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Research on surface roughness detection and prediction of ti-6Al-4v titanium alloy based on multi-feature fusion Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-03-14 Minghui Shao, Songyuan Li, You Li, Shuncai Li
Considering that titanium alloy is a critical aviation resource, ensuring its machining quality is of significant importance. Surface roughness remains a key parameter for surface quality inspectio...
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Advances in micro electro discharge machining of biomaterials: a review on processes, industrial applications, and current challenges Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-03-01 Akash Korgal, Arun Kumar Shettigar, Navin Karanth P, D. A. P. Prabhakar
Micro Electro-Discharge Machining is a precision machining process that uses electrical discharge to produce small-scale components with high accuracy. A metal workpiece is machined in this process...
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Into the boundary layer behavior of segmented grinding wheels and its illustration on Ti6Al4V Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-02-20 Sarath Babu Thekkoot Surendran, Sooraj V.S
Segmented grinding wheels, with active abrasive regions and passive slots, have been reported as a promising choice for controlling the grinding force via an intermittent cutting scheme. With an ap...
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Wear mechanisms and cutting performance of coated carbides in milling LPBF IN718 alloy under hybrid cryogenic conditions Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-02-10 Sarvesh Kumar Mishra, Gaizka Gómez Escudero, Haizea González-Barrio, Amaia Calleja-Ochoa, Octavio Pereira Neto, Luis Norberto López de Lacalle Marcaide
The present study investigates the milling of Inconel 718 (IN718) alloy fabricated using laser powder bed fusion (LPBF). Finish milling has been performed using Al-rich ternary-coated end mills und...
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Feasibility study on finishing the inner surface of SLA small holes by volume alternating cavitation shock wave Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-01-17 Chao Yu, Bo Zhang, Fuzhu Li, Peiyu He, Yun Wang, Kunlun Shen, Shangshuang Chen
Aiming at the technical problem of finishing the inner surface of additive manufacturing small holes, a novel volume alternating cavitation shock wave finishing (VACSWF) method was innovatively pro...
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Machine learning coupled with acoustic emission signal features for tool wear estimation during ultrasonic machining of Inconel 718 Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-01-10 Mehdi Mehtab Mirad, Bipul Das
The material removal in the ultrasonic machining process is due to the fracture of the workpiece material. The fracture is due to energy transfer by vibrating abrasive particles. The vibration ener...
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Investigating the supremacy of PVD S3p deposition over HiPIMS for AlTiN coating Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-01-08 Gaurav D. Sonawane
Dry machining of Duplex Stainless Steel 2205 (DSS2205) is a challenging task due to difficulties including high cutting temperatures, work hardening tendency and Built-up Layer (BUL) formation. Mor...
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Study on milling behavior of TiAlN coated tool with variable distribution density micro-texture Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-01-03 Shucai Yang, Lukai Liu, Chunsheng He
Considering that after milling titanium alloy with a ball-end milling cutter, the wear degree of different areas of the rake face is different, which indicates that the tool-chip contact conditions...
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Grinding optimization using nondestructive testing (NDT) and empirical models Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-01-03 Arttu Heininen, Suvi Santa-aho, Jannik Röttger, Pasi Julkunen, Kari T. Koskinen
Proper choice of grinding parameters is important because productivity is limited by the possibility of grinding burns. Nondestructive testing (NDT), as Barkhausen noise (BN), can provide a tool fo...
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Machining performance and sustainability analysis of Al2O3-CuO hybrid nanofluid MQL application for milling of Ti-6Al-4V Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-01-03 Bahram Lotfi, Ramazan Hakkı Namlu, S. Engin Kılıç
Machining of Ti-6Al-4V presents challenges due to its low thermal conductivity, and conventional cutting fluids (CCF) are inadequate in providing a productive and sustainable solution. This study a...
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Experimental comparison of the indexable drilling with different U drills on hole quality Mach. Sci. Tech. (IF 2.7) Pub Date : 2024-01-03 Aslan Akdulum, Yunus Kayir
U drills are estimated to account for around 53% of all drilling equipment’s market share. This study compared and contrasted the impacts of the balance angle, the U drill length/diameter ratio, an...
