Electric Discharge Machining, Casting through 3D printed patterns
10
Scopus Publications
140
Scholar Citations
5
Scholar h-index
5
Scholar i10-index
Scopus Publications
Viability and performance assessment of bipolar linear self-servo mechanism-based Maglev electrical discharge machining by processing Al-6062 alloy Siddhartha Kar, Rajesh Sahoo Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering, 2025 The enhancement of process efficiency and eradication of basic setbacks of the electrical discharge machining (EDM) process has paved the way for its technological advancement. The discharge irregularities observed during conventional EDM operation due to servo-feedback delay have been addressed by implementing a novel bipolar linear self-servo strategy in Maglev EDM. The paper evaluates the viability of the novel Maglev EDM and analyses its performance in machining aluminum (Al) 6062 alloy. The Maglev EDM uses a systematic combination of magnetic repulsive forces to attain tool positioning in the Z-direction, which serves as the servo gap control mechanism. Experiments were carried out on Al-6062 alloy by utilizing brass tools and surrounding air as dielectric. The voltage–current waveforms exhibited stable and uniform discharges devoid of the short-circuiting and arcing phenomenon. Material removal rate, specific energy, and centerline average surface roughness of 6.717 µg/s, 2.397 J/µg, and 3.735 to 4.507 µm were attained at a discharge power of 16.1 J/s, proving the operational viability of the Maglev EDM. The experimental results were further compared with data available in the previously reported literature. Resolidified layers, globules, lumps of debris, melted debris, micro-pores, micro-voids, micro-cracks, and craters were detected from field emission scanning electron microscopy analysis of the processed work surface. The existence of tool material in the processed surface by energy-dispersive X-ray spectroscopy analysis certified the material migration and surface alloying.
Fabrication of micro-hole using novel Maglev EDM Rajesh Sahoo, Deepak Kumar, Nirmal Kumar Singh, Vivek Bajpai Journal of Micromanufacturing, 2023 In the current scenario, micro-manufacturing through the electro-discharge machining (EDM) process is a prominent technique for achieving desired complex micro/nano-features of any product. The precision and accuracy of producing features are the prerequisites of micro-machining. The current work aims to check the feasibility of the novel Maglev EDM for fabricating micro-holes on a thin nickel sheet (thickness = 500 μm). The study presents the viability of the newly developed system by comparing it with the conventional EDM process. A pure direct current power supply is assembled with a magnetic levitation-based gap monitoring mechanism to overcome the setbacks of conventional EDM. The novel setup utilizes the combined effect of the permanent electromagnet to diminish arcing and short-circuiting. The control parameters for the operation were 12 V open-circuit voltage and 2 A peak current while maintaining a duty factor of 95.564 percent. The measured discharge voltage and discharge current were 6.64 V and 900 mA, respectively. Tungsten rod (ø 650 μm) and deionized water were used as a tool and a dielectric medium, respectively, for the experiment. Further, the machined micro-hole and micro-tool analysis have been carried out using high-resolution microscopy, scanning electron microscopy and energy dispersive spectroscopy reports. The newly developed Maglev EDM’s feasibility to produce micro-holes on conductive materials has been confirmed in the present work with an average material removal rate of 40 μg/min.
