Articles written in Sadhana

    • Optimization in CNC end milling of UNS C34000 medium leaded brass with multiple surface roughnesses characteristics

      Bharat Chandra Routara Saumya Darsan Mohanty Saurav Datta Asish Bandyopadhyay Siba Sankar Mahapatra

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      The present study highlights a multi-objective optimization problem by applying utility concept coupled with Taguchi method through a case study in CNC end milling of UNS C34000 medium leaded brass. The study aimed at evaluating the best process environment which could simultaneously satisfy multiple requirements of surface quality. In view of the fact, the traditional Taguchi method cannot solve a multi-objective optimization problem; to overcome this limitation, utility theory has been coupled with Taguchi method. Depending on Taguchi’s Lower-the-Better (LB) response criteria; individual surface quality characteristics has been transformed into corresponding utility values. Individual utility values have been aggregated finally to compute overall utility degree which serves as representative objective function for optimizing using Taguchi method. Utility theory has been adopted to convert a multi-response optimization problem into a single response optimization problem; in which overall utility degree serves as the representative single objective function for optimization. The study of combined utility theory and Taguchi method for predicting optimal setting. Based on Taguchi’s Signal-to-Noise ratio (S/N), analysis has been made on the overall utility degree and optimal process environment has been selected finally which corresponds to highest S/N Ratio. Optimal result has been verified through confirmatory test. The case study indicates application feasibility of the aforesaid methodology proposed for multiresponse optimization and off-line control of multiple surface quality characteristics in CNC end milling.

    • Powder-mixed electro-discharge machining performance of Inconel 718: effect of concentration of multi-walled carbon nanotube added to the dielectric media


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      The present work reports an experimental investigation on Powder-Mixed Electro-Discharge Machining (PMEDM) of Inconel 718 superalloy using Multi-Walled Carbon Nanotubes (MWCNTs) dispersed in kerosene, as dielectric media. Effects of variation of peak discharge current along with concentration of carbon nanotubes in the dielectric fluid are studied in purview of machining performance indicators including material removal efficiency, tool wear rate, and surface integrity of the machined part. The obtained results are compared to that of conventional EDM which utilizes kerosene as dielectric media. Morphology and topography, these two aspects of machined surface integrity are deliberated. The following surface morphological features: uneven fusion structure, globules of debris, molten metal deposition, surface cracks, pockmarks, and recast layer are identified. Topographical study includes surface roughness, severity of surface cracking, recast layer thickness, transfer of foreign elements, surface metallurgical characteristics, residual stress, and microindentationhardness. It is observed that application of MWCNT mixed dielectric media substantially improves EDM performance of Inconel 718 over conventional EDM. This is due to excellent thermo-physical properties of carbon nanotubes.

    • Machinability of Ti-5Al-2.5Sn for electro-discharge machining: an experimental investigation


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      Present work attempts to investigate machinability of Ti-5Al-2.5Sn for Electro-Discharge Machining (EDM). Extent of machinability is determined through material removal efficiency, tool wear rate, and surface integrity of the EDMed specimen of Ti-5Al-2.5Sn. Detailed analysis of surface morphology followed by study of surface topographical features including surface roughness, crack density, thickness of the recast layer, foreign material migration, metallurgical phase, residual stress, and micro-indentation hardness are carried out. Disappointing morphology is noticed for EDMed work surface at higher values ofpeak current as well as pulse-on time values. It is experienced that occurrence of surface cracks depends on recast layer thickness. As compared to ‘as received’ workpiece exhibiting compressive residual stresses, tensile stresses are found induced after performing EDM operation. Similar phenomenon is experienced incase of tool electrode. EDM operation improves microhardness of the machined surface. For Ti-5Al-2.5Sn,such improvement is nearly three times than that of ‘as received’ work material. During EDM operation on Ti-5Al-2.5Sn, titanium carbide is formed over tool as well as work surface. Formation of such hard carbidesmay degrade machining efficiency

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