Madhanagopal Manoharan
@iiitdm.ac.in
Center for Smart Manufacturing, Indian Institute of Information Technology Design and Manufacturing Kancheepuram
IIITDM Kancheepuram
EDUCATION
M.E. (
RESEARCH, TEACHING, or OTHER INTERESTS
Multidisciplinary, Mechanical Engineering, Control and Systems Engineering, Human-Computer Interaction
Scopus Publications
Scholar Citations
Scholar h-index
Scholar i10-index
Scopus Publications
Perumal Sudalai and Madhanagopal Manoharan
Elsevier BV
Madhanagopal Manoharan and Senthilkumaran Kumaraguru
Informa UK Limited
ABSTRACT Direct Energy Deposition (DED) is one of the Metal Additive Manufacturing processes, which can be used to print near-net shapes and repair volumes using five-axis CNC or six-axis serial manipulator-based robotic systems. For such a system, robust algorithms are needed to decompose faceted solid models into programmable tool paths for multi-directional printing using multi-axis systems. In the past, many algorithms for volume decomposition have been developed for nesting parts inside the build envelope, improving the mechanical properties, and maintaining the printed part surface quality. This paper presents the use of a Volume Decomposition strategy to identify and decompose the overhang features in faceted models, which can be built using multi-axis DED systems. The Improved Convex Volume Decomposition algorithm presented in this work makes use of down-facing surface normal in the tessellated model as a reference for decomposing the overhang features, and also provides an opportunity to identify and decompose the presence of overhang features in the particular build direction of those overhang features. This methodology could eliminate the need for intrinsic mass property evaluations such as centroids, and silhouette edges for simple overhanging features. In addition, a test part was built in a multi-axis DED system to exemplify the benefits of overhang-angle-driven volume decomposition, which decomposes the overhang features in the decomposed Overhang Sub-Volumes. Furthermore, the post-processing time of multi-directional printed parts is reduced, and this multi-directional part printing may overcome the poor surface finish generally found in unidirectional printed parts.
Madhanagopal Manoharan, Chitikena Hareesh, and Senthilkumaran Kumaraguru
Springer Nature Singapore
Madhanagopal Manoharan, Karanam Sreedhar Sai Thilak, and Senthilkumaran Kumaraguru
IEEE
Collaborative robots are increasingly used in several industries because of their safety and easy deployment for increased productivity. This paper presents the motion control synchronization methods for controlling dual six-axis serial manipulators using network socket and microcontroller interface. The sequence of steps for network-based cooperative robot control with dual six-axis serial manipulators is also presented in this work. The proposed affordable collaborative robotic motion control may be useful to control multiple serial manipulators, which are deployed for operations in the industries. Even though microcontrollers can perform high-performance edge computing for robot motion control, it is always accompanied by a large number of wires. However, network synchronization using the server-client interface has some latency and security issues. But it has its capability for large-scale integration and possible adoption of new technologies such as remote monitoring, cloud computing, etc.
Madhanagopal Manoharan, Potnuru Hema Praneetha Naidu, Midhun Joy, and Senthilkumaran Kumaraguru
American Society of Mechanical Engineers
Abstract Additive Manufacturing (AM) eases the fabrication of multifunctional simultaneous printing of multi-materials, which is quite cumbersome to fabricate in traditional manufacturing processes. Heterogeneous objects are entities engineered with multiple materials, and their emergence with the advent of AM is sporadic. This paper presents the novel layer decomposition methodology by utilizing Medial Axis Transformation (MAT) to generate discrete volumes for multi-material printing. Further, these discrete geometries are printed using multi-material addons, such as Palette Pro for material extrusion-based Additive Manufacturing systems. Tensile testing is performed to analyze the effectiveness and characteristics of the layer decomposition strategy. However, fabrication of the generated heterogeneous objects utilizes a computational model that maps the geometry of the object with the material composition. This methodology can also be applicable to model compositional heterogeneity for part fabrication using a metal-based Direct Energy Deposition (DED) process.
