Pub Date : 2021-10-25DOI: 10.1080/10910344.2021.1971708
Houssem Ben Boubaker, K. Djaka, A. Moufki, M. Nouari, P. Laheurte, A. Tidu
Abstract In this work, the effect of the crystallographic anisotropy on machining forces is studied through a thermomechanical approach based on rate sensitive plasticity based model. A crystal plasticity framework is adopted to formulate the required constitutive equations. The present approach takes into account the material thermoviscoplastic response, the shear strain rate distribution in the primary shear zone and their effects on the lattice rotation. The machining forces as well as the corresponding specific energies are calculated using two methods: (a) the total power minimization procedure and (b) the Merchant shear angle procedure. The proposed model is validated using cutting force data available in the literature. Then, it is used to gain insight into the effect of the crystallographic anisotropy on machining forces. According to the results, a strong dependence of the machining forces to the crystallographic orientations is obtained. The model is also used to analyze the of the cutting velocity on the shearing along crystallographic slip systems through the material thermomechanical response. In addition, it is observed that, compared to the total power minimization procedure, the Merchant shear angle procedure allows capturing the specific cutting energy trends due to the crystallographic anisotropy, in terms of peaks and valleys.
{"title":"Thermomechanical modeling of crystallographic anisotropy effect on machining forces based on crystal plasticity framework","authors":"Houssem Ben Boubaker, K. Djaka, A. Moufki, M. Nouari, P. Laheurte, A. Tidu","doi":"10.1080/10910344.2021.1971708","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971708","url":null,"abstract":"Abstract In this work, the effect of the crystallographic anisotropy on machining forces is studied through a thermomechanical approach based on rate sensitive plasticity based model. A crystal plasticity framework is adopted to formulate the required constitutive equations. The present approach takes into account the material thermoviscoplastic response, the shear strain rate distribution in the primary shear zone and their effects on the lattice rotation. The machining forces as well as the corresponding specific energies are calculated using two methods: (a) the total power minimization procedure and (b) the Merchant shear angle procedure. The proposed model is validated using cutting force data available in the literature. Then, it is used to gain insight into the effect of the crystallographic anisotropy on machining forces. According to the results, a strong dependence of the machining forces to the crystallographic orientations is obtained. The model is also used to analyze the of the cutting velocity on the shearing along crystallographic slip systems through the material thermomechanical response. In addition, it is observed that, compared to the total power minimization procedure, the Merchant shear angle procedure allows capturing the specific cutting energy trends due to the crystallographic anisotropy, in terms of peaks and valleys.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"930 - 956"},"PeriodicalIF":2.7,"publicationDate":"2021-10-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42210051","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 : 2021-10-06DOI: 10.1080/10910344.2021.1971710
L. Gopinath, S. Jerome, B. Gopalsamy
Abstract The nominal cutting contour for the thin wall deviates in response to the cutting forces during the end milling process. Elimination of mass in the milling process links to loss of stiffness, which favors the wall to deflect and promote error. This article proposes a novel way of generating rigidity during the process of milling. The tool paths were drafted to mill away mass in the central region and make corrugations at the edges simultaneously. This approach mitigated the thin wall deformation. Comparison experiments were conducted to analyze between open wall conventional type (OWC) and end corrugated pillar type (ECP). Force polygons were constructed to evaluate the effectiveness of machining. The experiments resulted in 36% more effectiveness in up milling and with 93% in down milling. An increase in the cutting effectiveness exhibited error-free and minimized cutting point deviation at the top of the wall. Eventually, the error diminished as the tool traversed to the bottom edge of the wall.
