Article
Engineering, Manufacturing
Faiz Iqbal, Zafar Alam, Dilshad Ahmad Khan, Sunil Jha
Summary: Ball end magnetorheological finishing (BEMRF) is a process used for precision finishing of complex surfaces, requiring in situ roughness measurement. The compact design and lightweight capabilities of a confocal sensor make it suitable for such applications.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Mechanical
Gourhari Ghosh, Ajay Sidpara, P. P. Bandyopadhyay
Summary: The study focuses on MRF of WC-Co coating using B4C abrasives, and improves the processing efficiency by fabricating composite abrasives, achieving higher MRR and lower surface roughness.
TRIBOLOGY INTERNATIONAL
(2021)
Article
Engineering, Mechanical
Gourhari Ghosh, Ajay Sidpara, P. P. Bandyopadhyay
Summary: In this study, magnetorheological finishing (MRF) of WC-Co coating was carried out with theoretical models proposed for better understanding of the finishing mechanism. The models were experimentally verified and showed good correlations with the experimental values. The areal surface roughness of the coating was reduced to 130 nm by performing MRF with diamond abrasives.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2021)
Article
Materials Science, Coatings & Films
Christian Micallef, Karl Walton, Yuri Zhuk, Adrianus Indrat Aria
Summary: The impact of vibratory polishing on W/WC coating was investigated in this study. It was found that using a vibratory barrel setup and ceramic-based media could significantly improve the surface roughness of the coating within 4 hours. Additionally, the weight loss and hardness changes of the coating were negligible, while the compressive residual stresses increased with processing time.
SURFACE & COATINGS TECHNOLOGY
(2022)
Article
Chemistry, Multidisciplinary
Chao Xu, Xiaoqiang Peng, Hao Hu, Junfeng Liu, Huang Li, Tiancong Luo, Tao Lai
Summary: NiP coating is an excellent material for coating optical components. This study develops a magnetorheological fluid specifically for NiP coating processing and establishes a material removal model for magnetorheological finishing (MRF) polishing. The optimized MRF polishing process effectively removes the turning tool pattern and improves the surface quality of the NiP coating.
Article
Chemistry, Analytical
Xiaoyuan Li, Qikai Li, Zuoyan Ye, Yunfei Zhang, Minheng Ye, Chao Wang
Summary: The study found that normal stress has a greater impact on surface roughness during polishing of fused silica, and that the normal stress is sensitive to the immersion depth of the magnetorheological fluid, enabling fine-tuning for optimal surface roughness. This work fills gaps in understanding the stresses that influence surface roughness during MRF.
Article
Materials Science, Multidisciplinary
Chander Prakash, Sunpreet Singh, Alokesh Pramanik, Animesk Basak, Grzegorz Krolczyk, Marta Bogdan-Chudy, Yongling Linda Wu, H. Y. Zheng
Summary: The study investigates the effect of magnetorheological fluid assisted magnetic abrasive finishing (MRAF) process on the surface topography of high strength biomedical grade I3-phase Ti-Nb-Ta-Zr alloy. The study analyzed the impact of MRAF processing parameters on surface characteristics and found that the I3-TNTZ alloy exhibited excellent biomechanical properties. The optimal conditions for achieving the lowest surface roughness and highest material removal rate were identified for the raster path finishing strategy.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Optics
Mahender Kumar Gupta, D. Dinakar, Inder Mohan Chhabra, Sunil Jha, Buchi Suresh Madireddy
Summary: This paper introduces a non-conventional polishing technique for fused silica glass, achieving angstrom level surface finishing using the Ball End Magneto rheological finishing method (BEMRF). This method minimizes subsurface damage and improves the surface roughness and material removal of fused silica glass, allowing for highly polished and precise optics fabrication.
Article
Instruments & Instrumentation
Nitesh Kumar Dubey, Ajay Sidpara
Summary: The study investigates the influence function of magnetorheological finishing process through numerical simulation and experiments, analyzing the relationship between dynamic pressure, wall shear stress, and the workpiece surface. The correlation between depth of indentation and influence function is examined, with the understanding that spindle speed and working gap size affect both parameters.
