Article
Green & Sustainable Science & Technology
Vishal Kharka, Neelesh Kumar Jain, Kapil Gupta
Summary: This study evaluates the sustainability and performance of gear hobbing under different lubrication environments. The results show that hobbing with minimum quantity lubrication significantly reduces lubricant consumption, extends hob cutter life, improves productivity, and reduces energy consumption compared to hobbing with flood lubrication. Additionally, spur gears manufactured with minimum quantity lubrication have higher quality.
SUSTAINABLE MATERIALS AND TECHNOLOGIES
(2022)
Article
Automation & Control Systems
Yanzhong Wang, Guoying Su, Douwei Liu, Yizhan Huang, Mingke Xie, Wei Zhang
Summary: The study introduces a hobbing method for spur face gears with bidirectional modification and explores its practical application based on current machine tools. The prototype produced in the experiment demonstrates the feasibility of the method, and detection results indicate that hobbing is an effective approach for bidirectional modification of gear teeth.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Mechanical
Vishal Kharka, Neelesh Kumar Jain, Kapil Gupta
Summary: The paper presents a performance comparison of two green lubricants based on fatty alcohol and synthetic ester in hobbing. It is found that the fatty alcohol-based lubricant outperforms the synthetic ester-based lubricant in various aspects, contributing to the improvement of sustainability in hobbing.
TRIBOLOGY INTERNATIONAL
(2022)
Article
Engineering, Mechanical
M. Andersson, M. Sosa, U. Olofsson
Summary: This study analyzes the efficiency and temperature of superfinished gears compared to ground gears under different lubricating conditions. The results show that superfinished gears have higher efficiency and lower temperatures compared to ground gears.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART J-JOURNAL OF ENGINEERING TRIBOLOGY
(2022)
Article
Engineering, Mechanical
Sheng Li, Ahmet Kahraman
Summary: This study introduces a scuffing model for spur gear contacts and conducts simulations to demonstrate the influences of surface roughness and rotational speed on scuffing load.
MECHANISM AND MACHINE THEORY
(2021)
Article
Engineering, Mechanical
Fangyan Zheng, Jun Zhang, Ligang Yao, Rulong Tan
Summary: Recent studies have shown that proper cutter modification can enhance the wear resistance of gears, reducing wear and increasing the gear's lifespan.
Article
Engineering, Mechanical
Jiaxing Pei, Xu Han, Yourui Tao, Shizhe Feng
Summary: A method for analyzing the lubrication reliability of spur gear systems considering the randomness of external load and surface roughness is presented. The study captures the instantaneous failure probability of gear lubrication through a stochastic dynamics model and a reliability model of elastohydrodynamic lubrication (EHL), revealing higher lubrication failure probability in dedendum and single meshing region.
TRIBOLOGY INTERNATIONAL
(2021)
Article
Engineering, Mechanical
Duan Yang, He Liu, Jianfeng Zhong, Xiang Zhu, Yu Dai
Summary: This paper investigates the impact of nozzle layouts on the lubrication and cooling performance of spur gears under oil jet lubrication conditions. A heat-flow coupled analysis method is introduced to predict the temperature field of the tooth surface with different nozzle layouts. The numerical results show that the heat-flow coupled model provides accurate temperature prediction and the nozzle layouts significantly influence the lubrication and cooling performance. Additionally, the study reveals that the lubrication performance is relatively superior when the nozzle approaches the side of the pinion.
Article
Engineering, Mechanical
Xiaozhou Hu, Pengfei Li, Can Quan, Jianing Wang
Summary: The meshless Lattice Boltzmann Method (LBM) is successfully employed to simulate the jet lubrication problem of spur gears and shows good qualitative agreement with experiments. A three-dimensional simulation model is established to investigate the evolution process of the oil jet and its effects on lubrication performance under different operating conditions.
Article
Mechanics
Xingbao Huang, Weijun Wang, Lichao Ding, Bintang Yang
Summary: Ferrofluids, favored for their unique properties, exhibit superior lubrication performance in enhancing anti-wear and prolonging service life of gear pairs, with factors such as magnetic field intensity, ferromagnetic particle size, and bulk concentration significantly affecting their tribological properties and film stiffness in oil-based ferrofluids.
Article
Thermodynamics
Changjiang Zhou, Mingcai Xing, Hongbing Wang, Bo Hu
Summary: This paper introduces a thermal network model to predict the contact temperature of spur gears, which is validated through numerical simulations. The study shows that increasing geometric parameters can decrease the contact temperature, while increasing operational parameters can increase it.
INTERNATIONAL JOURNAL OF THERMAL SCIENCES
(2021)
Article
Engineering, Electrical & Electronic
Zoltan Tomori
Summary: The paper introduces a new method for selecting profile shift coefficients, ensuring a positive impact on gear failures and operational conditions of gear pairs, while also proposing the concept of cumulative effectiveness.
