Himadri Majumder | National Institute of Technology Rourkela (original) (raw)

Uploads

Papers by Himadri Majumder

The international journal of advanced manufacturing technology/International journal, advanced manufacturing technology, Jun 21, 2024

Journal of engineering, 2024

Journal of engineering, Feb 2, 2024

Journal of optimization, Feb 10, 2024

International Journal of Energy Research, Aug 30, 2023

Lecture notes in mechanical engineering, Oct 16, 2023

Materials Today: Proceedings, May 1, 2023

The present paper deals with the performance enhancement of the solar air collector with the use ... more The present paper deals with the performance enhancement of the solar air collector with the use of herringbone corrugated fins attached below the absorber plate along the fluid flow channel. A theoretical model is developed based on energy balance equation of the new design solar air heater and is solved with the use of MATLAB simulation code. The effect of operating parameters viz. mass flow rate, system parameter viz. fin pitch, fin spacing ratio, flow cross section aspect ratio and metrological parameter viz. solar intensity on the thermal performance of the herringbone corrugated finned solar air heater is investigated. It is observed that the thermal efficiency of the conventional solar air heater improves from 36.2% to 56.6% with fin pitch 2.5 cm at fixed mass flow rate of 0.026 kg/s but at the penalty of increased pressure drop. To account for this the term "effective or thermohydraulic efficiency" is included.

With the development of the modern manufacturing industry, the demands for hard and difficult-to-... more With the development of the modern manufacturing industry, the demands for hard and difficult-to-cut materials having properties like biocompatibility, corrosion resistance, toughness, light weight, environmental and health friendly nature are increasing day by day. Some of the common difficult-to-cut materials are shape memory alloys (SMA), titanium based alloys, nickel based alloys, etc. are found to be widely used in biomedical, automobile, aerospace and micro-engineering industries. Continuous development and innovation of modern engineering materials as well as the necessity for complex shaped components have made wire electrical discharge machining (WEDM) an imperative choice in production industry. The unique ability of SMA to memorize its previous form has drawn notable attention recently in a wide range of commercial applications. In recent years, development and growth of SMA nitinol applications in the manufacturing industry have also been fairly strong. For the manufacturing sector, machinability study of nitinol has become a significant feature. The choice of the titanium alloy grade 6 was made taking into account its widespread area of applications for airframe, propellant containment for rockets and space vehicles. Further, to face the global competitiveness in manufacturing industry, selection of the best process, machine and equipment, the best parameter setting for preferred outcomes is absolutely important. The contradictive nature of responses and the availability of numerous options make it extremely difficult to select the best prediction and selection procedure. At the beginning, the effect of different independent input parameters like pulse-on time (TON), discharge current (I), wire tension (WT), wire speed (WS) and flushing pressure (FP) on the key machinability aspects namely kerf width (KW), arithmetic mean roughness (Ra), material removal rate (MRR) and micro-hardness (μh) of SMA nitinol during WEDM was analyzed. It was observed that lower level of WEDM process parameters were more favorable to obtain the least KW and Ra values. On the contrary, higher value of MRR and μh can be attained at higher level of I, WT and FP. Further, the effect of uncoated and zinc coated brass wire electrodes were also studied considering four responses, viz. Ra, KW, machining time (MT) and μh. It was apparent that, zinc coated brass wire was more preferable for responses like Ra, KW and μh compared to uncoated brass wire counterparts. FESEM analysis discovered that micro and large cracks, wide craters, recast layer, surface crack density, etc. were more prominent on the machined surface of brass wire compare to zinc coated brass wire. In efforts to precisely predict and compare few significant WEDM machinability aspects of SMA nitinol, the soft computing technique general regression neural network (GRNN) model was developed. The prediction error of the GRNN model was noted as ±5% within the studied range of machining parameters. A multivariate approach, Fuzzy logic coupled with VIKOR (Vise Kriterijumska Optimizacija Kompromisno Resenje) was also introduced to optimize different correlated responses. Confirmation test has been done to validate the optimum process combination which demonstrates the improvement in WEDM responses. In the next stage, two smart prediction tools, GRNN and multiple regression analysis (MRA) model were developed to predict and compare WEDM machinability aspects of titanium grade 6 which proposes that the GRNN model is more consistent and satisfactory than that of the MRA model. A mathematical model was also developed using MRA to define the important parameters stirring the responses. A multivariate hybrid approach, combining multi-objective optimization on the basis of ratio analysis (MOORA) and principal component analysis (PCA) was proposed to optimize different correlated responses during WEDM process of titanium grade 6. Multivariate hybrid approach MOORA-PCA was recognized to be time saving, effective, accurate and comprehensive approach to solve multi-criteria tasks in WEDM operation. In the final stage, a miniature spur gear using WEDM operation was successfully made from SMA nitinol plate. A multi-criteria decision making (MCDM) approach, desirability function analysis (DFA), was utilized to find out the optimum input parameter setting for the same. The optimum process parameters for each desired responses were also attained using Taguchi‘s signal-to-noise ratio. A 3D thermal model was developed for the optimum parametric condition to observe the total heat flux, temperature and equivalent stress distribution in nitinol

