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Mandal, Bijoy
- Improving Grindability of Inconel-600
Abstract Views :380 |
PDF Views:3
Authors
Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, IN
2 Department of Mechanical Engineering, Jadavpur University, Kolkata- 700 032, IN
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, IN
2 Department of Mechanical Engineering, Jadavpur University, Kolkata- 700 032, IN
Source
Journal of the Association of Engineers, India, Vol 85, No 3-4 (2015), Pagination: 15-26Abstract
Conventional fluid delivery system is not much effective to reduce heat generation due to presence of a stiff air layer covering the periphery of grinding wheel. Thermal damages in grinding a super alloy are stringent and problematic. In this paper, a report on the experimental investigation carried out on grinding a nickel based super alloy, Inconnel-600 is made. Different infeeds are considered with dry, wet and wet with pneumatic barrier conditions. To break the stiff air layer covering grinding wheel, high pressure air jet is employed just above the conventional grinding fluid nozzle to facilitate grinding fluid reach the wheel-workpiece interface area. This is termed as a pneumatic barrier. Grinding performance under these environmental conditions has been investigated. Results show better grinding performance with the application of pneumatic barrier in the wet condition as it tends to facilitate fluid reach deep inside the grinding zone effectively.Keywords
Surface Grinding, Grinding Fluid, Air Layer, Pneumatic Barrier; Grinding Chip, Surface Roughness, Grinding Forces, Flood Cooling Nozzle, Pneumatic Barrier Nozzle, Inconnel-600.- Influence of Using Rexine-Pasted Wheel or Pneumatic Barrier on Air Layer Pressure around a Grinding Wheel
Abstract Views :324 |
PDF Views:0
Authors
Bijoy Mandal
1,
Santanu Das
1
Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani, Nadia – 741235, West Bengal, IN
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani, Nadia – 741235, West Bengal, IN
Source
Journal of the Association of Engineers, India, Vol 84, No 1-2 (2014), Pagination: 61-68Abstract
In grinding, high heat is generated at the grinding zone per unit volume of material removed. To control this temperature, generally, grinding fluid is employed. Due to formation of a stiff air layer around the grinding wheel, grinding fluid cannot enter easily inside the grinding zone. In this experimental work, formation of air layer around a rotating grinding wheel has been investigated to observe variation of air layer pressure around the wheel periphery under different wheel speeds. Bare wheel, rexine-pasted wheel and bare wheel with pneumatic barrier set up have been employed to find out their effect on formation of air layer. Significantly less air layer pressure is noted around the wheel with both faces rexine-pasted, and using pneumatic barrier set up. In aggregate, about 50% reduction in the air layer pressure is achieved in the pneumatic barrier set up compared to that with the rexine-pasted wheel. Pneumatic barrier set up is thus quite effective to facilitate grinding fluid reach deep inside the grinding zone.Keywords
Grinding, Grinding Wheel, Air Layer, Rexine-Pasted Wheel, Pneumatic Barrier, Compressed Air.- Grinding Performance Using a Compound Nozzle Characterised by Small Discharge of Fluid
Abstract Views :344 |
PDF Views:0
Authors
Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, IN
2 Department of Mechanical Engineering, Jadavpur University, Kolkata-700032, IN
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, IN
2 Department of Mechanical Engineering, Jadavpur University, Kolkata-700032, IN
Source
Journal of the Association of Engineers, India, Vol 83, No 1 (2013), Pagination: 28-35Abstract
High grinding zone temperature often results in several grinding defects. For controlling this, usually large amount of grinding fluid is applied. However, synthetic grinding fluid or cutting fluid has some adverse impact on environment, and, hence, researchers are trying to reduce the application of grinding fluid. In this experimental investigation, a specially developed compound nozzle is used for delivering grinding fluid. Fluid may reach easily into grinding zone at low discharge by using this nozzle. Discharge of the nozzle is about 52% less than conventional flood cooling. Grinding results obtained under different environment are compared. It is found that better grinding performance is obtained by using this compound nozzle than conventional flood cooling grinding; as consumption of grinding fluid is substantially reduced, use of compound nozzle may be more economical and advantageous to control industrial pollution.Keywords
Surface Grinding, Compound Nozzle, Grinding Fluid, Surface Roughness, Flood Cooling.- A Comparative Study of Grinding Performance Using Different Fluid Delivery Techniques
Abstract Views :423 |
PDF Views:0
Authors
Affiliations
1 Dept. of Mechanical Engineering, Kalyani Government Engineering College, Kalyani–741 235, West Bengal, IN
