Overview
COVID-19 is a global pandemic caused by the novel coronavirus. Using a handheld key-like device can reduce the risk of transmission, especially in public places.
A novel design, the COVID key, features ten functions including doorknob opener, pushing, pulling, forceps action, sharp edge, key chain, and smartphone stand.
The design undergoes theoretical and computational analyses, topological optimization, 3D printing in ABS and PLA materials, testing with everyday actions, and user satisfaction scoring, with ABS preferred by users.
Development of a mathematical model for surface roughness in multi-jet printing at subzero temperatures.
Comparison of previous models: "Ice Line Model" for single jet dispensing and "Spherical Cap Model" for Stratasys' PolyJet process.
Addressing drawbacks: New model combines individual droplet consideration and staircase effect analysis.
Experimental validation: Printing samples with varying DPI and surface inclinations, comparing measured roughness with analytical values predicted by the model.
Polystyrene foam widely used in foundries for pattern making.
Steam moulding routes commonly utilized, but limited in producing complex geometries.
Machining route adopted by industries to overcome moulding method limitations.
New theory and mathematical model developed to predict and improve surface roughness in polystyrene foam machining.
Additive Manufacturing (AM) facilitates the physical realization of complex geometries.
Screw extrusion-based additive manufacturing (SEAM) employs a single screw extruder for continuous extrusion of thermoplastics.
Research focuses on analyzing single screw extrusion of thermoplastics for AM applications.
An analytical model is developed and experimentally verified, showing a high correlation of 94.56%, enabling estimation of crucial parameters for deposition.
Rapid Casting (RC) reduces production lead time using Additive Manufacturing (AM) or Rapid Prototyping (RP) techniques.
Rapid Ice Investment Casting (RIIC) utilizes AM to create complex shapes and sand 3D molds from CAD models.
A study compares RIIC with other RC processes such as Direct Wax Investment Casting, Lost Foam Casting, Lost PLA Casting, and Rapid Sand Casting, focusing on dimensional accuracy and surface finish.
RIIC excels in smooth surface finish, while Direct Wax IC and LFC show superiority in dimensional accuracy; shortcomings of RIIC and proposed solutions are also discussed.
Heterogeneous materials offer enhanced performance through gradual or abrupt changes in compositions, constituents, or microstructures along single or multiple spatial directions.
Multi-Station Multi-Axis - Hybrid Layer Manufacturing (MSMA-HLM) is a metal additive manufacturing technique capable of producing complex geometries with spatial and temporal control over microstructure.
Integration of a multi-wire cladding system into MSMA-HLM results in Multi-Wire Multi-Station Multi-Axis- Hybrid Additive Manufacturing (M3-HAM), featuring four wire exit nozzles for higher deposition rates and separate wire feeding mechanisms for multiple materials.
M3-HAM utilizes high-frequency power sources and gear mechanisms for wire angular oscillation to achieve uniform mixing (In-Situ alloy), enabling the creation of new alloy matrices with tailored properties for various applications such as composite dies, catalytic converters, and implants.
Indian Patent: 463334
Investment Casting (IC) with wax patterns yields high surface finish and complex geometries, but wax removal poses challenges like shell cracking and residue.
Ice patterns offer advantages, shrinking during phase change reduces cracking. Rapid Freeze Prototyping (RFP) and Freeze Cast Process (FCP) produce ice patterns.
Rapid Ice Investment Casting (RIIC) utilizes ice patterns invested with low-temperature ceramic slurry for metal casting; sublimation evacuates ice patterns.
A diffusion-based mathematical model is proposed and experimentally verified for sublimating ice patterns, showing close correlation (96.74%) with experimental results, demonstrating close dimensional accuracy.
Osseointegration has revolutionized implantology, emphasizing precise implant placement. CAD/CAM-guided surgery offers the most accurate approach.
A study utilized a high-quality desktop scanner to scan an edentulous case, generating an STL file processed in 3 Shape Implant Studio® for surgical guide planning.
The STL file was printed using an FDM printer with PLA, ABS, PETG, and Nylon materials. Deviations in internal/external diameter and depth were assessed.
PLA exhibited the least deviation (-0.88%, 0.83%, -1.37%), making it the most accurate material for surgical guides, followed by ABS and PETG, while Nylon showed the highest deviations.
