Dr. Saswat Khatai is a dedicated and accomplished young researcher from India. He began his academic journey by earning a Bachelor of Technology (B.Tech) degree from the Trident Academy of Technology, affiliated with the esteemed Biju Patnaik University of Technology in Odisha, India. Building upon his strong foundation in engineering, he completed his Master of Technology (M.Tech) degree at the School of Mechanical Engineering, KIIT Deemed to be University, in 2020. Driven by his passion for research, Dr. Khatai continued his academic journey as a Ph.D. research scholar and completed his Ph.D. in September 2024 from the School of Mechanical Engineering, KIIT Deemed to be University. Dr. Khatai’s research endeavors span a wide range of critical areas, including the synthesis and characterization of nano-cutting fluids, the enhancement of machinability performance for hard-to-cut materials and high-heat-resistant alloys, the development of sustainable cooling environments for machining
RESEARCH, TEACHING, or OTHER INTERESTS
Mechanical Engineering, Industrial and Manufacturing Engineering, Renewable Energy, Sustainability and the Environment, Materials Science
Performance assessment of the multi-nozzle injection MQL system for cleaner machining of hardened AISI D2 steel concerning power consumption Saswat Khatai, Ashok Kumar Sahoo, Ramanuj Kumar, Amlana Panda Canadian Metallurgical Quarterly, 2025 Sustainable hard machining is a pressing need in manufacturing industries for techno-social, economic and environmental benefits to machine difficult-to-cut materials. Thus the present study investigates finish turning of hardened AISI D2 steel using a MTCVD coated carbide insert (TiN-TiCN-Al2O3) with geometry CNMG120408FW and grade WK05CT under a multi-nozzle MQL system using LRT 30 mineral oil (50 ml/hr flow rate, 6 bar compressed air pressure, 30 mm nozzle distance from tool tip) for minimal quantity lubrication at both the rake and flank zones for assessment of machinability. Flank wear lies between 0.79 and 0.155 mm and within the failure criterion limit of 0.2 mm. Arithmetic surface roughness trials have been within 0.361–0.877 microns and within the 1.6 microns acceptable range. The cutting temperature has been between 80.7°C and 226.9°C and even below 200°C in the majority of runs. The cutting power lies within 0.432kW–0.804kW. The optimal parametric combination has been found to be d=0.1 mm, f=0.05 mm/rev and v=80 m/min respectively and improvement has been observed over dry cutting. RSM models are found to be statistically significant. Application of multi-nozzle MQL in machining of hardened steel outperformed through machinability assessment and may be adopted in shopfloor for sustainability..
Hard turning performance assessment of AISI D2 steel under dual nozzle MQL assisted ZrO2 and GO nano-cutting fluids: A sustainability approach Saswat Khatai, Ashok Kumar Sahoo, Ramanuj Kumar, Amlana Panda Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science, 2024 “Green manufacturing” is often referred as a sustainable manufacturing process where ecofriendly cutting fluids are used to achieve social, economic, and environmental goals, which mitigates the soil, air, and water contamination and enhances operator’s health and safety. In this current study, mineral oil based ZrO2 and GO nano-cutting fluids are utilized for the cooling and lubrication purpose during the machining of hardened AISI D2 steel (55 ± 1 HRC). Machinability characteristics such as tool wear, surface roughness, cutting temperature, power consumption, and the span of the tool has been investigated in this study along with the sustainability aspects such as machining cost, carbon, and noise emissions during the machining process. Machining under GO nano-cutting fluid coupled with dual nozzle assisted MQL outperformed other environments such as ZrO2 NFMQL, pure mineral oil MQL and dry conditions in all aspects. The maximum tool life was achieved under GO NFMQL condition as 136.16 min followed by 94.41, 65.52, 20.58 min under ZrO2 NFMQL, pure oil MQL, and dry conditions. A substantial impact has been noticed on the cost savings under GO-NFMQL condition and cost saving have been reduced by 2.07%, 5.19%, and 5.48%, compared to ZrO2-NFMQL, MQL and dry environments respectively. Further, GO NFMQL environment performed better in both machinability and sustainability aspects than other environments as it gets the highest score of 11 in Pugh matrix sustainability assessment approach.
