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, 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
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, 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
Aref Azami, Ali Khoshanjam, Ramon Jerez-Mesa, Jordi Lluma-Fuentes, Jose Antonio Travieso-Rodriguez
Summary: Rotational abrasive finishing (RAF) is a new nano-finishing technique that utilizes stirring-blades and the workpiece to apply finishing forces. A theoretical model was proposed to gain deeper insights into the material removal mechanism, surface roughness prediction, and forces in the RAF process. The experimental results were in good agreement with the theoretical results, with a maximum error of about 24%. The initial theoretical assumptions were identified as the main reason for the difference between the two.
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
Automation & Control Systems
Atul Singh Rajput, Ambrish Singh, Sajan Kapil, Manas Das
Summary: A computer numerical controlled magnetorheological fluid assisted finishing process can super-finish metallic surfaces without human intervention. This study investigates different toolpath strategies and finds that the Trochoidal toolpath is the most suitable for the process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(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
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)
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
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
Multidisciplinary Sciences
Manjesh Kumar, Manas Das
Summary: This study investigates the super-finishing of glass-ceramic workpieces using rotational-magnetorheological glass-ceramic polishing (R-MRGP) process. Two different experimental setups are compared in terms of surface roughness, reflectance characteristics, topographical images, and material removal rate (MRR). Finite element analysis (FEA) is used to analyze the magnetic flux density, axial velocity, and shear stress. The study concludes that R-MRGP is a viable option for ultra-precision polishing of glass-ceramics, achieving excellent surface quality.
ARABIAN JOURNAL FOR SCIENCE AND 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
Manjesh Kumar, Rahul Kumar Bharti, Manas Das
Summary: This study utilized a novel uniform flow restrictor for the nano-finishing of miniature gears, ensuring consistent and precise polishing to improve gear surface quality. Experimental results showed that the new method effectively reduced surface roughness and completely eliminated manufacturing defects.
Article
Engineering, Mechanical
Manpreet Singh, Sunil Kumar Paswan
Summary: Aluminium is a versatile engineering material widely used in various industries. The aluminium cylindrical roller plays a significant role in printing machines, but achieving uniform and fine finishing is challenging using conventional methods. Therefore, the rotary magnetorheological method is employed to optimize the finishing parameters and validate the surface texture and geometric measurements.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(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, Mechanical
Manjesh Kumar, Rahul Kumar Bharti, Manas Das
Summary: This study utilized a novel uniform flow restrictor for the nano-finishing of miniature gears, ensuring consistent and precise polishing to improve gear surface quality. Experimental results showed that the new method effectively reduced surface roughness and completely eliminated manufacturing defects.
Article
Engineering, Manufacturing
Manjesh Kumar, Anupam Alok, Vikash Kumar, Manas Das
Summary: Surface quality is crucial for product durability and functionality, with conventional finishing methods often causing defects. Advanced finishing techniques, using or not using magnetic fields, play a key role in processing complex products. The selection of polishing particles is essential for ultra-fine finishing of complex free-form products.
MATERIALS AND MANUFACTURING PROCESSES
(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
Automation & Control Systems
Atul Singh Rajput, Ambrish Singh, Sajan Kapil, Manas Das
Summary: A computer numerical controlled magnetorheological fluid assisted finishing process can super-finish metallic surfaces without human intervention. This study investigates different toolpath strategies and finds that the Trochoidal toolpath is the most suitable for the process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(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)
Proceedings Paper
Materials Science, Multidisciplinary
Abhinav Kumar, Manjesh Kumar, Hns Yadav, Manas Das
Summary: This paper investigates the effects of two different tool tips in the electrochemical micromachining process. By simulating and modeling in COMSOL Multiphysics (R) software, it is observed that the ball end provides better machining results with a more uniform current distribution and more effective removal of debris particles from the interelectrode gap.
MATERIALS TODAY-PROCEEDINGS
(2022)
Article
Multidisciplinary Sciences
Manjesh Kumar, Manas Das
Summary: This study investigates the super-finishing of glass-ceramic workpieces using rotational-magnetorheological glass-ceramic polishing (R-MRGP) process. Two different experimental setups are compared in terms of surface roughness, reflectance characteristics, topographical images, and material removal rate (MRR). Finite element analysis (FEA) is used to analyze the magnetic flux density, axial velocity, and shear stress. The study concludes that R-MRGP is a viable option for ultra-precision polishing of glass-ceramics, achieving excellent surface quality.