Journal of The Brazilian Society of Mechanical Sciences and Engineering, Jun 29, 2019

Electrical discharge machining (EDM) is an extensively used non-traditional machining process use... more Electrical discharge machining (EDM) is an extensively used non-traditional machining process used for conductive materials to get intricate or complex shapes. For any manufacturing industry, optimum parameters of control variables are of sheer importance to improve multiple performance characteristics like surface integrity and productivity. This paper presents multi-objective optimization on the basis of ratio analysis (MOORA) method coupled with principal component analysis (PCA) in order to achieve the optimal combination of EDM parameters. In this research work, response surface methodology was used for designing the experiments considering three input parameters, namely pulse-on time, pulse-off time and pulsed current. All the experiments were conducted at different parametric combinations and the performance, namely material removal rate (MRR) and surface roughness (R a). Proposed MOORA-PCA hybrid results and conventional MOORA results were compared, and it is found that proposed methods are accurate for predicting the responses. Finally, the control variables, namely pulse-on time (T ON), pulse-off time (T OFF) and pulsed current (I p), were set to 300 µs, 85 µs and 18 A, respectively, to get maximum MRR and minimum surface roughness.

Nucleation and Atmospheric Aerosols, 2023

The fused deposition modeling (FDM) process is one of the rapid prototyping technique using therm... more The fused deposition modeling (FDM) process is one of the rapid prototyping technique using thermoplastics materials such as polylactide (PLA) and acrylonitrile butadiene styrene (ABS) in a molten state to produce products directly from the CAD model to 3D fabricated part. FDM is an additive manufacturing (AM) process where products made by, layer by placing a layer of melted plastic material on the platform from bottom to the top. In this study the impact of FDM process parameters on the various mechanical properties like fill density, extruder temperature; platform temperature; print speed; travel speed; stress, strain and total deformation of parts fabricated on a 3D printer with PLA and ABS is evaluated. Influence of process parameters was examined through a design of experiments (DOE) approach. For the study square block selected and analysis of tensile test; compressive test results was processed with the ANSYS software. The obtained deformation, strain and stress results indicate the influence of process parameters used in FDM on mechanical properties of 3D printed thermoplastic parts.

Advances in Materials Science and Engineering

In this study, friction stir processing (FSP) was used to create new surface properties of the Al... more In this study, friction stir processing (FSP) was used to create new surface properties of the Al 6101-SiC composite, and different types of friction stir process tools are used like cylindrical with thread and conical with thread. The SEM and EDAX analyses made it evident that texture appeared in FSPed Al6101 both with and without SiC. Due to the refined grain structure and the inclusion of SiC in the composite, both FSPed samples’ hardness and tensile strength were found to be higher than those of the base alloy. In contrast to FSPed and base material, the composite had a lower percentage of elongation. Drilling experiments led to machining research that showed FSPed Al6101 to have larger cutting forces than the base and composite materials. These findings revealed that SiC served as reinforcement in the material, increasing hardness and cutting forces during drilling. Electrochemical tests on the corrosion behavior showed that the composite had less corrosion resistance than the ...

Materials Today: Proceedings

INSTRUMENTATION ENGINEERING, ELECTRONICS AND TELECOMMUNICATIONS – 2021 (IEET-2021): Proceedings of the VII International Forum

International Journal of Energy Research

This paper deals with the numerical investigation of split hemispherical fins mounted staggered o... more This paper deals with the numerical investigation of split hemispherical fins mounted staggered over a base plate. The thermal and flow analyses have been carried out to evaluate the Nusselt number (Nu), pressure drop Δ P , and hydrothermal performance factor (HTPF) with air as a medium and Reynolds number ( Re = / 3000 to 15000). The cylindrical fin (CF) and hemispherical fin (HF, of radius R ) of the same volume and height have been formed and placed in the computational domain. Results reveal that the Nu for CF compared to HF is 1.3-1.4 times higher, with approximately 1.5 times higher Δ P for the given Re range. The value of HTPF for HF is greater than unity (/1.13-1.20) for all the considered Re values. Secondly, the HF gets split into longitudinal and transverse flow directions for better solid-fluid interaction. The geometrical parameters are transverse offset TO (/= 0 − R / 8 ), longitudinal offset LO (/= 0 − R / 8 ), and Re. Results show that the highest value of Nu (/=384....

