Ranga Komanduri

Machining and Grinding - Machining and grinding are material removal processes for producing parts of desired shape, size, accuracy, and surface integrity. Over $300 billion/year is expended in the U.S. for these operations (labor and overhead only, not including materials or equipment). As these processes are of technological and economic significance, fundamental understanding of these processes is critical for the advancement of these fields.

Diamond Coatings - Low pressure synthesis of diamond films and diamond crystals by chemical vapor deposition (CVD) and by combustion techniques has opened up new opportunities for this high-tech material. Diamond is the hardest known material. It also has very high thermal conductivity (2-5 times that of copper), corrosion and wear resistance. Diamond coatings or crystals can be used for a variety of manufacturing applications including wheels for grinding, cutting tools for machining, and dies for metal forming. These films can also be used for tribological (e.g. bearings for low friction and corrosion resistance), ultra precision machining, optical (e.g. IR windows) and semiconducting (e.g. heat sinks, P and N materials) applications.

Tribology - Tribology, the science and technology of interacting surfaces in relative motion, has evolved from the classical fields of friction, lubrication, and wear. It plays a pivotal role in manufacturing, particularly in materials processing such as metal forming and cutting. A basic understanding of the complex processes that occur at the interface between a tool or die and the work material (wear, adhesion, material transfer, and chemical interactions between the surfaces in relative motion) can contribute significantly towards reduction of wear of tools or dies and increase productivity.

Ultra Precision Machining - Single crystal diamond tools are used on specially designed machine tools for precision machining of metal mirrors and aspheric optics with surface roughness approaching a few nanometers r.m.s. Ceramics and glasses are now machined at very small depths of cut ("gentle" grinding) to minimize surface cracks. The mechanics of machining at such fine depths are not well understood. This is an area of great technological significance. Molecular dynamics (MD) simulation is used to study the chip formation process at fine depths of cut (nanometric cutting).

Non-Traditional Processing - Many advanced materials such as ceramics, composites, and other difficult-to-machine materials are being introduced for high performance applications. These materials have to be processed by such non-traditional processing techniques as electro-discharge machining (EDM), electrochemical maching (ECM), abrasive water jet cutting, laser processing, and plasma processing. A fundamental understanding of the mechanics of these processes, process capabilities, and limitations would be of great scienticfic and technolgical value.

Molecular Dynamics Simulations of Nanometric Cutting & Tribology - Molecular dynamics (MD) simulations can play a significant role in addressing a number of machining and tribological problems at the atomic scale. In fact, such data may not be obtained readily in any other way, theory or experiment. At OSU, we are addressing MD simulations of various workmaterials both metals and semiconductor materials, effect of crystal orientation and cutting direction, geometry of the tool, exit-failure, atomic scale friction, nanomechanical properties. We are also extending this work to MD/Monte Carlo (MC) simulations as well as parallel processing.

Thermal Aspects of Various Manufacturing Processes - Considerable amount of heat is generated in various manufacturing processes due to plastic deformation and friction. High temperatures in the cutting tool and/or steep temperature gradients in the workmaterial can limit the productivity in manufacturing due to rapid tool wear or objectionable metallurgical damage/residual stresses in the workmaterial. Thermal analysis of various manufacturing processes will enable us to address these issues and optimize the process parameters. At OSU we are addressing thermal aspects of various manufacturing processes including cutting, high-speed machining, polishing, grinding, welding, heat treatment, and tribological problems.

Selected Publications

Komanduri, R. and Z. B. Hou, “Thermal Analysis of Shear Instability in the Machining of Titanium Alloys,” Metallurgical and Materials Transactions 33A (2002) 2995-3010.

Komanduri, R. and L. M. Raff, "A Review on the Molecular Dynamics (MD) Simulation of Machining," Proc. of the I. Mech. E. (Lon) 215 B (2001) 1639-1672.

