Somnath Chattopadhyaya | Indian School of Mines, Dhanbad (original) (raw)

Papers by Somnath Chattopadhyaya

Sustainability

In industry 4.0, industry individuals implement lean and smart manufacturing to improve shop floo... more In industry 4.0, industry individuals implement lean and smart manufacturing to improve shop floor management systems. Shop floor management is used to control operational performance and enhance production within limited constraints. Various shop floor management approaches are used in the present scenario of industry 4.0, and mainly include value stream mapping, total productive maintenance, Internet of Things, artificial intelligence, machine learning, and fuzzy logic. The present research aims to develop an open innovation method to achieve sustainability in shop floor management systems in industry 4.0 by using lean and smart manufacturing concepts. The proposed method has been validated by an enhancement obtained in a real case of the shop floor management system in industry 4.0. The authors are confident that the proposed method would provide sustainability in the shop floor management system within limited constraints in industry 4.0.

Advances in Manufacturing Engineering and Materials, 2018

The collision of a high-velocity liquid mass with a solid generates short high pressures transien... more The collision of a high-velocity liquid mass with a solid generates short high pressures transients, which is responsible for the damage to the surface and its interior. The main advantage of the pulsating jet as compared to the continuous water-jet technology is that the impact pressure (due to hammering effect) is several times greater in pulsating water jet. The impact of the pulses induces fatigue stresses in the target material due to cyclic loading which is the most influential factor responsible for the disintegration. However, this technology is reported to the current trend of the application. During the laboratory experiments on Silesian granite were examined the relationship between the acoustic emission and parametric conditions of the pulsating water-jet. This research paper deals with an application of acoustic emission measurement as an on-line monitoring tool for analyzing the disintegration phenomenon of rock by pulsating water jet which locally affects the structural integrity of rocks. The correlation between rock disintegration and dynamic signal performance was obtained for several rock materials at various settings of jet parameters.

Lecture Notes on Multidisciplinary Industrial Engineering, 2019

Green-machining is an environment-friendly and cost-effective metalcutting process because it doe... more Green-machining is an environment-friendly and cost-effective metalcutting process because it does not use cutting fluids. This paper focusses on the study of green-machining characteristics and comparison of AISI-1055 and AISI-4340 steels in meso-scale end-milling. All the experiments were conducted with fourflute solid-carbide end-mill tool of 2 mm diameter under dry cutting condition using Taguchi L9 orthogonal array (OA) design. Machining parameters were optimized using S/N-ratio of Taguchi design technique. Analysis of variance was used for investigating the effect of cutting parameters on the burr width (BW) and surface roughness (Ra). All the experimental data obtained for "Ra" and "BW" were used to develop their regression models. The developed regression models for "Ra" and "BW" could be used for predicting the responses in meso-scale end-milling of AISI-1055 and AISI-4340 steels with minute error. At last, a comparison between AISI-1055 and AISI-4340 steels with respect to "Ra" and "BW" obtained in meso-scale end-milling was carried out. The comparative analysis between the two materials in meso-scale end-milling depicts that the machining performance of steel AISI-4340 is more effective than the machining performance of steel AISI-1055 on the basis of obtained "Ra" and "BW".

Mechanical Behaviour of Biomaterials, 2019

Abstract This study analyzes the femoral neck in an artificial hip joint and explores design vari... more Abstract This study analyzes the femoral neck in an artificial hip joint and explores design variations using finite element analysis to compile an optimum design. An effective prosthesis should have minimal stress concentration and deformation as well as versatility to handle different loads applied at various angles. Different femoral neck designs were modeled using Ti-6Al-4V alloy material with the following loads; 1962, 2354.4, 2746.8 and 3139.2 N, and applied at angles of 35, 45, 55, and 65 degrees. The minimum stress concentrations, deformation, and stress distribution were analyzed and compared while varying the boundary conditions. The final design was selected based on the analysis of which was the most effective and versatile design, consisting of a straight-edged profile and trapezoidal cross-section.