{"title":"Mitigation of cutting point deviation by generating provisional corrugations during milling of thin walls","authors":"L. Gopinath, S. Jerome, B. Gopalsamy","doi":"10.1080/10910344.2021.1971710","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971710","url":null,"abstract":"Abstract The nominal cutting contour for the thin wall deviates in response to the cutting forces during the end milling process. Elimination of mass in the milling process links to loss of stiffness, which favors the wall to deflect and promote error. This article proposes a novel way of generating rigidity during the process of milling. The tool paths were drafted to mill away mass in the central region and make corrugations at the edges simultaneously. This approach mitigated the thin wall deformation. Comparison experiments were conducted to analyze between open wall conventional type (OWC) and end corrugated pillar type (ECP). Force polygons were constructed to evaluate the effectiveness of machining. The experiments resulted in 36% more effectiveness in up milling and with 93% in down milling. An increase in the cutting effectiveness exhibited error-free and minimized cutting point deviation at the top of the wall. Eventually, the error diminished as the tool traversed to the bottom edge of the wall.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"984 - 1009"},"PeriodicalIF":2.7,"publicationDate":"2021-10-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46184117","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 : 2021-09-16DOI: 10.1080/10910344.2021.1971709
M. Javidikia, Morteza Sadeghifar, V. Songmene, M. Jahazi
Abstract The present research study aimed to investigate the influences of turning environments and parameters on machining temperature (MT), machining forces (MFs), and axial surface residual stresses (ASRS) in turning operation of AA6061-T6. Turning environments included DRY, minimum quantity lubrication (MQL), and WET modes, and turning parameters consisted of cutting speed ( ), feed rate ( ), depth of cut ( ), tool nose radius ( ), side cutting edge angle (SCEA), and back rake angle (BRA). A 3D finite element (FE) model was developed to predict MT, MFs, and ASRS for different turning environments and parameters and was validated by experimental measurements. The results showed that increasing feed rate led to a higher tensile ASRS while using tools with a nose radius of 0.4 resulted in lower ASRS. In addition, the deviation of SCEA from 0° to positive or negative values caused higher tensile ASRS. ASRS increased with decreasing BRA from 0° to –15°. The variation of ASRS was found to be more sensitive to thermal effects than to mechanical ones. The results further confirmed that in a turning process, the competition between the machining forces and temperature was the fundamental factor that determined the extent of residual stresses.
{"title":"3D FE modeling and experimental analysis of residual stresses and machining characteristics induced by dry, MQL, and wet turning of AA6061-T6","authors":"M. Javidikia, Morteza Sadeghifar, V. Songmene, M. Jahazi","doi":"10.1080/10910344.2021.1971709","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971709","url":null,"abstract":"Abstract The present research study aimed to investigate the influences of turning environments and parameters on machining temperature (MT), machining forces (MFs), and axial surface residual stresses (ASRS) in turning operation of AA6061-T6. Turning environments included DRY, minimum quantity lubrication (MQL), and WET modes, and turning parameters consisted of cutting speed ( ), feed rate ( ), depth of cut ( ), tool nose radius ( ), side cutting edge angle (SCEA), and back rake angle (BRA). A 3D finite element (FE) model was developed to predict MT, MFs, and ASRS for different turning environments and parameters and was validated by experimental measurements. The results showed that increasing feed rate led to a higher tensile ASRS while using tools with a nose radius of 0.4 resulted in lower ASRS. In addition, the deviation of SCEA from 0° to positive or negative values caused higher tensile ASRS. ASRS increased with decreasing BRA from 0° to –15°. The variation of ASRS was found to be more sensitive to thermal effects than to mechanical ones. The results further confirmed that in a turning process, the competition between the machining forces and temperature was the fundamental factor that determined the extent of residual stresses.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"957 - 983"},"PeriodicalIF":2.7,"publicationDate":"2021-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46823030","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 : 2021-09-09DOI: 10.1080/10910344.2021.1971712
Yu Su, W. Gao, Haifeng Jiang, Zhiqiang Liu
Abstract Electrostatic spraying (ES) can improve the machining and environmental effects of minimum quantity lubrication (MQL). Compared with ES, composite electrostatic spraying (CES) presents better results because of excellent charging and cooling/lubrication performances. This article investigated the performance of CES milling using different inner/outer fluid combinations in terms of milling force, tool wear and oil mist concentration. Four inner/outer fluid combinations were employed in the study, namely, water/LB2000, multiwalled carbon nanotubes (MWCNTs)-water nanofluid/LB2000, water/MWCNTs-LB2000 nanofluid and MWCNTs-water nanofluid/MWCNTs-LB2000 nanofluid. For the analysis of the performance of CES milling, the charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. The results show that MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling from the view point of machining and environmental performances because of superior charging property, atomization stability and friction-reducing effect of nanoparticles. Highlights The performance of CES milling using different inner/outer fluid combinations was studied in terms of milling force, tool wear and oil mist concentration. The charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling.
