Fabrication and control architecture of novel hybrid metal additive manufacturing incremental forming technology Mithilesh Kumar Tiwari, Shekhar Srivastava, K Ponappa, Puneet Tandon Proceedings of the Institution of Mechanical Engineers Part L Journal of Materials Design and Applications, 2025 Hybrid manufacturing processes redefine production dynamics by harnessing the synergistic interplay between process mechanisms, energy sources, and tools to impact manufacturing quality, productivity, and sustainability significantly. Accordingly, this article focuses on hybrid additive manufacturing incremental forming, where additive manufacturing and incremental forming are integrated in a unified setup, driven by a single power source. This integration opens avenues for innovative component and production design, capitalizing on the strengths of both methods while mitigating drawbacks. The fabrication of the hybrid additive manufacturing incremental forming setup involves crucial components like a hybrid extrusion forming unit, supporting plates, hopper-barrel assembly, band heaters, solenoid setup, and a comprehensive control architecture. Addressing challenges, particularly overheating in the hopper, and feeding zone, ensures effective material transformation with the hybrid extrusion forming unit. The subsequent section provides analytical analysis and validation of the hybrid extrusion unit. This technology enhances the entire process and addresses issues related to metal additive manufacturing, such as porosity and material shrinkage. The maximum tensile force sustained in hybrid additive manufacturing incremental forming before fracture demonstrates a notable enhancement of about 20% from 670 N in additive manufacturing to 805 N in hybrid additive manufacturing incremental forming. It also removes micro-cracks, and voids, and improves the inter-layer bonding, as observed through scanning electron microscopy. The results highlight hybrid additive manufacturing incremental forming's superior enhancement of mechanical properties and surface quality compared to traditional additive manufacturing approaches.
ON THE COMPARISON OF MCDM TECHNIQUES FOR THE SELECTION OF POLYMER-BASED ADDITIVE MANUFACTURING PROCESSES Jairam Raigar, Shekhar Srivastava, Vishal S. Sharma, Ramesh Chand, Jaivir Singh, Rajiv K Garg Decision Making Models and Applications in Manufacturing Environments, 2024 Additive manufacturing (AM) have been widely explored for the fabrication of end use components directly from a 3D CAD design in a single step. Recently, there are number of AM processes available for manufacturing a single component. Therefore, it is critical to select an appropriate AM process with reference to the component’s quality, such as mechanical properties, dimensional accuracy, surface texture, fatigue life, production time and cost etc. In order to overcome these challenges Multi-Criteria Decision Making (MCDM) techniques are more suitable option. In this work a hybrid MCDM technique has been proposed to select an appropriate AM process according to the part’s requirements. The hybrid approach includes best worst method (BWM) to determine optimal criteria weights, and the proximity indexed value (PIV) method to rank the selected AM processes. 294The rank 1, be the most appropriate AM process for manufacturing of the desired product attributes. Additionally, to benchmark the properties of an AM process, a conceptual model of spur gear was fabricated by four AM processes, vat photopolymerization (VP), material extrusion (ME), powder bed fusion (PBF), and material Jetting (MJ). Seven most significant criteria such as Surface roughness (R), dimensional accuracy (A), tensile strength (S), elongation at break (%E), heat deflection temperature (HDT), part cost (PC), and build time (BT) has been considered for database creation. Further, to validate the reliability of the results obtained from the hybrid MCDM approach, sensitivity analysis have been performed. The results obtained using the hybrid BWM-PIV MCDM approach is consistent and reliable.