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Investigation of performance characteristics amid nano powder mixed electrical discharge micro-milling on Hastelloy C 276 Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-11-16 Souradeep Dutta, Deba Kumar Sarma, Hrishikesh Dutta
Powder mixed electrical discharge micro-milling (EDMM) has been introduced as a novel variant of EDM operation, which can generate complex 3D micro features by CNC programming through the rotating ...
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Research on topological grinding of bionic structured scale surface for reducing contact friction and fluid drag resistance Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-11-16 Yushan Lyu, Guoxun Wang, Xingshan Li, Liuwan Xu
The structured scale surface is an important functional surface that reduces the drag resistance of fluids and contact friction resistance. In order to grind the bionic scale structure on the workp...
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Ultrasonic Vibration Assisted Electrical Discharge Machining and Micro-Electrical Discharge Machining: A Review Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-11-16 Ibrahem Maher, Hassan El-Hofy, Mohamed H. El-Hofy
Material is removed during electrical discharge machining (EDM) because of the high temperatures. Hence, tiny components of the tool and workpiece melt and evaporate, causing molten metal to solidi...
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Development of a predictive analytical cutting force and torque model for flat bottom drilling of metals using mechanistic approach Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-11-16 Nima Zoghipour, Yusuf Kaynak
By far a large scale of industrial components is being manufactured from metallic materials. Most of these components possess holes in order to fulfill design and application requirements, such as ...
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In process temperature and tool wear for the machining of aeronautic aluminum under different lubrication conditions Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-09-14 Bruno Lavisse, Xavier Tardif, Dmitry Bondarenko, Mathieu Ritou, Guénaël Germain
The use of aluminum-lithium alloys in aeronautics is an efficient solution for lightweight structures, but its machinability can cause increased tool wear. The cutting temperature is one of the mos...
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Dosage Based Directional Minimum Quantity Fluid Application in Machining Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-09-11 Chandra Sekhar Rakurty, Himabindu Nunna, Alagar K. Balaji
There is an ever-increasing focus on surface integrity and machined surface quality of the machined surface and sub-surface to improve product quality, thereby improving its service life and sustai...
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A review on the production of grinding tools through additive manufacturing processes: From current possibilities to future perspectives Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-09-09 Diego Jorge Alves Borges, Adriel Magalhães Souza, Eraldo Jannone da Silva
Additive manufacturing (AM) processes have emerged as alternatives for the production of grinding tools. This article addresses a comprehensive overview on the historical-scientific evolution of th...
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The Effect of High-Pressure Jet Cooling on Surface Roughness, Cutting Force and Chip Formation of Ti-6Al-4V ELI in High-Speed Turning Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-08-28 Fatih Taylan, Tolgahan Ermergen
In the machining of difficult-to-machine metals, such as titanium-based alloys, the delivery of coolant with high pressure can increase machining efficiency and improve process stability through mo...