{"title":"Experimental investigation on the performance of composite electrostatic spraying milling using different inner/outer fluid combinations","authors":"Yu Su, W. Gao, Haifeng Jiang, Zhiqiang Liu","doi":"10.1080/10910344.2021.1971712","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971712","url":null,"abstract":"Abstract Electrostatic spraying (ES) can improve the machining and environmental effects of minimum quantity lubrication (MQL). Compared with ES, composite electrostatic spraying (CES) presents better results because of excellent charging and cooling/lubrication performances. This article investigated the performance of CES milling using different inner/outer fluid combinations in terms of milling force, tool wear and oil mist concentration. Four inner/outer fluid combinations were employed in the study, namely, water/LB2000, multiwalled carbon nanotubes (MWCNTs)-water nanofluid/LB2000, water/MWCNTs-LB2000 nanofluid and MWCNTs-water nanofluid/MWCNTs-LB2000 nanofluid. For the analysis of the performance of CES milling, the charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. The results show that MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling from the view point of machining and environmental performances because of superior charging property, atomization stability and friction-reducing effect of nanoparticles. Highlights The performance of CES milling using different inner/outer fluid combinations was studied in terms of milling force, tool wear and oil mist concentration. The charging property and atomization stability of CES and the electrowetting performance of composite droplet were measured. MWCNTs-water nanofluid/LB2000 was the optimal inner/outer fluid combination for CES milling.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"1010 - 1030"},"PeriodicalIF":2.7,"publicationDate":"2021-09-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45186433","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 : 2021-09-07DOI: 10.1080/10910344.2021.1971714
Roan M. Kirwin, M. Jahan
Abstract Wire lag plays a major role in causing inaccuracies in certain geometrical shapes and profiles during machining of complex structures using wire-EDM. While previous studies focused on investigating effects of electrical parameters on machining performance and accuracy during wire EDM, the effects of non-electrical parameters on corner and profile accuracies have not been studied comprehensively. The objective of this study is to investigate effects of non-electrical parameters on the geometric and profile accuracies as well as surface and subsurface characteristics during WEDM of Ti-6Al-4V alloy. A complex part including corners with 45°, 90°, and 112.5° as well as thin wall section for measuring the kerf accuracy was designed. It is found that the profile accuracy improves as the wire tension increases. However, too high wire tension results in curved path in the sharp corners. The effect of wire tension is more pronounced on the workpiece with higher thickness. Too high wire feed rate reduces the accuracy for target angles, especially for lower thickness of workpiece. The kerf width is smaller for thinner workpiece and improves with lower wire feed rate and wire tension. While the wire tension and wire feed rate do not have an impact on surface roughness, higher surface feed rate increases surface roughness. Higher wire tensions lead to higher surface cracking due to more rapid cooling. With increase of surface feed, the percentage of arcing pulses increases due to increased instability, which results in rougher surface and increased percentage of beta phases at the subsurface.
{"title":"Effects of non-electrical parameters on profile accuracies and surface characteristics during wire-EDM of titanium alloy","authors":"Roan M. Kirwin, M. Jahan","doi":"10.1080/10910344.2021.1971714","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971714","url":null,"abstract":"Abstract Wire lag plays a major role in causing inaccuracies in certain geometrical shapes and profiles during machining of complex structures using wire-EDM. While previous studies focused on investigating effects of electrical parameters on machining performance and accuracy during wire EDM, the effects of non-electrical parameters on corner and profile accuracies have not been studied comprehensively. The objective of this study is to investigate effects of non-electrical parameters on the geometric and profile accuracies as well as surface and subsurface characteristics during WEDM of Ti-6Al-4V alloy. A complex part including corners with 45°, 90°, and 112.5° as well as thin wall section for measuring the kerf accuracy was designed. It is found that the profile accuracy improves as the wire tension increases. However, too high wire tension results in curved path in the sharp corners. The effect of wire tension is more pronounced on the workpiece with higher thickness. Too high wire feed rate reduces the accuracy for target angles, especially for lower thickness of workpiece. The kerf width is smaller for thinner workpiece and improves with lower wire feed rate and wire tension. While the wire tension and wire feed rate do not have an impact on surface roughness, higher surface feed rate increases surface roughness. Higher wire tensions lead to higher surface cracking due to more rapid cooling. With increase of surface feed, the percentage of arcing pulses increases due to increased instability, which results in rougher surface and increased percentage of beta phases at the subsurface.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"1031 - 1052"},"PeriodicalIF":2.7,"publicationDate":"2021-09-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45293007","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 : 2021-09-03DOI: 10.1080/10910344.2021.1971704
Tuğçe Tezel
Abstract Fused deposition modeling (FDM) is an additive manufacturing (AM) technique that has emerged as a suitable application in different areas, including machine design and manufacturing. The main advantages of this method over conventional methods include that it is faster and produces less material waste. Besides, AM offers computer-aided design and manufacturing but does not include any limitations on the product's geometry and does not require any extra tools. End milling is a conventional manufacturing process used for profiling, slotting, and facing. In this study, at the point of overcoming the weaknesses of AM surface quality, it was investigated whether the cast polymer's surface quality could be reached with hybrid manufacturing (AM + milling). For this reason, the parts produced by FDM were subjected to end milling, and the effect of cutting depth, feed rate, and rotation speed on surface quality and chip type were investigated. The results obtained are compared with the results of the milling operation of cast polyamide. For all results, surface quality increases with a rising feed rate. In general, the surface quality obtained by milling parts produced using FDM is low, but each manufacturing technique is affected differently by the end milling conditions. Low rotation speed and high feed rates should be preferred to obtain the desired surface quality from FDM printed polyamide parts.