1 Dept. of Mechanical Engineering, Kalyani Government Engineering College, Kalyani–741 235, West Bengal, IN
Source
Journal of the Association of Engineers, India, Vol 83, No 3-4 (2013), Pagination: 63-70Abstract
Grinding fluids, commonly termed as coolants, play a vital role in controlling the heat produced during the process and the consequent thermal damage associated with it. These fluids are to be applied into the grinding zone in a suitable and effective manner, so as to reduce the heat generated and to carry away the heat produced as well as for efficient chip disposal. In this work, three different methods, namely normal flood cooling, mist cooling and multi-nozzle cooling arrangements are employed for delivering the fluid into the grinding zone. A comparative study is made among the three coolant delivery systems to assess the grinding performance. It is found that the multi-nozzle cooling arrangement produces best results in terms of force requirement and ground surface quality.Keywords
Surface Grinding, Flood Cooling, Mist Cooling, Multi-Nozzle.- An Experimental Investigation on Surface Roughness Achieved During Abrasive Water-Jet Machining of Low Carbon Steel
Abstract Views :354 |
PDF Views:7
Authors
Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, West Bengal, IN
2 CSIR-Central Glass and Ceramic Research Institute, Jadavpur, Kolkata-700032, IN
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, West Bengal, IN
2 CSIR-Central Glass and Ceramic Research Institute, Jadavpur, Kolkata-700032, IN
Source
Journal of the Association of Engineers, India, Vol 87, No 1-2 (2017), Pagination: 26-32Abstract
In Abrasive Water Jet Machining (AWJM), abrasive particles suspended in high pressure water are impinged on work surface for removal of excess materials. A nozzle is fitted in front of workpiece to provide high velocity jet. In this work, appropriate machining condition is tried to evaluate to yield minimum surface roughness by employing Response Surface Methodology (RSM) while machining low carbon steel. Radius of curvature is also observed during abrasive water jet machining. A statistical model is generated for predicting surface roughness. It is observed that at low feed rate condition, better surface is obtained expectedly.Keywords
Abrasive Water Jet Machining, AWJM, Optimisation, Response Surface Methodology, RSM, Surface Roughness.References
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- Grinding of Titanium Using Alumina and Silicon Carbide Wheel
Abstract Views :265 |
PDF Views:7
Authors
Arnab Kundu
1,
Manish Mukhopadhyay
2,
Ayan Banerjee
2,
Sirsendu Mahata
2,
Bijoy Mandal
2,
Santanu Das
2
Affiliations
1 Department of Mechanical Engineering, JIS College of Engineering, Phase III, Kalyani-741235, West Bengal, IN
2 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani - 741235, West Bengal, IN
1 Department of Mechanical Engineering, JIS College of Engineering, Phase III, Kalyani-741235, West Bengal, IN
2 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani - 741235, West Bengal, IN
Source
Journal of the Association of Engineers, India, Vol 88, No 1-2 (2018), Pagination: 53-63Abstract
In the ever prospering manufacturing sector, titanium is considered as an important material due to its mechanical properties, but grinding of titanium is quite a challenging task that needs necessary attention in order to improve its grindability. Past research works reported the success of sub-zero degree cooling for enhancing grindability of several materials. The present experimental work explores the effect of application of environment friendly liquid CO2 during grinding of titanium grade I alloy compared to that under dry condition. Grindability of silicon carbide and alumina wheel is investigated and compared. Experimental results indicate that alumina wheel performs better with liquid CO2 than SiC wheel and that in dry condition while grinding titanium grade I. Therefore, liquid CO2 based cooling system may be used in industry with alumina wheel when grinding titanium grade I.Keywords
Grinding, Grindability, Sub-Zero, Cooling, Titanium, Alumina, SiC, CO2.References
- Pervaiz, S., Rashid, A., Deiab, I. and Nicolescu, C.M., An experimental investigation on effect of minimum quantity cooling lubrication (MQCL) in machining titanium alloy (Ti6Al4V), The International Journal of Advanced Manufacturing Technology, Vol. 87, No. 5-8, pp.1371-1386, 2016.
- Mahata, S., Mandal, B., Mistri, J. and Das, S., Effect of fluid concentration using a multi-nozzle on grinding performance, International Journal of Abrasive Technology, Vol. 6, No. 4, pp.257-268, 2012.
- Mahata, S., Mistri, J., Mandal, B. and Das, S., A comparative study of grinding performance using different fluid delivery techniques, Journal of the Association of Engineers, Vol. 83, No. 3-4, pp.63-70, 2013.
- Mandal, B., Das, G.C., Das, S. and Banerjee, S., Improving grinding fluid delivery using pneumatic barrier and compound nozzle, Production Engineering Research and Development, Vol. 8, No. 1-2, pp.187-193, 2014.