ARABIAN JOURNAL FOR SCIENCE AND ENGINEERING
(2022)
Article
Engineering, Multidisciplinary
Junichi Kouguchi, Hayato Yoshioka
Summary: A new monitoring method for milling process using signal analysis of acceleration sensors is proposed in this research, which can solve the difficulty in estimating cutting forces for small diameter tools.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Weijie Wang, Yanling Tian, Zhao Zhang, Zhilai Lu, Fujun Wang, Dawei Zhang
Summary: This paper proposes a comprehensive model for predicting the cutting depth and contact area in nanoscratching. The model takes into account the geometric shape of the indenter and elastic recovery, reducing prediction errors. The study also analyzes the influence of the indenter geometry on the contact area, with the face angle of the pyramid identified as a key factor.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Qiaolin Li, Yuki Shimizu, Xiaohao Wang, Xinghui Li, Wei Gao
Summary: This paper introduces a stitching linear scan method for roundness and diameter measurement of small cylinders, using a ruby ball stylus as hardware filtering to eliminate the influence of high-frequency data. Experimental results show that the repeatability of the ruby ball stylus is better than the diamond stylus.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Chaturaporn Kerdkaew, Surasak Kaewpho, Sakchai Chomkokard, Theera Yaemglin, Ittipon Cheowanish, Noparit Jinuntuya, Wiwat Wongkokua
Summary: A new calibration standard for a CMOS-based autocollimator using an optical angle generator with a submillimeter strip reflector (OAG-SSR) is proposed. This method provides angular values along the measuring range of the autocollimator without any mechanical movement, enabling a faster calibration process, which is suitable for integration with production lines.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Haohao Tao, Tongjie Li, Feng Chen, Jinwei Fan, Ri Pan
Summary: In this paper, a novel OTA method is proposed that considers the relationship between tolerance of machine tools' key parts and volumetric error. A volumetric error prediction model is established based on the bridge between geometric error and tolerance. Additionally, a Processing Simplicity Index (PSI) is introduced to replace manufacturing cost and a tolerance-PSI model is established. An OTA model is formulated to minimize volumetric error and maximize PSI. The feasibility and effectiveness of the method are validated through simulations and experiments.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Xiumin Zhang, Jianhua Liu, Huanxiong Xia, Xiaohui Ao, Jiechen Zhou, Zhihao Fu
Summary: A comprehensive finite-element model was developed in this paper to study the evolution of surface figure in high-precision bonded mirrors. The cure kinetics and mechanical behaviors of the optical adhesive were experimentally examined and modeled, and the effects of environmental factors on the surface-figure accuracy and stability were further investigated.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Peng Wang, Bin Chen, Jian Li, Jianwei Wang, Yingjie Zhang, Kai Feng
Summary: This paper proposes an aerostatic bearing with damper modules to suppress vibration on the bearing surface. The stiffness and damping characteristics can be adjusted by changing the thickness of the sheets, resulting in effective vibration suppression.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Lei Yang, Xiaoguang Guo, Renke Kang, Xianglong Zhu, Yufan Jia, Hao Wang
Summary: This paper develops an analytical model that takes into account the pad surface morphology to predict the evolution of the workpiece surface shape. The model considers the cross-scale relationship between the formation of lapped surface shape and the scratching process of a single abrasive grain. The simulated and experimental results validate the correctness and validity of the model, providing new ideas for controlling the workpiece surface.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Gabriele Piscopo, Alessandro Salmi, Eleonora Atzeni
Summary: This paper proposes an artifact for the LP-DED process and evaluates its dimensional accuracy and geometrical tolerances. The findings show that the tolerances of the LP-DED process are comparable to sand casting, lower than LB-PBF technologies, but similar to EB-PBF technologies.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Liang Xue, Ningsong Qu
Summary: This study focuses on the key issues of improving material removal rate and surface quality in macro-electrolyte jet machining. By introducing a novel tool with the rear-end tilted, the current density of the workpiece surface can be increased, leading to improved machining performance. Experimental results show that the tool with a rear-end tilt angle of 15 degrees significantly enhances the material removal rate and reduces surface roughness compared to the standard tool.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Ping Yang, Kaixin Luo, Runxi Wu
Summary: This article proposes a new calibration device to measure the spatial errors of a six-axis serial robot. The device compensates for errors by modifying angles and identifying stiffness parameters, and experiments verify its effectiveness.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Shilei Wu, Mingxiang Ling, Yingbin Wang, Tao Huang
Summary: This paper studies the electromechanical behavior of elliptical APAs by analyzing the multi-domain dynamics of piezoelectric stacks and compliant mechanisms using a novel electro-mechanical transfer matrix method. An analytical electro-elasto transfer matrix of piezoelectric stacks operating at the d33 mode is derived in the form of Taylor's series. The dynamic response spectrum of displacement and impedance for elliptical APAs is accurately captured by this electro-mechanical model, and different topologies of elliptical APAs are compared to suggest the optimal configuration.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Lei Meng, Yusheng Liu, Ying Yan, Dongming Guo, Ping Zhou
Summary: This study explores electrochemically induced chemical etching (ECICE) as a method to achieve nanogram-level, low-cost, stress-free, and stable material removal of fused quartz. The key factors affecting removal minimum and stability are revealed through modeling analysis and testing. A proposed method achieves precision stable removal with satisfactory results at the nanogram level.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Hong Yao, Hai Bi, Junjie Wei, Shuo Zhan, Fangxin Chen, IEEE
Summary: This paper presents a dual-loop control syringe-based picoliter-scale injection system for high-precision microinjection. The system utilizes an inner pneumatic servo loop and an outer position servo loop to achieve precise control. The experimental results demonstrate that the system can regulate the smallest droplet size to within 0.25 pL.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
Article
Engineering, Multidisciplinary
Jinchun Yuan, Jiasheng Li, Ye Ding
Summary: In this paper, a simple and effective internal model control (IMC) system is proposed to attenuate thrust ripples in ultraprecision air-bearing linear feed systems, based on a modified modeling and identification method of permanent magnet linear synchronous motors (PMLSMs). The performance of the proposed method in overcoming nonlinearity and achieving smooth velocities in steady states is demonstrated through analysis and experiments.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2024)
