Suresh Kumar Reddy Narala

Suresh Kumar Reddy Narala
BITS Pilani, Hyderabad · Department of Mechanical Engineering

PhD (IIT Delhi)

About

72
Publications
9,161
Reads
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1,241
Citations
Additional affiliations
July 2018 - present
BITS Pilani, Hyderabad
Position
  • Professor (Full)
February 2013 - June 2018
BITS Pilani, Hyderabad
Position
  • Professor (Associate)
September 2010 - January 2013
BITS Pilani, Hyderabad
Position
  • Professor (Assistant)

Publications

Publications (72)
Article
The present research aims to develop a suitable cooling strategy in conjunction with the oxidation time during thermal oxidation to develop a TiO2 layer on Ti–6Al–4V substrate that could improve wettability and promote osseointegration. The study was carried out to verify if a change in cooling methods in conjunction with the change in oxidation ti...
Article
The production of aluminum metal matrix composites (AMMCs) has been a great challenge for commercial sectors and the research fraternity. Over the past few decades, many modifications and hybrid techniques have been designed and developed by the researchers to address the manufacturing issues and reduce the production cost in developing AMMCs. In t...
Article
To improve the quality and productivity of the process or system before resorting to expensive and laborious experimental tests, it is essential to model and predict the system performance concerning its operational parameters. Predictive modeling and parameter optimization through machine learning techniques has been the most advantageous process...
Article
Over the years, aluminum metal matrix composites (AMMCs) have transitioned into a viable replacement for traditional metals due to their exceptional strength-to-density ratio, higher modulus, excellent wear resistance, and anti-corrosive properties. An economical and efficient technique that uniformly distributes reinforcement particles into liquid...
Article
Finite element analysis has become an indispensable tool, often used in research and development, to provide valuable insights into the process. The studies in the metal cutting area mostly employ the Finite element method (FEM) due to its ability to highlight the physics involved in chip formation and the range of force generated in the cutting zo...
Article
Manufacturers across varied segments look for materials having appreciable machinability and surface integrities. Machinability of Mg alloys is a vital aspect during their acceptance for different applications. The chip shape generated in the cutting operation is a crucial attribute dominating the surface roughness, besides the dimension’s precisio...
Article
In this paper, the machinability of a fabricated AM alloy (Mg-7 wt%Al-0.9 wt%Mn) has been examined. The novel AM alloy was subjected to turning using a systemized CNC setup. The input turning variables: feed ( f), cutting speed ( v), and depth of cut (DOC) were suitably altered to analyze effects on response variables such as cutting force ( F c ),...
Article
Full-text available
The improved scratch resistance of epoxy-based coatings on titanium alloy is greatly needed in the current biomedical device sector. Due to commercial factors, this improvement must be either non-consumptive or inherited from the antecedent machining steps. This study contributes an extensive understanding of Ti-6Al-4 V surface topography, microstr...
Article
Purpose Production schedules, if not met as per timelines may result in heavy losses to a company in terms of its standing and the overall profit. Production scheduling is generally planned by not taking preventive maintenance schedules into consideration. Most of the plants allocate discrete hours/time for preventive maintenance activities. These...
Article
This article presents a critical review on various kinds of high energy absorbing materials pertinent to structural and mechanical integrity of military armor vehicles including material related technologies. It is well known that the integrity of armor vehicle obviously is of utmost importance for military planners as well as designers. The profil...
Article
This study aimed to analyze the feed force, cutting force, and surface roughness deviations through CNC lathe turning operation of AM series magnesium alloy. Machining operations were performed using Tungsten Carbide insert with nose radius of 0.8 mm and by varying the basic cutting parameters like feed, cutting speed, and depth of cut. Throughout...
Article
In this paper, a novel AM series Mg alloy developed through a stir casting process has been discussed. The current research utilizes an improved stir casting setup with a systemized inert facility. The effects of the processing parameters viz. stirring speed and holding temperature on microstructure and mechanical properties of the novel AM alloy (...
Article
Machining parameters play a significant role in controlling the response variables such as cutting force, temperature, surface roughness, chip shape, etc. Therefore, a judicious selection of machining parameters becomes vital. Many studies have been done to analyze the effect of turning parameters on the response variables in the past. However, the...
Article
Magnesium alloys are being used in different sectors for several applications. The low density and high strength to weight ratio have made them indispensable. However, it is observed that Mg alloys are less preferred for the fabrication of critical and complex parts. The inferior mechanical and corrosive properties, along with high inflammability,...
Article
Magnesium alloys are widely used in different engineering sectors due to their lightweight, high stiffness, and damping properties. However, there are challenges with machining these alloys because of their mechanical properties and inflammability. In this study, a newly developed Aluminum-Manganese (AM) series Mg alloy was subjected to a turning o...
Article
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 inter...
