vinayak malik | Indian Institute of Science (original) (raw)

Papers by vinayak malik

Research paper thumbnail of A Green Synthesized SnO2 Photo-Catalyst for Effective Degradation of Biomedical Industrial Waste

Key Engineering Materials

Using a green synthesis approach, we have synthesized SnO2 nanoparticles. The morphology of the n... more Using a green synthesis approach, we have synthesized SnO2 nanoparticles. The morphology of the nanoparticles are characterise by scanning electron microscopy. The UV-vis spectroscopy technique was used to study the optical characteristics. The different parameters such as dosage of catalyst, initial concentration of drugs, effect of pH and other parameters were estimated. The Visible light was irradiated over sample solution at different pH values, and the photo-catalytic effect of the SnO2 nanoparticle was observed for degradation of ciprofloxacin drugs. The absorption spectra showed a stronger absorption peak at 273 nm representing the ciprofloxacin drugs. The photo-generated electron of nanoparticles degradation drugs, which shows decrease absorption intensity. The results revealed that the photo-catalytic degradation process works well at pH 7. The higher degradation efficiency was observed by following the pseudo-first-order kinetics.

Research paper thumbnail of Modeling and Prediction of Grain Size and Hardness of ZE41/ZrO$$_2$$ Nano-surface Composite Using Multiple Regression, Power Law and Artificial Intelligence Techniques

Transactions of the Indian Institute of Metals

In this work, nano-ZrO 2 particles were incor-porated in cast rare earth ZE41 magnesium alloy by ... more In this work, nano-ZrO 2 particles were incor-porated in cast rare earth ZE41 magnesium alloy by friction stir processing (FSP) and a surface composite layer of ZE41/ZrO 2 was fabricated. The relationship of FSP parameters with the grain size and hardness was estab-lished using multiple regression and artificial neural network (ANN) techniques. The experimental results showed that ZrO 2 particles were not uniformly distributed in the stir zone (SZ) and SZ was divided into two regions. For modelling by these techniques, the input parameters used were tool rotational speed, tool traverse speed and the type of SZ region and outputs were grain size and hardness. The models can be used to predict grain size and hardness as a function of rotational speed, traverse speed and type of region. Moreover, a sensitivity analysis was done to study the impact of the parametric inputs on the model output using the power law model. The mean square error (MSE) for grain size was found to be 0.3418 (regression model) and 0.000121 (ANN), whereas MSE for hardness was found to be 1.0211 (regression model) and 0.00018 (ANN). The value of coefficient of correlation (R 2 ) for training and testing for grain size and hardness was found close to 1. These values of MSE and R 2 indicate a good agreement between predicted and experimental results. Hence, in this work, the possibility of using multiple regression, power law and ANN for the calculation of grain size and hardness of ZE41/ZrO 2 surface composite produced by FSP without carrying out the experiments has thus been established.

Research paper thumbnail of Synthesis and Characterization of PVDF/Graphene Nanocomposite Membrane for Water Treatment Applications

Key Engineering Materials

Membrane technology advancement has gained momentous consideration around the globe because of th... more Membrane technology advancement has gained momentous consideration around the globe because of their appealing highlights, such as effectiveness, low expenses, and effective solutions for longstanding issues in alchemical industries. This study expected to incorporate graphene nanoparticles into Polyvinylidene difluoride (PVDF) to form nanofiltration (NF) layers using DMF (Dimethyl formamide) as solvent via DIPS (diffusion induced phase separation) technique. PVDF polymer membrane performances with varied percent (1 – 6% wt.) of graphene concentrations are studied Infrared spectral, water uptake, water contact angle, and ion rejection measurements. Scanning electron microscope (SEM) analysis showed that the pore size is often regulated by incorporating graphene nanoparticles (80-90 nm) as compared to PVDF membranes. The PVDF membranes exhibited a relative increase in the contact angle from PVDF to PVDF-G6% i.e. 50.3° to 63.46 ± .3, thus, showing a relative increase in hydrophobicity...

