Dr Raju S Pawade | Dr. Babasaheb Ambedkar Technological University, Lonere (original) (raw)
Papers by Dr Raju S Pawade
Journal of Manufacturing Science and Engineering
The implantation of stents and instruments with capillary action demands super-finished internal ... more The implantation of stents and instruments with capillary action demands super-finished internal surfaces of the manufactured product. Elasto-abrasives magneto-spiral finishing (EAMSF) enhances the productivity of finishing by incorporating the abrasive flow in spiral motion due to the presence of the magnetic field. Here, novel impregnated elasto-magnetic abrasive particles (IMPs) are used in a magnetic field-assisted environment to polish the inner walls of the workpiece. In EAMSF, magnetic force provides excess finishing pressure to the abrasives whereas the elasticity of the high impact polystyrene (HIPS) absorbs the excess force of the IMPs on the finishing surface. An indigenous mathematical relation taking into account the physics of process indicating material removal shows a close resemblance to the experimental results with an error percentage of 1.03 has been developed. The results of experimentation revealed that with 50% concentration of abrasives and a magnetic field d...
Volume 1: Processes, 2017
Manufacturing of aspheric profile of lens at nanometric level is difficult but the measurement an... more Manufacturing of aspheric profile of lens at nanometric level is difficult but the measurement and evaluation of metrology parameters is still a bigger challenge. For successful results of the lens systems, precise and defect free lenses are required. The manufacturing conditions have direct effect on the metrological parameters. For appropriate evaluation of metrology parameters, proper interpretation of aspheric surface parameters must be known. . In this study, the mechanical parameters, such as radius of curvature, slope error, tilt, centre thickness, and sag value of lens, were measured by using contact type form talysurf, non-contact type fizeau interferometers, and other instruments. The experimental results reveal that an increase in the spherical aberration is caused by increasing the lens thickness beyond 4.995mm or by increasing the radius of curvature beyond −13.8396mm or by increasing the aspheric higher order coefficients. Also its dependencies on the diameter of least...
Lecture Notes in Mechanical Engineering, 2022
Volume 2B: Advanced Manufacturing, 2021
The aero engine turbine blades made of Inconel 718, have thermal barrier coatings (TBC) to sustai... more The aero engine turbine blades made of Inconel 718, have thermal barrier coatings (TBC) to sustain high temperature air stream and cooling holes to reduce severe heat load. The complex physical and chemical properties of metal and ceramic layers pose challenges in a drilling these holes. Therefore, researchers have used laser and electrical discharge machining processes, which are time-consuming, costly, and inflict surface damages in and around the holes. To overcome these drawbacks, conventional micro-holes drilling has been adopted in this work. Drilling thrust distribution over cutting edges of micro-drills while drilling straight and inclined holes, under different cutting conditions has been analysed. The input parameters include: spindle speed, drill feed, and workpiece inclination, each at two levels. Each experiment was performed on TBC IN 718 sheet using a 600 μm TiAlN coated carbide drill under a dry peck-drilling cycle and was repeated twice. The results show that maximu...
Manufacturing of an optical lenses demand a specialized technology and thus needs sophisticated p... more Manufacturing of an optical lenses demand a specialized technology and thus needs sophisticated precision manufacturing process. PMMA is one of the most used optical polymer for manufacturing of optical lenses, the shaping of which into the required precision and accuracy is a challenging task. The focus of the present paper is to understand the effect of machining parameters on the surface characteristics especially flatness obtained in single point diamond turning (SPDT). The experiments were conducted according to Taguchi L9 design. The machining parameters chosen are feed rate, spindle speed, depth of cut and cutting environment. Analysis of results reveals that the spindle speed is more influential on the surface flatness generated by the SPDT. All the flatness measurements were done by the non contact type of measurement. It is observed that the minimum PV value produced is 0.837 µm.
Drilling of bone is a challenging task for surgeons due to its effect on bone tissues. During dri... more Drilling of bone is a challenging task for surgeons due to its effect on bone tissues. During drilling, it is noted that the temperature of bone increases. This increase in temperature if above 47°C causes thermal necrosis. Experiments were conducted to study the effect of input drilling parameters and drill bit parameters on bone health. To plan experiments a full factorial design method was used. An analysis is done on the effect of input parameters on thrust force and temperature of bone. The analysis of results shows an increase in thrust force and temperature when the feed rate increases and the spindle speed decreases. Further, the analysis of results shows an increase in thrust force and temperature when point angle increases and helix angle decreases. The increase in thrust force results in temperature rise. Scanning electron microscopy is done to analyze the surface topography of drilled hole. SEM image analysis shows an increase micro-crack in the drilled area when the thr...