Energy Sources, Part A: Recovery, Utilization, and Environmental Effects, 2020

Rapidly intensifying necessitates of energy and depletion of accessible fossil resources has made... more Rapidly intensifying necessitates of energy and depletion of accessible fossil resources has made a remarkable interest in investigation of the alternative fuels. The current investigational work was performed to examine the use of multi-objective optimization (MOP) based on response surface methodology (RSM) to investigate the impact of compression ratio (CR), biogas flow rate and engine load on the performance of dual-fuel engine. An engine load of 80%, compression ratio of 18, and biogas flow rate of 2.8 kg/h were observed to be optimal condition. According to these optimized parameters, the value of BTE, NO X , UHC, CO and smoke opacity were found to be 18.51(%), 13.5 (g/ kW.hr), 0.49 (g/kW.hr), CO (0.08% vol.) and 23.6 (%), respectively. Compared with conventional diesel fuel, dual-fuel operational mode can improve brake specific energy consumption and reduce NO X as well as Smoke opacity, while producing higher emissions of CO and UHC.

Applications of Fluid Dynamics, Nov 5, 2017

Over the decades water jet cutting has been widely used for rock disintegration in mining operati... more Over the decades water jet cutting has been widely used for rock disintegration in mining operations and quarrying purposes. The impact of high pressure waterjet on hard material like rock,coal ruins the original structure of the material therefore low pressure water-jet come into the existence. In recent year pulsating water jet has been applied in numerous ways such as surface cleaning, exclusion of damaged material layers, preparation of surfaces, and disintegration of materials. It has also a great potential for application in hard rock breakage as conventional methods are cumbersome, not readily accessible and have economical limitations.The performanceof the jet increses significantly by the generation of pulses causing disintegration of material at a relatively lower energy and costs. This paper focuses on the study of the disintegration processes of marble and granite by pulsating water jet subjected to erosion via accoustic emission.The experiments are performed by using pulsating water jet with modulation frequency of 20.20 kHz. The MVT circular nozzle with an orifice diameter of 0.9 mm, standoff distance from the target material was 6 mm, traverse speed varied from 2-16 mm/s and pump pressure 60 MPa was used for water jetting .The topography of granites and marble on the cut depth and surface quality were investigated by the optical profile-meter. Moreover, dependable relations between some physical and mechanical properties of the rocks and the depth of cut were observed. The online monitoring of acoustic emission shows the change in the response to the pulse frequency at different time intervals.

Measurement, 2018

Residual stress and surface properties of stainless steel welded joints induced by ultrasonic pul... more Residual stress and surface properties of stainless steel welded joints induced by ultrasonic pulsed water jet peening,

Arabian Journal for Science and Engineering, 2015

This paper examines linear cutting operation of coal samples by using two kinds of conical picks,... more This paper examines linear cutting operation of coal samples by using two kinds of conical picks, each made of different materials. The first one is the conventional pick. It has an abrasive-resistant WC–Co conical tip. The second tool has newly been developed by using cast iron mixed with 21 % (by weight) mild steel. The tip of the newly developed pick has been coated with an alloy LH710 (hardness 40 RC). Coal sample was cut linearly by using the picks at different tilt angles. The most optimum tilt angle was selected on the basis of two criteria: (1) the amount of coal removed and (2) the temperature generated during coal cutting. A comparative analysis of both the picks has been carried out on the basis of these findings. A combined multiple attribute decision-making method has also been used to select the best tilt angle and to simultaneously corroborate the results obtained by the experiments. After linear cutting of coals, a brief wear analysis of both the tools has been performed to compare their deteriorated condition.

