Pub Date : 2023-09-03DOI: 10.1080/10910344.2023.2253027
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 the AM production of grinding/abrasive tools and provides future trends in the field. Bibliometric and systematic reviews of the literature verified the technological frontiers of each AM method, indicating current possibilities and potential gaps for future perspectives.
{"title":"A review on the production of grinding tools through additive manufacturing processes: From current possibilities to future perspectives","authors":"Diego Jorge Alves Borges, Adriel Magalhães Souza, Eraldo Jannone da Silva","doi":"10.1080/10910344.2023.2253027","DOIUrl":"https://doi.org/10.1080/10910344.2023.2253027","url":null,"abstract":"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 the AM production of grinding/abrasive tools and provides future trends in the field. Bibliometric and systematic reviews of the literature verified the technological frontiers of each AM method, indicating current possibilities and potential gaps for future perspectives.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"45 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2023-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134948415","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-08-28DOI: 10.1080/10910344.2023.2246052
F. Taylan, Tolgahan Ermergen
Abstract 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 more efficient chip breaking and better cooling. Proper selection of machining conditions can also increase the productivity of the process by reducing cutting forces and tool wear rate. To investigate the effect of high-pressure jet cooling (HPJC) on cutting force, surface roughness, and chip formation of Ti-6Al-4V ELI in high-speed turning, Grade 5 Ti ELI turning tests were carried out under coolant pressure of 200 bar. A lower pressure of 6 bar was also used in this study to compare the results of the pressure change. In general, surface roughness increased as the feed rate increased at constant cutting speeds in experiments with both 6 bar and 200 bar coolant pressures. Even though 200 bar pressure provided a better cooling thus reduced cutting force, and tool wear rate; the surface roughness values obtained from the experiments with 200 bar were relatively worse than the experiments with 6 bar pressure. It was also seen that 200 bar coolant pressure may result in instabilities in the turning process in terms of chip geometries and formations.
{"title":"The Effect of High-Pressure Jet Cooling on Surface Roughness, Cutting Force and Chip Formation of Ti-6Al-4V ELI in High-Speed Turning","authors":"F. Taylan, Tolgahan Ermergen","doi":"10.1080/10910344.2023.2246052","DOIUrl":"https://doi.org/10.1080/10910344.2023.2246052","url":null,"abstract":"Abstract 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 more efficient chip breaking and better cooling. Proper selection of machining conditions can also increase the productivity of the process by reducing cutting forces and tool wear rate. To investigate the effect of high-pressure jet cooling (HPJC) on cutting force, surface roughness, and chip formation of Ti-6Al-4V ELI in high-speed turning, Grade 5 Ti ELI turning tests were carried out under coolant pressure of 200 bar. A lower pressure of 6 bar was also used in this study to compare the results of the pressure change. In general, surface roughness increased as the feed rate increased at constant cutting speeds in experiments with both 6 bar and 200 bar coolant pressures. Even though 200 bar pressure provided a better cooling thus reduced cutting force, and tool wear rate; the surface roughness values obtained from the experiments with 200 bar were relatively worse than the experiments with 6 bar pressure. It was also seen that 200 bar coolant pressure may result in instabilities in the turning process in terms of chip geometries and formations.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"453 - 471"},"PeriodicalIF":2.7,"publicationDate":"2023-08-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41993301","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-04DOI: 10.1080/10910344.2023.2235610
Van-Hai Nguyen, Tien-Thinh Le, M. V. 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 efficient output. Nowadays, meta-heuristic algorithms effectively solve multi-objective optimization in machining problems instead of single-objective one. Along with that, the mathematical predictive models used for single-objective optimization are gradually being replaced by machine learning algorithms, which are highly robust and efficient in terms of prediction performance. Therefore, this work addresses the prediction and optimization of average surface roughness (Ra) and tool wear (VB) in Ti6Al4V alloy turning, using a WC tool coated by chemical vapor deposition (CVD) and physical vapor deposition (PVD), with dry machining. We apply a two-pronged approach combining machine learning (ML) and Non-Dominated Sorting Genetic Algorithm (NSGA-II), to model and optimize Ra and VB. The four ML models – Linear Regression (LIN), Support Vector Machine Regression (SVR), Extreme Gradient Boosting (XGB), and Artificial Neural Network (ANN) – are used to predict Ra and VB. The input variables of the turning process – feed rate, depth of cut, cutting speed, cutting time, and tool materials – are the major factors affecting surface quality and tool wear. By the error metrics such as root mean squared error (RMSE), mean absolute error (MAE), and coefficient of determination (R2), ANN is found to offer the best predictive performance. An ML and NSGA-II-based approach is then employed for multi-objective optimization of cutting parameters in Ti6Al4V turning. Fifty Pareto solutions are identified in the range of Ra and VB between (1.332 and 1.441 µm) and (0.100 and 0.125 mm), respectively. In this work, the Pareto solutions are selected based on their ranked performances. This aligns with the decision criterion employed to select the most robust cutting parameters. The definitive optimal Ra and VB are obtained by formulating a robust decisive multi-criterion function which integrates performance, preferred decision criterion, and trustworthiness. Finally, this produces the optimal solution for Ra and VB − 1.439 µm and 0.100 mm, respectively. Experimental validation confirms that the final optimum solution is within the acceptable range.