OPERATIONAL FEASIBILITY OF MAGLEV EDM USING DIFFERENT NON-CONDUCTIVE POWDER MIXED DIELECTRIC FOR MACHINING INCONEL 625 ALLOY Nirmal Kumar Singh, Rajesh Sahoo, Vivek Bajpai Proceedings of ASME 2023 18th International Manufacturing Science and Engineering Conference Msec 2023, 2023 Currently, powder mixed dielectric application in electro-discharge machining (EDM) is an emerging field to enhance process efficiency and achieve better surface quality along with surface modification. The current investigation utilizes two non-conductive powder mixed dielectrics i.e., urea mixed distilled water and silica mixed distilled water for feasibility analysis by machining Inconel 625 alloy in Maglev EDM. The study emphasizes on the effect of both the dielectrics on material removal rate (MRR), tool wear rate (TWR) and surface roughness (Ra) achieved during Maglev EDM operation. The investigation has been performed using a cylindrical brass tool at discharge voltage (26V) and discharge current (200mA) for both dielectrics. The voltage-current (V-I) waveform acquired during machining operation illustrates better stability and consistency in discharge. The surface topology of the processed workpiece have been inspected using 3D surface profiles and scanning electron microscopy (SEM) for both the dielectric conditions to analyze the presence of surface anomalies and debris particles. The elemental analysis of machined surface examines the surface alloying phenomena due to material migration effect. Maximum MRR (961.5 μg/min) and lower Ra (4.71 μm) were observed using urea mixed dielectric condition, and low TWR (144 μg/min) was achieved using silica powder mixed condition.
Machinability characteristics of titanium diamond using EDM and its parametric optimization Rajesh Sahoo, Tapas Debnath, Promod Kumar Patowari Materials and Manufacturing Processes, 2023 The current research aims at analyzing the machining performance measures of titanium diamond using electro-discharge machining (EDM) process. The selected control variables are peak current and pulse-on-time (Ton) while maintaining a 50% to 75% duty factor during experimental runs. The output responses considered for this operation are material removal rate (MRR), tool wear rate (TWR) and average surface roughness (Ra). A full factorial design (L16) has been employed to execute the current investigation. Analysis of variance along with overall evaluation criteria (OEC) is also carried out for determining the optimal input parametric combination. The work is further supported by mean effect plots and 3D performance plots for visual illustration of outputs. Analyzed results show that current has the most impact on MRR and Ra, while Ton has the most impact on TWR. The obtained results show MRR of 7.753 mg/min (highest), TWR of 0.02 mg/min (lowest) and Ra of 5.46 µm at the optimum parametric combination. Moreover, x-ray diffraction (XRD), scanning electron micrograph (SEM), and energy-dispersive x-ray (EDX) analysis also help in identifying different phases of material on machined work surface.
Experimental study on Titanium diamond by fabricating micro-holes using Micro-EDM with Taguchi's method and response surface method Rajesh Sahoo, Siddhartha Kar, Promod Kumar Patowari Engineering Research Express, 2020 Titanium alloys are very hard to machine materials, which can be machined effectively by using advanced manufacturing processes. Electro discharge machining (EDM) process is one of the most efficient methods of machining electrically conductive materials. EDM is focused more on the precision and accuracy of the machined parts. This particular work focuses on the machinability study of titanium diamond using micro-EDM. Input parameters such as voltage, capacitance, feed rate and tool rotation speed (TRS) are varied and their effects are analyzed by evaluating responses such as material removal rate (MRR), machining time (MT), overcut (OC) and circularity error (CE). X-ray diffraction (XRD) analysis of the material is also conducted to observe the material phases and elements. The observed responses are simultaneously optimized by formulating overall evaluation criteria (OEC) for generating the optimal value of process parameters. Further, the analysis of variance (ANOVA) provides the influence of input parameters on each output response. The variation of different response measures with respect to input parameters is shown through 3D response surface plots. It is observed in micro EDM that the MT decreases with the increase in voltage, capacitance, feed rate and TRS, whereas MRR and OC increase with an increase in voltage and capacitance. In the case of CE, it decreases with the increase in voltage and it increases with the increase in capacitance.