Distribution of temperature and residual stresses in GMA-DED based wire-arc additive manufacturing Shekhar Srivastava, Rajiv Kumar Garg, Anish Sachdeva, Vishal S. Sharma, Sehijpal Singh, Munish Kumar Gupta Rapid Prototyping Journal, 2023 Purpose Gas metal arc-based directed energy deposition (GMA-DED) process experiences residual stress (RS) developed due to heat accumulation during successive layer deposition as a significant challenge. To address that, monitoring of transient temperature distribution concerning time is a critical input. Finite element analysis (FEA) is considered a decisive engineering tool in quantifying temperature and RS in all manufacturing processes. However, computational time and prediction accuracy has always been a matter of concern for FEA-based prediction of responses in the GMA-DED process. Therefore, this study aims to investigate the effect of finite element mesh variations on the developed RS in the GMA-DED process. Design/methodology/approach The variation in the element shape functions, i.e. linear- and quadratic-interpolation elements, has been used to model a single-track 10-layered thin-walled component in Ansys parametric design language. Two cases have been proposed in this study: Case 1 has been meshed with the linear-interpolation elements and Case 2 has been meshed with the combination of linear- and quadratic-interpolation elements. Furthermore, the modelled responses are authenticated with the experimental results measured through the data acquisition system for temperature and RS. Findings A good agreement of temperature and RS profile has been observed between predicted and experimental values. Considering similar parameters, Case 1 produced an average error of 4.13%, whereas Case 2 produced an average error of 23.45% in temperature prediction. Besides, comparing the longitudinal stress in the transverse direction for Cases 1 and 2 produced an error of 8.282% and 12.796%, respectively. Originality/value To avoid the costly and time-taking experimental approach, the experts have suggested the utilization of numerical methods in the design optimization of engineering problems. The FEA approach, however, is a subtle tool, still, it faces high computational cost and low accuracy based on the choice of selected element technology. This research can serve as a basis for the choice of element technology which can predict better responses in the thermo-mechanical modelling of the GMA-DED process.
Distribution of Residual Stress in Wire-Arc Additively Manufactured Small-Scale Component: Single-Versus Multi-Level Heat Input Shekhar Srivastava, Rajiv Kumar Garg, Anish Sachdeva, Vishal S. Sharma Journal of Manufacturing Science and Engineering, 2023 Accumulated heat input during layer deposition causes high residual stress in the Wire-Arc Additive Manufacturing (WAAM) components. The developed residual stress results in defects like distortion, delamination, cracks, and low fatigue life. To deal with such engineering problems, numerical methods have always been required. It gives an insight into the system that can be used for real-world applications. Consequently, a sequentially coupled finite element model has been developed to simulate the thermal–structural behavior of the feedstock during and after deposition in the WAAM process. Precisely, a novel multi-level layer-wise heat input approach characterized by four different stages is compared with the layer-wise single heat input strategy. The variation of thermal and residual stress distributions has been studied based on the different cases proposed related to layer-wise multi-level heat loading. A good agreement between predicted and experimentally observed temperature and residual stress values has been observed. The developed framework predicted thermal distribution with an average error of 9.71%, 9.13%, 7.57%, and 4.52% for case #1, case #2, case #3, and case #4, respectively. In addition to that, longitudinal stresses in the modeled component recorded a reduction of 17.94% for four-level heat input (case #4) compared to the respective value observed in case #1. Therefore, a multi-level heat input strategy is recommended over a single-level heat input approach for the components with small deposition lengths manufactured through the WAAM process.
Developing Superhydrophobic Surface Using Multi Jet 3D Printing Durability Analysis Ramesh Chand, Vishal S. Sharma, Rajeev Trehan, Rajeev Verma, Munish Kumar Gupta, Shekhar Srivastava Journal of Materials Engineering and Performance, 2023 Superhydrophobicity is a surface property used in several sectors, including self-cleaning, drag reduction, improved buoyancy, and antibacterial behavior of the surfaces. The majority of available approaches for creating superhydrophobic surfaces (SHS) are complex and time-consuming. Goal: This article aims to fabricate the SHS by using Multi jet printer three-dimensional (3D) printing. Methods: The texture of cylindrical protrusions (diameter 300 Micro Meter (µm), pitch 400 and 500 µm) and pyramidical (side 200 µm, side by side distance 200 µm, and height 800 µm) micro-pattern were created using Three-Dimensional Printing (3DP) to achieve the SHS. Results: The fabricated geometries yielded a water contact angle of 145 and 148°, respectively. In order to enhance the durability and Water Contact Angle (WCA), 3D printed geometry was treated with an aqueous solution of silica nanoparticles and Hexafor 644-D, which increased the contact angles to 161 and 160° for cylindrical and pyramid patterns, respectively. The reported geometries are durable against peeling tape tests. Hence MJP, based on 3DP, can be used to fabricate the SHS having the geometries height in micron (µm).
