Advances in Unconventional Machining and Composites Proceedings of AIMTDR 2018

Lecture Notes on Multidisciplinary Industrial Engineering

Series Editor J. Paulo Davim , Department of Mechanical Engineering, University of Aveiro, Aveiro, Portugal “Lecture Notes on Multidisciplinary Industrial Engineering” publishes special volumes of conferences, workshops and symposia in interdisciplinary topics of interest. Disciplines such as materials science, nanosciences, sustainability science, management sciences, computational sciences, mechanical engineering, industrial engineering, manufacturing, mechatronics, electrical engineering, environmental and civil engineering, chemical engineering, systems engineering and biomedical engineering are covered. Selected and peer-reviewed papers from events in these ﬁelds can be considered for publication in this series.

More information about this series at http://www.springer.com/series/15734 M. S. Shunmugam • M. Kanthababu Editors

123 Editors M. S. Shunmugam M. Kanthababu Manufacturing Engineering Section Department of Manufacturing Engineering Department of Mechanical Engineering College of Engineering, Guindy Indian Institute of Technology Madras Anna University Chennai, Tamil Nadu, India Chennai, Tamil Nadu, India

ISSN 2522-5022 ISSN 2522-5030 (electronic) Lecture Notes on Multidisciplinary Industrial Engineering ISBN 978-981-32-9470-7 ISBN 978-981-32-9471-4 (eBook) https://doi.org/10.1007/978-981-32-9471-4

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This Springer imprint is published by the registered company Springer Nature Singapore Pte Ltd. The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore AIMTDR 2018 Conference’s Core Organizing Committee

Patrons

Dr. M. K. Surappa, Vice Chancellor, Anna University Dr. J. Kumar, Registrar, Anna University

President (NAC-AIMTDR)

Mr. P. Kaniappan, Managing Director, WABCO India Ltd.

Vice-President (NAC-AIMTDR)

Dr. Uday Shanker Dixit, Professor, IIT Guwahati, India

Co-patrons

Dr. A. Rajadurai, Dean, MIT Campus, Anna University Dr. T. V. Geetha, Dean, CEG Campus, Anna University Dr. L. Karunamoorthy, Chairman, Faculty of Mechanical Engineering, Anna University Dr. S. Rajendra Boopathy, Head, Department of Mechanical Engineering, Anna University

v vi AIMTDR 2018 Conference’s Core Organizing Committee

Chairman

Dr. S. Gowri, Honorary Professor, Department of Manufacturing Engineering, Anna University

Co-chairman

Dr. P. Hariharan, Professor, Department of Manufacturing Engineering, Anna University

Organizing Secretary

Dr. M. Kanthababu, Professor and Head, Department of Manufacturing Engineering, Anna University

Joint Organizing Secretaries

Dr. M. Pradeep Kumar, Professor, Department of Mechanical Engineering, Anna University Dr. A. Siddharthan, Associate Professor, Department of Production Technology, Anna University

International Scientiﬁc Committee

Prof. Abhijit Chandra, Iowa State University, USA Prof. Ajay P. Malshe, University of Arkansas, USA Prof. Andrew Y. C. Nee, NUS, Singapore Prof. Chandrasekar S., Purdue University, USA Prof. Dean T. A., University of Birmingham, UK Prof. Hong Hocheng, National Tsing Hua University, Taiwan Prof. John Sutherland, Purdue University, USA Prof. Kamlakar P. Rajurkar, University of Nebraska, USA Prof. Kornel Ehmann, Northwestern University, USA Prof. Liao Y. S., National Taiwan University, Taiwan Prof. McGeough J. A., University of Edinburgh, UK Prof. Mustaﬁzur Rahman, NUS, Singapore AIMTDR 2018 Conference’s Core Organizing Committee vii

Prof. Philip Koshy, McMaster University, Canada Prof. Rakesh Nagi, University of Buffalo, USA Prof. Shiv Gopal Kapoor, University of Illinois, USA Prof. Srihari Krishnasami, Binghamton University, USA Prof. Tae Jo Ko, Yeungnam University, South Korea Prof. Tugrul Ozel, State University of New Jersey, USA