SMART MATERIALS AND STRUCTURES
(2021)
Article
Engineering, Manufacturing
Kunal Arora, Anant Kumar Singh
Summary: The fine finishing of polymer bevel gears is crucial for defining the functionality of industrial components. A novel magnetorheological bevel gear finishing process is used to efficiently finish the entire surface of polyamide bevel gears, resulting in improved surface characteristics and tooth accuracy.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Engineering, Manufacturing
Bin Luo, Qiusheng Yan, Jisheng Pan, Jiabin Lu, Youzhi Fu
Summary: Magnetorheological finishing is a novel machining method that can achieve ultra-smooth and even surfaces. By varying the machining gap, the polishing efficiency and surface quality can be improved.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Xulong Zhuang, Mingming Lu, Jiakang Zhou, Jieqiong Lin, Weixing Li
Summary: By optimizing the shape of the arc permanent magnet through finite element simulation, the polishing efficiency of planar optical elements can be improved, resulting in better processing quality. Experimental results demonstrate that the use of arc permanent magnets can significantly reduce surface roughness and improve surface accuracy.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: Surface roughness improvement is crucial for enhancing the functionality of components, and a novel method called Hybrid Chemo-Magnetorheological Finishing (HC-MRF) is proposed in this study. HC-MRF utilizes the synergic action between magnetorheological finishing and chemical etching to reduce surface roughness without affecting the surface topography of the workpiece.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Mayank Kumar, Ajay M. Sidpara, Vikranth Racherla
Summary: In this study, open-cell porous flexible abrasive tools were developed for super finishing of copper disks, achieving a good surface finish.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2023)
Article
Engineering, Manufacturing
Mohsen Derakhshan-Samani, Abdolreza Rahimi
Summary: This research presents an improved design of the BEMRF tool for polishing borosilicate glass lenses. Through simulation and experimentation, it was found that the optimized fluid composition achieved a 59% improvement in surface roughness.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Thermodynamics
Akash Chowdhury, Anandaroop Bhattacharya, P. P. Bandyopadhyay
Summary: This report numerically investigates the dynamics of a metal droplet impacting on a substrate surface. The numerical solutions show that the interaction of different forces, including inertia, viscous, and surface tension, coupled with solidification, leads to complex flow dynamics. The change in density and viscosity caused by temperature variation significantly influences the spreading of the droplet.
JOURNAL OF THERMAL SCIENCE AND ENGINEERING APPLICATIONS
(2022)
Article
Chemistry, Multidisciplinary
V. Ambardekar, T. Bhowmick, P. P. Bandyopadhyay, S. B. Majumder
Summary: This paper investigates the ethanol and acetone sensing behavior of atmospheric plasma sprayed copper oxide coating. Gas responses towards ethanol and acetone were observed, with different concentrations showing variations in the response transients. The study found that gas sensing is influenced by analyte properties, sensing surface nature, and reaction pathways during gas-solid interaction.
JOURNAL OF PHYSICS AND CHEMISTRY OF SOLIDS
(2022)
Article
Engineering, Mechanical
Suman Saha, Sankha Deb, Partha Pratim Bandyopadhyay
Summary: This study investigates the correlation between changes in edge features and reduction in outer diameter to more accurately calculate tool wear in micro-milling. Analytical expressions for different wear scenarios are derived and validated through sustainable MQL-assisted micro-milling. The diameter reduction is established as a reliable variable for drawing tool life curves.
Article
Materials Science, Ceramics
Rajib Das, P. P. Bandyopadhyay
Summary: The study utilized a novel technique known as heterocoagulation to produce solid lubricant doped ceramic matrix composite powder for plasma spraying. By measuring zeta potential and wettability test results, appropriate ceramic matrix and low-temperature, high-temperature solid lubricants were identified for plasma spraying applications.
CERAMICS INTERNATIONAL
(2022)
Article
Chemistry, Physical
V Ambardekar, T. Bhowmick, P. P. Bandyopadhyay
Summary: This paper investigates the hydrogen gas sensing performances of plasma sprayed SnO2/WO3 coatings in comparison to stand-alone WO3 and SnO2 coatings. The results show that the SnO2/WO3 sensor exhibits a maximum response of 90% at a lower operating temperature compared to the individual WO3 and SnO2 sensors. The SnO2/WO3 sensor also demonstrates selective sensing towards hydrogen gas and possesses stable base resistance and repeatable characteristics.
INTERNATIONAL JOURNAL OF HYDROGEN ENERGY
(2022)
Article
Engineering, Mechanical
Suman Saha, Sankha Deb, Partha Pratim Bandyopadhyay
Summary: Minimum quantity lubrication (MQL) is beneficial in metal cutting for improving machinability. However, in micro-milling, the presence of a shadow zone restricts the deposition of oil droplets on the cutting edges, resulting in reduced lubrication effectiveness. The impact of the shadow zone intensifies with increasing axial depth of cut and top-burr height.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2022)
Article
Materials Science, Coatings & Films
Tina Ghara, P. P. Bandyopadhyay
Summary: A comparative study was conducted on ceramic coatings produced using plasma spraying under comparable conditions. The coatings were characterized for their mechanical properties and residual stress profiles. The results showed that the residual stress field in the coatings depended on their coefficient of thermal expansion and that the highly compressive residual stress in the substrate was relaxed after coating deposition.
