Akash Subhash Awale
@iitbhu.ac.in
Research Scholar, Department of Mechanical Engineering
Indian Institute of Technology (BHU), Varanasi
I, Akash Subhash Awale completed PhD from Department of Mechanical Engineering, Indian Institute of Technology (BHU) Varanasi. He received Master (M.Tech) degree from Walchand College of Engineering, Sangli. He does research in Sustainable Manufacturing Engineering. His area of interest is Grinding, High Speed Machining, Biomedical Implants, Optimization, Material Characterization and Non-destructive Characterization technique like Magnetic Barkhausen Noise
EDUCATION
Ph.D in Mechanical Engineering
RESEARCH INTERESTS
My primary area of research interest is sustainable machining of “difficult-to-cut” materials i.e., Bioceramics and tool steels as well as thermal damage assessment of ground sample by magnetic Barkhausen noise technique.
Scopus Publications
Scholar Citations
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Scholar i10-index
Scopus Publications
Ashwani Sharma, Abhimanyu Chaudhari, Vikas Diwakar, Akash Subhash Awale, Mohd Zaheer Khan Yusufzai, and Meghanshu Vashista
Elsevier BV
Akash Subhash Awale, Ashish Srivastava, Arvind Kumar, Mohd Zaheer Khan Yusufzai, and Meghanshu Vashista
Elsevier BV
Abhimanyu Chaudhari, Ashwani Sharma, Akash Subhash Awale, Mohd Zaheer Khan Yusufzai, and Meghanshu Vashista
ASME International
Abstract In the precision fabrication industries, ultrasonic vibration-assisted grinding is widely utilized for the finishing of “difficult-to-cut” materials due to its intermittent cutting mechanism and brittle-to-ductile mode machining. In this study, a two-dimensional finite element model (FEM) of single grit ultrasonic vibration-assisted dry grinding (UVADG) and conventional dry grinding (CDG) of AISI D2 steel has been developed, which taken into account the influence of longitudinal ultrasonic vibration on the workpiece with variable downfeed. The effects of ultrasonic vibration and downfeed on the chip formation mechanism, temperature field, grinding force, and equivalent stress and strain were evaluated by analytical and simulation methods. The results show that the formation of the grinding chips under UVADG is much shorter and straighter than CDG mode at all respective downfeed. The validation experiment compared the simulated and experimental grinding force in both grinding modes to verify the reliability of the FEM results. The validation results demonstrate that the FEM model can accurately describe the single grit UVADG and CDG grinding. At each downfeed, the CDG mode has generated a larger equivalent plastic strain than the UVADG mode, resulting in a higher thermomechanical load on the workpiece. According to the findings, UVADG mode has the least plastic damage on the ground surface, which may improve the surface integrity of the ground component.
Akash Subhash Awale, Abhimanyu Chaudhari, Arvind Kumar, Mohd Zaheer Khan Yusufzai, and Meghanshu Vashista
Elsevier BV
Shiv Sunder Singh, Akash Subhash Awale, and Binayaka Nahak
Pleiades Publishing Ltd
Abhimanyu Chaudhari, Ashwani Sharma, Akash Subhash Awale, Mohd Zaheer Khan Yusufzai, and Meghanshu Vashista
Springer Science and Business Media LLC
Atul Kumar Shrivastava, Ashwani Sharma, Akash Subhash Awale, Mohd Zaheer Khan Yusufzai, and Meghanshu Vashista
Springer Science and Business Media LLC
The aim of present study is to experimentally investigate and compare the effect of grinding parameters, i.e. downfeed, work velocity and lubricating environments, on the surface integrity of hardened AISI D2 tool steel. The surface integrity of ground surface was evaluated in terms of surface roughness, surface topography, microstructure and microhardness variation. Grinding performance was investigated concerning grinding force, specific grinding energy and grinding temperature. Quasi-steady-state moving heat source model was used to estimate grinding temperature under different environments, viz. dry and flood. The second objective of the present work is the non-destructive evaluation of thermally damaged ground surface by the novel Barkhausen noise technique. The results showed that flood environment reduces grinding force, specific grinding energy and grinding temperature owing to effective cooling and lubrication medium. A thick redeposition layer over ground surface along with minimum surface roughness was observed under dry grinding. Further, drastic change in microstructure and microhardness was observed under dry environment due to a number of passes of grinding wheel over ground surface without coolant, which induced excess heat and developed martensite layer near the nascent surface. Finally, poor BN response such as lower root mean square (rms) and peak value was found in thermally damaged sample owing to large obstacles for magnetic domain wall displacement.
