Advances in Unconventional Machining and Composites

M. S. ShunmugamM. Kanthababu Editors

Proceedings of AIMTDR 2018

Lecture Notes on Multidisciplinary Industrial EngineeringSeries Editor: J. Paulo Davim

Lecture Notes on Multidisciplinary IndustrialEngineering

Series Editor

J. Paulo Davim , Department of Mechanical Engineering, University of Aveiro,Aveiro, Portugal

“Lecture Notes on Multidisciplinary Industrial Engineering” publishes specialvolumes of conferences, workshops and symposia in interdisciplinary topics ofinterest. Disciplines such as materials science, nanosciences, sustainability science,management sciences, computational sciences, mechanical engineering, industrialengineering, manufacturing, mechatronics, electrical engineering, environmentaland civil engineering, chemical engineering, systems engineering and biomedicalengineering are covered. Selected and peer-reviewed papers from events in thesefields can be considered for publication in this series.

More information about this series at http://www.springer.com/series/15734

M. S. Shunmugam • M. KanthababuEditors

Advances in UnconventionalMachining and CompositesProceedings of AIMTDR 2018

123

EditorsM. S. ShunmugamManufacturing Engineering SectionDepartment of Mechanical EngineeringIndian Institute of Technology MadrasChennai, Tamil Nadu, India

M. KanthababuDepartment of Manufacturing EngineeringCollege of Engineering, GuindyAnna UniversityChennai, Tamil Nadu, India

ISSN 2522-5022 ISSN 2522-5030 (electronic)Lecture Notes on Multidisciplinary Industrial EngineeringISBN 978-981-32-9470-7 ISBN 978-981-32-9471-4 (eBook)https://doi.org/10.1007/978-981-32-9471-4

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AIMTDR 2018 Conference’s Core OrganizingCommittee

Patrons

Dr. M. K. Surappa, Vice Chancellor, Anna UniversityDr. J. Kumar, Registrar, Anna University

President (NAC-AIMTDR)

Mr. P. Kaniappan, Managing Director, WABCO India Ltd.

Vice-President (NAC-AIMTDR)

Dr. Uday Shanker Dixit, Professor, IIT Guwahati, India

Co-patrons

Dr. A. Rajadurai, Dean, MIT Campus, Anna UniversityDr. T. V. Geetha, Dean, CEG Campus, Anna UniversityDr. L. Karunamoorthy, Chairman, Faculty of Mechanical Engineering,Anna UniversityDr. S. Rajendra Boopathy, Head, Department of Mechanical Engineering,Anna University

v

Chairman

Dr. S. Gowri, Honorary Professor, Department of Manufacturing Engineering,Anna University

Co-chairman

Dr. P. Hariharan, Professor, Department of Manufacturing Engineering,Anna University

Organizing Secretary

Dr. M. Kanthababu, Professor and Head, Department of ManufacturingEngineering, Anna University

Joint Organizing Secretaries

Dr. M. Pradeep Kumar, Professor, Department of Mechanical Engineering,Anna UniversityDr. A. Siddharthan, Associate Professor, Department of Production Technology,Anna University

International Scientific Committee

Prof. Abhijit Chandra, Iowa State University, USAProf. Ajay P. Malshe, University of Arkansas, USAProf. Andrew Y. C. Nee, NUS, SingaporeProf. Chandrasekar S., Purdue University, USAProf. Dean T. A., University of Birmingham, UKProf. Hong Hocheng, National Tsing Hua University, TaiwanProf. John Sutherland, Purdue University, USAProf. Kamlakar P. Rajurkar, University of Nebraska, USAProf. Kornel Ehmann, Northwestern University, USAProf. Liao Y. S., National Taiwan University, TaiwanProf. McGeough J. A., University of Edinburgh, UKProf. Mustafizur Rahman, NUS, Singapore

vi AIMTDR 2018 Conference’s Core Organizing Committee

Prof. Philip Koshy, McMaster University, CanadaProf. Rakesh Nagi, University of Buffalo, USAProf. Shiv Gopal Kapoor, University of Illinois, USAProf. Srihari Krishnasami, Binghamton University, USAProf. Tae Jo Ko, Yeungnam University, South KoreaProf. Tugrul Ozel, State University of New Jersey, USA

National Advisory Committee

Prof. Ahuja B. B., Government College of Engineering PuneProf. Amitabha Ghosh, BESUProf. Bijoy Bhattacharyya, Jadavpur University, KolkataProf. Biswanath Doloi, Jadavpur University, KolkataProf. Chattopadhyay A. K., IIT KharagpurProf. Deshmukh S. G., IIT GwaliorShri. Dhand N. K., MD, Ace Micromatic, BangaloreProf. Dixit U. S., IIT Guwahati, GuwahatiProf. Jain P. K., IIT Roorkee, RoorkeeProf. Jain V. K., IIT KanpurProf. Jose Mathew, NIT CalicutShri. Lakshminarayan M., WABCO India Ltd.Prof. Lal G. K., IIT KanpurProf. Mehta N. K., IIT RoorkeeProf. Mohanram P. V., PSG Institute of Technology and Applied ResearchShri. Mohanram P., IMTMA, BangaloreDr. Mukherjee T., Tata Steel Ltd., JamshedpurShri. Muralidharan P., Lucas TVS Ltd., VelloreProf. Narayanan S., VIT University, VelloreMr. Niraj Sinha, Scientist ‘G’, PSA, GOIProf. Pande S. S., IIT Bombay, MumbaiDr. Prasad Raju D. R., MVGRECProf. Radhakrishnan P., PSG Institute of Advanced Studies, CoimbatoreProf. Radhakrishnan V., IIST, TrivandrumProf. Ramaswamy N., IIT Bombay (Former)Prof. Ramesh Babu N., IIT MadrasShri. Rangachar C. P., Yuken India Ltd., BangaloreProf. Rao P. V., IIT DelhiDr. Santhosh Kumar, IIT BHUDr. Sathyan B. R., CMTI, BangaloreProf. Satyanarayan B., Andhra University (Former)Prof. Selvaraj T., NIT TrichyProf. Shan H. S., IIT Roorkee (Former)Prof. Shunmugam M. S., IIT Madras