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3D modeling of turning of Ti-6Al-4V titanium alloy using a constitutive model considering the state of stress Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-08-03 Wenyu Cheng, Jose Outeiro, Jean-Philippe Costes, Habib Karouni, Theo Dorlin, Rachid M’Saoubi
Abstract For decades many models of orthogonal cutting have been developed with limited practical application. In the scope of Industry 4.0, a need is felt to develop models of practical machining operations, like turning, milling, and drilling. This research work contributes for the development of reliable 3D models of practical machining operations by proposing a model of turning using a constitutive
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An experimental and FEM study on ultrasonic-assisted turning of titanium alloy Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-07-22 E. Bachir, R. Bejjani
Abstract The increase in demand for aerospace parts leads to a need for effective and efficient machining methods to enhance the machinability of titanium alloys. This research investigates the effect of ultrasonic-assisted turning (UAT) on aerospace titanium alloy Ti-6Al-4V by varying cutting parameters. Ultrasonic turning experiments were conducted to investigate the reduction in cutting forces and
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Multi-objective optimization based on machine learning and non-dominated sorting genetic algorithm for surface roughness and tool wear in Ti6Al4V turning Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-07-21 Van-Hai Nguyen, Tien-Thinh Le, Minh Vuong Le, Hoang Dao Minh, Anh-Tu Nguyen
Abstract Titanium alloys are notoriously difficult to machine. They are used in the manufacture of various types of lightweight components. It is therefore important to improve their machinability and thus achieve sustainability in machining such alloys, by selecting appropriate influential factors: cutting parameters, tool material, geometric form, coolant types, and hybrid machining methods, to deliver
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Combined use of ultrasonic-assisted drilling and minimum quantity lubrication for drilling of NiTi shape memory alloy Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-06-24 Ramazan Hakkı Namlu, Bahram Lotfi, S. Engin Kılıç, Okan Deniz Yılmaz, Samet Akar
Abstract The drilling of shape-memory alloys based on nickel-titanium (Nitinol) is challenging due to their unique properties, such as high strength, high hardness and strong work hardening, which results in excessive tool wear and damage to the material. In this study, an attempt has been made to characterize the drillability of Nitinol by investigating the process/cooling interaction. Four different
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The grindability performance and measurement of surface functional parameter capabilities of difficult-to-machine tool steel under tangential ultrasonic-vibration-assisted dry grinding Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-06-24 Abhimanyu Chaudhari, Ashwani Sharma, Mohd Zaheer Khan Yusufzai, Meghanshu Vashista
Abstract The grinding performance of the finished component is significantly affected by the consistency and durability of the grinding mode used in its formation. The current research attempted to evaluate the influence of worktable feed rate and ultrasonic vibration amplitude on grinding outcomes responses such as ground forces, ground surface morphology, surface roughness and topography, surface
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Correlation between surface integrity characteristics in high-speed grinding of Ti-6Al-4V Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-06-24 Anirban Naskar, S. Paul
Abstract The present article establishes a fundamental correlation between surface integrity characteristics of the finished surface with the normal to tangential force ratio (Fn/Ft) in the grinding of Ti-6Al-4V. The subsurface deformation, crystallographic texture, surface redeposition, and residual stress were studied in the surface integrity characteristics. The XRD result indicated deformation-induced
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Investigation on grinding-induced cracking mechanism of 40Cr steel camshaft Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-06-24 Jianzhi Chen, Yan Wang, Guochao Li, Zhen Xu, Han Gao, Xucheng Deng, Shuhao Zhang, Honggen Zhou
Abstract The generation of grinding cracks during the grinding process will adversely affect the service performance of the workpiece and even cause the workpiece to be scrapped. However, the microscopic formation mechanism of grinding cracks is still unclear at present. In this regard, the morphologies of grinding cracks on the surface of the cam were characterized, and the initiation and propagation
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Finite element modeling and experimental validation of turning process using bio-mimicked structured tool for outcomes relevant to industry Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-06-04 Priya Ranjan, Somashekhar Shambulingayya Hiremath
Abstract Martensitic stainless steels are extensively used in aerospace, medical, and oil and gas industries because of their superior properties such as high hardness, strength, and corrosion resistance properties. However, the machining of this work material becomes difficult due to its high hardness and low thermal conductivity leading to high cutting force requirements and tool wear. Recently,
