In-House Developed Facilities

Development of adaptive feedback controlled electric hydro dissection device

A hydro dissection device with feedback control facility was developed, which can be used for cleft lip and palate surgery. This innovative device provides smooth and controlled injection. Also, the device has special feature of monitoring and recording live data during the surgical procedure.

Team Members:

• Mr. Rajendra Kumar Arya

• Prof. Akshay Dvivedi

Nominated as best amongst all the innovations from the IIT Roorkee for the year 2019.

Nominated for the 100 best innovations by the Indian Innovators Association Award.

The Adaptive Feedback Controlled Electric Hydro-Dissection Device was Showcase Exhibit at the “World Conference on Access to Medical Products”, organized by the Ministry of Health and Family Welfare, GOI and WHO.

Development of Ultrasonic Micromachining Facility

Using this facility features less than 200 microns were successfully developed. This developed machining process can be used for drilling of micro holes; machining of micro channels, micro arrays and micro moulds on hard and brittle materials.

Team Members:

• Dr. Manjot Singh Cheema

• Prof. Akshay Dvivedi

• Prof. Apurbba Kumar Sharma

(a) Micro-USM facility for machining 3-D micro-moulds

(b) generator (c) Acoustic based system

Near-Dry Electric Discharge Machining (EDM) Facility

The conventional liquid dielectric was replaced by two-phase dielectric (gaseous and liquid phase). The advantage being no harmful fumes are liberated while machining. This results in process being economical and eco-friendly. The developed process provided material removal rate and surface quality in comparison with conventional EDM higher by nearly five times and three times, respectively.

Team Members:

• Dr. Krishnakant Dhakar

• Prof. Akshay Dvivedi

Development of Rotary Tool Near-Dry Electric Discharge Machining (EDM) Facility

The capabilities of Near-Dry Electric Discharge Machining (EDM) process were improved manifold by providing tool rotation during multi-phase flow of dielectric medium. The developed process provided material removal rate and surface quality in comparison with conventional EDM higher by nearly ten times and five times, respectively.

Team Members:

• Dr. Vineet Yadav

• Prof. Pradeep Kumar

Development of Grinding assisted rotary disc electrochemical discharge machining (GA-RDECDM) facility

The developed grinding assisted rotary disk electrochemical discharge machining (GA-RDECDM) process integrates the concept of triplex hybridization. In GA-RDECDM, an abrasive coated rotary disk was used as a tool electrode. The abrasive coated disk provides micro gaps between the tool electrode and work material surface and thereby it results in thin and stable gas film formation. The breakdown of thin and stable gas films produce high frequency, low intensity discharges and consequently improves the machining performance. The additional abrasion that is imparted by rotating disk ensures the continuation of ECDM process. The major contribution of this research work is the development of a novel method for the fabrication of the slits on MMCs, slots and cutting of ceramic materials.

Team Members:

• Dr. Tarlochan Singh

• Mr. Rajendra Kumar Arya

• Prof. Akshay Dvivedi

Development of Pressurized feeding system for ECDM process

The development of pressurized feeding system was motivated to control the working gap during ECDM process. In pressurized feeding system, the exerted pressure over the tool electrode maintains constant working gap (almost zero) between tool tip and work material. There is also a provision in the developed system to hold the work material, and to provide an appropriate feeding motion to maintain constant working gap during machining.

Team Members:

• Dr. Tarlochan Singh

• Prof. Akshay Dvivedi

Development of Multi-Phase Flow ECDM Facility

Multi-Phase Flow ECDM facility was developed for drill of high aspect ratio holes on glass and ceramics. This facility extends the discharge regime to hydrodynamic regime.

Team Members:

• Mr. Rajendra Kumar Arya

• Prof. Akshay Dvivedi

Development of Adaptive Cutting Force Control System for Process Stability of Micro-USM Process

A closed loop adaptive cutting force control system (modular system) was developed to provided excellent control over machining gap in USM process. This system keeps the process in control at all times throughout the machining and ensures improved results with higher efficiency with high quality of machined features. The developed system is flexible and it can also be used for other non-traditional machining processes both in macro and micro domain.

Team Members:

• Mr. Karan Bagla

• Mr. Rishabh Gupta

• Mr. Antriksh Mathur

• Mr. Kuldeep Singh

• Prof. Akshay Dvivedi

Development of Ultrasonic assisted ECDM Facility

Ultrasonic assisted ECDM Facility was developed with objective of enhancing the efficiency of ECDM. This facility in comparisons with conventional ECDM is able to achieve higher depth of machining with low values of hole cut and thermal damage.

