In this research, the effects of high speed milling on the main surface integrity characteristics, including surface roughness and topography, microhardness, white layer thickness, and surface chemical composition of Ti-6Al-4V were empirically studied. Totally, 18 experiments were carried out using a full factorial design of experiments method in the presence of minimum quantity lubricant. The results

In order to accurately decompose the surface morphology of machined surface and trace the potential errors of the machine, a comprehensive improved algorithm is proposed, which combines wavelet packet decomposition (WPD) and improved complete ensemble empirical modal decomposition of adaptive noise (Improve CEEMDAN). Firstly, the cost function is used to find the optimal wavelet packet base and the

Electrochemical discharge machining (ECDM) process is prominent machining process for processing of composites, glass, ceramics, and super-alloys. In the recent years, the ECDM process has attained popularity due to its applicability to generate micro-holes, micro-channels on different materials irrespective to their properties. This study presents the various environmental aspects of ECDM process

Chatter frequently occurs during cutting operations, which seriously restricts the machining productivity and workpiece accuracy. Consequently, accurate and efficient stability prediction is of great significance to determine stable machining parameters. A cubic Hermite–Newton approximation method which can determine the chatter stability boundaries more efficiently is presented in this paper. The

In the current study, a predictive model on tool flank wear rate during ultrasonic vibration-assisted milling is proposed. One benefit of ultrasonic vibration is the frequent separation between tool and workpiece as the cutting time is reduced. In order to account for this effect, three types of tool–workpiece separation criteria are checked based on the tool center instantaneous position and velocity

The performance of electrical discharge machining (EDM) primarily depends on the spark quality generated in the inter-electrode gap (IEG) between the tool and workpiece. A method for obtaining accurate information about the spark gap is required to effectively monitor the EDM process. The rise and fall of thermal energy in the discharge zone at a rapid rate during the dielectric breakdown produces

This article reveals the formation mechanism of surface topography and the formation and coupling mechanism of residual stress field (RSF) after abrasive water jet sequential peening (AWJSP) that can sequential peening on the material surface at a certain distance interval, and proposes a mathematical model of surface dimple characteristic verified by simulation results. In addition, the influences

This study proposes a combined method for the electrochemical mill-grinding of Ti–6Al–4V alloy to achieve a high material removal rate, high machining accuracy and good surface quality based on rough and finish machining. In the rough machining stage, a maximum feed rate of 2.7 mm min−1 and a material removal rate of 248.3 mm3 min−1 were achieved experimentally at a 10 mm cut depth using an abrasive

Micro-milling is a fast, cheap and controlled process compared to other micro-fabrication processes such as lithography, laser/electron/ion beam machining, etc. However, scarcity of cutting tools of very small dimensions often results in limited application of micro-milling. In the present study, electro discharge machining (EDM) is used for fabrication of micro-end mill tool. To ensure high dimensional

In the present work, rotary mode electrochemical discharge drilling (RM-ECDD) was employed to machine the Al-6063 SiCp metal matrix composites (MMC’s). The effect of various process parameters such as applied voltage, pulse on time, tool rotation rate, electrolyte concentration and current on quality characteristics (hole over cut and depth of penetration) of the drilled holes was investigated. The

The C/SiC ceramic matrix composites are widely used for high-value components in the nuclear, aerospace and aircraft industries. The cutting mechanism of machining C/SiC ceramic matrix composites is one of the most challenging problems in composites application. Therefore, the effects of machining parameters on the machinability of milling 2.5D C/SiC ceramic matrix composites is are investigated in

Die-sinking electrical discharge machining (EDM) is widely used in die and mold-making industry. Finish EDM conditions are often selected to produce good quality surfaces. Attempts to enhance the finishing capabilities using ultrasonic vibration and powder-added dielectric medium have been reported in the literature. However, the changes in the gap phenomena with ultrasonic assistance and powder addition