Recent research progress on various cooling and lubrication techniques used in sustainable hard machining: A comprehensive review Saswat Khatai, Ashok Kumar Sahoo, Ramanuj Kumar, Amlana Panda Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering, 2024 In recent research, hard machining is an essential manufacturing technology to meet the demand for various industrial product quality and precision. Several key issues like higher heat generation, higher tool wear, higher cutting force and inappropriate surface quality were found in hard machining. Researchers have examined several hard machining-related issues and developed their own suggestions for solutions. It was attempted to research the effects of tool geometry, tool materials and coatings, cutting parameters, and different cooling strategies (coolant and its delivery techniques) on various machinability responses, such as tool wear, tool life, cutting forces, surface roughness, chip morphology etc. In this review article, the different methodologies of cooling and lubrication utilized during hard machining processes have been analysed and their potential application towards sustainable machining is explored. This paper addressed the needs, challenges, and trends towards achieving sustainable hard machining of hard-to-cut materials through the application of dry, minimum quantity lubrication, cryogenic and nanofluids-assisted minimum quantity lubrication cooling strategies. It will be helpful to achieve environmental, economical, ecological and societal benefits to justify sustainable machining. Minimum quantity lubrication hard machining and nano-cutting fluid-assisted minimum quantity lubrication hard machining for sustainability will be immensely beneficial for the replacement of traditional cooling strategies for machining hard-to-cut hardened steel. Furthermore, different computational methods adopted in hard machining for optimization and modelling were also explored to get the optimal solution for industrial applications.
Chip morphology assessment in turning of hardened AISI 52100 steel under ZnO nanofluid environment K M Abdur Rahman, Priyaranjan Sethy, Saswat Khatai, Ramanuj Kumar, Amlana Panda, Rasmi Ranjan Mishra, Ashok Kumar Sahoo Journal of Physics Conference Series, 2024 The chip morphology in hard turning significantly impacts tool performance influenced by factors like strain softening, machining parameters, workpiece hardness, and tool geometry. In this current study, AISI 52100 steel of hardness (∼ 55 HRC) has been taken into consideration for the hard turning experiment and a detailed chip morphology study was conducted under ZnO nanofluid MQL (Minimum quantity lubrication) condition assisted by dual nozzle set up. The influence of machining parameters such as cutting speed, feed, depth of cut, and MQL flow rate on different chip morphology criteria like chip reduction coefficient, chip curl angle, chip pitch length, chip pattern, and colour has been studied thoroughly in this investigation. From the experimental study, it was observed that CRC is influenced by the depth of cut while chip curl angle and chip pitch length are majorly influenced by feed followed by cutting speed. Helical, wavy, and spiral shape chips followed by saw-tooth formation chips were observed in the entire investigation. However, spiral chips and blue colour chips were noticed at higher feed and higher cutting speed conditions respectively.
A contemporary advancement of intelligent machining and sustainability aspects in hard machining area: A Critical Review Saswat Khatai, Ashok Kumar Sahoo, Ramanuj Kumar, Amlana Panda E3s Web of Conferences, 2023 The intelligent manufacturing devotes considerable effort to towards machining process. This phenomenon is engendered by the growing demand for advanced machining process for manufacturing of precise parts by adopting optimization techniques. This article illustrates the most significant developments in the sustainability aspects as well as optimization and modelling techniques adopted to solve the problems and complexity in hard machining process. Machining realisation necessitates recent and future breakthroughs in technological innovations for Industry 4.0. A significant amount of focus is also paid to the different sustainability aspects, modelling strategies and performance analysis during hard machining process. Many avenues for future study on the needs of intelligent manufacturing are discussed in this article. The future directions for intelligent machine systems and sustainability factors are also discussed for the green, sustainable, and high dimensional accuracy manufacturing in hard machining area.
WASPAS Based Multi Response Optimization in Hard Turning of AISI 52100 Steel under ZnO Nanofluid Assisted Dual Nozzle Pulse-MQL Environment Saswat Khatai, Ramanuj Kumar, Amlana Panda, Ashok Kumar Sahoo Applied Sciences Switzerland, 2023 Hard turning is an emerging machining technology that evolved as a substitute for grinding in the production of precision parts from hardened steel. It offers advantages such as reduced cycle times, lower costs, and environmental benefits over grinding. Hard turning is stated to be difficult because of the high hardness of the workpiece material, which causes higher tool wear, cutting temperature, surface roughness, and cutting force. In this work, a dual-nozzle minimum quantity lubrication (MQL) system’s performance assessment of ZnO nano-cutting fluid in the hard turning of AISI 52100 bearing steel is examined. The objective is to evaluate the ZnO nano-cutting fluid’s impacts on flank wear, surface roughness, cutting temperature, cutting power consumption, and cutting noise. The tool flank wear was traced to be very low (0.027 mm to 0.095 mm) as per the hard turning concern. Additionally, the data acquired are statistically analyzed using main effects plots, interaction plots, and analysis of variance (ANOVA). Moreover, a novel Weighted Aggregated Sum Product Assessment (WASPAS) optimization tool was implemented to select the optimal combination of input parameters. The following optimal input variables were found: depth of cut = 0.3 mm, feed = 0.05 mm/rev, cutting speed = 210 m/min, and flow rate = 50 mL/hr.