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Modeling and validation of residual stresses induced by heat treatment of AA 7075-T6 samples toward the prediction of part distortion Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-06-02 Mohamed Ali Louhichi, Gerard Poulachon, Philippe Lorong, José Outeiro, Eric Monteiro, Dominique Cotton
Abstract Residual stresses distributions induced by heat treatment of AA 7075-T6 alloy were modeled and simulated. Models of quenching followed by tempering were developed and simulated using the Finite Element Method (FEM). To determine the convection coefficients used in these models, an inverse method coupled with optimization algorithms was developed. The simulated residual stresses distributions
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A review on sustainable alternatives for conventional cutting fluid applications for improved machinability Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-24 D. J. Hiran Gabriel, M. Parthiban, I. Kantharaj, N. Beemkumar
Abstract Cutting fluid is used in the field of engineering for hundreds of years, and it plays a critical role in component processing efficiency and surface quality. Water-based cutting fluid accounts for more than 90% of cutting fluid used. Conventional cutting fluids and conventional methods of coolant application are not sustainable, economical, and environmentally friendly. Cutting fluid application
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Surface integrity in 3D ultrasonic vibration-assisted turning driven by two actuators Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-18 Shiyu Wei, Ping Zou, Jingwei Duan, Kornel Ehmann
Abstract The surface integrity of machined parts is critical to their in-service function, longevity and overall performance. The integrity of the surface is dominantly affected by the chip formation process that can be significantly altered and controlled, among other methods, by ultrasonic vibration assistance. This work will explore the integrity of surfaces generated in three-dimensional ultrasonic
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A review on performance evaluation of liquid nitrogen as coolant in turning Ti-6Al-4V alloy Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-13 M. Dhananchezian
Abstract During cutting operations, cutting fluids increase heat carrying capacity from the cutting area and reduce friction at the chip-tool interface. It also offers benefits like favorable chip form, enhancement in the finish of product and tool life, lower cutting forces and power consumption during any cutting operations. But the inadequate application of cutting fluids and disposal creates several
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Dislocation density evolution and hardening mechanism of AA7050-T7451 surface layer based on anisotropy Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-13 Zhenda Wang, Yongzhi Pan, Hui Wang, Zewen Zhang, Xiuli Fu, Xiuhua Men
Abstract Based on the modified KM (Kock–Mecking) model, a cutting constitutive model of AA7050-T7451 considering anisotropy is established in this article. With the aid of high-speed cutting FEM simulation and experiment, the micro-influence mechanism of anisotropy on high-speed cutting hardening of AA7050-T7451 was studied from three aspects: micro-morphology, residual strain, and plastic deformation
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Finite difference numerical modeling and experimental validation of workpiece surface temperature in micro-grinding Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-08 Ashwani Pratap, Anastasia E. Gorodkova, Karali Patra, Aleksandr A. Dyakonov
Abstract The objective of this work is to characterize the heat transfer and temperature generation into the workpiece during micro-slot grinding. A numerical model for predicting micro-grinding temperature is established based on the finite difference method (FDM). Workpiece volume is divided into small elementary sections and temperature in small sections near and away from the machining zone is
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Toward green electrical discharge machining (EDM): state of art and outlook Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-08 Israa Dheyaa Khalaf Alrubaye, Gualtiero Fantoni
Abstract The electrical discharge machining process is useful to manufacture complex shaped parts with high accuracy; however, it has unfriendly environmental impacts such as toxic emissions and health hazards; these impacts do not align with the recent orientation toward green industrial environments. Nowadays, researchers, practitioners, and designers focus on implementing sustainable EDM-based green
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Influence of ultrasonic vibration on machining quality of down/up grinding in ultrasonic vibration assisted grinding of silicon carbide Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-08 Haotian Li, Tao Chen, Hongbo Li, Yiwen Zhang
Abstract Conventional surface grinding can be divided into up grinding and down grinding according to rotation direction of spindle. Nevertheless, the effects and differences of ultrasonic vibration on the two machining methods have been less reported. The influence of ultrasonic vibration amplitude on cutting force, surface roughness and surface topography were investigated in this paper by conducting
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Inhibition behavior of milling hole outlet defects inhibition on quartz fiber polyimide composite through LN2 inner cooling Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-08 Fengbiao Wang, Mathew Kuttolamadom
