Manufacturing Processes, Non traditional Micro Machining process, Optimizations Techniques.
8
Scopus Publications
17
Scholar Citations
3
Scholar h-index
Scopus Publications
Micromachining through Ultrasonic-Assisted Electrochemical Discharge Process: A Review Mehul S. Prajapati, Devdas I. Lalwani SAE International Journal of Materials and Manufacturing, 2025 <div>As demand for microcomponents has escalated in diverse areas of automotive, medicine, communications, electronics, optics, biotechnology, and avionics industries, there is a need for hybrid manufacturing techniques that can effectively micromachine hard and brittle materials. Electrochemical discharge machining (ECDM) is an advanced manufacturing process for machining difficult-to-cut materials. With a need for precision and accuracy, tool kinematics is a potential research area in ECDM for achieving geometrical dimensioning and tolerances (GD&amp;T). Therefore, the present study reviews the ultrasonic vibration–assisted ECDM (UA-ECDM) hybrid process and the performance of its process parameters (voltage, electrolyte type and its concentration, electrode material, pulse duration, and amplitude) on the material removal rate (MRR), tool electrode wear (TEW), surface integrity, and difficult-to-cut materials. Also, the present work mentions current problems (debris and bubbles trapped, electrolyte circulation, and gas film formation) faced and future research directions to increase the process capabilities based on published research in the UA-ECDM process.</div>
Investigation of concurrent tool rotation with ultrasonic vibration on dimensional accuracy in ECDM Mehul S. Prajapati, Devdas I. Lalwani Materials and Manufacturing Processes, 2025 A systematic investigation elucidates the impact of process variables (voltage, pulse on time, tool vibration amplitude, and tool rotation) on responses, namely, hole deviation (HD), entrance hole overcut (EHOC), and depth of penetration (DOP) during micro-drilling of glass using ultrasonic vibration-assisted rotary tool electrochemical discharge machining (UA-RT-ECDM). The experimental study employed a face-centered central composite design. Voltage has negligible influence on hole deviation and depth of penetration, with only a minor effect on entrance hole overcut. Pulse on time is insignificant for hole deviation and entrance hole overcut. A linear model fits hole deviation and entrance hole overcut. For HD, tool rotation and vibration amplitude contribute 72.86% and 20.2%, respectively. Tool rotation is the leading cause of EHOC, contributing 83.66%. A quadratic model describes DOP, which also includes the interaction effect between vibration amplitude and rotation speed. All developed models demonstrate strong agreement with the experimental data within the considered range.
Micromachining through Ultrasonic-Assisted Electrochemical Discharge Process: A Review Prajapati, Mehul S, Devdas I Lalwani SAE International Journal of Materials and Manufacturing 19 (3), 1-21 , 2025 2025
Investigation of concurrent tool rotation with ultrasonic vibration on dimensional accuracy in ECDM MS Prajapati, DI Lalwani Materials and Manufacturing Processes 40 (14), 1855-1871 , 2025 2025 Citations: 1
Productivity Improvement by Applying Lean Tools for Manufacturing of Mechanical Seal A Shah, S Sane, M Prajapati Proceedings of International Conference on Intelligent Manufacturing and … , 2023 2023 Citations: 1
Study on evolution of hydrogen gas bubble on the performance of the µ-ECDM process M Prajapati, D Lalwani Proceedings of International Conference on Intelligent Manufacturing and … , 2023 2023 Citations: 4
Seal Face Design of Dry Running Seal Assembly to Reduce Gas Leakage S Purohit, A Shaikh, M Prajapati Proceedings of International Conference on Intelligent Manufacturing and … , 2023 2023 Citations: 1
Experimental Investigation During Machining of P20 Tool Steel Using EDM M Kumar, AD Oza, M Prajapati, G Joshi International Conference on Advances in Materials Processing & Manufacturing … , 2021 2021 Citations: 6
Optimization of CNC die-sinking EDM process parameters based on MRR and EWR by taguchi method using copper electrode on P20 tool steel M Prajapati, S Trivedi Proceedings of International Conference on Intelligent Manufacturing and … , 2020 2020 Citations: 1
Development of Storage System by Designing a Magazine for Forged Rings M Karelia, M Prajapati, V Salian Proceedings of International Conference on Intelligent Manufacturing and … , 2020 2020
Optimization of CNC Die-Sinking EDM M Prajapati, S Trivedi Proceedings of International Conference on Intelligent Manufacturing and … , 2020 2020
Analysis of pressure relief valve using matlab simulink DDN Raut, MS Prajapati Proceedings of the 37th National & 4th International conference on fluid … , 2010 2010 Citations: 3
MOST CITED SCHOLAR PUBLICATIONS
Experimental Investigation During Machining of P20 Tool Steel Using EDM M Kumar, AD Oza, M Prajapati, G Joshi International Conference on Advances in Materials Processing & Manufacturing … , 2021 2021 Citations: 6
Study on evolution of hydrogen gas bubble on the performance of the µ-ECDM process M Prajapati, D Lalwani Proceedings of International Conference on Intelligent Manufacturing and … , 2023 2023 Citations: 4
Analysis of pressure relief valve using matlab simulink DDN Raut, MS Prajapati Proceedings of the 37th National & 4th International conference on fluid … , 2010 2010 Citations: 3
Investigation of concurrent tool rotation with ultrasonic vibration on dimensional accuracy in ECDM MS Prajapati, DI Lalwani Materials and Manufacturing Processes 40 (14), 1855-1871 , 2025 2025 Citations: 1
Productivity Improvement by Applying Lean Tools for Manufacturing of Mechanical Seal A Shah, S Sane, M Prajapati Proceedings of International Conference on Intelligent Manufacturing and … , 2023 2023 Citations: 1
Seal Face Design of Dry Running Seal Assembly to Reduce Gas Leakage S Purohit, A Shaikh, M Prajapati Proceedings of International Conference on Intelligent Manufacturing and … , 2023 2023 Citations: 1
Optimization of CNC die-sinking EDM process parameters based on MRR and EWR by taguchi method using copper electrode on P20 tool steel M Prajapati, S Trivedi Proceedings of International Conference on Intelligent Manufacturing and … , 2020 2020 Citations: 1
Micromachining through Ultrasonic-Assisted Electrochemical Discharge Process: A Review Prajapati, Mehul S, Devdas I Lalwani SAE International Journal of Materials and Manufacturing 19 (3), 1-21 , 2025 2025
Development of Storage System by Designing a Magazine for Forged Rings M Karelia, M Prajapati, V Salian Proceedings of International Conference on Intelligent Manufacturing and … , 2020 2020
Optimization of CNC Die-Sinking EDM M Prajapati, S Trivedi Proceedings of International Conference on Intelligent Manufacturing and … , 2020 2020
