Research Groups

Machining Research Group (MRG)
The Machining Research Group (MRG) at NCAIR is pursuing state-of-art research in machining processes for aerospace applications. The focus is on optimisation of machining processes for advanced metallic materials such as Titanium, Inconel, and Heat Resistant Super Alloys so that overall cycle times can be reduced while ensuring the required quality is attained. This involves physics-based modelling of the machining process incorporating aspects of:

  • material behaviour of the part being machined, and machining parameters
  • geometric and material characteristics of the cutting tool and tool wear
  • tool path analysis and optimisation
  • machine dynamics and tool vibrations
  • machined surface quality

The research further involves studying the interplay between these aspects, and how the process can be modeled accurately and subsequently optimised to achieve reduced cycle times and improved quality.

The Advanced Machining Excellence Cell (AMEC) at NCAIR is a state-of-art machining experimentation facility which houses a DMG Mori DMC 125FD duoblock 5-axis machine with Sandvik Coromant cutting tools. The machine has a mill-turn configuration which gives the capability to perform both milling as well as turning operations in the same setting. The machine is also instrumented with dynamometers for in-situ measurement of cutting forces and torques during machining operations. This facility is used extensively for model validation and machining process optimisation studies.

Advanced Composites Group (ACG)
The Advanced Composites Group (ACG) at NCAIR, comprising of two sub-groups experimental and computational modelling, studies the behaviour of aerospace grade fibre composites to analyse the materials and technology used in composite manufacturing. The experimental team is involved in the making of composite parts and prototypes at ACG's Composite Manufacturing Laboratory. Additionally, it also performs material characterisation at state-of-the-art microscopy laboratories at IIT Bombay. The computational team works on simulation of critical manufacturing challenges pertaining to the complex multi-physics phenomena that drive the resin infusion process, coupled with curing and fluid-structure interaction.

FATIGUE MODELING GROUP (FMG)
This group focuses on research in Fatigue and damage tolerance of advanced structural systems, and the development of necessary computational methods and tools to meet the structural integrity compliance of aircraft components.

Mechanical Design Group (MDG)
This group is responsible for design, development and improvements of existing and new mechanical systems. Design constraints can be weight, Materials, Fatigue, Fracture and shocks given in standards like MIL etc. Materials we deal with are CFRP, GFRP, Titanium, Invar, Inconel and aluminium foams. Group uses software packages for modelling and analysis and comparesthe results obtained with experiments carried out inside the IITB facilities.

GEOMETRICAL STUDY & SOFTWARE INCORPORATION GROUP (GS&SIG)
SA&DG works collaboratively with all other groups and Involved in development of advanced software applications related to aerospace manufacturing to help partners in the aerospace and other high-value industries.

CYBER SYSTEMS ENGINEERING AND ANALYTICS GROUP (CSE&A)
The Cyber Systems Engineering and Analytics Group is the youngest group at NCAIR. It is an interdisciplinary group which is currently focused on analysis of various kinds of data, estimating mission reliability for equipments by mapping the effect of every intrinsic and extrinsic factor/event affecting the equipment's reliability during its lifetime.

The group also researches in the area of Smart Manufacturing. With recent advancements in the domains of sensing technologies, computational capabilities and artificial intelligence, leading to a realization of an entirely new industrial revolution - Industry 4.0 or Smart Manufacturing, connected assets within an Industrial Internet will mean access to more and relevant data, enabling more-informed decision-making, increased facility utilization, reduced production time and increased customization. However, given the heterogeneous composition of industrial assets in terms of its automation levels and machine-tool manufacturers of a typical industry shop-floor, independent solutions need to devised to observe manufacturing intelligence. The group is working on these lines to develop a system to monitor machine states without accessing the machine's controller. Data extracted from the system would be analyzed to derive performance metrics of the machines across the shop-floor.