Additive Manufacturing (AM) typically operates within controlled temperature and pressure ranges, often at ambient or higher temperatures.
Sub-Zero Additive Manufacturing (SZ-AM) refers to processes involving unique materials like bio gels and medicines, conducted at temperatures below 0°C.
A review article compiles recent research on SZ-AM, providing insights into applications across various fields and technical aspects.
The review highlights challenges and future prospects for commercial SZ-AM machines, with case studies assessing feasibility for potential applications of unique materials.
Porosity poses a significant challenge in laser powder bed fusion systems (PBF), impacting fatigue life.
Thermal management is employed to minimize porosity formation by optimizing process parameters, but other factors like irregular gas flow affect repeatability.
This study investigates how local disturbances in shielding gas flow and adjacent raster interactions lead to defect formation in 316 stainless steel cuboids.
X-ray computed tomography reveals spatially aligned pores, with the pore pattern matching the print cell layout during melting of odd layers, where disrupted gas flow creates regions with low velocity, causing concentrated keyhole defects due to heat retention.
An analytical model predicts surface roughness of inclined surfaces produced via Laser Powder Bed Fusion (LPBF).
Melt pools are modeled as parabolic curves, intersecting to reveal the recurring surface, analyzed for roughness using first principles.
The model accounts for unprocessed powder particles, divided into four cases based on melt pool interaction and overhang angle.
Results show close correlation between experimental and predicted values, especially for overhangs beyond 20 degrees, suggesting suitability for high overhangs and validation at different energy densities.
Collaborative work with Purdue University-2023
Auxetic structures, exhibiting negative thermal expansion (NTE), hold promise for food-based additive manufacturing (AM) to replicate natural meat products.
Leveraging edible materials and AM's design flexibility, these structures can mimic meat in taste, texture, and behavior.
A research study introduces a closed-form analytical solution to determine the negative coefficient of thermal expansion (CTE) of dual-extruded polymeric 2D mesh, considering material properties and mesh design.
Analyzing thermal properties aids in predicting the behavior of auxetic structures, crucial for optimizing their performance in food-based AM applications.
Collaborative work with Purdue University-2022
Additive manufacturing (AM) employs layer-by-layer deposition from 3D models, with thermoplastic fabrication being a common application using material extrusion (MEX) techniques.
Screw extrusion additive manufacturing (SEAM) utilizes a single-screw extruder for continuous extrusion and selective deposition, offering cost and time savings along with enhanced part strength.
Heating is crucial in MEX processing, traditionally managed through active cooling methods, which can be costly and complex to maintain.
This study presents a passive cooling device based on fins for SEAM setups, validated through computational simulations and physical testing, demonstrating an 80% improvement over standard liquid cooling setups, offering a simpler yet effective solution to enhance SEAM performance.
Accepted in 9th International Conference of Asian Society for Precision Engineering and Nanotechnology (ASPEN 2022) Nanyang Technological University (NTU), Singapore, 2022
Acrylonitrile Butadiene Styrene (ABS) is a widely used thermoplastic polymer in Injection Moulding (IM) and Additive Manufacturing (AM).
ABS is typically processed in granular form using screw extrusion, a high-pressure process where the material is melted and extruded through a nozzle, resulting in die-swell.
Die-swell refers to the expansion of extrudate size compared to the nozzle size, with the effect studied experimentally in this research.
Results show that screw speed and nozzle diameter positively affect die-swell, while nozzle temperature and length have a decreasing effect; die-swell can reach up to 1.1 times the nozzle diameter and should be minimized for dimensional stability.
Additive Manufacturing (AM) enables 3D model realization via layered deposition, with Material Extrusion (MEX) being a widely used technique.
Screw Extrusion-based AM (SEAM) is versatile, involving continuous extrusion via an extruder screw, often employing ironing to enhance surface morphologies and z-height maintenance.
Research investigates ironing effects during SEAM deposition using wider nozzles (w/d up to 40), focusing on surface finish, interlayer strength, and geometrical conformance.
Optimal dimensional stability is achieved with stand-off distance (SOD) set between 75% to 100% of the nozzle diameter, while ironing consistently improves surface finish and interlayer strength by averages of 50% and 200%, respectively.