Research paper thumbnail of Metallographic Study and Sliding Wear Optimization of Nano Si3N4 Reinforced High-Strength Al Metal Matrix Composites

Lubricants

The strongest among the all-aluminum alloy series is 7xxx due to its unique composition of alloyi... more The strongest among the all-aluminum alloy series is 7xxx due to its unique composition of alloying elements, making it perfect for automotive and aerospace applications. The present research included manufacturing of Si3N4 reinforced aluminum alloy (AA) 7068 nanocomposites via stir casting combined with ultrasonication, followed by a bottom pouring technique. The Si3N4 reinforcement has been conducted in different fractions (0.5, 1, 1.5, and 2%) by weight. The microstructure characterization of prepared composites was conducted using FESEM, EDS, and elemental mapping. The microstructure of the AA7068 matrix was significantly refined after incorporating Si3N4 nanoparticles. The hardness of alloy increased with reinforcement addition and maximized at 1.5 wt.% due to the combined effect of hard Si3N4, difference in thermal co-efficient, Hall-Petch, and Orowan strengthening mechanism. The wear resistance significantly increased after incorporating (Si3N4)np in the alloy by increased lo...

Research paper thumbnail of Modelling and optimization of selective laser melting parameters using Taguchi and super ranking concept approaches

International Journal on Interactive Design and Manufacturing (IJIDeM)

Research paper thumbnail of Significance of Alloying Elements on the Mechanical Characteristics of Mg-Based Materials for Biomedical Applications

Crystals

Magnesium alloys are widely employed in various applications due to their high strength-to-weight... more Magnesium alloys are widely employed in various applications due to their high strength-to-weight ratio and superior mechanical properties as compared to unalloyed Magnesium. Alloying is considered an important way to enhance the strength of the metal matrix composite but it significantly influences the damping property of pure magnesium, while controlling the rate of corrosion for Mg-based material remains critical in the biological environment. Therefore, it is essential to reinforce the magnesium alloy with a suitable alloying element that improves the mechanical characteristics and resistance to corrosion of Mg-based material. Biocompatibility, biodegradability, lower stress shielding effect, bio-activeness, and non-toxicity are the important parameters for biomedical applications other than mechanical and corrosion properties. The development of various surface modifications is also considered a suitable approach to control the degradation rate of Mg-based materials, making lig...

Research paper thumbnail of Effect of interlock angle and bottom die flange diameter on clinching joint load bearing capacity in cross-tensile loading

International Journal on Interactive Design and Manufacturing (IJIDeM)

Research paper thumbnail of Design and Fabrication of Injection Molds to Manufacture Double Channel Laryngoscope for Effective Airway Management: Taguchi Method for Surface Roughness Optimization

Key Engineering Materials

The present work focuses on the mold design and production of the multifunctional device laryngos... more The present work focuses on the mold design and production of the multifunctional device laryngoscope with surface quality through the injection molding process. A laryngoscope is a device used by anesthesiologists to lift the tongue that facilitates to fix the air pipe in the larynx. Demand still exists in the laryngoscope part to assist anesthesiologists to take care of the airway without causing chest compression and ensure visualization of vocal cords. Therefore, the present work aims at developing a laryngoscope with a double channeled device, wherein one for aligning the camera and another for the air pipe. The paper outlines the design parameters required for manufacturing a single cavity mold to produce a laryngoscope viz. injection molding machine. The mold has multiple plates with complex fluid channels which ensures effective thermal management in-mold system. The mold is manufactured using high-strength tool steel materials and the product laryngoscope (ABS: Acrylonitril...

