Lecture Notes in Mechanical Engineering M. S. Shunmugam Biswanath Doloi R. Ramesh A. S. Prasanth   Editors Advances in Modern Machining Processes Proceedings of AIMTDR 2021 Lecture Notes in Mechanical Engineering Series Editors Fakher Chaari, National School of Engineers, University of Sfax, Sfax, Tunisia Francesco Gherardini , Dipartimento di Ingegneria “Enzo Ferrari”, Università di Modena e Reggio Emilia, Modena, Italy Vitalii Ivanov, Department of Manufacturing Engineering, Machines and Tools, Sumy State University, Sumy, Ukraine Editorial Board Francisco Cavas-Martínez , Departamento de Estructuras, Construcción y Expresión Gráfica Universidad Politécnica de Cartagena, Cartagena, Murcia, Spain Francesca di Mare, Institute of Energy Technology, Ruhr-Universität Bochum, Bochum, Nordrhein-Westfalen, Germany Mohamed Haddar, National School of Engineers of Sfax (ENIS), Sfax, Tunisia Young W. Kwon, Department of Manufacturing Engineering and Aerospace Engineering, Graduate School of Engineering and Applied Science, Monterey, CA, USA Justyna Trojanowska, Poznan University of Technology, Poznan, Poland Lecture Notes in Mechanical Engineering (LNME) publishes the latest develop- ments in Mechanical Engineering—quickly, informally and with high quality. Original research reported in proceedings and post-proceedings represents the core of LNME. Volumes published in LNME embrace all aspects, subfields and new challenges of mechanical engineering. To submit a proposal or request further information, please contact the Springer Editor of your location: Europe, USA, Africa: Leontina Di Cecco at [email protected] China: Ella Zhang at [email protected] India: Priya Vyas at [email protected] Rest of Asia, Australia, New Zealand: Swati Meherishi at [email protected] Topics in the series include: . Engineering Design . Mechanical Structures and Stress Analysis . Engine Technology . Nanotechnology and Microengineering . Control, Robotics, Mechatronics . MEMS . Theoretical and Applied Mechanics . Fluid Mechanics . Engineering Thermodynamics, Heat and Mass Transfer . Manufacturing . Precision Engineering, Instrumentation, Measurement . Tribology and Surface Technology Indexed by SCOPUS and EI Compendex. All books published in the series are submitted for consideration in Web of Science. To submit a proposal for a monograph, please check our Springer Tracts in Mechanical Engineering at https://link.springer.com/bookseries/11693 · · · M. S. Shunmugam Biswanath Doloi R. Ramesh A. S. Prasanth Editors Advances in Modern Machining Processes Proceedings of AIMTDR 2021 Editors M. S. Shunmugam Biswanath Doloi Department of Mechanical Engineering Production Engineering Indian Institute of Technology Madras Jadavpur University Chennai, India Kolkata, India R. Ramesh A. S. Prasanth Department of Mechanical Engineering Department of Mechanical Engineering PSG Institute of Technology and Applied PSG College of Technology Research Coimbatore, India Coimbatore, India ISSN 2195-4356 ISSN 2195-4364 (electronic) Lecture Notes in Mechanical Engineering ISBN 978-981-19-7149-5 ISBN 978-981-19-7150-1 (eBook) https://doi.org/10.1007/978-981-19-7150-1 © The Editor(s) (if applicable) and The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2023 This work is subject to copyright. All rights are solely and exclusively licensed by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. 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The registered company address is: 152 Beach Road, #21-01/04 Gateway East, Singapore 189721, Singapore Preface All India Manufacturing Technology, Design and Research (AIMTDR) is a reputed international conference series focused on the domain of manufacturing. The first All India Machine Tool Design and Research conference, also abbreviated as AIMTDR, was organized by Jadavpur University, Kolkata, in the year 1967. Those were the days when the main focus of manufacturing was toward efficient design and utiliza- tion of machine tools. PSG College of Technology, Coimbatore, organized the 7th and 15th AIMTDR conferences in 1976 and 1992, respectively. Other institutes that organized this conference before the 15th AIMTDR conference are Central Machine Tool Institute (CMTI), Indian Institute of Technology (IIT) Bombay, IIT Madras, University of Roorkee, IIT Kanpur, Central Mechanical Engineering Research Insti- tute and IIT Delhi, some of them multiple times. After the 15th AIMTDR conference, the necessity of widening the scope of the conference arose. It was decided to encom- pass