International Journal of Advance Research and Innovative Ideas in Education, 2021

A composite material is a combination of two materials with different physical and chemical prope... more A composite material is a combination of two materials with different physical and chemical properties. When they are combined they create a material for instance to become stronger, lighter or resistant to electricity. Composites are one of the most advanced and adaptable engineering materials. Composite materials have properties such as high strength to weight ratio. Structural analysis of non-circular shaped had already done. So there was necessity of work on cylindrical shaped composite materials. This report give idea about why composite materials are better than non-composite material.

Surface Review and Letters

Excellent qualities including a good balance of strength and toughness, good wear resistance, cos... more Excellent qualities including a good balance of strength and toughness, good wear resistance, cost-effectiveness, high machinability, functionality, durability, and reliability make C-45 steel a desirable option for automotive, tool and die-making industries, agricultural, railway, power transmission equipment, etc. When accuracy and precision are crucial, C-45 can be machined using wire electrical discharge machining (WEDM). In this study, input parameters like pulse-on time ([Formula: see text]), pulse-off time ([Formula: see text]), wire feed (WF), and wire tension (WT) were taken to investigate three crucial machining outputs namely average cutting speed (V), kerf width (KW), and material removal rate (MRR), using 0.25 mm brass wire. Taguchi’s ([Formula: see text]) orthogonal array has been utilized to perform the trial runs. A hybrid approach combining VIKOR in conjunction with the analytical hierarchy process (AHP) is used to identify optimal WEDM process parameters. Finally, ...

This investigation, presents the optimization process for MRR of die-sinking electrical discharge... more This investigation, presents the optimization process for MRR of die-sinking electrical discharge machining on Inconel 800 material by using RSM. Inconel 800 is widely used in construction of equipment that must have high strength and resist carburization, oxidation and other harmful effects of high temperature exposure. For conducting the experiment three controllable input parameter like pulse on time, pulse off time and pulsed current has been considered and oxygen free high conductivity copper (99.99% copper) has been also as the electrode material. An RSM method, central composite design, has been used to design the experiment and to model a second order response surface. A total of 51 experiments have been carried out for different combination of process parameter. The experimental results have been analyzed using RSM. The models have been developed at 95% confidence level. From the analysis, it has been found that pulse on time, pulsed current, pulse off time and the interact...

Journal of King Saud University - Engineering Sciences, 2016

Surface Review and Letters, 2021

Shape memory alloy (SMA), a distinctive class of material, can possess its preceding form when su... more Shape memory alloy (SMA), a distinctive class of material, can possess its preceding form when subjected to definite thermo-mechanical energy. Nitinol, an SMA, having an admirable shape memory effect, super elastic, and biomechanical properties, has developed a vast application in the field of biomedical, automobile, robotics, aerospace, etc. Wire electrical discharge machining (WEDM) technique is employed for machining of electrically conductive materials like SMAs, high tech ceramics, smart materials, etc. This paper is focused on analyzing the effect of different significant input parameters on the vital machinability aspects of SMA nitinol during WEDM. Independent input variables like pulse-on time ([Formula: see text], discharge current ([Formula: see text], wire-speed (WS), wire tension (WT) and flushing pressure (FP) were considered to find out their influence on the kerf width (KW), material removal rate (MRR), arithmetic mean roughness ([Formula: see text], and microhardnes...

The international journal of advanced manufacturing technology/International journal, advanced manufacturing technology, Jun 21, 2024

Journal of engineering, 2024

Journal of engineering, Feb 2, 2024

Journal of optimization, Feb 10, 2024

International Journal of Energy Research, Aug 30, 2023

Lecture notes in mechanical engineering, Oct 16, 2023

Materials Today: Proceedings, May 1, 2023

Journal of The Brazilian Society of Mechanical Sciences and Engineering, Jun 29, 2019

Nucleation and Atmospheric Aerosols, 2023

Advances in Materials Science and Engineering

Materials Today: Proceedings

INSTRUMENTATION ENGINEERING, ELECTRONICS AND TELECOMMUNICATIONS – 2021 (IEET-2021): Proceedings of the VII International Forum

International Journal of Energy Research

International Journal of Advance Research and Innovative Ideas in Education, 2021