Research paper thumbnail of Energy-efficient method for developing in-situ Al-Cu metal matrix composites using microwave sintering and friction stir processing

Materials Research Express

The problems associated with the fabrication of in situ metal matrix composites (MMC) by conventi... more The problems associated with the fabrication of in situ metal matrix composites (MMC) by conventional methods can be avoided by using microwave sintering and friction stirring in combination. The current study investigates the mechanical and electrical properties of pure aluminum (Al-100 wt%) and Al-Cu MMC. The results showed that excellent ultimate tensile strength, toughness, and electrical conductivity can be acquired simultaneously. The obtained ultimate tensile strength in the case of Al-100wt% (184.5 MPa) has improved two-fold than that of a typical commercially pure aluminum AA1016 (90 MPa). Similarly, the electrical conductivity of developed pure aluminum (88.87% IACS) is 1.4 times higher compared to AA1016 alloy (62% IACS). For Al-Cu MMC the copper is added in steps of 5 wt% (5%, 10%, 15%, and 20%). The maximum ultimate tensile strength (205.2 MPa) and the electrical conductivity (71.53% IACS) obtained for Al-10wt%Cu are higher compared to the AA1016 alloy. The present inve...

Research paper thumbnail of Investigations on FSW of nylon micro-particle enhanced 3D printed parts applied to a Clark-Y UAV wing

Research paper thumbnail of Adhesive bonding of similar/dissimilar three-dimensional printed parts (ABS/PLA) considering joint design, surface treatments, and adhesive types

Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science

Three-dimensional printing (3D), a vital technological pillar of industry 4.0 suffers from an imp... more Three-dimensional printing (3D), a vital technological pillar of industry 4.0 suffers from an important bed size limitation, wherein it cannot print any part larger than its bed size. Unfortunately, research in this domain has not kept pace with the other limitations hindering the acceptability of fused deposition modeling (FDM)-3D printers. This paper investigates the adhesive joining of dissimilar 3D-printed parts made from usually preferred materials (Acrylonitrile Butadiene Styrene (ABS), Polylactic Acid (PLA)) having different geometric joint designs (lap, scarf, stepped) employing diverse adhesives (epoxy, cyanoacrylate, polyurathane-based) subjected to different surface treatments (sanding, vapor, plasma). The aim is two-fold: to enhance the joint strength making adhesive bonding a suitable solution for complex structural application, as well as to overcome the bed size limitation of commercially available 3D printers. The individual and combined effect of the parameters, pre...

Research paper thumbnail of Influence of foaming agents on mechanical and microstructure characterization of AA6061 metal foams

Proceedings Of The Institution Of Mechanical Engineers, Part E: Journal Of Process Mechanical Engineering, May 26, 2022

Research paper thumbnail of Effect of process parameters on surface composite fabrication of newly commercialized Mg-ZE41 alloy by friction stir processing (FSP): microstructural development and microhardness

World Journal of Engineering

Purpose Altering the microstructure and developing the surface metal matrix composites (MMCs) in ... more Purpose Altering the microstructure and developing the surface metal matrix composites (MMCs) in a solid-state by friction stir processing (FSP) has been on trend for the past decade. The microstructural modification increases the material properties, which are structure sensitive. The microstructural evolution is highly influenced by the selection of process parameters in FSP. In this study, the effect of process parameters on the microstructure evolution and microhardness of the fabrication of surface MMCs of newly commercialized Mg-ZE41 alloy by the incorporation of different reinforcement particles such as ZrO2, CeO2 and Al2O3 is investigated. Design/methodology/approach By making use of Taguchi’s design of experimentation, which recognizes the crucial factors and ascertain their effect on the properties of the material, the optimization of process parameters for this study was done using MATLAB-14 software. The parameters were adopted along with the levels throughout the FSP fo...

