Pub Date : 2021-01-01DOI: 10.1051/mfreview/2021017
Eman El Shrief, A. El-Megharbel, Aly El Domiaty, H. Abd El-Hafez
Welded joints are sensitive to fatigue failure due to cyclic loading, as well as fatigue crack propagation influenced by the distribution of welding residual stress. In this study, the fatigue crack propagation rates in butt-welded joints for 304 stainless steel sheets were evaluated in the presence of welding residual stresses. The analysis consisted of two separate models: first, a 3D-finite element (FE) model was used to predict the residual stresses due to welding; second, a numerical study was undertaken to predict fatigue crack propagation in the presence and absence of residual stress using the extended finite element method (XFEM). The crack growth model (NASGRO) and available experimental data were applied to verify the simulation results. The XFEM without residual stress effects shows good agreement with the experimental data and the NASGRO model. However, in the presence of residual stress, the simulation results show less agreement with the NASGRO model. The level and the nature of residual stress have significant effects on crack growth. A faster crack propagation rate is recognized due to the effect of tensile residual stress at the crack tip, while a higher resistance to crack growth is developed due to a compressive residual stress field.
{"title":"Residual stress effects on fatigue crack propagation in Butt–Welded joints for 304 stainless steel sheets","authors":"Eman El Shrief, A. El-Megharbel, Aly El Domiaty, H. Abd El-Hafez","doi":"10.1051/mfreview/2021017","DOIUrl":"https://doi.org/10.1051/mfreview/2021017","url":null,"abstract":"Welded joints are sensitive to fatigue failure due to cyclic loading, as well as fatigue crack propagation influenced by the distribution of welding residual stress. In this study, the fatigue crack propagation rates in butt-welded joints for 304 stainless steel sheets were evaluated in the presence of welding residual stresses. The analysis consisted of two separate models: first, a 3D-finite element (FE) model was used to predict the residual stresses due to welding; second, a numerical study was undertaken to predict fatigue crack propagation in the presence and absence of residual stress using the extended finite element method (XFEM). The crack growth model (NASGRO) and available experimental data were applied to verify the simulation results. The XFEM without residual stress effects shows good agreement with the experimental data and the NASGRO model. However, in the presence of residual stress, the simulation results show less agreement with the NASGRO model. The level and the nature of residual stress have significant effects on crack growth. A faster crack propagation rate is recognized due to the effect of tensile residual stress at the crack tip, while a higher resistance to crack growth is developed due to a compressive residual stress field.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964323","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/mfreview/2021023
O. Ayodele, M. Awotunde, B. J. Babalola, P. Olubambi
The densification process and grain analysis of consolidated NiAl-CNT composites at 1000 °C, and at varied heating rates from 50 °C/min to 150 °C/min was investigated. The results revealed the effect of heating rate on the densification behaviour of the samples. The displacement of the composites decreased from 3.39 mm to 2.63 mm with increasing heating rate, while the porosity increased by 69% at rapid heating rate. The grain analysis of the sintered samples through the electron backscattered (EBSD) technique indicates the evolution of bigger grains as the heating rate proceeds higher. Furthermore, the mean grain size of the consolidated composites increased from 3.93 μm, to 8.05 μm due to the concentration of defects. Interestingly, there was no texture or predominance of any color evolution in the sintered materials.
{"title":"Spark plasma sintering of CNT-NiAl nanocomposites – Process parameter, densification mechanism, and grain analysis","authors":"O. Ayodele, M. Awotunde, B. J. Babalola, P. Olubambi","doi":"10.1051/mfreview/2021023","DOIUrl":"https://doi.org/10.1051/mfreview/2021023","url":null,"abstract":"The densification process and grain analysis of consolidated NiAl-CNT composites at 1000 °C, and at varied heating rates from 50 °C/min to 150 °C/min was investigated. The results revealed the effect of heating rate on the densification behaviour of the samples. The displacement of the composites decreased from 3.39 mm to 2.63 mm with increasing heating rate, while the porosity increased by 69% at rapid heating rate. The grain analysis of the sintered samples through the electron backscattered (EBSD) technique indicates the evolution of bigger grains as the heating rate proceeds higher. Furthermore, the mean grain size of the consolidated composites increased from 3.93 μm, to 8.05 μm due to the concentration of defects. Interestingly, there was no texture or predominance of any color evolution in the sintered materials.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964449","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/mfreview/2021026
Haishang Wu
Additive manufacturing (AM) enables cost-effective and efficient production toward sustainability. However, a rigorous evaluation method is required to further investigate the measurement method and efficiency before AM can be well-positioned in sustainable manufacturing and become the industry mainstream. Cost savings play a key role in the manufacturing industry. Compared to conventional manufacturing (CM), the cost of AM is volume-independent. In contrast, CM production requires a certain volume to share the initial tooling costs to achieve cost reduction. This constraint limits CM from service on demand and leaves ambiguity in the threshold setting of that critical batch volume. In addition, the invisibility of AM advantages in cost factors blocks AM technologies from appropriate processes and affects its applications. To address these issues, this paper proposes a business model. The major issues encountered by AM are the scaling, speed, and size of products. The enhancement of cost modeling and addressing speed, scale, and size issues are the novelties of this study and provide a breakthrough in AM issues. Generic equations are derived using the convergence effect and cost–volume intersection calculation between AM and CM. Furthermore, the divide-and-conquer approach is proposed to support scaling factors and dependencies for both AM and CM. Consequently, appropriate AM technologies can be compared with the CM convergence threshold to contribute to decision-making. Next, the advantages and weaknesses of AM are identified, and a collaboration pattern is proposed to connect large enterprises, small-and medium-sized enterprises, and home-based manufacturers into an AM society. Through this society, the advantages of AM can be fully exploited, scaling and speed issues can be addressed, and AM's dominant role in sustainable manufacturing can be made feasible.
