ACADEMIC PROFILE OF Dr. SACHIN WAIGAONKAR

1. PERSONAL

2. EDUCATIONAL

Degree

University/ Institution

Year Subjects/ Area of

Specialization

%of Marks/ Division/Grade

Remarks

B.E.(MECH) Dr. BAMU A’bad

1998 Mechanical 72 Distinction

M.E.(Prod) Pune University, COEP

2000 Production Engg. 69 First Div

Ph.D BITS Pilani 2010 Polymer and Composite Materials

NA NA

3. PRESENT EMPLOYMENT DETAILS

Designation Organization From To Roles and responsibilities Assistant Professor

BITS Pilani Goa campus

1/6/2011

Till Date

Teaching UG and WILP courses in Mechanical engineering, Research in Polymer and Composite Materials

Name WAIGAONKAR SACHIN DAMODHARRAO

Address for Correspondence Department Of Mechanical Engg.

BITS Pilani K K Birla Goa Campus

Zuarinagar Goa,India-403726

Email sdw@goa.bits-pilani.ac.in

Phone 91-832-2580118

Mobile 91-9422388190

4. TEACHING EXPERIENCE

Duration Organization Area(s) 16/7/2004 to Till Date (9 years) BITS Pilani Goa

Campus Manufacturing Engineering

1/7/2000 to 15/7/2004 (4 years 15 days)

LTCOE, Mumbai Mechanical Engineering

5. COURSES TAUGHT First Degree (UG Level):

• Production Techniques-I (Revised Curriculum)

• Production Techniques ( Old Curriculum)

• Quality Control, Assurance and Reliability

• Workshop Practice

• Thermodynamics

Higher Degree (PG Level):

• Material Technology and Testing

• Product Design

Work Integrated Learning Programme (WILP):

• Flexible Manufacturing System ( On line Lecture Series)

6. CURRENT AREAS OF RESEARCH: Rotational Moulding of Thermoplastics

with nanoscale composites, Structure-property-Processibility studies of Polymeric and

Composite Materials, Manufacturing Engineering, Design and Analysis of Experiments.

7. RESEARCH PROJECTS

7.1. Experimental Investigations of Rotational Moulding Process Using Nano-Scale

Fumed Silica Composites.

Funding Agency: Department of Science and Technology (DST), Govt. of India.

Period: 2012-2015.

Grant Sanctioned: INR 17 Lakhs

7.2. Rotational Moulding of LLDPE using Nano scale Fumed Silica Composites.

Funding Agency: MHRD / UGC (Start up Grant).

Period: 2012-2015.

Grant Sanctioned: INR 6 Lakhs.

7.3. FIST Project under the thrust area of Polymer and Composite Material

Processing.

Funding Agency: DST/BITS Pilani Goa Campus.

Period: 2012-2017.

Grant Sanctioned: INR 18 Lakhs

7.4. Research Initiation Grant on Rotational Moulding of Plastics

Funding Agency: BITS Pilani Goa Campus.

Period: 2012-2014.

Grant Sanctioned: INR 2 Lakhs.

8. CONSULTANCY PROJECTS 8.1. Analysis of FRP Sectional Panel Tanks

Organization: BTCL Composites Goa

Period: 2 months (2013)

Amount: INR 50,000

Principle Investigator: Prof. BJC Babu

8.2. Thermo-structural Analysis of Sea Harrier Platform Organization: Indian Navy

Period: 6 months (2010)

Amount: INR 50,000

Principle Investigator: Prof. BJC Babu

9. PUBLISHED PAPERS IN JOURNALS 1. PL. Ramkumar, D.M. Kulkarni and Sachin D. Waigonkar (2013). Effect of Cycle Time

on Mechanical Properties of LLDPE during rotational moulding process. Journal of

Polymer Research (Accepted).

2. Raghav Bansal and Sachin Waigaokar (2012): Thermal Analysis of Rotational

Moulding Process: An Application to Multilayer Moulding, Journal of Manufacturing

Engineering, Vol.7 (3), pp 158-163.

3. Babu B.J.C., Waigaonkar S.D. and Rajput A. (2011): Experimental investigations and

optimization of processibility of sheet molding compound, Journal of Polymer

Engineering, Vol. 31 (2-3), 309-317.

4. Waigaonkar S.D., Babu B.J.C. and Rajput A. (2011): Six sigma DOE approach: a

case study of rotational moulding process, International journal of Six Sigma and

Competitive Advantage, Vol.6 (4), 256-277.

5. Waigaonkar S.D., Babu B.J.C. and Rajput A. (2011): Curing studies of unsaturated

polyester resin used in FRP products, Indian Journal of Engineering and Material

Sciences, Vol.18, pp.31-39.