Research paper thumbnail of Product Re-Designing and Development of Key Duplicating Machine - a Case Study

International Journal on Design and Manufacturing Technologies, 2008

Research paper thumbnail of Understanding tool–workpiece interfacial friction in friction stir welding/processing and its effect on weld formation

Advances in Materials and Processing Technologies, 2022

Research paper thumbnail of of Friction Stir Welding and its Importance in Manufacturing Process Modeling Applications

Abstract: Friction Stir Welding (FSW) is a relatively new joining process which is gaining signif... more Abstract: Friction Stir Welding (FSW) is a relatively new joining process which is gaining significance in many joining applications. The development in Finite element (FE) modeling is also aiding in widening the applicability of FSW by simulating the process for better understanding. The success of modeling of FSW depends on selection of suitable techniques and models/laws irrespective of FE package used for simulation. The principal equations that govern modeling of FSW are the material model and the friction model. This paper aims at discussing the effect of variation in Coefficient of Friction (COF) on simulation outputs. It also highlights the modification required in friction model to get the realistic results from FSW simulations using ABAQUS.

Research paper thumbnail of An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

Rapid Prototyping Journal

Purpose Three-dimensional (3D) printing, one of the important technological pillars of Industry 4... more Purpose Three-dimensional (3D) printing, one of the important technological pillars of Industry 4.0, is changing the landscape of future manufacturing. However, the limited build volume of a commercially available 3D printer is one inherent constraint, which holds its acceptability by the manufacturing business leaders. This paper aims to address the issue by presenting a novel classification of the possible ways by which 3D-printed parts can be joined or welded to achieve a bigger-sized component. Design/methodology/approach A two-step literature review is performed. The first section deals with the past and present research studies related to adhesive bonding, mechanical interlocking, fastening and big area additive manufacturing of 3D printed thermoplastics. In the second section, the literature searches were focused on retrieving details related to the welding of 3D printed parts, specifically related to friction stir welding, friction (spin) welding, microwave and ultrasonic we...

Research paper thumbnail of Studies on the Effect of Process Aspects on Material Mixing and Defect Formation in Friction Stir Welding

Friction Stir Welding (FSW) is a rapidly growing solid state welding process and has been a prove... more Friction Stir Welding (FSW) is a rapidly growing solid state welding process and has been a proven method for welding high strength aluminium alloys which were formerly not recommended for joining by conventional fusion welding methods. Based on the information acquired from previous studies, to obtain a defect free Friction Stir (FS) weld with suitable strength, three basic requirements need to be fulfilled (i) Filling of the cavity created behind the tool pin during its traverse and ensuring satisfactory contact of filled material with newly generated surface (on advancing side trailing edge of the pin) (ii) Disrupting and distributing the oxide layer at the initial weld interface (iii) Adequate level of mixing of both side material (Adjacent and Retreating side) in similar welding. In the case of dissimilar welding mixing is desired in controlled amount (to prevent or curtail formation of intermetallics) depending on material combination. Failure to achieve the first precondition...

Research paper thumbnail of Review on modelling of friction stir welding using finite element approach and significance of formulations in simulation

International Journal of Manufacturing Research

Research paper thumbnail of Review on Modeling of Friction Stir Welding Using Finite Element Approach and Significance of Formulations in Simulation

International Journal of Manufacturing Research

Friction stir welding (FSW) is a solid-state joining process, which is gaining significance in ma... more Friction stir welding (FSW) is a solid-state joining process, which is gaining significance in many joining applications, by overcoming the limitations of other fusion welding processes. For successful incorporation of its potential during industrial applications, mechanism of joining needs to be properly comprehended. The solution lies in developing effective and reliable finite element (FE) model of the FSW process, which would help in getting an insight of the process phenomena (like material flow, heat generation, etc.) during the process. The overall result could be used to observe the effect of process parameters on weld quality. Several attempts have been made to develop an FE model for FSW using different techniques. However, building an efficient model that emulates reality is still to be realised. Here, a review is made to know the current state of various FE modelling techniques and identifying better techniques for simulating FSW and its variants. This review also highlights shortcomings (for ex: mesh distortion, simulation time, the capability of defect prediction) of previous models and discusses on grey areas which are still to be addressed in the broader perspective of FSW and its allied processes using FE approach. [Submitted 06 July 2017; Accepted 29 September 2018]

