Senthilkumaran Kumaraguru

• PhD
• Professor (Assistant) at Indian Institute of Information Technology, Design and Manufacturing, Kancheepuram

Sustainability characterization of manufacturing processes is key to the inventory data development for life cycle analysis of products and processes in manufacturing industries. The ability of an organization to compare and contrast this sustainability performance in a variety of manufacturing process categories is crucial for purposes of evaluati...

Purpose The purpose of this paper is to report experimental investigations performed to analyze the effect of process parameters on the shape accuracy of selective laser sintered (SLS) parts. Design/methodology/approach The effect of process parameters, namely build orientation, laser power, scan speed, cylinder diameter and build chamber temperat...

This paper presents a new model for shrinkage and a new approach for shrinkage compensation to enhance the accuracy of parts produced by selective laser sintering (SLS)–a solid freeform fabrication process. The present prevailing approach as proposed by machine manufacturers is simple but not accurate. A new shrinkage model which accounts for part...

Shrinkage in selective laser sintering process is primarily influenced by material, process parameters and the geometry of the fabricated part. The part inaccuracy due to this shrinkage is overcome by calibrating and compensating it. Further improvements in accuracy of the part can be achieved by conducting more studies to appreciate the nature of...

Direct Energy Deposition (DED) is an additive manufacturing process used to fabricate thin/thick-walled structures and high-value component restorations. As blown powder-based DED gains prominence, catchment efficiency becomes imperative for enhancing material utilization and process effectiveness. This study focuses on predicting catchment efficie...

The additive manufacturing industry requires effective and standardized methods for selecting design variants generated through computational tools. To address this need and overcome the current barriers in the industry, a decision support system based on quantitative metrics is necessary. This research aims to establish multiple criteria for evalu...

The support structures used in additive manufacturing (AM) techniques cause poor surface quality in the contact areas of the support with the printed parts. Thereby, this support structure usage is a critical issue that needs to be controlled for minimizing the printing time and post-processing challenges associated with AM parts. To alleviate the...

This study investigates the influence of process parameters on catchment efficiency and geometric characteristics such as track height, track width, and wetting angle for low energy density inputs in the blown powder Laser Metal Deposition (LMD) process for building thin-walled parts or repair volumes. Initially, a pilot study was conducted to exam...

Direct Energy Deposition (DED) is one of the Metal Additive Manufacturing processes, which can be used to print near-net shapes and repair volumes using five-axis CNC or six-axis serial manipulator-based robotic systems. For such a system, robust algorithms are needed to decompose faceted solid models into programmable tool paths for multi-directio...

Additive Manufacturing (AM) eases the fabrication of multifunctional simultaneous printing of multi-materials, which is quite cumbersome to fabricate in traditional manufacturing processes. Heterogeneous objects are entities engineered with multiple materials, and their emergence with the advent of AM is sporadic. This paper presents the novel laye...

The industry needs generic methods for selecting design variants obtained from the computational tools of Design for Additive Manufacturing (DfAM). Therefore, a decision support system based on quantitative metrics for selecting a design variant is needed to overcome the current industry's barriers to using the unique capabilities of the additive m...

Purpose This paper aims to propose a view similarity-based shape complexity metric to guide part selection for additive manufacturing (AM) and advance the goals of design for AM. The metric helps to improve the selection process by objectively screening a large number of parts and identifying the parts most suited for AM and enabling experts to pri...

Metal additive manufacturing paves the way for industries to create new applications through unique design capabilities. The powder bed fusion process is one among many metal additive manufacturing technologies that are commercially successful. Despite its numerous advantages and application in various fields, defects may occur during processing, w...

The support structures used in Additive Manufacturing (AM) techniques cause poor surface quality in the contact areas of the support with the printed parts. Thereby this support structure usage is a critical issue, which needs to be controlled for minimizing the printing time and post-processing challenges associated with AM parts. To alleviate the...

The present work proposes a data-driven method to address the issue of increased computational time in predicting the thermal field in the Powder Bed Fusion process (PBF). Understanding the temperature field evolution is essential in metal Additive Manufacturing (AM) process like PBF technology to produce the right quality parts. As the process of...

In the past few years, Hybrid Additive Manufacturing has emerged to take advantage of both Additive Manufacturing and Subtractive Manufacturing processes and also to overcome the limitation of one process with the other. In aerospace applications, material wastage has become an issue in conventional machining process which reflects in total product...

Design for additive manufacturing (DfAM) creates opportunities for improved product design. Part consolidation (PC) is an important design opportunity in DfAM. The existing methodologies for part consolidation in DfAM are mostly based on expert judgment or heuristic rules. In addition, they only suggest the candidates for part consolidation. They d...

Organizations have been facing quite a few challenges, including a growing global competitive market, shorter time to market, rising product variants, and adjustments in production because of fluctuation in demand. To handle these challenges, industries need to connect engineering technology with enterprise systems to transform their practices towa...

Metal based additive manufacturing (AM) techniques are continuously adopted by aerospace, automobile, defense, and healthcare industries. The primary concern for the components used in these applications is high precision. Despite being able to produce complex shapes, they lack in precision due to the distortions in shape and size of the part durin...

The quality of data used for the Life Cycle Assessment (LCA) is of prime importance as they influence the outcomes of the impact assessments. Most of the LCI data has validity periods as the data gets outdated due to introduction of new technology and process. In order to replace outdated data with most recent value we have developed a device calle...