{"title":"Multi-objective optimization based on machine learning and non-dominated sorting genetic algorithm for surface roughness and tool wear in Ti6Al4V turning","authors":"Van-Hai Nguyen, Tien-Thinh Le, M. V. Le, Hoang Dao Minh, Anh-Tu Nguyen","doi":"10.1080/10910344.2023.2235610","DOIUrl":"https://doi.org/10.1080/10910344.2023.2235610","url":null,"abstract":"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 efficient output. Nowadays, meta-heuristic algorithms effectively solve multi-objective optimization in machining problems instead of single-objective one. Along with that, the mathematical predictive models used for single-objective optimization are gradually being replaced by machine learning algorithms, which are highly robust and efficient in terms of prediction performance. Therefore, this work addresses the prediction and optimization of average surface roughness (Ra) and tool wear (VB) in Ti6Al4V alloy turning, using a WC tool coated by chemical vapor deposition (CVD) and physical vapor deposition (PVD), with dry machining. We apply a two-pronged approach combining machine learning (ML) and Non-Dominated Sorting Genetic Algorithm (NSGA-II), to model and optimize Ra and VB. The four ML models – Linear Regression (LIN), Support Vector Machine Regression (SVR), Extreme Gradient Boosting (XGB), and Artificial Neural Network (ANN) – are used to predict Ra and VB. The input variables of the turning process – feed rate, depth of cut, cutting speed, cutting time, and tool materials – are the major factors affecting surface quality and tool wear. By the error metrics such as root mean squared error (RMSE), mean absolute error (MAE), and coefficient of determination (R2), ANN is found to offer the best predictive performance. An ML and NSGA-II-based approach is then employed for multi-objective optimization of cutting parameters in Ti6Al4V turning. Fifty Pareto solutions are identified in the range of Ra and VB between (1.332 and 1.441 µm) and (0.100 and 0.125 mm), respectively. In this work, the Pareto solutions are selected based on their ranked performances. This aligns with the decision criterion employed to select the most robust cutting parameters. The definitive optimal Ra and VB are obtained by formulating a robust decisive multi-criterion function which integrates performance, preferred decision criterion, and trustworthiness. Finally, this produces the optimal solution for Ra and VB − 1.439 µm and 0.100 mm, respectively. Experimental validation confirms that the final optimum solution is within the acceptable range.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"380 - 421"},"PeriodicalIF":2.7,"publicationDate":"2023-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41710841","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-04DOI: 10.1080/10910344.2023.2231066
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 tool wear at different cutting parameters with wear and surface roughness analysis. Consequently, a finite element model is used to simulate the ultrasonic turning of titanium to have a better understanding of the effect of UAT on stresses and temperature profiles in the process and help explain the results found experimentally. Separation time between the tool and chip was found to be inversely proportional to the cutting speed and the depth of cut with a reduction in cutting forces and surface roughness of up to 42.5% and 61.4%, respectively, for low cutting speed and depth of cut. Tool wear is also shown to decrease in the ultrasonic machining where adhesion-diffusion wear is reduced on the rake face due to separation in the tool-chip interface. The chip temperature was found to increase while the tool temperature is found to decrease with the motion of the tool.
