NEERAJ KUMAR BHOI | Banasthali Vidyapith (original) (raw)

Papers by NEERAJ KUMAR BHOI

International Journal on Interactive Design and Manufacturing (IJIDeM)

Journal of Materials Engineering and Performance

The present study was aimed at investigating the machinability characteristics of titanium alloy ... more The present study was aimed at investigating the machinability characteristics of titanium alloy (Ti6Al4V) by electro-discharge machining (EDM) process. The machining was performed using composite tools made of Cu-W-B4C having different compositions manufactured with the help of hybrid microwave sintering (MWS) process. For this experimental investigation, machining performances in terms of material removal rate, tool wear rate and surface characteristics of the machined surfaces were measured as outcomes. The surface characteristics like surface cracks and white layer formation were evaluated with the help of micrographs of the machined surfaces using scanning electron microscope. Phase identification of the machined surface was carried out with the help of X-ray diffraction (XRD) analysis to identify the effect of sintered tools on the machined surface. The energy-dispersive X-ray spectroscopy (EDS) result of the machined surfaces revealed transfer of tool materials (copper and tungsten) onto the machined surface. The removed tool materials deposited on the machined surfaces form white layer which was found responsible for increasing the micro-hardness of the machined surface. The EDS results of the machined zone were seen in good agreement with the phases identified with XRD analysis with the formation of metal carbides such as titanium carbide and vanadium carbide. The study will serve as a test bed in developing a strong link between the MWS composite tool and machining behavior during EDM of titanium alloys.

Materials Science and Engineering: B, 2022

OPSEARCH, 2021

Abrasive water jet cutting is one of the most prominent technique for the cutting of wide range o... more Abrasive water jet cutting is one of the most prominent technique for the cutting of wide range of materials. Selection of the input process parameter with optimized condition determines the productivity and process applicability. Present paper describes the nature inspired meta-heuristic chemical reaction optimization (CRO) algorithm for the selection of input process parameter for the most favorable material removal rate (MRR). In the present paper ductile material model for the MRR is considered by CRO for the solution approach. Five input variables namely water jet pressure, diameter of nozzle, feed rate of nozzle, mass flow rate of abrasive and mass flow rate of water were considered for the material removal rate in abrasive water jet machining. It was found that CRO algorithms delivers improved performance compare to different algorithms such as genetic algorithm, cuckoo search, teaching learning-based optimization and teaching learning based cuckoo search algorithm. The predicted results can be used for the identification of the input process parameter to enhance outcome at the acceptable range for machining.

Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2022

In the present study, a finite element model of microwave hybrid sintering along with experimenta... more In the present study, a finite element model of microwave hybrid sintering along with experimental validation was developed. Multiphysics simulation at 2.45 GHz was carried out to understand the heat transfer behaviour and electric field distribution during the microwave hybrid sintering process. The proposed work presents an innovative and integrated approach for sintering aluminium utilizing microwave energy. Comparison with numerical simulation results and experimental data of temperature variation during microwave hybrid sintering was done. The maximum error predicted by the simulation model and experimental investigation for temperature variation in sintering was found to be within 10%. The X-ray diffraction analysis, relative density and microstructure analysis of the sintered aluminium was done to gain an insight into the material characteristics. The microhardness and nanoindentation tests were carried out to determine the hardness and elastic modulus. Good consolidation beh...

