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Sounak Kumar Choudhury

Other affiliations: Indian Institutes of Technology
Bio: Sounak Kumar Choudhury is an academic researcher from Indian Institute of Technology Kanpur. The author has contributed to research in topics: Machining & Tool wear. The author has an hindex of 28, co-authored 80 publications receiving 2702 citations. Previous affiliations of Sounak Kumar Choudhury include Indian Institutes of Technology.


Papers
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TL;DR: In this article, the authors present an effort to review some of these works and to understand the key issues related to process performance, including the type of tool material, cutting edge geometry and cutting parameters.
Abstract: Hard turning is gaining grounds for machining hardened steels as it has several benefits over grinding. There are several issues, which should be understood and dealt with, to achieve successful performance of the process. Researchers have worked upon several aspects related to hard turning. The present work is an effort to review some of these works and to understand the key issues related to process performance. The review shows that the type of tool material, cutting edge geometry and cutting parameters affect the process efficiencies in terms of tool forces, surface integrities integrity, and white layer. Adequate machine rigidity is a must essential to minimize the process inaccuracies. Also moreover, for finish hard turning, where the depth of cut is less than the nose radius of the tool, the forces deviate from the conventional trends as the radial force component is the maximum and axial force component becomes minimum. The present work finally lists down certain areas that can be taken up for further research in hard turning.

234 citations

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TL;DR: In this paper, the effect of cryogenic cooling on tool wear and high frequency dynamic cutting forces generated during high speed machining of stainless steel was investigated in dry and cryogenic conditions.

178 citations

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TL;DR: A comprehensive literature review on machining of hardened steels using coated tools, studies related to hard turning, different cooling methods and attempts made so far to model machining performance(s) so as to give proper attention to the various researcher works as discussed by the authors.
Abstract: The researchers have worked on many facets of machining of hardened steel using different tool materials and came up with their own recommendations. Researchers have tried to investigate the effects of cutting parameters, tool materials, different coatings and tool geometry on different machinability aspects like, the tool life, surface roughness, cutting forces, chip morphology, residual stresses and the tool–chip interface temperature under dry and/or semi-dry and/or flood cooling environment during machining of hardened steels while many of them have ventured to characterize the wear phenomenon. Good amount of research has been performed on an analytical and/or numerical and/or empirical modeling of the cutting forces, tool–chip interface temperature, and tool wear under orthogonal/oblique cutting conditions during machining of hardened steels. This paper presents a comprehensive literature review on machining of hardened steels using coated tools, studies related to hard turning, different cooling methods and attempts made so far to model machining performance(s) so as to give proper attention to the various researcher works.

175 citations

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TL;DR: In this article, the effect of gap voltage, discharge current, pulse-on time, duty factor, air pressure and spindle speed on material removal rate (MRR), surface roughness (Ra) and tool wear rate (TWR) was investigated.
Abstract: Dry electric discharge machining (EDM) is an environment-friendly modification of the oil EDM process in which liquid dielectric is replaced by a gaseous medium. In the current work, parametric analysis of the process has been performed with tubular copper tool electrode and mild steel workpiece. Experiments have been conducted using air as the dielectric medium to study the effect of gap voltage, discharge current, pulse-on time, duty factor, air pressure and spindle speed on material removal rate (MRR), surface roughness (Ra) and tool wear rate (TWR). First, a set of exploratory experiments has been performed to identify the optimum tool design and to select input parameters and their levels for later stage experiments. Empirical models for MRR, Ra and TWR have then been developed by performing a designed experiment based on the central composite design of experiments. Response surface analysis has been done using the developed models. Analysis of variance (ANOVA) tests were performed to identify the significant parameters. Current, duty factor, air pressure and spindle speed were found to have significant effects on MRR and Ra. However, TWR was found to be very small and independent of the input parameters.

149 citations

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TL;DR: In this article, an electrochemical spark abrasive drilling (ECSAD) experiments have been conducted using abrasive cutting tools, with a view to enhance the capabilities of the process.
Abstract: Machining of electrically non-conducting materials like alumina and glass is still a major problem. Electrochemical spark machining (ECSM) process is a potential process for machining these materials. However, ECSM has its own inherent limitations. So far, only ordinary cutting tools have been used during ECSM by previous researchers, but the results obtained are not as good as anticipated. In the present work, electrochemical spark abrasive drilling (ECSAD) experiments have been conducted using abrasive cutting tools, with a view to enhance the capabilities of the process. Use of an abrasive cutting tool, when compared to a conventional cutting tool, has been found to improve the process performance, viz. enhanced material removal and increased machined depth. The workpiece materials used are alumina and borosilicate glass.

133 citations


Cited by
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Journal Article
TL;DR: This book by a teacher of statistics (as well as a consultant for "experimenters") is a comprehensive study of the philosophical background for the statistical design of experiment.
Abstract: THE DESIGN AND ANALYSIS OF EXPERIMENTS. By Oscar Kempthorne. New York, John Wiley and Sons, Inc., 1952. 631 pp. $8.50. This book by a teacher of statistics (as well as a consultant for \"experimenters\") is a comprehensive study of the philosophical background for the statistical design of experiment. It is necessary to have some facility with algebraic notation and manipulation to be able to use the volume intelligently. The problems are presented from the theoretical point of view, without such practical examples as would be helpful for those not acquainted with mathematics. The mathematical justification for the techniques is given. As a somewhat advanced treatment of the design and analysis of experiments, this volume will be interesting and helpful for many who approach statistics theoretically as well as practically. With emphasis on the \"why,\" and with description given broadly, the author relates the subject matter to the general theory of statistics and to the general problem of experimental inference. MARGARET J. ROBERTSON

13,333 citations

Journal ArticleDOI
TL;DR: In this paper, the past contributions of CIRP in these areas are reviewed and an up-to-date comprehensive survey of sensor technologies, signal processing, and decision making strategies for process monitoring is provided.

1,074 citations

Journal ArticleDOI
TL;DR: In this paper, the authors review and identify the materials known as difficult-to-machine and their properties and major health and environmental concerns about their usage in material cutting industries are defined.
Abstract: Machining difficult-to-machine materials such as alloys used in aerospace, nuclear and medical industries are usually accompanied with low productivity, poor surface quality and short tool life. Despite the broad use of the term difficult-to-machine or hard-to-cut materials, the area of these types of materials and their properties are not clear yet. On the other hand, using cutting fluids is a common technique for improving machinability and has been acknowledged since early 20th. However, the environmental and health hazards associated with the use of conventional cutting fluids together with developing governmental regulations have resulted in increasing machining costs. The aim of this paper is to review and identify the materials known as difficult-to-machine and their properties. In addition, different cutting fluids are reviewed and major health and environmental concerns about their usage in material cutting industries are defined. Finally, advances in reducing and/or eliminating the use of conventional cutting fluids are reviewed and discussed.

658 citations

Journal ArticleDOI
TL;DR: A review of the main developments in cutting technology since the foundation of CIRP over fifty years ago is given in this paper, where the main technological developments associated with the cutting tool and tool materials, the workpiece material, the machine tool, the process conditions and the manufacturing environment are given detailed consideration.

624 citations

Journal ArticleDOI
TL;DR: In this article, the state-of-the-art in predictive performance models for machining operations is presented, and a critical assessment of the relevant modelling techniques and their applicability and/or limitations for the prediction of the complex machining operation performed in industry.

622 citations