Senthil kumaar
@psr.edu.in
Professor and Mechanical Engineering
PSR Engineering College
EDUCATION
ME., PhD
RESEARCH INTERESTS
Artificial intelligence, Machine learning, Optimization, IIoT
Scopus Publications
Scopus Publications
Chinnathambi Natesamurthi, Vellaisamy Kumaresan, Satchisathiya Christopher, Karachangal S. Raghavan, and Jayalakshmi S. Senthilkumaar
Wiley
Ilangovan Arun, C. Yuvaraj, P. Selvarani, J. S. Senthilkumaar, S. Thamizhmanii, and P. Muruganandam
Springer Science and Business Media LLC
AbstractElectric discharge coating is an alternative process for surface modification/alloying/coating requirements to improve mechanical and metallurgical properties of the materials. The high-pressure compacted electrode is made of the semi-sintered nickel and tungsten during the electric discharging process which influences the material migration towards substrate. In this proecess addtiton of pyrolysis carbon from dielectric togeather with the alloying elements and substrate material results in formation of metal matrix composite coating. It depended on the stabilization pressure of spark which increases the deposition rate of alloying materials and reduces the carbon, brittleness, cracks, voids, blowhole on the surface and made the layer to be desired metallurgical properties. Modified layer shows higher in hardness value of 1100 HV0.5 and reduction in specific wear to 0.082 × 10−5 mm3/Nm compared with uncoated substrate material. Inclusion of the alloying material and reduction of the carbon percentage consequences in self-lubricant properties which alter the wear rate and coefficient of friction. Surfaces topography obtained during alloying, material migration and the mechanism have been characterized through scanning electron microscopy and energy-dispersive X-ray spectroscopy. The wear behaviour has been analysed by using pin-on-disc tribometer.
A. Saravanan, J. S. Senthilkumaar, S. Jaisankar, and J. Ananth
Informa UK Limited
ABSTRACT The effect of helix twisted tape with several twist ratios (Y = 3, 4, 5 and 6) in a V-trough solar water heater for enhancing heat transfer, thermal performance and the friction factor has been examined experimentally in forced circulation with the Reynolds number ranging from 3000 to 23,000. The experimental results of plain V-trough solar collector (PVT) fitted with the standard equations and the variation in the Nusselt number are ±7.23% and the variation in friction factor is about ±5.91%. The PVT has been compared with plain flat plate (PFP) collector. The obtained result shows that the average Nusselt number of PVT performs better than PFP by 8.4%. This is owing to the additional reflectors, reflection of the solar incident rays to the receiver plate, which tend to rise in the temperature gradient of water inlet and outlet of the system. The thermal performance has been increased further by inserting the helix twisted tape with several twist ratios and the results are also presented. The minimum twist ratio 3 provides a higher heat transfer rate and friction factor owing to the increase in the hydraulic length and swirl flow. The experimental Nusselt number and friction factor are correlated and the deficiency falls ±6.44% and ±11.91%, respectively.
S. Thamizhmanii, C. Yuvaraj, J.S. Senthilkumar, Arun I, and Sulaiman
Elsevier BV
Abstract Machining is a process of removing unwanted material by the effective use of cutting tools to reduce the lead time. The material like Titanium, Stain steel and Inconel are considered difficult to cut metals. The difficult to cut metals require tough cutting edges to reduce the tool wear and to get smooth surface finish and product size. The cutting tools are required to be tough enough to resist wear by surface treatment like cryogenic treatment. In this research, CBN cutting inserts was used. The CBN tools was kept in nitrogen atmosphere at -176 degree centigrade in closed chamber for more than 36 hours to produce tough cutting edge, which is known as cryogenic process. In this research, treated CBN cutting tools used to turn Titanium and Inconel 718 materials. The operating parameters used were cutting speeds of 30, 40 and 50 m/min, feed rates of 0.05, 0.10 and 0.15 mm /rev and depths of cut of 0.5, 0.75 and 1.00 mm. The treated cutting inserts produced less flank wear and smooth surface roughness compared to un-treated tools. The crater wear is not in the scope of this research.