Now a days Nickel material have growing applications in the manufacturing of various components ... more Now a days Nickel material have growing applications in the manufacturing of various components and structure due to their inherent properties, the Nickel all oys are widely used in aerospace, marine, and nuclear power generation, chemical, petrochemical and process industries. Nickel is a versatile element and will alloy with most metals. At present very few researchers developed manufacturing technology for the production of highly precise Nickel products. Better surface topography can be achieved by the CNC turning process than with conventional grinding technique. The need of finding out machining characteristics of Nickel using high quality machine tools like CNC turning, the experiments were done according to Taguchi DOE. Present paper focuses the CNC turning experiments were conducted on one of the alloy of Nickel i.e. Nickel -200 for analyzing surface characteristics.
Electrical discharge machining (EDM) process, at present is still an experience process, where th... more Electrical discharge machining (EDM) process, at present is still an experience process, where the selected parameters are often far from the optimum, and at the same time selecting optimization parameters is costly and time consuming.The process parameters include duty cycle, pulse current, pulse on time, electrode type and gap voltage. Experiments were conducted using Taguchi L18 orthogonal array. An Artificial Neural Network (ANN) model which adapts Levenberg-Marquardt algorithm has been set up to represent the relationship between output parameters and input parameters so that optimization results are obtained.The results showed that the ANN model can be used easily for prediction of output parameters and hence helps in optimum selection of machining parameters for the purpose of process planning and optimization of machining parameters in EDM.
International Journal of Innovative Research in Science, Engineering and Technology, 2014
This paper is aimed at an experimental investigation of the ball end milling of Inconel 718 canti... more This paper is aimed at an experimental investigation of the ball end milling of Inconel 718 cantilevers, design and modeling of the process with the aid of the response surface methodology (RSM) utilizing the experimental data.TheExperiments were conducted according to the central composite design (CCD) with four factors of spindle speed, feed, workpiece thickness and workpiece inclination with toolpath orientation. The responses measured for each experiment were deflection (Def.) at free end, the experimental data was analysed to obtain the effect of various parameters on the response. The results of analysis of variance (ANOVA) indicated that the proposed mathematical models have been carried out to ensure the validity of the developed model. Confirmation test experiments have also been done to compare the experimental results and model result. The response surface model was found to be in good agreement.
Proceedings of the International Conference on Communication and Signal Processing 2016 (ICCASP 2016), 2017
This paper investigates the effect of material removal rate (MRR) and mainly machining environmen... more This paper investigates the effect of material removal rate (MRR) and mainly machining environment on resultant surface integrity in high-speed machining (HSM) of Inconel 718. For this high-speed turning is carried out for three different cutting speeds, feedrates and depth of cut under dry, flood coolant and water vapour machining environments. The results show that flood cooling is ineffective in high-speed machining. Water vapours acts as a coolant and lubricant, and hence is highly effective in lowering surface roughness and surface damages in machining. However at very high material removal rates, dry machining seems to be an economical option. Under all the environments the residual stresses were found to be compressive in nature at all MRR levels. Keeping in view green manufacturing, good productivity and better quality, it is suggested that machining of Inconel 718 under water vapour environment is an ideal approach.
International Journal of Precision Technology, 2016
The severe urge for need of cleaner machining techniques has led to continuous exploration of var... more The severe urge for need of cleaner machining techniques has led to continuous exploration of various alternative cooling and lubrication methods. Surface integrity of machined components play a crucial role, but the same cannot be the only criteria for deciding on the machinability aspects as well as eco-friendliness of specific machining approach. This paper proposes a model for sustainability assessment of machining considering surface integrity aspects along with machining environment aspects for better understanding of sustainability in machining. High-speed turning of Inconel 718 at varying MRR levels depicting productivity rates has been carried out under dry, flood coolant and water vapour machining environments, and then sustainability assessment has been carried out using the developed model. Within the investigated experimental regime, the results show that the use of water vapour as coolant and lubricant in machining gives highest product sustainability index (PSI) of 82.92% thus suggesting it to be a promising eco-friendly machining technique.
Journal for Manufacturing Science and Production, 2015
This paper presents the application of Response Surface Methodology (RSM) coupled with Teaching L... more This paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.
