primary crack) or 1 for alarm (presence of primary crack) in breakout conditions. Comparison of the network1 with network2 showed that network2 has less output error, better performance and identifies primary crack more accurately. Performance of neural networks are done using Levenberg–Marquardt training algorithm, and also log sigmoid transfer function is used for both the hidden and output layer. The neural networks model training, validation and testing is done by simulating in Mat-Lab/Simulink.
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Breakout is one of the major accidents that often arise in the continuous casting shops of steel slabs in Bokaro Steel Plant, Jharkhand, India. Breakouts cause huge capital loss, reduced productivity, and create safety hazards. The... more
Breakout is one of the major accidents that often arise in the continuous casting shops of steel slabs in Bokaro Steel Plant, Jharkhand, India. Breakouts cause huge capital loss, reduced productivity, and create safety hazards. The existing system is not capable of predicting breakout accurately, as it considers only one process parameter, i.e., thermocouple temperature. The system also generates false alarms. Several other process parameters must also be considered to predict breakout accurately. This work has considered multiple process parameters (casting speed, mold level, thermocouple temperature, and taper/mold) and developed a breakout prediction system (BOPS) for continuous casting of steel slabs. The BOPS is modeled using an artificial neural network with a backpropagation algorithm, which further has been validated by using the Keras format and TensorFlow-based machine learning platforms. This work used the Adam optimizer and binary cross-entropy loss function to predict t...
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Conventional machining of aluminium foams is a difficult task because of the fact that their cells and cell edges are damaged and/or collapsed during the machining processes and thereby their original properties deteriorated. This problem... more
Conventional machining of aluminium foams is a difficult task because of the fact that their cells and cell edges are damaged and/or collapsed during the machining processes and thereby their original properties deteriorated. This problem can be overcome to a certain extent by machining this material by Electro Discharge Machining (EDM) process. The present paper deals with identifying the various control parameters responsible for effective machining of aluminium foam. Taguchi-Fuzzy Logic based technique is used for parameter design of performance characteristics to determine optimal machining parameters for maximum Material Removal Rate (MRR) and minimum Tool Wear Rate (TWR) in EDM. Taguchi-fuzzy based mapping of MRR and TWR with productivity revealed that in order to achieve higher productivity while machining aluminium foam, the two parameters, pulse current and pulse-On time are required to be set high in combination with the low setting of duty cycle.
Research Interests: Engineering and TECHNICAL
Continuous casting of steel is a process in which liquid steel is continuously solidified into semi-finished or finished product. Depending on the dimensions of the strand, these semi-finished products are called slabs, blooms or billets.... more
Continuous casting of steel is a process in which liquid steel is continuously solidified into semi-finished or finished product. Depending on the dimensions of the strand, these semi-finished products are called slabs, blooms or billets. Bokaro Steel Limited has slab caster that is used to produce slabs in different dimensions. In Bokaro Steel Plant, whenever there is requirement of different sizes of slabs, it essential to stop the casting and manually adjust the mould or exchange the mould as per the required size. It requires lot of time to prepare the caster in different mould sizes. Due to manual adjustment of the mould, it affects the productivity, pains manpower for preparation of mould size as per desired grade of steel and slabs sizes, and provides delay in casting. To avoid this problem, an online mould width adjustment system is developed to provide a compact system which has the capability for fast and precise mold width adjustments during full casting speed without sto...
The present work reports the influence of various Electric-Discharge Machining (EDM) process parameters on the surface morphology and EDM characteristics of thixoformed A356-5TiB2 in-situ composites. The important EDM parameters such as... more
The present work reports the influence of various Electric-Discharge Machining (EDM) process parameters on the surface morphology and EDM characteristics of thixoformed A356-5TiB2 in-situ composites. The important EDM parameters such as pulse current, pulse-on time, Duty Cycle, etc. on Surface morphology and Material removal rate of the thixoformed A356-5TiB2 in-situ composites have been investigated. Further, the machining parameters were optimized using Fuzzy-logic and grey relational analysis approach. The effect of EDM parameters and their interactions on the erosion behavior of A356-5TiB2 in-situ composites on various aspects of surface integrity and Material Removal rate (MRR) is reported. The surface integrity during EDM was characterized by Scanning Electron Microscope and analyzed from the machinability point of view. Thus, this work is an attempt to study the machinability behavior of thixoformed A356-5TiB2 in-situ composites.