AIMTDR 2018 Conference’s Core Organizing Committee vii

Shri. Shirgurkar S. G., Ace Designers Ltd., BangaloreDr. Sumantran V., Celeris TechnologiesDr. Suri V. K., BARC, MumbaiShri. Venu Gopalan P., DRDL HyderabadProf. Vinod Yadav, Motilal Nehru National Institute of Technology, Allahabad

viii AIMTDR 2018 Conference’s Core Organizing Committee

Foreword

It gives us immense pleasure to present the Advances in Manufacturing Technologyand Design—Proceedings of All India Manufacturing Technology, Design andResearch (AIMTDR) Conference 2018.

We would like to express our deep gratitude to all the members of OrganizingCommittee of AIMTDR 2018 Conference and also to authors, reviewers, sponsors,volunteers, etc., for their wholehearted support and active participation. Our specialthanks to Mr. P. Kaniappan, Managing Director, WABCO India Ltd., Chennai, whokindly agreed to act as President of National Advisory Committee (NAC) of theAIMTDR 2018 Conference. We also express our sincere thanks to ChairmanDr. S. Gowri, Honorary Professor, and Co-chairman Dr. P. Hariharan, Professor,Department of Manufacturing Engineering, Anna University, Chennai, for theirwholehearted support. We would like to express our sincere thanks to researchscholarsMr. K. R. Sunilkumar,Mr. U. Goutham,Mr. V.Mohankumar,Mr. R. Prabhuand also UG/PG students of the Department of Manufacturing Engineering, AnnaUniversity, for their contributions in the preparation of this volume.

High-quality papers have been selected after peer review by technical experts.We hope you find the papers included in the Proceedings of AIMTDR 2018Conference are interesting and thought-provoking.

We also like to express our gratitude for the support provided by Wabco IndiaLtd., Chennai, Kistler Instruments India Pvt. Ltd., Chennai, Ametek InstrumentsIndia Pvt. Ltd., Bengaluru, Central Manufacturing Technology Institute, Govt. ofIndia, Bengaluru, Defence Research and Development Organisation, Governmentof India, New Delhi, and Ceeyes Engineering Industries Pvt. Ltd., Trichy.

Finally, we would like to express our gratitude to National Advisory Committee(NAC)members of AIMTDR2018 for providing the necessary guidance and support.

Guwahati, India Uday Shanker DixitVice-President

National Advisory CommitteeAIMTDR

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Preface

All India Manufacturing Technology, Design and Research (AIMTDR) Conferenceis considered globally as one of the most prestigious conferences held once in twoyears. It was started in 1967 at national level at Jadavpur University, Kolkata, India,and achieved the international status in the year 2006. It was organized by variousprestigious institutions such as Jadavpur University, IIT Bombay, IIT Madras,CMTI Bangalore, PSG Tech, IIT Kanpur, CMERI, IIT Delhi, NIT Warangal, IITKharagpur, BITS Ranchi, VIT Vellore, IIT Roorkee, Andhra University, IITGuwahati and College of Engineering Pune.

The recent edition of the AIMTDR Conference, 7th International and 28th AllIndia Manufacturing Technology, Design and Research (AIMTDR) Conference2018, was jointly organized by the Departments of Manufacturing Engineering,Mechanical Engineering and Production Technology during 13–15 December2018, at College of Engineering, Guindy, Anna University, Chennai, India, with thetheme ‘Make in India – Global Vision’. A major focus was given on recentdevelopments and innovations in the field of manufacturing technology and designthrough keynote lectures. About 550 participants registered for the conference.During the conference, researchers from academia and industries presented theirfindings and exchanged ideas related to manufacturing technology and design.

Of the 750 papers received initially, 330 papers were finally selected after rigorousreview process for publication in the Springer Proceedings. Selected papers fromthe conference are being published by Springer in the series Lecture Notes onMultidisciplinary Industrial Engineering in five volumes, namelyVolume 1—AdditiveManufacturing and Joining, Volume 2—Forming, Machining and Automation,Volume 3—UnconventionalMachining and Composites,Volume 4—Micro andNanoManufacturing and Surface Engineering and Volume 5—Simulation and ProductDesign and Development.