JOURNAL OF THERMAL SPRAY TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Mayank Kumar, Ajay M. Sidpara, Vikranth Racherla
Summary: In this study, open-cell porous flexible abrasive tools were developed for super finishing of copper disks, achieving a good surface finish.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2023)
Article
Engineering, Multidisciplinary
Gourhari Ghosh, Ajay Sidpara, P. P. Bandyopadhyay
Summary: Thermally sprayed tungsten carbide coating is widely used for wear resistance applications. In this study, magnetorheological fluid based finishing (MRF) process with diamond powder abrasive particles is used to achieve a nanolevel surface finish on pre-polished tungsten carbide coating. The incorporation of a chemical etchant in MRF results in a higher finishing rate. However, the MRF technique's effectiveness is limited at higher wheel velocities. To overcome this, CIPdiamond and CIP-diamond-graphene composite abrasives are introduced, which show higher material removal rates and better stability at elevated wheel speeds. The MRF process with CIPdiamond-graphene abrasives achieves the lowest surface roughness (Sa) of 55 nm and highest MRR.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Article
Chemistry, Inorganic & Nuclear
Mayank Kumar, Tharra Bhavani, Sunil Rawal, Ajay Sidpara
Summary: This research reports a method of nanofinishing on chemically nickel-plated surfaces and studies the effect of chemical treatment on surface properties. Hydrogen peroxide forms a passivated layer for easy material removal, while hydrofluoric acid improves surface quality and removes contaminants.
Article
Engineering, Mechanical
Mayank Kumar, Ajay Sidpara, Vikranth Racherla
Summary: This study uses the solvent casting method to fabricate a porous elastomeric tool with self-replenishing and self-lubrication properties. By selecting different materials as workpieces, the wear mechanisms and loading of the flexible abrasive tool are studied, and the mechanism of tool wear and tool loading is analyzed.
Article
Engineering, Manufacturing
Nitesh Kumar Dubey, Ajay Sidpara, Rajaram Lakkaraju
Summary: Magnetorheological fluid-based finishing is a recognized technique for precise finishing of components, with material removal depending on MR fluid ribbon's velocity and compression during interaction with the workpiece. This article investigates the ejection of magnetic and abrasive particles during carrier wheel rotation by balancing centrifugal and magnetic forces. Experimental results demonstrate reduction in MR fluid ribbon thickness and surface roughness initially decreases and then increases with increasing carrier wheel speed. The theoretical and actual departure speed of magnetic particles from the MR fluid ribbon show good agreement.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART B-JOURNAL OF ENGINEERING MANUFACTURE
(2023)
Article
Materials Science, Multidisciplinary
Nitesh Kumar Dubey, Ajay Sidpara, Rajaram Lakkaraju
Summary: A dynamic viscosity model is proposed based on the varying magnetic flux density of the neodymium permanent magnet. The model provides a better analysis of the influence function compared to standard non-Newtonian fluid models. Numerical and experimental investigations are conducted to examine the flow behavior of the MR fluid on a freeform surface and understand its influence function.
JOURNAL OF MAGNETISM AND MAGNETIC MATERIALS
(2023)
Article
Engineering, Electrical & Electronic
Sunil Rawal, Mayank Kumar, Ajay M. Sidpara, Jinu Paul
Summary: This study investigated the fabrication of micro channels on stir cast Al6061 alloy using the bottom pouring stir casting method. The influence of micromachining parameters on burr formation, cutting force, and surface roughness was studied. The surface morphology of the micro channels and the mechanism of top burr formation in stir cast Al6061 alloy were analyzed. The results showed that at the optimum parameter, the stir cast Al6061 alloy exhibited improved cutting performance and surface quality compared to the base Al6061 alloy.
JOURNAL OF MICROMECHANICS AND MICROENGINEERING
(2023)
Article
Polymer Science
Jomy Joseph, Ajith Koroth Koyadan, Ajay M. Sidpara, Jinu Paul
Summary: Hybrid composites of PMMA/graphene/Bentonite and PVC/graphene/Bentonite were prepared by solution casting method and studied for thermal stability, electrical conductivity, and EMI shielding effectiveness in X-band. The presence of Bentonite in the hybrid composites was found to improve thermal stability but decrease electrical conductivity and overall shielding effectiveness in X band. Absorption played a significant role in the overall shielding effectiveness of the hybrid nanocomposites compared to polymer/graphene composites.
POLYMER-PLASTICS TECHNOLOGY AND MATERIALS
(2022)