Unconventional wire electrical discharge machining technology is an indispensable part of the production of many industrial devices. Material separation takes place at very high local temperatures, and therefore, some undesirable surface and sub-surface defects are formed. Not only the occurrence of defects but also the quality of the machined surface is very important for the end customer, so it is

The current research comprises of various machinability aspects of 4340 hardened alloy steel which are scrutinized with in context of improvements in main cutting force, tool flank wear, crater wear, surface roughness, micro-hardness, machined surface morphology, chip morphology, chip reduction coefficient and apparent coefficient of friction under three different cutting fluid applications i.e. compressed

An aluminum-based printed circuit board (Al-PCB) is a composite material comprising a copper layer, an insulating layer, and an aluminum base layer. In the drilling of Al-PCBs, exit burrs are formed because of the plastic deformation of the remnant aluminum under high drilling temperatures. In this work, a new method using cryogenic media is suggested to prevent exit burrs in Al-PCB drilling. The effects

Powder mixed EDM (PMEDM) is recognized as an advanced and innovative technique with enhanced performance and limited drawbacks in comparison to conventional EDM method. This study investigates the effect of powder particle size, various powder concentrations (Cp), and surfactant concentrations (Cs) on the performance of EDM. Since the machining characteristics are highly dependent on the dielectric

The characteristics of shearing force and shearing surface, working hardening at the shearing edge, and structural evolution of microstructures during the transverse shearing of thin silicon steel sheet (SSS) were explored. On this basis, the influences of the thickness and grain size of the thin SSS and lateral clearance of the tool on shearing deformation processes were further analyzed. The results

In drilling in titanium alloys, heat trapped in a hole adversely affects tool life, hole surface quality and integrity. Therefore, modeling temperature distribution in drilling is vital for effective heat dissipation and improving quality of drilled surfaces. The existing numerical and finite element models consider only frictional heat, whereas the effect of shear heat generation and tertiary heat

The numerical analysis, based on the finite element modeling (FEM), presents nowadays an efficient computational tool. It allows a better understanding of several thermo-mechanical phenomena involved during the machining process. However, its reliability heavily depends on the accurate definition of the numerical model. In this regard, a FE analysis focused on the 2D modeling of the Ti6Al4V dry orthogonal

Wire electrical discharge machining (WEDM) is always significant for its high-precision machining. However, due to the generation of high discharge energy during machining, machined surfaces are often got distorted. These might be upgraded by choosing the correct tool with proper machining condition. The effects of the electrode materials and process parameters on different responses of WEDM like average

Electrochemical trepanning process is an advanced manufacturing technology suitable for the machining of aero-engine components such as blades and diffusers. Tool-electrode (cathode) with special electrical isolation is adopted in the experimental investigations of this article using the electrochemical trepanning to produce a flow mode in which the electrolyte is supplied evenly to the blade being

Material measures are used to calibrate topography measuring instruments. Micro-milling is a suitable process for the manufacturing of areal material measures in particular of material measures featuring freeform surfaces. To improve their surface quality and to minimize their deviations from the target geometry, the cutting parameters feed per tooth respectively feed rate and spindle speed are examined

Polycarbonates have found important applications in various types of industries including optical, automotive, aerospace, biomedical, and defense manufacturing industries. Conventional mechanical machining has the capability to create complex multi-scale parts and components for various materials including polymeric materials. This study investigates the cutting forces generated during the machining

In this study, a FEM-based tool wear approach with a focus on the geometry of the worn tool, especially the changes of flank wear land inclination angle, was developed. The relationship between the variables of the wear rate equation and the average nodal temperature on the flank wear land through integrating FE-simulations of the cutting process and Response Surface Methodology (RSM) was determined

Cryogenic assisted machining is experiencing growing popularity and acceptance as a toxic-free, eco-friendly, hazardless process producing improved structural components. This article deals with the analysis of 3D and 2D roughness profiles, surface morphology, residual stress and microhardness of 55NiCrMoV7 die steel after end milling operation under dry, wet, cryogenic CO2 and LN2 cooling environments