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Dive into the research topics where I.A. Palani is active.

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Featured researches published by I.A. Palani.


Materials and Manufacturing Processes | 2014

On Use of Pulsed-Electrochemical Honing to Improve Micro-Geometry of Bevel Gears

Sunil Pathak; Neelesh Kumar Jain; I.A. Palani

Accuracy in micro-geometry is an important issue for gears because it affects noise generation and transmission characteristics and consequently determines the operating performance and service life of the gears. Various post-manufacturing processes are required to achieve the desired level of accuracy in micro-geometry of the gears. This paper reports on use of pulsed-electrochemical honing (PECH) process to improve micro-geometry of the straight bevel gears and presents experimental optimization of three important parameters of PECH namely pulse-on time, pulse-off time, and finishing time. Seventeen experiments were conducted according to central composite rotatable approach of response surface methodology. The improvements in micro-geometry of bevel gears in terms of average percentage improvement in single pitch error, adjacent pitch error, cumulative pitch error, and in total runout were found as 34.22%, 39.58%, 13.34%, and 18.88%, respectively. These improvements are better than those achieved using constant power supply due to efficient cleaning of the narrow inter-electrode gap during pulse-off time. These improvements lead to improve the gear quality up to seven for Deutsche Normen standard. Optimized values of input parameters for achieving these results are pulse-on time (2 ms), pulse-off time (4.5 ms), and finishing time (6 min).


Materials and Manufacturing Processes | 2015

Process Performance Comparison of ECH and PECH for Quality Enhancement of Bevel Gears

Sunil Pathak; Neelesh Kumar Jain; I.A. Palani

This paper presents a comparative analysis of constant-current electrochemical honing (ECH) and pulsed electrochemical honing (PECH) for quality enhancement of straight bevel gears. The quality of straight bevel gears after finishing by ECH and PECH is compared focusing on tooth flank finish and microgeometry. Tooth flank finish was evaluated in terms of percentage enhancement in average roughness value, maximum roughness value, and 5-point roughness value. Percentage enhancements in pitch error, pitch variation error, accumulated pitch error, and total runout were used to evaluate the microgeometry of the bevel gears. It was found that the PECH process is capable of simultaneously enhancing the tooth flank finish and microgeometry of bevel gears by more than 50% as compared with ECH-finished bevel gears. The PECH-finished gears also exhibited superior microstructure as compared with ECH-finished gears. These improvements will enhance the service life and working performance of gears.


Materials and Manufacturing Processes | 2017

Effect of applied voltage and electrolyte parameters on pitch, runout, flank topology, and finishing productivity of the straight bevel gears in PECH process

Sunil Pathak; Neelesh Kumar Jain; I.A. Palani

ABSTRACT This paper describes improvements in the considered parameters of micro-geometry: flank surface topology and finishing productivity of 20MnCr5 alloy steel straight bevel gears through their finishing by pulsed electrochemical honing (PECH) process. Effects of three most important parameters of PECH process, namely applied voltage, electrolyte composition, and electrolyte concentration were investigated to identify their optimum values. Pre-identified values of other PECH parameters and an aqueous mixture of NaCl and NaNO3 as an electrolyte were used in the present work. Errors in pitch (i.e., single pitch error, adjacent pitch error, and cumulative pitch error) and runout were used to evaluate micro-geometry of the straight bevel gears while volumetric material removal rate was used to judge the finishing productivity of the PECH process. Topology of the gear tooth flank surface and microstructure of the best-finished bevel gears were also studied. The results revealed considerable improvements in the micro-geometry, flank surface topology, and microstructure of the bevel gears finished by PECH. Applied voltage of 8u2009V, electrolyte composition of 75u2009wt.% NaClu2009+u200925u2009wt.% NaNO3, and electrolyte concentration of 7.5u2009wt.% were identified as the optimum values to achieve simultaneous improvement in all the considered responses.


Transactions of The Institute of Metal Finishing | 2016

Experimental investigations on redefining the surface quality of bevel gears by pulsed electrochemical honing

Sunil Pathak; Neelesh Kumar Jain; I.A. Palani

This paper reports on the influence of electrolyte flow rate and rotary speed of workpiece on the quality of straight bevel gears finished by a pulsed electrochemical honing process. Electrolyte flow rate was varied at four levels and rotary speed at three levels. The quality of bevel gear was studied in terms of the percentage variations in three surface roughness parameters (i.e. centre line roughness, maximum height of roughness and average maximum height of roughness), microgeometry parameters (i.e. variation in pitch and runout) and surface topography (i.e. vertical deviation from the ideal flank surface of gear tooth). Pre-identified values of electrolyte composition, pulse-on time, pulse-off time and finishing time were used. Microstructure and microhardness of the best finished gear were also studied. The optimised values of electrolyte flow rate (20u2005Lpm) and rotary speed of workpiece gear (40u2005rpm) yielded significant percentage enhancements in surface roughness parameters i.e. 62.45% in Ra, 60.58% in Rt and 53.98% in Rz, in addition improvement in microgeometry and surface topography enhanced bevel gear quality from DIN 8 to DIN 6 standard for the best finished gear.


Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture | 2016

Laser annealing of laser additive–manufactured Ni-Ti structures: An experimental–numerical investigation:

S. Shiva; I.A. Palani; Cp Paul; B. Singh

Tailored structures of Ni-Ti shape memory alloys for micro-electro-mechanical systems can be fabricated using laser additive manufacturing, and requisite homogeneous microstructure for predictive design and fabrication of micro-electro-mechanical systems devices can be achieved by annealing. Investigation has been performed on the laser annealing of laser additive–manufactured Ni-Ti structures using a pulsed green laser through numerical simulation and experimental studies. The parametric dependence showed that a laser energy density of 1100u2009mJu2009cm−2 has a considerable influence in annealing of Ni-Ti structures. The surface morphology, phase transformation temperature and microstructure of laser-annealed Ni-Ti structures were studied with scanning electron microscopy, differential scanning calorimetry, X-ray diffraction and atomic force microscopy. Laser energy density of 1100u2009mJu2009cm−2 was used for annealing the samples as identified in the simulation. Surface annealing of Ni-Ti led to a uniform surface of the material with an increase in grain size and surface roughness. A decrease in the micro-hardness of the samples was obtained as a result of laser annealing. Thus, the investigations demonstrated the improved properties of laser additive–manufactured Ni-Ti structures by laser annealing.


Archive | 2019

Comparative Investigation on the Effects of Laser Annealing and Laser Shock Peening on the As-Manufactured Ni–Ti Shape Memory Alloy Structures Developed by Laser Additive Manufacturing

S. Shiva; I.A. Palani; C. P. Paul; B. Singh

An indigenously developed laser additive manufacturing (LAM) system was deployed to fabricate complex structures of Ni–Ti shape memory alloys. LAM is opted for samples development as it gives the advantage of fabricating complex structure precisely as per the requirement with good composition control. As-made samples were brought under two different surface processing techniques of laser annealing (LA) and laser shock peening (LSP). In general, LA is carried out to reduce the residual stress to improve the sample’s functional life, and LSP is done to induce compressive stress in the samples to improve the fatigue life and prevent the samples from fracture. Wide research has been done in the past to find the effects of LA and LSP on the samples to characterize the improvement of the samples in their respective accord. Both LA and LSP were carried out using pulsed green Nd:YAG laser. Since Ni–Ti is a shape memory alloy (SMA), there is no much exposure about the shape memory property of the sample before and after LA and LSP. In this chapter, an attempt has been made to investigate the surface morphology, crystallinity and shape memory effect of Ni–Ti fabricated by LAM. Obtained results are homogenous microstructure, good crystalline nature and better shape memory effects through LA or LSP. The surface morphology, phase transformation temperature and microstructure of laser annealed Ni–Ti structures were studied with scanning electron microscopy (SEM), X-ray diffraction (XRD) and atomic force microscopy (AFM). Laser energy density of 1100 mJ/cm2 at 532 nm wavelength was used for LA. Same laser energy density at 1064 nm wavelength was used for LSP. Novel output regarding the shape memory nature of the materials was obtained.


The International Journal of Advanced Manufacturing Technology | 2016

Investigations on surface quality, surface integrity and specific energy consumption in finishing of straight bevel gears by PECH process

Sunil Pathak; Neelesh Kumar Jain; I.A. Palani


Journal of Materials Processing Technology | 2016

Investigations on phase transformation and mechanical characteristics of laser additive manufactured TiNiCu shape memory alloy structures

S. Shiva; I.A. Palani; Cp Paul; S.K. Mishra; B. Singh


Archive | 2014

Improving Surface Quality of Bevel Gears by Pulsed-Ech Process

Sunil Pathak; Neelesh Kumar Jain; I.A. Palani


Archive | 2016

Investigations on the performance characteristics of straight Bevel gears by Pulsed Electrochemical Honing (PECH) process

Sunil Pathak; I.A. Palani

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Neelesh Kumar Jain

Indian Institute of Technology Indore

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Sunil Pathak

Indian Institute of Technology Indore

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B. Singh

Raja Ramanna Centre for Advanced Technology

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S. Shiva

Indian Institute of Technology Indore

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Cp Paul

Homi Bhabha National Institute

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Agnel D'Souza

Indian Institute of Technology Indore

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AgnelD’ Souza

Indian Institute of Technology Indore

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C. P. Paul

Raja Ramanna Centre for Advanced Technology

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Deepak Raj

Indian Institute of Technology Indore

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Mayur S. Sawant

Indian Institute of Technology Indore

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