Chennai, India M. S. ShunmugamMay 2018 M. Kanthababu

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Contents

Part I Unconventional Machining

1 Powder Mixed Near Dry Electric Discharge MachiningParameter Optimization for Tool Wear Rate . . . . . . . . . . . . . . . . . 3Sanjay Sundriyal, Ravinder Singh Walia and Vipin

2 Comparative Study of Dielectric and Debris Flowin Micro-Electrical Discharge Milling ProcessUsing Cylindrical and Slotted Tools . . . . . . . . . . . . . . . . . . . . . . . . 17S. A. Mullya and G. Karthikeyan

3 Parametric Investigation into Electrochemical Micromachiningfor Generation of Different Micro-surface Textures . . . . . . . . . . . . 27S. Kunar, S. Mahata and B. Bhattacharyya

4 Investigations into Wire Electrochemical Machining of StainlessSteel 304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Vyom Sharma, V. K. Jain and J. Ramkumar

5 Nanofinishing of External Cylindrical Surface of C60 SteelUsing Rotating Core-Based Magnetorheological FinishingProcess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Manpreet Singh, Ashpreet Singh and Anant Kumar Singh

6 Effect of Laser Parameters on Laser-Induced Plasma-AssistedAblation (LIPAA) of Glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Upasana Sarma and Shrikrishna N. Joshi

7 An Experimental Study of Electrochemical Spark Drilling(ECSD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Arvind Kumar Yadav and S. K. S. Yadav

8 Development and Experimental Study of Ultrasonic AssistedElectrical Discharge Machining Process . . . . . . . . . . . . . . . . . . . . . 89Shubham Srivastava, Pravendra Kumar and S. K. S. Yadav

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9 Effect of Finishing Time on Surface Finish of Spur Gearsby Abrasive Flow Finishing (AFF) Process . . . . . . . . . . . . . . . . . . . 101Anand C. Petare, Neelesh Kumar Jain and I. A. Palani

10 Experimental Study on Improving Material Removal Rateand Surface Roughness in Wire-Cut EDM of Low ConductiveMaterial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113Dhiraj Kumar, Sadananda Chakraborty, Anand Ranjanand Dipankar Bose

11 Machining Performance Evaluation of Al 6061 T6Using Abrasive Water Jet Process . . . . . . . . . . . . . . . . . . . . . . . . . 127Pankaj Kr. Shahu and S. R. Maity

12 Formulating Empirical Model of MRR in Near-Dry EDM . . . . . . . 141Gurinder Singh Brar, Nimo Singh Khundrakpamand Dharmpal Deepak

13 A Model for Average Surface Roughness for Abrasive WaterjetCut Metal Matrix Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149N. R. Prabhu Swamy and S. Srinivas

14 Abrasive Jet Machining of Soda Lime Glass and LaminatedGlass Using Silica Sand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163A. Karmakar, D. Ghosh, Deb Kumar Adak, Bijoy Mandal,Santanu Das, Ahmed Mohammed and Barun Haldar

15 A Novel Magnetorheological Grinding Process for Finishingthe Internal Cylindrical Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . 179Ankit Aggarwal and Anant Kumar Singh

16 A Study on Micro-tool and Micro-feature Fabricationin Micro-EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Biswesh Ranjan Acharya, Abhijeet Sethi, Akhil Dindigala,Partha Saha and Dilip Kumar Pratihar

17 Influence of Graphite Nanopowder-Mixed Dielectric Fluidon Machining Characteristics of Micro Electric DischargeMilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203K. V. Arunpillai and P. Hariharan

18 Realization of Green Manufacturing Using Citric AcidElectrolyte for WC–Co Alloy Micro-tool Fabricationin Micro-WECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Abhijeet Sethi, Biswesh Ranjan Acharya, Pranai Kumar,Rajib Chakraborty and Partha Saha

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19 Effect of Powder Mix and Ultrasonic Assistance on PulseTrain-Based Specific Energy in EDM of D3 Steel . . . . . . . . . . . . . . 225R. Rajeswari and M. S. Shunmugam

20 Performance Evaluation of Si–Cu-Hybrid Dust as a PowderAdditive of EDM Dielectrics to Machine Ti6Al4Vwith Copper Electrode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239Shirsendu Das, Swarup Paul, Biswanath Doloi and Kumar Rahul Dey

21 Experimental Study on Material Removal Rate and Over-Cutin Electrochemical Machining of Monel 400 Alloyswith Coated Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255S. Ayyappan and N. Vengatajalapathi

22 Experimental Investigations into Ultrasonic-Assisted MagneticAbrasive Finishing of Freeform Surface . . . . . . . . . . . . . . . . . . . . . 269Akshay Kumar Singh, Girish Chandra Verma, Vipin Chandra Shuklaand Pulak Mohan Pandey

23 Fiber Laser Cutting of Nimonic C263 Alloy and Investigationof Surface Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287Mukul Anand, Niladri Mandal, Vikas Kumar, Shakti Kumar,A. K. Sharma and Alok Kumar Das

24 Generation of Three-Dimensional Features on Ti6Al4Vby EC Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299K. Mishra, S. Sinha, B. R. Sarkar and B. Bhattacharyya

25 Enhancement in Machining Efficiency and Accuracy of ECDMProcess Using Hollow Tool Electrode . . . . . . . . . . . . . . . . . . . . . . . 313Rajendra Kumar Arya and Akshay Dvivedi

26 Evaluation of Cutting Force and Surface Roughness of Inconel718 Using a Hybrid Ultrasonic Vibration-Assisted Turningand Minimum Quantity Lubrication (MQL) . . . . . . . . . . . . . . . . . . 325Habtamu Alemayehu, Sudarsan Ghosh and P. V. Rao