Article
For over a decade, the hard coatings have been providing wear resistance to cutting tools materials. The industrial prerequisites and advancements in hard coatings provide drastic improvements with respect to productivity, component lifetimes and hence reduces cost. However, selection of desirable coating is often not straight forward, in view of t...
Article
The rapid wear of materials and inferior surface quality due to friction is a critical issue to address the high strength materials. A promising route to overcome the drawbacks by virtue of nanocomposite coating materials and adopt new coating techniques that can enhance the performance than the existing coating technology. An approach providing hi...
Article
The excellent properties such as high strength to weight ratio and biocompatibility possessed by Titanium make it a highly beneficial material. Titanium is used in aerospace, armor plating, naval ships, missiles and surgical implants. In addition, the allotropic transformation nature of this metal further gives a wider scope of applications. The ba...
Article
In the present day manufacturing industry, achieving machining accuracy, high production rate, and high material removal rate and increasing tool cutting life is becoming more vital and challenging task. Machining of hard materials is difficult to carry out because of high temperature generation between tool-workpiece interface which results in sig...
Article
Mechanical parts in modern machining systems are often subjected to friction and wear causing high heat generation at the contact zones leading to reduced lifecycle and increased power consumption of machinery. Coolants, despite controlling this high contact zone heat, are uneconomical due to their high cost. Various researchers across industries h...
Conference Paper
Aluminum matrix composites (AMCs) have evolved into a unique field of materials science and engineering by becoming a premise for consistent research due to their excellent strength, low density, improved wear resistance, and enhanced thermal properties. The essence of AMCs lies in their ability to offer countless opportunities to tailor material p...
Article
Wear mechanism plays a dominant part in minimizing the tool life in the course of machining difficult to machine materials. Issues related to wear mechanisms, namely spring back, variation in chips, and high-pressure loads, are accountable for tool wear. For machining numerous tool materials are not suitable due to volume specific heat and low ther...
Article
The nanocomposite coating has immense significance because of its high hardness and excellent oxidation resistance desired for a cutting tool. A systematic approach needs to be designed and developed to achieve high-performance nanocomposite coating to enhance the tribological and mechanical properties. Therefore, the current research attributes a...
Article
In order to enhance the efficiency of cutting process before resorting to costly and time consuming experimental trials, it is necessary to model and simulate the machining process by using Finite Element (FE) analysis. However, modeling of composite machining is difficult owing to its distinctive structure and composition which is anisotropic and...
Article
Full-text available
In the present paper, the artificial neural network (ANN) and response surface methodology (RSM) are used in modeling of surface roughness in WS2 (tungsten disulphide) solid lubricant assisted minimal quantity lubrication (MQL) machining. The real time MQL turning of Inconel 718 experimental data considered in this paper was available in the litera...
Article
Full-text available
Wear mechanism takes predominant role in reducing the tool life during machining of Titanium alloy. Challenges of wear mechanisms such as variation in chip, high pressure loads and spring back are responsible for tool wear. In addition, many tool materials are inapt for machining due to low thermal conductivity and volume specific heat of these mat...
Article
Full-text available
Solid lubrication by soft coatings is an important technique for superior tribological performance in machine contacts involving high pressures. Coating with soft materials ensures that the subsurface machine component wear decreases, ensuring longer life. Several soft metal coatings have been studied but zinc coatings have not been studied much. T...
Article
Finite element (FE) modeling of a machining process in current industrial practice is highly essential to model and simulate the metal cutting process before resorting to costly and time consuming experimental trials. The current work describes a FE evaluation of machining process when simulating AA7075-T6 cutting process and comparison of predicte...
Article
The scope of this study is to optimize the electrostatic solid lubricant coating deposition process parameters such as electric potential, solid lubricant feed pressure and distance between the nozzle tip to metal substrate on its average surface roughness of the coatings. Statistical design approach was used to plan and confirm the experimental in...
Article
In modern industry, mechanical parts are subjected to friction and wear, leading to heat generation, which affects the reliability, life, and power consumption of machinery. Effective cooling and lubrication in the machining zone are essential to improve friction and temperatures by efficient heat dissipation which increases tool life and surface q...
Article
The current research is to focus on developing a liquid nitrogen diffusion system to optimize the usage of liquid nitrogen and maximizing cooling and lubrication capability by effective penetration. An atomized liquid nitrogen spray system was developed to diffuse liquid nitrogen effectively at a low flow rate (10–12 L/h) and as a high velocity (8–...
Article
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 surfa...
Article