6. Waigaonkar S.D., Babu B.J.C. and Rajput A. (2011): Parametric optimization to

enhance impact strength of rotationally molded products: A six sigma approach,

Journal of Manufacturing Technology Research, vol.3 (1-2).

7. Waigaonkar S.D., Babu B.J.C. and Durai Prabhakaran R.T. (2008): A new approach

of resin selection in rotational molding, Journal of Reinforced Plastics and

Composites, Vol. 27, pp. 1021 – 1037.

8. Waigaonkar S.D. and Babu B.J.C. (2008): Application of concurrent engineering for rotationally molded fuel tanks, Rotoworld (formerly Rotation), Vol.4 (4), pp.72-77.

10. PUBLISHED PAPERS IN NATIONAL AND INTERNATIONAL CONFERENCES

10.1 International Conference Held Abroad:

1. Waigaonkar S.D., Babu B.J.C. and Rajput A. (2011): Experimental

Investigations and Optimisation of Curing of Unsaturated Polyester Resin.

Composites-2011 organized by American Composites manufacturers Association

(ACMA), Ft. Lauderdale, Florida, USA, pp.55-61.

10.2 International Conference Held in India:

1. Sachin Waigaonkar and BJC Babu (2012): Compression Moulding Technique

for FRP fasteners and Sectional Panel Tanks. International Conference on Wind

Energy: Materials, Engineering and Policies, organized by Technical University

of Denmark (DTU) and BITS Pilani Hyderabad Campus pp.23-30.

2. Waigaonkar S.D., Babu B.J.C. and Rajput A. (2010): Investigating impact

strength of roto-molded products: a comparison of DOE with Shainin Variable Search Technique. Proceedings of 2nd International Conference on Polymer Processing and Characterization, Institute of Macromolecular Science and

Engineering Kerala, pp. 156-162.

3. Babu B.J.C., Waigaonkar S.D. and Rajput A.(2010): Experimental investigations

and optimization of processibility of glass fiber-polyester resin molding

compound, Proceedings of 2nd International Conference on Polymer Processing

and Characterization, Institute of Macromolecular Science and Engineering

Kerala, pp.60-66.

4. Waigaonkar S.D. and Babu B.J.C. (2008): DFX analysis of rotationally molded

fuel tanks, Proceedings of 2nd International and 23rd AIMTDR Conference, IIT

Madras, Chennai, pp. 1003-1008.

5. Waigaonkar S.D. and Babu B.J.C. (2007): Modeling of rotational molding

process using Shining Variable Search Technique, Proceedings of International

conference on Advancements in Mechanical Engineering (ICAME-2007), MIT

Manipal.

6. Waigaonkar S.D., Navale L.G. and Kajale S.R. (2000): Optimisation of Magnetic

abrasive Finishing Process, Proceedings of 19th AIMTDR Conference, IIT

Madras, Chennai, pp. 110-116.

10.3 National Conference

1. Raghav Bansal and Sachin Waigaokar (2012): Thermal Analysis of Rotational

Moulding Process: An Application to Multilayer Moulding, 3rd National Conference

on Recent Advances in Manufacturing, NIT Surat.

Note: The above conference paper has been accepted by Journal of

Manufacturing Engineering

11. IMPORTANT CONFERENCES/ WORKSHOPS ATTENDED

1. Future Composites Technology for Wind Mill Blades, IIT Delhi October 8-9, 2012.

2. Short term course on ‘Micromanufacturing’ at IIT Kanpur 2010

3. 4th Annual ARM SARD conference at Goa (Association of Rotational Moulders –South Asia Regional Development) 2007

4. 3rd Annual ARM SARD conference at Mumbai2006

5. Workshop on Industrial Automation at ISBT Goa, 2006

6. 7th National Convention of ISTE, Science Technology and Spirituality, 2003

12. AWARDS AND RECOGNITIONS

DST Travel Grant for Young Scientist to attend the conference in USA.

13. ADMINISTRATIVE EXPERIENCE

Designation Organization From To Roles and responsibilities

Nucleus

Member

Central

Workshop

BITS Pilani K K

Birla Goa Campus

2008 2013

Workshop equipments purchases,

maintenance, human resources

planning, Lab scheduling, etc.

Annexure-1

Major Projects Worked Upon (Related to Polymer and Composites Processing)

1. Study of Sheet Moulding Compounds for producing FRP fasteners.

In this project, we have produced fasteners (bolts and nut) made out of sheet

moulding compounds (SMC). Such fasteners can be extremely useful in corrosive

environments where conventional steel fasteners limit their applicability. Though

commercially pultruded fasteners are available, compression moulding was not

used to produce such components till date. It results in very short cycle times and a

near net shaped product. The subtasks to produce these fasteners included: • Preparation of SMC: SMC was prepared using Unsaturated Polyester (UP) resin

and Glass Fiber reinforcements along with other fillers and additives. Devices like

sigma mixer and rolling mill were used to ensure better impregnation of glass fibers

with the resin.

