Experimental study of surface modification of aluminium 7075 alloy by reverse EDM process using SiC-Cu powder metallurgy green compact electrode and Taguchi experimental design Lokesh Kumar Ranjan, Sujoy Chakraborty, Uttam Kumar Mandal International Journal of Machining and Machinability of Materials, 2024 In this work, an attempt has been made to alter the surface of Al-7075 substrate using SiC and Cu powder mixed electrodes in Die sink EDM. Experiments have been carried out using Taguchi L-9 orthogonal array. There are three input parameters in this experiment like compaction load, peak current, and tool composition. Analysis of variance (ANOVA) and main effect analysis have also been performed for the output responses like material deposition rate (MDR), tool wear rate (TWR) and surface roughness (SR) respectively. Material deposition rate of 0.385 (mg/min), tool wear rate of 4.37 (mg/min), average surface roughness of 2.101 (μm) and average layer thickness of 25.01 μm have been successfully achieved. Furthermore, examining the nature of surface geology; scanning electron microscope (SEM), energy dispersive spectrometer (EDS) and X-Ray diffraction (XRD) analysis have also been performed which supports the transfer of tool ingredients over work piece samples with enhanced surface characteristics.
Experimental investigations and optimization of process variables of electro discharge coating process for Al-7075 alloy: a hybrid MCDM approach Lokesh Kr. Ranjan, Sujoy Chakraborty, Uttam Kumar Mandal Journal of Adhesion Science and Technology, 2024 The present study aimed to improve and assess the electrical discharge coating (EDC) factors with aluminium 7075 alloy as a substrate. The results of input variables like current, composition, and compaction load on EDC responses, including material deposition rate (MDR), tool wear rate (TWR), and surface roughness (Ra) were studied. Taguchi’s L9 experiment design was employed with GRA (grey relational analysis), ARAS (Additive Ratio Assessment), and preference value (Ki) was measured. The experiments determined the best parametric setting for more MDR, less TWR, and less Ra. The level of contribution of the process parameters to the response was evaluated by a statistical test known as ANOVA, wherein current appeared as the most noteworthy parameter, followed by composition and compaction load. The results of GRA and ARAS were compared with a prominent MCDM method known as TOPSIS, which substantiated the outcomes of both methods. Successfully attained rates for material deposition, tool wear, and average surface roughness were 0.385 mg/min for material, 4.37 mg/min for tool wear, and 2.101 µm for surface roughness. Finally, a sensitivity study is used to validate the hybrid model’s constancy with a strong correlation. The topography of the deposited surface was analyzed by SEM, wherein base material, deposition, and interface were distinctly visible with the occurrence of a few micro-cracks. The XRD contour of the coating exhibited peaks of Al, Al2Cu, Cu, and SiC. Additionally, the pin-on-disc wear result yielded a substantial drop in the wear of the coated samples as compared to the substrate material.
Surface Modification of Al-7075 Alloy by SiC-Cu Ceramic Electrode in Electrical Discharge Coating Lokesh Kumar Ranjan, Sujoy Chakraborty, Uttam Kumar Mandal, Siddhartha Kar, Arabinda Meher Journal of Scientific and Industrial Research, 2024 The present study aims to enhance and evaluate Electrical Discharge Coating (EDC) on Al-7075 alloy using SiC-Cu ceramic electrode. The study analyses the impact of input parameters such as current, composition and compaction load on EDC responses, including Material Deposition Rate (MDR), Tool Wear Rate (TWR) and Surface Roughness (SR). Trial tests were performed using Taguchi's L9 experimental design, and thereafter, Grey Relational Analysis (GRA) and technique for order preference by similarity to an ideal solution (TOPSIS) were implemented to optimize all the responses. The experiments were optimized to achieve a higher MDR, lower TWR and lower SR. Analysis of variance was also employed to statistically investigate the experimental data and determine the contribution of each parameter to achieve better results. Optimum condition was achieved with a compaction load of 5 ton, current 6 A and composition 50:50, using both the GRA and TOPSIS methods. At the optimum condition, there was an improvement in GRA from 0.5603 to 0.7778, while TOPSIS showed an improvement from 0.2418 to 0.7659. Further, the morphology of the coated surface was investigated using scanning electron microscopy images and X-ray diffraction analyses, which confirmed the migration of SiC-Cu from the tool materials.