Accepted in 52nd SME North American Manufacturing Research Conference (NAMRC-52), University of Tennessee Knoxville, USA, 2024
Kinematics is integral to additive manufacturing (AM), governing movements and positioning of machine components for creating intricate 3D models.
Understanding machine kinematics is crucial for achieving high-quality prints, including complex geometries and difficult-to-reach features.
Factors such as machine type, material choice, resolution requirements, and software influence kinematic requirements.
Research explores state-of-the-art AM setups like Multi-Station Multi-Axis Hybrid Layered Manufacturing (MSMA-HLM), Electron Beam Hybrid Manufacturing (EBHM), Plastic Additive Manufacturing (PAM), Foam Additive Manufacturing (FAM), Sand 3D Printing (Sand-3DP), Optimal Laminated Additive Manufacturing (Opti-LAM), and Sub-zero Additive Manufacturing (SAM), with described applications and fabricated sample parts.
Investigating diverse kinematic setups enhances AM capabilities and efficiency, fostering rapid manufacturing advancements.
Accepted in 9th International & 30th All India Manufacturing Technology, Design and Research Conference (AIMTDR), Indian Institute of Technology (IIT) BHU, Varanasi, India, 2023.
Additive Manufacturing (AM) enables layer-by-layer deposition of geometries, with Screw Extrusion-based Additive Manufacturing (SEAM) offering continuous extrusion and selective deposition.
SEAM is susceptible to oozing defects, where material overflow occurs after screw rotation stops, leading to surface degradation and dimensional inaccuracies.
A novel mathematical model is proposed to estimate oozed-out material during SEAM of thermoplastic ABS, attributing oozing to screw twisting caused by viscous drag and pressure buildup.
The model, validated experimentally, shows oozing mass positively dependent on screw speed and negatively dependent on barrel temperature, with a high correlation (> 90%) between predicted and experimental values.
Additive Manufacturing (AM) facilitates layered realization of 3D models, offering benefits like total automation and fabrication of complex geometries.
Material Extrusion (MEX) is a widely used AM technique, involving solid feedstock extrusion and selective deposition.
The stepover parameter in MEX, determining material overlap and surface finish, is crucial for dimensional accuracy.
Research investigates optimal stepover for optimum surface finish using screw extrusion with thermoplastic ABS.
Hypothesis suggests a stepover 1.57 times the layer height for complete valley area filling, validated through analytical modeling and physical experimentation.
Introduction to Additive Manufacturing (AM) and the challenge of overhangs in layer-by-layer fabrication.
Issue with support structures in techniques like Material Extrusion (MEX): increased material usage, print time, and cost.
Novel analytical model based on beam bending principle to determine material's self-supporting limit for overhangs.
Results and implications: Overhang angles up to 80° possible without external support, increasing printing efficiency and reducing material wastage.
Introduction to Polymer Additive Manufacturing (PAM) as a cutting-edge setup within the additive manufacturing (AM) domain, also known as 3D Printing (3DP).
Explanation of the layer-by-layer approach in conventional AM techniques, enabling fabrication of complex geometries but posing limitations.
Description of PAM's foundation in material extrusion (MEX), such as fused deposition modeling (FDM) or fused filament fabrication (FFF), and its limitations mainly for prototyping purposes.
Identification of four major bottlenecks in AM: low part strength, high fabricating cost, lengthy printing time, and poor surface finish, necessitating the development of advanced manufacturing techniques to address these issues simultaneously.
Applied for Indian Patent
Application Number: 202421056286
Introduction to Additive Manufacturing (AM) or 3D printing as a revolutionary technique for layered fabrication of solid geometries.
Description of Material Extrusion (MEX) as a common AM method relying on melt extrusion through a solid nozzle, crucial for shaping the extruded material.
Limitations of current nozzle designs: lack of dynamism, difficulty in printing complex geometries and various materials due to fixed size and shape.
Introduction of the iris nozzle as a solution: a single setup capable of accommodating various diameters, eliminating the need for nozzle replacement for different printing parameters.
Applied for Indian Patent
Application Number: 202421049942
Description of the scissor mechanism's capability for high motion multiplication in lifting applications, albeit limited to a single axis and degree of freedom (DoF).