Procedia Materials Science, 2014
Volume 2: Processing, 2014
The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever p... more The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever plate of Inconel 718. It is noticed that the workpiece deflection has significantly contributed to machined surface integrity in terms of surface topography and subsurface microhardness. The ball end milling performed with 15° workpiece inclination with horizontal tool path produced higher surface integrity which varies with the location of machined surface region. In general, the mid portion of the machined plate shows lower surface roughness and microhardness with less surface defects.
Procedia Materials Science, 2014
Machining Science and Technology, 2011
The mechanism of serrated chip formation during high-speed turning of Inconel 718 using PCBN cutt... more The mechanism of serrated chip formation during high-speed turning of Inconel 718 using PCBN cutting tools has been investigated with the aid of scanning electron microscopy and optical microscopy. A conceptual model of chip formation has been developed knowing ...
International Journal of Mechatronics and Manufacturing Systems, 2012
ABSTRACT
International Journal of Machine Tools and Manufacture, 2003
Understanding the effects of cutting speed, feed rate and cutting depth on surface integrity is v... more Understanding the effects of cutting speed, feed rate and cutting depth on surface integrity is very important for the control of workpiece quality. This paper presents a global experimental study of surface integrity in the case of high speed end milling. In the global term, we include measurements of residual stresses, surface roughness and cutting forces. Our observations and conclusions are mainly concentrated on the effect of depth of cut with a set of constant parameters, such as cutting speed, feed rate, and tool/material couple. This set of constants has been determined using the theory of stability lobes. All experiments have been performed with an electro-spindle equipped with magnetic bearings. The results lead to a good understanding of the influence of cutting conditions on surface integrity in high speed milling of a low alloyed steel. The discussion examines a specific point where the residual stress and residual stress gradient are lowest and also the origin of the residual stress value.
Advances in Sustainable Machining and Manufacturing Processes
International Journal of Mechatronics and Manufacturing Systems, 2021
Journal of Manufacturing Science and Engineering
The implantation of stents and instruments with capillary action demands super-finished internal ... more The implantation of stents and instruments with capillary action demands super-finished internal surfaces of the manufactured product. Elasto-abrasives magneto-spiral finishing (EAMSF) enhances the productivity of finishing by incorporating the abrasive flow in spiral motion due to the presence of the magnetic field. Here, novel impregnated elasto-magnetic abrasive particles (IMPs) are used in a magnetic field-assisted environment to polish the inner walls of the workpiece. In EAMSF, magnetic force provides excess finishing pressure to the abrasives whereas the elasticity of the high impact polystyrene (HIPS) absorbs the excess force of the IMPs on the finishing surface. An indigenous mathematical relation taking into account the physics of process indicating material removal shows a close resemblance to the experimental results with an error percentage of 1.03 has been developed. The results of experimentation revealed that with 50% concentration of abrasives and a magnetic field d...
Volume 1: Processes, 2017
Manufacturing of aspheric profile of lens at nanometric level is difficult but the measurement an... more Manufacturing of aspheric profile of lens at nanometric level is difficult but the measurement and evaluation of metrology parameters is still a bigger challenge. For successful results of the lens systems, precise and defect free lenses are required. The manufacturing conditions have direct effect on the metrological parameters. For appropriate evaluation of metrology parameters, proper interpretation of aspheric surface parameters must be known. . In this study, the mechanical parameters, such as radius of curvature, slope error, tilt, centre thickness, and sag value of lens, were measured by using contact type form talysurf, non-contact type fizeau interferometers, and other instruments. The experimental results reveal that an increase in the spherical aberration is caused by increasing the lens thickness beyond 4.995mm or by increasing the radius of curvature beyond −13.8396mm or by increasing the aspheric higher order coefficients. Also its dependencies on the diameter of least...
Lecture Notes in Mechanical Engineering, 2022
Volume 2B: Advanced Manufacturing, 2021
The aero engine turbine blades made of Inconel 718, have thermal barrier coatings (TBC) to sustai... more The aero engine turbine blades made of Inconel 718, have thermal barrier coatings (TBC) to sustain high temperature air stream and cooling holes to reduce severe heat load. The complex physical and chemical properties of metal and ceramic layers pose challenges in a drilling these holes. Therefore, researchers have used laser and electrical discharge machining processes, which are time-consuming, costly, and inflict surface damages in and around the holes. To overcome these drawbacks, conventional micro-holes drilling has been adopted in this work. Drilling thrust distribution over cutting edges of micro-drills while drilling straight and inclined holes, under different cutting conditions has been analysed. The input parameters include: spindle speed, drill feed, and workpiece inclination, each at two levels. Each experiment was performed on TBC IN 718 sheet using a 600 μm TiAlN coated carbide drill under a dry peck-drilling cycle and was repeated twice. The results show that maximu...