Research paper thumbnail of A Green Synthesized SnO2 Photo-Catalyst for Effective Degradation of Biomedical Industrial Waste

Key Engineering Materials

Using a green synthesis approach, we have synthesized SnO2 nanoparticles. The morphology of the n... more Using a green synthesis approach, we have synthesized SnO2 nanoparticles. The morphology of the nanoparticles are characterise by scanning electron microscopy. The UV-vis spectroscopy technique was used to study the optical characteristics. The different parameters such as dosage of catalyst, initial concentration of drugs, effect of pH and other parameters were estimated. The Visible light was irradiated over sample solution at different pH values, and the photo-catalytic effect of the SnO2 nanoparticle was observed for degradation of ciprofloxacin drugs. The absorption spectra showed a stronger absorption peak at 273 nm representing the ciprofloxacin drugs. The photo-generated electron of nanoparticles degradation drugs, which shows decrease absorption intensity. The results revealed that the photo-catalytic degradation process works well at pH 7. The higher degradation efficiency was observed by following the pseudo-first-order kinetics.

Research paper thumbnail of Modeling and Prediction of Grain Size and Hardness of ZE41/ZrO$$_2$$ Nano-surface Composite Using Multiple Regression, Power Law and Artificial Intelligence Techniques

Transactions of the Indian Institute of Metals

In this work, nano-ZrO 2 particles were incor-porated in cast rare earth ZE41 magnesium alloy by ... more In this work, nano-ZrO 2 particles were incor-porated in cast rare earth ZE41 magnesium alloy by friction stir processing (FSP) and a surface composite layer of ZE41/ZrO 2 was fabricated. The relationship of FSP parameters with the grain size and hardness was estab-lished using multiple regression and artificial neural network (ANN) techniques. The experimental results showed that ZrO 2 particles were not uniformly distributed in the stir zone (SZ) and SZ was divided into two regions. For modelling by these techniques, the input parameters used were tool rotational speed, tool traverse speed and the type of SZ region and outputs were grain size and hardness. The models can be used to predict grain size and hardness as a function of rotational speed, traverse speed and type of region. Moreover, a sensitivity analysis was done to study the impact of the parametric inputs on the model output using the power law model. The mean square error (MSE) for grain size was found to be 0.3418 (regression model) and 0.000121 (ANN), whereas MSE for hardness was found to be 1.0211 (regression model) and 0.00018 (ANN). The value of coefficient of correlation (R 2 ) for training and testing for grain size and hardness was found close to 1. These values of MSE and R 2 indicate a good agreement between predicted and experimental results. Hence, in this work, the possibility of using multiple regression, power law and ANN for the calculation of grain size and hardness of ZE41/ZrO 2 surface composite produced by FSP without carrying out the experiments has thus been established.

Research paper thumbnail of Synthesis and Characterization of PVDF/Graphene Nanocomposite Membrane for Water Treatment Applications

Key Engineering Materials

Membrane technology advancement has gained momentous consideration around the globe because of th... more Membrane technology advancement has gained momentous consideration around the globe because of their appealing highlights, such as effectiveness, low expenses, and effective solutions for longstanding issues in alchemical industries. This study expected to incorporate graphene nanoparticles into Polyvinylidene difluoride (PVDF) to form nanofiltration (NF) layers using DMF (Dimethyl formamide) as solvent via DIPS (diffusion induced phase separation) technique. PVDF polymer membrane performances with varied percent (1 – 6% wt.) of graphene concentrations are studied Infrared spectral, water uptake, water contact angle, and ion rejection measurements. Scanning electron microscope (SEM) analysis showed that the pore size is often regulated by incorporating graphene nanoparticles (80-90 nm) as compared to PVDF membranes. The PVDF membranes exhibited a relative increase in the contact angle from PVDF to PVDF-G6% i.e. 50.3° to 63.46 ± .3, thus, showing a relative increase in hydrophobicity...