Experimental Investigation of Physical and Mechanical Properties of Al-Cu-ZrO2TiO2 Composites Debashis Podder, S. Chakraborty, U. Mandal Journal of Scientific and Industrial Research, 2022 Composite Materials plays a vital role in the formation of mankind, ranging from the habitation of early civilisation to enable future modernisation. In this present work titania and zirconia reinforced Al6063-Cu composite has been developed by using a new casting process comprising of clay soil and sand mold. On top of that stirrer mechanism has also been used to mix the hybrid abrasive particles of Single Particle Size (SPS), Double Particle Size (DSP) and Triple Particle Size (TPS) in the Al-Cu alloy which is a completely new approach. Taguchi L18 orthogonal arrays have been used in this study to reduce the number of tests. For this present research work, 5%, 7.5% and 10% of hybrid abrasive have been mixed in the alloy to investigate its different properties like elastic modulus, ductility and density. It has been observed that in addition of the reinforcements in the newly developed composites elastic modulus, ductility and density have been improved to 31.42%, 40% and 19.81% respectively. Due to this improved properties this composite can be used to manufacture bearing, valve, aircraft electronics and many other appliances. The experimental results were analyzed by the SN ratio plot and an RSM model was used to predict these properties and to estimate the affecting factors for each property. Further, the RSM models have been corroborated by performing the experiments on the newly manufactured composites for elastic modulus, ductility and density. The result obtained from RSM model shows good similarity with the experimental results.
Evaluation of Microstructure and Mechanical Properties of Al-Cu-TiO2-ZrO2 Composites Journal of Scientific and Industrial Research, 2022
Multi attribute decision making for determining optimum process parameter in EDC with SI and Cu mixed powder green compact electrodes Journal of Scientific and Industrial Research, 2018
Stress analysis and design optimization of piston slipper assembly in an axial piston pump Journal of Scientific and Industrial Research, 2014
Performance prediction of Centrifugal Pumps with variations of blade number Journal of Scientific and Industrial Research, 2013
CFD analysis of centrifugal pumps with variations of blade number at 3300 RPM International Journal of Applied Engineering Research, 2013
Numerical analysis of centrifugal pumps with fluent software International Journal of Applied Engineering Research, 2011
RECENT SCHOLAR PUBLICATIONS
Gray Relational Optimization of Dry Electrical Discharge Coating Parameters for Copper-Graphene Coating on Al6061 Alloy in Argon Atmosphere P Goswami, S Chakraborty, V Dey, D Podder Journal of Materials Engineering and Performance, 1-16 , 2026 2026
Influence of Gaseous Dielectric Environments on Dry Electro Discharge Coating of Al 6061 Alloy with Zirconia–Copper Electrodes P Goswami, S Chakraborty, V Dey, D Podder Journal of Materials Engineering and Performance, 1-16 , 2026 2026 Citations: 1
Surface modification of Al-6061 alloy by copper/graphene green compact electrode in dry electro discharge coating with nitrogen gas as dielectric P Goswami, S Chakraborty, V Dey Journal of Adhesion Science and Technology 40 (1), 1-28 , 2026 2026 Citations: 3
Experimental Investigation of Electric Discharge Machining of Nimonic C263 Using Circular Shaped Copper Tool Electrode S Chakraborty, UK Mandal, D Podder, LK Ranjan, D Boro 6th International Conference on Recent Advancements in Mechanical … , 2025 2025
Experimental investigations and optimization of process variables of electro discharge coating process for Al-7075 alloy: a hybrid MCDM approach LK Ranjan, S Chakraborty, UK Mandal Journal of Adhesion Science and Technology 38 (10), 1756-1781 , 2024 2024 Citations: 9
