rakesh kumar gunda
@mgit.ac.in
Assistant Professor, Mechanical Engineering Department
mahatma gandhi institute of technology
RESEARCH, TEACHING, or OTHER INTERESTS
Mechanical Engineering, Industrial and Manufacturing Engineering, Mechanics of Materials, Aerospace Engineering
Scopus Publications
Scopus Publications
Venkata Kasi Viswanadham Kolipakula, Chandra Sekhara Kumar Aduru, Ravinder Reddy Pinninti, and Rakesh Kumar Gunda
SAGE Publications
Metal glass fibre reinforced composites which are considered as advanced composite materials play a significant role in aerospace, marine and automotive industries. In the current study, an attempt has been made to examine the tribological characteristics of glass fibre reinforced plastic (GFRP) composite filled with aluminium oxide (Al2O3) and silicon carbide (SiC) powder particles. Experiments were performed on pin-on-disc tribometer to evaluate the friction and wear rate as a function of normal load and sliding velocity under different conditions. For each composition of glass-epoxy composite filled with and without fillers, sliding tests were performed with normal load (20 N, 40 N, 60 N, 80 N 100 N) and sliding velocity (2.62 m/s, 4.18 m/s, 5.23 m/s, 6.85 m/s, 7.85 m/s) respectively. The metal GFRP composites were fabricated using hand-lay-up technique. The filler content (SiC & Al2O3) in epoxy-glass composite were varied. SiC was varied from 0 to 10% while Al2O3 was kept constant at 5%. To study the worn surface of glass-epoxy composite material scanning electronic microscopy is used. Before and after the experiment, weights of the composites (pin specimens) were studied on digital balance for wear loss. The present studies reported that the fabricated metal epoxy-fibre composite has performed excellent wear resistance when compared with epoxy-fibre composite without metal powders. The present work findings offer new insights into reinforcement in epoxy-glass composites with metal powders.
Rakesh Kumar Gunda and Suresh Kumar Reddy Narala
SAGE Publications
Titanium alloys are considered as hard-to-cut material due to its relatively high resistance to corrosion, low thermal conductivity and high chemical reactivity. Effective penetration of sufficient amount of lubricant in the metalworking process is of utmost importance to (a) reduce frictional resistance at the high-temperature tool–workpiece interface and (b) avert the formation of built-up edge in machining process. Traditionally, the lubricant forms a thin fluid film to reduce the friction. In order to reduce or eliminate coolant usage and to apply lubri-coolant efficiently at tool–chip–workpiece interface, a novel near-dry machining technique called electrostatic charged solid lubricant spray system has been developed. In electrostatic charged solid lubricant spray technique, the aerosolized micro-droplet particles were sprayed from the nozzle tip which uses a phenomenon called contact-charge electrification principle. The quick penetration and wettability of charged atomized droplet particles are impinged with high velocity at the tool–chip interface. The focus of the present experimental research is to analyse the optimum lubrication process parameters of the experimental set-up in terms of effectively applying cutting fluid in the machining zone. The study shows that the desired atomization and machining performance of the electrostatic charged solid lubricant spray technique can be obtained by governing different spray parameters (lubricant flow rate, air pressure, spray nozzle position, nozzle distance, electrostatic voltage). The results revealed that when the charged lubricants are applied with high velocity and large number of droplets, it will have significant influence on surface roughness and cutting force. The fabricated electrostatic charged solid lubricant spray technique provides us with an efficient and economic machining solution by applying solid lubricants effectively at tool–material interface during turning of Ti-6Al-4V alloy material. The present approach and the obtained results will help in better understanding of the machinability of hard-to-cut materials in manufacturing industries.
Sai Kiran Chary Nalband, Kalyan Pamidimukkala, Prathik Akkapally, Muralidhar Reddy Challa, Yeshwanth Prasanna Kirupakaran, Hitesh Dammu, Ajay Thati, Sachin Jacob Abraham, and Rakesh Kumar Gunda
IOP Publishing
Abstract In the present-day manufacturing industry, achieving machining accuracy, high production rate, high material removal rate and increasing tool cutting life is becoming more vital and a particularly difficult task. Machining of hard material imposes a lot of challenges, mainly high temperature generation between tool-workpiece interface. Enormous heat generation adversely affects surface roughness, tool life, dimensional quality of the workpiece and deteriorates the tool life significantly. The use of proper lubrication in machining processes is critically important to modify the conditions of contact area by effective control over frictional interaction which should ensure change in tool-chip interface and machining mechanics. In the present work an experimental investigation was carried out on various MQSL parameters on surface roughness and tool temperature in turning EN 31 steel and the results are compared with dry turning. In order to apply lubricants at shearing interface (chip flow at the rake face of the tool) high velocity MQSL set-up is fabricated. The present work has achieved significant results and helped in concluding the influence of lubricant parameters of MQSL in turning process.