Surface Review and Letters

Journal of King Saud University - Engineering Sciences, 2016

Surface Review and Letters, 2021

—This investigation, presents the optimization process for MRR of die-sinking electrical discharg... more —This investigation, presents the optimization process for MRR of die-sinking electrical discharge machining on Inconel 800 material by using RSM. Inconel 800 is widely used in construction of equipment that must have high strength and resist carburization, oxidation and other harmful effects of high temperature exposure. For conducting the experiment three controllable input parameter like pulse on time, pulse off time and pulsed current has been considered and oxygen free high conductivity copper (99.99% copper) has been also as the electrode material. An RSM method, central composite design, has been used to design the experiment and to model a second order response surface. A total of 51 experiments have been carried out for different combination of process parameter. The experimental results have been analyzed using RSM. The models have been developed at 95% confidence level. From the analysis, it has been found that pulse on time, pulsed current, pulse off time and the interaction terms have significant effect on MRR. From this observation, it can be concluded that pulsed current and pulse on time are directly and pulse off time is reciprocally proportional to the MRR. The model sufficiency has very satisfactory for MRR as the coefficient of determination (R2) 97.9% and R-Sq (adj) 97.4%.

The present paper envisagesthe effect and optimization of machining parameters on the material re... more The present paper envisagesthe effect and optimization of machining parameters on the material removal rate (MRR) and surface roughness (Ra). Application of NSGA-II used for the selection of optimal process parameters during machining of Inconel 718. The machining parameters considered in the study are wire tension, wire speed, discharge current and Pulse on time. The experimental design using 27 orthogonal array are conducted viaTaguchi design of experiment to predict the MRR and Ra properties using Inconel 718 super alloy as a workpiece and brass wire as tool. The level of importance of the machining parameters on the cutting Ra and MRR is determined by applying ANOVA. Using the signal-to-noise (S/N) ratio optimum machining parameters combination has been obtained. To validate a mathematical model between control factors and responses like MRR and Raare established by means of nonlinear regression analysis. To achieve multi-response optimization, NSGA-II has been adopted. Optimal machining parameters were obtained from the Pareto front graph.

Plasma arc cutting process is widely used in metal cutting industries and modern fabrication unit... more Plasma arc cutting process is widely used in metal cutting industries and modern fabrication units. Precise cutting of high strength material is still a challenging task to the industries. This process involves thermal cutting phenomena. Abrex is a high strength and high abrasion resistant material which is used in manufacturing of body parts of dump truck, buckets, barges, front loaders etc. This special alloy material is identified as " hard-to-cut " type materials. Cutting of this material create a heavy challenge in order to meet the quality. Therefore, optimization and selection of optimal process parameter plays a vital role in cutting such type of material using plasma arc cutting process. This present work proposes an experimental investigation of plasma arc cutting process of abrex high strength material. Experiments were conducted based on Taguchi's L9 orthogonal array design. The cutting parameters analysed were arc current, stand-off distance and cutting speed whereas material removal rate, kerf and dross were selected as output responses. Also, a prediction model was developed to estimate the responses using multiple regression analysis. Analysis of variance (ANOVA) and analysis of means (ANOM) were used to verify the effect of each parameter on the surface quality to be assessed. INTRODUCTION In 1950, plasma arc cutting machine was introduced in fabrication unit to cut the steel and aluminum materials. Modern fabrication units have greater flexibility to adopt an advance or special materials. In this era, cutting the materials with higher accuracy, reduced time and better quality product is a challenging tasks to manufacturing sectors. There is a lot of cutting process to cut the materials, but plasma arc cutting process is quietly economic process comparing to other. Plasma is a forth state of matter. Solid, liquid, gaseous and plasma are the matters. While excess heating of gaseous medium, it acts like a plasma. It is highly energized in nature and electrically conductive medium [1]. Plasma arc cutting is a thermal cutting process which involves high energized plasma gas to cut the high strength material. While cutting process, high velocity ionized plasma gas is impinges to the workpiece through the nozzle. The arc generates between the nozzle and work material. The temperature around the arc gap reaches to 20,0000C. By this process, the workpiece gets melted and blown away by the help of pressure of high velocity plasma jet [2]. A combination of response surface methodology coupled with grey relational analysis and principal component analysis was introduced to find the optimization of plasma arc cutting process of AISI 304L stainless steel [3]. The responses were measured as material removal rate, dross, chamfer, kerf and surface roughness. Experimental modeling was established using general regression analysis and ANOVA while machining of Ti-6Al-4V titanium alloy [4]. Parametric optimization of plasma arc cutting process of stainless steel 304L obtained using grey-Taguchi based response surface methodology [5]. Taguchi's optimization technique is used to find the optimum condition of plasma arc cutting process of 1017 steel and Taguchi's L27 orthogonal array utilized to outline the design [6]. Desirability function and response surface methodology are applied to optimize automated plasma arc cutting process [7].