Abstract The helical milling hole process of quartz fiber reinforced polyimide composites (QFRP) aimed to remove high-strength fiber and low-strength resin through thermodynamic interaction. But the defects, especially delamination at hole outlet, were difficult inhabited because of heterogeneous and anisotropic of composite. A mechanics model of milling hole force of QFRP was established by considering
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Electrical discharge machining as a surface treatment process for improving the performance of microbial fuel cells Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-04-05 Hung-Yin Tsai, Wei-Hsuan Hsu, Ming-Zhe You
Abstract Microbial fuel cells (MFCs), which generate low-pollution power through feeding organic trace minerals to bacteria, are crucial for applications involving energy recovery and environmental protection. In MFCs, electrodes critically influence the electrocatalytic process. In this study, an electrical-discharge-machining (EDM)-based surface treatment method for MFC electrodes was applied to
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A review of cutting tools for ultra-precision machining Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-03-20 Ganesan G., Ganesh Malayath, Rakesh G. Mote
Abstract Ultra-precision cutting (UPC) is an advanced machining process capable of fabricating components with a surface finish and dimensional accuracy in the nanometer range. The cutting tool edge should possess ultra-sharpness and controlled waviness to bring off a higher degree of finish and accuracy. It also should have high hardness, toughness, thermal resistance and chemical inertness. As the
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Longitudinal-torsional complex-mode ultrasonic actuator for vibration-assisted drilling of CFRP Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-02-23 Chen Zhang, Xiaoxue Wang, Vadim V. Silberschmidt
Abstract Carbon-fiber-reinforced plastic (CFRP) composites are intensively used in aircraft and aerospace industry thanks to their superior properties. Comparing to the conventional drilling (CD), vibration-assisted drilling (VAD) is a novel machining technique suitable for drilling CFRP. Still, multi-mode excitations with elliptical locus and low vibration performance limit the applications of current
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Performance analysis of EDM electrode manufactured by direct metal laser sintering during machining of titanium alloy (Ti6Al4V) Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-02-23 Anshuman Kumar Sahu, Siba Sankar Mahapatra
Abstract Recently, additive manufacturing based rapid tooling (RT) is gaining popularity in manufacturing industries because tool fabrication time and cost can be substantially reduced. In this regard, an experimental investigation is made to explore the machining performance of AlSi10Mg tool electrode manufactured through direct metal laser sintering and compared with commonly used copper and graphite
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Effect of chemical composition and microstructure on the crack growth and machinability of GG20 gray cast iron for brake drum application Mach. Sci. Tech. (IF 2.7) Pub Date : 2023-02-23 Hanie Ghanbari, Mostafa Ketabchi, Esmaeil Damavandi
Abstract The objective of the present study is to investigate the effect of chemical composition and microstructure on machinability, mechanical properties, and crack growth of GG-20 gray cast iron for brake drum application. The effects of a reduction in C and Si on microstructural parameters such as type, size, and aspect ratio of graphite particles, interlamellar spacing of pearlite, and the presence
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The hole entrance damage in longitudinal torsional ultrasonic helical milling of CFRP composites Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-11-12 Xue Wang, Feng Jiao, Shun Zhang, Yuanxiao Li, Jinglin Tong, Zhibin Feng
Abstract Carbon fiber reinforced polymer (CFRP) is prone to surface damage such as delamination, uncut fibers and tear during the process of hole-making in aerospace field. Helical milling greatly improves the exit damage of CFRP holes, but the entrance damage will further deteriorate. To further diminish hole entrance damage and enhance hole machining quality, this paper proposed a longitudinal torsional
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Machining and characterization of holes machined on a biomaterial Ti-6Al-4V ELI using an indigenously developed electrochemical machining cell with IEG control mechanism Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-28 S Aravind, Somashekhar S Hiremath
Abstract This article presents a comprehensive study on the machining and characterization of the holes machined on a biomaterial Ti-6Al-4V ELI of 350 µm thickness with hollow stainless steel tool electrode of outside diameter 250 µm using the tailor-made µ-ECM experimental setup. The distinct feature of the experimental unit is an indigenously made pulse generator circuit and a closed-loop tool feed
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Development of a new in-situ rotating magnetorheological honing technique for fine finishing the inner cylindric surfaces Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-27 Sunil Kumar Paswan, Anant Kumar Singh