Journal of Inorganic and Organometallic Polymers and Materials, 2022

The current study is focused on the microstructure, phase transition, and mechanical properties o... more The current study is focused on the microstructure, phase transition, and mechanical properties of the aluminum yttrium oxide (Al–Y2O3) composite material. Microwave hybrid sintering using Y2O3 nanoparticles as reinforcement at various (i.e., 0.5, 2, 3.5 and 5) wt% was used. Simultaneous thermal analysis (STA) and X-ray photoelectric spectroscopy (XPS) were used to investigate the chemical interaction between Al and Y2O3. This research will aid in gaining a better knowledge of the changes in thermal characteristics and compositional changes that occur throughout the microwave hybrid sintering process. The insight into material properties reveals that intermetallic Al3Y and Al2O3 are generated during the synthesis process, which was substantiated by X-ray diffraction (XRD) and energy dispersive spectroscopy (EDX) analysis. The Al–Y2O3 composite material has a well-consolidated microstructure and improved mechanical characteristics. To further understand material behaviour, a robust and non-destructive depth sensing nano-indentation technology was being used. With the addition of 5 wt% Y2O3, the microhardness of composite material is enhanced by 1.62 times. Furthermore, with 5 wt% Y2O3, the produced composite's nano hardness and elastic modulus augmented by 2.43 and 1.8 times, respectively. It is caused by the presence of intermetallic in the composite material, as well as the prevalence of uniform reinforcement distribution.

The systematic use of abrasive water jet machining (AWJM) started in the year 1983 with the aim t... more The systematic use of abrasive water jet machining (AWJM) started in the year 1983 with the aim to reduce the overall process time and get rid of the adverse thermal defects which occur generally in case of other nontraditional manufacturing processes. Initially, the AWJM process was limited for the softer materials but the advent in technology and generation of very high-pressure water jets led to the cutting of any type of material without affecting the properties of the work material. Typically, the water jet cutting system can cut a material of thickness up to 24 inches with the accuracy of 0.001 inch with the same setup for all types of materials. AWJM is widely employed for the manufacturing of precision gears, 3D profiling, drilling, milling, cleaning, and nuclear plant dismantling. This chapter presents the developments in abrasive water jet machining technology with focus on the process mechanism, parameters, machine tool system, applications, and review of some past work.

Lecture Notes in Mechanical Engineering, 2020

The abrasive water jet machining (AWJM) process utilized a wide industrial application due to its... more The abrasive water jet machining (AWJM) process utilized a wide industrial application due to its unique capabilities of cutting any soft or hard material. AWJM uses high-velocity water and abrasives to remove the material with the concept of the impact of high kinetic energy jet on the work material. During AWJM, the accuracy of cutting geometry primarily depends on the size of nozzle orifice and then on standoff distance (SOD), tool path and slurry velocity. In order to reach an accurate and reliable quality control of a mechanical part produced using AWJM, material and process parameter-based control strategies have developed with the objective to reduce down the nozzle erosion. Furthermore, these strategies help to achieve low-cost machining, high level of productivity and increased reliability due to reduced scrap rate by increasing the nozzle life span. In this paper, various developed strategies made by researchers to monitor the nozzle condition during machining are summarized. It is found that to improve the reliability and performance of the AWJM operation, more efforts should be paid to developing nozzles, and a relationship between the work surfaces and the nozzles must be listed.

Advanced Composite Materials, 2021

In this work Al-ZnO-Y2O3 hybrid composites were fabricated utilizing powder metallurgy and hybrid... more In this work Al-ZnO-Y2O3 hybrid composites were fabricated utilizing powder metallurgy and hybrid microwave sintering approach from the powder blend of Al, ZnO and Y2O3. Depth sensing nano-indentation technique was adopted to assess the nano-hardness and elastic modulus of the composite material. Thermal analysis of the composite materials was done to gain an insight into surface decomposition and phase transformation behaviour. A strong interfacial bonding with clear interface between matrix and reinforcement was observed during the microstructural analysis of the composite material. The results of the current study exhibit ~89% improvement in the nano-hardness and ~11% improvement in the elastic modulus value. The improvement in the material response is attributed to the reasonably uniform distribution of ZnO and Y2O3 in the hybrid composite materials. The results of this study validate the capability of combined presence of ZnO and Y2O3 reinforcements to enhance the hardness and elastic modulus of aluminium.