Article
Engineering, Mechanical
Yanzhong Wang, Guoying Su, Xiaomeng Chu, Yizhan Huang, E. Shiyuan, Wei Zhang, Yang Liu
Summary: This study investigates a shaving method for face gears, examining its theory, the causes of mid-concave phenomena, a solution for the modification coefficient of the shaving cutter, and a control method for the cutter location point. Experimental results demonstrate that this method can achieve the finishing of continuous generation and improve the surface integrity of the gear.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2021)
Article
Engineering, Chemical
Reza Bayat, Arto Lehtovaara
Summary: The experimental results suggest that there exists a threshold pressure for tribofilm formation where the growth rate is maximum. Above this threshold, the formation of tribofilm is unstable and wear dominates. Below this threshold, the growth rate of tribofilm increases with pressure, providing stable protection for gear contact.
Review
Engineering, Mechanical
Victor Roda-Casanova, Carlos M. C. G. Fernandes
Summary: This paper provides a detailed background and methods of theoretical models that affect the temperature rise phenomena of polymer gears, including the methods suggested by Hachmann, Takanashi, and Mao. Conclusions are drawn and recommendations for application are provided through numerical examples and comparison with experimental results.
MECHANISM AND MACHINE THEORY
(2022)
Article
Engineering, Chemical
Pradyumn Kumar Arya, Neelesh Kumar Jain, Jayaprakash Murugesan, Vinay Kumar Patel
Summary: This review paper discusses the challenges and advancements in joining dissimilar aluminum and magnesium alloy using Friction Stir Welding, with a focus on the formation of intermetallic compounds and ways to mitigate their negative impact on the mechanical properties of the joint.
JOURNAL OF ADHESION SCIENCE AND TECHNOLOGY
(2022)
Review
Materials Science, Multidisciplinary
Sujeet Kumar Chaubey, Kapil Gupta
Summary: This paper presents a review of previous research on turning miniature cylindrical bars using thermoelectric-erosion based turning processes, highlighting process parameters, performance evaluation, and key findings.
Article
Chemistry, Analytical
Rabelani Duncan Ramulifho, Kapil Gupta, Daniel Glaser
Summary: This study analyzed the issues with the preheating system design in the additive manufacturing of titanium material using selective laser melting. The inefficient design, caused by heat loss due to metal components in contact and inadequate insulation, was identified. Improving sub-component configurations can enhance the performance of the preheating system.
Article
Automation & Control Systems
Vivek Rana, Neelesh Kumar Jain, Sunil Pathak
Summary: This paper describes the reduction in noise, vibrations, transmission errors, and runout of spur gears by using flank modifications through a non-contact advanced finishing process. Different combinations of flank modifications were effectively applied to improve the functional performance of spur gears. The results showed significant reductions in noise, vibrations, and transmission errors for all modified gears, leading to enhanced operating performance and service life.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Chemistry, Physical
Naresh Kumar Wagri, Neelesh Kumar Jain, Anand Petare, Sudhansu Ranjan Das, Mohammed Y. Y. Tharwan, Abdulkarim Alansari, Bader Alqahtani, Majed Fattouh, Ammar Elsheikh
Summary: The hardness of materials greatly affects their machinability, which in turn affects power consumption, cutting tool life, and surface quality during component machining. In this study, annealed AISI 4340 alloy steel was machined using a coated carbide tool in a dry environment. The microhardness of annealed and non-annealed workpieces was compared, and a significant reduction was found in the microhardness of annealed samples. The microstructure examination revealed the formation of coarse pearlite in the annealed sample, indicating a reduction in hardness and improved ductility. A commercially available CVD multilayer coated carbide cutting tool was used to evaluate the surface quality, machining forces, flank wear, and chip morphology during the turning of quenched and tempered AISI 4340 alloy steel, with the machining speed, rate of feed, and depth of cut varied. The findings showed that the feed rate had a high impact on surface finish, followed by cutting speed. The study concludes that annealing is a cost-effective and economical process to enhance the machinability of alloy steel.
