Ashok Kumar Sahoo

Mathematical modelling and multi-response optimisation using response surface methodology and grey based Taguchi method: an experimental investigation

The present study deals with the application of full factorial design of experiment and response surface methodology in developing mathematical model considering input variables, i.e., cutting speed, feed and depth of cut for flank wear and surface roughness when hard turning AISI 4340 steel (HRC 47±1) using multilayer coated carbide insert (TiN/TiCN/Al2O3/ZrCN) under dry environment. Mathematical model output concluded that the RSM models proposed are statistically significant and adequate because of higher R2 value. It shows the high correlation between the experimental and predicted values. From ANOVA table, it is evident that, feed is the significant factor affecting surface roughness followed by cutting speed. Depth of cut is found to be insignificant from the studied range. For flank wear, cutting speed is the most significant factor followed by depth of cut. Feed is found to be insignificant for flank wear. The improvement of grey relational grade from initial parameter combination (d2-f3-v4) to th...

Performance assessment in hard turning of AISI 1015 steel under spray impingement cooling and dry environment

This work investigates the effects of cutting parameters on surface roughness (Ra, µm), cutting temperature (T, °C) at the chip–tool interface and the material removal rate during hard machining of AISI 1015 (43 ± 1 HRC) steel using carbide insert under dry and spray impingement cooling environment. A combined technique using orthogonal array and analysis of variance was employed to investigate the contribution of spindle speed, feed rate, depth of cut and air pressure on responses. It is observed that with spray impingement cooling, cutting performance improves compared to dry cutting. The predicted multi-response optimization setting (N3-f1-d1-P2) ensures minimization of surface roughness, cutting temperature and maximization of material removal rate.

Synthesis and characterization of Al & SiCp nano particles by non-contact ultrasonic assisted method

The present study deals with proper mixing of SiCp nano particle in the aluminum metal matrix in two stages of processing i.e. primary and secondary. During primary processing, the breaking of agglomeration of nano particles take place and these are mixed with liquid aluminum powder using high frequency(35kHz) mechanical vibration. But, during secondary processing, mixing of nano particles along with subsequent cooling take place using high frequency non contact ultrasonic method. The study also reveals that in the liquid metal nano particle were uniformly dispersed and the segregation of the particles near the grain boundaries is due to pushing of the nano particle during grain growth. The study was performed by taking aluminum as matrix and SiCp as reinforcement with weight fraction of 2% and 3% and SiCp particles sizes of 30nm each. Scanning electron microscopy(SEM) and X-ray diffraction(XRD) were conducted for characterization of nano composite material.The present study deals with proper mixing of SiCp nano particle in the aluminum metal matrix in two stages of processing i.e. primary and secondary. During primary processing, the breaking of agglomeration of nano particles take place and these are mixed with liquid aluminum powder using high frequency(35kHz) mechanical vibration. But, during secondary processing, mixing of nano particles along with subsequent cooling take place using high frequency non contact ultrasonic method. The study also reveals that in the liquid metal nano particle were uniformly dispersed and the segregation of the particles near the grain boundaries is due to pushing of the nano particle during grain growth. The study was performed by taking aluminum as matrix and SiCp as reinforcement with weight fraction of 2% and 3% and SiCp particles sizes of 30nm each. Scanning electron microscopy(SEM) and X-ray diffraction(XRD) were conducted for characterization of nano composite material.