Ashwani Sharma, Abhimanyu Chaudhari, Akash Subhash Awale, Mohd Zaheer Khan Yusufzai, and Meghanshu Vashista
Pleiades Publishing Ltd
Nowadays, precision manufacturing industries are required faster surface inspection tools for the achievement of high productivity. In this context, the Barkhausen noise (BN) technique is adopted as a quick response technique in the grinding for qualitative evaluation of surface integrity of AISI D2 tool steel. Present work investigates the effect of eco-friendly coolant, i.e., cryogenic, on surface integrity of ground sample in the plunge grinding mode at different downfeed and compared with dry and wet environments. Surface integrity was assessed in respect of surface roughness, microstructure, and microhardness. Magnetic response of ground surface was reported by Barkhausen noise analyzer in the form of root mean square (rms), peak, and number of pulses. From the outcomes, it was perceived that no significant variations were found in the microstructure and microhardness of the ground surface and subsurface after cryo-grinding owing to lower thermo-mechanical loading. Besides, lower surface roughness was obtained in the case of cryo-grinding because of thermal softening effect. A linear correlation between BN input parameters, i.e., magnetic field intensity and BN responses at different magnetizing frequency could be achieved. Finally, better BN responses, including higher rms, peak, and number of pulses, were found under the cryogenic environment.
Akash Awale, Atul Kumar Shrivastava, Abhimanyu Chaudhari, Meghanshu Vashista, and Mohd Zaheer Khan Yusufzai
Inderscience Publishers
Akash Subhash Awale, Meghanshu Vashista, and Mohd Zaheer Khan Yusufzai
Informa UK Limited
ABSTRACT In recent years, increasing demand for biodegradable lubricants has been observed in precision machining owing to ISO 14000, which draws more attention toward the operator’s health and environmental issues. In this context, vegetable oils are adopted as eco-friendly lubricants in sustainable lubrication techniques such as Small Quantity Lubrication (SQL). The grinding performance and surface integrity of AISI H13 die steel may also be improved via SQL. The present study aims at revealing the best lubricant for work material by comparing the lubricating characteristic of vegetable oils like castor, groundnut, sunflower, and soybean. The lubrication characteristics were studied in terms of force ratio, surface roughness, surface topography, microchip morphology, and wettability. Experiential results revealed that castor oil exhibited superior lubricating performance, including the lowest force ratio and surface roughness (Rɑ : 0.147 µm and Rz : 1.122 mm), and outstanding surface quality. Furthermore, the wide bearing area (BC) curve and a higher BC ratio (81.76%) indicated the development of an excellent antifriction ground surface in the case of castor oil. The spherical and burnt chips were observed at an infeed of 32 µm in the case of soybean oil. The viscosity of the lubricant significantly influenced the wettability. The lower viscous soybean oil promoted better lubricant wettability in the machining zone.
Akash Subhash Awale, Meghanshu Vashista, and Mohd Zaheer Khan Yusufzai
Elsevier BV
Abstract Nowadays, Minimum Quantity Lubrication (MQL) technique with eco-friendly groundnut oil is adopted in precision machining to tackle the operator health and environmental issues owing to petroleum based cutting fluid. The effectiveness of this technique depends on mixture quality of MQL mist. Hence, the objective of present work is to optimize the MQL mist parameters i.e. air pressure (P), flow rate (Q), and stand-off distance (ds) to minimize the effect of MQL based plunge grinding on hardened AISI H13 tool steel in terms of lowest grinding force, specific energy, grinding temperature, and surface roughness using grey relational analysis. Taguchi’s L16 orthogonal array was utilized for conducting the final experiments and mist parameters varied through four levels include P (2, 3, 4, and 5 bar), Q (50, 100, 150, and 200 L/h) and ds (40, 50, 60, and 70 mm). Further, experimental analysis was carried out to compare the effect of optimal and worst mist parameters on ground surface and microchip by using microhardness, scanning electron microscope, and atomic force microscopy. According to validation test, P: 4 bar, Q:200 mL/h, and ds:50 mmare optimal mist parameters for multi-response variables of MQL grinding. Effective mist quality i.e. average droplet size of 51.03 μm was obtained at nozzle angle of 12°. Excellent ground surface quality with negligible microhardness variation and no wear tract microchip were observed under optimal mist setting.