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— Continuous casting of steel is a process in which liquid steel is continuously solidified into semi-finished or finished product (slabs, blooms or billets). There are many problems associated with continuous casting shop which affect... more
— Continuous casting of steel is a process in which liquid steel is continuously solidified into semi-finished or finished product (slabs, blooms or billets). There are many problems associated with continuous casting shop which affect the casting process. A major problem is associated in continuous casting shop is breakout of molten steel. Breakout leads to temporary shutdown of caster, damage of machinery due to splash of molten steel, capital loss, safety hazards etc. In Bokaro steel plant a logical based breakout prediction system is used to predict the breakout. This system sometimes generates false alarm and sometimes even fail to generate an alarm before breakout. Also the logical model has lot of dependence on specific equipment, process and calibration. Neural network can be implemented for a better breakout prediction system. So, in this paper a back-propagation neural network model is developed for predicting the existence of primary cracks that might lead to a breakout. The network gets its input temperatures from thermocouples which are attached to the wide and narrow sides of the mould. The output of the neural network is either logic 1 (for presence of crack) or logic 0 (for no crack). Testing the network shows excellent result as evident from the confusion matrix and performance plot. The neural network model is validated by simulating in MatLab/Simulink. The developed network may be used effectively in predicting breakouts during continuous casting. Such effective prediction can go a long way in reducing production losses in steel manufacturing.
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In the present article, an attempt is made to develop aluminium foam indigenously. The experimental setup for the production of aluminium foam is designed and fabricated. Investigation are made into the use of dual foaming agents (i.e.... more
In the present article, an attempt is made to develop aluminium foam indigenously. The experimental setup for the production of aluminium foam is designed and fabricated. Investigation are made into the use of dual foaming agents (i.e. TiH2 and CaCO3) along with SiC to develop suitable aluminium foams which can be utilized for various engineering products like load-bearing elements, crash resistance elements etc. The process is standardized to produce aluminium foam with specific density with minimum variability. This aluminium foam produced possesses a very low coefficient of friction. This work successfully characterized the frictional properties of the developed material. In order to define the Frictional properties of this material, a mathematical model which uniquely defines the frictional behavior of this modified Al-MMC foam has been developed.
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Saetak Specijalni konačni elementi (KE) koriste se za modeliranje posebnih fenomena u ponaanju konstrukcija. Izraz" specijalni" označava KE sa specifičnim svojstvima (parametri krutosti, ponaanje pod opterećenjem, itd.) i... more
Saetak Specijalni konačni elementi (KE) koriste se za modeliranje posebnih fenomena u ponaanju konstrukcija. Izraz" specijalni" označava KE sa specifičnim svojstvima (parametri krutosti, ponaanje pod opterećenjem, itd.) i posebnom ulogom u modeliranju, po čemu ...
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Abstract Experimental investigation of sound absorption characteristics of aluminium foam is carried out under laboratory test conditions. The studies revealed that the developed aluminium foam have excellent sound absorption properties... more
Abstract Experimental investigation of sound absorption characteristics of aluminium foam is carried out under laboratory test conditions. The studies revealed that the developed aluminium foam have excellent sound absorption properties and is comparable with other ...
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ABSTRACT Aluminium alloy composite foams reinforced by 5% vol. SiC particles were fabricated with melt foaming route using TiH2 -CaCO3 dual foaming agent. The compressive modulus and strength of two different relative density aluminium... more
ABSTRACT Aluminium alloy composite foams reinforced by 5% vol. SiC particles were fabricated with melt foaming route using TiH2 -CaCO3 dual foaming agent. The compressive modulus and strength of two different relative density aluminium foams were investigated experimentally. An empirical relationship was established between normalized change in density and strain, using experimental data of compression tests up to different strain levels. Sound absorption property of the developed material was found out by impedance tube method. Acoustic test results indicate the potential of the material as sound absorber.
Aluminium alloy composite foams are produced in the laboratory using TiH 2 -CaCO 3 dual foaming agents. The density of the developed material varied along various cross sections. There exists a more pronounced variation in density along... more
Aluminium alloy composite foams are produced in the laboratory using TiH 2 -CaCO 3 dual foaming agents. The density of the developed material varied along various cross sections. There exists a more pronounced variation in density along the direction of foaming. Compressive and ...
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Additive manufacturing (AM) has developed and gained popularity across the globe into a multi-billion-dollar industry that involves many materials and techniques. AM has created itself as a technology for the manufacturing of metallic... more
Additive manufacturing (AM) has developed and gained popularity across the globe into a multi-billion-dollar industry that involves many materials and techniques. AM has created itself as a technology for the manufacturing of metallic parts with enhanced mechanical characteristics that are scientifically sound and commercially feasible. However, there are various challenges, from business point of view, like high machine and material costs. Considering the complexities involved, sustainable manufacturing, optimization tools, and simulation models are necessary in order to save time and costly trial and errors. Topology optimization and simulation of AM processes are commercially available and are receiving attention from scientists and industry. Thus, this chapter is designed to provide readers with a brief introduction to AM technologies with typical applications. The main objective of this chapter is to provide the current trends and innovations in the field of design for additive manufacturing (DFAM), topology optimization, and simulation technologies.