27 On Performance Evaluation of Helical Grooved Tool DuringRotary Tool Micro-ultrasonic Machining . . . . . . . . . . . . . . . . . . . . 335Sandeep Kumar and Akshay Dvivedi

28 Experimental Investigation on Surface Topographyof the Natural Ceramics in Abrasive Water Jet Cuttingand Its Optimization Validation by Formulated Model . . . . . . . . . . 347Vijay Mandal, Amandeep Singh, Ganesh Singh Yadav,J. Ramkumar and S. Agrawal

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29 Prediction and Comparison of Vision Parameter of SurfaceRoughness in WEDM of Al-6%Si3N4 and Al-10%Si3N4

Using ANN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361H. R. Gurupavan, H. V. Ravindra and T. M. Devegowda

30 Performance Study of Electrical Discharge Drilling of MetalMatrix Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373Anjani Kumar Singh and Vinod Yadava

31 Multi-objective Optimisation of Electro Jet Drilling ProcessParameters for Machining of Crater in High-Speed SteelUsing Grey Relational Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385Kalinga Simant Bal, Amal Madhavan Nair, Dipanjan Dey,Anitesh Kumar Singh and Asimava Roy Choudhury

32 Machining of Bio-Implant Materials Using WEDMand Optimization of Process Parameters . . . . . . . . . . . . . . . . . . . . . 397P. Hema, J. Mallikarjuna Rao and C. Eswara Reddy

33 Experimental Investigations of Abrasive Waterjet MachiningParameters on Titanium Alloy Ti-6Al-4V Using RSMand Evolutionary Computational Techniques . . . . . . . . . . . . . . . . . 413A. Gnanavelbabu and P. Saravanan

34 Design of Fixture for Trimming of a Composite Material Shimby Abrasive Water Jet Machining . . . . . . . . . . . . . . . . . . . . . . . . . 427Kushal Singh, Ch. Venkateswarlu, B. Hari Prasad and A. P. Dash

35 Fabrication and Characterization of Helical Grooved CylindricalElectrodes Generated by WED Turning Process . . . . . . . . . . . . . . . 437Jacob Serah Krupa and G. L. Samuel

36 A Study of Wire Electrical Discharge Machining of CarbonFibre Reinforced Plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Hrishikesh Dutta, Kishore Debnath and Deba Kumar Sarma

37 Development of a Bore Using Jet Electrochemical Machining(JECM) in SS316 Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461J. Deepak, N. Vivek, B. MouliPrasanth and P. Hariharan

38 Machining and Characterization of Channels on Quartz Glassusing Hybrid Non-conventional Machining Process µ-ECDM . . . . . 473J. Bindu Madhavi and Somashekhar S. Hiremath

39 Parametric Study of a Newly Developed MagnetorheologicalHoning Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483Talwinder Singh Bedi and Anant Kumar Singh

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40 Investigation on Surface Roughness During Finishing of Al-6061Hybrid Composites Tube with Traces of Rare Earth MetalsUsing Magnetic Abrasive Flow Machining . . . . . . . . . . . . . . . . . . . 493V. K. Sharma, V. Kumar and R. S. Joshi

41 Part Program-Based Process Control of Ball-EndMagnetorheological Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503F. Iqbal, Z. Alam, D. A. Khan and S. Jha

42 Modelling and Analysis of Change in Shape of sintered Cu–TiCtool tip during Electrical Discharge Machining process . . . . . . . . . 515Arminder Singh Walia, Vineet Srivastava, Vivek Jainand Mayank Garg

43 Experimental Investigations on C-263 Alloyby Electrochemical Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 527K. Mishra, S. Sinha, B. R. Sarkar and B. Bhattacharyya

44 Influence of Discharge Energy on Electrical DischargeMachining of Ti-Foam Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 537S. Avinash, Karthick Chetti, M. Haribaskar, S. Jeyanthi,Abimannan Giridharan and R. Krishnamurthy

45 Gang Drilling of Square Micro-Holes on Glass Using USM . . . . . . 549T. Debnath, K. K. Patra and P. K. Patowari

46 Parametric Optimization of Micro Ultrasonic Drillingof Quartz Based on RSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559S. Kumar, B. Doloi and B. Bhattacharyya

47 Investigations into the Effect of Varying Electrode Diameteron Cutting Rate and Kerf Width in WEDM of VaryingThickness Inconel718 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571Susheel Ramchandra Dhale and Bhagyesh B. Deshmukh

48 Comparative Evaluation of Drilling on GFRP Madeby Different Fabrication Techniques . . . . . . . . . . . . . . . . . . . . . . . . 583R. Raja and Sabitha Jannet

49 An Experimental Analysis of Square Stepped Hole Fabricationon Zirconia Bio-Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599S. Das, S. Kumar, B. Doloi and B. Bhattacharyya

50 Pulse and Work Revolution Parameters of Wire ElectricalDischarge Turning on Ti-6Al-4V Alloy . . . . . . . . . . . . . . . . . . . . . . 611S. Ram Prakash, K. Rajkumar and G. Selvakumar

Contents xvii

51 Modeling of Areal Surface Roughness Using Soft-Computing-Based ANN and GA to Estimate Optimal Process ParametersDuring Wire Electrical Discharge Turning of Inconel 825 . . . . . . . 621Jees George, G. Ravi Chandan, R. Manu and Jose Mathew

