BITS Faculty Publications

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    Influence of gaseous dielectrics on the wettability of Al-6061 alloy using dry µ-electrical discharge milling
    (Elsevier, 2025-03) Roy, Tribeni
    Superhydrophobic surfaces are essential for applications such as self-cleaning and corrosion resistance. This study explores the fabrication of superhydrophobic surfaces on Al-6061 alloy using dry micro electrical discharge milling (µEDM milling) and investigates the effects of gaseous dielectrics on wettability under atmospheric conditions. Surfaces machined in an oxygen environment showed a surface area roughness (Sa) of 4.68 µm, 73.3 % higher than those machined in argon, attributed to enhanced metal oxide formation. Energy Dispersive X-ray Analysis (EDAX) indicated a significantly elevated O/Al atomic ratio of 0.80 for oxygen-machined samples, which was 73.9 % greater than argon-machined samples, suggesting the presence of hydrophilic compounds such as AlO(OH) and Al2O3. Additionally, X-ray Photoelectron Spectroscopy (XPS) revealed that Al2O3 peaks on oxygen-machined surfaces were broadened and shifted to higher binding energies, correlating with decreased contact angles and increased surface hydrophilicity. These results suggest that using oxygen as a dielectric in the electrical discharge machining (EDM) process promotes oxide layer formation, resulting in hydrophilic characteristics, while machining in argon encourages organic adsorption and greater hydrophobicity. The findings of this research provide insights that can inform future efforts to tailor surface properties for advancements in aerospace, automotive, and biomedical engineering applications.
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    Size Reduction
    (Springer, 2023-07) Jindal, Anil B.
    Size reduction refers to the process of the formation of small particles with a large surface area. The stress-strain curve of the material determines the energy needed for size reduction with a desirable particle size distribution. The study of equipment used for size reduction and their process parameters helps to reduce the energy supply. In this chapter, we have discussed the theories describing the energy required during milling, and the equipment used for milling including the ball mill, hammer mill, fluid energy mill, cutter mill, and oscillating granulator. Further, we have explained the factors affecting the size reduction process.
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    An Investigation on Reduction of Cutting Energy Consumption Using High Efficiency Machining Strategy
    (Elsevier, 2022) Bera, T.C.; Sangwan, Kuldip Singh
    A large number of machine tools are used on regular basis consuming a large amount of energy. Moreover, the machine tools have poor energy efficiencies and thus, they are ideal candidates for energy saving strategies. Improvement in energy efficiency of machining system will not only benefit the industries economically but also help the world in taking care of energy crisis and air pollution. Therefore, an attempt has been made in the present work to reduce the cutting power consumption using a high efficiency machining (HEM) strategy. The HEM strategy has been used primarily for roughing operation utilizing a lower radial depth of cut (RDOC) and a higher axial depth of cut (ADOC) for milling. During machining, the radial chip thinning occurs with varying RDOC that results into variation in uncut chip thickness and respective chip load. Based on process geometry of milling, a specific energy consumption (SEC) model has been analyzed for the milling. Next, the cutting power has been reduced using high efficiency milling approach. The proposed HEM strategy can reduce cutting time that results into less power consumption and increased productivity of milling by removing more material in unit time. Therefore, the present study is able to contribute significantly towards energy-efficient manufacturing and cleaner production.
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    Modelling of spindle energy consumption in CNC milling
    (Elsevier, 2022) Sangwan, Kuldip Singh; Bera, T.C.
    In manufacturing industries, machine tools are frequently used and required a lot of energy to work. Spindle acceleration is a common process when machine tools are in use. It generates a high-energy intensive power peak. The total energy consumption of machine tools in the machining process is strongly affected by these high-power peaks of short duration. Many researchers have overlooked the energy consumption of spindle acceleration resulting into inaccuracies in the prediction of overall energy consumption of machine tools. Therefore, the present study aims to develop a model to predict the spindle acceleration energy consumption of computer numerical control (CNC) milling machines. The proposed model is based on the principle of spindle motor control and includes the computation of moment of inertia of the spindle drive system. To validate the effectiveness of the proposed model, machining experiments are carried out on a CNC milling machine. Without performing time-consuming experiments, the proposed models can be utilized to estimate the power, time, and energy consumption of spindle acceleration. The proposed model helps to determine total energy consumption during machining process correctly.
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    Developing Energy Efficient Milling Strategy for Variable Curved Geometry Using Constant Engagement Method
    (Elsevier, 2023) Sangwan, Kuldip Singh; Bera, T.C.
    The continuous fluctuation in force profile in milling of variable curved geometry creates a barrier in stable machining and in cutting power consumption. The fluctuation in force profile happens due to alteration in chip load in the presence of workpiece curvature. The present study aims to develop an energy efficient machining strategy for milling of variable curved geometries where more uniform cutting force and cutting power consumption profiles are accomplished due to constant chip load along the peripheral length of curved geometry. The proposed strategy involves mechanics of milling, instantaneous cutting force and cutting power consumption. It is formulated based on constant chip load by regulating entry angle of milling cutter according to workpiece curvature along the peripheral length. Thus, the cutting power fluctuation that is occurred due to variation of workpiece curvature is reduced by regulating tool-workpiece engagement. The energy consumption is reduced almost 18 % using the proposed approach. It results into developing an energy efficient machining strategy for milling of variable curved geometry. It also provides stable machining process and increased tool life by reducing tool wear due to reduction of force fluctuation during metal removal process.