The current research work makes an attempt to develop a methodology in order to produce high quality Al-TiCp composites by using systemized inert atmospheric stir casting facility. The quality of produced composites were characterized using micro structural, Energy-dispersive X-ray spectroscopy (EDX) and machinability studies. Atomized-Cryogenic-Li...
Article
Full-text available
Machining of composite materials is difficult due to the high abrasiveness of reinforcing constituents. This creates friction between work piece-tool-chip interfaces resulting in high temperatures. The risk of developing elevated temperatures can be controlled by coolants, however, they are known to cause environmental problems. In the interest of...
Article
Full-text available
Turning is one of the most fundamental and indispensable processes of metal removal in industry. Increasing pollution-preventing initiatives globally and consumer focus on environmentally conscious products has put increased pressure on industries to minimize or eliminate the use of cutting fluids. The use of solid lubricant in machining operation...
Article
Full-text available
The current research work demonstrates through experiment, the effect of solid lubricant assisted minimum quantity lubrication (MQL) turning of Inconel 718 on the finish quality of machined surface. In MQL application, micron sized tungsten disulfide (WS2) solid lubricant powder particles were dispersed (0.5% wt.) in emulsifier oil based cutting fl...
Article
In modern industry, mechanical parts are subjected to friction and wear, leading to heat generation, which affects the reliability, life and power consumption of machinery. The study of lubricant film formed between various geometric shapes are inherently complicated and interconnected, making it necessary to understand the concepts of tribological...
Article
Full-text available
Cryogenic technology is used in various engineering and industrial applications such as aerospace, automotive, defence and medical fields due to its better cooling and /or lubrication action. Conventional materials used in cryo-techniques are substituted with metal matrix composites (MMCs) due to their high strength-to-weight ratio. Aluminium-reinf...
Article
Full-text available
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 machinabilit...
Article
A judicious material constitutive model used as input to the numerical codes to denote elastic, plastic, and thermomechanical behavior under elevated temperatures and strain rates is essential to analyze and design a process. This work describes the formulation of different constitutive models, such as Johnson–Cook, Zerilli–Armstrong, Arrhenius, an...
Article
The purpose of this study is to investigate the friction and wear behavior of novel electrostatic micro-solid lubricant (EMSL) bonded molybdenum disulfide (MoS2) coatings on cemented carbide tools under dry slide condition. Pin-on-disc tribological tests between titanium alloy Ti–6Al–4 V and uncoated/coated cemented tungsten carbide–cobalt alloy (W...
Article
Developing improved coated cutting tools to achieve a better cutting performance is one of the key factors in enhancing machining productivity. The present article contributes to the development of electrostatic solid lubricant coating technology to produce high-performance coated tools for machining process improvement. Machining tests and finite...
Article
Aluminum based Titanium carbide particulate reinforced metal matrix composite (Al-TiC PMMC) draws attention by many researchers & industries over alloy materials because of its excellent thermo-physical and mechanical characteristics. Despite of its superior properties of Al-TiC MMC, its complexity in manufacturing process and poor machinability ha...
Article
A consistent and reasonable description of the constitutive behavior of material under the coupled effect of strain, strain rate and temperature on the flow stress of the material is highly essential in current industrial practice to design and optimize the process parameters in manufacturing operations. In order to formulate a suitable constitutiv...
Article
Conventional metal cutting processes involve massive consumption of energy where the specific cutting energy is usually high. A major division of this energy is converted into heat, which creates detrimental effects on cutting tool wear, surface quality of machined workmaterial and dimensional accuracy. Although cutting fluids are effective to coer...
Conference Paper
Accurately predicting the tool wear in any machining process play an important role in enhancing the manufacturing process performance. In all machining operations, cutting tool wear is strongly influenced by contact temperatures, stresses, and relative sliding velocity at the machining interface. Based on cutting temperatures and stresses on the t...
Article
Accurately predicting the tool wear in any machining process play an important role in enhancing the manufacturing process performance. In all machining operations, cutting tool wear is strongly influenced by contact temperatures, stresses, and relative sliding velocity at the machining interface. Based on cutting temperatures and stresses on the t...
Conference Paper
Machining of high strength materials is associated with generation of high Machining of high strength materials is associated with generation of high cutting temperature, which results in premature failure of cutting tools and hence there is a need to look into new machining methods to withstand high temperature generation. In this research work, t...
Conference Paper
Dry sliding experiences high friction and wear thus influencing the life and quality of the parts under sliding. To provide low friction and improve wear resistance, solid lubricants have an edge over conventional choice. This article features a specific study of the application of solid lubricant in dry sliding operations and presents its influenc...
Conference Paper