• Study of maturation quality of SMC: Extensive experimentation using Statistical

DOE techniques were employed to get optimal maturation quality (tack-free

condition) of SMC prepeg. Built simple testing devices in laboratory to assess the

maturation quality.

• Study of Curing of the resin: Curing of UP resin was also monitored and modeled

using DOE methods. Regression equations were established which were

subsequently used to optimise the process performance in terms of gel time and

peak exothermic temperature. This ensured optimal cycle time and product quality

(by preventing cracking of polymer).

After testing in corrosive environments, we have found that these fasteners gave

excellent results. They are being tested in field at surrounding chemical industries in Goa

region at present. This project was sponsored by Department of Science and technology

(DST), Govt. of India (SR/S3/ME/37/2005 dated 19/04/2007). The Components produced

and their X ray (showing Glass Fiber Orientation is shown in Fig. 1 and Fig. 2

Fig. 1 M14x2 FRP bolts produced Fig. 2 X ray of bolts to study fiber orientation

2. Rotational Moulding of LLDPE

Rotational moulding is a potential process used to produce hollow plastics products at

a low cost. It offers several advantages I terms of mechanical properties. We have

investigated this process and the major contribution towards this research is as

follows:

• The investigations for thermoplastics polymer processing have been carried out

for a typical rotational moulding process. For this purpose LLDPE was used as

material and the impact strength was selected as one of the quality measures of

the product. Six-sigma technique has been applied through the ‘Define, Measure,

Analyze, Improve and Control i.e. ‘DMAIC’ algorithm of six sigma. The oven

temperature, oven time, powder particle size and cooling media were selected as

model parameters. Applications of Design of Experiment (DOE) method for this

process revealed the non-linear effects of process variables on the impact

strength.

• The automobile industry is looking forward to rotational moulding on account of its

ability to produce complex hollow parts at a low cost. As an emerging application

of this process, a fuel tank was selected for a case study. Considering the

importance of appropriate resin selection for such products, a ‘Multiple Attribute

based Decision Making’ (MADM) selection procedure based on ‘Technique of

Order Preference by Similarity to Ideal Solution’ (TOPSIS) was explored to assist

the rotomoulder to select suitable resin from a long list. The selection was also

compared with other graphical methods of decision making.

• Concurrent engineering studies were carried out to compare and select the

appropriate materials for design of a rotationally moulded fuel tank. This method is

based simultaneous consideration of the several aspects of design commonly

identified as ‘DFX’. Along with the polymeric materials, the existing metal forming

process of making fuel tanks from cold drawn steel sheets was accounted for a

comprehensive analysis. The principles of graph theory were used to obtain each

‘DFX’ aspect, using a ‘Permanent function’ approach. The comparison of the

materials was done based on values of permanent functions.

• As a part of this study, Finite Element Analysis has been done to find the transient

temperature distribution in a Typical Rotational Moulding Process. A 1000 L

overhead water tank was taken for analysis. This tank is made up from LLDPE

material. The mould is modeled using PrO_E software which was subsequently

analysed in special software Rotosim. The temperature distribution within the

mould was predicted along with the thickness distribution of the polymer. Finally

conditions were predicted to obtain the optimal thickness. The simulation studies

have shown close agreement with the industrial findings at M/s GMI Zarahk

Moulderes Pvt. Ltd. Verna, Goa. Following figures shows the details of the

simulation studies performed.

Fig. 3 Simulation Environment for Process

Fig. 4 Transient Temperature Distribution in the Process

Fig. 5 Thickness Distribution of Polymer (LLDPE) in Tank

3. Analysis of FRP Sectional Panel Tanks

This project was carried out for BTCL Composites, Goa who manufacture FRP

sectional Panel tanks. These panels are made from GF/PE resin composites by

compression moulding process. The design thickness and stiffness features have been

simulated using Finite element Analysis using ANSYS 13.0. Singapore Standards SS 245:

1992 were used for this purpose. Different loading conditions like hydrostatic, wind and

seismic were considering during this design analysis. With this analysis, it is possible to

decide the thickness of panel and hence design the mould for compression moulding

process. It also assists to prevent the excessive deflection and failure of the panel tanks

under loading conditions. Fig. 6represents the meshed model of FRP panel while

deflection predicted under hydrostatic loading conditions for such panel is shown in

Fig. 7.