National Advisory Committee

Prof. Ahuja B. B., Government College of Engineering Pune Prof. Amitabha Ghosh, BESU Prof. Bijoy Bhattacharyya, Jadavpur University, Kolkata Prof. Biswanath Doloi, Jadavpur University, Kolkata Prof. Chattopadhyay A. K., IIT Kharagpur Prof. Deshmukh S. G., IIT Gwalior Shri. Dhand N. K., MD, Ace Micromatic, Bangalore Prof. Dixit U. S., IIT Guwahati, Guwahati Prof. Jain P. K., IIT Roorkee, Roorkee Prof. Jain V. K., IIT Kanpur Prof. Jose Mathew, NIT Calicut Shri. Lakshminarayan M., WABCO India Ltd. Prof. Lal G. K., IIT Kanpur Prof. Mehta N. K., IIT Roorkee Prof. Mohanram P. V., PSG Institute of Technology and Applied Research Shri. Mohanram P., IMTMA, Bangalore Dr. Mukherjee T., Tata Steel Ltd., Jamshedpur Shri. Muralidharan P., Lucas TVS Ltd., Vellore Prof. Narayanan S., VIT University, Vellore Mr. Niraj Sinha, Scientist ‘G’, PSA, GOI Prof. Pande S. S., IIT Bombay, Mumbai Dr. Prasad Raju D. R., MVGREC Prof. Radhakrishnan P., PSG Institute of Advanced Studies, Coimbatore Prof. Radhakrishnan V., IIST, Trivandrum Prof. Ramaswamy N., IIT Bombay (Former) Prof. Ramesh Babu N., IIT Madras Shri. Rangachar C. P., Yuken India Ltd., Bangalore Prof. Rao P. V., IIT Delhi Dr. Santhosh Kumar, IIT BHU Dr. Sathyan B. R., CMTI, Bangalore Prof. Satyanarayan B., Andhra University (Former) Prof. Selvaraj T., NIT Trichy Prof. Shan H. S., IIT Roorkee (Former) Prof. Shunmugam M. S., IIT Madras viii AIMTDR 2018 Conference’s Core Organizing Committee

Shri. Shirgurkar S. G., Ace Designers Ltd., Bangalore Dr. Sumantran V., Celeris Technologies Dr. Suri V. K., BARC, Mumbai Shri. Venu Gopalan P., DRDL Hyderabad Prof. Vinod Yadav, Motilal Nehru National Institute of Technology, Allahabad Foreword

It gives us immense pleasure to present the Advances in Manufacturing Technology and Design—Proceedings of All India Manufacturing Technology, Design and Research (AIMTDR) Conference 2018. We would like to express our deep gratitude to all the members of Organizing Committee of AIMTDR 2018 Conference and also to authors, reviewers, sponsors, volunteers, etc., for their wholehearted support and active participation. Our special thanks to Mr. P. Kaniappan, Managing Director, WABCO India Ltd., Chennai, who kindly agreed to act as President of National Advisory Committee (NAC) of the AIMTDR 2018 Conference. We also express our sincere thanks to Chairman Dr. S. Gowri, Honorary Professor, and Co-chairman Dr. P. Hariharan, Professor, Department of Manufacturing Engineering, Anna University, Chennai, for their wholehearted support. We would like to express our sincere thanks to research scholars Mr. K. R. Sunilkumar, Mr. U. Goutham, Mr. V. Mohankumar, Mr. R. Prabhu and also UG/PG students of the Department of Manufacturing Engineering, Anna University, for their contributions in the preparation of this volume. High-quality papers have been selected after peer review by technical experts. We hope you ﬁnd the papers included in the Proceedings of AIMTDR 2018 Conference are interesting and thought-provoking. We also like to express our gratitude for the support provided by Wabco India Ltd., Chennai, Kistler Instruments India Pvt. Ltd., Chennai, Ametek Instruments India Pvt. Ltd., Bengaluru, Central Manufacturing Technology Institute, Govt. of India, Bengaluru, Defence Research and Development Organisation, Government of India, New Delhi, and Ceeyes Engineering Industries Pvt. Ltd., Trichy. Finally, we would like to express our gratitude to National Advisory Committee (NAC) members of AIMTDR 2018 for providing the necessary guidance and support.

