Article
Engineering, Manufacturing
Atul Singh Rajput, Ambrish Singh, Sajan Kapil, Manas Das
Summary: This paper presents a method called magnetorheological fluid assisted finishing (MFAF) for achieving a mirror-like polished surface. By using trochoidal toolpaths, the surface quality can be significantly improved. The impact of different process parameters on the surface quality is analyzed and optimized using experiments and response surface methodology (RSM). The biocompatibility of the polished surface is also investigated.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Computer Science, Interdisciplinary Applications
Atul Singh Rajput, Sajan Kapil, Manas Das
Summary: Magnetorheological Finishing (MRF) process is used for advanced surface finishing to provide mirror-like polished surfaces for various applications. However, holes and pockets on the workpiece surface present challenges in achieving a uniform finish. A Feature-based Hybrid MRF Planning System (FHMRF-PS) is developed to deposit paraffin wax in these features before MRF to improve surface quality. The system includes toolpath strategies for deposition and MRF to enhance efficiency, and a case study confirms the effectiveness of the FHMRF-PS.
INTERNATIONAL JOURNAL OF COMPUTER INTEGRATED MANUFACTURING
(2023)
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, Manufacturing
Manjesh Kumar, Sarfraz Ahmad, Manas Das
Summary: In this study, a novel uniform flow restrictor was designed and developed for precise finishing of miniature gears using rotational magnetorheological fluid-based process. The impact of critical parameters on performance was analyzed through response surface methodology, resulting in improved surface roughness and texture after finishing. The use of different magnetorheological fluids with and without flow restrictors successfully removed manufacturing defects and achieved ultrafine surface roughness on SS316L miniature spur gears. Simulation of the forces involved in finishing gear profiles and a mathematical model for material removal during finishing were also carried out for a better understanding of the controlling mechanisms.
MATERIALS AND 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
Materials Science, Coatings & Films
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: Bone plate surface quality is vital for its sustainability under adverse conditions. A feature-based hybrid MRF planning system has been developed to improve the surface characteristics of polished bone plates, leading to enhanced wear and corrosion resistance.
SURFACE ENGINEERING
(2022)
Review
Engineering, Manufacturing
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: This article explores the evolution, development, applications, process parameters, composition, and analytical models of MR fluid-assisted finishing processes. The key capabilities and limitations of different MR fluid-assisted finishing processes are discussed and compared, providing an overview.
MACHINING SCIENCE AND TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
S. Karthikeyan, B. Mohan, S. Kathiresan
Summary: The R-MRAFF process significantly improves the surface uniformity of SS 316L stainless steel and demonstrates excellent biocompatibility. The study shows that R-MRAFF promotes stable oxide formation on the surface and reduces corrosion rate significantly.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2021)
Article
Engineering, Multidisciplinary
Yan Gu, Mingshuo Kang, Jieqiong Lin, Ao Liu, Bin Fu, Penghui Wan
Summary: The study introduces a vibration-assisted magnetorheological finishing method to enhance the shearing effects of polishing. Experimental results show that variations in vibration parameters affect surface quality and polishing forces, with higher amplitudes and frequencies leading to better surface quality.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2021)
Article
Engineering, Mechanical
Manjesh Kumar, Chandan Kumar, Amit Kumar, Debashish Gogoi, Manas Das
Summary: The magnetorheological fluid-based finishing method is effectively used for the nano-scale surface finishing of narrow and complicated poppet valve profiles. The method removes manufacturing defects and improves the working lifespan of poppet valves.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2022)
Article
Acoustics
Yahya Choopani, Mohammad Reza Razfar, Mohsen Khajehzadeh, Mohammadreza Khosrojerdi
Summary: This study proposes the ultrasonic assisted-rotational magnetorheological abrasive flow finishing (UA-RMRAFF) process as a solution to the challenges of the rotational-magnetorheological abrasive flow finishing (R-MRAFF) process. Experimental results show that the UA-RMRAFF process provides a uniform and fine surface finish, increases material removal, and performs surface modification faster than the R-MRAFF process.
Article
Engineering, Mechanical
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: Additive Manufacturing (AM) is used for manufacturing biomedical implants to achieve customized fabrication of complex shapes with reduced time and waste. However, poor surface quality is a major concern. Magnetorheological Fluid Assisted Finishing (MFAF) is an advanced process used to improve surface quality without altering topography. This study utilizes Selective Laser Melting (SLM) to fabricate biomaterials, followed by MFAF process to enhance surface quality.
