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":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":"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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":null,"pages":null},"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.
{"title":"Correlation between surface integrity characteristics in high-speed grinding of Ti-6Al-4V","authors":"Anirban Naskar, S. Paul","doi":"10.1080/10910344.2023.2224866","DOIUrl":"https://doi.org/10.1080/10910344.2023.2224866","url":null,"abstract":"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.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44293072","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: 10.1080/10910344.2023.2224870
Jianzhi Chen, Yan Wang, Guochao Li, Z. 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 behaviors of grinding cracks were analyzed from the perspectives of element composition, micro-structure and surface work hardening. Based on the experimental results and analysis, the generation mechanism of grinding cracks is clarified, and measures to prevent the grinding cracks are proposed.
{"title":"Investigation on grinding-induced cracking mechanism of 40Cr steel camshaft","authors":"Jianzhi Chen, Yan Wang, Guochao Li, Z. Xu, Han Gao, Xucheng Deng, Shuhao Zhang, Honggen Zhou","doi":"10.1080/10910344.2023.2224870","DOIUrl":"https://doi.org/10.1080/10910344.2023.2224870","url":null,"abstract":"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 behaviors of grinding cracks were analyzed from the perspectives of element composition, micro-structure and surface work hardening. Based on the experimental results and analysis, the generation mechanism of grinding cracks is clarified, and measures to prevent the grinding cracks are proposed.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-05-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49385432","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 : 2023-03-27DOI: 10.1080/10910344.2023.2194961
Israa Dheyaa Khalaf Alrubaye, G. 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 environmental principles. Thus, this article presents an extensive overview of most of the enhancement and eco-friendly technologies for improving the efficiency of the EDM process (material removal rate, lower electrode wear ratio, and surface roughness) and lowering the environmental impacts. These enhancement technologies have been classified into four drivers. The advantages and limitations of each technology have been discussed. Then, the maturity of each technology has been estimated through technology readiness levels. Highlights EDM technology is in its maturity stage. The main research contributions in the last 10 years are on. The highest mature technologies are the cryogenic treatment, hybrid EDUVM, and PMEDM technologies. The CNT powder mixed EDM and the additive manufacturing technologies have been successfully applied in roughing processes and we expect more industrial applications. The high energy consumption with hybrid EDAM technology is nowadays limiting its maturity therefore further research is necessary to come to an industrially viable process.
{"title":"Toward green electrical discharge machining (EDM): state of art and outlook","authors":"Israa Dheyaa Khalaf Alrubaye, G. Fantoni","doi":"10.1080/10910344.2023.2194961","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194961","url":null,"abstract":"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 environmental principles. Thus, this article presents an extensive overview of most of the enhancement and eco-friendly technologies for improving the efficiency of the EDM process (material removal rate, lower electrode wear ratio, and surface roughness) and lowering the environmental impacts. These enhancement technologies have been classified into four drivers. The advantages and limitations of each technology have been discussed. Then, the maturity of each technology has been estimated through technology readiness levels. Highlights EDM technology is in its maturity stage. The main research contributions in the last 10 years are on. The highest mature technologies are the cryogenic treatment, hybrid EDUVM, and PMEDM technologies. The CNT powder mixed EDM and the additive manufacturing technologies have been successfully applied in roughing processes and we expect more industrial applications. The high energy consumption with hybrid EDAM technology is nowadays limiting its maturity therefore further research is necessary to come to an industrially viable process.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41872344","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 : 2023-03-04DOI: 10.1080/10910344.2023.2194968
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 the shearing force of single fiber and temperature. A liquid nitrogen (LN2) inner-cooling machining equipment was employed for cryogenic milling hole testes. Compared with the conventional dry milling hole, the processed composite surface morphologies, cutting temperature, and milling force were investigated at hole outlet in detail. The study results show the predict values of the established model are compared and verified through the experimental measurement. And the cryogenic coolant processes can improve the composite mechanics properties, milling forces, and cutting heat. The composite can be completely chip breaking in cryogenic cooling, and the burr and delamination are effectively inhabited at hole outlet. Meanwhile, the rapid decline of cutting force and lower interlamination bonding force problems can be solved by the cryogenic cooling cutting. And the fiber avoidance can be improved through the increased tangential force, and the fiber can be efficiency chip breaking under the bigger tangential force. In addition, LN2 cooling can inhabit the cutting high temperature and increase the bonding force, the delamination defect of composite can be adequately improved in cryogenic.
{"title":"Inhibition behavior of milling hole outlet defects inhibition on quartz fiber polyimide composite through LN2 inner cooling","authors":"Fengbiao Wang, Mathew Kuttolamadom","doi":"10.1080/10910344.2023.2194968","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194968","url":null,"abstract":"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 the shearing force of single fiber and temperature. A liquid nitrogen (LN2) inner-cooling machining equipment was employed for cryogenic milling hole testes. Compared with the conventional dry milling hole, the processed composite surface morphologies, cutting temperature, and milling force were investigated at hole outlet in detail. The study results show the predict values of the established model are compared and verified through the experimental measurement. And the cryogenic coolant processes can improve the composite mechanics properties, milling forces, and cutting heat. The composite can be completely chip breaking in cryogenic cooling, and the burr and delamination are effectively inhabited at hole outlet. Meanwhile, the rapid decline of cutting force and lower interlamination bonding force problems can be solved by the cryogenic cooling cutting. And the fiber avoidance can be improved through the increased tangential force, and the fiber can be efficiency chip breaking under the bigger tangential force. In addition, LN2 cooling can inhabit the cutting high temperature and increase the bonding force, the delamination defect of composite can be adequately improved in cryogenic.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42727180","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 : 2023-03-04DOI: 10.1080/10910344.2023.2194966
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 in large amounts also causes health issues for the operator. Researchers have developed and implemented sustainable methods like solid lubrication, cryogenic cooling, minimum quantity lubrication (MQL), and heat pipe-assisted cooling processes in the past two decades. The introduction of environmentally friendly machining techniques has considerably improved machinability in recent years. In the presented review, adverse effects of water based cutting fluids and sustainable alternative means to cut down on heat during machining and applying coolants were studied, and their pros and cons are listed. The review focuses on identifying the best available sustainable method that is economic, environmental, and is operator-friendly.
{"title":"A review on sustainable alternatives for conventional cutting fluid applications for improved machinability","authors":"D. J. Hiran Gabriel, M. Parthiban, I. Kantharaj, N. Beemkumar","doi":"10.1080/10910344.2023.2194966","DOIUrl":"https://doi.org/10.1080/10910344.2023.2194966","url":null,"abstract":"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 in large amounts also causes health issues for the operator. Researchers have developed and implemented sustainable methods like solid lubrication, cryogenic cooling, minimum quantity lubrication (MQL), and heat pipe-assisted cooling processes in the past two decades. The introduction of environmentally friendly machining techniques has considerably improved machinability in recent years. In the presented review, adverse effects of water based cutting fluids and sustainable alternative means to cut down on heat during machining and applying coolants were studied, and their pros and cons are listed. The review focuses on identifying the best available sustainable method that is economic, environmental, and is operator-friendly.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":null,"pages":null},"PeriodicalIF":2.7,"publicationDate":"2023-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"49192023","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}
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