52 Investigation on the Influence of Process Parameters on SurfaceRoughness and Kerf Properties in Abrasive Water JetMachining of Carbon Fibre Vinyl Ester Composite . . . . . . . . . . . . 631Bhavik Tank and Shailendra Kumar

53 Fluidized Bed Hot Abrasive Jet Machining (FB-HAJM)of K-60 Alumina Ceramic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 641B. K. Nanda, A. Mishra, Sudhansu Ranjan Das and D. Dhupal

54 Performance Evaluation of Abrasive Water Jet Machiningon AA6061-B4C-HBN Hybrid Composites Using TaguchiMethodology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651A. Gnanavelbabu, K. T. Sunu Surendran and K. Rajkumar

55 Empirical Modelling and Optimisation of Bio-Micromachiningon Antimicrobial Copper to Fabricate Micromixing System . . . . . . 661Abhishek Singh, Arul Manikandan, M. Ravi Sankar, K. Pakshirajanand L. Roy

56 Investigation on Magnetic Field-assisted Near-dry ElectricalDischarge Machining of Inconel 600 . . . . . . . . . . . . . . . . . . . . . . . . 671G. Mannoj Rajkumar, Abimannan Giridharan, R. Oyyaraveluand A. S. S. Balan

Part II Composites

57 Selection of Aluminum Hybrid Metal Matrix Composite MaterialUsing Additive Ratio Assessment Approach and Comparingwith the Experimental Results Varying Different WeightPercentage of the Reinforcements . . . . . . . . . . . . . . . . . . . . . . . . . . 687Soutrik Bose and Titas Nandi

58 The Role of HBN Solid Lubricant Reducing Cutting Forcesof Dry Machined Al-B4C Composite . . . . . . . . . . . . . . . . . . . . . . . . 697M. Rajesh, K. Rajkumar, A. Gnanavelbabu and K. M. Nambiraj

59 Experimental Investigation on Influence of Process Parametersof Abrasive Water Jet Machining on Kerf Taper of GlassFiber-Reinforced Polymer Composites . . . . . . . . . . . . . . . . . . . . . . 707H. J. Prajapati, Puneet Kumar, Shailendra Kumar and Ravi Kant

60 WEDM Studies on TiB2-15% SiC Ceramic Composite ProcessedThrough SPS Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 715K. Jayakumar

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61 Study of Mechanical Properties and Thermal Conductivityof Carbon and Basalt Fibre-Reinforced Hybrid PolymerComposites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 725V. Durga Prasada Rao, N. V. N. Sarabhayya and A. Balakrishna

62 Design and Fabrication of Aluminium/Alumina Ultra-fineComposite and Functionally Graded Material Using PowderMetallurgy Route . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 739Aravind Tripathy, Rajat Gupta, Saroj Kumar Sarangiand Anil Kumar Chaubey

63 Mechanical and Crystallization Behaviour of Sisal Fiberand Talc Reinforced Polylactic Acid Composites . . . . . . . . . . . . . . 749A. Suresh Babu, M. Jaivignesh and D. Poovarasan

64 Assessment on Hole Quality During Drilling of Al/CFRPStack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 757Tarakeswar Barik, Swagatika Sarangi and Kamal Pal

65 Experimental and Analytical Outcomes of Carbon FiberOrientation in Epoxy Resin Composite LaminateUnder Tensile Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 771A. Rajesh, S. Deva Prasad, B. Singaravel, T. Niranjanand T. Shravan Kumar

Contents xix

About the Editors

M. S. Shunmugam is a Professor (Emeritus) in the Manufacturing EngineeringSection in the Department of Mechanical Engineering, Indian Institute ofTechnology (IIT) Madras. After receiving his PhD in Mechanical Engineering fromIIT Madras in 1976, he has worked in IIT Bombay (from 1977 to 1980) and in IITMadras from 1980 onwards. He was a visiting faculty member at MichiganTechnological University during 1989-1991 and was a member in the board ofgovernors of IIT Madras during 2012-2013. Dr. Shanmugam’s research interestsinclude metrology, machine tools, manufacturing, gears, micro-machining andcomputer applications in manufacturing. He has published about 130 peer-reviewedinternational journal papers, 15 peer-reviewed national journal papers, 75 interna-tional conferences and about 80 national conferences.

M. Kanthababu is a Professor in the Department of Manufacturing Engineering inAnna University, Chennai, India and the Director of the Centre for IntellectualProperty Right and Trade Marks in Anna University. He has completed his MS inMechanical engineering and PhD in Advanced Manufacturing Technology from IITMadras. Prof Kanthababu's research interests include manufacturing technology,composite materials and machining, and automation in manufacturing. He haspublished more than 30 peer reviewed international journal papers and 2 books, andholds one patent.

xxi

Part IUnconventional Machining

Chapter 1Powder Mixed Near Dry ElectricDischarge Machining ParameterOptimization for Tool Wear Rate

Sanjay Sundriyal, Ravinder Singh Walia and Vipin

Abstract The powder mixed near dry electric discharge machining (PMND-EDM)is an advanced process for machining very hard and complex geometries. PMND-EDM is an eco-friendly process, which uses minute amount of metalworking fluids(MWF) with metallic powders for machining purposes. In this study, an approachhas been made to reduce tool wear rate (TWR) by optimizing process parametersusing Taguchi optimization technique. Taguchi (L9) array has been used for fourparameters and three levels. Parameters selected for the study were tool diameter,flow rate, metallic powder concentration, and pressure of dielectric mist. It has beenvalidated by the experiments and analysis that PMND-EDM has led to considerablereduction in TWR. The effect of influencing input parameters was analyzed and itwas revealed that tool dimensions played a major role in effecting TWR. Second,powder concentration was effective in reducing TWR followed by flow rate whilepressure of mist was least significant parameter.

