Advanced Manufacturing Research Group

Research Interests

Research Collaborators

mypic/Dr. Pranjal Chandra
BSBE, IIT Guwahati
Laser based manufacturing: machining and forming mypic/Dr. Saurav Goel
Cranfield University, UK
Ultra-precision machining mypic/Prof P. J. Davim
University of Aveiro,Portugal
Manufacturing process modeling and optimization mypic/Prof. S. S. Pande
IIT Bombay, India
Mechatronics and manufacturing automation mypic/Prof. Alika Khare
IIT Guwahati, India
mypic/Prof. Uday S. Dixit
IIT Guwahati, India
mypic/Ms. Neha Khatri
mypic/Mr. Vinod Mishra

Research Overview

Numerical and experimental investigations on Laser bending process
Magnesium alloys have low density, high specific strength and stiffness, superior damping capacity, high thermal conductivity and good electromagnetic shielding characteristics. They are the lightest metals and are widely used in industries. In present work, experimental and numerical studies were carried out to assess the feasibility, productivity and product quality during laser based bending of magnesium alloys. Experimental studies were carried out to assess the feasibility of laser bending for magnesium alloy sheets. It was observed that the specimen did not catch fire for any set of process conditions. Experiments showed that magnesium alloys can be bent with laser bending process without much deterioration in mechanical properties. Numerical model was developed by considering temperature and strain rate dependent material properties and the effect of melting. A model based on standard beam propagation equations was used to obtain beam diameter from stand-off distance. The straight line, curvilinear and multi-scan laser bending of magnesium alloy M1A sheet was investigated by using developed numerical model. The effects of process parameters, viz. laser power, scan speed, beam diameter, scanning path curvature and number of scans on performance parameters such as temperature and stress-strain distribution, bend angle, edge displacement and edge effect were studied. It was observed that laser process parameters have a complex interactive non-linear effect on performance parameters. In curvilinear laser bending, it was found that bending does not occurs over the irradiation path and it has some offset towards outside of the scanning path. Multi-scan laser bending was able to generate a large bend angle up to 18º in ten scans. The change in bending mechanism, bend angle and edge effect with number of scans were explored during multi-scan laser bending process. A novel integrated, simple and efficient technique viz. laser assisted bending with moving pre-displacement load was proposed for bending of large sized sheets. The experimental setup was designed and developed to achieve the defined objectives. It was observed that the proposed technique was able to generate large bend angle in a scan. The numerical model was developed and validated for the proposed technique. The validated model was used to investigate the effects of laser power, scan speed, beam diameter and pre-displacement on the bending mechanism, edge displacement, residual stresses, bend angle, edge effect and spring-back effect during laser assisted bending with moving pre-displacement. The present research work contributed systematic and extensive numerical as well as experimental studies on laser bending of magnesium alloy M1A. mypic/

Process modelling and optimization of single point diamond turning
Single point diamond turning (SPDT) is an ultra-precision machining process. Understanding of the effect of process parameters of SPDT on its performance parameters such as machining forces, surface roughness, material removal rate (MRR) is important for improving the product quality and process efficiency. However, high capital and operating costs limit the extensive experimental studies of SPDT. Physics-based modeling and simulation provides a better way for understanding the machining processes under different cutting conditions. A need thus identified to develop an alternate and efficient process model to the costly and time consuming experimental studies of SPDT by using numerical techniques such as finite element method (FEM). Thus the main objective of the proposed work was derived to make a guideline for SPDT process of Silicon and Silicon Carbide as well as evaluate the surface quality during machining with SPDT. In the present work, nano-indentation simulations are carried out to determine the mechanical properties (such as hardness, Young’s modulus, fracture toughness etc.) of silicon and silicon carbide. This analysis will be used to determine the critical thickness for ductile to brittle transition. Based on this, numerical FE model has been developed for single point diamond turning of silicon and silicon carbide. The developed model is used to investigate effect of various process parameters such as cutting speed, feed/depth of cut, rake angle and edge radius on cutting force and thrust force. A comparative study on the performance of the numerical model with two different material models viz. Johnson-Cook (JC) and Drucker-Prager (DP) was carried for the assessment of generalized material model for finite element simulation of SPDT of silicon and silicon carbide. A new integrated finite element method-image processing techniques (FEM-IPT) has been developed to predict the surface roughness of the machined surface. For this purpose, a 3D turning simulation is carried out on Al6061-T6 aluminum alloy. Initially the surface roughness predicted from the FEM-IPT has been compared with the surface roughness due to tool feed marks obtained based on analytical computations. Experimental study has been carried out with available material i.e. Al6061 and resources for the experimental validation of developed integrated surface roughness model. mypic/

Efficient process planning for machining of thin wall components
I am currently a Ph.D student in mechanical engineering at IITG working with Prof. S.N. Joshi in the Advanced Manufacturing Laboratory (AML). My research focuses on precision machining of thin-wall components which are widely machined and used in automobile, aerospace, electronics and mould making industries. Main objective of the work was to develop strategies and guidelines for machining thin-wall components to help small and medium scale industries which have financial constraints and limited resources. The research focuses on analytical, finite element based simulation and experimental aspects of thin-wall machining process. Work has been carried out to understand the physics of thin-wall machining at lower speed which can be incorporated by small and medium scale industries. As a part of research work, structural and thermo-structural finite element modeling of machining thin-wall parts has been carried out. To further the understanding, analytical model has been developed which takes into account the material properties, cutting parameters and the tool parameters. On the practical front, experiments were conducted for simple and as well as complex wall geometries by varying the process and tool parameters. Soft computing based techniques were used to obtain optimal process parameters which can be used for practical applications. mypic/

Numerical and experimental investigations on Laser micro machining
Microfluidics is a common platform for people from engineering, physics, chemistry, nanotechnology and biotechnology to develop a system for studying the behavior of fluid and also for manipulating and controlling of fluid in channel of dimension in micro length scale. It has also wide impact on manufacturing sector for the challenges it face in production of channel in micro scale. My research area lies in laser micromachining of channel for microfluidics application. mypic/

Studies on electro-discharge deposition for tool repairs
High value surface components such as tools, turbine blades and internal combustion engine parts operating in stringent environmental conditions undergo high degradation of the surface such as wear, corrosion, etc. These have led to the increase in demand for advanced materials like nickel super alloys, aluminium/titanium alloys, high temperature steels etc, possessing high hardness, high toughness, high fatigue, corrosive resistant, wear resistant, etc. However, bulky work-parts or components entirely made up of these materials are not economical. Therefore, application of coating with required surface properties can be an alternative cost effective process. In view of this, surface alloying by Electrical Discharge Processing (EDP) is one of the developing non-traditional techniques used for alloying/surface modification of work material for obtaining specific functional characteristics like improved hardness, resistance to wear, erosion, indentation, corrosion, lubrication, reduce friction, etc and also for biomedical applications. mypic/

Thin Wall Machining
Thin wall machining is basically employed in aerospace and automobile industries as weight reduction is directly concerned with fuel efficiency. My research work is focused upon experimental investigations of important aspects of thin wall machining process such as deformation, surface roughness and low MRR. The main aim of this work is to obtain optimum values of different process parameters to increase the productivity of the process without compromisingthe quality by using various optimization tools such as genetic algorithm, firefly algorithm, NSGA-II. mypic/