Article
Materials Science, Multidisciplinary
Pankaj Kumar, Neelesh Kumar Jain, Saumya Jaiswal, Sharad Gupta
Summary: This paper describes the development of equiatomic Ti-Ta-Nb-Mo-Zr high-entropy alloy (HEA) for knee implant applications using the m-plasma arc additive manufacturing process. The microstructure and biocompatibility of the HEA were studied, including cell viability, released metallic ions, and corrosion behavior. The HEA exhibited a fine dendritic and inter-dendritic structure with BCC major and minor phases. The cell viability decreased with increasing media concentration, and the overall average viability for HeLa, HEK-293, and BHK cells was 90%, 88%, and 92%, respectively. The released amounts of Ti, Ta, Nb, Mo, and Zr ions were estimated in simulated body fluid solution for different immersion durations. The HEA showed excellent biocompatibility and minimal corrosion parameters, making it a promising biomaterial for knee implants.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Automation & Control Systems
Pankaj Kumar, Mayur S. Sawant, Neelesh Kumar Jain, Anshu Kumari, Sharad Gupta
Summary: This study reports the development of Co-Cr-Mo-xTi alloys as biomaterial for knee implant applications using mu-plasma-based 3D-printing, and evaluates their in-vitro biocompatibility through cell viability, metallic ion release, and corrosion behavior analysis. The study identifies Co-Cr-Mo-4Ti alloy as a better biocompatible biomaterial for knee implants due to its superior cell viability, metallic ion release, and corrosion behavior.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Vivek Rana, Neelesh Kumar Jain, Sunil Pathak
Summary: This paper presents the use of pulsed electrochemical flank modification (PECFM) process with a newly designed cathodic gear tool and apparatus for tip relieving of spur gears. Experimental findings on tip relieving and surface finish are reported by varying parameters such as electrolyte concentration, flow rate, temperature, modification duration, and cathodic gear rotational speed. Optimum values for these parameters are determined to achieve effective tip relieving and improved surface quality. The application of PECFM in gear manufacturing industry will be beneficial for productive tip relieving.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Chemistry, Physical
Sujeet Kumar Chaubey, Kapil Gupta
Summary: This paper examines the surface quality of a miniature cylindrical titanium rod/bar (MCTB) after being turned by the wire electrical discharge turning (WEDT) process. The mean roughness depth was used as the key parameter to evaluate the surface quality. Through a Box-Behnken design and grey relational analysis optimization, the optimum combination of WEDT's variable parameters was determined, resulting in a 37% reduction in surface roughness and favorable tribological characteristics. The findings of this study are significant for the micro-turning of difficult-to-machine cylindrical bars.
Article
Chemistry, Analytical
Itemogeng Bernatt Babe, Kapil Gupta, Sujeet Kumar Chaubey
Summary: This paper investigates the turning of stainless steel 316 using microwave-treated cutting tool inserts. The results show that a 20-minute microwave treatment improves the tool hardness and metallurgical characteristics. By varying the cutting speed, feed rate, and depth of cut, the study finds that tool flank wear increases with all three parameters, while surface roughness decreases. The optimal machining parameters determined by the grey relational analysis technique are a cutting speed of 170 m/min, a feed rate of 0.2 mm/rev, and a depth of cut of 1 mm.
Article
Materials Science, Multidisciplinary
Sujeet Kumar Chaubey, Kapil Gupta
Summary: This article presents an experimental study on wire spark erosion turning of Titanium grade 5 miniature cylindrical bars, focusing on roundness deviation and material erosion rate as the main output parameters. Through Grey relational analysis, the optimum process parameters of WSET were determined and the best values of roundness deviation and material erosion rate were obtained. The results show that the work presented in this article is better than previous studies and has further practical application value in the fabrication of miniature products from difficult-to-machine materials like Titanium.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Materials Science, Multidisciplinary
Bhavesh Chaudhary, Mahesh Patel, Neelesh Kumar Jain, Jayaprakash Murugesan, Vivek Rana
Summary: This study explores friction stir powder additive manufacturing for aerospace grade Al 6061, specifically focusing on multi-track single-layer and multi-track multi-layer depositions. The results show that using a 4 mm overlap for the depositions improves the interface bonding and prevents failure. Furthermore, the microhardness is marginally decreased in the overlapping regions compared to the non-overlapping regions.
Review
Chemistry, Analytical
Pudhupalayam Muthukutti Gopal, Vijayananth Kavimani, Kapil Gupta, Dragan Marinkovic
Summary: Ceramics are widely used in various industries, but conventional processes for fabrication and machining are difficult due to their hardness. Laser-based processes offer high precision, reduced thermal damage, and the ability to work with complex geometries. This paper explores different laser-based ceramic processing techniques and focuses on optimizing process parameters to improve output quality, providing knowledge for researchers in the field.
Proceedings Paper
Green & Sustainable Science & Technology
Thobadingoe Craven Phokane, Kapil Gupta
Summary: This paper presents the optimization of wire-EDM parameters using Fuzzy-TOPSIS integrated hybrid multi-criteria decision making technique, aiming to improve gear quality and process productivity simultaneously. After conducting a series of experiments, the optimal combination of voltage, pulse-on time, pulse-off time, and wire feed rate has been identified to achieve the desired outcomes. The results of this study provide practical wire-EDM parameters for manufacturing high-quality gears with good productivity.
SMART TECHNOLOGIES IN URBAN ENGINEERING, STUE-2022
(2023)
Article
Engineering, Mechanical
Vishal Kharka, Vivek Rana, Neelesh Kumar Jain, Kapil Gupta
Summary: This study compares the influence of three lubrication environments on the performance of spur gears and finds that hobbing with minimum quantity lubrication (HWMQL) results in gears with higher accuracy, better wear resistance, and smoother and quieter operation compared to hobbing with flood lubrication (HWFL) and hobbing without any lubrication (HWAL).