Keywords Powder mixed near dry EDM · Tool wear rate · Taguchi · ANOVA ·Residual stress

1.1 Introduction

Near dry machining (NDM) is done with a very small quantity of liquid dropletsor in a form of mist, which is almost equal to dry situation of machining. It wasbeneficial in terms of reducing cost of machining. Metalworking fluids (MWFs) orlubricants needed were very minute amount of quantity, therefore, it led to reductionin cost of production. Near dry machining was first explored in 1989 [1]. NDM canbe performed in electric discharge machining, which eventually led to new method

S. Sundriyal · R. S. Walia (B) · VipinProduction Engineering, Department of Mechanical Engineering, Delhi Technological University,Delhi 110042, Indiae-mail: waliaravinder@yahoo.com

S. Sundriyale-mail: ss95576@yahoo.in

© Springer Nature Singapore Pte Ltd. 2020M. S. Shunmugam and M. Kanthababu (eds.), Advances in UnconventionalMachining and Composites, Lecture Notes on MultidisciplinaryIndustrial Engineering, https://doi.org/10.1007/978-981-32-9471-4_1

3

4 S. Sundriyal et al.

of machining known as near dry EDM. This method of machining eliminated prob-lems like improper flushing and debris attachment. At the same time, this technologyalso led to the reduction of harmful gases that are evolved while machining whichmade it an eco-friendly process. There are several advantages of NDM such as easycontrol of liquid concentration with air and other gases, which could be tailored togive required quality of dielectric medium in EDM process according to the userneed in order to achieve required output in machining such as low tool wear rate(TWR) and production-related benefits [2]. NDM led to increase in tool life as com-pared to shorter tool life in dry machining or machining with dielectric in completegaseous formwithout liquid aerosols [3]. New trending method of machining knownas powder mixed near dry EDM (PMND-EDM) came into existence after furtherresearch in ND-EDM [4]. Near dry machining was proved advantageous in terms ofgood characteristics of product developed such as high quality of machined product,which was quite economically produced. At the same time, it led to reduction inharmful fumes evolved while machining.

1.2 Indigenous Developed Setup for Powder Mixed NearDry EDM

The setup was built indigenously in Delhi Technological University, Delhi at preci-sion manufacturing lab. The setup comprises of control panel for control of mist flowrate and its pressure. A separate dielectric tankwasmadewhere liquid dielectric is fedalong with metallic powder and other stabilizing agents such as glycerol in appropri-ate proportion. This mixture of dielectric is converted into a form of high-pressuremist with the help of pressurized compressed air generated from air compressor.Figure 1.1 represents the complete setup along with EDMmachine (Sparkonix Indialimited). Specially designed tools of copper material were fabricated and designedin precision engineering lab, DTU. Figure 1.2a shows internal design features of toolwhile Fig. 1.2b shows external features of different tools developed for experimen-tation. Table 1.1 shows the different dimensions of tools.

1.3 Working Principle of PMND-EDM

The working principle of machining in PMND-EDM is quite similar to EDM. InPMND-EDM the machining takes due to high electrothermal energy of sparking atthe interelectrode gap (IEG) tool. This sparking is responsible for erosion of materialfrom theworkpiece aswell as thewear of the electrode. InPMND-EDM, thedielectrickerosene oil has been replaced by themist of kerosene oil along withmetallic powderto enhance the machining rate and reduce the tool wear. The dielectric mist is fedthrough the hollow copper electrode under high pressure. The erosion process starts

1 Powder Mixed Near Dry Electric Discharge Machining … 5

Fig. 1.1 Developed experimental setup for PMND-EDM

as themist comes out from the sparking end. The presence ofmetallic powder forms abridge of chain of conductive metallic powder particles, which increases the thermalconductivity and thus also reduces the insulation effect which eventually results inmore energized plasma of arc at the IEG as shown in Fig. 1.3. This reduced electricaldensity enhances the gap size or the IEG, which results in larger and more uniformlydistributed plasma for machining.

1.4 Process Parameters Selection and Experimentation

1.4.1 Selection of Workpiece and Tool

En-31 material was used as the workpiece due to its favorable properties like goodthermal conductivity, hardness, tensile strength, and melting point with excellentmachinability properties. Copper electrode was chosen as tool for the machiningpurpose.

6 S. Sundriyal et al.

Fig. 1.2 a Design and top view of tool developed for powder mixed NDEDM. b Hollow copperelectrode of different dimensions

Table 1.1 Dimensions oftools developed forexperimentation

Tool type Dimensions of tool

Inner dia (Ø) mm Outer dia (Ø) mm

Tool 1 2 3

Tool 2 3 4

Tool 3 4 5

1.4.2 Response Characteristic (Tool Wear Rate)

Tool wear rate signifies the amount of material removed from the tool duringmachin-ing.

