Surface and subsurface characteristics of wire-electrical discharge machined Al-alloy and composite: a fundamental study on the role of machining variables Gaurav Anand, Santanu Sardar, Satesh Sah, Ashim Guha, Ibrahim Albaijan, Debdulal Das Journal of Materials Research and Technology, 2025 For hard-to-machine materials like discontinuous particulate reinforced Al-matrix composites, wire-electrical discharge machining (wire-EDM) is increasingly preferred for manufacturing intricately shaped parts with high dimensional accuracies and surface finishes. The wire-EDM process involves a large number of machining variables apart from parameters associated with the workpiece, dielectric, and electrode; therefore, research on wire-EDM is often performed on the basis of the design of experiments , which is somewhat limited the fundamental understanding of the role of various influencing variables. The current experimental research reports the influences of major wire-EDM machining variables on the surface and subsurface characteristics of 20 vol.% in-situ Al 3 Fe reinforced Al-2Mg alloy in reference to the unreinforced matrix alloy. The cutting velocity (CV), kerf width (KW), surface roughness (SR), and surface chemistry (SC, =ΣO+Zn+Cu) of the composite and base alloy have been determined over a wide range of peak current (I P , 70-150 A), pulse-on time (T ON , 5-25 μs), pulse-off time (T OFF , 51-63 μs), servo voltage (S V , 40-80 V), wire feed rate (W FR , 6-10 m min -1 ) and wire tension (WT, 4-12 N), varying one parameter at a time and keeping all others constant at their mid-levels. The surface and subsurface of the wire-EDMed composite and alloy specimens have been extensively characterized employing FESEM coupled with EDS microanalyses, including the change in surface chemistry due to the in-situ oxidation and transfer of elements from the brass wire electrode, while a noncontact optical profilometer has been employed to determine the surface roughness. The CV, KW, and SR are found to increase monotonically with increasing I P and T ON but decreasing T OFF, while the reverse trend has been observed for SC; these influences are more pronounced for base alloy over composite except for SR. Higher S V diminishes CV and markedly raises SC; in contrast, enhanced WT decreases only KW, and greater W FR increases SC only. Variations in the mechanisms of material removal and, subsequently, the alterations in the surface and subsurface of machined alloy and composite have been proposed.
Role of spark energy and frequency on wire-EDM performances of Al-2Mg alloy and Al-2Mg/20 Al3Fe composite: a comparative study Gaurav Anand, Santanu Sardar, Ashim Guha, Debdulal Das Advances in Materials and Processing Technologies, 2025 The performance of wire-electric discharge machining (WEDM) method is inevitably affected by the electric spark. A comparative study is presented related to the influences of spark energy (SE, 1.68–8.40 mJ) and spark frequency (SF, 12.82–15.15 kHz) on machining responses of Al-2Mg/20 vol.% in-situ Al3Fe composite with respect to Al-2Mg alloy. Such comparison is scanty in the literature. Machining performances were measured concerning material removal rate (MRR), cutting speed (CS), and surface roughness (SR) apart from the morphological evolution of machined surfaces. Irrespective of machining condition (for instance, at SE of 5.04 mJ), composite exhibited lower CS (1.27 mm/min), MRR (4.20 mm3/min), and SR (4.42 µm) due to the insulating effect of reinforcement than alloy (i.e. 1.70 mm/min, 5.81 mm3/min, and 4.82 µm, respectively). For both alloy and composite, all three machining performances increased linearly with rising the SE and SF, although the influence of SE was more pronounced over SF. With increasing SE, the difference in the magnitudes of CS and MRR between alloy and composite widened, while the same for SR narrowed. Formations of micro-cracks, lumps of debris, craters, and re-solidified layers were observed more on alloy machining surface than composite; these features enlarged with increasing SE and SF.