Ashish Srivastava, Akash Awale, Meghanshu Vashista, and M. Z. Khan Yusufzai
Springer Science and Business Media LLC
The present investigation utilizes the micromagnetic Barkhausen noise and hysteresis loop technique to evaluate the surface integrity of ground steel. The grinding experiment was performed on IS-2062 steel by varying the process parameters. The magnetic parameters such as root-mean-square value of Barkhausen noise signal and average permeability of hysteresis loop are correlated with surface integrity such as metallurgical changes, surface roughness, and residual stress of the ground surface. The result shows that microstructural alteration in the ground surface has insignificant effect on the measured magnetic parameter. The surface roughness value is obtained in the range (0.4279-0.6498 µm) which is very small and thus having insignificant contribution for variation in magnetic parameters. However, root-mean-square value as well as average permeability increases with the increase in peak shift of the XRD peak. The correlation coefficient between root-mean-square value and peak shift was observed to be 0.9707, and those between average permeability and peak shift was 0.9510. The present study shows that Barkhausen noise signal and hysteresis loop technique provides a new dimension in the characterization of the ground surface.
Akash Awale and Kedar Inamdar
Springer Science and Business Media LLC
Nowadays, die manufacturing industries prefer eco-friendly machining, i.e., high-speed turning for hardened AISI S7 tool steel followed by the conventional grinding process. The effectiveness of this eco-friendly turning depends on selection of appropriate process parameters, which decides the surface integrity of machined components. Hence, the first objective of present research work is to optimize the turning parameters for lower cutting force, machining temperature, surface roughness and higher material removal rate simultaneously using grey relational analysis (GRA). ANOVA utilized to identify the significant effect of each turning parameter on the response variables. Secondly, the effects of turning parameters such as tool nose radius ( R n ), cutting speed ( V c ), feed rate ( V f ) and depth of cut ( d c ) on tool wear and finished surface topography were studied through scanning electron microscopy (SEM) and atomic force microscope (AFM). Optimal turning parameters for multi-performance responses were R n : 1.2 mm, V c : 450 m/min, V f : 0.05 mm/rev and d c : 0.2 mm. The confirmation test was conducted on the optimal parameter level. According to ANOVA, depth of cut was the major influencing factor on all response variables. AFM and SEM micrograph indicated that excellent surface quality with lower surface roughness ( S a : 64.21 nm and S q : 90.34 nm) was observed at higher cutting speed. Flank and crater wear were observed in cutting tool faces owing to thermo-mechanical loading. Different wear mechanisms like abrasion, adhesion, built-up edge formation and chipping hammering were found in the alumina-mixed ceramic insert at higher cutting speed and depth of cut.
Ashish Srivastava, Akash Awale, Meghanshu Vashista, and Mohd Zaheer Khan Yusufzai
Springer Science and Business Media LLC
Thermal damage restrict the capability of grinding in achieving the desired production rate; therefore, the present study focuses on the employment of a non-destructive Barkhausen noise (BN) technique in the assessment of thermal damages produced from grinding of hardened IS 2062 steel under dry (no lubrication) and wet (with lubrication) conditions. Optical microscopy along with microhardness measurement was utilized to reveal the microstructural and hardness alternation occurred in the ground and subsurface of sample. X- ray diffraction peak shift was measured and used for qualitative analysis of residual stress. Furthermore, surface topography was obtained by scanning electron microscope. The magnetic response from ground surface were measured in terms of Barkhausen noise (root mean square) and hysteresis loop (average permeability). The result shows very poor magnetic response from ground hardened steel due to higher carbon content. A non-linear variation is observed between peak shift and root mean square value of Barkhausen noise. However, average permeability derived from hysteresis loop shows good correlation with the peak shift with a correlation coefficient of approximately 0.8149.
