Indian Institute of Technology Palakkad&nbsp;(IIT Palakkad or IIT PKD) is a public autonomous&nbsp;engineering&nbsp;and&nbsp;research&nbsp;institute located in&nbsp;Palakkad,&nbsp;Kerala. It was&nbsp;one of the five new&nbsp;IITs&nbsp;proposed in the&nbsp;2014 Union budget of India. The campus was inaugurated on 3 August 2015. The institute has 94 faculty, 978 students, and 63 non-teaching staffs.

IT Palakkad currently offers four-year Bachelor of Technology (B.Tech) and two years MS programmes in 8 different engineering disciplines including&nbsp;Computer Science, Electrical, Mechanical, Civil among others.

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IIT Palakkad

Inconel 706 is a newly developed superalloy, which offers high mechanical strength alongwith easy fabricability thus making it suitable for turbine disk applications. Although Inconel 706 exhibits a substantial increase in stress rupture and tensile yield strength compared to other superalloys, its conventional machining yields poor surface finish and low dimensional accuracy of the machined components. Hence, wire electrical discharge machining (WEDM) of Inconel 706 has been performed and various performance attributes such as material removal rate (MRR), surface roughness (SR), recast surface, topography, microhardness, microstructural and metallurgical changes of the machined components have been evaluated. The experimental results revealed that servo voltage, pulse on time, and pulse off time greatly influence the MRR and SR. Due to high toughness of Inconel 706, no micro cracks were observed on the machined surface. Micro voids and micro globules are significantly reduced at low pulse on time and high servo voltage. But, there is a propensity of thick recast layer formation at high pulse on time and low servo voltage. EDAX analysis of recast surface exposed the existence of Cu and Zn which have migrated from the brass wire. The subsurface microhardness was changed to 80. μm due to significant thermal degradation. © 2015 Elsevier Ltd.

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Department of Mechanical Engineering

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Materials and Design

Evaluation of WEDM performance characteristics of Inconel 706 for turbine disk application

In this paper an experimental investigation was carried out to optimize the performance characteristics (surface roughness and Metal removal rate) simultaneously in hot machining process. The experiments were conducted on 15-5PH stainless steel using K313 carbide tool based on Taguchi L27 orthogonal array design. The work-piece material was heated using oxy-acetylene gas flame which is the cost effective method compare to other heating technique used in hot machining process. Analysis of variance is performed to get the contribution of each parameter on the performance characteristics and it was observed that cutting speed is most significantly affect the performance characteristics compare to feed, depth of cut and temperature. The optimal set of process parameters were found to be cutting speed at 31 m/min, feed rate at 0.4mm/rev, depth of cut at 0.4mm and workpiece temperature at 400°C to maximize material removal rate and minimize surface roughness.

Procedia Materials Science

Multi Objective Optimization of Hot Machining of 15-5PH Stainless Steel Using Grey Relation Analysis

Electrochemical machining is one of the widely used non-traditional machining processes to machine complicated shapes for electrically conducting but difficult-to-machine materials such as superalloys, Ti-alloys, alloy steel, tool steel, stainless steel, etc. Use of optimal ECM process parameters can significantly reduce the ECM operating, tooling, and maintenance cost and will produce components of higher accuracy. This paper investigates the effect and parametric optimization of process parameters for Electrochemical machining of EN-31 steel using grey relation analysis. The process parameters considered are electrolyte concentration, feed rate and applied voltage and are optimized with considerations of multiple performance characteristics including material removal rate, overcut and cylindricity error. Analysis of variance is performed to get contribution of each parameter on the performance characteristics and it was observed that feed rate is the significant process parameter that affects the ECM robustness. The experimental results for the optimal setting show that there is considerable improvement in the process. The application of this technique converts the multi response variable to a single response Grey relational grade and, therefore, simplifies the optimization procedure. © (2012) Trans Tech Publications, Switzerland.

Applied Mechanics and Materials

Parametric optimization in electrochemical machining of EN-31 steel based on grey relation approach

Electrochemical machining is a non conventional machining process, used for machining complicated shapes, high strength and high temperature materials. The selection of proper process parameters for electrochemical machining process is crucial to have the efficient and high quality output. In this study, the Taguchi method, a powerful tool for optimization is used to find the optimal machining parameters for electrochemical machining. Based on this technique, experiments were designed and conducted on Inconel 625 alloy to machine circular holes using electrochemical machining with NaCI solution as electrolyte and electrolyte grade copper as tool. An orthogonal array, the signal-to-noise (S/N) ratio, and the analysis of variance (ANOVA) were employed to investigate the optimum process parameters and their effect on the response parameters i. e. , material removal rate and overcut. Through this study not only the optimal machining parameters are obtained, but also the main process parameters that affect the machining performance in electrochemical machining are found. Conformation tests are also conducted to verify the experimental results.