Surface Modification of Al-7075 Alloy by SiC-Cu Ceramic Electrode in Electrical Discharge Coating: SURFACE MODIFICATION OF ALUMINIUM 7075 ALLOY BY SILICON CARBIDE THROUGH EDC LK Ranjan, S Chakraborty, UK Mandal, S Kar, A Meher Journal of Scientific & Industrial Research (JSIR) 83 (1), 5-14 , 2024 2024 Citations: 3
Analysis of surface wear behavior during electrical discharge coating process using powder metallurgy compacted electrodes: a review DV Goswami P, Chakraborty S Recent Advancements in Electrical Discharge Machining , 2024 2024
Selection of Best Alternative in Intelligent Manufacturing System by Hybrid AHP and Fuzzy-TOPSIS Environment Mandal UK, Chakraborty S, Podder D, Biswas N 56th Annual Convention of Operational Research Society of India (2023-ORSI … , 2023 2023
Experimental study of surface modification of aluminium 7075 alloy by reverse EDM process using SiC-Cu powder metallurgy green compact electrode and Taguchi experimental design LK Ranjan, S Chakraborty, UK Mandal International Journal of Machining and Machinability of Materials 25 (3-4 … , 2023 2023 Citations: 2
Experimental investigation of physical and mechanical properties of Al-Cu-ZrO-TiO composites D Podder, S Chakraborty, UK Mandal J Sci Ind Res 81, 720-729 , 2022 2022 Citations: 3
Evaluation of Microstructure and Mechanical Properties of Al-Cu-TiO2-ZrO2 Composites D Podder, S Chakraborty, UK Mandal Journal of Scientific & Industrial Research 81, 39-50 , 2022 2022
RSM analysis of impact property and characterization of Al6063-Cu-TiO 2 -ZrO 2 composites fabricated by stir casting process D Podder, S Chakraborty, UK Mandal Sādhanā 46 (2), 72 , 2021 2021 Citations: 9
Study on Mechanical Properties of Aluminium-Copper Matrix Composites D Podder, S Chakraborty, UK Mandal 2nd International Conference on Industrial & Manufacturing Systems (CIMS-2021) , 2021 2021
ANALYSIS OF SURFACE WEAR BEHAVIOR DURING ELECTRICAL DISCHARGE COATING PROCESS USING POWDER METALLURGY COMPACTED ELECTRODES: A REVIEW P Goswami, S Chakraborty, V Dey 2nd International Conference on Advances in Material Science 2021 (ICAMS 2021) , 2021 2021
A Study on Surface Roughness and Micro-hardness Obtained by using Die Sinking EDM Machine: A Review LK Ranjan, S Chakraborty, UK Mandal 2nd International Conference on Advances in Material Science 2021 (ICAMS 2021) , 2021 2021
Surface Modification of Al-7075 Alloy by Electro-Discharge Coating Process using SiC/Cu Green Compact Electrode LK Ranjan, S Chakraborty, UK Mandal, V Dey, K Jha 8th International & 29th All India Manufacturing Technology, Design and … , 2021 2021
Preparation of SiC and Al2O3 of Single, Double and Triple Particle Size Reinforced AMC by using Vacuum Moulding and Stir Casting to Investigate the MRR of the AMC UK Mandal, D Podder, S Chakraborty, B Karmakar International Conference on Advances in Mechanical Engineering ICAME-2020 , 2020 2020
Preparation of a New Hybrid Reinforced MMC by Using a Commercially Low Cost New Casting Process to check the mechanical property and microstructure P D, M UK, C S, B N International Conference on Clean and Renewable Energy (ICCARE 2019) , 2019 2019
The phenomenon of surface modification by electro-discharge coating process: a review S Chakraborty, S Kar, V Dey, SK Ghosh Surface Review and Letters 25 (01), 1830003 , 2018 2018 Citations: 50
Multi Attribute Decision Making for Determining Optimum Process Parameter in EDC with Si and Cu Mixed Powder Green Compact Electrodes S Chakraborty, S Kar, V Dey, SK Ghosh Journal of Scientific & Industrial Research 77, 229-236 , 2018 2018 Citations: 21
MOST CITED SCHOLAR PUBLICATIONS
A review on the use of dielectric fluids and their effects in electrical discharge machining characteristics S Chakraborty, V Dey, SK Ghosh Precision Engineering 40, 1-6 , 2015 2015 Citations: 234
Numerical Studies on Effects of Blade Number Variationson Performance of Centrifugal Pumps at 4000 RPM S Chakraborty, KM Pandey International Journal of Engineering and Technology 3 (4), 410 , 2011 2011 Citations: 56
The phenomenon of surface modification by electro-discharge coating process: a review S Chakraborty, S Kar, V Dey, SK Ghosh Surface Review and Letters 25 (01), 1830003 , 2018 2018 Citations: 50