{"title":"The effect of machining parameters on the surface quality of 3D printed and cast polyamide","authors":"Tuğçe Tezel","doi":"10.1080/10910344.2021.1971704","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971704","url":null,"abstract":"Abstract Fused deposition modeling (FDM) is an additive manufacturing (AM) technique that has emerged as a suitable application in different areas, including machine design and manufacturing. The main advantages of this method over conventional methods include that it is faster and produces less material waste. Besides, AM offers computer-aided design and manufacturing but does not include any limitations on the product's geometry and does not require any extra tools. End milling is a conventional manufacturing process used for profiling, slotting, and facing. In this study, at the point of overcoming the weaknesses of AM surface quality, it was investigated whether the cast polymer's surface quality could be reached with hybrid manufacturing (AM + milling). For this reason, the parts produced by FDM were subjected to end milling, and the effect of cutting depth, feed rate, and rotation speed on surface quality and chip type were investigated. The results obtained are compared with the results of the milling operation of cast polyamide. For all results, surface quality increases with a rising feed rate. In general, the surface quality obtained by milling parts produced using FDM is low, but each manufacturing technique is affected differently by the end milling conditions. Low rotation speed and high feed rates should be preferred to obtain the desired surface quality from FDM printed polyamide parts.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"703 - 720"},"PeriodicalIF":2.7,"publicationDate":"2021-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"42463044","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 : 2021-09-03DOI: 10.1080/10910344.2021.1971705
Jing Shu, W. Liao, K. Zheng, Amro M. Fikry Hussein Youssef
Abstract Carbon-carbon composites (C/C composites) is typical high temperature resistant material. Therefore it is applied in solid rocket motor (SRM) throat mostly. Because the throat is mostly single piece and mini-batch, which is not suitable for mold forming. Usually, numerical control machining is still the main method. Due to high strength and heterogeneous composites, the machining damage defects are obvious and quality is poor. Thus, from the perspective of C/C composites ablation resistance, rotary ultrasonic machining technology effect on C/C composites surface defects and damage is investigated. Moreover, the influence of ultrasonic vibration on fiber cutting angle and machined surface morphology is analyzed. Meanwhile, based on comparative experiment, fiber pull-out length and surface porosity are presented as characterization parameters. The results show that ultrasonic vibration not only improves fiber cutting angle effectively, but also reduces pores and cracks on machined surfaces. Moreover, it reduces fiber pull-out length by 10%–50% numerically when along fiber milling. When fiber is perpendicular to the cutting direction, the pull-out length becomes shorter. The above study provides a theoretical basis for subsequent machined damage influence on ablation resistance of C/C throat.