Research paper thumbnail of Metallographic Study and Sliding Wear Optimization of Nano Si3N4 Reinforced High-Strength Al Metal Matrix Composites

Lubricants

The strongest among the all-aluminum alloy series is 7xxx due to its unique composition of alloyi... more The strongest among the all-aluminum alloy series is 7xxx due to its unique composition of alloying elements, making it perfect for automotive and aerospace applications. The present research included manufacturing of Si3N4 reinforced aluminum alloy (AA) 7068 nanocomposites via stir casting combined with ultrasonication, followed by a bottom pouring technique. The Si3N4 reinforcement has been conducted in different fractions (0.5, 1, 1.5, and 2%) by weight. The microstructure characterization of prepared composites was conducted using FESEM, EDS, and elemental mapping. The microstructure of the AA7068 matrix was significantly refined after incorporating Si3N4 nanoparticles. The hardness of alloy increased with reinforcement addition and maximized at 1.5 wt.% due to the combined effect of hard Si3N4, difference in thermal co-efficient, Hall-Petch, and Orowan strengthening mechanism. The wear resistance significantly increased after incorporating (Si3N4)np in the alloy by increased lo...

Research paper thumbnail of Modelling and optimization of selective laser melting parameters using Taguchi and super ranking concept approaches

International Journal on Interactive Design and Manufacturing (IJIDeM)

Research paper thumbnail of Significance of Alloying Elements on the Mechanical Characteristics of Mg-Based Materials for Biomedical Applications

Crystals

Magnesium alloys are widely employed in various applications due to their high strength-to-weight... more Magnesium alloys are widely employed in various applications due to their high strength-to-weight ratio and superior mechanical properties as compared to unalloyed Magnesium. Alloying is considered an important way to enhance the strength of the metal matrix composite but it significantly influences the damping property of pure magnesium, while controlling the rate of corrosion for Mg-based material remains critical in the biological environment. Therefore, it is essential to reinforce the magnesium alloy with a suitable alloying element that improves the mechanical characteristics and resistance to corrosion of Mg-based material. Biocompatibility, biodegradability, lower stress shielding effect, bio-activeness, and non-toxicity are the important parameters for biomedical applications other than mechanical and corrosion properties. The development of various surface modifications is also considered a suitable approach to control the degradation rate of Mg-based materials, making lig...

Research paper thumbnail of Effect of interlock angle and bottom die flange diameter on clinching joint load bearing capacity in cross-tensile loading

International Journal on Interactive Design and Manufacturing (IJIDeM)

Research paper thumbnail of Design and Fabrication of Injection Molds to Manufacture Double Channel Laryngoscope for Effective Airway Management: Taguchi Method for Surface Roughness Optimization

Key Engineering Materials

The present work focuses on the mold design and production of the multifunctional device laryngos... more The present work focuses on the mold design and production of the multifunctional device laryngoscope with surface quality through the injection molding process. A laryngoscope is a device used by anesthesiologists to lift the tongue that facilitates to fix the air pipe in the larynx. Demand still exists in the laryngoscope part to assist anesthesiologists to take care of the airway without causing chest compression and ensure visualization of vocal cords. Therefore, the present work aims at developing a laryngoscope with a double channeled device, wherein one for aligning the camera and another for the air pipe. The paper outlines the design parameters required for manufacturing a single cavity mold to produce a laryngoscope viz. injection molding machine. The mold has multiple plates with complex fluid channels which ensures effective thermal management in-mold system. The mold is manufactured using high-strength tool steel materials and the product laryngoscope (ABS: Acrylonitril...

