Rajesh Sahoo

@iitism.ac.in/iitismnew

PhD scholar, Mechanical Engineering
IIT (ISM) Dhanbad



                 

https://researchid.co/sahoo246

RESEARCH INTERESTS

Electric Discharge Machining, Casting through 3D printed patterns

10

Scopus Publications

89

Scholar Citations

5

Scholar h-index

4

Scholar i10-index

Scopus Publications

  • Maglev Electric Discharge Machine (MEDM): Design and Development
    Vivek Bajpai and Rajesh Sahoo
    Springer Nature Singapore

  • Investigation of Machining Characteristics Using Different Types of Plant-Based Bio-dielectrics in Maglev EDM
    Amit Kumar Parida, Rajesh Sahoo, Nirmal Kumar Singh, and Vivek Bajpai
    Springer Nature Singapore

  • Effect of Polarity Variation in Maglev EDM Using Nitrogen-Rich Powder-Mixed Dielectric
    Diptiranjan Swain, Rajesh Sahoo, Nirmal Kumar Singh, and Vivek Bajpai
    Springer Nature Singapore


  • Fabrication of micro-hole using novel Maglev EDM
    Rajesh Sahoo, Deepak Kumar, Nirmal Kumar Singh, and Vivek Bajpai
    SAGE Publications
    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.

  • A novel approach for modeling MRR in EDM process using utilized discharge energy
    Rajesh Sahoo, Nirmal Kumar Singh, and Vivek Bajpai
    Elsevier BV

  • OPERATIONAL FEASIBILITY OF MAGLEV EDM USING DIFFERENT NON-CONDUCTIVE POWDER MIXED DIELECTRIC FOR MACHINING INCONEL 625 ALLOY
    Nirmal Kumar Singh, Rajesh Sahoo, and Vivek Bajpai
    American Society of Mechanical Engineers
    Abstract 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.

  • Viability and performance assessment of bipolar linear self-servo mechanism-based Maglev electrical discharge machining by processing Al-6062 alloy
    Siddhartha Kar and Rajesh Sahoo
    SAGE Publications
    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.

  • Machinability characteristics of titanium diamond using EDM and its parametric optimization
    Rajesh Sahoo, Tapas Debnath, and Promod Kumar Patowari
    Informa UK Limited
    ABSTRACT 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, and Promod Kumar Patowari
    IOP Publishing
    Abstract 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

  • 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

  • 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

  • Adaptive pulse width control system by actuating tool position for electro-discharge machine
    V Bajpai, R Sahoo, P Shukla
    IN Patent App. 202,431,055,777 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

  • 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

  • A method of hybrid metal rapid manufacturing by fused filament fabrication and sand casting
    V Bajpai, P Anand, R Sahoo
    IN Patent App. 202,331,086,020 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

  • Fabrication of micro-hole using novel Maglev EDM
    R Sahoo, D Kumar, NK Singh, V Bajpai
    Journal of Micromanufacturing 6 (2), 141-150 2023

  • 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 2023

  • 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

  • Maglev Electric Discharge Machine (MEDM): Design and Development
    V Bajpai, R Sahoo
    International Conference on Processing and Fabrication of Advanced Materials 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

  • 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

  • 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

  • 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

  • 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

  • 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

  • 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

  • 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

  • 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

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
    Citations: 31

  • 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
    Citations: 21

  • 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
    Citations: 16

  • Fabrication of micro-hole using novel Maglev EDM
    R Sahoo, D Kumar, NK Singh, V Bajpai
    Journal of Micromanufacturing 6 (2), 141-150 2023
    Citations: 11

  • 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
    Citations: 6

  • 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 2023
    Citations: 3

  • 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
    Citations: 1