Abstract The present research study aimed to investigate the influences of turning environments and parameters on machining temperature (MT), machining forces (MFs), and axial surface residual stresses (ASRS) in turning operation of AA6061-T6. Turning environments included DRY, minimum quantity lubrication (MQL), and WET modes, and turning parameters consisted of cutting speed ( V), feed rate ( f)

Abstract Electric discharge machining (EDM) is a nontraditional machining process based on the thermal erosion of the electrically conductive workpiece and tool electrodes. The product cost manufactured by the EDM process mainly depends on the tooling cost, which comprises the cost of tool material, tool fabrication, and tool maintenance. The properties of tool material affect the machining performance

Abstract Electrostatic spraying (ES) can improve the machining and environmental effects of minimum quantity lubrication (MQL). Compared with ES, composite electrostatic spraying (CES) presents better results because of excellent charging and cooling/lubrication performances. This article investigated the performance of CES milling using different inner/outer fluid combinations in terms of milling

Abstract Ti-6Al-4V is widely used in aerospace, medical and defense industries where materials with superior characteristics are needed. However, Ti-6Al-4V is categorized as a difficult-to-cut material, and machining of this alloy is highly challenging. Ultrasonic Assisted Milling (UAM) is a quite recent method to facilitate the machining of difficult-to-cut materials. This method has numerous advantages

Abstract Wire lag plays a major role in causing inaccuracies in certain geometrical shapes and profiles during machining of complex structures using wire-EDM. While previous studies focused on investigating effects of electrical parameters on machining performance and accuracy during wire EDM, the effects of non-electrical parameters on corner and profile accuracies have not been studied comprehensively

Abstract The main objective of this study is to initially simulate the cutting process of hardened AISI630 stainless steel to implement thermally enhanced turning followed by hot turning (HT) experiments to demonstrate the effectiveness of the process and identify cutting parameters that would yield the optimum results in terms of sustainability. To precisely predict the chip morphology, as well as

Abstract In recent years, demand of titanium alloy (Ti6Al4V) in various industries especially aerospace industries drastically increased. Several exceptional properties of titanium alloy that contribute to its popularity include high compressive and tensile strength, fracture toughness oxidation resistance and high strength-to-weight ratio. However, due to these superior properties, titanium alloys

Abstract The uncertainty in the prediction of machining stability increases with the increasing flexibility of the workpiece. The past research showed that the process cannot be stabilized even using the largest pockets in the stability diagrams due to high flexibility of the parts. Therefore, the present research emphasizes extensive experimental analysis where the uncertainty of the stability lobe

Abstract Broaching is very efficient for machining complex-shaped slots in turbine disks made of high thermal resistant super-alloys. However, large cutting forces and high thermal flux lead to high tool wear. To reduce the broaching forces, this paper proposes a vibration assisted broaching system, including the main components of a hydraulic horizontal internal broaching machine, an electrohydraulic

Abstract This study was to determine to what extent a cryogenic surface treatment technique could improve the wear resistance of a Co-Cr-Mo hip implant material. Dry and cryogenic treatments were used to create different surface and sub-surface conditions. The Co-Cr-Mo samples were wear-tested using a pin-on-disk tester in a simulated implant environment. A change in the wear response was found as

Abstract Elastomers have visco-elastic behavior and are widely used in general utility as well as sophisticated applications. Generally, elastomer components are produced by molding process. But it is not economical for complicated geometrical elastomeric components of small batch size. Hence, machining is an alternative method of the molding. However, high elasticity, low Young’s modulus and low thermal

Abstract In the present investigation, water based multi-walled carbon nanotube (MWCNT) dispersed nanofluid was produced and used as a cutting fluid in small quantity cooling lubrication (SQCL) assisted grinding of hardened AISI52100 steel. The work material was ground by an alumina wheel. The SQCL technology utilizes atomized aerosol of liquid grinding fluid. Use of MWCNT nanofluid aerosol in place

Abstract This article presents flank wear estimation during the turning process of Inconel 718 in dry cutting condition using unscented Kalman filter (UKF). A discrete flank wear model is developed where two components of flank wear due to abrasion and diffusion are considered as state variables and the cutting force is taken as the output variable. The proposed model can be implemented for online