RECENT SCHOLAR PUBLICATIONS
A method of hybrid metal rapid manufacturing by fused filament fabrication and sand casting V Bajpai, P Anand, R Sahoo IN Patent 573,151 , 2025 2025
Viability and performance assessment of bipolar linear self-servo mechanism-based Maglev electrical discharge machining by processing Al-6062 alloy S Kar, R Sahoo Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2025 2025 Citations: 3
An Online Dielectric Deionization system for Electrical discharge machining (EDM) process V Bajpai, R Sahoo, D Bajpai IN Patent 569,525 , 2025 2025
Adaptive pulse width control system by actuating tool position for electro-discharge machine V Bajpai, R Sahoo, P Shukla IN Patent 561,545 , 2025 2025
Dual synchronous suction-ejection portable dielectric flushing system and method for electro-discharge machining process R Sahoo, V Bajpai, NK Singh IN Patent App. 202,531,003,748 , 2025 2025
A robotic vacuum cleaner with an integrated exhaust air guidance system to enhance drying of mopped area V Bajpai, D Bajpai, R Sahoo IN Patent App. 202,431,070,877 , 2024 2024
A variable diameter E-shaped rail-clip fastened on rail for uniform stress distribution V Bajpai, R Sahoo, NK Singh IN Patent 543,584 , 2024 2024
Advanced boring tool assembly with multiple rollers for elongated cylindrical boring operation V Bajpai, A Kar, R Sahoo IN Patent App. 202,431,037,149 , 2024 2024
Approach towards green manufacturing in Maglev EDM using different biodegradable dielectrics at variable discharge conditions R Sahoo, NK Singh, V Bajpai Journal of Cleaner Production 430, 139623 , 2023 2023 Citations: 18
Fabrication of micro-hole using novel Maglev EDM R Sahoo, D Kumar, NK Singh, V Bajpai Journal of Micromanufacturing 6 (2), 141-150 , 2023 2023 Citations: 14
Smart flow governing system for dielectric circulation and filtration V Bajpai, R Sahoo, S Kumar, SS Singh IN Patent App. 202,331,048,632 , 2023 2023
Maglev Electric Discharge Machine (MEDM): Design and Development V Bajpai, R Sahoo International Conference on Processing and Fabrication of Advanced Materials … , 2023 2023
Operational feasibility of maglev EDM using different non-conductive powder mixed dielectric for machining Inconel 625 alloy NK Singh, R Sahoo, V Bajpai International Manufacturing Science and Engineering Conference 87240 … , 2023 2023 Citations: 1
Operational feasibility of Maglev EDM using powder mixed dielectric for machining Ti-grade 5 alloy R Sahoo, V Bajpai, NK Singh Manufacturing Technology Today 22 (5), 50-55 , 2023 2023
A novel approach for modeling MRR in EDM process using utilized discharge energy R Sahoo, NK Singh, V Bajpai Mechanical Systems and Signal Processing 185, 109811 , 2023 2023 Citations: 54
Machinability characteristics of titanium diamond using EDM and its parametric optimization R Sahoo, T Debnath, PK Patowari Materials and Manufacturing Processes 38 (1), 78-88 , 2023 2023 Citations: 29
Effect of Polarity Variation in Maglev EDM Using Nitrogen-Rich Powder-Mixed Dielectric D Swain, R Sahoo, NK Singh, V Bajpai International Conference on Industrial Problems on Machines and Mechanism … , 2022 2022
Investigation of Machining Characteristics Using Different Types of Plant-Based Bio-dielectrics in Maglev EDM AK Parida, R Sahoo, NK Singh, V Bajpai International Conference on Industrial Problems on Machines and Mechanism … , 2022 2022 Citations: 1
Feasibility assessment of novel Maglev dry-EDM by machining aerospace Al-6062 alloy R Sahoo, NK Singh, V Bajpai World Congress on Micro and Nano Manufacturing (WCMNM 2022), 110-116 , 2022 2022
Fabrication of micro-hole using Maglev EDM R Sahoo, D Kumar, NK Singh, V Bajpai Proceedings of the World Congress on Micro and Nano Manufacturing (WCMNM), 20-23 , 2021 2021 Citations: 1
MOST CITED SCHOLAR PUBLICATIONS