Guwahati, India Uday Shanker Dixit Vice-President National Advisory Committee AIMTDR

ix Preface

All India Manufacturing Technology, Design and Research (AIMTDR) Conference is considered globally as one of the most prestigious conferences held once in two years. It was started in 1967 at national level at Jadavpur University, Kolkata, India, and achieved the international status in the year 2006. It was organized by various prestigious institutions such as Jadavpur University, IIT Bombay, IIT Madras, CMTI Bangalore, PSG Tech, IIT Kanpur, CMERI, IIT Delhi, NIT Warangal, IIT Kharagpur, BITS Ranchi, VIT Vellore, IIT Roorkee, Andhra University, IIT Guwahati and College of Engineering Pune. The recent edition of the AIMTDR Conference, 7th International and 28th All India Manufacturing Technology, Design and Research (AIMTDR) Conference 2018, was jointly organized by the Departments of Manufacturing Engineering, Mechanical Engineering and Production Technology during 13–15 December 2018, at College of Engineering, Guindy, Anna University, Chennai, India, with the theme ‘Make in India – Global Vision’. A major focus was given on recent developments and innovations in the field of manufacturing technology and design through keynote lectures. About 550 participants registered for the conference. During the conference, researchers from academia and industries presented their findings and exchanged ideas related to manufacturing technology and design. Of the 750 papers received initially, 330 papers were finally selected after rigorous review process for publication in the Springer Proceedings. Selected papers from the conference are being published by Springer in the series Lecture Notes on Multidisciplinary Industrial Engineering in five volumes, namely Volume 1—Additive Manufacturing and Joining, Volume 2—Forming, Machining and Automation, Volume 3—Unconventional Machining and Composites, Volume 4—Micro and Nano Manufacturing and Surface Engineering and Volume 5—Simulation and Product Design and Development.

Chennai, India M. S. Shunmugam May 2018 M. Kanthababu

xi Contents

Part I Unconventional Machining 1 Powder Mixed Near Dry Electric Discharge Machining Parameter Optimization for Tool Wear Rate ...... 3 Sanjay Sundriyal, Ravinder Singh Walia and Vipin 2 Comparative Study of Dielectric and Debris Flow in Micro-Electrical Discharge Milling Process Using Cylindrical and Slotted Tools ...... 17 S. A. Mullya and G. Karthikeyan 3 Parametric Investigation into Electrochemical Micromachining for Generation of Different Micro-surface Textures ...... 27 S. Kunar, S. Mahata and B. Bhattacharyya 4 Investigations into Wire Electrochemical Machining of Stainless Steel 304 ...... 41 Vyom Sharma, V. K. Jain and J. Ramkumar 5 Nanoﬁnishing of External Cylindrical Surface of C60 Steel Using Rotating Core-Based Magnetorheological Finishing Process ...... 53 Manpreet Singh, Ashpreet Singh and Anant Kumar Singh 6 Effect of Laser Parameters on Laser-Induced Plasma-Assisted Ablation (LIPAA) of Glass ...... 67 Upasana Sarma and Shrikrishna N. Joshi 7 An Experimental Study of Electrochemical Spark Drilling (ECSD) ...... 77 Arvind Kumar Yadav and S. K. S. Yadav 8 Development and Experimental Study of Ultrasonic Assisted Electrical Discharge Machining Process ...... 89 Shubham Srivastava, Pravendra Kumar and S. K. S. Yadav