Manufacturing of an optical lenses demand a specialized technology and thus needs sophisticated p... more Manufacturing of an optical lenses demand a specialized technology and thus needs sophisticated precision manufacturing process. PMMA is one of the most used optical polymer for manufacturing of optical lenses, the shaping of which into the required precision and accuracy is a challenging task. The focus of the present paper is to understand the effect of machining parameters on the surface characteristics especially flatness obtained in single point diamond turning (SPDT). The experiments were conducted according to Taguchi L9 design. The machining parameters chosen are feed rate, spindle speed, depth of cut and cutting environment. Analysis of results reveals that the spindle speed is more influential on the surface flatness generated by the SPDT. All the flatness measurements were done by the non contact type of measurement. It is observed that the minimum PV value produced is 0.837 µm.
Drilling of bone is a challenging task for surgeons due to its effect on bone tissues. During dri... more Drilling of bone is a challenging task for surgeons due to its effect on bone tissues. During drilling, it is noted that the temperature of bone increases. This increase in temperature if above 47°C causes thermal necrosis. Experiments were conducted to study the effect of input drilling parameters and drill bit parameters on bone health. To plan experiments a full factorial design method was used. An analysis is done on the effect of input parameters on thrust force and temperature of bone. The analysis of results shows an increase in thrust force and temperature when the feed rate increases and the spindle speed decreases. Further, the analysis of results shows an increase in thrust force and temperature when point angle increases and helix angle decreases. The increase in thrust force results in temperature rise. Scanning electron microscopy is done to analyze the surface topography of drilled hole. SEM image analysis shows an increase micro-crack in the drilled area when the thr...
Now a days Nickel material have growing applications in the manufacturing of various components ... more Now a days Nickel material have growing applications in the manufacturing of various components and structure due to their inherent properties, the Nickel all oys are widely used in aerospace, marine, and nuclear power generation, chemical, petrochemical and process industries. Nickel is a versatile element and will alloy with most metals. At present very few researchers developed manufacturing technology for the production of highly precise Nickel products. Better surface topography can be achieved by the CNC turning process than with conventional grinding technique. The need of finding out machining characteristics of Nickel using high quality machine tools like CNC turning, the experiments were done according to Taguchi DOE. Present paper focuses the CNC turning experiments were conducted on one of the alloy of Nickel i.e. Nickel -200 for analyzing surface characteristics.
Electrical discharge machining (EDM) process, at present is still an experience process, where th... more Electrical discharge machining (EDM) process, at present is still an experience process, where the selected parameters are often far from the optimum, and at the same time selecting optimization parameters is costly and time consuming.The process parameters include duty cycle, pulse current, pulse on time, electrode type and gap voltage. Experiments were conducted using Taguchi L18 orthogonal array. An Artificial Neural Network (ANN) model which adapts Levenberg-Marquardt algorithm has been set up to represent the relationship between output parameters and input parameters so that optimization results are obtained.The results showed that the ANN model can be used easily for prediction of output parameters and hence helps in optimum selection of machining parameters for the purpose of process planning and optimization of machining parameters in EDM.
International Journal of Innovative Research in Science, Engineering and Technology, 2014
This paper is aimed at an experimental investigation of the ball end milling of Inconel 718 canti... more This paper is aimed at an experimental investigation of the ball end milling of Inconel 718 cantilevers, design and modeling of the process with the aid of the response surface methodology (RSM) utilizing the experimental data.TheExperiments were conducted according to the central composite design (CCD) with four factors of spindle speed, feed, workpiece thickness and workpiece inclination with toolpath orientation. The responses measured for each experiment were deflection (Def.) at free end, the experimental data was analysed to obtain the effect of various parameters on the response. The results of analysis of variance (ANOVA) indicated that the proposed mathematical models have been carried out to ensure the validity of the developed model. Confirmation test experiments have also been done to compare the experimental results and model result. The response surface model was found to be in good agreement.
