Advanced Manufacturing Processes

 

Advanced processes for Micro- and Nano-manufacturing

 

In this area, various nano-finishing processes and strategies like Magentorhelogical Abrasive flow finishing (MRAFF) is utilized to develop surface finishes less than 100nm which are heavily utilized for prosthetics, implants, nuclear reactors, micro-mirrors etc. The magnetorheological fluids demonstrate change in apparent viscosity under external magnetic fields. In this process, a viscous slurry made of Carbonyl Iron Particle and the abrasive grains are passed through external magnetic fields resulting in their local increase in viscosity. This leads to positive pressure of the abrasive particles on the metal pipe interiors through which the slurry is passed.

Research Areas

 

Micromachining of channels using ECDM processes, nanofinishing using MRAFF, and MAF processes

 

Research Laboratories:

 

Manufacturing Science Laboratory

 

Associated Faculty

 

V. K. Jain, PhD (Roorkee): Advanced Machining Processes, Accelerated Cutting, CAM Machining of Advanced Engineering Materials


Magnetorheological Abrasive Flow Finishing (MRAFF) Process


Nanofinishing of knee joint implant (Ti alloy) by MRF

 
 

 

  

Sanjeev Kumar Verma

Designation:

Senior Technical Superintendent

Office Address:

Manufacturing Science Lab (NL-1-115-A)

Contact numbers:

0512-2597923 (O), 0512-2598039 (R)

+ - Experience Click to collapse

  • From May 2003 to till now working in Manufacturing Science Lab, Mechanical Engg., IIT Kanpur.

  • Worked with Rico Auto Industries Ltd Gurgaon. As Engineer (Production CNC) from March 2000 to March 2002.

  • Worked with Track Parts of India Ltd, Govind Nagar Kanpur. As Assistant Engineer (Production) from January 1994 to March 2000.

+ - Special Skills Click to collapse

  • Good knowledge of open loop & close loop CNC programming and operating

  • Good knowledge of Additive Manufacturing (3D Printing Metallic and polymer)

  • A good experience in engineering drawing (CAD, CAM, Solidworks etc.)

  • Good knowledge of various CNC Turning centres & CNC Machining centres programming with various controls (Fanuc, Siemens & Hinumeric).

  • Good Knowledge of various Metrological Instruments such as Co-ordinate measuring machine, Roughness measuring machine, Atomic force measurement machine, Roundness Measuring Machine, Anton Paar Rheological Measuring Machine & various microscope.

  • Good knowledge of non-traditional machining process such as EDM, ECM, AFM, MAF, MRAFF, AJM & LASER Machining etc.

  • Good knowledge of conventional machining process such as Lathe, Milling, Grinding & Micromachining 3D printing (Rapid prototyping) etc.

  • Good knowledge of corrective and Preventive Maintenance of Conventional & non- conventional machines.

+ - Activities Click to collapse

  • Design and Fabrication of experimental setups for post graduate and research students.

  • Conducting ME361A Lab classes for under graduate students.

  • Determine & Demonstrate on various conventional, non-conventional, advance machining and measuring Instrumental machines to under graduate, post graduate and research students.

  • Corrective and Preventive Maintenance of conventional & non-conventional machines and Measuring Instrumental machines etc.

 

 
 


Materials Testing Laboratory

Teaching Laboratory

ME 222: Nature and Properties of Materials

Overview:

Objective is to give a broad understanding of common materials related to mechanical engineering with an emphasis on the fundamentals of structure-property-application relationships.