Titanium alloys are classified as well-known " Space-Age-Metal " due to their inherent characteri... more Titanium alloys are classified as well-known " Space-Age-Metal " due to their inherent characteristics such as high chemical affinity, superior resistance to corrosion, highest strength-to-weight ratio etc. In spite of the aforesaid properties these alloys are also identified as " hard-to-cut " type materials. Machining of such materials offer a significant challenge to the scientific community around the globe. Therefore, selecting an appropriate combination of process parameters become an essential task in order to confirm the dimensional accuracy as well as the quality of the end product. The present paper proposes an approximation tool for the estimation of various cutting responses during machining of commercially pure titanium (CP-Ti) grade 2. A series of experiments were conducted based on Taguchi's L 9 orthogonal array design. Cutting speed, feed rate and depth of cut were considered as three distinct input variables whereas cutting force (F c) and surface roughness (R a) were selected as output parameters. Further, a prediction model was also developed to estimate the aforementioned responses using multiple regression analysis (MRA). The adequacy of the model was verified by performing analysis of variance (ANOVA) test. The results indicated that the proposed regression model was capable of estimating F c and R a competently as the values of determination coefficient was noticed as 0.99 and 0.98 respectively. INTRODUCTION Titanium and its alloys are gaining enormous attention from numerous industries due to their attractive inherent properties such as highest strength-to-weight ratio, low density, superior corrosion resistance and excellent bio-compatibility [1-5]. Because of the aforesaid qualities these alloys are widely used in space craft, aerospace, marine, medical and chemical processing industries [6]. Therefore, titanium alloys are receiving an appreciable attention around the globe and the researchers are focusing on exploration of various machinability aspects of these alloys. In spite of the afore-mentioned activities, the investigations on titanium alloys are sturdily limited because of the high cost and difficulty associated with their extraction. In addition to that, low thermal conductivity and high chemical reactivity also act as a barrier during the study of the key machining characteristics of titanium alloys. Poor thermal conductivity of these alloys restricts high speed machining and hence resulted in low production rate. According to the available literature on titanium machining, the suggested values of the spindle speed during titanium machining ranges from 30 to 60 m/min when using uncoated carbide inserts. On the other hand, high speed machining of these alloys causes high cutting temperature owing to rapid tool wear. Tool failure at its premature stage also contributes in diminishing the quality of the machined surface as well as the dimensional accuracy of the end product. Furthermore, high chemical reactivity of titanium alloys introduces several defects such as built-up edge formation, chipping, development of shear cracks etc. which in turn curtails the life cycle of the cutting tool material. In such situation, an appropriate selection of machining parameter becomes necessary in order to attain an efficient machining performance without compromising the quality. In turning operation, surface quality of the machined part is signified as one of the most desirable need for an end user and is termed as surface roughness. This surface phenomena is strongly influenced by the process parameters viz. tool geometry (i.e. nose radius, rake angle etc.) and cutting condition (i.e. speed, feed and depth of cut). In the past few decades, several techniques were employed to identify the influence of cutting variables on the surface quality of the finished product. In addition to that, various statistical prediction tool were also suggested

Shape memory alloy has a unique capability to return to its original shape after physical deforma... more Shape memory alloy has a unique capability to return to its original shape after physical deformation by applying heat or thermo-mechanical or magnetic load. In this experimental investigation, desirability function analysis (DFA), a multi-attribute decision making was utilized to find out the optimum input parameter setting during wire electrical discharge machining (WEDM) of Ni-Ti shape memory alloy. Four critical machining parameters, namely pulse on time (TON), pulse off time (TOFF), wire eed (WF) and wire tension (WT) were taken as machining inputs for the experiments to optimize three interconnected responses like cutting speed, kerf width, and surface roughness. Input parameter combination TON= 120 μs., TOFF= 55 μs., WF= 3 m/min. and WT= 8 kg-F were found to produce the optimum results. The optimum process parameters for each desired response were also attained using Taguchi’s signal-to-noise ratio. Confirmation test has been done to validate the optimum machining parameter combination which affirmed DFA was a competent approach to select optimum input parameters for the ideal response quality for WEDM of Ni-Ti shape memory alloy.