Abhimanyu Chaudhari, Akash Subhash Awale, and Ajit Kumar Chakrabarti
IOP Publishing
Grinding is the final process in the manufacturing of precise components with adequate surface integrity. Surface integrity has significant effect on the working life of component. The aim of the present work is to experimentally investigate the effect of eco-friendly grinding i.e. dry, belt and pedestal grinding on the surface integrity of different stainless steels (SS) like austenitic AISI 304SS, martensitic AISI 410SS, and ferritic AISI 430SS. Surface integrity was assessed by surface topography, surface roughness, microchip morphology, metallographic of microchip and thermal damage of ground surface. The surface topography of microchip and ground samples was observed by scanning electron microscope (SEM) and energy dispersive X-ray spectroscopy (EDX). Grinding performance was investigated in terms of grinding force. Further, corrosion performance of different grade SS was measured using potentiodynamic corrosion test in 0.9N NaCl solution under different grinding condition. The result shows that excellent ground surface quality with lowest surface roughness was obtained in AISI 304SS under all grinding modes. Spherical and ribbon microchips were observed during belt and pedestal grinding. SEM-EDX analysis indicated that iron-chromium oxide nodules were formed on ground surface and microchip. Lower grinding force was obtained during dry grinding of AISI 430SS. Finally, maximum corrosion rate was found in all grades of stainless steel during pedestal grinding owing to rupture of Cr2O3 protective layer.
Akash Awale, Ashish Srivastava, Meghanshu Vashista, and M Z Khan Yusufzai
IOP Publishing
A. S. Awale, A. Srivastava, M. Vashista, and M. Z. Khan Yusufzai
Springer Science and Business Media LLC
In grinding process, cutting fluids play an important role to control high grinding zone temperature. However, their use causes detrimental effect on the operator’s health and environment. On the other hand, dry grinding not only results in thermal damage to ground surface but also deteriorates the surface quality and dimensional accuracy of the ground component. The possible solution is to apply cutting fluids using minimum quantity lubrication (MQL) technique. The objective of present research work is to investigate and compare the effect of different grinding environments: dry, flood, MQL with deionized water (DIW), MQL with liquid paraffin oil (LP), and MQL with castor oil based on vegetable oil (VO) during grinding of hardened H13 hot die steel. Grinding performance was evaluated in terms of specific grinding force, specific grinding energy, grinding force ratio, surface roughness, and microhardness. Ground surface and debris morphology were also analyzed using scanning electron microscope, atomic force microscope, and energy-dispersive X-ray spectroscopy to validate the grinding performance. The results showed that MQL-VO grinding leads to minimum specific grinding force, specific grinding energy, and grinding force ratio. Further, surface roughness was considerably reduced under MQL-VO grinding, where Rɑ and Rz were 0.245 μm and 1.846 μm, respectively. AFM analysis indicated that the surface roughness of MQL-VO grinding was nearly 29.88% less as compared to dry grinding. Smooth ground surface topography, as well as long, thin, and no wear track grinding debris, were observed under MQL-LP and MQL-VO conditions. Moreover, dry grinding resulted in lower microhardness in comparison to other grinding conditions.
Shiv Sunder Singh, Akash Subhash Awale, Anurag Chaudhari, and Binayaka Nahak
Elsevier BV
Abstract Heat treatment plays an important role to improve the thermo-mechanical properties of different carbon steel. This paper focus on a study the effect of different heat treatment process i.e. annealing, normalising, and quenching on the microstructure of medium carbon steel using non-destructive techniques like Barkhausen Noise (BN) and Hysteresis Loop (HL). Microstructural behavior was evaluated in terms of phase transformation, BN-peak value, differential permeability, and core loss at different austenitizing temperature. BN and HL analysis indicated that higher BN-peak and differential permeability were obtained in annealed sample. Further, higher core loss was obtained in quenched sample.
Bhagwan F. Jogi, A.S. Awale, S.R. Nirantar, and H.S. Bhusare
Elsevier BV
Abstract Welding parameters play a great significant role in determining the weld joint quality in terms of weld-bead geometry. To obtain a good quality weld, it is necessary to select the proper welding parameters. This study focuses on the optimization parameters for Metal Inert Gas (MIG) welding on AISI 1018 mild steel by Teaching-Learning Based Optimization (TLBO) algorithm. The input parameters considered are welding current, workpiece thickness, voltage and wire feed rate. Taguchi’s L 27 orthogonal array have been used for design of experiment (DoE) and the mathematical models have been developed for output response using MINITAB16. Results show that welding current and voltage are statistical significance on overall MIG welding performance.
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I have one year academic experience. During my Assistant Professor experience at Dr. Babasaheb Ambedkar Technological
University, Lonere, I taught various subjects, such as Advanced Manufacturing Processes, Engineering Drawing, Engineering Mechanics, and Fluid Mechanics.
INDUSTRY EXPERIENCE
I have 2 years 3 month industrial experience. I worked in the design and development of jig and fixture, broaches, face and side cutter, and high and low pressure die casting dies at Maharashtra Scooters Ltd., Satara.