{"title":"Business model and methods of evaluation in sustainable manufacturing","authors":"Haishang Wu","doi":"10.1051/mfreview/2021026","DOIUrl":"https://doi.org/10.1051/mfreview/2021026","url":null,"abstract":"Additive manufacturing (AM) enables cost-effective and efficient production toward sustainability. However, a rigorous evaluation method is required to further investigate the measurement method and efficiency before AM can be well-positioned in sustainable manufacturing and become the industry mainstream. Cost savings play a key role in the manufacturing industry. Compared to conventional manufacturing (CM), the cost of AM is volume-independent. In contrast, CM production requires a certain volume to share the initial tooling costs to achieve cost reduction. This constraint limits CM from service on demand and leaves ambiguity in the threshold setting of that critical batch volume. In addition, the invisibility of AM advantages in cost factors blocks AM technologies from appropriate processes and affects its applications. To address these issues, this paper proposes a business model. The major issues encountered by AM are the scaling, speed, and size of products. The enhancement of cost modeling and addressing speed, scale, and size issues are the novelties of this study and provide a breakthrough in AM issues. Generic equations are derived using the convergence effect and cost–volume intersection calculation between AM and CM. Furthermore, the divide-and-conquer approach is proposed to support scaling factors and dependencies for both AM and CM. Consequently, appropriate AM technologies can be compared with the CM convergence threshold to contribute to decision-making. Next, the advantages and weaknesses of AM are identified, and a collaboration pattern is proposed to connect large enterprises, small-and medium-sized enterprises, and home-based manufacturers into an AM society. Through this society, the advantages of AM can be fully exploited, scaling and speed issues can be addressed, and AM's dominant role in sustainable manufacturing can be made feasible.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964515","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/MFREVIEW/2021008
V. Popov, F. Maccari, I. Radulov, A. Kovalevsky, A. Katz-Demyanetz, M. Bamberger
Bulk Mn52Al46C2 in τ-phase was prepared by vacuum induction melting and used as precursor for the production bulk permanent magnets by suction casting and hot-extrusion. Part of the precursor alloy was mechanically milled into a τ-phase powder and used as precursor for production of samples by electron beam melting, hot-compaction and high pressure torsion processes. The microstructure and magnetic properties of all samples were investigated and correlated. It was found that the mechanical deformation enhances coercivity, up to 0.58 T, while the absence of this strain is beneficial for magnetization. Among the observed techniques, hot extrusion and high pressure torsion have shown promising possibilities to further develop Mn-Al-C as permanent magnets. However, it should be taken into account the challenges related to design a proper processing window for hot extrusion and the limitation of HPT regarding the absence of texture.