Introduction of a novel parallel tri-axial motion system based on scissor kinematics, offering 3 DoF: one translation (Z) and two rotations (A & B).
Enhancement achieved by integrating double universal joints with the standard scissor mechanism, enabling end effector rotation in two directions.
Presentation of inverse kinematics (IK) and proof-of-concept (PoC) fabrication using custom 3D-printed parts, demonstrating the system's potential for vertical translation and tilt adjustment, suitable for applications like space posture adjustment and additive manufacturing (AM).
Introduction to PETG as a commonly used thermoplastic in additive manufacturing (AM), with promising applications like transparent prototypes.
Description of a screw extrusion-based additive manufacturing (SEAM) setup used for fabricating cuboidal PETG samples, with barrel temperature and screw rotational speed as key process parameters.
Investigation of 3 levels of barrel temperature (210°C and 230°C) and 3 levels of screw speed (10, 12, and 15 RPM) to characterize extrusion capabilities.
Findings: Dimensional conformance of printed parts more affected by screw speed at lower barrel temperatures, while transparency influenced by both parameters. Best transparency observed at lowest levels of both parameters, while higher dimensional stability at higher temperature levels. Applications of study results in obtaining clear transparent prints for PETG applications like medical implants and packaging materials.
Submitted as a book chapter in Advances in 3D and 4D Printing of Medical Robots and Devices, CRC Press, 2024.
Introduction to Powder Management System (PMS) in Powder-Bed Additive Manufacturing (PBAM) Systems and the need for user intervention in most existing systems due to separate subsystems for powder handling and Z-axis motion.
Description of a novel PMS for PBAM consisting of powder handling systems and scissor kinematics, comprising three mechanisms: indexed upward-downward motion using a unique scissor configuration, powder dispensing & spreading resembling a spiral motion, and integral powder collection using cylindrical confinement and collection chamber.
Components of the powder handling system: powder storage, innovative powder dispenser (escapement mechanism), powder spreader, powder bed, cylindrical confinement chamber, guider tray, and circular powder collection tray.
Description of the proposed scissor mechanism: triangular-shaped, double-stage repetition based on a four-bar rhombus configuration, utilizing only a rotary joint and a vertical ballscrew arrangement for stability and space-saving.
Applied for Indian Patent (Application No.: 202321015972)
Description of single screw extrusion as a widely used manufacturing process for thermoplastic processing, characterized by complex relationships with various processing parameters.
Introduction of Taguchi's Method-based process optimization using L9 (33) orthogonal array arrangement for screw extrusion of thermoplastic ABS.
Simultaneous optimization of process parameters including screw speed, peak temperature, and thermal gradient for high output and dimensional stability, focusing on maximizing specific velocity of extrusion.
Findings: Screw rotation (RPM) identified as having the most dominant effect, with specific velocity above 100 /min recommended for optimal results in terms of throughput and dimensional stability.
Introduction to Additive Manufacturing (AM) as a non-conventional process enabling solid realization of models, with various techniques offering flexibility over material, quality, and cost.
Description of Screw Extrusion-based Additive Manufacturing (SEAM) as a novel technique using single-screw extruder for continuous extrusion and selective deposition of thermoplastic materials, with process parameters heavily dependent on extruder screw geometry.
Objective: Geometric design optimization of indigenously fabricated single-screw extruder set-up for AM applications, focusing on optimizing helix angle of extruder screw for maximum output flow rate.
Findings: Optimum helix angle determined to be 20.18 degrees, resulting in nearly 1.5 times improvement in flow rate and 50% reduction in overall size of set-up. Optimized screw geometry yields improved results across various temperature and rotation conditions, demonstrating potential application of similar heuristics to other screw-extruder set-ups.
Accepted in 4th Structural Integrity Conference and Exhibition (SICE), Indian Structural Integrity Society (InSIS), Indian Institute of Technology (IIT), Hyderabad, India, 2022.
Introduction to conventional metal casting using solid patterns, highlighting challenges such as numerous steps, mismatch errors, and sensitivity of sand patterns to vibration and breakage.
Description of a novel approach for investment metal casting, termed Soluble Pattern Casting (SPC), where water-soluble material is used for pattern generation via material extrusion additive manufacturing (AM).