A novel approach for modeling MRR in EDM process using utilized discharge energy R Sahoo, NK Singh, V Bajpai Mechanical Systems and Signal Processing 185, 109811 , 2023 2023 Citations: 54
Machinability characteristics of titanium diamond using EDM and its parametric optimization R Sahoo, T Debnath, PK Patowari Materials and Manufacturing Processes 38 (1), 78-88 , 2023 2023 Citations: 29
Experimental study on Titanium diamond by fabricating micro-holes using Micro-EDM with Taguchi’s method and response surface method R Sahoo, S Kar, PK Patowari Engineering Research Express 2 (4), 045026 , 2020 2020 Citations: 19
Approach towards green manufacturing in Maglev EDM using different biodegradable dielectrics at variable discharge conditions R Sahoo, NK Singh, V Bajpai Journal of Cleaner Production 430, 139623 , 2023 2023 Citations: 18
Fabrication of micro-hole using novel Maglev EDM R Sahoo, D Kumar, NK Singh, V Bajpai Journal of Micromanufacturing 6 (2), 141-150 , 2023 2023 Citations: 14
Viability and performance assessment of bipolar linear self-servo mechanism-based Maglev electrical discharge machining by processing Al-6062 alloy S Kar, R Sahoo Proceedings of the Institution of Mechanical Engineers, Part E: Journal of … , 2025 2025 Citations: 3
Operational feasibility of maglev EDM using different non-conductive powder mixed dielectric for machining Inconel 625 alloy NK Singh, R Sahoo, V Bajpai International Manufacturing Science and Engineering Conference 87240 … , 2023 2023 Citations: 1
Investigation of Machining Characteristics Using Different Types of Plant-Based Bio-dielectrics in Maglev EDM AK Parida, R Sahoo, NK Singh, V Bajpai International Conference on Industrial Problems on Machines and Mechanism … , 2022 2022 Citations: 1
Fabrication of micro-hole using Maglev EDM R Sahoo, D Kumar, NK Singh, V Bajpai Proceedings of the World Congress on Micro and Nano Manufacturing (WCMNM), 20-23 , 2021 2021 Citations: 1
A method of hybrid metal rapid manufacturing by fused filament fabrication and sand casting V Bajpai, P Anand, R Sahoo IN Patent 573,151 , 2025 2025
An Online Dielectric Deionization system for Electrical discharge machining (EDM) process V Bajpai, R Sahoo, D Bajpai IN Patent 569,525 , 2025 2025
Adaptive pulse width control system by actuating tool position for electro-discharge machine V Bajpai, R Sahoo, P Shukla IN Patent 561,545 , 2025 2025
Dual synchronous suction-ejection portable dielectric flushing system and method for electro-discharge machining process R Sahoo, V Bajpai, NK Singh IN Patent App. 202,531,003,748 , 2025 2025
A robotic vacuum cleaner with an integrated exhaust air guidance system to enhance drying of mopped area V Bajpai, D Bajpai, R Sahoo IN Patent App. 202,431,070,877 , 2024 2024
A variable diameter E-shaped rail-clip fastened on rail for uniform stress distribution V Bajpai, R Sahoo, NK Singh IN Patent 543,584 , 2024 2024
Advanced boring tool assembly with multiple rollers for elongated cylindrical boring operation V Bajpai, A Kar, R Sahoo IN Patent App. 202,431,037,149 , 2024 2024
Smart flow governing system for dielectric circulation and filtration V Bajpai, R Sahoo, S Kumar, SS Singh IN Patent App. 202,331,048,632 , 2023 2023
Maglev Electric Discharge Machine (MEDM): Design and Development V Bajpai, R Sahoo International Conference on Processing and Fabrication of Advanced Materials … , 2023 2023
Operational feasibility of Maglev EDM using powder mixed dielectric for machining Ti-grade 5 alloy R Sahoo, V Bajpai, NK Singh Manufacturing Technology Today 22 (5), 50-55 , 2023 2023
Effect of Polarity Variation in Maglev EDM Using Nitrogen-Rich Powder-Mixed Dielectric D Swain, R Sahoo, NK Singh, V Bajpai International Conference on Industrial Problems on Machines and Mechanism … , 2022 2022
