Energy crisis poses a major challenge in the modern industrial scenario. Electrification of autom... more Energy crisis poses a major challenge in the modern industrial scenario. Electrification of automotive may provide a potential solution to this problem. The performance of the battery electric vehicles mainly depends on the energy capacity of batteries. In this regard, the lithiumion (Li-ion) batteries grab a great deal of attention due to its high energy storing capacity as compared with conventional lead-acid batteries. Manufacturing of Li-ion batteries involve a significant amount of joining to reduce the power loss and gain of desired power during the transmission process. Thus, a conservative and energy-efficient method is necessary. However, the joining of these highly conductive dissimilar metals using any other conventional welding processes such as resistance spot welding and laser welding is extremely challenging due to varying physical, chemical, and thermal properties, the formation of the heat-affected zone and intermetallic compounds. Recently, ultrasonic spot welding ...
Indian Journal of Engineering and Materials Sciences, 2002
The metal n ow in th e extrusi on process is an important fac tor in cont rolling the mechanical ... more The metal n ow in th e extrusi on process is an important fac tor in cont rolling the mechanical properties of the cxt ru ded products . It is, however, diffi cult to predic t the metal now in three-dimensio nal ext ru sio n of sect ions unl ess a co ntinu ous ve locit y field is employed fo r th e analysis. On th e oth er hand, ana lys is of cxtrusion of sect ion s with re- entrant co rn crs is not cas il y amc na ble to techniques employing cont inu ous vclocity fields . The spatial elementary ri gid regi on (SE RR ) tec hnique, whi ch employs a di scontinuous ve loci ty field, is eminently applicable fo r the anal ys is of th is class of prob lems. Some expc rim cntal studies havc bee n ca rri ed out with a view to compare it wi th the th eo reti ca l results predicted usin g th e SERR analysi s. Experiments are carried out for obtai nin g square and I- secti ons fro m rectan gular billets throu gh sq uare dies usi ng direct extrusion process. An ex perimental se t-up has been de...
ABSTRACT Principally, hard material such as SS304 deployed a huge stress to process through conve... more ABSTRACT Principally, hard material such as SS304 deployed a huge stress to process through conventional machining. Since, ultrasonic-assisted turning involves a synchronized ultrasonic vibration to the tool to establish intermittent cutting and could be a feasible choice. Thus, a comprehensive study was exercised to design horn-tool assembly for ultrasonic assisted turning and fabricated a potential experimental setup to address its machining potential to machine stainless steel. ANSYS® was incorporated to perform Harmonic and Modal analysis to obtained the horn-tool natural frequency, optimum shape and length respectively. The analysis showed 19925.5 Hz natural frequency and amplitude propagation approximately 4 times for 126 mm length along with 5 mm tool insert thickness. Further Taguchi method employed for the design of experiment and performed gray Taguchi for multi objective optimization. Investigation shows the induced cutting force and the surface roughness reduced significantly as low as to 53.89% and 54.5%, respectively, by ultrasonic turning. The machining parameters found optimum at a parametric setting: depth of cut 0.2 mm, feed 0.06 mm/rev and cutting velocity 38.48 m/min respectively favorable for getting low cutting force and high surface finish. Finally, results of the experiment invoked that ultrasonic assisted turning is a promising technique for hard material.
CIRP Journal of Manufacturing Science and Technology
Abstract Additive manufacturing (AM) route is a promising approach for fabricating complex and li... more Abstract Additive manufacturing (AM) route is a promising approach for fabricating complex and lightweight metallic structures that have applications in various sectors such as automotive, aerospace, and biomedical industries. Laser, electron beam, and electric arc are the common power sources available for AM. Out of different metal AM techniques, wire-feed additive manufacturing has been considered as a promising alternative for fabricating metallic parts for various applications. As it provides a high deposition rate, material utilization, density, and low cost with a low risk of contamination and porosity compared to powder-based raw material. Gas metal arc welding-based additive manufacturing (GMAW-AM) is a specific approach based on wire-feed AM. This technology uses a low-cost equipment which is suitable for fabricating components with large geometries and moderate structural complexity. These advantages attract the researchers and production industries for further developments in GMAW-AM to enhance its deposition performance, process capability, and applicability in various fields. The quality of metal deposited in GMAW-AM is generally represented by the surface form, dimensional quality, mechanical properties, relative density, hardness, etc. The present paper encompasses the research developments that occurred in the field of GMAW-AM in recent years. This review begins with the GMAW-AM procedure, performance capability, identification of factors affecting the deposition performance, and strategies adopted to overcome these issues. Several aspects such as mathematical modelling, optimization, key process parameters, and their combinations for a wide range of wire electrode material and percentage contributions are also reviewed and depicted in detail. Also, a comprehensive conclusion of this review, along with future perspectives, is explored subsequently. The current review work will help future researchers to select different wire materials and GMAW-AM parameters to achieve better performances. Lastly, several future research directions are suggested, specifically the need of a framework for GMAW-AM processes for fabricating quality products with minimum distortion.