{"title":"Surface morphology on carbon fiber composites by rotary ultrasonic milling","authors":"Jing Shu, W. Liao, K. Zheng, Amro M. Fikry Hussein Youssef","doi":"10.1080/10910344.2021.1971705","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971705","url":null,"abstract":"Abstract Carbon-carbon composites (C/C composites) is typical high temperature resistant material. Therefore it is applied in solid rocket motor (SRM) throat mostly. Because the throat is mostly single piece and mini-batch, which is not suitable for mold forming. Usually, numerical control machining is still the main method. Due to high strength and heterogeneous composites, the machining damage defects are obvious and quality is poor. Thus, from the perspective of C/C composites ablation resistance, rotary ultrasonic machining technology effect on C/C composites surface defects and damage is investigated. Moreover, the influence of ultrasonic vibration on fiber cutting angle and machined surface morphology is analyzed. Meanwhile, based on comparative experiment, fiber pull-out length and surface porosity are presented as characterization parameters. The results show that ultrasonic vibration not only improves fiber cutting angle effectively, but also reduces pores and cracks on machined surfaces. Moreover, it reduces fiber pull-out length by 10%–50% numerically when along fiber milling. When fiber is perpendicular to the cutting direction, the pull-out length becomes shorter. The above study provides a theoretical basis for subsequent machined damage influence on ablation resistance of C/C throat.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"721 - 737"},"PeriodicalIF":2.7,"publicationDate":"2021-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46874245","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 : 2021-09-03DOI: 10.1080/10910344.2021.1971706
Ramazan Hakkı Namlu, B. L. Sadigh, S. E. Kilic
Abstract Ti-6Al-4V is widely used in aerospace, medical and defense industries where materials with superior characteristics are needed. However, Ti-6Al-4V is categorized as a difficult-to-cut material, and machining of this alloy is highly challenging. Ultrasonic Assisted Milling (UAM) is a quite recent method to facilitate the machining of difficult-to-cut materials. This method has numerous advantages over the Conventional Milling (CM) method, such as reduced cutting forces and increased surface quality. Besides, Minimum Quantity Lubrication (MQL) is an alternative cooling method to enhance the process efficiency with respect to conventional cooling methods. Cutting force and surface roughness are essential measures to evaluate the cutting performance of a machining process. However, the simultaneous effects of implementing MQL and ultrasonic vibrations in milling operations are not much researched yet. In this study, the combined effects of UAM and MQL on cutting forces and surface roughness during the machining of Ti-6AL-4V are investigated. Results show that the combination of MQL and UAM enhances the cutting forces in rough cutting operations and the surface roughness in both finish and rough cutting operations significantly compared to conventional processes. Consequently, it is concluded that simultaneous implementation of UAM and MQL enhances overall cutting performance in end-milling operation of Ti-6Al-4V.
{"title":"An experimental investigation on the effects of combined application of ultrasonic assisted milling (UAM) and minimum quantity lubrication (MQL) on cutting forces and surface roughness of Ti-6AL-4V","authors":"Ramazan Hakkı Namlu, B. L. Sadigh, S. E. Kilic","doi":"10.1080/10910344.2021.1971706","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971706","url":null,"abstract":"Abstract Ti-6Al-4V is widely used in aerospace, medical and defense industries where materials with superior characteristics are needed. However, Ti-6Al-4V is categorized as a difficult-to-cut material, and machining of this alloy is highly challenging. Ultrasonic Assisted Milling (UAM) is a quite recent method to facilitate the machining of difficult-to-cut materials. This method has numerous advantages over the Conventional Milling (CM) method, such as reduced cutting forces and increased surface quality. Besides, Minimum Quantity Lubrication (MQL) is an alternative cooling method to enhance the process efficiency with respect to conventional cooling methods. Cutting force and surface roughness are essential measures to evaluate the cutting performance of a machining process. However, the simultaneous effects of implementing MQL and ultrasonic vibrations in milling operations are not much researched yet. In this study, the combined effects of UAM and MQL on cutting forces and surface roughness during the machining of Ti-6AL-4V are investigated. Results show that the combination of MQL and UAM enhances the cutting forces in rough cutting operations and the surface roughness in both finish and rough cutting operations significantly compared to conventional processes. Consequently, it is concluded that simultaneous implementation of UAM and MQL enhances overall cutting performance in end-milling operation of Ti-6Al-4V.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"738 - 775"},"PeriodicalIF":2.7,"publicationDate":"2021-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46653354","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 : 2021-09-03DOI: 10.1080/10910344.2021.1971711
Deepak Sharma, S. Hiremath
Abstract Electric discharge machining (EDM) is a nontraditional machining process based on the thermal erosion of the electrically conductive workpiece and tool electrodes. The product cost manufactured by the EDM process mainly depends on the tooling cost, which comprises the cost of tool material, tool fabrication, and tool maintenance. The properties of tool material affect the machining performance parameters like material removal rate (MRR), tool wear rate (TWR), and surface roughness. The performance parameters are also influenced by the tool geometry, tool fabrication method, and the way by which both tools and workpiece interact with each other. In the EDM process, tool wear is difficult to avoid and high TWR decreases the accuracy of the machined parts. Therefore, to obtain the desired accuracy it is necessary to calculate TWR and provide wear compensation. The tool electrode fabrication method also decides the TWR. Tool electrodes are generally manufactured by metal forming techniques like forging and drawing, other than that, powder metallurgy, additive manufacturing are also being used. The process performance of the tool can be improved by cryogenic treatment and coating of the tool electrodes. This review provides the literature survey about the different types of tools used in the EDM process, methods of fabrication, tool wear types; measurement and compensation techniques.