Research paper thumbnail of Energy-efficient method for developing in-situ Al-Cu metal matrix composites using microwave sintering and friction stir processing

Materials Research Express

The problems associated with the fabrication of in situ metal matrix composites (MMC) by conventi... more The problems associated with the fabrication of in situ metal matrix composites (MMC) by conventional methods can be avoided by using microwave sintering and friction stirring in combination. The current study investigates the mechanical and electrical properties of pure aluminum (Al-100 wt%) and Al-Cu MMC. The results showed that excellent ultimate tensile strength, toughness, and electrical conductivity can be acquired simultaneously. The obtained ultimate tensile strength in the case of Al-100wt% (184.5 MPa) has improved two-fold than that of a typical commercially pure aluminum AA1016 (90 MPa). Similarly, the electrical conductivity of developed pure aluminum (88.87% IACS) is 1.4 times higher compared to AA1016 alloy (62% IACS). For Al-Cu MMC the copper is added in steps of 5 wt% (5%, 10%, 15%, and 20%). The maximum ultimate tensile strength (205.2 MPa) and the electrical conductivity (71.53% IACS) obtained for Al-10wt%Cu are higher compared to the AA1016 alloy. The present inve...

Research paper thumbnail of Investigations on FSW of nylon micro-particle enhanced 3D printed parts applied to a Clark-Y UAV wing

Research paper thumbnail of Adhesive bonding of similar/dissimilar three-dimensional printed parts (ABS/PLA) considering joint design, surface treatments, and adhesive types

Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science

Three-dimensional printing (3D), a vital technological pillar of industry 4.0 suffers from an imp... more Three-dimensional printing (3D), a vital technological pillar of industry 4.0 suffers from an important bed size limitation, wherein it cannot print any part larger than its bed size. Unfortunately, research in this domain has not kept pace with the other limitations hindering the acceptability of fused deposition modeling (FDM)-3D printers. This paper investigates the adhesive joining of dissimilar 3D-printed parts made from usually preferred materials (Acrylonitrile Butadiene Styrene (ABS), Polylactic Acid (PLA)) having different geometric joint designs (lap, scarf, stepped) employing diverse adhesives (epoxy, cyanoacrylate, polyurathane-based) subjected to different surface treatments (sanding, vapor, plasma). The aim is two-fold: to enhance the joint strength making adhesive bonding a suitable solution for complex structural application, as well as to overcome the bed size limitation of commercially available 3D printers. The individual and combined effect of the parameters, pre...

Research paper thumbnail of Influence of foaming agents on mechanical and microstructure characterization of AA6061 metal foams

Proceedings Of The Institution Of Mechanical Engineers, Part E: Journal Of Process Mechanical Engineering, May 26, 2022

Research paper thumbnail of Effect of process parameters on surface composite fabrication of newly commercialized Mg-ZE41 alloy by friction stir processing (FSP): microstructural development and microhardness

World Journal of Engineering

Purpose Altering the microstructure and developing the surface metal matrix composites (MMCs) in ... more Purpose Altering the microstructure and developing the surface metal matrix composites (MMCs) in a solid-state by friction stir processing (FSP) has been on trend for the past decade. The microstructural modification increases the material properties, which are structure sensitive. The microstructural evolution is highly influenced by the selection of process parameters in FSP. In this study, the effect of process parameters on the microstructure evolution and microhardness of the fabrication of surface MMCs of newly commercialized Mg-ZE41 alloy by the incorporation of different reinforcement particles such as ZrO2, CeO2 and Al2O3 is investigated. Design/methodology/approach By making use of Taguchi’s design of experimentation, which recognizes the crucial factors and ascertain their effect on the properties of the material, the optimization of process parameters for this study was done using MATLAB-14 software. The parameters were adopted along with the levels throughout the FSP fo...