Komanduri, R., "Proposal for a New Course on the Thermal Aspects of Manufacturing,” Guest Editorial, Heat Transfer Engineering 22 (2001) 1-3.

Komanduri, R., Chandrasekaran, N., and L. M. Raff, "Molecular Dynamics Simulation of the Nanometric Cutting of Silicon,” Philosophical Magazine B 81 (2001) 1989-2019.

Komanduri, R., and Z. B. Hou, "Thermal Analysis of the Laser Surface Transformation Hardening Process,” Int. J of Heat and Mass Transfer 44 (2001) 2845-2862.

Komanduri, R., Chandrasekaran, N., and L. M. Raff, "MD Simulation of Single Crystal Aluminum - Effect of Crystal Orientation and Direction of Cutting," Wear 242 (2000) 60-88.

Komanduri, R. and Z. B. Hou, "A Review of the Experimental Techniques for the Measurement of Heat and Temperatures Generated in Some Manufacturing Processes and Tribology," Tribology International 34 (2001) 653-682.

Komanduri, R. and Z. B. Hou, "Tribology in Metal Cutting: Some Thermal Issues," Trans ASME J of Tribology 123 (2000) 799-815.

Komanduri, R., Chandrasekaran, N., and L. M. Raff, "MD Simulation of Atomic Scale Friction," Physical Review B 61 (2000) 14007-14019.

Zhen Bing Hou and R. Komanduri, "General Solutions for Stationary/Moving the Plane Heat Source Problems in Manufacturing and Tribology” Int. J of Heat & Mass Transfer 43 (2000) 1679-1698.

Yan. J., Yoshino, M., Kuriagawa, T., Shirakashi, T., Syoji, K. and R. Komanduri, "On the Ductile Machining of Silicon for Micro Electro Mechanical (MEMS), Opto-electronic and Optical Applications," Materials Science and Engineering, B 297/1-2 (2000) 230-234.

Komanduri, R. and Z. B. Hou, "Thermal Analysis of the Arc Welding Process: Part I General Solutions," Metallurgical and Materials Transactions 31B (2000) 1353-1370.

Komanduri, R., Hou, Z. B., Umehara, N., Raghunandan, M., Ming Jiang, Bhagavatula, S. R., Noori-Khajavi, A., and N. O. Wood, "A 'Gentle' Method for Finishing Si3N4 Balls for Hybrid Bearing Applications," Tribology Letters 7 (1999) 39-49.

Mallika, K. and R. Komanduri, "Low Pressure Microwave CVD Diamond Coatings on Cemented Tungsten Carbide Tools," Wear 224 (1999) 245-266.

Ming Jiang, Wood, N. O., and R. Komanduri, "On the Chemo-Mechanical Polishing of Si3N4 Bearing Balls with Various Abrasives" Wear 220 (1998) 59-71.

Ming Jiang, Wood, N. O., and R. Komanduri, "On the Chemo-Mechanical Polishing of Si3N4 Bearing Balls with CeO2," Trans ASME, J of Engineering Materials & Technology, 120 (1998) 304-312.

Komanduri, R., "Machining of Fiber-Reinforced Composites," J of Machining Science and Technology, 1(1) (1997) 113-151.

Komanduri, R., "Tool Materials," Encyclopedia of Chemical Technology, John Wiley & Sons, Inc. Vol.24 (1997) 390-455.

Komanduri, R., Lucca, D. A., and Y. Tani, "Technological Advances in Fine Abrasive Processes," Annals of CIRP 46/2 (1997) 545-596.

Zhen Bing Hou and R. Komanduri, "Modeling of Thermo-Mechanical Shear Instability in Machining," Int. J. of Mechanical Sciences, 9 (1997) 1273-1314.

Bhagavatula, S. R. and R. Komanduri, "On Chemo-Mechanical Polishing of Silicon Nitride with Chromium Oxide Abrasive," Philosophical Magazine A 74 (1996) 1003-1017.