Separation and Purification Technology, 2008

The present study is an experimental and numerical analysis of trichloroethylene (TCE) removal fr... more The present study is an experimental and numerical analysis of trichloroethylene (TCE) removal from soil by ozone oxidation combined with acetic acid flushing. A one-dimensional advective-dispersive flow model is proposed to mathematically describe the TCE dissolution and oxidation from the porous medium using acetic acid and ozone, respectively. The model could reasonably well predict the experimental data in the effluent for dissolution, oxidation, and total removal of TCE. Sensitivity analyses evaluated the effects of different parameters, such as ozone and acetic acid concentration, flow rate, and initial TCE concentration, on the dissolution and oxidation processes. Remediation time was reduced by more than 29% by applying acetic acid solutions saturated with ozone. Increasing the ozone concentration was the best method for reducing remediation time, followed by increasing acetic acid concentration and increasing flow rate.

FRONTIERS SCIENCE SERIES, 2007

International Journal, 2010

ABSTRACT: In submerged arc welding (SAW), selecting appropriate values for process variables is e... more ABSTRACT: In submerged arc welding (SAW), selecting appropriate values for process variables is essential in order to control bead size and quality. Also, condition must be selected that will ensure a predictable weld bead, which is critical for obtaining high quality. In this investigation, mathematical models (based on multi regression method) have been developed and side by side Prediction through artificial neural networks has been made. A comparative study also has been done. Based on multi regressions and a neural network, ...

Advances in Materials Science and Engineering, 2013

Temperature distribution during any welding process holds the key for understanding and predictin... more Temperature distribution during any welding process holds the key for understanding and predicting several important welding attributes like heat affected zone, microstructure of the weld, residual stress, and distortion during welding. The accuracy of the analytical approaches for modeling temperature distribution during welding has been constrained by oversimplified assumptions regarding boundary conditions and material properties. In this paper, an attempt has been made to model the temperature distribution during submerged arc welding process using finite element modeling technique implemented in ANSYS v12. In the present analysis, heat source is assumed to be double-ellipsoidal with Gaussian volumetric heat generation. Furthermore, variation of material properties with temperature and both convective and radiant heat loss boundary condition have been considered. The predicted temperature distribution is then validated against the experimental results obtained by thermal imaging...

DISCUSSION ON IMPORTANCE OF TUNGSTEN CARBIDE-COBALT (WC-Co) CEMENTED CARBIDE AND ITS CRITICAL CHA... more DISCUSSION ON IMPORTANCE OF TUNGSTEN CARBIDE-COBALT (WC-Co) CEMENTED CARBIDE AND ITS CRITICAL CHARACTERIZATION FOR WEAR MECHANISMS BASED ON MINING APPLICATIONS OMÓWIENIE ROLI WĘGLIKA SPIEKANEGO Z KOBALTEM WC-Co ORAZ OKREŚLENIE JEGO KLUCZOWEJ CHARAKTERYSTYKI NIEZBĘDNEJ DO ROZPOZNANIA MECHANIZMÓW ZUŻYCIA W KONTEKŚCIE ZASTOSOWAŃ W GÓRNICTWIE Cemented carbide (CC) is an important material for the mining tools. During mining applications, the service life of the CC gets highly reduced due to complex conditions offered by mines. In various applications, such as, rock drilling and coal cutting, the tools show different type of wear behaviour. Wear assessment has been an important area of research for a long time. In order to develop improved mechanical properties in the tools, it is necessary to know the characteristics and cause of wear mechanisms. For analyzing wear mechanisms in the CC, researchers have adopted mainly three different conditions. They are: rock drilling, coal cutting, and laboratory wear test methods. In the present work, an attempt has been made to review and summarize all those wear mechanisms found in the CC. The causes and effects of each mechanism are also explained comprehensively. In addition, various properties of recently developed cemented carbide have also been discussed.