Madhanagopal Manoharan, Arul Kulandaivel, Adinarayanan Arunagiri, Mohamad Reda A. Refaai, Simon Yishak, and Gowthaman Buddharsamy
Hindawi Limited
Milling is the surface machining process by removing material from the raw stock using revolving cutters. This process accounts for a major stake in most of the Original Equipment Manufacturing (OEM) industries. This paper discusses optimizing process parameters for machining the AA 2014 T 651 using a vertical milling machine with coated cutting tools. The process parameters such as cutting speed, depth of cut, and type of the cutting tool with all its levels are identified from the previous literature study and several trial experiments. The Taguchi L9 Orthogonal Array (OA) is used for the experimental order with the chosen input parameters. The commonly used cutting tools in the machining industry, such as High-Speed Steel (HSS) and its coated tools, are considered in this study. These tools are coated with Titanium Nitride (TiN) and Titanium Aluminum Nitride (TiAlN) by Physical Vapor Deposition (PVD) technique. The output responses such as cutting forces along the three-axis are measured using a milling tool dynamometer for the corresponding input factors. The input process parameters are optimized by considering the output responses such as MRR, machining torque, and thrust force. Grey Taguchi-based Response Surface Methodology (GTRSM) is used for multiobjective multiresponse optimization problems to find the optimum input process parameter combination for the desired response. Polynomial regression equations are generated to understand the mathematical relation between the input factor and output responses as well as Grey Relational Grade (GRG) values. The optimum process parameter combination from the desirability analysis is the HSS tool coated with TiAlN at a cutting speed of 270 rpm and a depth of cut value of 0.2 mm.
Madhanagopal Manoharan, Aditya Navghare Shridhar, Vivek Yadav Vinod, and Senthilkumaran Kumaraguru
IEEE
This work presents a methodology to decompose part volume into sub-volumes for work allocation to multiple robots considering the effect of bonding. The use of Industrial Robots in Additive Manufacturing (AM) increases due to its flexibility to print complex geometrical features with AM processes. Usually, the work volume for multi-robots is decomposed into two equal sub-volumes for allocating the work to multi-robot configurations. The Corrugated Partition for Intersected Sandwich Layers (CPISL) methodology addresses the bonding issue between the printed sub-volumes and enhances the process speed and productivity. From the print time analysis, the sub-volumes obtained with the CPISL methodology take nearly the same time for part printing than sub-dividing the same part into two equal sub-volumes. This technique may find applications for the multiple Industrial robots used in polymer-based Material Extrusion or metalbased Direct Energy Deposition (DED) processes. A unified software interface is developed to control dual robot arms and the extruder attached to its end effector for material extrusion application. This work may be useful to aerospace, defense, construction, and automobile industries for printing large volumes with improved mechanical properties.
Hemnath Anandan Kumar, Peter Francis Reginald Elvis, Madhanagopal Manoharan, Jayakrishnan Jayapal, and Senthilkumaran Kumaraguru
Springer Singapore
Madhanagopal Manoharan and Senthilkumaran Kumaraguru
IEEE
This paper discusses the issues and opportunities in using stand-alone and collaborative robots in Additive Manufacturing (AM) processes. Recently, the six-axes robots are beginning to find its use in many AM processes for the production of complex shapes and increasing the productivity. These robots help to overcome the challenges in CNC based system and to address various complexities that are unique for AM parts. In this paper, we investigate the different path planning patterns used in the past and their application to robotic based AM processes. We also propose methods of path planning for Collaborative Robots (CoBots) to build parts quickly. The work presented in this paper would be useful for the aerospace and automotive industries when CoBots are adopted to speed-up their AM processes.
Thamilarasan Kollapuri, Madhanagopal Manoharan, Rajendra Boopathy Sadayan, and Rama Koteswara Rao Sajja
American Society of Mechanical Engineers
Stress Corrosion Cracking (SCC) is the initiation and slow growth of cracks under the influence of tensile stresses and aggressive corrosion environment. Al alloy 2014 T 651 was solution heat treated and stress-relieved. In the present work, Stress Corrosion Cracking (SCC) experimental arrangement has been used to test the severity of aluminium alloys under particular environmental conditions. Sound welds were obtained with Friction Stir Welding at rotational speed of 800 rpm and welding speed of 200 mm/min. Friction Stir Welds were cut into standard tensile specimens as per ASTM E8 standards. Time to failure of the welds were obtained using 3.5 wt% NaCl solution at pH 10 in 0.7 and 1.1 yields by Stress Corrosion Cracking. Vickers micro-hardness was taken along various regions of the weld. Optical micro-graphs and scanning electron fractographs were taken to analyse the fracture behavior and fracture morphology of Friction Stir Welded aluminium alloy specimens, subjected to Stress Corrosion Cracking.