{"title":"Review on tools and tool wear in EDM","authors":"Deepak Sharma, S. Hiremath","doi":"10.1080/10910344.2021.1971711","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971711","url":null,"abstract":"Abstract Electric discharge machining (EDM) is a nontraditional machining process based on the thermal erosion of the electrically conductive workpiece and tool electrodes. The product cost manufactured by the EDM process mainly depends on the tooling cost, which comprises the cost of tool material, tool fabrication, and tool maintenance. The properties of tool material affect the machining performance parameters like material removal rate (MRR), tool wear rate (TWR), and surface roughness. The performance parameters are also influenced by the tool geometry, tool fabrication method, and the way by which both tools and workpiece interact with each other. In the EDM process, tool wear is difficult to avoid and high TWR decreases the accuracy of the machined parts. Therefore, to obtain the desired accuracy it is necessary to calculate TWR and provide wear compensation. The tool electrode fabrication method also decides the TWR. Tool electrodes are generally manufactured by metal forming techniques like forging and drawing, other than that, powder metallurgy, additive manufacturing are also being used. The process performance of the tool can be improved by cryogenic treatment and coating of the tool electrodes. This review provides the literature survey about the different types of tools used in the EDM process, methods of fabrication, tool wear types; measurement and compensation techniques.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"802 - 873"},"PeriodicalIF":2.7,"publicationDate":"2021-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48914410","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 : 2021-09-03DOI: 10.1080/10910344.2021.1971715
K. Biswas, Shirsendu Das, Swarup Paul, B. Doloi
Abstract The Inconel 718 has captured global attention for its huge applications in the aerospace and defense field. However, a limited approach is noticed to investigate this material's responses and morphological features after electrical discharge machining operation. This study wants to offer a more detailed investigating approach, including the analysis of morphological features, recast layer, microhardness, elemental composition, and several textural defects and basic responses. Scanning electron microscopy is used to investigate several textural features, defects, cracks, and recast layers. The findings claim 538 nm–2.168 µm and 14–41 µm variations in crack width and recast thickness, respectively, which increase with pulse current and pulse on-time. However, the low discharge energy can provide better micro-hardness than higher discharge conditions due to having sufficient time for flushing and heat dissipations. The recast surface and the interfaces are, respectively, 7.58%–13.16% and 22.75%–32.74% harder with low discharge condition than the intermediate and higher discharge condition. Moreover, the Energy Dispersive X-ray analysis reported the emigration of 17.81% of carbon and 0.33% of copper from the dielectric and tool during the machining.
{"title":"A morphological and textural analysis of Inconel-718 aerospace alloy processed through electrical discharging machining","authors":"K. Biswas, Shirsendu Das, Swarup Paul, B. Doloi","doi":"10.1080/10910344.2021.1971715","DOIUrl":"https://doi.org/10.1080/10910344.2021.1971715","url":null,"abstract":"Abstract The Inconel 718 has captured global attention for its huge applications in the aerospace and defense field. However, a limited approach is noticed to investigate this material's responses and morphological features after electrical discharge machining operation. This study wants to offer a more detailed investigating approach, including the analysis of morphological features, recast layer, microhardness, elemental composition, and several textural defects and basic responses. Scanning electron microscopy is used to investigate several textural features, defects, cracks, and recast layers. The findings claim 538 nm–2.168 µm and 14–41 µm variations in crack width and recast thickness, respectively, which increase with pulse current and pulse on-time. However, the low discharge energy can provide better micro-hardness than higher discharge conditions due to having sufficient time for flushing and heat dissipations. The recast surface and the interfaces are, respectively, 7.58%–13.16% and 22.75%–32.74% harder with low discharge condition than the intermediate and higher discharge condition. Moreover, the Energy Dispersive X-ray analysis reported the emigration of 17.81% of carbon and 0.33% of copper from the dielectric and tool during the machining.","PeriodicalId":51109,"journal":{"name":"Machining Science and Technology","volume":"25 1","pages":"776 - 801"},"PeriodicalIF":2.7,"publicationDate":"2021-09-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46445887","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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