Article
Engineering, Manufacturing
O. Rodriguez-Alabanda, G. Guerrero-Vaca, E. Molero, P. E. Romero
Summary: The study evaluates the deep slot milling process of EN AW 2024-T3 aluminium alloy using a stretched trochoidal toolpath, with a focus on optimizing rules for material removal rate, surface roughness, and electric energy consumption under different machining conditions. Cutting speed and feed/tooth have significant effects on material removal rate, while surface quality is mainly influenced by radial depth of cut and feed/tooth. Linear regression models generated from the results show good reliability in predicting and optimizing MRR, EEC, and Ra-wall and Ra-bottom.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Industrial
Ritam Sarma, Amit Kumar Singh, Sajan Kapil, Swarup Bag, Shrikrishna N. Joshi
Summary: This study proposes the application of wire-arc-based directed energy deposition (DED) for building up three-dimensional structures of low-carbon steel. A classical trochoidal trajectory-based toolpath is used to rapidly build up structures with near homogeneous mechanical properties. The deposition process results in a uniform distribution of grains with degenerate pearlite phases, which is unusual for low-carbon steel. The built-up part exhibits improved mechanical properties, with uniform hardness and tensile strength, as well as enhanced elongation and wear resistance compared to the base material. The study presents a novel methodology for achieving near isotropic properties in arc-based DED process.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Engineering, Mechanical
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: The sustainability of biomaterials depends on their interaction with substances in the human body, and their surface roughness parameters and mechanical properties play a role in reducing degradation and enhancing lifespan. The Magnetorheological Fluid Assisted Finishing (MFAF) process can improve the quality of biomaterials' surface through nano-level average surface roughness. The wear resistance and corrosion resistance of the biomaterials were tested, and it was found that the MFAF process improved their performance.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2022)
Article
Engineering, Manufacturing
Manjesh Kumar, Manas Das
Summary: This article presents a method for precisely finishing narrow ridge profiles of poppet valves using the rotational-magnetorheological fluid-based finishing process. The impact of process parameters is determined through statistical analysis and simulation of finishing forces. The results show that the finished poppet valves have a smaller surface roughness and may have a longer service life and improved wear and corrosion resistance.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Engineering, Multidisciplinary
Anwesa Barman, Manas Das, Vimal Kumar Pathak
Summary: This study investigated the potential of magnetic field assisted finishing (MFAF) in the precise finishing of bio-titanium alloy femoral knee implants at the nanometric level. By using response surface methodology and fuzzy logic model, the study established prediction models and analyzed the impact of parameters on surface roughness. An improved salp swarm algorithm (ISSA) was proposed for further optimizing the final surface roughness, resulting in a significant improvement in surface finish compared to default experimental trials.
INTERNATIONAL JOURNAL OF MODELLING AND SIMULATION
(2022)
Article
Engineering, Mechanical
Manjesh Kumar, Manas Das, Nan Yu
Summary: This article introduces a new flow restrictor for precise polishing of miniature gear profiles in the rotational-magnetorheological process, investigates the effects of key factors on polishing performance using response surface method and simulation in COMSOL® software, aiding in accurately understanding the processing mechanism.
JOURNAL OF THE BRAZILIAN SOCIETY OF MECHANICAL SCIENCES AND ENGINEERING
(2022)
Article
Engineering, Manufacturing
Atul Singh Rajput, Ambrish Singh, Sajan Kapil, Manas Das
Summary: This paper presents a method called magnetorheological fluid assisted finishing (MFAF) for achieving a mirror-like polished surface. By using trochoidal toolpaths, the surface quality can be significantly improved. The impact of different process parameters on the surface quality is analyzed and optimized using experiments and response surface methodology (RSM). The biocompatibility of the polished surface is also investigated.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Multidisciplinary
Manjesh Kumar, Manas Das
Summary: This article reports on a novel method for uniformly polishing narrow poppet valve profiles to reduce hydrocarbon emissions in aerospace gas propulsion engines. By using different combinations of magnetorheological polishing (MRP) fluid, precise finishing of Nickel aluminium bronze poppet profiles is achieved, resulting in ultrafine surface roughness.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2022)
Article
Engineering, Mechanical
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: The sustainability of biomaterials depends on their interaction with substances in the human body, and their surface roughness parameters and mechanical properties play a role in reducing degradation and enhancing lifespan. The Magnetorheological Fluid Assisted Finishing (MFAF) process can improve the quality of biomaterials' surface through nano-level average surface roughness. The wear resistance and corrosion resistance of the biomaterials were tested, and it was found that the MFAF process improved their performance.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2022)
Article
Materials Science, Multidisciplinary
Hari Narayan Singh Yadav, Alok Kumar Das, Manas Das
Summary: This study focuses on the morphology, shape, and size of NPs in nanotechnology. The production of tungsten carbide nanoparticles and the tool wear rate were investigated under different voltage and duty factors in two different dielectrics, EDM oil and kerosene. The results showed that the generation of NPs and tool wear rate increased with an increase in voltage at a constant duty factor. Using EDM oil generated more NPs and less carbide compared to kerosene.
ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES
(2023)
Article
Engineering, Chemical
Ambrish Singh, Atul Singh Rajput, Sajan Kapil, Manas Das
Summary: This work focuses on the parameter sensitivity analysis of the Discrete Element Method (DEM) simulation for bladed centrifugal spreader dispersing metallic powder. The study finds that the coefficient of static friction (COSF) plays a dominant role in the spatial particle distribution, while the temporal distribution is strongly affected by COSF, coefficient of rolling friction (CORF), and their interaction with the coefficient of restitution (COR).
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
Sadaival Singh, Ambrish Singh, Sajan Kapil, Manas Das
Summary: Toolpath planning is crucial in Additive Manufacturing (AM). This paper proposes a TSP-based algorithm for efficient and accurate area filling with minimum tool retractions and turns. The digitization process is explored to generate grid points, and a novel method for reducing turns in the toolpath is introduced. The proposed path planning method allows for orientation of the toolpath, favoring one direction of motion over the other.
ADDITIVE MANUFACTURING
(2022)
Article
Engineering, Mechanical
Atul Singh Rajput, Manas Das, Sajan Kapil
Summary: Hybrid Chemo-Magnetorheological Finishing (HC-MRF) process combines Magnetorheological Finishing and chemical etching to improve the surface roughness of cemented carbide cutting tools. Murakami's reagent is used as the medium for chemical etching and mechanical abrasion. Process parameters are optimized using Response Surface Methodology (RSM) and Genetic Algorithm (GA) to achieve the best surface quality. The most significant parameter is the vol.% of Murakami's reagent in the MR fluid.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
(2023)