Performance assessment of single-and dual-jet enriched MQL-assisted machining of hardened steel toward environmental sustainability S Khatai, AK Sahoo, R Kumar, A Panda Journal of Materials Engineering and Performance 35 (1), 258-281 , 2026 2026 Citations: 7
Investigation on machinability and sustainability aspects during hard turning under GO nanofluid MQL environment for precision and cleaner manufacturing S Khatai, AK Sahoo, R Kumar, A Panda Precision Engineering 95, 379-408 , 2025 2025 Citations: 13
Performance assessment of the multi-nozzle injection MQL system for cleaner machining of hardened AISI D2 steel concerning power consumption S Khatai, A Kumar Sahoo, R Kumar, A Panda Canadian Metallurgical Quarterly 64 (3), 1684-1707 , 2025 2025 Citations: 10
Sustainable hard machining under zirconia nano-cutting fluid: A step towards a green and cleaner manufacturing process S Khatai, AK Sahoo, R Kumar, A Panda Measurement 242, 116087 , 2025 2025 Citations: 31
Hard turning performance assessment of AISI D2 steel under dual nozzle MQL assisted ZrO 2 and GO nano-cutting fluids: A sustainability approach S Khatai, AK Sahoo, R Kumar, A Panda Proceedings of the Institution of Mechanical Engineers, Part C: Journal of … , 2024 2024 Citations: 12
Recent research progress on various cooling and lubrication techniques used in sustainable hard machining: A comprehensive review S Khatai, AK Sahoo, R Kumar, A Panda Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2024 2024 Citations: 33
Performance assessment of graphene oxide based nano-cutting fluids during sustainable hard turning through synthesis, characterization and machinability investigation S Khatai, AK Sahoo, R Kumar, A Panda Diamond and Related Materials 149, 111657 , 2024 2024 Citations: 24
Chip morphology assessment in turning of hardened AISI 52100 steel under ZnO nanofluid environment KM Abdur Rahman, P Sethy, S Khatai, R Kumar, A Panda, ... Journal of Physics: Conference Series 2818 (1), 012045 , 2024 2024 Citations: 2
Comparison of single nozzle and dual nozzle MQL performance in hardened steel turning: a case study R Mallick, S Khatai, R Kumar, A Panda, AK Sahoo, RR Mishra Materials Today: Proceedings , 2023 2023 Citations: 8
WASPAS based multi response optimization in hard turning of AISI 52100 steel under ZnO nanofluid assisted dual nozzle pulse-MQL environment S Khatai, R Kumar, A Panda, AK Sahoo Applied Sciences 13 (18), 10062 , 2023 2023 Citations: 30
A contemporary advancement of intelligent machining and sustainability aspects in hard machining area: A Critical Review S Khatai, AK Sahoo, R Kumar, A Panda E3S Web of Conferences 430, 01296 , 2023 2023 Citations: 3
Environmental sustainability during machining of hardened steel using nanofluid: A case study S Khatai, AK Sahoo, R Kumar, A Panda E3S Web of Conferences 405, 04042 , 2023 2023 Citations: 2
Effect of ZrO 2 Nanofluid Concentrations in Hard Turning of AISI D2 Steel S Khatai, AK Sahoo, R Kumar, A Panda International conference on Advances in Materials and Manufacturing, 961-971 , 2022 2022
On Machining behaviour of various cutting Inserts: A review on hardened steel S Khatai, AK Sahoo, R Kumar, A Panda Materials Today: Proceedings 62, 3485-3492 , 2022 2022 Citations: 19
Investigation on tool wear and chip morphology in hard turning of EN 31 steel using AlTiN-PVD coated carbide cutting tool S Khatai, R Kumar, AK Sahoo, A Panda Materials Today: Proceedings 59, 1810-1816 , 2022 2022 Citations: 25
HARD TURNING ASSESSMENT ON EN31 STEEL IN DRY AND WET COOLING ENVIRONMENTS USING GREY-FUZZY HYBRID OPTIMIZATION APPROACH. S Khatai, R Kumar, AK Sahoo International Journal of Modern Manufacturing Technologies (IJMMT) 13 (2) , 2021 2021 Citations: 10
Metal-oxide based nanofluid application in turning and grinding processes: A comprehensive review S Khatai, R Kumar, AK Sahoo, A Panda, D Das Materials Today: Proceedings 26, 1707-1713 , 2020 2020 Citations: 42