xiii xiv Contents

9 Effect of Finishing Time on Surface Finish of Spur Gears by Abrasive Flow Finishing (AFF) Process ...... 101 Anand C. Petare, Neelesh Kumar Jain and I. A. Palani 10 Experimental Study on Improving Material Removal Rate and Surface Roughness in Wire-Cut EDM of Low Conductive Material ...... 113 Dhiraj Kumar, Sadananda Chakraborty, Anand Ranjan and Dipankar Bose 11 Machining Performance Evaluation of Al 6061 T6 Using Abrasive Water Jet Process ...... 127 Pankaj Kr. Shahu and S. R. Maity 12 Formulating Empirical Model of MRR in Near-Dry EDM ...... 141 Gurinder Singh Brar, Nimo Singh Khundrakpam and Dharmpal Deepak 13 A Model for Average Surface Roughness for Abrasive Waterjet Cut Metal Matrix Composites ...... 149 N. R. Prabhu Swamy and S. Srinivas 14 Abrasive Jet Machining of Soda Lime Glass and Laminated Glass Using Silica Sand ...... 163 A. Karmakar, D. Ghosh, Deb Kumar Adak, Bijoy Mandal, Santanu Das, Ahmed Mohammed and Barun Haldar 15 A Novel Magnetorheological Grinding Process for Finishing the Internal Cylindrical Surfaces ...... 179 Ankit Aggarwal and Anant Kumar Singh 16 A Study on Micro-tool and Micro-feature Fabrication in Micro-EDM ...... 191 Biswesh Ranjan Acharya, Abhijeet Sethi, Akhil Dindigala, Partha Saha and Dilip Kumar Pratihar 17 Inﬂuence of Graphite Nanopowder-Mixed Dielectric Fluid on Machining Characteristics of Micro Electric Discharge Milling ...... 203 K. V. Arunpillai and P. Hariharan 18 Realization of Green Manufacturing Using Citric Acid Electrolyte for WC–Co Alloy Micro-tool Fabrication in Micro-WECM ...... 211 Abhijeet Sethi, Biswesh Ranjan Acharya, Pranai Kumar, Rajib Chakraborty and Partha Saha Contents xv

19 Effect of Powder Mix and Ultrasonic Assistance on Pulse Train-Based Speciﬁc Energy in EDM of D3 Steel ...... 225 R. Rajeswari and M. S. Shunmugam 20 Performance Evaluation of Si–Cu-Hybrid Dust as a Powder Additive of EDM Dielectrics to Machine Ti6Al4V with Copper Electrode ...... 239 Shirsendu Das, Swarup Paul, Biswanath Doloi and Kumar Rahul Dey 21 Experimental Study on Material Removal Rate and Over-Cut in Electrochemical Machining of Monel 400 Alloys with Coated Tools ...... 255 S. Ayyappan and N. Vengatajalapathi 22 Experimental Investigations into Ultrasonic-Assisted Magnetic Abrasive Finishing of Freeform Surface ...... 269 Akshay Kumar Singh, Girish Chandra Verma, Vipin Chandra Shukla and Pulak Mohan Pandey 23 Fiber Laser Cutting of Nimonic C263 Alloy and Investigation of Surface Integrity ...... 287 Mukul Anand, Niladri Mandal, Vikas Kumar, Shakti Kumar, A. K. Sharma and Alok Kumar Das 24 Generation of Three-Dimensional Features on Ti6Al4V by EC Milling ...... 299 K. Mishra, S. Sinha, B. R. Sarkar and B. Bhattacharyya 25 Enhancement in Machining Efﬁciency and Accuracy of ECDM Process Using Hollow Tool Electrode ...... 313 Rajendra Kumar Arya and Akshay Dvivedi 26 Evaluation of Cutting Force and Surface Roughness of Inconel 718 Using a Hybrid Ultrasonic Vibration-Assisted Turning and Minimum Quantity Lubrication (MQL) ...... 325 Habtamu Alemayehu, Sudarsan Ghosh and P. V. Rao 27 On Performance Evaluation of Helical Grooved Tool During Rotary Tool Micro-ultrasonic Machining ...... 335 Sandeep Kumar and Akshay Dvivedi 28 Experimental Investigation on Surface Topography of the Natural Ceramics in Abrasive Water Jet Cutting and Its Optimization Validation by Formulated Model ...... 347 Vijay Mandal, Amandeep Singh, Ganesh Singh Yadav, J. Ramkumar and S. Agrawal xvi Contents