Noori-Khajavi, A and Komanduri, R., "Frequency and Time Domain Analyses of Sensor Signals in Drilling. Part I Correlation with Drill Wear," Int. J. of Mach. Tools and Manufacturing, 35 (1995) 775-793.

Noori-Khajavi, A and Komanduri, R., "Frequency and Time Domain Analyses of Sensor Signals in Drilling. Part II Investigation on the Problems Associated with Sensor Integration," Int. J. of Mach. Tools and Manufacturing 35 (1995) 795-815.

Fox, M., Agarwal, K., Noori-Khajavi, A., Shinmura, T., and Komanduri, R., "Magnetic Abrasive Finishing of Non-Magnetic Stainless Steel Rods," Annals of CIRP v. 44, n. 1, 1994, pp. 181-184.

Komanduri, R. and S. Nandyal, "Low-Pressure Diamond Synthesis of Polycrystalline Diamond Abrasive," Int. J. Machine Tools Manufacturing v. 33, n. 2, 1993, pp. 285-296.

Komanduri, R.," Machining of Fiber-Reinforced Composites," ASME Mechanical Engineering, v. 114, 1993, pp. 58-64.

Komanduri, R., "Machining and Grinding - A Historical Review of Classical Papers," ASME Applied Mechanics Review 46 (1993) 80-132.

Komanduri, R., "Machining and Grinding - A Historical Review of the Classical Papers," ASME Applied Mechanics Review, v. 46, 1993, pp. 80-132.

Ikawa, N., Donaldson, R. R. Komanduri, R., Konig, W., McKeown, P. A., Moriwaki, T. and I, Stowers, "Ultraprecision Metal Cutting - The Past, the Present, and the Future," Annals of CIRP v. 40, n. 2, 1991, pp. 587-594.

Komanduri, R and J. Larsen-Basse, "Tribology: The Cutting Edge," ASME Mechanical Engineering v. 110, 1989, p. 74.

Komanduri, R. and J. Larsen-Basse, "Tribology: The Cutting Edge," ASME Mechanical Engineering, 111, No. 1 (January 1989) 74-79.

Komanduri, R., "High Speed Machining," ASME Mechanical Engineering 107, No. 12 (1985).

Komanduri, R. and M. Lee, "Ledge Tool: A New Cutting Tool Insert," Trans ASME J. of Eng. for Ind. 107 (May 1985) 99.

Komanduri, R., Hazra, J., Schroeder, T. A., von Turkovich, B. F., and D. G. Flom, "On the Catastrophic Shear Instability in High Speed Machining of an AISI 4340 Steel," Trans ASME, J. of Engg. for Ind. 104 (May 1982) 121.

Komanduri, R. and R. H. Brown, "On the Mechanics of Chip Segmentation in Machining," Trans ASME, J. of Engg. for Ind. 103 (1981) 33.

Komanduri, R. and B. F. von Turkovich, "New Observations on the Mechanism of Chip Formation When Machining a Titanium Alloy," Wear 69 (1981) 179.

Komanduri, R. and M. C. Shaw, "Attritious Wear of Silicon Carbide Abrasive," Trans ASME, J. of Engg. for Ind. 98, (Nov, 1976) 1125.

Komanduri, R. and M. C. Shaw, "On the Diffusion Wear of Diamond in Grinding Pure Iron," Philosophical Magazine 34 (1976) 195.

Komanduri, R. and M. C. Shaw, "Scanning Electron Microscope Study of Surface Characteristics of Abrasive Materials," Trans ASME, J. of Engg. Mat. and Tech. 96 (1974) 145.

Komanduri, R. and M. C. Shaw, "Surface Morphology of Synthetic Diamonds and Cubic Boron Nitride," Int. J. of Mach. Tool Des. Res., 14 (1974) 63.

Komanduri, R., "Some Aspects of Machining with Negative Rake Tools Simulating Grinding," Int. J. of Mach. Tool Des. Res., 11 (1971) 223.

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