This paper proposes a classification scheme for performance metrics for smart manufacturing systems. The discussion focuses on three such metrics: agility, asset utilization, and sustainability. For each of these metrics, we discuss classification themes, which we then use to develop a generalized classification scheme. In addition to the themes, w...

The emerging concept of smart manufacturing systems is defined in part by the introduction of new technologies that are promoting rapid and widespread information flow within the manufacturing system and surrounding its control. These systems can deliver unprecedented awareness, agility, productivity, and resilience within the production process by...

The emerging concept of smart manufacturing systems is defined in part by the introduction of new technologies that are promoting rapid and widespread information flow within the manufacturing system and surrounding its control. These systems can deliver unprecedented awareness, agility, productivity, and resilience within the production process by...

The ability to predict performance of manufacturing equipment during early stages of process planning is vital for improving efficiency of manufacturing processes. In the metal cutting industry, measurement of machining performance is usually carried out by collecting machine-monitoring data that record the machine tool’s actions (e.g. coordinates...

This paper prescribes an energy assessment methodology, including the procedure and mathematical foundation for evaluating total use and efficiency, for mechanical and electrical product assembly processes. The majority of major manufacturers assemble components and subsystems often produced by suppliers in their supply chains. Differing measuremen...

Laser sintering is one of the techniques used in additive manufacturing processes. The main objective of the work is to study the effects of process parameters on wetting phenomenon and interfacial energy during laser melting of stainless steel powder. This paper reports wetting of laser melted powder particles and its use for the determination of...

This paper proposes an approach to integrate real-time analytics with continuous performance management. The proposed system exploits the increasing availability of industrial process and production performance data. This paper identifies components of such a system and the interface between components within the system. The components presented in...

This paper presents numerical and experimental investigations on laser melting of SS grade 316L powder on top of AISI 316L substrate using a pulsed Nd:YAG laser. The objectives of the present study are to understand the effect of process parameters such as laser power, scanning speed and beam size on geometry characteristics of the melt zone and ba...

Selective laser sintering (SLS) is one of the most rapidly developing additive manufacturing technologies used to build parts layer over layer from the CAD model. Generally the quality of the fabricated part is influenced by the process parameters and build conditions. This paper reports the numerical simulation of the SLS process built to study th...

A key factor deciding the capacity to increase the sustainability of final products is the energy efficiency. The energy embodied in a product is an aggregation of all of the energy embodied in the products' components and subsystems, expended through its manufacturing processes and logistical activities. Currently, accurate estimation of this ener...

Tissue engineering uses the principle from the tissue science for the functional replacement of the tissues. Tissue engineering is successfully applied in the areas of skin and bone. In this article we are mainly concentrating on the bone tissue engineering. When bone got damaged a three dimensional structure called scaffold is placed for support a...

This paper presents an on-going effort at NIST to model the energy information in assembly and logistics processes as a part of a larger sustainabil-ity improvement goal. Energy information comprises energy input, baseline en-ergy consumption, and energy performance. An information model in this paper is developed for enabling integration of energy...

In this study an investigation of surface roughness and morphology is presented for laser melted stainless steel 316L alloy. Single track formation has been produced using different laser process parameters. Furthermore, macro, micro and surface roughness has been analyzed using metallurgical tools like macroscope, Scanning Electron Microscope (SEM...

Selective laser sintering (SLS) / melting (SLM) is a manufacturing technique which holds a very special place in the layer manufacturing process due to its widest range of material processing capability which no other technique can offer. It can process metals, rubber, composites, polymers and ceramics etc. As laser sintering technique is emerging...

Understanding the behavior of weldment at elevated temperatures and especially the corrosion behavior has become an object of scientific investigation recently. Investigation has been carried out on friction welded AISI 4140 and AISI 304 in molten salt of K2SO4–60% NaCl environment at 550, 600 and 650 °C under cyclic condition. The resulted oxide s...

The design cycle of a typical new military aircraft from conceptual stage to first flight takes about 15 years. This is so because the aircraft design involves integrating of complex interdependencies between sub systems, low volume of production and very high value addition. There is also an additional complexity of committing on technologies whos...

Ground Penetrating Radars (GPR) finds its applications in civil engineering, archeology, earth sciences, military and environmental studies. This paper proposes a framework for using GPR as a digitizing technique that can make 3D digitization/measurement of the buried objects. Currently, the 3D radar volume data is acquired by dense subset of paral...

This paper presents new approach for shrinkage compensation in selective laser sintering (SLS) process to improve the accuracy of parts produced. Shrinkage is compensated along single direction dexel space generated from the part geometry. The scaling factor used in this compensation is calculated from shrinkage model (It is the empirical relation...

This paper deals with design and process planning issues for improving part accuracy in Selective Laser Sintering (SLS) process. SLS, earlier used for prototyping purposes, is now fully capable of producing functional components and rapid tools with the development of metallic prototypes or metal and polymer blends. SLS process involves heat transf...

Rapid Prototyping (RP) is two decade old technology to quickly produce tangible objects directly from a 3D CAD model and is being used to shorten and simplify the product development cycle for many applications including aerospace, automobile and home appliances etc., It involves adding material successively, in layers, to create a solid of a prede...