M.R. Subbarayan and J.S. Senthil Kumaar
Informa UK Limited
An experimental investigation of diesel engine using cottonseed oil biodiesel and its blends with exhaust gas recirculation (EGR) techniques has been carried out. An optimum nozzle opening pressure of 250 bar and lower static injection timing of 20° before top dead centre (bTDC) are considered because it has been observed that these conditions only give minimum emissions. From the test results, it could be noted that there is an increasing trend of emission characteristics of HC, smoke density and NOx for both cold and hot EGR for all blends of fuel with respect to brake power. As compared with cold EGR, the hot EGR gives lower emissions at all loads. In hot EGR, among the blends, at no-load and full-load conditions, the B100 gives the highest reduction in NOx of 14.23% and 7.91%, respectively. However, the use of EGR leads to a rise in soot emission because of soot–NOx trade-off for both the cases.
M.R. Subbarayan, J.S. Senthil Kumaar, and M.R. Anantha Padmanaban
Elsevier BV
An experimental study to measure the evaporation rates, engine performance and emission characteristics of cotton seed biodiesel (cotton seed oil methyl ester) and its blends in different volumetric proportions with diesel is presented. The thermo-physical properties of all the fuel blends have been measured and presented. Evaporation rates of neat cotton seed biodiesel, neat diesel and their bends have been measured under slow convective environment of air flowing with a constant temperature. Evaporation constants have been determined by using the droplet regression rate data. The neat fuels and fuel blends have been utilized in a test engine with different load conditions to evaluate the performance, combustion and emission characteristics of the fuels. The specific fuel consumption values of the two blends, viz. B25 and B75 are found to be same. At the highest load, B0 records the lowest CO volume followed by B100. From the observed evaporation, performance and emissions characteristics, it is suggested that a blend of B50 and B75 can be optimally used in standard diesel engine settings.
A. Saravanan, J.S. Senthilkumaar, and S. Jaisankar
Elsevier BV
Abstract The experimental investigation has been carried out in V-trough solar water heater fitted with helix twisted tape (HT), helix twisted tape with square cut (HSC) and helix twisted tape with V-cut (HVC), under two different twist ratios (Y = 3, 4 & 5) in same operating condition. Solar concentration has increased while using additional reflection surface on the absorber plate which in turn increased thermal performance in Plain V-Trough (PVT) solar water heater. The experimental result has been verified with fundamental equation and the discrepancy is less than ±14.54% and ±5.5% for Nusselt number and friction factor respectively. The twist tape with lower twist ratio (Y = 3) gives higher thermal performance than higher twist ratio (Y = 5). The obtained results have shown that the Nusselt number and frictional factor are higher in HVC than in HSC. Correlations have been developed for Nusselt number and friction factor to match the experimental results and deviation fall within ±10.17% and ±4.395% respectively.
A. Saravanan, J.S. Senthilkumaar, and S. Jaisankar
Elsevier BV
Experimental investigations of friction factor and thermal performance of V-trough thermosyphon solar water heater with helical twisted tapes of various twist ratios (Y = 3, 4, 5 & 6) have been performed and presented. Experimental trials were made under same operating conditions and results were compared with plain tube V-trough (PVT) solar water heater and also with plain tube flat plate (PFP) solar water heater. Experimental data for the PVT solar water heater is compared with the fundamental equations and found the discrepancy of ±15.06% and ±3.91% for Nusselt number and friction factor respectively. Results show that PVT collector offers better thermal performances when compared to PFP collector. It is due to the increase in solar concentration by the use of additional reflecting surfaces in solar collector. Moreover the usage of helical twisted tape creates the swirl flow inside the riser tube, which in turn increases the thermal performance and pressure drop. The minimum twist ratio 3 offers 19.01% higher thermal efficiency when compared to plain V-trough collector. Empirical correlations have been developed for Nusselt number and friction factor to match the experimental results and deviation fall within ±10.3% and ±6.74% respectively.