Tool wear rate was calculated from the formula:

TWR = (Ti − Tf)/Tm

where

Ti Weight of tool before machiningTf Weight of tool after machiningTm Time taken for machiningTWR mg/min.

1 Powder Mixed Near Dry Electric Discharge Machining … 7

Fig. 1.3 Working principle and erosion process in PMND-EDM

Table 1.2 Operatingconditions in PMND-EDM[5, 6, 12]

Process parameters Values

Powder concentration (g/l) 2, 5, 8

Dielectric pressure (MPa) 0.4, 0.5, 0.6

Mist flow rate (ml/min) 5, 10, 15

Electrode polarity Positive

Duty factor 0.86

Dielectric fluid Kerosene (LL21)

Stabilizing agent Glycerol

Grain size of metallic powder (μm) 2.5

Electronic balance of least count 0.001 g was used to measure weight of the tool(Asia Techno weigh India).

The process parameters were constant in nature. The values of the constant param-eters for experimentation are shown in Table 1.2.

1.4.3 Scheme of Experiments

Design of experiments was performed to study the effect of input parameters on outresponse such as tool wear rate (TWR). Taguchi orthogonal array of L9 was usedwith three levels and four parameters as per the data shown in Table 1.3.

8 S. Sundriyal et al.

Table 1.3 Process parameters and their values at different levels [5, 6]

Symbol Process parameters Unit Level 1 Level 2 Level 3

A Tool dia mm 2 3 4

B Flow rate ml/min 5 10 15

C Powder conc g/l 2 5 8

D Pressure MPa 0.4 0.5 0.6

Values of other constant parameters: Machining time 10 min; Ton 500 μs; Toff 75 μs; Dischargecurrent 12 A; Tool electrode Copper; Workpiece EN-31

Table 1.4 Experimental results for TWR as per L9 orthogonal array

Exp. No Parameter trial condition TWR S/N (db)

A B C D R1 R2 R3

1 2 5 2 4 1.65 1.45 1.81 −4.31

2 2 10 5 5 1.70 1.42 1.39 −3.57

3 2 15 8 6 1.50 1.78 1.60 −4.24

4 3 5 5 6 1.37 1.23 1.11 −1.87

5 3 10 8 4 0.41 0.55 0.78 4.44

6 3 15 2 5 0.91 0.85 0.90 1.04

7 4 5 8 5 0.77 0.65 0.98 1.81

8 4 10 2 6 0.55 0.75 0.61 3.84

9 4 15 5 4 1.4 1.55 1.58 −3.59

Total 10.26 10.23 10.76

Overall mean TWR (T ) =1.15 mg/min

As per design of experiments, the experiments were conducted successfully forthree runs. The results of TWR at different levels are shown in Table 1.4. The exper-iments were performed in three runs under the same condition of parameter trialcondition.

1.5 Results and Discussion

1.5.1 Effect of Machining Parameters on TWR

Powder concentration is a significant factor affecting TWR [5]. At low concentration,the heat dissipation is not proper due to small discharge gap and leads to increase intoolwear butwith increasing of powder concentration, discharge gap is enlarged. Thisresulted in improvement of cooling in discharge gap, as a result, TWR is decreasedas shown in Fig. 1.4c.

1 Powder Mixed Near Dry Electric Discharge Machining … 9

Fig. 1.4 Effect of differentdimension of tools, flow rate,powder concentration, andpressure on TWR

Wear

The TWR decreases with increase in dimensions of tool diameter because theflushing takes place more efficiently which provides better cooling condition at thetooltip, which brings down the temperature at the sparking ends of the hollow toolelectrodes. However with further increase in tool diameters, there is no significanteffect on TWR as seen in Fig. 1.4a. TWR first decreases at low flow rate due topoor heat dissipation [6] and this resulted in some part of molten eroded materialforming a solidified layer at the tooltip, which reduces the wear at the tool endbut further increases in flow rate facilitates material removal of the tool electrodebecause simultaneously more material is also gets eroded from the workpiece whichconsumes the tooltips rapidly due to bettermachining efficiency as shown inFig. 1.4b.The powder concentration effects theTWR in a certainmanner. Initiallywith increaseof powder concentration, the TWR increases but afterward with further increase inpowder concentration the TWR starts decreasing as shown in Fig. 1.4c. The reasonis that powder concentration influences the heat received by the tool and adhesion ofmolten material on the face of the tool [6]. Due to this phenomenon, molten materialssolidification takes place in discharge gap. As a result, materials that can adhere ontothe surface of tool electrode are reduced, and thereforeTWRis increased.On the otherhand with further increase of metallic powder concentration, heat at discharge gapgets increased which forms adhesive layer over the tool end which reduces TWR.Powder concentration was significant factor affecting TWR. TWR increases withlower range of powder concentration but then decreases [5]. Parametric optimizationof TWR was studied with different combinations of tool electrode composition suchas half of the chemical composition of tool was made up of conductive materialsuch as copper and another half of the tool composition is made up of conductiveabrasive [7]. It was revealed with the study that the with abrasives the TWR tendsto decrease as compared to simple conductive tool without any conductive abrasiveparticles embedded in the tool. By addition of graphite powder the discharge gap wasincreased and stablemachiningwas initiatedwith reduced gap voltagewhich reducedthe TWR [7]. The wear of sparking end of the tool electrode tip after machining canbe seen in Fig. 1.5.