Fig. 6 Design of FRP sectional Panel tanks Fig. 7 Analysis of FRP sectional Panel tanks

Annexure-2

Experimental Facilities Created at BITS Pilani K K Birla Goa Campus

Following is the list of a few polymer processing and testing equipments to facilitate the

research work in this area:

1. Dynamic Mechanical Analyser (DMA) with Gas Cooling Accessory (GCA):

Make TA instruments, USA. As polymers are visco-elastic in nature, DMA is used

to investigate their dynamic mechanical properties. It is used to determine the

mechanical properties as a function of temperature, time and frequency. Herein the

samples are subjected to sinusoidal force which results in similar deformation. By

evaluating the course of deformation over time, the viscoelastic behavior materials

like storage modulus, loss modulus and loss factor (tan δ) can be calculated.

2. Melt Flow Indexer: Make Dynisco, USA. The Melt flow of the polymer blends is

determined as per ASTM-1238 using the MFI tester manufactured by

3. Lab scale single screw extruder with Torque Rheometer: To melt blend

polymers with proposed additives, masterbatches and investigate their torque

rheometric properties.

4. Lab Scale Rotational Moulding Machine: An electrically heated biaxial lab scale

rotational moulding machine to take trials of rotational mouldings.

5. Lab Scale Compression Moulding Press: A compression moulding press of 32 T

will be used to get the sheets of polymer and FRP composites.

6. Tensile Testing machine (0-10 KN): The tensile testing of the plastics and

composite samples cut using standard set of dies. Same machine can be used to

conduct the Flexural testing.

7. Impact Testing: Izod and Charpy impact testing of the specimens is done using

this machine.

8. HDT VICAT softening point: This is used to obtain the heat deflection

temperature and VICAT softening of the polymers.

Annexure-3

Significant Contributions and Achievements

1. Involved in laboratory developments like Central Workshop, Pneumatics,

Hydraulic Machines, etc. at BITS Pilani, K.K. Birla-Goa Campus.

2. As a part of ‘Production Techniques’ course at UG level, developed experimental set-

ups and plans for conducting practicals in CNC machining, non conventional

machining, pneumatics, alignment testing of machine tools, casting and plastic

processing. A laboratory manual was also prepared for the above.

3. Conducted a short term course on CNC programming at BITS Pilani, K.K. Birla-Goa

Campus.

4. Developed an experimental set-up for the DST project on Sheet Moulding

Compounds (SMC). It included the integration of hydraulic press (32 Ton capacity)

with the electro pneumatic actuators. The work included design and fabrication of dies

and a specially constructed softness indicator (produced in house) to monitor the

maturation quality of SMC. The other facility also included a sigma mixer (25 L) and a

two roll mill for proper impregnation of SMC.

5. Developed experimental set-up to study rotational moulding of plastics. It included a

lab scale electrically heated oven with different moulds and a dart impact testing

apparatus (produced in house).

6. Selected for the award of International Travel Support Scheme (IST) of DST (Young

Scientist) for presenting the paper in international conference viz. ‘Composites -2011’

organized by American Composites manufacturers Association (ACMA) at Ft.

Lauderdale Florida, USA during February2-4,2011.

7. Delivered a talk on ‘Design and Analysis of Experiments’ in workshop on

Research Methodologies at BITS Pilani, K.K Birla, Goa Campus.

8. Worked as Reviewer for Computational Material Science and International Journal of

Materials Engineering Innovation.

9. Working as member of Doctoral Advisory Committee (DAC) at Bits Pilani -K.K. Birla

Goa Campus and reviewed two Ph.D. theses as DAC member.

10. Involved in organisation of Indo-Russian Workshop on Tropical Problems in Solid

Mechanics at BITS Pilani, K.K Birla, Goa Campus.

11. Co-ordinated the Practice School activities of institute at Mishra Dhatu Nigam Ltd.

(MIDHANI), Hyderabad and Care Hospitals, Hyderabad.

12. Visited Grasim Industries and Grasim Chemicals Nagda, Madhya Pradesh to identify

the practice school projects for BITS Students and to make the practice school

program more effective. .

13. Worked as proctor for the on line admission test of BITS (BITSAT-2010).

14. Presently working as nucleus member of Central Workshop. Here the main activities

include recruiting and allotting technical staff in workshop as well as other labs,

scheduling maintenance activities for different machines, scheduling workshop for

different fabrication related activities, etc.

15. Worked as nucleus member of ‘Student Activity Center (SAC)’. Here the role included

the coordination of sports activities and monitoring the sport facilities of the institute.

16. Worked as panel member of syllabus revision committee (Manufacturing Engineering,

in particular) at YCCE, Nagpur.

17. Worked as a member of Educational Audit Team for the Educational Audit conducted

at Navy Children School, Vasco Goa.

(Dr. Sachin Waigaonkar)