entire manufacturing technologies in its fold, rather than just focusing on the technologies related to machine tools. Accordingly, the phrase “machine tool design” was replaced by “manufacturing technology, design”. Thus, the conference series was rechristened as All India Manufacturing Technology, Design and Research, without making any alteration to the acronym AIMTDR. Thus, the 16th AIMTDR confer- ence with a new unabridged title was organized at CMTI, Bangalore, in 1994. It is interesting to note that CMTI renamed itself from Central Machine Tool Institute to Central Manufacturing Technology Institute in 1992, adapting to the current trends in manufacturing. AIMTDR received its international status in the year 2006, when the first Inter- national and 22nd National AIMTDR was organized at IIT Roorkee. Subsequent conferences were held at IIT Madras, Andhra University, Jadavpur University, IIT Guwahati, College of Engineering Pune and Anna University. The recent edition of the conference, viz., the 8th international and 29th national conference, was jointly organized by the Departments of Mechanical Engineering of PSG College of Tech- nology, Coimbatore, and PSG Institute of Technology and Applied Research, Coim- batore, during 9–11 December 2021 in virtual mode. The theme of AIMTDR 2021 was “Transformational Changes in Manufacturing”. v vi Preface After a rigorous review process, about 250 technical papers from academia and industry were accepted for presentation at the conference. In addition, eight keynote talks on advanced technologies such as the development of high-precision machine tools, simulation of material flow, nanostructured surfaces, additively controlled material mechanics, product development platforms, next-generation milling, diamond turning and hybrid machining were delivered by experts. Further, two case studies from the industry highlighting the innovation practices and challenges in machine tool structure design were presented. Select papers from the conference are being published by Springer in the series— Lecture Notes in Mechanical Engineering, in five volumes—Volume 1: Advances in Modern Machining Processes; Volume 2: Advances in Additive Manufacturing and Metal Joining; Volume 3: Advances in Simulation, Product Design and Development; Volume 4: Advances in Forming, Machining and Automation; Volume 5: Advances in Micro and Nano Manufacturing and Surface Engineering. Volume 1 entitled “Advances in Modern Machining Processes” covers neoteric advances in the realms of Electro-Physical and Chemical Machining, Machining Optimization, Surface Morphology and Sustainable Machining. We hope that this book will evoke interest among academicians, researchers and practicing engineers who aspire to comprehend advances pertaining to the domain of modern machining processes. We sincerely thank National Advisory Committee members of AIMTDR, orga- nizers, reviewers, authors and participants. Special thanks to Springer for publishing the select papers of AIMTDR since AIMTDR 2014. Readers are requested to send us their feedback about this volume. Chennai, India M. S. Shunmugam Kolkata, India Biswanath Doloi Coimbatore, India R. Ramesh Coimbatore, India A. S. Prasanth Contents Electro-Physical and Chemical Machining A Sustainable Die-Sinking Electrical Discharge Machining of Ti6Al4V Using Jatropha Bio-Dielectric ............................ 3 Shirsendu Das, Swarup Paul, and Biswanath Doloi Comparative Evaluation of Machining Performance of Nimonic 263 in Powder Mixed EDM ......................................... 13 Deepti Ranjan Sahu and Amitava Mandal Effect of Peak Current and Pulse-On Time on MRR and TWR in EDM of Ti-6Al-4 V .............................................. 29 Shubham Jaiswal, N. V. Prajina, Basil Kuriachen, and Jose Mathew Electro Discharge Machining of Advanced Engineering Ceramics ...... 39 Sandip Kumar Chaudhury, Bijoy Bhattacharyya, Biplab Ranjan Sarkar, Rohit Upadhyay, and Koushik Mishra Enhancement of MRR of Inconel 718 During EDM by Numerical and Experimental Approaches ...................................... 51 Munna Kumar, Bibin K. Tharian, and R. Manu Experimental Investigation into Electrochemical Discharge Milling of Glass by Bottom Feeding the Tool Electrode ................ 65 S. Santra, B. R. Sarkar, B. Doloi, and B. Bhattacharyya Experimental Investigations into Erosion of Zinc-Coated Brass Wire Electrode During WEDM of Ti-6Al-4 V Alloy ................... 