Machining Science and Technology最新文献

{"title":"Research on topological grinding of bionic structured scale surface for reducing contact friction and fluid drag resistance","authors":"Yushan Lyu, Guoxun Wang, Xingshan Li, Liuwan Xu","doi":"10.1080/10910344.2023.2260476","DOIUrl":"https://doi.org/10.1080/10910344.2023.2260476","url":null,"abstract":"AbstractThe 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 workpiece, based on the topological theory and the principle of grinding kinematics, a novel topological grinding strategy was proposed. To this end, the topological feature vectors of the structured scale surface and the grinding wheel surface were established by analyzing the biomimetic structured scale surface; The Topological space of grinding process is constructed and the topological mapping equation of grinding process is established; The feasibility of this grinding strategy was verified through simulation and grinding experiments. The research results indicate that the established topological mapping equation is correct; Under the condition of maintaining design parameters, the errors of the feature parameters of the ground structured scale surface are between 2.8% and 8%; As the grinding parameters change, the feature parameters of the ground scale surface will also change, but they can still maintain the same topological attributes as the designed scale surface. Therefore, the proposed topology grinding strategy is feasible.Keywords: Grindingtopological grindingstructured scale surfacestructured grinding wheel Disclosure statementNo potential conflict of interest was reported by the authors.Additional informationFundingThe authors gratefully acknowledge the support for this work from Chinese National Natural Science Foundation. (No. 51875368)","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-11-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135093354","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}

{"title":"Ultrasonic Vibration Assisted Electrical Discharge Machining and Micro-Electrical Discharge Machining: A Review","authors":"Ibrahem Maher, Hassan El-Hofy, Mohamed H. El-Hofy","doi":"10.1080/10910344.2023.2263780","DOIUrl":"https://doi.org/10.1080/10910344.2023.2263780","url":null,"abstract":"AbstractMaterial 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 solidify and form debris. This debris affects process efficiency if not flushed out. To ensure continuous flushing, tools, workpiece or dielectric motion are necessary. Introducing ultrasonic vibrational motion to the tool, workpiece or the dielectric liquid became a viable alternative for the evacuation of debris during the ultrasonic assisted electrical discharge machining (USEDM) and ultrasonic assisted micro-electrical discharge machining (USµEDM) processes. In addition to the US vibration, powder mixed to the dielectric medium, using gas as a dielectric medium, and adopting the magnetic field (MF) assistance in USEDM are additional attempts to improve the performance of these processes. This article reviews the main research directions, process parameters and performance indicators of USEDM and USµEDM processes. Extra enhancement to their performance using powder mixing, gas or MF assistance was also presented. Numerous modeling and optimization methods have also been examined. The study demonstrated the benefits of using US vibration assistance to EDM and micro-electrical discharge machining regarding a faster material removal rate, improved surface quality and decreased electrode wear rate. Finally, the current article identifies potential directions for future studies.Keywords: AmplitudeEDMfrequencymagnetic fieldmaterial removal ratenano-powdersurface roughnesstool wearultrasonicvibration Author contributionsNot applicable.Ethical approval statementNot applicable.Consent formNot applicable.Consent for publicationNot applicable.Disclosure statementThe authors declare no conflict of interest.Data availability statementNot applicable.Code availability statementNot applicable.Additional informationFundingThis work received no specific grant from any funding agency in the public, commercial or not-for-profit sectors.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135758765","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}

{"title":"Investigation of performance characteristics amid nano powder mixed electrical discharge micro-milling on Hastelloy C 276","authors":"Souradeep Dutta, Deba Kumar Sarma, Hrishikesh Dutta","doi":"10.1080/10910344.2023.2263776","DOIUrl":"https://doi.org/10.1080/10910344.2023.2263776","url":null,"abstract":"AbstractPowder 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 micro-tool. It enhances the material removal rate (MRR), decreases the tool wear rate (TWR) and provides superior surface characteristics. The present work investigates the impact of powder concentration, gap voltage, and capacitance on the micro-hardness (MH), material removal rate (MRR), tool wear rate (TWR), surface roughness (SR), overcut (OC), taper angle (TA) and surface morphology during graphene nano powder added EDMM of Hastelloy C 276. The powder concentration of 0.25 g/L significantly enhanced the MRR and decreased the TWR, respectively. A drastic reduction in SR has been observed for 0.4 g/L concentration compared to plain dielectric. Lower OC and higher TA has been found for plain dielectric system. Field emission scanning electron microscopy (FESEM) is used in both cases to examine the surface morphology and recast layer of the milled micro-channels. The MH of the milled micro-channels is raised by 2.3 times at 0.4 g/L concentration. Energy-dispersive X-ray spectroscopy (EDS) confirms the migration of materials from the dielectric and graphene nano powder to the milled micro-channels on HC 276.Keywords: Capacitancedielectric concentrationelectrical discharge micro-millinggap voltagegraphene nano powderHastelloy C 276 AcknowledgmentsThe authors would like to acknowledge Dr. Bibhuranjan Nayak, CSIR-Institute of Minerals and Materials Technology (CSIR-IMMT) Bhubaneswar, Orissa, India for the FESEM facility.Disclosure statementNo potential conflict of interest was reported by the author(s).","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135141555","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}