Multi-objective optimization to enhance surface integrity in WEDM for Al-matrix composite: A comparative assessment of self-weight adjusting MCDMs and objective weight integrated hybrid TOPSIS methods Gaurav Anand, Santanu Sardar, Satesh Sah, Ashim Guha, Debdulal Das Results in Surfaces and Interfaces, 2025 Wire-electrical discharge machining (WEDM) is immensely preferred for fabricating intricately shaped components made of advanced materials, such as composite materials, maintaining excellent precision and surface finish. The process involves a large number of input variables associated with workpiece and tool materials as well as machine and dielectric media, while the output responses are often contradictory. Therefore, the commercial adaptation of WEDM requires multi-objective optimization, which could be done by multi-criteria decision-making (MCDM) techniques. The present research performed a comprehensive evaluation of two distinct variants of MCDM techniques, namely, self-weight adjusting (GRA, PSI, SECA, and DEAR) and external weight (SD, Entropy, CRITIC, CILOS, IDOCRIW, and MEREC) integrated TOPSIS methods. These techniques were assessed for the optimization of modification in surface chemistry (MSC), surface roughness (SR), and cutting velocity (CV) in WEDM of an in-situ stir-cast Al–Mg/20 Al3Fe composite employing the experimental results conducted based on RSM-CCD layout considering input variables of pulse-on time, servo voltage, peak current, and wire-feed rate. It was found that the optimal solution varied widely among the self-weight adjusting MCDMs; however, the external weight integrated TOPSIS methods provided the exact optimal solution even though the relative weights of CV, SR, and MSC varied considerably. The DEAR method, which was relatively simple to implement, matched the robust TOPSIS method and, hence, could be explored in manufacturing sectors. The function of process variables on the integrity of the machined surfaces was corroborated through meticulous characterizations of the surfaces and sub-surfaces of the identified best and worst machining conditions.
Mechanical and Swelling Properties of EPDM/SBR Nanocomposites Containing Resorcinol-and Hexamethylenetetramine-Modified HNTs V. Sivaramakrishnan, S. Vishvanathperumal, V. Navaneethakrishnan, G. Anand Polymer Korea, 2024 This research explores the impact of varying concentrations of resorcinol- and hexamethylenetetramine-modified halloysite nanotubes (RH-HNTs) on the curing behavior, mechanical properties, and swelling resistance of blended polymeric matrices (80:20) comprising ethylene propylene diene monomer/styrene butadiene rubber (EPDM/SBR). The incorporation of RH-HNTs resulted in enhanced abrasion resistance, hardness, tear strength, compression set, and swelling resistance in the nanocomposites, while simultaneously reducing elongation at break and rebound resilience. The fractured surfaces of the EPDM/SBR nanocomposite specimens were examined using FESEM. Notably, the results reveal that nanocomposites containing 6 phr of RH-HNTs exhibit significant improvements in both tensile strength and abrasion resistance. RH-HNTs reinforced EPDM/SBR at 6 phr showed a 66% increase in stress at 100% elongation due to enhanced cross-linking, along with a 143% improvement in tensile strength. Incorporating RH-modified HNTs into EPDM/SBR nanocomposites resulted in superior properties compared to those reinforced solely with HNTs across all proportions.
Cold-sprayed AA2024/YSZ metal matrix composite coatings on AZ31B magnesium alloy: microstructure, interfacial adhesion, and tribological performance A Mohankumar, V Packkirisamy, A Gobiraman, J Rajabov, ... Journal of Adhesion Science and Technology, 1-30 , 2026 2026 Citations: 2
Wire plus arc additive manufacturing of stainless steel wall for predicting parametric influences on strength: Experimentation and finite-element analysis approach A Thirugnanasambandam, MK Subramaniyan, A Gobiraman, V Elumalai Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2026 2026 Citations: 3
Microstructure and finite element simulation (tensile test) of stainless steel wall produced by wire and arc additive manufacturing A Thirugnanasambandam, MK Subramaniyan, A Gobiraman Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2026 2026 Citations: 2