Sustainability, 2021

Worldwide, industries are emphasizing the development of an agile system to sustain higher produc... more Worldwide, industries are emphasizing the development of an agile system to sustain higher productivity, which can be applied to ensure improvements in all production conditions in industry 4.0. In the present scenario, several methods are used for improvements in production, such as value stream mapping, kaizen, just in time, Kanban, and total productive maintenance, etc., The objective of the present research article is to produce an agile system to sustain improvements in productivity through a methodology coupled with value stream mapping in industry 4.0. Value stream mapping is a lean-based method and is used for the maximization of productivity by the elimination of non-value-added activities. The proposed methodology has been validated by productivity enhancements achieved in a case study of the earthmoving machinery manufacturing sector. The study establishes that the proposed methodology would encourage industry personnel during decision-making processes, which would lead t...

IOP Conference Series: Materials Science and Engineering, 2018

Materials Today: Proceedings, 2019

Abstract Micro-friction stir welding (μFSW) is a revolutionary joining process which is usually u... more Abstract Micro-friction stir welding (μFSW) is a revolutionary joining process which is usually used for the welding of metallic alloys, like aluminium, magnesium, copper, lead, zinc, titanium and other softer structural alloys. Micro-friction stir welding is employed to join thin electrical components and micro-mechanical components which is primarily used in industries like; aerospace, automotive and other industrial applications. Tool rotational speed along with speed of welding and angle of tool tilting are most vital parameters for the μFSW process which affects the joint property. It gives better joint properties than the base material properties.

International Journal of Surface Science and Engineering, 2019

This paper investigates the effect of SAE grade 20W50 engine oil as a lubricant on the wear behav... more This paper investigates the effect of SAE grade 20W50 engine oil as a lubricant on the wear behaviour of chromium nitride (CrN) coating deposited by PVD process at higher loads and speeds by pin on disc tribometer. The specific wear rate ranges from 9.82 × 10-5 to 2.87 × 10-5 mm3/Nm in dry condition whereas in lubricated condition 0.97 × 10-5 to 0.19 × 10-5 mm3/Nm. Successive increase of speed and load rises the temperature of wear track from 65°C to 178°C in dry condition while 34°C to 40°C in lubricated conditions results to decrease in friction coefficient, which has immense influence on the wear resistance of coating. The wear mechanism of the coatings was analysed by SEM and EDS and found deformation, cracks and, nitride particle pull-out, built up edge formation, erosion and adhesive wear coupled with oxidation wear. The highlights of the paper are: 1) tribology of CrN coating against cylinder liner material as counter face summarised; 2) research has practical applications for piston ring with the influence of engine oil; 3) temperature ranges from 65°C to 178°C in dry and 34°C to 39°C in lubrication during wear test; 4) the wear mechanism is combination of three body abrasion, metal transfer and oxidation.

Materials Today: Proceedings, 2018

Abstract Friction surfacing is a solid state processing technology in the context of localized su... more Abstract Friction surfacing is a solid state processing technology in the context of localized surface engineering. It is mainly used for coating applications to repair damaged or worn parts, to improve wear and corrosion resistance, to enhance surface properties at a specified area of the parts and tools and also to make metal matrix composites. This process is an environment-friendly technique in which friction between the substrate and consumable rod and the deformation of the consumable rod is the only source to generate heat. The different parameters for this process are rotational speed, pressure or force applied, tilt angle and friction time. The present study is a review of microstructructural evaluation of different materials after the friction surfacing process.

Journal of Failure Analysis and Prevention, 2016

The present paper deals with the characterization of failure behavior in the cemented carbide (WC... more The present paper deals with the characterization of failure behavior in the cemented carbide (WC 94–Co 6%) tips of two cutters, i.e., conical cutter and radial cutter, which were used for coal cutting operation in an underground mine. High-resolution microscopes (FESEM and EDS) were used to assess wear mechanisms. The cemented carbide has been studied for its wear behavior for a long time. The ongoing research is necessary because wear mechanisms cannot be classified in single way. The variations in application of the tools may change the tribological characteristics in the cemented carbide. In this study, mainly four wear mechanisms, such as Cracks, Abrasion, Corrosion, and Intermixing of external elements, have been reported.