Vijay Sekar

• PhD
• Professor & Head at Sri Sivasubramaniya Nadar College of Engineering

Keywords: TIG Filler metals ER4043 ER5183 SEM Corrosion A B S T R A C T This study examines the impact of filler metal on the mechanical, microstructural and corrosion properties of an aluminium alloy 5083-F welded employing tungsten inert gas (TIG) welding. The filler metals ER4043 and ER5183 were used to make the joints. The metallurgical charact...

Citation: Vijaysekar, K.S.; Gobivel, K.; Selvan, C.P.; Krishnanand, M.; Malarmathi, E.; Mohamed Saajid, N.; Mohanraj, A. Investigation into the End-Milling Parameters of Mg/B 4 C Metal Matrix Composites. Eng. Proc. 2024, 61, 33. https://doi. Abstract: The automotive, biomedical, and aerospace industries are attracted towards magnesium-based alloys...

The present study examined the friction stir welding (FSW) of joints made from the interfacially layered dissimilar AA1200-H14 and AA6061-T6 using scandium about the UTS, frictional heat, and metallurgical properties. The experimental examination is carried out utilising a three-level, three factors, Box-Behnken Design matrix (17 tests) in response...

High-strength steels, such as 42CrMo, are frequently used in a variety of technological domains for highly dynamically loaded components. In the automobile sector, there are more demands for material characteristics due to increased efficiency, performance and weight requirements. To combat this, FE simulations have been used, which reduce the need...

The friction stir processing method was engaged on fusion welded AA5083-F/ER5356 and AA5083-F/ER5356+Sc joints to explore the impact of the process parameters on the mechanical and metallurgical characteristics of the processed weldments. The FSP approach was applied to the TIG-welded joints with pin-less FSP tool. Optical and SEM evaluation was co...

Magnesium-based MMCs are widely used in structural-based applications due to their lightweight, high hardness, corrosion and wear resistance. Also, machining is an important manufacturing process that is necessary to ensure dimensional accuracy and produce intricate shapes. In this context, the machining of Magnesium based metal matrix composites i...

Magnesium alloys are having the characteristics like light weight, wear, and corrosion resistance. Mg alloys find usage in a wide range of applications such as engine block of automobile parts, laptop cases, aircraft fuselages and mobile outer cases. However, in dry machining, many challenges restrict its development during fitment. In this researc...

Machinability studies on hard-to-cut material is very important to understand how to achieve better tool life and select optimal cutting parameters. This paper investigates the chip formation, cutting force, thrust force, temperature, and tool wear when machining Ti-6Al-4 V by comparing two different coated inserts. TiN and Al2O3 coated tools were...

Hastelloy based nickel materials are hard to cut category due to their properties like high strength during elevated temperature and excellent stress corrosion resistance. The machinability of such alloy is very much essential during fitment meanwhile tool wear need to be considered with utmost care. This study focused on turning operation of Haste...

Titanium alloys are used as an aerospace material due to their inherent properties such as high strength to weight ratio, corrosion, and fracture resistance. However, the low conductivity and reactivity towards plastic deformation causes these materials to be difficult to cut category. The prediction of various parameters like chip formation and ac...

Titanium Metal Matrix Composites have high specific strength and offer high stiffness compared with Nickel alloys and steel. While maintaining equivalent strength, it can reduce 50% weight relative to other super alloys. In this work, preparation of Silicon Carbide reinforced Titanium Metal Matrix Composite by powder metallurgy and drilling of the...

Super-alloys encompass great challenges in machinability. One such alloy of much interest in applications is Inconel 718. Its increased hardness, low thermal diffusivity and high temperature strength make it desirable for applications, at the same time rendering its machining a demanding task. Extensive studies have been performed on machinability...

Inconel 718 is a nickel-based super alloy well suited for high-temperature applications encountered in space shuttles, aircraft black box and turbocharger due to their inherent properties. Taking into account of extreme working conditions, efficiency in the process of machining without affecting the nature of the surface integrity with utmost care...

Simulation of metal cutting by Finite Element Method largely depends on material model and friction model. Inconel 625 is one of the super alloys, which has numerous applications but has no specific material model and friction model for simulating metal cutting. The Inconel 625 has a behaviour of softening at higher strain and strain rates. Materia...

In recent time, carbon fiber reinforced plastics (CFRP) are used in important applications in aerospace, automobile, sporting equipment’s, biomedical instruments, etc. High-speed machining of this material can regulate the cutting conditions to maximize production output. Investment for this process is at minimal cost which has been the generic aim...