Uma Maheshwera Reddy Paturi, Sumanth Methuku, Sumanth S. Siripragada, Yeshwanth Sangishetty, and Rakesh Kumar Gunda
Elsevier BV
Saikiran Chary Nalband, Kalyan Pamidimukkala, Rakesh Kumar Gunda, and Uma Maheshwera Reddy Paturi
Elsevier BV
Gunda Rakesh Kumar and Narala Suresh Kumar Reddy
Elsevier BV
Rakesh Kumar Gunda, Suresh Kumar Reddy Narala, Venkata Kasi Viswanadham Kolipakula, and Sreenivasulu Reddy Goda
Elsevier BV
Rakesh Kumar Gunda and Suresh Kumar Reddy Narala
SAGE Publications
In any machining operation, a major division of energy is converted into heat which creates detrimental effects on tool wear, tool life and surface quality of machined work material. Effective cooling/lubrication in the machining zone is essential to improve friction and temperatures by efficient heat dissipation which increases tool life and surface quality. But adverse health effects caused by use of flood cooling are drawing manufacturers’ attention to develop methods for controlling occupational exposure to cutting fluids. In demanding the improvement of productivity and product quality of machining, use of solid lubricant thin film was suggested as one of the necessary alternative machining techniques to apply lubricants effectively to the high-temperature zone. There is a general concern in the machining process in terms of applying lubricants effectively to the machining zone. Therefore, this research work contributes to the development of a novel approach to apply lubricants effectively to the rake face and flank face of the cutting tool without polluting the environment. Electrostatic high-velocity solid lubricant assisted machining is a novel technique used in the machining process with a very low flow rate (1–20 mL/h) to enhance the process performance of turning difficult-to-cut materials. The performance of electrostatic high-velocity solid lubricant technique is studied in comparison to minimum quantity solid lubricant, minimum quantity lubricant and dry and wet (flood cooling) to assess the performance considering surface roughness, cutting force and tool wear as performance indices. The experimental results revealed that electrostatic high-velocity solid lubricant with MoS2 solid lubricant at low volume and constant flow rate has observed high potential to apply lubricants effectively in the machining zone when compared with the considered environmental conditions. This work is expected to form a scientific basis toward developing electrostatic high-velocity solid lubricant technique for reducing the manufacturing impact in the machining of aerospace components such as Ti–6Al–4V alloy in terms of both machinability and environmental perspectives.
Rakesh Kumar Gunda and Suresh Kumar Reddy Narala
Elsevier BV
A Marques, Suresh Kumar Reddy Narala, AR Machado, Rakesh Kumar Gunda, Sravan Kumar Josyula, RB Da Silva, and MB Da Silva
SAGE Publications
Abundant application of cutting fluids may increase production cost and cause environmental and health damages, particularly when not properly managed. Thus, alternative measures are needed to overcome the difficulties of using cutting fluids. If sustainable and ecological manufacturing aspects are envisaged, any attempt to improve the machinability of such difficult-to-machine material is always welcome. In this direction, this research work aims to develop experimental set-up as a possible approach to fostering sustainability in metal cutting lubrication to supply solid lubricant at minimum quantity and also to study the effect of applying solid lubricant (molybdenum disulphide and graphite) mixed with oil, during turning of Inconel 718 using cemented carbide tools. The concentration of the solid lubricant in the fluid and the flow rate of the mixture were varied to analyse the main output parameters such as surface roughness, cutting forces and tool life. Experimental findings of this study show that minimum quantity solid lubricant consisting of molybdenum disulphide and oil mixture performed better, and therefore, it may be considered to be a cost-effective and environmental-friendly lubrication technique than flood coolant and sprayed oil with or without graphite to retard all types of damaging processes and to improve machinability characteristics of Inconel 718.
Rakesh Kumar Gunda and Suresh Kumar Reddy Narala
Elsevier BV
Rakesh Kumar Gunda, Narala Suresh Kumar Reddy, and H.A. Kishawy
Elsevier BV