Proceedings of the International Conference on Communication and Signal Processing 2016 (ICCASP 2016), 2017
This paper investigates the effect of material removal rate (MRR) and mainly machining environmen... more This paper investigates the effect of material removal rate (MRR) and mainly machining environment on resultant surface integrity in high-speed machining (HSM) of Inconel 718. For this high-speed turning is carried out for three different cutting speeds, feedrates and depth of cut under dry, flood coolant and water vapour machining environments. The results show that flood cooling is ineffective in high-speed machining. Water vapours acts as a coolant and lubricant, and hence is highly effective in lowering surface roughness and surface damages in machining. However at very high material removal rates, dry machining seems to be an economical option. Under all the environments the residual stresses were found to be compressive in nature at all MRR levels. Keeping in view green manufacturing, good productivity and better quality, it is suggested that machining of Inconel 718 under water vapour environment is an ideal approach.
International Journal of Precision Technology, 2016
The severe urge for need of cleaner machining techniques has led to continuous exploration of var... more The severe urge for need of cleaner machining techniques has led to continuous exploration of various alternative cooling and lubrication methods. Surface integrity of machined components play a crucial role, but the same cannot be the only criteria for deciding on the machinability aspects as well as eco-friendliness of specific machining approach. This paper proposes a model for sustainability assessment of machining considering surface integrity aspects along with machining environment aspects for better understanding of sustainability in machining. High-speed turning of Inconel 718 at varying MRR levels depicting productivity rates has been carried out under dry, flood coolant and water vapour machining environments, and then sustainability assessment has been carried out using the developed model. Within the investigated experimental regime, the results show that the use of water vapour as coolant and lubricant in machining gives highest product sustainability index (PSI) of 82.92% thus suggesting it to be a promising eco-friendly machining technique.
Journal for Manufacturing Science and Production, 2015
This paper presents the application of Response Surface Methodology (RSM) coupled with Teaching L... more This paper presents the application of Response Surface Methodology (RSM) coupled with Teaching Learning Based Optimization Technique (TLBO) for optimizing surface integrity of thin cantilever type Inconel 718 workpiece in ball end milling. The machining and tool related parameters like spindle speed, milling feed, axial depth of cut and tool path orientation are optimized with considerations of multiple response like deflection, surface roughness, and micro hardness of plate. Mathematical relationship between process parameters and deflection, surface roughness and microhardness are found out by using response surface methodology. It is observed that after optimizing the process that at the spindle speed of 2,000 rpm, feed 0.05 mm/tooth/rev, plate thickness of 5.5 mm and 15° workpiece inclination with horizontal tool path gives favorable surface integrity.
Procedia Materials Science, 2014
Volume 2: Processing, 2014
The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever p... more The paper presents the surface integrity analysis in ball end milling of thin shaped cantilever plate of Inconel 718. It is noticed that the workpiece deflection has significantly contributed to machined surface integrity in terms of surface topography and subsurface microhardness. The ball end milling performed with 15° workpiece inclination with horizontal tool path produced higher surface integrity which varies with the location of machined surface region. In general, the mid portion of the machined plate shows lower surface roughness and microhardness with less surface defects.
Procedia Materials Science, 2014
Machining Science and Technology, 2011
The mechanism of serrated chip formation during high-speed turning of Inconel 718 using PCBN cutt... more The mechanism of serrated chip formation during high-speed turning of Inconel 718 using PCBN cutting tools has been investigated with the aid of scanning electron microscopy and optical microscopy. A conceptual model of chip formation has been developed knowing ...
International Journal of Mechatronics and Manufacturing Systems, 2012
ABSTRACT
International Journal of Machine Tools and Manufacture, 2003
Understanding the effects of cutting speed, feed rate and cutting depth on surface integrity is v... more Understanding the effects of cutting speed, feed rate and cutting depth on surface integrity is very important for the control of workpiece quality. This paper presents a global experimental study of surface integrity in the case of high speed end milling. In the global term, we include measurements of residual stresses, surface roughness and cutting forces. Our observations and conclusions are mainly concentrated on the effect of depth of cut with a set of constant parameters, such as cutting speed, feed rate, and tool/material couple. This set of constants has been determined using the theory of stability lobes. All experiments have been performed with an electro-spindle equipped with magnetic bearings. The results lead to a good understanding of the influence of cutting conditions on surface integrity in high speed milling of a low alloyed steel. The discussion examines a specific point where the residual stress and residual stress gradient are lowest and also the origin of the residual stress value.
Advances in Sustainable Machining and Manufacturing Processes
International Journal of Mechatronics and Manufacturing Systems, 2021