M.R. Subbarayan and J.S. Senthil kumaar
Informa UK Limited
An experimental investigation of diesel engine performance fuelled with cotton seed oil methyl ester (COME), pumpkin seed oil methyl ester (POME) and its blends with neat diesel using Exhaust Gas Recirculation technique have been carried out. An optimum nozzle opening pressure of 250 bar and lower static injection timing of 20° bTDC is considered as it has been observed that these conditions offer better performance and are lower in emissions. From the experimental results, it could be observed that there is a decreasing trend of emission characteristics of Hydro Carbon, smoke density and NOx for Exhaust Gas Recirculation (EGR) for both COME and POME at full load with respect to blend ratio. The percentage reduction in oxides of nitrogen for B100 COME-EGR is 1.39% and for B100 POME-EGR is 1.11% as compared to B100 conventional method. The percentage reduction in oxides of nitrogen for B25 COME-EGR is 0.94% and for B25 POME-EGR is 0.13% as compared to B25 conventional method at full load condition. The same trend is followed for all other blends such as B50 and B75. However, the use of EGR leads to a rise in soot emission because of the soot–NOx trade-off for both cases.
K. Senthil Kumar, J.S. Senthilkumaar, and R. Thirumalai
Trans Tech Publications, Ltd.
In this paper, a detailed comparison between dry, wet and gas-cooled turning has been presented based on experimental study. Machining of super duplex stainless steel is considered. Cutting tool considered in this paper is uncoated carbide tool. It was observed that gas cooled machining provides a better machining performance while compared with the dry and the wet machining. Gas cooled machining is particularly needed in case of high speed machining and hard turning. In this study we investigated the chip morphology for various condition of machining and concludes that gas cooled machining is suitable for machining at higher production rate..
R Thirumalai, JS Senthilkumaar, P Selvarani, and S Ramesh
SAGE Publications
Extensive researchers have conducted several experiments in the past for selecting the optimum parameters in machining nickel based alloy – Inconel 718. These experiments conducted so far are dealt with dry machining and flooded coolant machining of nickel alloy Inconel 718. In this research study, the usage of refrigerated coolant is also dealt with and it is compared with dry machining and flooded coolant machining. Cutting speed, feed and depth of cut are considered as the machining parameters. The effectiveness of the refrigerated coolant in machining the heat resistant super alloy material Inconel 718 with respect to these machining parameters are described in this article. The machinability studies parameters were generated with surface roughness and flank wear. The performance of uncoated carbide cutting tool was investigated at various cutting condition under dry, flooded coolant and refrigerated coolant machining. The relationship between the machining parameters and the performance measures were established and using analysis of variance significant machining parameters determined. This article made an attempt to Taguchi optimization technique to study the machinability performances of Inconel 718. Taguchi approach is an efficient and effective experimental method in which a response variable can be optimized, given various control and noise factors, using fewer experiments than a factorial design. Taguchi’s optimization analysis indicates that the factors level, its significance to influence the surface roughness and flank wear for the machining processes. Confirmation tests were conducted at an optimal condition to make a comparison between the experimental results foreseen from the mentioned correlations.
R. Thirumalai and J. S. Senthilkumaar
Springer Science and Business Media LLC
Taguchi’s methods and design of experiments are invariably used and adopted as quality improvement techniques in several manufacturing industries as tools for offline quality control. These methods optimize single-response processes. However, Taguchi’s method is not appropriate for optimizing a multi-response problem. In other situations, multi-responses need to be optimized simultaneously. This paper presents multi-response optimization techniques. A set of non-dominated solutions are obtained using non-sorted genetic algorithm for multi-objective functions. Multi-criteria decision making (MCDM) is proposed in this work for selecting a single solution from nondominated solutions. This paper addresses a new method of MCDM concept based on technique for order preference by similarity to ideal solution (TOPSIS). TOPSIS determines the shortest distance to the positive-ideal solution and the greatest distance from the negative-ideal solution. This work involves the high-speed machining of Inconel 718 using carbide cutting tool with six objective functions that are considered as attributes against the process variables of cutting speed, feed, and depth of cut. The higher-ranked solution is selected as the best solution for the machining of Inconel 718 in its respective environment.