Silicon, 2021

Sustainable product development and efficient use of resources is prime and major concern in the ... more Sustainable product development and efficient use of resources is prime and major concern in the present era of modern manufacturing practice. In the current work energy efficient microwave heating techniques is employed for the four different kind (i.e. silicon carbide, graphite, A5grade alumina and pulverized charcoal) of microwave absorbing material. The finite element modeling of susceptor heating was done using COMSOL multi-physics environment. These susceptor material were tested for different microwave power input with fixed exposure time and microwave frequency of 2.45 GHz. It was observed that the A5 grade alumina and silicon carbide material giving higher amount of heating rate for a comparable operating condition of different susceptor material. The experimental validation for the three different power input (540, 720 and 900 W) were done for silicon carbide susceptor material utilizing 2.45 GHz microwave frequency. The results obtained are in close agreement with finite element modeling. The present study will develop a cogent link between the modeling and experimental study of microwave heating behavior under room temperature application for numerous material processing applications.

Composite Materials, 2021

Abstract Composite material is a material system that combines different metallic and nonmetallic... more Abstract Composite material is a material system that combines different metallic and nonmetallic materials with different shapes, constituents, and chemical differences with separate interfaces. The prime essence of the present chapter is to provide directive information about newly developed strategies for the synthesis of aluminum metal-matrix composites (Al-MMCs) keeping the processing and mechanical aspect as a prime consideration. The evolution of the mechanical property of the Al-MMCs with different processing circumstances and strengthening mechanism is given to corelate the material response with different reinforcing elements. Accordingly, the present chapter focuses on newly developed strategies for the synthesis and processing of Al-MMCs for numerous structural applications.

Sustainable Engineering Products and Manufacturing Technologies, 2019

Abstract Nowadays, energy conservation, reliable product, economic and environmental processes ar... more Abstract Nowadays, energy conservation, reliable product, economic and environmental processes are the prime considerations in the modern manufacturing world. The key reasons behind are due to a rapid growth of advanced/hybrid manufacturing processes and the issues of global warming. Microwave processing of material is one of its kind in terms of very short processing time, rapid and volumetric heating with less energy and minimal stress to the environment. Present chapter reports the various manufacturing operation such as joining, sintering, drilling, cladding, and casting by the use of microwave energy. The chapter demonstrates the working phenomenon in detail, effect of process parameters, and numerous possibilities in the industrial applications which can be implemented in the near future.

Lecture Notes on Multidisciplinary Industrial Engineering, 2020

The requirement of better functional surface and enhanced product performance has always been thr... more The requirement of better functional surface and enhanced product performance has always been thrust for the industrial and academia. The surface modification through microwave energy has been developed and relatively new innovative method for various coatings on the substrate material. The present study involves the hybrid microwave cladding of aluminum and silicon carbide composite in the mild steel substrate at lower cost and processing circumstances. In the present case, pure aluminum and pure Al + 5 wt%SiC were utilized for the cladding over the mild steel substrate material. To investigate the output response, corrosion behavior of the material is tested under two different acidic environments (i.e., sodium chloride and nitric acid). The weight loss measurement is done with the fixed interval of time to know the corrosion behavior of the material. The performance of the clad surface shows the better outcomes compared to the monolithic substrate material. The bonding between the clad and substrate is in excellent accord with the performance improvement as observed by the use of scanning electron microscope.

Lecture Notes in Mechanical Engineering, 2021

Functional and Smart Materials, 2020

Journal of Composite Materials, 2020

The study focuses on the microstructural, phase transformation, and physical and mechanical aspec... more The study focuses on the microstructural, phase transformation, and physical and mechanical aspects of aluminum/zinc oxide composite produced by a hybrid microwave sintering technique. In the present case, zinc oxide nanorods were synthesized through a cost-effective thermal decomposition method. The obtained zinc oxide nanorods’ length was in the range of 76–168 nm observed through high-resolution transmission electron microscopy images and crystallinity nature was confirmed by the bright spot in the selected area electron diffraction pattern. Two different wt% (i.e. 0.5 and 2) of zinc oxide nanorods were utilized for the fabrication of the composite material. The diffraction pattern of the milled powder and energy dispersive spectroscopy results shows effective diffusion of zinc oxide nanorods in the aluminum. The elemental mapping of milled powder illustrates the uniform distribution of the reinforcement over matrix material. The micro-hardness results exhibit a higher hardness o...