Abstract A new in-situ rotary magnetorheological honing (RMRH) approach has been developed in this study to fine-finish the machined inner surface of cylindric workpieces with increased productivity and dimensional accuracy. A single in-situ honing tool is used for performing both traditional as well as magnetorheological (MR) honing. The tool is fabricated based on the designed tool through magnetostatic
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Machining-induced surface integrity and nanocrystalline surface layers in cryogenic finishing turning of Inconel 718 Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-22 Guher Pelin Toker, Julius Schoop, Haluk Karaca
Abstract In this study, the effects of cryogenic and flood cooling on the surface integrity of Inconel 718 are investigated for face turning with four selected cutting speeds of 25, 50, 75 and 100 m/min. Surface integrity of machined samples was characterized in terms of surface morphology, sub-surface microstructure, microhardness, x-ray diffraction textures, and residual stresses. While the differences
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A comprehensive review of magnetorheological fluid assisted finishing processes Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-21 Atul Singh Rajput, Manas Das, Sajan Kapil
Abstract In today’s manufacturing sector, it is required to manufacture products that have an exceptionally low tolerance. The desired high precision (or low tolerance) can be obtained through various finishing processes, which consist of bonded (honing, grinding, lapping, etc.) or unbonded (abrasive flow finishing) forms of the tool. An unbonded form of tool is more reliable and beneficial because
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Developments in tandem micro-machining processes to mitigate the machining issues at micron level: a systematic review, challenges and future opportunities Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-20 Sahil Sharma, Tarlochan Singh, Akshay Dvivedi
Abstract The requirement to fabricate the micro features in difficult-to-machine materials has increased the demand for new micro-machining processes. Over the years, various micro-machining processes have emerged, such as non-conventional, hybrid, and tandem micro-machining processes. Recently, among all of these processes, the tandem micro-machining processes have gained substantial attention. In
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Rotational feeding combined with shift feeding in the electrochemical trepanning of a blisk Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-19 Gaopan Lei, Dong Zhu, Mingzhu Ren, Di Zhu
Abstract The structure of the blades on a blisk is generally characterized by spatial distortion and spatial bending. Electrochemical trepanning (ECTr) is an effective roughing method in blisk manufacturing. To improve the structural characteristics and the allowance distribution uniformity manufactured by ECTr, a new feeding strategy, in which the relative motion of the cathode and the workpiece is
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Performance evaluation of HiPIMS, S3p and CAE deposited coatings during dry turning of Dss2205 Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-19 Gaurav D. Sonawane, Vikas G. Sargade
Abstract The present study is an extension of our previous work. Performance evaluation of single-layer AlTiN coating deposited by Scalable Pulse Power Plasma (S3p) and High Power Impulse Magnetron Sputtering (HiPIMS), with multi-layer TiN/TiAlN and AlTiN/TiAlN coating deposited by Cathodic Arc Evaporation (CAE) is carried out. Taguchi’s full factorial design with L9 orthogonal array was used for machining
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Effect of cutting edge radius when milling hardened steels: a finite element analysis and surface integrity investigation Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-19 Mohamd Imad, Hossam A. Kishawy, Nima Z. Yussefian, Ali Hosseini
Abstract This work investigated the impact of cutting tools varying edge radii by presenting a 3-dimensional finite element analysis (3D FEA) model during the milling of hardened steels. The proposed numerical model was able to capture the effect of micro geometrical changes between cutting tools of five different edge radii (25 μm, 30 μm, 35 μm, 40 μm, and 45 μm). Experimental milling tests were performed
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Comparing surface roughness and tool wear when milling convex surface of hardened steel using different milling strategies Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-19 A. L. Pissolatti, A. Magri, A. Í. S. Antonialli, A. E. Diniz
Abstract Regarding milling of dies and molds, there are several geometric requirements, and it is absolutely not trivial to machine complex either concave or convex surfaces. Since the contact between tool and workpiece changes all the time, making the components of the milling forces also to change, it is fundamental to find the correct milling strategies which cause the smallest variation of cutting
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The evaluation of machining performances and recast layer properties of AISI H13 steel processed by tungsten carbide powder mixed EDM process in the semi-finishing process Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-19 Van Tao Le
Abstract In the literature, investigations on the electrical discharge machining (EDM) process with Tungsten carbide powder mixed into dielectric fluid, also called PMEDM, are still limited. In this study, machining performances of PMEDM, including material removal rate (MRR) of AISI H13 steel and tool wear rate (TWR), were investigated in the semi-finishing process. Thereafter, recast layer properties