Team Members:

• Mr. Ranjeet Singh Rathore

• Prof. Akshay Dvivedi

Development of pressurized tool feeding system for ECDM process

A pressurized tool feeding system was developed for ECDM process. This system provides constant working gap during machining with balancing the feed force at a single location. The developed system can simultaneously machine multiple holes and complicated geometries on a single work material.

Team Members:

• Mr. Rajendra Kumar Arya

• Prof. Akshay Dvivedi

Development of Rotary Tool micro-USM process

Rotary tool micro USM Process is a process variant of conventional micro USM process where in the tool has simultaneous vibration and rotation. The integration of rotary motion of tool in USM process facilitates the evacuation of debris from the machining zone and thereby enhances the performance of micro USM. By providing rotary motion to the tool improved the machining rate of USM by approximately 150% and 140% during machining of micro holes and micro-channels respectively.

Team Members:

• Dr. Sandeep Kumar

• Prof. Akshay Dvivedi

Development of ultrasonic assisted electrochemical discharge trepanning (UA-ECDT) Facility

The developed facility of ultrasonic assisted electrochemical discharge trepanning (UA-ECDT) process integrates the concept of triplex hybridization. Where a tool electrode was made offset from the spindle axis as per the desired diameter of the hole to be machined, and an orbital motion along with the ultrasonic vibrations was provided to the tool electrode. The integration of ultrasonic vibrations in ECDT process facilitates evacuation of the sludge/debris from the machining zone. Also, it generates thin and stable gas film over the tool electrode. The use of UA-ECDT process improves the energy channelization index (ECI), and exhibits 10 times more ECI than the ECDT process.

Team Members:

• Mr. Kapil Pawaria

• Prof. Akshay Dvivedi

Development of Ultrasonic Turning

Ultrasonic energy was effectively utilized for turning of hard-and-brittle materials. This resulted in development of a new machining process. This process is now being used for machining threads on hard-and-brittle materials.

Team Members:

• Dr. Manjot Singh Cheema

• Prof. Akshay Dvivedi

• Prof. Apurbba Kumar Sharma

Development of Electromagnetic Stir Casting Facility

Electromagnetic stir casting facility was developed to add the particulate reinforcement in to the matrix melt. The objective was to overcome the problems of particle agglomeration and porosity during stir casting.

Team Members:

• Mr. Saurab Gupta

• Prof. Akshay Dvivedi

Development of Rotary Electric Discharge Machining facility

Rotary tool electric discharge machining (REDM) is a process variant of EDM in which the tool electrode is rotated with simultaneous electrical discharges. The centrifugal force near discharge area in REDM provides effective flushing of inter electrode gap. Consequently, material removal rate and surface finish improves.

Team Members:

• Mr. Sudeep Biswas

• Prof. Akshay Dvivedi

Development of Shaped Tube Electrolytic Machining Facility

A facility to drill high aspect ratio holes on difficult to machine materials was developed. An adaptive feed control system was also developed to control inter electrode gap as desired, to work in macro to micromachining domain.

Team Members:

• Mr. Anuj Vats

• Prof. Akshay Dvivedi

• Prof. Pradeep Kumar

Development of setup for stir casting facility

Manufacturing of Near-Net Shape MMC through development of stir casting retaining its cost effectiveness and still producing acceptable results. A novel setup was developed in-house for fabrication of Near-Net-Shape MMC using stir-squeeze-Quench casting route.

Team Members:

• 1. Dr. Sarbjeet

• Prof. Akshay Dvivedi

• Prof. Inderdeep Singh

Development of Powder Electric Discharge Machining (PEDM) facility

Powder Electric Discharge Machining is a process variant of EDM. The powders (conductive/non-conductive) are mixed with dielectric fluid of EDM. The mixing of powders changes the conductivity of the dielectric further and improves spark discharge. This improves material removal rate and produces mirror finish surfaces in hard-to-machine materials.

Team Members:

• Prof. Akshay Dvivedi

Modular accessory for mobility enhancement of manual wheel chair

A high quality, modular and compact attachment was developed to provide effortless motion to the manually operated wheelchair. The cost of the developed attachment is only 2.75% of existing products (784% reduction in cost). The attachment is compact, flexible and can be attached to any wheelchair with minor modifications. It is easy to install, lightweight and easy to use.

Team Members:

• Prof. Akshay Dvivedi

• Mr. Vaibhav Agarwal

• Mr. Aditya Pesin