29 Prediction and Comparison of Vision Parameter of Surface Roughness in WEDM of Al-6%Si3N4 and Al-10%Si3N4 Using ANN ...... 361 H. R. Gurupavan, H. V. Ravindra and T. M. Devegowda 30 Performance Study of Electrical Discharge Drilling of Metal Matrix Composite ...... 373 Anjani Kumar Singh and Vinod Yadava 31 Multi-objective Optimisation of Electro Jet Drilling Process Parameters for Machining of Crater in High-Speed Steel Using Grey Relational Analysis ...... 385 Kalinga Simant Bal, Amal Madhavan Nair, Dipanjan Dey, Anitesh Kumar Singh and Asimava Roy Choudhury 32 Machining of Bio-Implant Materials Using WEDM and Optimization of Process Parameters ...... 397 P. Hema, J. Mallikarjuna Rao and C. Eswara Reddy 33 Experimental Investigations of Abrasive Waterjet Machining Parameters on Titanium Alloy Ti-6Al-4V Using RSM and Evolutionary Computational Techniques ...... 413 A. Gnanavelbabu and P. Saravanan 34 Design of Fixture for Trimming of a Composite Material Shim by Abrasive Water Jet Machining ...... 427 Kushal Singh, Ch. Venkateswarlu, B. Hari Prasad and A. P. Dash 35 Fabrication and Characterization of Helical Grooved Cylindrical Electrodes Generated by WED Turning Process ...... 437 Jacob Serah Krupa and G. L. Samuel 36 A Study of Wire Electrical Discharge Machining of Carbon Fibre Reinforced Plastic ...... 451 Hrishikesh Dutta, Kishore Debnath and Deba Kumar Sarma 37 Development of a Bore Using Jet Electrochemical Machining (JECM) in SS316 Alloy ...... 461 J. Deepak, N. Vivek, B. MouliPrasanth and P. Hariharan 38 Machining and Characterization of Channels on Quartz Glass using Hybrid Non-conventional Machining Process µ-ECDM ..... 473 J. Bindu Madhavi and Somashekhar S. Hiremath 39 Parametric Study of a Newly Developed Magnetorheological Honing Process ...... 483 Talwinder Singh Bedi and Anant Kumar Singh Contents xvii

40 Investigation on Surface Roughness During Finishing of Al-6061 Hybrid Composites Tube with Traces of Rare Earth Metals Using Magnetic Abrasive Flow Machining ...... 493 V. K. Sharma, V. Kumar and R. S. Joshi 41 Part Program-Based Process Control of Ball-End Magnetorheological Finishing ...... 503 F. Iqbal, Z. Alam, D. A. Khan and S. Jha 42 Modelling and Analysis of Change in Shape of sintered Cu–TiC tool tip during Electrical Discharge Machining process ...... 515 Arminder Singh Walia, Vineet Srivastava, Vivek Jain and Mayank Garg 43 Experimental Investigations on C-263 Alloy by Electrochemical Milling ...... 527 K. Mishra, S. Sinha, B. R. Sarkar and B. Bhattacharyya 44 Inﬂuence of Discharge Energy on Electrical Discharge Machining of Ti-Foam Material ...... 537 S. Avinash, Karthick Chetti, M. Haribaskar, S. Jeyanthi, Abimannan Giridharan and R. Krishnamurthy 45 Gang Drilling of Square Micro-Holes on Glass Using USM ...... 549 T. Debnath, K. K. Patra and P. K. Patowari 46 Parametric Optimization of Micro Ultrasonic Drilling of Quartz Based on RSM ...... 559 S. Kumar, B. Doloi and B. Bhattacharyya 47 Investigations into the Effect of Varying Electrode Diameter on Cutting Rate and Kerf Width in WEDM of Varying Thickness Inconel718 ...... 571 Susheel Ramchandra Dhale and Bhagyesh B. Deshmukh 48 Comparative Evaluation of Drilling on GFRP Made by Different Fabrication Techniques ...... 583 R. Raja and Sabitha Jannet 49 An Experimental Analysis of Square Stepped Hole Fabrication on Zirconia Bio-Ceramics ...... 599 S. Das, S. Kumar, B. Doloi and B. Bhattacharyya 50 Pulse and Work Revolution Parameters of Wire Electrical Discharge Turning on Ti-6Al-4V Alloy ...... 611 S. Ram Prakash, K. Rajkumar and G. Selvakumar xviii Contents