Abstract High-speed ultrasonic vibration cutting has been proven to be effective in prolonging tool life, as well as reducing cutting force and cutting temperature at certain cutting speeds, which is higher than both the critical cutting speed of traditional ultrasonic vibration cutting and the range of conventional high-speed cutting in recent research. However, the surface topography results from

Abstract As industries are increasingly adopting the laser powder bed fusion (LPBF) additive manufacturing (AM) process, it is crucial to understand the process closely and to find ways to improve the final quality of the finished parts. The LPBF process is capable of producing tailored designs, which are lighter in weight and having strength comparable to conventional components. However, the acquired

Abstract An accurate prediction of cutting force is significant, as it plays a critical role on surface quality and tool wear. In micro-endmilling, the machined feature size and feed/tooth are comparable to the material grain size and the edge radius of the endmill. Hence, the effects of scaling issues, material micro-structure and cutting temperature on the machining performance need to be addressed

Abstract The finite element method is an important supplement to the experiment on the research of metal cutting mechanism. A 3D thermo-mechanical coupling model was established based on ABAQUS, in which a model of the tool with real structure and a simplified model of the work-piece based on the cutting zone were established. It can greatly improve the computational efficiency because the volume of

Abstract The tool material properties are essential key factors for the enhancement of electro discharge machining performance mainly, resistance to the wear of tool, removal of material from workpiece, and machined surface quality. In this study, copper-based multi-wall carbon nanotube (MWCNT) composite coated 316 L stainless steel electrode was fabricated by electrodeposition method and used in EDM

Abstract The tool material properties are essential key factors for the enhancement of electro discharge machining performance mainly, resistance to the wear of tool, removal of material from workpiece, and machined surface quality. In this study, copper-based multi-wall carbon nanotube (MWCNT) composite coated 316 L stainless steel electrode was fabricated by electrodeposition method and used in EDM

Magnetic abrasive finishing (MAF) process is the superfinishing process used to enhance the surface quality of metallic and nonmetallic materials such as alloys, composites and ceramics etc. This p...

Abstract Post-mixed waterjet peening is an effective treatment method for compressive residual stress field. After peening, the surface quality of the parts is low, and the hardness is usually higher than 60HRC. A fine manufacturing process should be carried out to obtain a satisfactory surface roughness without side effect on existing residual stress. In this article, the 18CrNiMo7-6 steel after carburization

Abstract The main goal of this article is to study the effects of tool nose radius on some performances in turning process. An analytical approach is developed and adapted for cutting with round inserts or when only the round edge was engaged in the metal. The uncut chip area is evaluated as function to tool nose radius and discretized into some elements which are defined by their average uncut chip

Abstract Process parameters that are addressed in literature to affect lapping process includes, abrasive grain size, types of abrasive, concentration of abrasives, viscosity of the compound, lapping pressure, lapping speed, lapping time, and lap material/disc material. However, a trajectory analysis of a single fixed abrasive particle shows various paths for different rotational speed ratio between

Abstract Cryogenic machining is one of the emerging manufacturing techniques in the field of metal cutting industries due to the new stringent environmental regulations in terms of utilization and disposal of chemically contaminated conventional coolants. The method of supply of cryogenic coolants at the machining zone significantly influences the machined product functional performance. In this context

Abstract Serrated chip is a typical characteristic of high-speed cutting. It is an important aspect of high-speed cutting mechanism, and has significant influence on cutting force, cutting temperature and tool wear. For the observation of serrated chip, optical microscope (OM) and scanning electron microscope (SEM) are usually used. The main problem of OM observation is time-consuming and that of SEM

The performance characteristics of micro-EDM dressing were investigated based on some real-time and offline responses for the fabrication of micro-rod(s) on a novel Ti-6Al-7Nb biomedical material. ...

The structure and physical properties of quartz fiber reinforced polyimide composite (QFRP) lead to the milling hole defects of crimp, ablation and delamination, as well as serious tool wear and li...

Steel foams are a new class of engineering materials with exceptional structure and properties. Foams produced by powder metallurgy generally have a near-net shape, however, sometimes machining ope...

