Vishal Agrawal

- Developed computational simulation models of pulsed-Electrochemical Machining (PECM) Process in COMSOL to study the current density patterns as well as predict and validate the experimental outcomes. - Developed a reverse engineering methodology using UV 3D Scanner to extract the workpiece coordinates and generate 5-Axis CNC Machining code to finish curved workpiece surfaces using Magnetic Abrasive Finishing.

"Investigation of Abrasive Electrochemical Machining (A-ECM) Process on Titanium Alloys". - Performed experimentation and parametric analysis for process optimization to machine high-precision micro holes in Titanium Alloys. - Developed an analytical model of the A-ECM Process to predict the final diameter of the machined micro-holes.

- Developed a new electrolyte supply technique & reduced toxic-electrolyte consumption in Electrochemical Machining (ECM) Process by 90%. - A flexible ECM tool was designed and fabricated to make micro-textures on free-formed metallic surfaces. - Performed RSM analysis and process optimization of ECM for high-precision machining. - Developed computational models of ECM process in COMSOL to predict and validate the experimental results and study the current density patterns in the machining zone.

- Optimized welding parameters (voltage, gas composition, travel speed etc.) of the GAS Metal Arc Welding (GMAW) Process to uniformly clad Copper on Mild Steel. - Performed microstructural analysis to study the quality of cladded samples.

Worked as an Intern in the Advanced Systems Laboratory of the Defense Research and Development Laboratory. Here, I learned about the manufacturing and testing processes involved in the production of carbon fabric composites for aerospace applications.