A multi-objective optimisation of TIG welding parameters using response surface methodology Shekhar Srivastava, Sandeep Kumar, Rajiv Kumar Garg International Journal of Computer Aided Engineering and Technology, 2021 This study is aimed to examine the effect of different variables such as gas flow rate, travel speed and current for the welding of mild steel (IS: 2062) with TIG welding. In this study, an effect of the identified variables has been studied on bead width, bead height and penetration. Pilot experiments were performed to find the most effective levels of factors to be used for experimentation. Experimental runs have been designed using central composite design (CCD) technique and analysis has been done to inquest the action of different input parameters on output parameters quality characteristics. The selection of the range of input parameters was done on the basis of the size of the specimen. On the basis of experimental observation, the mathematical model has been formed using regression analysis through a statistical software. An attempt has been made to minimise the bead width and height and maximise the depth of penetration using response surface methodology.
A SMART POWDER DOSING SYSTEM R Soni, S Srivastava, K Ponappa, P Tandon IN Patent 202,421,050,733 , 2024 2024
Fabrication and control architecture of novel hybrid metal additive manufacturing incremental forming technology MK Tiwari, S Srivastava, K Ponappa, P Tandon Proceedings of the Institution of Mechanical Engineers, Part L: Journal of … , 2024 2024 Citations: 5
Distribution of temperature and residual stresses in GMA-DED based wire-arc additive manufacturing MKG Shekhar Srivastava, Rajiv Kumar Garg, Anish Sachdeva, Vishal S. Sharma ... Rapid Prototyping Journal , 2023 2023 Citations: 10
On the Comparison of MCDM Techniques for the Selection of Polymer-Based Additive Manufacturing Processes J Raigar, S Srivastava, VS Sharma, R Chand, J Singh, RK Garg Decision-Making Models and Applications in Manufacturing Environments, 293 , 2023 2023 Citations: 6
Distribution of Residual Stress in Wire-Arc Additively Manufactured Small-Scale Component: Single- versus Multi-Level Heat Input S Srivastava, RK Garg, A Sachdeva, VS Sharma Journal of Manufacturing Science and Engineering 142 (2), 021008 , 2023 2023 Citations: 28
Modelling and Analysis of Metal Additive Manufacturing Process using FEM Approach S Srivastava National Institute of Technology, Jalandhar , 2022 2022
Experimental investigation and optimization of WEDM process for AISI 420 stainless steel RKGSS Mukulanand Jha IOP Conference Series Materials Science and Engineering 1259 , 2022 2022 Citations: 3
An Experimental–Numerical Investigation for Layer-Wise-Heat-Input Management in GMA-Based Additive Manufacturing S Srivastava, RK Garg, A Sachdeva, VS Sharma, S Singh Journal of The Institution of Engineers (India): Series C , 2022 2022 Citations: 7
Developing Superhydrophobic Surface Using Multi Jet 3D Printing Durability Analysis R Chand, VS Sharma, R Trehan, R Verma, MK Gupta, S Srivastava Journal of Materials Engineering and Performance , 2022 2022 Citations: 9
A multi-tier layer-wise thermal management study for long-scale wire-arc additive manufacturing S Srivastava, RK Garg, A Sachdeva, VS Sharma Journal of Materials Processing Technology 306 (11), 117651 , 2022 2022 Citations: 23
A multi-objective optimization of TIG welding parameters using response surface methodology S Srivastava, S Kumar, RK Garg International Journal of Computer Aided Engineering and Technology 14 (4 … , 2021 2021 Citations: 6
Measurement and Mitigation of Residual Stress in Wire-Arc Additive Manufacturing: A Review of Macro-Scale Continuum Modelling Approach S Srivastava, RK Garg, VS Sharma, A Sachdeva Archives of Computational Methods in Engineering 28 (5), 3491 - 3515 , 2021 2021 Citations: 91