{"title":"An experimental and FEM study on ultrasonic-assisted turning of titanium alloy","authors":"E. Bachir, R. Bejjani","doi":"10.1080/10910344.2023.2231066","DOIUrl":"https://doi.org/10.1080/10910344.2023.2231066","url":null,"abstract":"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 tool wear at different cutting parameters with wear and surface roughness analysis. Consequently, a finite element model is used to simulate the ultrasonic turning of titanium to have a better understanding of the effect of UAT on stresses and temperature profiles in the process and help explain the results found experimentally. Separation time between the tool and chip was found to be inversely proportional to the cutting speed and the depth of cut with a reduction in cutting forces and surface roughness of up to 42.5% and 61.4%, respectively, for low cutting speed and depth of cut. Tool wear is also shown to decrease in the ultrasonic machining where adhesion-diffusion wear is reduced on the rake face due to separation in the tool-chip interface. The chip temperature was found to increase while the tool temperature is found to decrease with the motion of the tool.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"350 - 379"},"PeriodicalIF":2.7,"publicationDate":"2023-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46779804","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-07-04DOI: 10.1080/10910344.2023.2241140
W. Cheng, J. Outeiro, J. Costes, Habib Karouni, T. Dorlin, R. 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 model considering the effects of the state of stress and strain-rate on the elasto-viscoplastic and damage behaviors of Ti-6Al-4V alloy. The accuracy of the 3D turning model was evaluated by comparing the predicted machining outcomes (forces, chip thickness, residual stresses, and thickness of strain-hardened layer) with those obtained experimentally. The model can predict quite well the cutting force but underestimate the feed force. The predicted residual stresses match reasonably well the experimental ones in both circumferential and axial direction, and the simulated thicknesses of strain hardened layer were close to the experimental ones. ANOVA permitted to investigate the influence of the cutting conditions on the thermomechanical phenomena and surface integrity. Suggestions to improve 3D models of practical machining operations are proposed.
{"title":"3D modeling of turning of Ti-6Al-4V titanium alloy using a constitutive model considering the state of stress","authors":"W. Cheng, J. Outeiro, J. Costes, Habib Karouni, T. Dorlin, R. M'Saoubi","doi":"10.1080/10910344.2023.2241140","DOIUrl":"https://doi.org/10.1080/10910344.2023.2241140","url":null,"abstract":"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 model considering the effects of the state of stress and strain-rate on the elasto-viscoplastic and damage behaviors of Ti-6Al-4V alloy. The accuracy of the 3D turning model was evaluated by comparing the predicted machining outcomes (forces, chip thickness, residual stresses, and thickness of strain-hardened layer) with those obtained experimentally. The model can predict quite well the cutting force but underestimate the feed force. The predicted residual stresses match reasonably well the experimental ones in both circumferential and axial direction, and the simulated thicknesses of strain hardened layer were close to the experimental ones. ANOVA permitted to investigate the influence of the cutting conditions on the thermomechanical phenomena and surface integrity. Suggestions to improve 3D models of practical machining operations are proposed.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"422 - 451"},"PeriodicalIF":2.7,"publicationDate":"2023-07-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45837241","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-06-24DOI: 10.1080/10910344.2023.2224860
Ramazan Hakkı Namlu, Bahram Lotfi, S. A, Okan Deniz Y ı lmaz, Samet Akar, Ramazan Hakk ı
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 combinations of process/cooling have been studied as conventional drilling with flood cooling (CD-Wet) and with minimum quantity lubrication (CD-MQL), ultrasonic-assisted drilling with flood cooling (UAD-Wet) and with MQL (UAD-MQL). The drill bit wear, drilling forces, chip morphology and drilled hole quality are used as the performance measures. The results show that UAD conditions result in lower feed forces than CD conditions, with a 31.2% reduction in wet and a 15.3% reduction in MQL on average. The lowest feed forces are observed in UAD-Wet conditions due to better coolant penetration in the cutting zone. The UAD-Wet yielded the lowest tool wear, while CD-MQL exhibited the most severe. UAD demonstrated a ∼50% lower tool wear in the wet condition than CD and a 38.7% in the MQL condition. UAD is shown to outperform the CD process in terms of drilled-hole accuracy.