Numerical analysis on effects of blade number variations on performance of centrifugal pumps with various rotational speeds S Chakraborty, KM Pandey, B Roy International Journal of Current Engineering and Technology 2 (1), 143-152 , 2012 2012 Citations: 47
Optimization and surface modification of al-6351 alloy using SiC–cu green compact electrode by electro discharge coating process S Chakraborty, S Kar, V Dey, SK Ghosh Surface Review and Letters 24 (01), 1750007 , 2017 2017 Citations: 46
Optimization of surface roughness parameters of Al-6351 alloy in EDC process: a taguchi coupled fuzzy logic approach S Kar, S Chakraborty, V Dey, SK Ghosh Journal of The Institution of Engineers (India): Series C 98 (5), 607-618 , 2017 2017 Citations: 39
Performance prediction of Centrifugal Pumps with variations of blade number S Chakraborty, K Choudhuri, P Dutta, B Debbarma Journal of Scientific and Industrial Research 72 (6), 373-378 , 2013 2013 Citations: 38
Parametric optimization of electric discharge coating on Aluminium-6351 alloy with green compact silicon carbide and copper tool: a Taguchi coupled utility concept approach S Chakraborty, S Kar, SK Ghosh, V Dey Surfaces and Interfaces 7, 47-57 , 2017 2017 Citations: 36
Selection of optimal aluminum alloy using TOPSIS method under fuzzy environment P Bhattacharjee, A Debnath, S Chakraborty, UK Mandal Journal of Intelligent & Fuzzy Systems 32 (1), 871-876 , 2017 2017 Citations: 25
Numerical studies on effects of blade number variations on performance of centrifugal pumps AT 2500 rpm KM Pandey, AP Singh, S Chakraborty Journal of Environmental Research And Development 6 (3A), 863-68 , 2012 2012 Citations: 24
Multi Attribute Decision Making for Determining Optimum Process Parameter in EDC with Si and Cu Mixed Powder Green Compact Electrodes S Chakraborty, S Kar, V Dey, SK Ghosh Journal of Scientific & Industrial Research 77, 229-236 , 2018 2018 Citations: 21
Stress analysis and design optimization of piston slipper assembly in an axial piston pump K Choudhuri, S Chakraborty, P Chakraborti, P Dutta J. Sci. Ind. Res 73 (5), 318-323 , 2014 2014 Citations: 20
A simple case study of material requirement planning A Sarkar, D Das, S Chakraborty, N Biswas IOSR Journal of Mechanical and Civil Engineering 9 (5), 58-64 , 2013 2013 Citations: 18
Synthesis and optimization of low-cost and high efficient zirconium-aluminium modified iron oxide nano adsorbent for fluoride removal from drinking water M K Adak, S Chakraborty, S Sen, D Dhak Advanced Materials Proceedings 2 (11), 716-724 , 2017 2017 Citations: 15
Experimental investigations and optimization of process variables of electro discharge coating process for Al-7075 alloy: a hybrid MCDM approach LK Ranjan, S Chakraborty, UK Mandal Journal of Adhesion Science and Technology 38 (10), 1756-1781 , 2024 2024 Citations: 9
RSM analysis of impact property and characterization of Al6063-Cu-TiO 2 -ZrO 2 composites fabricated by stir casting process D Podder, S Chakraborty, UK Mandal Sādhanā 46 (2), 72 , 2021 2021 Citations: 9
CFD analysis of flow through compressor cascade KM Pandey, S Chakraborty, K Deb International Journal of soft computing and Engineering 2 (1) , 2012 2012 Citations: 9
A Review Paper of Wind Energy S Chakraborty, A Sinha, S Dutta, N Biswas National Conference on Advances and Research in Electrical System Technology … , 2011 2011 Citations: 9
Surface modification of Al-6061 alloy by copper/graphene green compact electrode in dry electro discharge coating with nitrogen gas as dielectric P Goswami, S Chakraborty, V Dey Journal of Adhesion Science and Technology 40 (1), 1-28 , 2026 2026 Citations: 3
Surface Modification of Al-7075 Alloy by SiC-Cu Ceramic Electrode in Electrical Discharge Coating: SURFACE MODIFICATION OF ALUMINIUM 7075 ALLOY BY SILICON CARBIDE THROUGH EDC LK Ranjan, S Chakraborty, UK Mandal, S Kar, A Meher Journal of Scientific & Industrial Research (JSIR) 83 (1), 5-14 , 2024 2024 Citations: 3