77 Sanghamitra Das and Shrikrishna N. Joshi Improving Material Removal Rate in Machining of Micro-holes Using Hybrid EDM Process ........................................ 87 R. Naveen Anthuvan, V. Krishnaraj, Jayakrishnan Nampoothiri, M. Parthiban, and Sivaroopan vii viii Contents Machining of Maraging Steel Through Al O Abrasive Powder 2 3 Assisted Electrochemical Discharge Machining ....................... 101 Niladri Mandal, Nitesh Kumar, and Alok Kumar Das Performance Analysis of Dynamic Magnetic Field-Assisted Electrochemical Spark Drilling ..................................... 111 R. Singh, Dhirendra K. Singh, and J. Singh Performance of Electrochemical Micromachining of Magnesium Alloy Through Sodium Nitrate Electrolyte ........................... 119 N. Sivashankar and R. Thanigaivelan Study of Machining Characteristics During WEDM of Titanium Matrix Composite ................................................. 129 Dwaipayan De, Titas Nandi, and Asish Bandyopadhyay Machining Optimization Experimental Investigation into Ultrasonic Machining of Titanium Alloy Ti6Al4V ..................................................... 145 Sayan Doloi, Amlana Panda, and Ashok Kumar Sahoo Experimental Investigation of Process Parameters in Boring Process with a Novel MR Fluid Damper Assisted Machining Setup ..... 161 R. Sridhar, T. Karthik, and N. Srinivasan Experimental Studies on Laser Marking Characteristics of Stainless Steel 304 ............................................... 173 M. Pandey and B. Doloi Investigations and Optimization of EDM Parameters of Conductive Ceramic Composites: A Review ..................................... 185 L. Selvarajan, K. Venkataramanan, N. Senthilkumar, R. Sasikumar, and A. Aravindhan Multi-objective Optimization of Powder Mixed Green-EDM Parameters on Machining of HcHcr Steel Using an Integrated MCDM Approach ................................................. 199 Sandeep Kumar and Abhishek Singh Multi-objective Parametric Optimization During WEDM of Silicon Through MOGWO ....................................... 215 Anmol Singh Verma and Shankar Singh Optimization of Process Variables in Sinking EDM Using Artificial Neural Network (ANN) Method ..................................... 227 S. Kumar, Sanjoy K. Ghoshal, Pawan K. Arora, and Leeladhar Nagdeve Contents ix Optimization of Wire-EDM Process Parameters for Ti6Al4V Alloy Cutting Using Mayfly Algorithm .................................... 243 Anitesh Kumar Singh, Kalinga Simant Bal, Dipanjan Dey, Abhishek Rudra Pal, Dilip Kumar Pratihar, and Asimava Roy Choudhury Parametric Optimization of MRR During Ultrasonic Machining Process ........................................................... 257 B. Banerjee, S. Doloi, S. Das, and D. Dhupal Preliminary Study on EDM of Inconel-625 and Assessment of Process Parameters Using OFAT Technique ....................... 271 Mohd. Yunus Khan, P. S. Rao, and B. S. Pabla Process Competencies of Modulation-Assisted Machining ............. 283 Malkeet Singh, Sahil Dhiman, Harpreet Singh, and Christopher C. Berndt RSM-Based GA Model for Optimization of Machining Parameter of Ti–6Al–4 V in WEDM Process ................................... 295 S. Biswas, A. R. Paul, M. Mukherjee, and Y. Singh Surface Morphology and Sustainable Machining Belt-Type Magnetorheological Finishing Setup—A Novel Design and Simulation Study .............................................. 311 P. Oliver Horo and D. Ahmad Khan Deposition and Characterization of 80%8YSZ/20%Al O Plasma 2 3 Sprayed Thermal Barrier Coating .................................. 321 Somesh Sharma, Pravesh Chandra Shukla, and Soumya Gangopadhyay Development of Electrolyte Through Spindle System in EC Milling for Enhancement of Surface Quality ................................ 333 K. Mishra, B. R. Sarkar, and B. Bhattacharyya Effect of Heat Treatment on Mechanical Behavior of Al7075-Based Hybrid Composites ................................................ 345 Siddesh Matti, B. P. Shivakumar, Suresh Holi, and P. N. Siddappa Effect of Powder-Mixed Dielectrics on Performance Measures and Surface Morphology During PMEDM of Ti6Al4V ................ 361 T. Bhavani, S. V. V. N. Siva Rao, John Deb Barma, and Subrata Kumar Ghosh Experimental Investigation on Temperature-Induced Geometrical Variations of AISI 316 Steel During Plasma Arc Cutting Process ....... 375 A. Mohan, A. Prabukarthi, S. Samsudeensadham, and M. Kirubakaran Influence of Heat Treatment on Hardness and Microstructure of Cast Fe–Ni–Cr Alloy ............................................ 387 Harsh Dave and Kaustubh Samvatsar