The applications of the glass fiber-reinforced polymers (GFRP) composites are increasing every day because of its superior properties when compared with conventional materials. The modern industries in the field of aviation, aerospace, construction, marine and automobiles are using the composites very effectively to reduce the weight and to increas...

Proceedings of ICEMMM2018, Int. conference on Materials, Metallurgy and Manufacturing, held between Feb 15-16, 2018, SSN College of Engineering, Chennai, India.

The applications of glass fiber reinforced polymer composite materials are increasing in many industries, such as automobile, aerospace, construction, marine, and defense. The slot milling is an important machining operation to reduce the excess material and to bring the component to the required final shape and size. However, machining the glass f...

Slot milling is one of the complex metal cutting process which is to be investigated to make it cost effective and to improve the quality of the machined components by reducing or eliminating the machining induced damages. Hence, in this research work a realistic 3D Finite Element Model is developed in ABAQUS\Explicit to simulate the slot milling p...

A number of research papers are available in the public domain related to the mechanics of machining processes. In the Industry today, machining processes are vital to the manufacture of a product but also a troublesome area since large number of experimental trials are needed to optimize the processes. In this regard, Finite element analysis plays...

Glass Fiber Reinforced Polymers (GFRP) composites are used in making the primary structures of aircraft, marine and automobiles due to their superior properties over conventional metals. Drilling is an important machining process of making precise holes during the preassembly operations of composite laminates. Hole with a good dimensional accuracy...

Al 2024 T351 is an important alloy used in the construction of aircrafts due to its inherent qualities such as higher strength to weight, durability and machinability. Extensive experimental trials are needed to understand the material behaviour at dynamic loading conditions which is not feasible given the costs and time involved. Finite element (F...

Carbon fiber reinforced polymeric (CFRP) composite materials are widely used in aerospace, automobile and biomedical industries due to their high strength to weight ratio, corrosion resistance and durability. High speed machining (HSM) of CFRP material is needed to study the impact of cutting parameters on cutting forces and chip microstructure whi...

Carbon fiber reinforced polymeric (CFRP) composite materials are widely used in aerospace, automobile and biomedical industries due to their high strength to weight ratio, corrosion resistance and durability. High speed machining (HSM) of CFRP material is needed to study the impact of cutting parameters on cutting forces and chip microstructure whi...

In recent days, Carbon Fiber Reinforced Polymers (CFRP) composites are used in making the primary structures of aircraft, marine vessels and automobiles due to their superior properties. Composite laminates need limited traditional machining methods like drilling and milling to achieve the desired shape. However, the slot milling process is influen...

The application of Metal Matrix Composite (MMC) has been increasing due to its superior strength and wear characteristics but the major challenge is its poor machinability due to the presence of reinforcement in the matrix which is a hindrance during machining. The material behaviour during machining varies with respect to input variables. In this...

The present work aims in creating the Finite Element Models for the conventional and the Cryogenic Orthogonal machining process. Finite Element Modelling (FEM) of the orthogonal machining operation was performed using DEFORM – 2D which is based on a modified Lagrangian formulation. Finite Element models were developed for various experimental condi...

Titanium alloys are commonly used for many aerospace and medical applications because of their properties like high strength to weight ratio, corrosion resistance and heat treatment capabilities. But, due to the factors like low thermal conductivity and chemical reactivity with the cutting tool, it poses a challenge for the machining operations. In...

This paper provides an inclusive review of literature, mostly from the past decade, on optimization techniques of composite materials machining, both conventional and non-conventional process. Composite materials are continually replacing conventional materials due to their excellent corrosion resistance, higher strength to weight ratio, but the ma...

The objective of this study is to evaluate the wear progression of cryogenically treated and untreated tungsten carbide inserts during face milling of Grey Cast Iron which is a commonly used material in machine tool beds and automotive components due to low cost, high vibration damping capability, and easiness of manufacturing. Commercially availab...

Inconel 718, a Nickel based superalloy is widely used for aerospace applications mainly due to its high temperature resistance and high strength to weight ratio. Its poor machinability is a limiting factor in commercial, cost intensive applications. This paper investigates the machinability of Inconel 718 in high speed drilling. The impact of the m...

Titanium Alloys are unique due to their high strength-weight ratio,good fracture and corrosion resistance characteristics.They form a significant metal portion of the aircraft structural and engine components. However, their low thermal conductivity and high reactivity with cutting tools during machining, makes them difficult-to-machine materials....

Composite materials are in-homogenous, anisotropic and cause high tool wear at high cutting speeds in machining. Industrial practices worldwide reveal a need to use high speed machining to achieve the desired material removal rate, surface finish and to reduce cost cutting. In this research work, impact of turning glass fibre reinforced polymer tub...