Abstract In order to construct the constitutive model for high speed machining of aviation aluminum alloy with different forming directions, the Split Hopkinson Pressure Bar (SHPB) impact compression experiment and the high speed orthogonal cutting experiment are carried out in the normal direction (ND), rolling direction (RD) and transverse direction (TD) of aviation aluminum alloy 7050-T7451 rolling

As the final step to fabricate the optical parts, the deterministic polishing process is usually used to reduce the roughness and correct the surface form. In this article, a new compensation metho...

Appropriate selection of tool material is very important for effective machining of ‘difficult-to-cut’ aerospace superalloy Inconel 718, especially, under dry condition. Present work aims at invest...

The use of ultrasonic vibration on milling has several benefits including reduction of the machining forces. However, the mechanism behind this phenomenon is unclear, and reported analytical studie...

Abstract 17-4PH stainless steel is widely used for applications of critical importance owing to its favorable property profile. However, the great mechanical performance of 17-4PH stainless steel is at the cost of its unsatisfied machinability. Exploring suitable cooling method becomes an effective way to improve its machinability. This study aims to explore the applicability and feasibility of oils-on-water

Minimum Quantity Lubrication (MQL) has increased in popularity over the last two decades, owing to its economic and environmental benefits over flood cooling. But there are still challenges in the ...

Abstract In this work, machining performance of Ti-6Al-4V is studied in consideration with cutting force, tool-tip temperature, tool wear mechanisms, chip morphology and roughness of the machined surface. Machining experiments are carried out by varying cutting speed (Vc) with constant feed and depth-of-cut. Uncoated WC-Co insert is used as cutting tool. Multi-walled carbon nanotubes (MWCNTs) added

Abstract Glass-fiber reinforced polymers (GFRP) are widely used for printed circuit boards (PCBs) in automotive and aircraft structural applications. The performance of micro-drilling in high ceramic-content particle-filled GFRP heavily influences the signal transmission quality and speed available from these PCBs. Chip adhesion is one of the biggest obstacles to high-performance micro-drilling especially

Abstract The proposed work deals with the investigation of magnetorheological based minimum quantity lubrication of graphene oxide (GO) based jojoba oil as bio-lubricant on machinability and tool wear mechanism of turning Monel K500 alloy. Experiments were carried out for dry, flooded, minimum quantity lubrication (MQL) and magnetorheological (MR–MQL) conditions using medium duty lathe. The process

Abstract Abrasive flow finishing (AFF) is an advanced finishing process employed for finishing macro- to micro-features of workpieces. Finishing improves the functioning of the components by reducing their surface roughness. AFF process uses a polymer-based flexible medium containing abrasive particles as a finishing tool. Medium used during the AFF process plays a vital role in deciding the final

Abstract Many studies were performed about the influence of minimum quantity lubrication (MQL) technique on cutting performance in the literature, but there is no paper examining the effect of different MQL flow rates and cutting parameters on machinability of AISI 4140 material as a whole. In this study, the effects of different MQL flow rates and cutting parameters on surface roughness, main cutting

Abstract In this study, micro machinability of Mg5Sn4Zn (TZ54) alloy produced by a hot-pressing process (one of the powder metallurgy methods) is investigated. For this purpose, micro-milling experiments were carried out, considering different cutting parameters. In order to determine the appropriate cutting parameters, the variation of cutting forces, surface quality and burr width were investigated

Abstract Dry machining is receiving immense attention worldwide to eliminate or minimize the harmful environmental effects of cutting fluids. The present work investigates dry machining performance of a bilayer coating with top-layer of hard-lubricious TiN–WSx, supported by a hard TiN under layer. During dry turning of AISI 1060 steel, the bilayer coated carbide tool registered significantly less cutting

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract The present study focuses on the effects of cutting speed, feed rate and cutting tool material on the machining performance of carbon graphite material. Polycrystalline Diamond (PCD) cutting tools are used in machining experiments and its performance is compared with the tungsten carbide (WC) and Cubic Boron Nitride (CBN) tools. Machining performance criteria such as flank and nose wear and

Abstract 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

Abstract 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

Abstract 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

Abstract 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

Abstract 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