Green solvent assisted hybrid synthesis of PLA/TiO₂ nanocomposite filaments for 3D printing: Mechanical, rheological, and microstructural characterization SC Amith, SR Swain, A Gobiraman, A Thirugnanasambandam Materials Letters, 139837 , 2025 2025
Enhancing SBR/XNBR blend nanocomposites through HNTs reinforcement V Sivaramakrishnan, S Vishvanathperumal, G Anand, ... Journal of Rubber Research, 1-19 , 2025 2025 Citations: 13
Wire Arc Additive Manufacturing of Stainless Steel 347 Wall for Pressure Vessel Application: Microstructural Performance and Finite Element Analysis of Tensile Test P Castro, A Thirugnanasambandam, A Gobiraman, MK Subramaniyan, ... Journal of Materials Engineering and Performance 34 (19), 21764-21772 , 2025 2025
Carbon nanotubes (CNTs) impact on the mechanical properties and swelling behavior of EPDM/SBR blend nanocomposites S Vishvanathperumal, KN Ramu, G Anand, V Navaneethakrishnan Journal of Rubber Research 28 (3), 463-480 , 2025 2025 Citations: 22
Mechanical strength and swelling resistance enhancement in Ethylene-Propylene-Diene Monomer/Styrene-Butadiene rubber (EPDM/SBR) nanocomposites using 1-Octadecanol-Modified … S Vishvanathperumal, KN Ramu, G Anand, C Dhanesh Journal of Polymer Research 32 (7), 232 , 2025 2025 Citations: 27
Morphology and performance of nanosilica filler filled NR/NBR rubber composites V Sivaramakrishnan, S Vishvanathperumal, V Navaneethakrishnan, ... Journal of Rubber Research 28 (2), 269-289 , 2025 2025 Citations: 30
Mechanical and swelling properties of EPDM/SBR nanocomposites containing resorcinol-and hexamethylenetetramine-modified HNTs V Sivaramakrishnan, S Vishvanathperumal, V Navaneethakrishnan, ... 폴리머 48 (6), 677-692 , 2024 2024 Citations: 40
A comprehensive review on polymers and metal additive manufacturing BA Praveena, N Santhosh, G Anand Advances in Additive Manufacturing, 405-418 , 2024 2024 Citations: 4
An insight investigation on mechanical and corrosion behavior of ultrasonic squeeze casting processed Mg based alloy composites for bio-implantation A Thirugnanasamabandam, A Gobiraman, MR Karim Results in Engineering 23, 102850 , 2024 2024 Citations: 11
Fabrication of stainless steel 308L wall through wire+ arc additive manufacturing: microstructure and numerical prediction of tensile test A Thirugnanasambandam, MK Subramaniyan, A Gobiraman, ... Proceedings of the Institution of Mechanical Engineers, Part L: Journal of … , 2024 2024 Citations: 5
Investigation on the Mechanical Property and Wear Characteristics of Aluminium-6061 Hybrid Composite Reinforced with Graphene-Nanoplatelets by Stir Casting A Gobiraman, N K, S P J. Inst. Eng. India Ser. C , 2024 2024 Citations: 10
An investigation on the effect of the surface modifications and HNTs loading on the cure behaviours, abrasion resistance, mechanical and morphological properties of NR/EPDM … S Vishvanathperumal, JV Roy, G Anand, KN Ramu, S Praveenkumar Silicon 16 (5), 2267-2284 , 2024 2024 Citations: 59
Tribological characterization of the natural fiber‐reinforced polyimide composites A Gobiraman, S Nagaraja, V Sathiyamoorthi Tribological properties, performance and applications of biocomposites, 115-128 , 2024 2024 Citations: 41
Polyester‐based biocomposites for tribological applications A Gobiraman, S Nagaraja, V Sathiyamoorthi Tribological properties, performance and applications of biocomposites, 47-63 , 2024 2024 Citations: 42
The effect of nanosilica on mechanical and swelling resistance properties of ternary rubber (NR/SBR/NBR) blends nanocomposites with and without bis (triethoxysilylpropyl … J Srinivas, MS Jagatheeshwaran, S Vishvanathperumal, G Anand Silicon 16 (4), 1669-1688 , 2024 2024 Citations: 61
Biodegradable polymeric nanofibers prepared via electrospinning A Gobiraman, N Santhosh, S Vishvanathperumal Electrospun nanofibres, 167-190 , 2023 2023 Citations: 38
Epoxy resin as matrix for polymer composites: factors influencing the properties of polymers and their composites A Gobiraman, S Nagaraja, V Sathiyamoorthi Epoxy-based biocomposites, 1-19 , 2023 2023 Citations: 45
MOST CITED SCHOLAR PUBLICATIONS
Effect of nanoclay/nanosilica on the mechanical properties, abrasion and swelling resistance of EPDM/SBR composites S Vishvanathperumal, G Anand Silicon 12 (8), 1925-1941 , 2020 2020 Citations: 113
Effect of nanosilica on the mechanical properties, compression set, morphology, abrasion and swelling resistance of sulphur cured EPDM/SBR composites S Vishvanathperumal, G Anand Silicon 14 (7), 3523-3534 , 2022 2022 Citations: 106