In this study, an upper-bound analysis is presented for the extrusion of bars of channel section ... more In this study, an upper-bound analysis is presented for the extrusion of bars of channel section from square/rectangular billets through rough square dies. A class of kinematically admissible discontinuous velocity fields, based on the reformulated SERR technique, is examined and the velocity field giving the lowest upper-bound is identified. This velocity fields is used to compute the upper-bound extrusion pressure
The plastic flow of metal in the extrusion process is an important factor in controlling the mech... more The plastic flow of metal in the extrusion process is an important factor in controlling the mechanical properties of the extruded products. It is, however, difficult to predict the metal flow in three dimensional extrusions of sections due to the involvement of re-entrant corners. The present study is to find an upper bound solution for the extrusion of triangular sectioned through taper dies from round sectioned billet. A discontinuous kinematically admissible velocity field (KAVF) is proposed. From the proposed KAVF, the upper bound solution on non-dimensional extrusion pressure is determined with respect to the chosen process parameters. The theoretical results are compared with experimental results to check the validity of the proposed velocity field. An extrusion setup is designed and fabricated for the said purpose, and all extrusions are carried out using circular billets. Experiments are carried out with commercially available lead at room temperature.
Energy crisis poses a major challenge in the modern industrial scenario. Electrification of autom... more Energy crisis poses a major challenge in the modern industrial scenario. Electrification of automotive may provide a potential solution to this problem. The performance of the battery electric vehicles mainly depends on the energy capacity of batteries. In this regard, the lithiumion (Li-ion) batteries grab a great deal of attention due to its high energy storing capacity as compared with conventional lead-acid batteries. Manufacturing of Li-ion batteries involve a significant amount of joining to reduce the power loss and gain of desired power during the transmission process. Thus, a conservative and energy-efficient method is necessary. However, the joining of these highly conductive dissimilar metals using any other conventional welding processes such as resistance spot welding and laser welding is extremely challenging due to varying physical, chemical, and thermal properties, the formation of the heat-affected zone and intermetallic compounds. Recently, ultrasonic spot welding ...
Indian Journal of Engineering and Materials Sciences, 2002
The metal n ow in th e extrusi on process is an important fac tor in cont rolling the mechanical ... more The metal n ow in th e extrusi on process is an important fac tor in cont rolling the mechanical properties of the cxt ru ded products . It is, however, diffi cult to predic t the metal now in three-dimensio nal ext ru sio n of sect ions unl ess a co ntinu ous ve locit y field is employed fo r th e analysis. On th e oth er hand, ana lys is of cxtrusion of sect ion s with re- entrant co rn crs is not cas il y amc na ble to techniques employing cont inu ous vclocity fields . The spatial elementary ri gid regi on (SE RR ) tec hnique, whi ch employs a di scontinuous ve loci ty field, is eminently applicable fo r the anal ys is of th is class of prob lems. Some expc rim cntal studies havc bee n ca rri ed out with a view to compare it wi th the th eo reti ca l results predicted usin g th e SERR analysi s. Experiments are carried out for obtai nin g square and I- secti ons fro m rectan gular billets throu gh sq uare dies usi ng direct extrusion process. An ex perimental se t-up has been de...