Course Content:

History of engineering materials, Engineering materials, Materials property chart, Crystal structure, Imperfections of solids, Mechanism of strengthening in metals, Hall-Petch effect, Xray diffraction, Fracture: Ductile, brittle, fatigue. Griffith criterion, S-N curve, Creep, Phase diagram (binary), Iron-carbon system, Heat treatment of metals, Electrical properties, Thermal properties, Magnetic properties, Optical properties, Corrosion, Oxidation, Thermal stability ,
Wear, abrasion, friction of materials, Characterization techniques: Optical microscopy, scanning electron microscopy, transmission electron microscopy, atomic force microscopy, Polymer and its characterization, Viscoleasticity, Nanomaterials and its important properties at nanoscale, Composites: Characterization of composites, Ionic polymer matrix composites, Shape memory alloy, Intelligent Multifunctional materials, Economics, Environment, and
Sustainability In addition to the lectures, the course is associated with a laboratory session. A group of 6/7 students can conduct experiment effectively. A total of six experiments for the duration of 2 hours each is proposed for this course.


Processing Equipment:

Environmental Controlled High Temperature Furnace: Heat treatment  in controlled atmosphere

Specification:

Temperature: Room temperature to 1400 0C
Heating rate : 0.5 0C/min to 10 0C/min
Environment : Air, Nitrogen, etc

Location: ACMS 207B


Processing Equipment:

Specimen Cutting Machine-  Metallic, polymer, etc

Specification:

RPM- 1500 max
Wheel size: 33 x 2 x 32 mm
Sample size (max): 30 mm x30 mm

Location:ACMS 203B

 


Processing Equipment:

Single/Double Disc Polishing Machine- Polishing of samples to get smooth surface finish


Specification:

Diameter of disc: 200 mm
Rotation: 300-650 rpm

Location: ACMS 203B

 


Characterization Equipment:

Universal Testing Machine- Studies of strain-strain behaviour of materials


Specification:

Max force- 100 kN
Cross head speed- 5 mm/min to 100 mm/min
Travel length- 450 mm
Test types- Tension, Compression, and Flexural

Location: NL-1, Room # 112


Characterization Equipment:

MTS 810 Testing Machine- Studies of mechanical properties of materials


Specification:

Max. Force- 100 kN
Travel length- 1308 mm
Controller: Flex test 40
Test types: Tension, compression, bending, and cyclic fatigue


Location: NL-1, Room # 112


Characterization Equipment:

Rotating Beam Fatigue Tester: Studies of fatigue life and endurance limits of metals


Specification:

Load- 10 Kg to 40 Kg
RPM – 1420

Location: ACMS, Room # 207B


Characterization Equipment:

Rotating Beam Reverse Bending Fatigue Testing Machine- Studies of fatigue life and endurance limits of metals


Specification:

RPM- 2800 - 6000
Load- 0.5 kg – 4 Kg
Sample- Dumbbell shape
Diameter of specimen: 8 mm

Location: ACMS 207B


Characterization Equipment:

Rotating Beam Reverse Bending Fatigue Testing Machine - Studies of fatigue life and endurance limits of metals


Specification:

Diameter of test specimen: 8 mm Maximum bending moment:  500 Kg. cm.
RPM- 1425
Load- 0.250 Kg to 50 Kg

Location: ACMS 207B


Characterization Equipment:


Shore A Durometer- Measurement of hardness for soft materials like rubber

Specification:

Preload: 0.45 Kgf
Major Load: 8.06 N
Indentor type- 35° truncated cone indenter
Type of load- Constant contact pressure

Location: ACMS 207B


Characterization Equipment:

Shore D Durometer- Measurement of harness for hard polymer

Specification:

Preload: 0.45 Kgf
Major Load: 44.48 N
Indentor type- 30° cone indenter
Type of load- Constant contact pressure

Location: ACMS 207B


Characterization Equipment:

Portable Hardness Tester- Rockwell hardness tester for measurement of hardness

Specification:

Rockwell test
Load – 10 Kg, 60 Kg,  100 Kg and 150 Kg
Indentor: Diamond /
1/16” ball

Location: ACMS 207B

 


Characterization Equipment:

Poldi Hardness Tester- Measurement of hardness

Specification:

Preload: 0.42 Kgf
Major Load: Hammer blow
Material -  Alloy steel EN-8 OR EN-9
Dia- 30mm
Length- 85 mm
Tungsten Carbide Ball
Dia- 10 mm
Poldy Bar
Material: Alloy steel EN-8 or EN-9 or Carbon Steel- WPS
Size- 12 mm X 12mm X 150 mm
Eyepiece- 8X, 25 X

Location: ACMS 207B

 


Characterization Equipment:

Ellipsometer- Thickness of thin film

Specification:

Range: 10 nm – 400 nm
 Source – Green laser, 532 nm

Location: ACMS 203F

 


Characterization Equipment:

Metallography Station Trinolcular Optical Microscope with Camera- To study surface morphology

Specification:

Magnification- 25 X to 1200X
Focusing: Coarse to fine
Head: Monocular, binocular/trinocular
Illumination- Halogen, incident light
Eye piece: 5X, 10X, 15X and 20 X
Objective: 5X, 10X 20X and 40X

Location: NL-1, Room # 112

 


Characterization Equipment:

Surface Roughness Tester- Measurement of surface hardness

Specification:

Range: 350 m (-200 m to 150 m)
Detecting mode: Skid measurement
Measuring force: 4mN or 0.75 mN (Low force type)
Stylus tip: Diamond, 900/mR (600/2mR: low force type)
Travelling length : 6 mm
Evolution length (mm) : 1.25,  4.0

Location: ACMS 207B

 


Characterization Equipment:

Superficial Rockwell Tester

Specification:

Range: 350 m (-200 m to 150 m)
Detecting mode: Skid measurement
Measuring force: 4mN or 0.75 mN (Low force type)
Stylus tip: Diamond, 900/mR (600/2mR: low force type)
Travelling length : 6 mm
Evolution length (mm) : 1.25,  4.0

Location: ACMS 207B

 


Characterization Equipment:

Brinell Hardness Tester- Brinell hardness test of Metals

Specification:

Preload: 250 Kgf
Major Load - 250-3000 Kgf in range of 250 Kgf
250, 500, 750, 1000, 1250, 1500 Kgf
Maximum test height- 410 mm
Depth of throat- 205 mm
Max depth of spindle below base – 180 mm
Steel ball diameter (Indentor)- 10 mm , 5 mm, 2.5 mm

Location: ACMS 203B

 


Characterization Equipment:

Vickers Hardness Tester- Vickers hardness tester of metals

Specification:

Load- 5 Kgf to 50 Kgf
30, 40, 50 Kgf (loads 5, 10, 15, 20 not working properly)
Indentor – diamond
Magnification- 25 X

Location: ACMS 203B

 

Associate Faculty: Prof. Kamal K. Kar, Prof. Bishakh Bhattacharya, Prof. J. Ramkumar

Staff: Mr. Suresh Chendra

Contact Person: Mr. Suresh Chendra
 

Micro/Nano-Texturing

Chromium Etching by Laser

 

The major research focus is on nano/ meso scale patterning in metals and polymers for developing different surfaces which have different wettabilities, adhesion and friction coefficients for tribological applications. The patterning is performed by using Excimer laser machining. The patterns can also be grown on surfaces by using chemical vapor deposition processes. Patterning thin chromium films with laser has been explored for a variety of mask fabrication processes for lithography applications. The lasing process is further optimized by exploring COMSOL models of light matter interaction.

Research Areas


Microtexturing on metals, polymers and semiconducting surfaces through Laser processes and using CVD growth


Research Laboratories:

 

Manufacturing Science Laboratory
Tribology and Surface Engineering Lab

 

Associated Faculty

 

J. Ramkumar, PhD (IIT Madras): Micro / Nano-Fabrication and finishing, Nano Composites and Tribology


Array of craters on silicon material fabrciated with Excimer laser machining process


SEM image of GaN nanostructures grown on silicon substrate