A decision support system for the selection of an additive manufacturing process using a new hybrid MCDM technique J Raigar, VS Sharma, S Srivastava, R Chand, J Singh Sādhanā Journal 45 (1), 1-14 , 2020 2020 Citations: 91
Multi-Physics Continuum Modelling Approaches for Metal Powder Additive Manufacturing: A Review S Srivastava, RK Garg, VS Sharma, NG ALBA-BAENA, A Sachdeva, ... Rapid Prototyping Journal 26 (4), 737-764 , 2020 2020 Citations: 27
Process parameter optimization of gas metal arc welding on IS: 2062 mild steel using response surface methodology S Srivastava, RK Garg Journal of Manufacturing Processes 25, 296-305 , 2017 2017 Citations: 181
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Process parameter optimization of gas metal arc welding on IS: 2062 mild steel using response surface methodology S Srivastava, RK Garg Journal of Manufacturing Processes 25, 296-305 , 2017 2017 Citations: 181
Measurement and Mitigation of Residual Stress in Wire-Arc Additive Manufacturing: A Review of Macro-Scale Continuum Modelling Approach S Srivastava, RK Garg, VS Sharma, A Sachdeva Archives of Computational Methods in Engineering 28 (5), 3491 - 3515 , 2021 2021 Citations: 91
A decision support system for the selection of an additive manufacturing process using a new hybrid MCDM technique J Raigar, VS Sharma, S Srivastava, R Chand, J Singh Sādhanā Journal 45 (1), 1-14 , 2020 2020 Citations: 91
Distribution of Residual Stress in Wire-Arc Additively Manufactured Small-Scale Component: Single- versus Multi-Level Heat Input S Srivastava, RK Garg, A Sachdeva, VS Sharma Journal of Manufacturing Science and Engineering 142 (2), 021008 , 2023 2023 Citations: 28
Multi-Physics Continuum Modelling Approaches for Metal Powder Additive Manufacturing: A Review S Srivastava, RK Garg, VS Sharma, NG ALBA-BAENA, A Sachdeva, ... Rapid Prototyping Journal 26 (4), 737-764 , 2020 2020 Citations: 27
A multi-tier layer-wise thermal management study for long-scale wire-arc additive manufacturing S Srivastava, RK Garg, A Sachdeva, VS Sharma Journal of Materials Processing Technology 306 (11), 117651 , 2022 2022 Citations: 23
Distribution of temperature and residual stresses in GMA-DED based wire-arc additive manufacturing MKG Shekhar Srivastava, Rajiv Kumar Garg, Anish Sachdeva, Vishal S. Sharma ... Rapid Prototyping Journal , 2023 2023 Citations: 10
Developing Superhydrophobic Surface Using Multi Jet 3D Printing Durability Analysis R Chand, VS Sharma, R Trehan, R Verma, MK Gupta, S Srivastava Journal of Materials Engineering and Performance , 2022 2022 Citations: 9
An Experimental–Numerical Investigation for Layer-Wise-Heat-Input Management in GMA-Based Additive Manufacturing S Srivastava, RK Garg, A Sachdeva, VS Sharma, S Singh Journal of The Institution of Engineers (India): Series C , 2022 2022 Citations: 7
On the Comparison of MCDM Techniques for the Selection of Polymer-Based Additive Manufacturing Processes J Raigar, S Srivastava, VS Sharma, R Chand, J Singh, RK Garg Decision-Making Models and Applications in Manufacturing Environments, 293 , 2023 2023 Citations: 6
A multi-objective optimization of TIG welding parameters using response surface methodology S Srivastava, S Kumar, RK Garg International Journal of Computer Aided Engineering and Technology 14 (4 … , 2021 2021 Citations: 6
Fabrication and control architecture of novel hybrid metal additive manufacturing incremental forming technology MK Tiwari, S Srivastava, K Ponappa, P Tandon Proceedings of the Institution of Mechanical Engineers, Part L: Journal of … , 2024 2024 Citations: 5
Experimental investigation and optimization of WEDM process for AISI 420 stainless steel RKGSS Mukulanand Jha IOP Conference Series Materials Science and Engineering 1259 , 2022 2022 Citations: 3
A SMART POWDER DOSING SYSTEM R Soni, S Srivastava, K Ponappa, P Tandon IN Patent 202,421,050,733 , 2024 2024
Modelling and Analysis of Metal Additive Manufacturing Process using FEM Approach S Srivastava National Institute of Technology, Jalandhar , 2022 2022