MOST CITED SCHOLAR PUBLICATIONS
Metal-oxide based nanofluid application in turning and grinding processes: A comprehensive review S Khatai, R Kumar, AK Sahoo, A Panda, D Das Materials Today: Proceedings 26, 1707-1713 , 2020 2020 Citations: 42
Recent research progress on various cooling and lubrication techniques used in sustainable hard machining: A comprehensive review S Khatai, AK Sahoo, R Kumar, A Panda Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2024 2024 Citations: 33
Sustainable hard machining under zirconia nano-cutting fluid: A step towards a green and cleaner manufacturing process S Khatai, AK Sahoo, R Kumar, A Panda Measurement 242, 116087 , 2025 2025 Citations: 31
WASPAS based multi response optimization in hard turning of AISI 52100 steel under ZnO nanofluid assisted dual nozzle pulse-MQL environment S Khatai, R Kumar, A Panda, AK Sahoo Applied Sciences 13 (18), 10062 , 2023 2023 Citations: 30
Investigation on tool wear and chip morphology in hard turning of EN 31 steel using AlTiN-PVD coated carbide cutting tool S Khatai, R Kumar, AK Sahoo, A Panda Materials Today: Proceedings 59, 1810-1816 , 2022 2022 Citations: 25
Performance assessment of graphene oxide based nano-cutting fluids during sustainable hard turning through synthesis, characterization and machinability investigation S Khatai, AK Sahoo, R Kumar, A Panda Diamond and Related Materials 149, 111657 , 2024 2024 Citations: 24
On Machining behaviour of various cutting Inserts: A review on hardened steel S Khatai, AK Sahoo, R Kumar, A Panda Materials Today: Proceedings 62, 3485-3492 , 2022 2022 Citations: 19
Investigation on machinability and sustainability aspects during hard turning under GO nanofluid MQL environment for precision and cleaner manufacturing S Khatai, AK Sahoo, R Kumar, A Panda Precision Engineering 95, 379-408 , 2025 2025 Citations: 13
Hard turning performance assessment of AISI D2 steel under dual nozzle MQL assisted ZrO 2 and GO nano-cutting fluids: A sustainability approach S Khatai, AK Sahoo, R Kumar, A Panda Proceedings of the Institution of Mechanical Engineers, Part C: Journal of … , 2024 2024 Citations: 12
Performance assessment of the multi-nozzle injection MQL system for cleaner machining of hardened AISI D2 steel concerning power consumption S Khatai, A Kumar Sahoo, R Kumar, A Panda Canadian Metallurgical Quarterly 64 (3), 1684-1707 , 2025 2025 Citations: 10
HARD TURNING ASSESSMENT ON EN31 STEEL IN DRY AND WET COOLING ENVIRONMENTS USING GREY-FUZZY HYBRID OPTIMIZATION APPROACH. S Khatai, R Kumar, AK Sahoo International Journal of Modern Manufacturing Technologies (IJMMT) 13 (2) , 2021 2021 Citations: 10
Comparison of single nozzle and dual nozzle MQL performance in hardened steel turning: a case study R Mallick, S Khatai, R Kumar, A Panda, AK Sahoo, RR Mishra Materials Today: Proceedings , 2023 2023 Citations: 8
Performance assessment of single-and dual-jet enriched MQL-assisted machining of hardened steel toward environmental sustainability S Khatai, AK Sahoo, R Kumar, A Panda Journal of Materials Engineering and Performance 35 (1), 258-281 , 2026 2026 Citations: 7
A contemporary advancement of intelligent machining and sustainability aspects in hard machining area: A Critical Review S Khatai, AK Sahoo, R Kumar, A Panda E3S Web of Conferences 430, 01296 , 2023 2023 Citations: 3
Chip morphology assessment in turning of hardened AISI 52100 steel under ZnO nanofluid environment KM Abdur Rahman, P Sethy, S Khatai, R Kumar, A Panda, ... Journal of Physics: Conference Series 2818 (1), 012045 , 2024 2024 Citations: 2
Environmental sustainability during machining of hardened steel using nanofluid: A case study S Khatai, AK Sahoo, R Kumar, A Panda E3S Web of Conferences 405, 04042 , 2023 2023 Citations: 2
Effect of ZrO 2 Nanofluid Concentrations in Hard Turning of AISI D2 Steel S Khatai, AK Sahoo, R Kumar, A Panda International conference on Advances in Materials and Manufacturing, 961-971 , 2022 2022