- Vazquez, E., Kemmoku, D.T., Noritomi, P.Y., Silva, J.V.L. and Ciurana, J., Computer fluid dynamics analysis for efficient cooling and lubrication conditions in micromilling of Ti6Al4V alloy, Materials and Manufacturing Processes, Vol. 29, No. 11-12, pp.1494-1501, 2014.
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- Guo, G., Liu, Z., An, Q. and Chen, M., Investigation on surface grinding of Ti-6Al-4V using minimum quantity lubrication, International Journal of Abrasive Technology, Vol. 5, No.3, pp.187-201, 2012.
- Sinha, M.K., Setti, D., Ghosh, S. and Rao, P.V., An alternate method for optimisation of minimum quantity lubrication parameters in surface grinding, International Journal of Machining and Machinability of Materials, Vol. 18, No. 5-6, pp.586-605, 2016.
- An, Q.L, Fu, Y.C. and Xu, J.H., Experimental study on the cooling effects of cryogenic pneumatic mist jet impinging cooling method, International Journal of Abrasive Technolgy, Vol. 1, No. 3/4, pp.241 – 250, 2008.
- Soni, S.K., Singh, V., Sahoo, A.K. and Ghosh, S., Improvement in grinding of composite ceramic by using cryogenic cooling technique, International Journal of Manufacturing Technology and Management, Vol. 25, No. 1/2/3, pp.60 – 77, 2012.
- Paul, S. and Ghosh, A., An experimental evaluation of solid lubricant based nanofluids in small quantity cooling and lubrication during grinding, Paper presented at the 5th International Conference on Material Science & Engineering Technology, University of Tokyo, Japan, 2016.
- Sahoo, A.K., Soni, S.K. Rao P.V. and Ghosh, S., Use of solid lubricants like graphite and MoS to 2 improve grinding of Ti-6Al-4V alloy, International Journal of Machining and Machinability of Materials, Vol. 12, No. 4, pp.297-307, 2012.
- Kundu, A., Mukhopadhyay, M., Mahata S., Banerjee, A., Mandal, B. and Das, S., Grinding Titanium grade 1 alloy with an alumina wheel using soap water, Procedia Manufacturing, Vol. 20, pp.338-343, 2018.
- Mahata, S., Kundu, A., Mukhopadhyay, M., Banerjee, A., Mandal, B. and Das, S., Exploring grindability of Inconel 718 using small quantity lubrication and cooling technique, Materials Today: Proceedings, Vol. 5, No. 2, Part 1, pp. 4523–4530, 2018.
- Nascimento, W.R., Yamamoto, A.A., Mello, H.J., Canarim, R.C., Aguiar, P.R. and Bianchi, E.C., A study on the viability of minimum quantity lubrication with water in grinding of ceramics using a hybrid-bonded diamond wheel, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, Vol. 230, No. 9, pp.1630-1638, 2016.
- Mandal, B., Singh, R., Das, S. and Banerjee, S., Improving grinding performance by controlling air flow around a grinding wheel, International Journal of Machine Tools and Manufacture, Vol. 51, No. 9, pp.670-676, 2011.
- Mandal, B., Singh, R., Das, S. and Banerjee, S., Development of a grinding fluid delivery technique and its performance evaluation, Materials and Manufacturing Processes, Vol. 27, No. 4, pp.436-442, 2012.
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- An Investigation on Deburring Performance for Drilling Burr Removal using EDM
Abstract Views :270 |
PDF Views:3
Authors
Affiliations
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, West Bengal, IN
1 Department of Mechanical Engineering, Kalyani Government Engineering College, Kalyani-741235, West Bengal, IN
Source
Journal of the Association of Engineers, India, Vol 89, No 3-4 (2019), Pagination: 35-43Abstract
Burrs are formed during various machining processes. These burrs result in difficulty in assembling operations. Being sharp, burrs may injure operators, cause electric short circuit problem, poor aesthetics of component, etc. So, deburring is commonly required to remove burrs. In the present work, drilling burrs formed on low alloy steel workpieces are tried to be removed by electro discharge machining. Electrolytic copper of 16.88 mm diameter is used as EDM tool which is made cathode and workpiece as anode. Parameters varied are peak current and pulse-on time whereas parameters such as duty factor, sparking time, lifting time, sensitivity, anti arcing, sparking gap voltage are kept constant. Peak currents are varied in the range of 4A-10A, and 50 ps, 100 ps, and 200 ps pulse-on time are taken. Initially sparking is found to be concentrated in a small area since only the burrs are attacked by the tool. When sparking spreads to the whole periphery of the tool, it indicates complete burr removal. The time taken for complete burr removal and surface roughness of specimen after deburring operation is measured. Some thickness loss of specimen has also been observed. Deburring time is found to be reduced with increase in peak current and pulseon time. At smaller values of peak current and pulse-on time, surface roughness and thickness loss are lower, but deburring time increases due to low energy of spark, which results in less heat generation and lesser melting and evaporation of burrs. Small depth of crater formed at low peak current and pulse-on time may be responsible for lower surface roughness. Parameters are optimized in order to obtain minimum deburring time, thickness loss and surface roughness.Keywords
EDM, Burr, Deburring, Deburring Time, Surface Roughness, Thickness Loss, RSM.References
- Aurich, J.C., Dornfeld, D., Arrazola, P.J., Franke, V., Leitz, L. and Min, S., Burrs-analysis, control and removal, CIRP Annals-Manufacturing Technology, Vol.58, pp.519-542,2009.