{"title":"Microstructure and magnetic properties of Mn-Al-C permanent magnets produced by various techniques","authors":"V. Popov, F. Maccari, I. Radulov, A. Kovalevsky, A. Katz-Demyanetz, M. Bamberger","doi":"10.1051/MFREVIEW/2021008","DOIUrl":"https://doi.org/10.1051/MFREVIEW/2021008","url":null,"abstract":"Bulk Mn52Al46C2 in τ-phase was prepared by vacuum induction melting and used as precursor for the production bulk permanent magnets by suction casting and hot-extrusion. Part of the precursor alloy was mechanically milled into a τ-phase powder and used as precursor for production of samples by electron beam melting, hot-compaction and high pressure torsion processes. The microstructure and magnetic properties of all samples were investigated and correlated. It was found that the mechanical deformation enhances coercivity, up to 0.58 T, while the absence of this strain is beneficial for magnetization. Among the observed techniques, hot extrusion and high pressure torsion have shown promising possibilities to further develop Mn-Al-C as permanent magnets. However, it should be taken into account the challenges related to design a proper processing window for hot extrusion and the limitation of HPT regarding the absence of texture.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964599","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/MFREVIEW/2021014
I. Nayak, J. Rana
Wire electrical discharge machining (WEDM) is a popular non-conventional machining process used particularly for making extrusion dies, blanking punches, and tools especially requiring tight dimensional tolerances. Because of the process limitation, the rate of cutting and maintenance of close dimensional tolerance is a challenging task. Given the above facts, the present work has been focused on achieving the maximum possible cutting rate (VC) maintaining good dimensional accuracy and corner radius (RC). In the present research work, a multi-response optimization method (i.e. Taguchi based Utility approach) has been used to obtain an optimum set of input parameters such as pulse on time (TON), pulse off time (TOFF), servo voltage (SV), and wire feed rate (WF) resulting into a best overall cutting performance. Analysis of variance (ANOVA) is also used to find out the significant effect of each machining parameter on the cutting performance. The analysis reported in this paper will be helpful for industry personnel to select the best set of process parameters for achieving a good result without the use of any software or statistical analysis.
{"title":"Multi-response optimization in wire electrical discharge machining (WEDM) of D2 steel using utility approach","authors":"I. Nayak, J. Rana","doi":"10.1051/MFREVIEW/2021014","DOIUrl":"https://doi.org/10.1051/MFREVIEW/2021014","url":null,"abstract":"Wire electrical discharge machining (WEDM) is a popular non-conventional machining process used particularly for making extrusion dies, blanking punches, and tools especially requiring tight dimensional tolerances. Because of the process limitation, the rate of cutting and maintenance of close dimensional tolerance is a challenging task. Given the above facts, the present work has been focused on achieving the maximum possible cutting rate (VC) maintaining good dimensional accuracy and corner radius (RC). In the present research work, a multi-response optimization method (i.e. Taguchi based Utility approach) has been used to obtain an optimum set of input parameters such as pulse on time (TON), pulse off time (TOFF), servo voltage (SV), and wire feed rate (WF) resulting into a best overall cutting performance. Analysis of variance (ANOVA) is also used to find out the significant effect of each machining parameter on the cutting performance. The analysis reported in this paper will be helpful for industry personnel to select the best set of process parameters for achieving a good result without the use of any software or statistical analysis.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964285","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/MFREVIEW/2021006
A. M. Okoro, S. Lephuthing, S. R. Oke, P. Olubambi
In this study, nickel aluminium bronze alloys (NAB) with appreciable densification and improved microhardness was consolidated via spark plasma sintering technique. The NAB alloy was synthesized from starting elemental powders comprised nickel (4 wt.%), aluminium (6, 8 & 10 wt.%) and copper using dry milling technique. Starting powders were homogeneously milled using gentle ball mill for 8 h at a speed of 150 rpm and a BPR of 10:1. Subsequently, the milled powders were consolidated using the spark plasma sintering technique at 750 °C under a compressive pressure of 50 MPa and rate of heating (100 °C/min). Furthermore, the powders and sintered alloys were characterized using SEM and XRD to ascertain the microstructural and phase evolutions during the synthesis of the NAB. The density and microhardness of the alloys were further investigated to ascertain the integrity of the sintered alloys. The results indicated that the increase in aluminium content resulted in the formation of intermetallic and beta phases on the alloy after sintering and the microhardness of the alloys improved with the increase in aluminium content.