Research paper thumbnail of Product Re-Designing and Development of Key Duplicating Machine - a Case Study

International Journal on Design and Manufacturing Technologies, 2008

Research paper thumbnail of Understanding tool–workpiece interfacial friction in friction stir welding/processing and its effect on weld formation

Advances in Materials and Processing Technologies, 2022

Research paper thumbnail of of Friction Stir Welding and its Importance in Manufacturing Process Modeling Applications

Abstract: Friction Stir Welding (FSW) is a relatively new joining process which is gaining signif... more Abstract: Friction Stir Welding (FSW) is a relatively new joining process which is gaining significance in many joining applications. The development in Finite element (FE) modeling is also aiding in widening the applicability of FSW by simulating the process for better understanding. The success of modeling of FSW depends on selection of suitable techniques and models/laws irrespective of FE package used for simulation. The principal equations that govern modeling of FSW are the material model and the friction model. This paper aims at discussing the effect of variation in Coefficient of Friction (COF) on simulation outputs. It also highlights the modification required in friction model to get the realistic results from FSW simulations using ABAQUS.

Research paper thumbnail of An overview on joining/welding as post-processing technique to circumvent the build volume limitation of an FDM-3D printer

Rapid Prototyping Journal

Purpose Three-dimensional (3D) printing, one of the important technological pillars of Industry 4... more Purpose Three-dimensional (3D) printing, one of the important technological pillars of Industry 4.0, is changing the landscape of future manufacturing. However, the limited build volume of a commercially available 3D printer is one inherent constraint, which holds its acceptability by the manufacturing business leaders. This paper aims to address the issue by presenting a novel classification of the possible ways by which 3D-printed parts can be joined or welded to achieve a bigger-sized component. Design/methodology/approach A two-step literature review is performed. The first section deals with the past and present research studies related to adhesive bonding, mechanical interlocking, fastening and big area additive manufacturing of 3D printed thermoplastics. In the second section, the literature searches were focused on retrieving details related to the welding of 3D printed parts, specifically related to friction stir welding, friction (spin) welding, microwave and ultrasonic we...

Research paper thumbnail of Studies on the Effect of Process Aspects on Material Mixing and Defect Formation in Friction Stir Welding

Friction Stir Welding (FSW) is a rapidly growing solid state welding process and has been a prove... more Friction Stir Welding (FSW) is a rapidly growing solid state welding process and has been a proven method for welding high strength aluminium alloys which were formerly not recommended for joining by conventional fusion welding methods. Based on the information acquired from previous studies, to obtain a defect free Friction Stir (FS) weld with suitable strength, three basic requirements need to be fulfilled (i) Filling of the cavity created behind the tool pin during its traverse and ensuring satisfactory contact of filled material with newly generated surface (on advancing side trailing edge of the pin) (ii) Disrupting and distributing the oxide layer at the initial weld interface (iii) Adequate level of mixing of both side material (Adjacent and Retreating side) in similar welding. In the case of dissimilar welding mixing is desired in controlled amount (to prevent or curtail formation of intermetallics) depending on material combination. Failure to achieve the first precondition...

Research paper thumbnail of Review on modelling of friction stir welding using finite element approach and significance of formulations in simulation

International Journal of Manufacturing Research

Research paper thumbnail of Review on Modeling of Friction Stir Welding Using Finite Element Approach and Significance of Formulations in Simulation

International Journal of Manufacturing Research

Friction stir welding (FSW) is a solid-state joining process, which is gaining significance in ma... more Friction stir welding (FSW) is a solid-state joining process, which is gaining significance in many joining applications, by overcoming the limitations of other fusion welding processes. For successful incorporation of its potential during industrial applications, mechanism of joining needs to be properly comprehended. The solution lies in developing effective and reliable finite element (FE) model of the FSW process, which would help in getting an insight of the process phenomena (like material flow, heat generation, etc.) during the process. The overall result could be used to observe the effect of process parameters on weld quality. Several attempts have been made to develop an FE model for FSW using different techniques. However, building an efficient model that emulates reality is still to be realised. Here, a review is made to know the current state of various FE modelling techniques and identifying better techniques for simulating FSW and its variants. This review also highlights shortcomings (for ex: mesh distortion, simulation time, the capability of defect prediction) of previous models and discusses on grey areas which are still to be addressed in the broader perspective of FSW and its allied processes using FE approach. [Submitted 06 July 2017; Accepted 29 September 2018]