Numerical simulations in machining processes are dependent on the flow stress input data. The flow stress is computed from empirical models which depend on number of material parameters, the values of which are derived from various mathematical optimization techniques. The derived flow stress parameters vary based on the nature of techniques used a...

Composite materials have high strength to weight ratio and hence are widely used in many industrial sectors such as aerospace, automobile and bio-medical. Finite element modelling of these composite materials are used in predicting the material behaviour under various conditions before being manufactured. In this study the orthogonal cutting proces...

This paper provides an inclusive review of literature, mostly from the past decade, on optimization techniques of composite materials machining, both conventional and non-conventional process. Composite materials are continually replacing conventional materials due to their excellent corrosion resistance, higher strength to weight ratio, but the ma...

The objective of this study is to evaluate the wear progression of cryogenically treated and untreated tungsten carbide 0inserts during face milling of Grey Cast Iron. Commercially available uncoated Tungsten Carbide insert with around 6% Co content were selected for the study and flank wear and nose wear were taken as the performance evaluation cr...

Titanium and Inconel alloys play a significant role in aircraft applications due to their high strength to weight ratio and high temperature resistance. However, their low thermal conductivity and high reactivity with cutting tools reduces their machinability, which is a limiting factor in commercial and cost intensive applications. The present stu...

Finite element (FE) analysis is used in many critical applications such as aerospace, biomedical sectors to simulate the material behavior before being manufactured. These industries are using composite materials extensively due to their inherent properties such as high strength to weight ratio, corrosion resistant and durability. Hence FE studies...

Flow stress is a vital input data for successful simulation of a machining process. However the flow stress data obtained from experiments do not represent the practical machining conditions which induce errors in the simulated output. In this research work the flow stress of Ti6Al4V titanium alloy is improved through a new integrated Taguchi – Fin...

Low density materials like Al 2024-T351 have found a wide range of applicability due to its capability of bearing high loads. To combat the need of extensive experimental trials to understand the orthogonal machining of Al 2024 T351, Finite element (FE) simulations have been employed. One of the most important parameters which determine the effecti...

Low density materials like Al 2024-T351 have found a wide range of applicability due to its capability of bearing high loads. To combat the need of extensive experimental trials to understand the orthogonal machining of Al 2024 T351, Finite element (FE) simulations have been employed. One of the most important parameters which determine the effecti...

Flow stress is a vital input data for machining simulations, which is experimentally measured from Split Hopkinson pressure bar (SHPB) tests. However such flow stress does not fit machining conditions of strain, strain rate and temperatures and lead to serious simulation errors. In this research work an integrated Taguchi – Finite element (FE) meth...

Aluminium alloys are widely used in the structural industry due to their inherent high strength to low weight ratio. In particular, AA 6082 (T6) is an AlSi1MgMn alloy known for its superior anti-corrosion and anti-oxidation properties combined with its excellent formability and machinability. The T6 temper in particular possesses higher tensile str...

The machining of titanium alloys poses several inherent difficulties owing to their unique mechanical properties and cutting characteristics. Finite element (FE) simulations have reduced the burden of extensive experimental trials in understanding the deformation behavior and optimize the cutting process. The FE code relies on the qualitative natur...

The machining of titanium alloys poses several inherent difficulties owing to their unique mechanical properties and cutting characteristics. Finite element (FE) simulations have reduced the burden of extensive experimental trials in understanding the deformation behavior and optimize the cutting process. The FE code relies on the qualitative natur...

The Finite element simulation of the orthogonal machining process of AA 6082(T6) alloy has been carried out in this work. The applicability of the Johnson – Cook (J-C) and the Zerilli – Armstrong (Z-A) flow stress models in describing the work material constitutive behavior has been evaluated. Orthogonal cutting experiments were carried out with a...

This work evaluates the effects of three different flow stress models on the finite element simulation of the orthogonal cutting process on AISI 1045 steel. The flow stress models, namely, Oxley, Johnson-Cook (J-C) and Modified Johnson-Cook (MJ-C), were used as the constitutive material behavioural models for the finite element simulation. Orthogon...

The effect of flow stress models on the Finite element simulation of the orthogonal cutting process on AISI 1045 steel have been undertaken in the present work.The Oxley,Johnson – Cook and Modified Johnson – Cook flow stress models were used to explain the constitutive material behaviour of AISI 1045 steel.The orthogonal cutting experiments were ca...

A Finite element analysis of the effect of cutting speeds on the orthogonal machining process of AA 6082 (T6) alloy material has been carried out in this research work. The work material constitutive behavior was modeled using the Johnson – Cook (J-C) and the Zerilli – Armstrong (Z-A) flow stress models. The orthogonal cutting experiments were carr...