{"title":"Influence of aluminium content on the microstructure and densification of spark plasma sintered nickel aluminium bronze","authors":"A. M. Okoro, S. Lephuthing, S. R. Oke, P. Olubambi","doi":"10.1051/MFREVIEW/2021006","DOIUrl":"https://doi.org/10.1051/MFREVIEW/2021006","url":null,"abstract":"In this study, nickel aluminium bronze alloys (NAB) with appreciable densification and improved microhardness was consolidated via spark plasma sintering technique. The NAB alloy was synthesized from starting elemental powders comprised nickel (4 wt.%), aluminium (6, 8 & 10 wt.%) and copper using dry milling technique. Starting powders were homogeneously milled using gentle ball mill for 8 h at a speed of 150 rpm and a BPR of 10:1. Subsequently, the milled powders were consolidated using the spark plasma sintering technique at 750 °C under a compressive pressure of 50 MPa and rate of heating (100 °C/min). Furthermore, the powders and sintered alloys were characterized using SEM and XRD to ascertain the microstructural and phase evolutions during the synthesis of the NAB. The density and microhardness of the alloys were further investigated to ascertain the integrity of the sintered alloys. The results indicated that the increase in aluminium content resulted in the formation of intermetallic and beta phases on the alloy after sintering and the microhardness of the alloys improved with the increase in aluminium content.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964544","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/mfreview/2021015
G. Bolar, S. N. Joshi
The selection of optimal process parameters is essential while machining thin-wall parts since it influences the quality of the product and affects productivity. Dimensional accuracy affects the product quality, whereas the material removal rate alters the process productivity. Therefore, the study investigated the effect of tool diameter, feed per tooth, axial and radial depth of cut on wall deflection, and material removal rate. The selected process parameters were found to significantly influence the in-process deflection and thickness deviation due to the generation of unfavorable cutting forces. Further, an increase in the material removal rate resulted in chatter, thus adversely affecting the surface quality during the final stages of machining. Considering the conflicting nature of the two performance measures, Non-dominated Sorting Genetic Algorithm-II was adopted to solve the multi-objective optimization problem. The developed model could predict the optimal combination of process variables needed to lower the in-process wall deflection and maintain a superior surface finish while maintaining a steady material removal rate.
{"title":"Experimental investigation and optimization of wall deflection and material removal rate in milling thin-wall parts","authors":"G. Bolar, S. N. Joshi","doi":"10.1051/mfreview/2021015","DOIUrl":"https://doi.org/10.1051/mfreview/2021015","url":null,"abstract":"The selection of optimal process parameters is essential while machining thin-wall parts since it influences the quality of the product and affects productivity. Dimensional accuracy affects the product quality, whereas the material removal rate alters the process productivity. Therefore, the study investigated the effect of tool diameter, feed per tooth, axial and radial depth of cut on wall deflection, and material removal rate. The selected process parameters were found to significantly influence the in-process deflection and thickness deviation due to the generation of unfavorable cutting forces. Further, an increase in the material removal rate resulted in chatter, thus adversely affecting the surface quality during the final stages of machining. Considering the conflicting nature of the two performance measures, Non-dominated Sorting Genetic Algorithm-II was adopted to solve the multi-objective optimization problem. The developed model could predict the optimal combination of process variables needed to lower the in-process wall deflection and maintain a superior surface finish while maintaining a steady material removal rate.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964300","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/mfreview/2021018
Guowei Li, Y. Wang, X. Xu
The electric field distortion caused by the high voltage current environment in the cable terminal will greatly increase the failure probability and reduce the operation safety; therefore, it is necessary to ensure the uniform distribution of the electric field in the terminal. This paper briefly introduced the high-voltage cable terminal and non-linear materials. The traditional silicone rubber and the silicone rubber added with nano-SiO2 were prepared. The electrical conductivity of the two silicone rubbers was tested, and the electric field of the cable terminal was simulated. The results demonstrated that the nano-SiO2 improved silicone rubber had a higher non-linear conductivity and was less affected by temperature. The calculation results of the simulation model also showed that the distribution of the internal field strength was more uniform, and the maximum field strength on the reinforced insulation was smaller after the improved silicone rubber was used as the reinforced insulation.
{"title":"Research on the electric field intensity distribution of high-voltage cable terminal improved by non-linear material","authors":"Guowei Li, Y. Wang, X. Xu","doi":"10.1051/mfreview/2021018","DOIUrl":"https://doi.org/10.1051/mfreview/2021018","url":null,"abstract":"The electric field distortion caused by the high voltage current environment in the cable terminal will greatly increase the failure probability and reduce the operation safety; therefore, it is necessary to ensure the uniform distribution of the electric field in the terminal. This paper briefly introduced the high-voltage cable terminal and non-linear materials. The traditional silicone rubber and the silicone rubber added with nano-SiO2 were prepared. The electrical conductivity of the two silicone rubbers was tested, and the electric field of the cable terminal was simulated. The results demonstrated that the nano-SiO2 improved silicone rubber had a higher non-linear conductivity and was less affected by temperature. The calculation results of the simulation model also showed that the distribution of the internal field strength was more uniform, and the maximum field strength on the reinforced insulation was smaller after the improved silicone rubber was used as the reinforced insulation.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964371","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/mfreview/2021022
A. Mathivanan, M. P. Sudeshkumar, R. Ramadoss, C. Ezilarasan, G. Raju, V. Jayaseelan
To-date, the usage of finite element analysis (FEA) in the area of machining operations has demonstrated to be efficient to investigate the machining processes. The simulated results have been used by tool makers and researchers to optimize the process parameters. As a 3D simulation normally would require more computational time, 2D simulations have been popular choices. In the present article, a Finite Element Model (FEM) using DEFORM 3D is presented, which was used to predict the cutting force, temperature at the insert edge, effective stress during turning of AISI 304 stainless steel. The simulated results were compared with the experimental results. The shear friction factor of 0.6 was found to be best, with strong agreement between the simulated and experimental values. As the cutting speed increased from 125 m/min to 200 m/min, a maximum value of 750 MPa stress as well as a temperature generation of 650 °C at the insert edge have been observed at rather higher feed rate and perhaps a mid level of depth of cut. Furthermore, the Response Surface Methodology (RSM) model is developed to predict the cutting force and temperature at the insert edge.