{"title":"Combined use of ultrasonic-assisted drilling and minimum quantity lubrication for drilling of NiTi shape memory alloy","authors":"Ramazan Hakkı Namlu, Bahram Lotfi, S. A, Okan Deniz Y ı lmaz, Samet Akar, Ramazan Hakk ı","doi":"10.1080/10910344.2023.2224860","DOIUrl":"https://doi.org/10.1080/10910344.2023.2224860","url":null,"abstract":"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 combinations of process/cooling have been studied as conventional drilling with flood cooling (CD-Wet) and with minimum quantity lubrication (CD-MQL), ultrasonic-assisted drilling with flood cooling (UAD-Wet) and with MQL (UAD-MQL). The drill bit wear, drilling forces, chip morphology and drilled hole quality are used as the performance measures. The results show that UAD conditions result in lower feed forces than CD conditions, with a 31.2% reduction in wet and a 15.3% reduction in MQL on average. The lowest feed forces are observed in UAD-Wet conditions due to better coolant penetration in the cutting zone. The UAD-Wet yielded the lowest tool wear, while CD-MQL exhibited the most severe. UAD demonstrated a ∼50% lower tool wear in the wet condition than CD and a 38.7% in the MQL condition. UAD is shown to outperform the CD process in terms of drilled-hole accuracy.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"325 - 349"},"PeriodicalIF":2.7,"publicationDate":"2023-06-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45683713","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-04DOI: 10.1080/10910344.2023.2224856
Abhimanyu Chaudhari, Ashwani Sharma, M. Z. K. Yusufzai, M. 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 bearing index, core fluid retention index, grinding temperature, and chip morphology. Experimental works were performed on a setup that was indigenously developed and manufactured. Experiments were conducted on AISI D2 tool steel workpiece material under the tangential ultrasonic-vibration-assisted dry grinding (TUDG), common dry grinding (CDG), and common flood grinding (CFG) modes to compare the effectiveness of each mode in terms of the responses of the grinding outcomes. A comprehensive comparative analysis of each grinding mode is demonstrated, along with observations of changes in the output responses under the effect of the investigated grinding parameters. Findings showed that under identical conditions, the TUDG mode’s surface bearing index and core fluid retention index was higher than that of the CDG and CFG modes. To elucidate these findings. Besides, small, thin chips generated in TUDG mode indicate the ease of grinding of AISI D2 tool steel.
{"title":"The grindability performance and measurement of surface functional parameter capabilities of difficult-to-machine tool steel under tangential ultrasonic-vibration-assisted dry grinding","authors":"Abhimanyu Chaudhari, Ashwani Sharma, M. Z. K. Yusufzai, M. Vashista","doi":"10.1080/10910344.2023.2224856","DOIUrl":"https://doi.org/10.1080/10910344.2023.2224856","url":null,"abstract":"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 bearing index, core fluid retention index, grinding temperature, and chip morphology. Experimental works were performed on a setup that was indigenously developed and manufactured. Experiments were conducted on AISI D2 tool steel workpiece material under the tangential ultrasonic-vibration-assisted dry grinding (TUDG), common dry grinding (CDG), and common flood grinding (CFG) modes to compare the effectiveness of each mode in terms of the responses of the grinding outcomes. A comprehensive comparative analysis of each grinding mode is demonstrated, along with observations of changes in the output responses under the effect of the investigated grinding parameters. Findings showed that under identical conditions, the TUDG mode’s surface bearing index and core fluid retention index was higher than that of the CDG and CFG modes. To elucidate these findings. Besides, small, thin chips generated in TUDG mode indicate the ease of grinding of AISI D2 tool steel.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"268 - 291"},"PeriodicalIF":2.7,"publicationDate":"2023-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45369437","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-04DOI: 10.1080/10910344.2023.2215309
Mohamed Ali Louhichi, G. Poulachon, P. Lorong, J. Outeiro, E. Monteiro, D. 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 were validated by comparing these stresses with those determined experimentally using layer removal and contour methods. The layer removal method consisting into remove successive layers of material by milling was also modeled and simulated using FEM to predict not only the residual stresses, but also part distortion. The predicted part distortion was close to that measured experimentally, which proves the hypothesis that the residual stresses induced by the layer removal method do not affect part distortion. The contour method was used to validate the residual stresses determined by layer removal, and to evaluate the effects of the temperature gradient on the residual stress distribution.