Proof of concept: Semi-complex non-prismatic geometry physically realized using SPC technique, with pattern 3D printed from water-soluble ABS thermoplastic using indigenously fabricated screw extrusion-based AM setup.
Process overview: Creation of ceramic mould around soluble pattern using plaster-of-Paris (PoP), dissolution of pattern to generate mould cavity, assisted by heated water bath with added turbulence via solid vibrations, followed by firing of mould cavity and metal pouring.
Analysis of dimensional accuracy and surface finish throughout the process, demonstrating potential applications in investment casting industries to reduce lead time and ensure excellent dimensional conformance and geometrical replication from pattern to cast.
Accepted in IJAMT
Introduction to Additive Manufacturing (AM) as a rapidly evolving field offering higher part quality and dimensional accuracy for complex parts.
Importance of Sacrificial Structures (SS) in achieving accurate layer deposition and eliminating defects during the building process.
Need for further research to understand the role, advantages, and effective utilization of SS in AM.
Coverage of various uses of sacrificial structures, innovative deposition methods, and their role in thermal and stress management.
Discussion on the effect of SS on material properties, an area requiring further exploration and attention.
Introduction to Additive Manufacturing (AM) and Fused Deposition Modeling (FDM) as a widely used technique for creating physical objects from 3D datasets.
Identification of warpage as a common defect in FDM printing caused by thermal strain incompatibility, resulting in bending of printed parts away from the build platform.
Objective of the study: Investigate warpage characteristics based on geometrical parameters and build orientations to reduce warpage extent.
Methodology: Printing cuboidal ABS samples ranging from 5 to 80 mm using a commercial MEX system and performing a Taguchi method-based design of experiment (DoE) trial to optimize part placement and orientation for minimal warpage.
Findings: Lower in-plane aspect ratio and thicker parts are favorable for minimal warpage. Parts should be placed near regions with the least thermal gradient. Proposal of a novel dimensionless parameter (Y) for minimal warpage.
Implications: Results can aid in improving design and part placement for FDM printing, thereby enhancing print quality.
Introduction to wire robots as cable-driven parallel robots (CDPR) capable of multi-axis motions with a simple, cost-effective design.
Exploration of wire robots for applications beyond material handling, including multi-axis additive manufacturing setups.
Description of innovative swiveling rotation-based float-float arrangement for wire robots, reducing strain on cable wires and increasing process reliability.
Discussion of associated inverse kinematics and feasible workspace, developed in conjunction with a material extrusion (MEX) based additive manufacturing setup.
Explanation of special constraints and designed features to optimize the motion system for additive manufacturing applications.
Under submission in 13th International Conference on Precision, Micro, Meso and Nano Engineering (COPEN-13), National Institute of Technology (NIT), Calicut, India.
Introduction to research focusing on mechanical characterization of pure ABS samples fabricated using three different techniques: Additive Manufacturing, Wire Extrusion, and Injection Molding.
Description of fabricated dog-boned and disc-shaped samples for tensile and compressive tests at low strain rate (6mm/min).
Findings: Tensile tests reveal that 3D printed samples exhibit a 50% and 67.8% improvement in tensile modulus compared to samples fabricated by Wire Extrusion and Injection Molding techniques.
Compressive results show that the compressive modulus of 3D printed samples is enhanced by 14% and 19.5% compared to samples fabricated by wire extrusion and injection molding techniques.
Conclusion: 3D printing offers improved mechanical properties and ease of fabrication, making it preferable for fabricating materials for automotive parts, engineering plastics, and household devices.
Introduction to the importance of analyzing human bite force, which is affected by various medical disorders and conditions such as occlusion, jaw deformity, and TMJ dysfunctions.
Objective of the paper: To analyze Maximum Bite Force (MBF) of men and women across different age groups, eating habits, chewing habits, and BMI.
Methodology: Collection of MBF data from ninety-eight North Indian individuals using an electro-mechanical bite force measuring device called MastiForce, with recordings taken for incisors and first molars.
Findings: MBF was higher in the age group of 26-45 years and for males, non-vegetarians, and unilateral chewers. No statistical relationship was found between MBF and BMI.