{"title":"Development of a predictive analytical cutting force and torque model for flat bottom drilling of metals using mechanistic approach","authors":"Nima Zoghipour, Yusuf Kaynak","doi":"10.1080/10910344.2023.2263867","DOIUrl":"https://doi.org/10.1080/10910344.2023.2263867","url":null,"abstract":"AbstractBy 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 assembly of screws, pins or passing channels for fluids. Depending on the utilized manufacturing method and positioning of these components during machining processes, these holes are being drilled even in vertical or inclined orientations with respect to the jig and fixturing systems. In vertical drilling of the flat surfaces conventional or indexable inserted drill are the commonly used tools. However, these types of tools do not demonstrate sufficient performance on the surfaces drilled holes due to the occurred run-out, vibrations when being used in inclined features. Therefore, flat bottom drills have been developed in order to be used for curved or inclined surfaces. Thus, optimization of the tool and components design requires a deeper knowledge on the cutting forces and torques when using flat bottom drills. In this study, a predictive analytical cutting force model is developed for flat bottom drills for both vertical and inclined plunging using mechanistic approach in Matlab. The model is established on the distributed elementally cutting along the tool radius considering both rake and relief faces based upon the orthogonal and oblique cut principles. Accordingly, the performance of the developed model for different cutting tools with various geometries and machining parameters have been evaluated and verified with experimental results of flat bottom drilling of brass alloy.Keywords: Bottom drillcutting forcesmechanistic force modelvertical-inclined drilling DISCLOSURE STATEMENTThe authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this article.FUNDINGThis work was supported by TUBITAK (The Scientific and Technological Research Council of Turkey) under project number 118C069.Additional informationFundingThis work was supported by TUBITAK (The Scientific and Technological Research Council of Turkey) under project number 118C069","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134976075","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}

{"title":"In process temperature and tool wear for the machining of aeronautic aluminum under different lubrication conditions","authors":"Bruno Lavisse, Xavier Tardif, Dmitry Bondarenko, Mathieu Ritou, Guénaël Germain","doi":"10.1080/10910344.2023.2255238","DOIUrl":"https://doi.org/10.1080/10910344.2023.2255238","url":null,"abstract":"AbstractThe 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 most important parameters controlling the tool wear and the quality of machined surfaces. Therefore, its measurement is of great interest to analyze the heat generation during the cut and then being able to limit it in the cutting edge. This article presents an original experimental study of the cutting temperature of two aluminum alloys (7000 series and Li-containing 2000 series), for dry, MQL: Minimum Quantity of Lubrication and wet machining conditions. The interactions between tool wear and cutting temperature are also investigated. To be able to observe tool wear, the milling of very large volumes of aluminum alloys has been necessary since the tool lifetime is several hours when machining this kind of material. To measure temperature as close as possible the cutting zone, an original set-up with machinable thermocouples was used, enabling measurements on a large frequency bandwidth. Complementary investigations by Second Ion Mass Spectroscopy revealed a diffusion of lithium in the cutting insert, which can reduce its lifetime (divided by 8, with the Li-containing 2000 series compared to the 7000 series).Keywords: Cutting temperaturelubricationmachinable thermocouplestool wear AcknowledgmentsThis study is part of the CUT project managed by IRT Jules Verne (French Institute in Research and Technology in Advanced Manufacturing Technologies for Composite, Metallic and Hybrid Structures). The authors wish to acknowledge the industrial and academic partners of this project, Constellium, Europe Technologies, Capacités, Airbus, l’Université de Nantes and Arts et Métiers. We also would like to sincerely acknowledge Kevin DAUVERGNE, from Europe Technologies, for his great help during this study.Disclosure statementNo potential conflict of interest was reported by the authors.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134947712","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}

{"title":"Dosage Based Directional Minimum Quantity Fluid Application in Machining","authors":"Chandra Sekhar Rakurty, Himabindu Nunna, Alagar K. Balaji","doi":"10.1080/10910344.2023.2254838","DOIUrl":"https://doi.org/10.1080/10910344.2023.2254838","url":null,"abstract":"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 sustainability. Machined sub-surface quality is influenced by the cutting tool system, cutting conditions and the cutting fluid system. However, past work on the influence of cutting fluid application, especially targeted application of minimal quantity fluid (MQF; varying minimum quantity of coolant and lubricant) which has never been addressed on surface integrity, is limited or non-existent. Thus, an experimental study involving face turning of AISI 1045 steel with flat-faced uncoated carbide tool was conducted with different cutting fluid combinations and at varied locations in the tool–workpiece space. This study is aimed to address machining performance effects (tool–chip contact area, cutting forces, etc.) and machining induced surface integrity (surface roughness and residual stresses). Results showed that the coolant application on the tool flank face improved the surface integrity. In addition, results emphasized the importance of targeted MQF on surface integrity and cutting tool performance, thus providing a cleaner and more efficient machining process.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":0.0,"publicationDate":"2023-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"135498709","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}

{"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":null,"pages":null},"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}

{"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":null,"pages":null},"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}

{"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":null,"pages":null},"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}

{"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":null,"pages":null},"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}