{"title":"Modeling and validation of residual stresses induced by heat treatment of AA 7075-T6 samples toward the prediction of part distortion","authors":"Mohamed Ali Louhichi, G. Poulachon, P. Lorong, J. Outeiro, E. Monteiro, D. Cotton","doi":"10.1080/10910344.2023.2215309","DOIUrl":"https://doi.org/10.1080/10910344.2023.2215309","url":null,"abstract":"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 were validated by comparing these stresses with those determined experimentally using layer removal and contour methods. The layer removal method consisting into remove successive layers of material by milling was also modeled and simulated using FEM to predict not only the residual stresses, but also part distortion. The predicted part distortion was close to that measured experimentally, which proves the hypothesis that the residual stresses induced by the layer removal method do not affect part distortion. The contour method was used to validate the residual stresses determined by layer removal, and to evaluate the effects of the temperature gradient on the residual stress distribution.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"247 - 267"},"PeriodicalIF":2.7,"publicationDate":"2023-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41936284","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-04DOI: 10.1080/10910344.2023.2215304
P. Ranjan, S. 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, the application of structured tools is one of the sustainable machining techniques used to enhance the machinability of work materials. Most of the researchers have studied only the influence of conventional structured geometries and have mainly concentrated on experiments. But the conduction of experiments involves bulky and costly experimental setups and also consumes a lot of time. Also, the bio-mimicked geometrical shapes and various geometrical parameters of structured tools on machining characteristics of martensitic AISI 420 steel have not been studied. Therefore finite element (FE) modeling proves to be a beneficial technique as it saves time and effort. In the current investigation, a 3D FE model is developed to examine performance of different geometrical structured tools in improving the machinability of AISI 420 steel. Johnson cook (JC) material model is utilized for modeling workpiece. Initially, the tangential force results obtained through simulation are validated with tangential forces obtained through experiments with an error of 6.65% using conventional tool and 5.57% using bio-mimicked structured tool, indicating the suitability of the machining model. Further, the effect of various structure shapes, mainly bio-mimicked crescent structure, dimple structure, and groove structure, was studied, and it is noticed that crescent-structured tool depicted better performances in lowering cutting force, effective stress, and cutting temperature. After getting superior geometry, i.e., crescent-structured geometry, the influence of variation in crescent structure parameters (radius, edge distance) was examined to study its influence on the above-mentioned machining responses. The variation in structure parameters significantly influences various output responses, indicating that bio-mimicked structured tools have a lot of potential to improve the machining performance of AISI 420 steel.
{"title":"Finite element modeling and experimental validation of turning process using bio-mimicked structured tool for outcomes relevant to industry","authors":"P. Ranjan, S. Hiremath","doi":"10.1080/10910344.2023.2215304","DOIUrl":"https://doi.org/10.1080/10910344.2023.2215304","url":null,"abstract":"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, the application of structured tools is one of the sustainable machining techniques used to enhance the machinability of work materials. Most of the researchers have studied only the influence of conventional structured geometries and have mainly concentrated on experiments. But the conduction of experiments involves bulky and costly experimental setups and also consumes a lot of time. Also, the bio-mimicked geometrical shapes and various geometrical parameters of structured tools on machining characteristics of martensitic AISI 420 steel have not been studied. Therefore finite element (FE) modeling proves to be a beneficial technique as it saves time and effort. In the current investigation, a 3D FE model is developed to examine performance of different geometrical structured tools in improving the machinability of AISI 420 steel. Johnson cook (JC) material model is utilized for modeling workpiece. Initially, the tangential force results obtained through simulation are validated with tangential forces obtained through experiments with an error of 6.65% using conventional tool and 5.57% using bio-mimicked structured tool, indicating the suitability of the machining model. Further, the effect of various structure shapes, mainly bio-mimicked crescent structure, dimple structure, and groove structure, was studied, and it is noticed that crescent-structured tool depicted better performances in lowering cutting force, effective stress, and cutting temperature. After getting superior geometry, i.e., crescent-structured geometry, the influence of variation in crescent structure parameters (radius, edge distance) was examined to study its influence on the above-mentioned machining responses. The variation in structure parameters significantly influences various output responses, indicating that bio-mimicked structured tools have a lot of potential to improve the machining performance of AISI 420 steel.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"27 1","pages":"209 - 246"},"PeriodicalIF":2.7,"publicationDate":"2023-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44368670","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2023-05-04DOI: 10.1080/10910344.2023.2224866
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 texturing of the α-002 basal plane of Ti-6Al-4V. The gradual reduction in texturing along the depth was confirmed by the Gi-XRD investigation. The relative intensity of the 002 peak was utilized as a quantitative indicator of subsurface deformation. The XRD and the metallographic study revealed a considerable amount of subsurface deformation at a higher grinding speed (vs ) and an enhanced material removal rate (MRR). Intense surface redeposition was also observed for higher vs and increased MRR grinding conditions. The surface redeposition was identified as an influencing factor that escalates the subsurface deformation and crystallographic texture. In addition, the residual stress was found to be more compressive at enhanced vs and MRR. Further, a higher force ratio Fn/Ft was noticed for the grinding conditions that revealed significant subsurface deformation, strong crystallographic texture, surface redeposition, and more compressive residual stress. Eventually, a correlation was found between the force ratio Fn/Ft and all these surface integrity characteristics.
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