Conclusion: MBF is influenced by various factors including age, gender, eating habits, and chewing habits. Higher MBF in certain groups may be attributed to factors such as tooth decay and reduction in androgenic hormones. Unilateral chewing may indicate a likelihood of TMJ disorders.
Introduction to the motion-sensing glove as a device designed to assess movement across finger joints for early detection of joint-related diseases and treatment effectiveness.
Description of the glove: Low-cost, soft, breathable cotton material-based glove with flex sensors to capture angular finger Proximal Inter-Phalangeal (PIP) and Meta Carpo Phalangeal (MCP) joint movements.
Development and testing: Gloves developed for both left and right hands, tested for linearity and repeatability.
Functionality: Real-time recording of joint movements through an Arduino-based electronics interface and user-friendly display.
User interface: Graphical User Interface (GUI) displays corresponding joint movement upon sensing finger joint bend, with resistance mapped to provide angular values.
Introduction to the development of a CAD model for evaluating the mechanical properties of 3D printed PLA specimens.
Description of 3D printing as an additive manufacturing technique used to convert CAD files into actual scale models, with FDM 3D printing being done layer by layer.
Discussion of the influence of infill density and pattern on the mechanical properties of 3D printed parts.
Focus on the gauge area as a primary factor affecting infill variation and mechanical behavior.
Proposal of a technique to accurately measure stress and modulus exhibited by 3D-printed bodies, aiding in the evaluation of mechanical properties.
Introduction to the project focusing on the design, development, and fabrication of a low-cost electromechanical hypotonic glove.
Objective: To provide extra external force to un-grasp the hand of patients suffering from hypotonia or medical injuries resulting in low muscle tone.
Description of the device: Utilizes a motor to generate actuation force needed to un-grasp the hand, lightweight, inexpensive, easy to use and maintain.
Target user: Any adult person of any gender or age suffering from hypotonia or similar medical conditions.
Significance: Provides assistance and support to individuals with low muscle tone, enhancing their ability to perform daily tasks and improving quality of life.
Introduction to Fused Deposition Modeling (FDM) based Additive Manufacturing (AM) process, which requires thermoplastic filament feedstock for layer-by-layer deposition.
Description of the traditional method: Commercially made filaments from thermoplastic pellets through screw extrusion process, with filament diameter around 1.73-1.75 mm for optimal AM machine operation.
Project objective: Development of a low-cost table-top wire-extrusion machine to fabricate FDM filaments from thermoplastic pellets.
Description of the machine: Based on single screw extrusion with two-stage heating process, using a geared induction motor to rotate the screw assembly.
Testing and results: Successful production of filaments within desired range, with ability to test various thermoplastic materials, and achieving same quality wire at 50% cost compared to commercial filaments.
Resources
Given below are some of the best resources I collected, as a Ph.D. student, that I feel are extremely helpful, for a budding researcher at any stage of their academic career. Hope you like it too!
Desmos-Graphing Calculator
Extremely interactive, powerful, open-source and online online tool that allows you to graph functions, plot points, and visualize algebraic equations. It has interactive sliders, animations, ability to convert from cartesian to polar graphs and accessible via mobile as well!
WolframAlpha- Integral Calculator
It was used to be my savior during high school and graduation. It is basically a comprehensive tool for solving direct and indirect integrals. Not only that, it can provide derivatives, mapping, singularities and even infinite series expansion. Try it, you won't be disappointed.
https://shorturl.at/B8Pwa- Close to a 1300 curated references
During my Ph.D. (and even still) I collect and curate research papers which are directly or indirectly related to my field. I present to you the (continuously growing) list of scientific paper, in alphabetical order of their names (surname_of_the_first_authorYEAR) along with their title, journal name and a little description. It helped me numerous times while writing papers and my dissertation. Hope it helps you too!
Copilot- Your everyday AI companion
Maybe not as powerful as GPT but definitely capable of creating some world class text-to-image. It can also go the reverse, give it an image and ask it to explain it (alternate text). It can also do the regular AI functions as well.
GPTZero- The anti-AI website
With so much artificiality around, it is necessary to separate the human from the computer. This AI tool can detect the presence of AI in the given text. Counter-intuitive but very helpful, especially in hiding AI generated text while writing a paper or mail. Check if this sentence is human or AI, :-P.