Materials Science Forum, 2018

Aluminum metal matrix composites (Al-MMCs) is a one of the most demanding engineering material du... more Aluminum metal matrix composites (Al-MMCs) is a one of the most demanding engineering material due to the combination of their light weight, excellent mechanical and tribological properties. To enhance the promising advantages of Al-MMCs, microwave sintering (MWS) is an ideal and emerging technique. The unique advantages of MWS of MMCs are ascribed to the size and distribution of the reinforcement, as well as to the grain size of the matrix along with uniform and efficient heating. The objective of this comprehensive review was to highlight the viability of sintering Al-MMC in a microwave oven, and compare the material characteristics of those with similar materials sintered in a conventional furnace.

Journal of Physics: Conference Series, 2019

Efficient use of available resources at controlled and potential manner required a systematic app... more Efficient use of available resources at controlled and potential manner required a systematic approach for the technological advancement and creating product solutions. The proper choice of susceptor material for the desired heating rate is a prime concern for the effective utilization of microwave radiation and lower down the energy requirement. The present paper presents a comparative analysis of three different susceptor materials namely graphite boat, charcoal, and silicon carbide for the use in microwave hybrid heating (MHH). These susceptor materials are tested experimentally with 900W and 2.45GHz electromagnetic frequency to highlight the key role of a hybrid mode during microwave processing. The results claimed that the maximum temperature achieved in case of graphite boat is 350 0C with 70 minutes of exposure. However, in the case of charcoal and silicon carbide, the maximum achieved temperature is 410 0C and 255 0C respectively at duration of 10 minutes.

Journal of Composite Materials, 2019

The micro/nano reinforced particle' aluminum metal matrix composites (Al-MMCs) are widely used in... more The micro/nano reinforced particle' aluminum metal matrix composites (Al-MMCs) are widely used in manufacturing sector due to lightweight , superior strength-to-weight ratio, better fracture toughness, improved fatigue, and tensile property, enhanced corrosion resistance to harsh environment, etc. This article provides an overview of the manufacturing processes and different reinforcing elements used during the synthesis of Al-MMCs. Generally, the reinforced particles like carbides, nitrides, and compounds of oxides are used. Different organic, inorganic, industrial and agricultural waste which can be used for reinforcement in the aluminum matrix is highlighted with their feasible applications. The common mechanical properties (i.e. hardness, tensile and compressive strength, etc.) reported by different researchers are thoroughly discussed with the aim to highlight the amount of reinforcement and improvement occurred during processing. The formation and methodology for mixing condition and sintering behaviour of Al-MMCs are discussed to impart knowledge about the processing circumstances in powder metallurgical route. The affecting conditions during operating and responsible factor for the tribological behaviour are deliberated in a precise manner to recognize the potentiality of reinforcing particles in Al-MMCs. Finally, the different shortcomings and future prospects of the Al-MMCs are given to encourage the future research directions.

The International Journal of Advanced Manufacturing Technology, 2017

Machining of aluminum and its alloy is very difficult due to the adhesion and diffusion of alumin... more Machining of aluminum and its alloy is very difficult due to the adhesion and diffusion of aluminum, thus the formation of built-up edge (BUE) on the surface. The BUE, which affects the surface integrity and tool life significantly, affects the service and performance of the workpiece. The minimization of BUE was carried out by selection of proper cutting speed, feed, depth of cut, and cutting tool material. This paper presents machining of rolled aluminum at cutting speeds of 336, 426, and 540 m/min, the feeds of 0.045, 0.06, and 0.09 mm/rev, and a constant depth of cut of 0.2 mm in dry condition. Five cutting tools WC SPUN grade, WC SPGN grade, WC + PVD (physical vapor deposition) TiN coating, WC + Ti (C, N) + Al 2 O 3 PVD multilayer coatings, and PCD (polycrystalline diamond) were utilized for the experiments. The surface roughness produced, total flank wear, and cut chip thicknesses were measured. The characterization of the tool was carried out by a scanning electron microscope (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction (XRD) pattern. The chip underface was analyzed for the study of chip deformation produced after machining. The results indicated that the PCD tool provides better results in terms of roughness, tool wear, and smoother chip underface. It provides promising results in all aspects.