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Finite element simulation and experimental investigation of machining induced residual stresses in ultrasonic elliptical vibration-assisted turning Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-10-19 Seyyed Sajjad Ahmadpoor, Mohsen Khajehzadeh, Mohammad Reza Razfar
Abstract In this study, an experimental study and three-dimensional finite element simulation of ultrasonic elliptical vibration-assisted turning (UEAT) are investigated. In addition, the comparison of this process with ultrasonic-assisted turning (UAT) and conventional turning (CT) is also provided. First, a three-dimensional FEM has been developed to study the cutting forces, friction coefficient
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A review on microholes formation in glass-based substrates by electrochemical discharge drilling for MEMS applications Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-04-11 Tarlochan Singh, Julfekar Arab, Pradeep Dixit
Abstract Continuous demands to develop advanced radio-frequency transmission at higher frequencies have initiated glass-based materials as a substrate in radio-frequency micro-electro-mechanical-systems (MEMS) applications. Due to its superior electrical insulation characteristics, glass has lower substrate losses than silicon when an electrical signal is transmitted at higher frequencies. The optical
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Performance monitoring and failure prediction system for wire electric discharge machining process through multiple sensor signals Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-04-10 P. M. Abhilash, Dupadu Chakradhar
Abstract This study aims to develop a pulse classification algorithm to understand wire electric discharge machining (wire EDM) process stability and performance based on the discharge pulse characteristics. Also, a process data driven failure prediction system is proposed. The wire EDM monitoring system includes high sampling rate differential probes and current probes. The features extracted through
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Machinability study on dry machining of white cast iron by polycrystalline cubic boron nitride inserts Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-04-09 Xin Guo, Ling Chen, Wu Zhao, Hao Wan, Huiting Wen, Jinming Zhou
Abstract The polycrystalline cubic boron nitride (PCBN) insert has been widely used in machining high chromium white cast iron (HCCI), which has the high hardness and abrasiveness. The aim of this article is to reveal that micro-mechanical properties play an essential role in assessing the machinability of high chromium cast iron. Grid nanoindentation is applied to measure the micro-hardness distribution
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Machining of Y2O3 reinforced magnesium rare earth alloys using wire electrical discharge turning process Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-04-08 Vignesh M, Ramanujam R, Gururaj Parande, Manoj Gupta
Abstract Advanced machining has become one of the inevitable processes for the fabrication of miniature industrial components that demands high dimensional accuracy. Magnesium (Mg) and its composites have widespread applications in the areas of aerospace, medical, and automobile sectors. The objective of this work is to analyze the machinability of Mg—rare earth (RE) alloy (Mg3Al2.5La)-based nanocomposites
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Kinematic planning and in-situ measurement of seven-axis five-linkage grinding and polishing machine tool for complex curved surface Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-03-18 Cheng Fan, Kun Xu, Lei Zhang, Qiang Yuan, Qian Wang, Kejun Wang, Lining Sun
Abstract An integrated polishing and in-situ measurement machine tool with seven-axis and five-linkage is developed for manufacturing and measuring the complex curved surface such as blisk. Firstly, this paper introduces the structure and configuration of the machine tool. Then, the kinematic analyses of the polishing side and measuring side of the machine tool are carried out respectively and the
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A comparative analysis of grinding of AISI D2 tool steel under different environments Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-03-18 Ashwani Sharma, Mohd Zaheer Khan Yusufzai, Meghanshu Vashista
Abstract Difficult-to-cut material, i.e., AISI D2 tool steel, has been widely adopted in metalworking industries to manufacture dies for piercing, blanking, drawing and thread rolling due to its excellent wear resistance and non-deforming properties. This article attempts an experimental study to determine the effect of cryogenic coolant (liquid nitrogen) on the grindability of AISI D2 tool steel as
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Effects of electrolytic copper and copper alloy electrodes on machining performance in electrical discharge machining (EDM) Mach. Sci. Tech. (IF 2.7) Pub Date : 2022-03-18 Ülke Şimşek, Can Çoğun, Ziya Esen
Abstract The most important cost element of electric discharge machining (EDM) is the production of tool electrode (shortly electrode). In the EDM process, copper and its alloys are often used as electrode materials. The machining with EDM without increasing the costs can be achieved by selecting the proper electrode with low production and material costs as well as high workpiece material removal