Investigation of drilling parameters on hybrid polymer composites using grey relational analysis, regression, fuzzy logic, and ANN models G Anand, N Alagumurthi, R Elansezhian, K Palanikumar, ... Journal of the Brazilian Society of Mechanical Sciences and Engineering 40 … , 2018 2018 Citations: 105
Properties of SBR/NR Blend: The Effects of Carbon Black/Silica (CB/SiO 2 ) Hybrid Filler and Silane Coupling Agent G Anand, S Vishvanathperumal Silicon 14 (14), 9051-9060 , 2022 2022 Citations: 101
Effect of nanosilica and crosslinking system on the mechanical properties and swelling resistance of EPDM/SBR nanocomposites with and without TESPT S Vishvanathperumal, G Anand Silicon 13 (10), 3473-3497 , 2021 2021 Citations: 96
Evaluation of crosslink density using material constants of ethylene-propylene-diene monomer/styrene-butadiene rubber with different nanoclay loading: finite element analysis … S Vishvanathperumal, V Navaneethakrishnan, G Anand, S Gopalakannan Advanced Science, Engineering and Medicine 12 (5), 632-642 , 2020 2020 Citations: 82
The effect of nanosilica on mechanical and swelling resistance properties of ternary rubber (NR/SBR/NBR) blends nanocomposites with and without bis (triethoxysilylpropyl … J Srinivas, MS Jagatheeshwaran, S Vishvanathperumal, G Anand Silicon 16 (4), 1669-1688 , 2024 2024 Citations: 61
An investigation on the effect of the surface modifications and HNTs loading on the cure behaviours, abrasion resistance, mechanical and morphological properties of NR/EPDM … S Vishvanathperumal, JV Roy, G Anand, KN Ramu, S Praveenkumar Silicon 16 (5), 2267-2284 , 2024 2024 Citations: 59
Epoxy resin as matrix for polymer composites: factors influencing the properties of polymers and their composites A Gobiraman, S Nagaraja, V Sathiyamoorthi Epoxy-based biocomposites, 1-19 , 2023 2023 Citations: 45
Polyester‐based biocomposites for tribological applications A Gobiraman, S Nagaraja, V Sathiyamoorthi Tribological properties, performance and applications of biocomposites, 47-63 , 2024 2024 Citations: 42
Tribological characterization of the natural fiber‐reinforced polyimide composites A Gobiraman, S Nagaraja, V Sathiyamoorthi Tribological properties, performance and applications of biocomposites, 115-128 , 2024 2024 Citations: 41
Mechanical and swelling properties of EPDM/SBR nanocomposites containing resorcinol-and hexamethylenetetramine-modified HNTs V Sivaramakrishnan, S Vishvanathperumal, V Navaneethakrishnan, ... 폴리머 48 (6), 677-692 , 2024 2024 Citations: 40
Effect of multiwalled carbon nanotubes on improvement of fracture toughness of spark-plasma-sintered yttria-stabilized zirconia nanocomposites T Arunkumar, G Anand, R Subbiah, R Karthikeyan, J Jeevahan Journal of Materials Engineering and Performance 30 (6), 3925-3933 , 2021 2021 Citations: 40
Introduction to aging in bio composites G Anand, N Santhosh, S Vishvanathperumal Aging effects on natural fiber-reinforced polymer composites: durability and … , 2022 2022 Citations: 39
Dynamic mechanical, thermal and wear analysis of Ni-P coated glass fiber/Al₂O₃ nanowire reinforced vinyl ester composite G Anand, N Alagumurthi, R Elansezhian, N Venkateshwaran Alexandria Engineering Journal 57 (2), 621-631 , 2018 2018 Citations: 39
Biodegradable polymeric nanofibers prepared via electrospinning A Gobiraman, N Santhosh, S Vishvanathperumal Electrospun nanofibres, 167-190 , 2023 2023 Citations: 38
Future perspectives of nanowires G Anand, N Santhosh, S Vishvanathperumal Nanowires, 395-409 , 2023 2023 Citations: 36
Morphology and performance of nanosilica filler filled NR/NBR rubber composites V Sivaramakrishnan, S Vishvanathperumal, V Navaneethakrishnan, ... Journal of Rubber Research 28 (2), 269-289 , 2025 2025 Citations: 30
Mechanical strength and swelling resistance enhancement in Ethylene-Propylene-Diene Monomer/Styrene-Butadiene rubber (EPDM/SBR) nanocomposites using 1-Octadecanol-Modified … S Vishvanathperumal, KN Ramu, G Anand, C Dhanesh Journal of Polymer Research 32 (7), 232 , 2025 2025 Citations: 27
Carbon nanotubes (CNTs) impact on the mechanical properties and swelling behavior of EPDM/SBR blend nanocomposites S Vishvanathperumal, KN Ramu, G Anand, V Navaneethakrishnan Journal of Rubber Research 28 (3), 463-480 , 2025 2025 Citations: 22