ABSTRACT Principally, hard material such as SS304 deployed a huge stress to process through conve... more ABSTRACT Principally, hard material such as SS304 deployed a huge stress to process through conventional machining. Since, ultrasonic-assisted turning involves a synchronized ultrasonic vibration to the tool to establish intermittent cutting and could be a feasible choice. Thus, a comprehensive study was exercised to design horn-tool assembly for ultrasonic assisted turning and fabricated a potential experimental setup to address its machining potential to machine stainless steel. ANSYS® was incorporated to perform Harmonic and Modal analysis to obtained the horn-tool natural frequency, optimum shape and length respectively. The analysis showed 19925.5 Hz natural frequency and amplitude propagation approximately 4 times for 126 mm length along with 5 mm tool insert thickness. Further Taguchi method employed for the design of experiment and performed gray Taguchi for multi objective optimization. Investigation shows the induced cutting force and the surface roughness reduced significantly as low as to 53.89% and 54.5%, respectively, by ultrasonic turning. The machining parameters found optimum at a parametric setting: depth of cut 0.2 mm, feed 0.06 mm/rev and cutting velocity 38.48 m/min respectively favorable for getting low cutting force and high surface finish. Finally, results of the experiment invoked that ultrasonic assisted turning is a promising technique for hard material.
CIRP Journal of Manufacturing Science and Technology
Abstract Additive manufacturing (AM) route is a promising approach for fabricating complex and li... more Abstract Additive manufacturing (AM) route is a promising approach for fabricating complex and lightweight metallic structures that have applications in various sectors such as automotive, aerospace, and biomedical industries. Laser, electron beam, and electric arc are the common power sources available for AM. Out of different metal AM techniques, wire-feed additive manufacturing has been considered as a promising alternative for fabricating metallic parts for various applications. As it provides a high deposition rate, material utilization, density, and low cost with a low risk of contamination and porosity compared to powder-based raw material. Gas metal arc welding-based additive manufacturing (GMAW-AM) is a specific approach based on wire-feed AM. This technology uses a low-cost equipment which is suitable for fabricating components with large geometries and moderate structural complexity. These advantages attract the researchers and production industries for further developments in GMAW-AM to enhance its deposition performance, process capability, and applicability in various fields. The quality of metal deposited in GMAW-AM is generally represented by the surface form, dimensional quality, mechanical properties, relative density, hardness, etc. The present paper encompasses the research developments that occurred in the field of GMAW-AM in recent years. This review begins with the GMAW-AM procedure, performance capability, identification of factors affecting the deposition performance, and strategies adopted to overcome these issues. Several aspects such as mathematical modelling, optimization, key process parameters, and their combinations for a wide range of wire electrode material and percentage contributions are also reviewed and depicted in detail. Also, a comprehensive conclusion of this review, along with future perspectives, is explored subsequently. The current review work will help future researchers to select different wire materials and GMAW-AM parameters to achieve better performances. Lastly, several future research directions are suggested, specifically the need of a framework for GMAW-AM processes for fabricating quality products with minimum distortion.
In this study, an upper-bound analysis is presented for the extrusion of bars of channel section ... more In this study, an upper-bound analysis is presented for the extrusion of bars of channel section from square/rectangular billets through rough square dies. A class of kinematically admissible discontinuous velocity fields, based on the reformulated SERR technique, is examined and the velocity field giving the lowest upper-bound is identified. This velocity fields is used to compute the upper-bound extrusion pressure
The plastic flow of metal in the extrusion process is an important factor in controlling the mech... more The plastic flow of metal in the extrusion process is an important factor in controlling the mechanical properties of the extruded products. It is, however, difficult to predict the metal flow in three dimensional extrusions of sections due to the involvement of re-entrant corners. The present study is to find an upper bound solution for the extrusion of triangular sectioned through taper dies from round sectioned billet. A discontinuous kinematically admissible velocity field (KAVF) is proposed. From the proposed KAVF, the upper bound solution on non-dimensional extrusion pressure is determined with respect to the chosen process parameters. The theoretical results are compared with experimental results to check the validity of the proposed velocity field. An extrusion setup is designed and fabricated for the said purpose, and all extrusions are carried out using circular billets. Experiments are carried out with commercially available lead at room temperature.
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