51 Modeling of Areal Surface Roughness Using Soft-Computing- Based ANN and GA to Estimate Optimal Process Parameters During Wire Electrical Discharge Turning of Inconel 825 ...... 621 Jees George, G. Ravi Chandan, R. Manu and Jose Mathew 52 Investigation on the Inﬂuence of Process Parameters on Surface Roughness and Kerf Properties in Abrasive Water Jet Machining of Carbon Fibre Vinyl Ester Composite ...... 631 Bhavik Tank and Shailendra Kumar 53 Fluidized Bed Hot Abrasive Jet Machining (FB-HAJM) of K-60 Alumina Ceramic ...... 641 B. K. Nanda, A. Mishra, Sudhansu Ranjan Das and D. Dhupal 54 Performance Evaluation of Abrasive Water Jet Machining on AA6061-B4C-HBN Hybrid Composites Using Taguchi Methodology ...... 651 A. Gnanavelbabu, K. T. Sunu Surendran and K. Rajkumar 55 Empirical Modelling and Optimisation of Bio-Micromachining on Antimicrobial Copper to Fabricate Micromixing System ...... 661 Abhishek Singh, Arul Manikandan, M. Ravi Sankar, K. Pakshirajan and L. Roy 56 Investigation on Magnetic Field-assisted Near-dry Electrical Discharge Machining of Inconel 600 ...... 671 G. Mannoj Rajkumar, Abimannan Giridharan, R. Oyyaravelu and A. S. S. Balan

Part II Composites 57 Selection of Aluminum Hybrid Metal Matrix Composite Material Using Additive Ratio Assessment Approach and Comparing with the Experimental Results Varying Different Weight Percentage of the Reinforcements ...... 687 Soutrik Bose and Titas Nandi 58 The Role of HBN Solid Lubricant Reducing Cutting Forces of Dry Machined Al-B4C Composite ...... 697 M. Rajesh, K. Rajkumar, A. Gnanavelbabu and K. M. Nambiraj 59 Experimental Investigation on Inﬂuence of Process Parameters of Abrasive Water Jet Machining on Kerf Taper of Glass Fiber-Reinforced Polymer Composites ...... 707 H. J. Prajapati, Puneet Kumar, Shailendra Kumar and Ravi Kant

60 WEDM Studies on TiB2-15% SiC Ceramic Composite Processed Through SPS Process ...... 715 K. Jayakumar Contents xix

61 Study of Mechanical Properties and Thermal Conductivity of Carbon and Basalt Fibre-Reinforced Hybrid Polymer Composites ...... 725 V. Durga Prasada Rao, N. V. N. Sarabhayya and A. Balakrishna 62 Design and Fabrication of Aluminium/Alumina Ultra-ﬁne Composite and Functionally Graded Material Using Powder Metallurgy Route ...... 739 Aravind Tripathy, Rajat Gupta, Saroj Kumar Sarangi and Anil Kumar Chaubey 63 Mechanical and Crystallization Behaviour of Sisal Fiber and Talc Reinforced Polylactic Acid Composites ...... 749 A. Suresh Babu, M. Jaivignesh and D. Poovarasan 64 Assessment on Hole Quality During Drilling of Al/CFRP Stack ...... 757 Tarakeswar Barik, Swagatika Sarangi and Kamal Pal 65 Experimental and Analytical Outcomes of Carbon Fiber Orientation in Epoxy Resin Composite Laminate Under Tensile Loading ...... 771 A. Rajesh, S. Deva Prasad, B. Singaravel, T. Niranjan and T. Shravan Kumar About the Editors

M. S. Shunmugam is a Professor (Emeritus) in the Manufacturing Engineering Section in the Department of Mechanical Engineering, Indian Institute of Technology (IIT) Madras. After receiving his PhD in Mechanical Engineering from IIT Madras in 1976, he has worked in IIT Bombay (from 1977 to 1980) and in IIT Madras from 1980 onwards. He was a visiting faculty member at Michigan Technological University during 1989-1991 and was a member in the board of governors of IIT Madras during 2012-2013. Dr. Shanmugam’s research interests include metrology, machine tools, manufacturing, gears, micro-machining and computer applications in manufacturing. He has published about 130 peer-reviewed international journal papers, 15 peer-reviewed national journal papers, 75 international conferences and about 80 national conferences.

M. Kanthababu is a Professor in the Department of Manufacturing Engineering in Anna University, Chennai, India and the Director of the Centre for Intellectual Property Right and Trade Marks in Anna University. He has completed his MS in Mechanical engineering and PhD in Advanced Manufacturing Technology from IIT Madras. Prof Kanthababu's research interests include manufacturing technology, composite materials and machining, and automation in manufacturing. He has published more than 30 peer reviewed international journal papers and 2 books, and holds one patent.

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