Now a days for machining operations apart from good tribological properties, the lubricant is also expected to be non-hazardous and non-polluting. When considering the ecological and environmental aspects in machining processes, the use of biodegradable oil can be an alternative source of lubricant due to its positive impact to employee health and...
Article
Dry sliding experiences high friction and wear thus influencing the life and quality of the parts under sliding. To provide low friction and improve wear resistance, solid lubricants have an edge over conventional choice. This article features a specific study of the application of solid lubricant in dry sliding operations and presents its influenc...
Article
Liquid lubricants have traditionally been used to control the high heat generation in machining; however, the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. Minimization or possible elimination of cutting fluids substituting their functions by some other means is emerging as a thrust a...
Article
The growing demands for high productivity of machining require the use of high cutting speeds and feed rates. Such machining inherently produces a high cutting temperature, which not only reduces tool life, but also impairs the product quality. Application of cutting fluid influences the performance of machining because of its lubrication and cooli...
Article
Control of machining zone temperature is achieved by providing effective cooling and lubrication. Though cutting fluids are widely used to carry away the heat in metal cutting, they cannot be recommended in the light of ecological and economic manufacture. Hence, there arises a need to identify eco-friendly and user-friendly alternatives to convent...
Conference Paper
The rapid wear rate of cutting tools due to high cutting temperature is a critical problem to be solved in machining of hardened steel. Application of cutting fluid influences the performance of machining because of its lubrication and cooling actions. But, the environmental concerns call for the reduced use of cutting fluids in machining operation...
Article
The quality of the components produced during end milling of Al/SiC particulate metal–matrix composites (PMMCs) is important as it influences the performance of the finished part to great extent. Hence, the estimation of surface integrity can cater to the requirements of performance evaluation. Therefore, an understanding of surface integrity provi...
Conference Paper
Drilling is one of the most commonly used machining processes in various industries such as automotive, aircraft and aerospace, die and molds, home appliance, medical and electronic equipment industries. In recent years, the improvement in the coatings of carbide tools and in the chemical and mechanical properties of tool materials has caused the i...
Article
Full-text available
Machining of materials has received substantial attention due to the increasing use of machining processes in various industrial applications. The research in this area is intended mainly to improve the machining of process so as to achieve the required surface quality. Machining processes, though employed widely as in metal removal process, have t...
Conference Paper
It is generally considered that the heat produced during the machining process is critical in terms of workpiece quality. So, effective control of heat generated at the cutting zone is essential to ensure the workpiece quality in machining, which can be achieved by using coolants. As the coolants are relatively inaccessible to the machining zone du...
Article
Full-text available
In any machining operation, the use of coolants is essential to dissipate heat generated during machining and hence to improve productivity, machinability, etc. However, the use of cutting fluids in machining operations may seriously degrade the quality of environment. New cutting techniques are to be investigated to alleviate the problems associat...
Article
Full-text available
Majority of machining operations require the cooling and lubricating action of cutting fluids. But, due to ecological and human health problems, manufacturing industries are now being forced to implement strategies to reduce the amount of cutting fluids used in their production lines. In the present work, experimental studies have been conducted to...
Conference Paper
The heat produced during machining is critical in terms of workpiece quality. So, effective control of heat generated at the cutting zone is essential to ensure the workpiece quality in machining, which can be achieved by using coolants. As the coolants are relatively inaccessible to the machining zone due to the typical nature of the process, it h...
Article
Milling is a widely employed material removal process for different materials. It is characterized by high material removal rate. Machining leads to high friction between tool and workpiece, and can result in high temperatures, impairing the dimensional accuracy and the surface quality of products. Application of conventional cutting fluid may not...
Article
Full-text available
In machining, coolants improve machinability, increase productivity by reducing tool wear and extend tool life. However, due to ecological and human health problems, manufacturing industries are now being forced to implement strategies to reduce the amount of cutting fluids used in their production lines. A trend that has emerged to solve these pro...
Article
Influence of tool geometry on the quality of surface produced is well known and hence any attempt to assess the performance of end milling should include the tool geometry. In the present work, experimental studies have been conducted to see the effect of tool geometry (radial rake angle and nose radius) and cutting conditions (cutting speed and fe...
Conference Paper
Coolants dissipate the heat generated during machining and hence improve productivity, machinability, etc. However, the use of cutting fluids in machining operations may seriously degrade the quality of environment. So, in recent years researchers have started machining with the use of solid lubricants with the aim of improving machining performanc...

Projects

Project (1)