K Senthil Kumar, J S Senthilkumaar, and A Srinivasan
Stellenbosch University
Modern manufacturers worldwide look for the cheapest quality-manufactured machined components to compete in the market. Good surface quality is desired for the proper functioning of the parts produced. The surface quality is influenced by the cutting speed, feed rate, depth of cut, and many other parameters. In this paper, the Taguchi method – a powerful tool to design optimisation for quality – is used to find the optimal machining parameters for the turning operation. An orthogonal array, the signal-to-noise (S/N) ratio, and the analysis of variance (ANOVA) are employed to investigate the machining characteristics of super duplex stainless steel bars using uncoated carbide cutting tools. The effect of machining parameters on surface roughness was discovered. Confirmation tests were conducted at optimal conditions to compare the experimental results with the predicted values. OPSOMMING In die huidige produksieomgewing wil vervaardigers die goedkoopste gehalte gemasjineerde komponente bekom om in die mark mee te ding. ’n Gehalte-oppervlakafwerking word verlang vir die behoorlike werking van die geproduseerde onderdele. Die oppervlakafwerking word beinvloed deur voertempo, snydiepte en vele ander masjineringsparameters. In hierdie artikel word die Taguchi-metode, ’n kragtige benadering om met die oog op gehalte te optimiseer, gebruik om die optimale masjineringsparameters vir draaiwerk te bepaal. ’n Ortogonale reeks, die sein-tot-ruis-verhouding en die analise van die variansie word gebruik om die masjineringseienskappe van superdupleks vlekvryestaal stawe, wat met onbedekte karbiedsnybeitels gemasjineer word, te ondersoek. Die invloed van masjineringsparameters op die oppervlakgrofheid is so gevind. Toetse onder optimale toestande is geloods om te bevestig dat die eksperimentele resultate met die voorspelde waardes ooreenstem. a a a a a a 1 The author is a full time Research Scholar in the Department of Mechanical Engineering, Anna University, Regional office, Coimbatore, Tamilnadu, India. This article is a part of his research work carried out for completing the PhD programme. * Corresponding author.
J. S. Senthilkumaar, P. Selvarani, and R. M. Arunachalam
Springer Science and Business Media LLC
The heat-resistant super alloy material like Inconel 718 machining is an inevitable and challenging task even in modern manufacturing processes. This paper describes the genetic algorithm coupled with artificial neural network (ANN) as an intelligent optimization technique for machining parameters optimization of Inconel 718. The machining experiments were conducted based on the design of experiments full-factorial type by varying the cutting speed, feed, and depth of cut as machining parameters against the responses of flank wear and surface roughness. The combined effects of cutting speed, feed, and depth of cut on the performance measures of surface roughness and flank wear were investigated by the analysis of variance. Using these experimental data, the mathematical model and ANN model were developed for constraints and fitness function evaluation in the intelligent optimization process. The optimization results were plotted as Pareto optimal front. Optimal machining parameters were obtained from the Pareto front graph. The confirmation experiments were conducted for the optimal machining parameters, and the betterment has been proved.
A. Srinivasan, R. Arunachalam, S. Ramesh and J. S. Senthilkumaar
Science Publications
Problem statement: Metal Matrix Composites (MMC) have become a leading material among composite materials and in particular, particle reinforced aluminum MMCs have received considerable attention due to their excellent engineering properties. These materials are known as the difficult-to-machine materials because of the hardness and abrasive nature of reinforcement element-like Alumina (Al2O3). Approach: In this study, an attempt has been made to model the machinability evaluation through the response surface methodology in machining of homogenized 10% micron Al2O3 LM25 Al MMC manufactured through stir casting method. Results: The combined effects of three machining parameters including cutting speed (s), feed rate (f) and depth of cut (d) on the basis of three performance characteristics of tool wear (VB), surface Roughness (Ra) and cutting Force (Fz) were investigated. The contour plots were generated to study the effect of process parameters as well as their interactions. Conclusion: The process parameters are optimized using desirability-based approach response surface methodology.
P. Asokan and J.S. Senthilkumaar
Inderscience Publishers
Selection of machining parameters in turning of Inconel 718 is the challenging task to the process planner. This research illustrates a new approach to selection of machining parameters by using the multi objective optimisation coupled with multiple attribute decision making method. Machining test has been carried out using uncoated carbide inserts under dry conditions. Using the experim developed for fitness function as well as constraintsental responses mathematical models are in the multi objective optimisation process. The optimisation process gives a set of non-dominated or Pareto optimal solutions for their multi-objective functions. The proposed multi attribute decision-making (MADM) method helps to evaluate and rank the machining conditions. The methodology is illustrated by an example.