- Chakrabarti, B. and Das, S., Recent research works on burr minimization in milling, Reason-ATechnical Magazine, Vol.10, pp.31-36, 2011.
- Das, A., Kundu, S. and Das, S., Burr formation and minimization strategies in drilling and milling, E-proceedings of the National Conference on Advances in Mechanical Engineering, Hyderabad, India, pp.36-43, 2010.
- Mondal, N., Sardar, B.S., Haider, R.N. and Das, S., Observation of drilling burr and finding out the condition for minimum burr formation, International Journal of Manufacturing Engineering, pp.1-12, 2014.
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- An Investigation on Turning of Hard Steel using Coated Carbide Inserts
Abstract Views :334 |
PDF Views:3
Authors
Affiliations
1 Mechanical Engineering Department, Bankura Unnayani Institute of Engineering, Bankura-722146, IN
2 Mechanical Engineering Department, Kalyani Government Engineering College, Kalyani- 741235, IN
1 Mechanical Engineering Department, Bankura Unnayani Institute of Engineering, Bankura-722146, IN
2 Mechanical Engineering Department, Kalyani Government Engineering College, Kalyani- 741235, IN
Source
Journal of the Association of Engineers, India, Vol 90, No 1-2 (2020), Pagination: 47-55Abstract
Employing conventional machining operations in material removal type manufacturing processes for processing difficult-to-machine hard materials through some ways and means is the focus of research by machining research groups across the globe since long. This gives considerable advantages over the grinding process in terms of higher material removal rate, better surface integrity of the work surface, etc., although grinding is commonly used for material removal of quite hard materials along with their finishing. In this paper, machinability of hard AISI 4340 steel is explored employing groove-type chip breaking coated carbide inserts under various cutting velocity and feed at dry condition. Hardened AISI 4340 is considered to be a difficult-to-machine material, and hence, recommendable machining conditions need to be found out. Favourable flat continuous chip is acquired at a cutting velocity of 231 m/min and at a feed of 0.08 mm/rev. At 391 m/min cutting velocity, cutting edges are detected to have worn-out quite fast.Keywords
Machining, Turning, Cutting Force, Chip, Insert, Coated Carbide.References
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- Bouacha, K., Yallese, M.A., Mabrouki, T. and Rigal, J.F., Statistical analysis of surface roughness and cutting forces using response surface methodology in hard turning of AISI 52100 bearing steel with cBN tool, International Journal of Refractory Metals and Hard Materials, Vol.28, pp.349-369, 2010.
- Mondal, K, Das, S., Mondal, B. and Sarkar, D., An investigation on turning hardened steel using different tool inserts, Materials and Manufacturing Processes, Vol.31, pp. 1770-1781, 2016.
- Kumar, S. and Patel, S.Kr., Effect of chip sliding velocity and temperature on the wear behaviour of PVDAICrN andAITiN coated mixed alumina cutting tools during turning of hardened steel, Surface & Coating Technology, Vol.334, pp.509-525, 2018.
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- Zhao T., Zhou, J.M., Bushlya, V. and Stahl, J.E.; Effect of cutting edge radius on surface roughness and tool wear in hard turning of AISI 52100 steel; International Journal of Advanced Manufacturing and Technology, Vol.91, pp.3611-3618, 2017.
- Grezesik, W. and Wanat, T., Surface finish generated in HT of quenched alloy steel parts using conventional and wiper ceramic inserts, International Journal of Machine Tools and Manufacture, Vol.46, pp. 1988-1995, 2006.
- More, A.S., Jiang, W., Brown, W.D. and Malshe, A.P, Tool wear and machining performance of cBN-TiN coated carbide inserts and PCBN compact inserts in turning AISI 4340 hardened steel, Journal of Materials Processing Technology, Vol. 180, pp.253-262, 2006.
- Jiang, W., More, A.S., Brown, W.D. and Malshe, A.P, AcBN-TiN composite coating for carbide inserts: coating characterization and its application for finish hard turning, Surface & Coating Technology, Vol.201, pp.2443-2449, 2006.
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