TWR shows the decreasing trend when the air pressure changes from 0.4 to0.5 Mpa as shown in Fig. 1.4d. With increase of air pressure, there were moremolecules at the IEG which enhances discharging. The discharge gap got enlargeddue to this phenomenon which led to improved deionization effect. Effects of abnor-mal short circuit and arc discharge were reduced, which eventually led to better

10 S. Sundriyal et al.

Fig. 1.5 Wear of toolelectrodes tip afterPMND-EDM process

0.8

1.05

1.3

1.55-4.05

-2.55

-1.05

0.45

2 3 4

TWR

(mg/

min

)

S/N

Rat

io (d

B)

Tool Diameter (mm)

S/N Raw data

0.8

1

1.2

1.4-2.5

-1.3

-0.1

1.1

5 10 15

TWR

(mg/

min

)

S/N

Rat

io (d

B)

Flow rate (ml/min)S/N Raw data

0.8

1

1.2

1.4-3.5

-2.3

-1.1

0.12 5 8

TWR

(mg/

min

)

S/N

Rat

io (d

B)

Powder conc (g/l)

S/N Raw data

1.051.131.211.29-1.2

-0.9-0.6-0.3

0.4 0.5 0.6

TWR

(mg/

min

)

S/N

Rat

io (d

B)

Pressure (MPa)

S/N Raw data

(a)

(b)

(c)

(d)

heat dissipation and reduced heat transfer at the tool. All these factors contributedto reduction in TWR till 0.5 Mpa. But with further increase of pressure, the gapvoltage increases due to which the plasma generated is not uniformly distributed andimproper erosion takes place which led to increase in TWR [8].

1 Powder Mixed Near Dry Electric Discharge Machining … 11

1.5.2 Taguchi Analysis

Therewere two types of data available as per analysis such as raw data and S/N data atthree levels L1, L2, andL3. The average%valuewas calculated for TWRfor differentparameters.After thatmain effects%ofTWRwere calculated by expression (L2–L1)and (L3–L2). Finally, the difference between L2, L1 and L3, L2 was calculated asshown in Table 1.5. Analysis of variance was done for TWR S/N ratio on the resultsobtained at 95% confidence level. Table 1.6 shows the pooled ANOVA raw data forTWR analysis at 95% confidence level and critical F-ratio of 3.55. Pooled ANOVAraw data (S/N) ratio for TWR at 95% confidence level and critical F-ratio of 19is shown in Table 1.7. The predicted values of TWR and experimental values atconfidence of intervals of confirmation of experiment and confidence of populationat 95% confidence level is shown in Table 1.8. The most optimum level of differentinput process parameter were A2, B2, C3, and D2. Among the process parameters,nonlinear behavior can be studied only if there are more than two levels of theparameters. Therefore, each parameter was analyzed at three levels [9–12].

1.5.3 Estimation of Optimum Performance Characteristics(TWR)

The optimum value of TWRwas predicted at the selected levels of significant param-eters A2, B2, C3, and D2 as per Table 1.7. The estimated mean of the responsecharacteristic (TWR) can be determined [13, 14] as

TWR = A2 + B2 + C3 + D2 − 3T (1.1)

where T (overall mean of TWR) = 1.15 mg/min (Table 1.4), A2 (Average TWR atthe second level of tool diameter) = 0.90 mg/min, B2 (Average TWR at the secondlevel of flow rate) = 0.90 mg/min, C3 (Average TWR at the third level of powderconcentration)= 1.00mg/min, andD2 (AverageTWRat the second level of pressure)= 1.06 mg/min.

Upon substituting the above values in Eq. (1.1),

TWR = 0.90 + 0.90 + 1.00 + 1.06 − 3 × 1.15 = 0.41mg/min.

The 95% confidence interval of conformation experiments (CICE) and confidenceinterval of population (CIPOP) was calculated by using the following equations:

CICE =√Fα(1, fe)Ve

[1

neff+ 1

R

]= ±0.21, (1.2)

12 S. Sundriyal et al.

Tabl

e1.

5Raw

dataandsign

alto

noiseratio

fordifferentp

aram

eters

Processparameter

Level

Tool

dia(A

)Flow

rate(B

)Po

wderconc

(C)

Pressure

(D)

Type

ofdata

S/NRatio

Raw

data

S/NRatio

Raw

data

S/NRatio

Raw

data

S/NRatio

Raw

data

Avg

values

(%TWR)

L1

−4.04

1.58

−1.45

1.22

0.19

1.05

−1.15

1.24

L2

1.20

0.90

1.56

0.90

−3.01

1.41

−0.24

1.06

L3

0.68

0.98

−2.26

1.34

0.66

1.00

−0.75

1.16

Maineffects(%

TWR)

L2–L1

5.24

−0.68

3.01

−0.32

−4.23

0.36

0.91

−0.18

L3–L2

−0.52

0.08

−3.82

0.44

3.67

−0.41

−0.51

0.10

Differences

(L3–L2)

−(L2–L1)

−5.76

0.76

−6.83

0.76

7.9

−0.77

−1.42

0.28

L1,

L2,

L3representlevels1,

2and3respectiv

elyof

parameters.(L2–L1)

istheaveragemaineffectwhenthecorrespondingparameter

changesfrom

Level1

toLevel2.

(L3–L2)

isthemaineffectwhenthecorrespondingparameter

changesfrom

Level2to

Level3