{"title":"Finite element simulation and regression modeling of machining attributes on turning AISI 304 stainless steel","authors":"A. Mathivanan, M. P. Sudeshkumar, R. Ramadoss, C. Ezilarasan, G. Raju, V. Jayaseelan","doi":"10.1051/mfreview/2021022","DOIUrl":"https://doi.org/10.1051/mfreview/2021022","url":null,"abstract":"To-date, the usage of finite element analysis (FEA) in the area of machining operations has demonstrated to be efficient to investigate the machining processes. The simulated results have been used by tool makers and researchers to optimize the process parameters. As a 3D simulation normally would require more computational time, 2D simulations have been popular choices. In the present article, a Finite Element Model (FEM) using DEFORM 3D is presented, which was used to predict the cutting force, temperature at the insert edge, effective stress during turning of AISI 304 stainless steel. The simulated results were compared with the experimental results. The shear friction factor of 0.6 was found to be best, with strong agreement between the simulated and experimental values. As the cutting speed increased from 125 m/min to 200 m/min, a maximum value of 750 MPa stress as well as a temperature generation of 650 °C at the insert edge have been observed at rather higher feed rate and perhaps a mid level of depth of cut. Furthermore, the Response Surface Methodology (RSM) model is developed to predict the cutting force and temperature at the insert edge.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964440","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2021-01-01DOI: 10.1051/MFREVIEW/2020039
C. Ezilarasan, M. Nagaraj, A. J. P. Kumar, A. Velayudham, Rishab Betala
Nimonic C263 is a super alloy and it is difficult to cut. As this alloy possess high proportion of chromium, cobalt, and molybdenum, which fortify the material by solution hardening, which inhibits the dislocation movement, resulting in higher plastic deformation. In this research, an attempt has been made to model, analysis and investigate the machining characteristics such as thrust force, temperature at drill cutting edge, flank wear and surface finish during drilling of this alloy using silver nano fluid mixed Minimum Quantity Lubrication (MQL) environment. Residual stress at various combinations of process parameters was also observed and discussed. RSM based empirical models of the process parameters and optimization of multi response was developed. Thrust force, Temperature at drill cutting edge, surface roughness and tool wear affected by feed rate (percentage of contribution-60%), spindle speed (percentage of contribution-88.63%), spindle speed (percentage of contribution-71.42%) and feed rate (percentage of contribution-67.76%) respectively followed by other parameters.
{"title":"Experimental analysis of process parameters in drilling nimonic C263 alloy under nano fluid mixed MQL environment","authors":"C. Ezilarasan, M. Nagaraj, A. J. P. Kumar, A. Velayudham, Rishab Betala","doi":"10.1051/MFREVIEW/2020039","DOIUrl":"https://doi.org/10.1051/MFREVIEW/2020039","url":null,"abstract":"Nimonic C263 is a super alloy and it is difficult to cut. As this alloy possess high proportion of chromium, cobalt, and molybdenum, which fortify the material by solution hardening, which inhibits the dislocation movement, resulting in higher plastic deformation. In this research, an attempt has been made to model, analysis and investigate the machining characteristics such as thrust force, temperature at drill cutting edge, flank wear and surface finish during drilling of this alloy using silver nano fluid mixed Minimum Quantity Lubrication (MQL) environment. Residual stress at various combinations of process parameters was also observed and discussed. RSM based empirical models of the process parameters and optimization of multi response was developed. Thrust force, Temperature at drill cutting edge, surface roughness and tool wear affected by feed rate (percentage of contribution-60%), spindle speed (percentage of contribution-88.63%), spindle speed (percentage of contribution-71.42%) and feed rate (percentage of contribution-67.76%) respectively followed by other parameters.","PeriodicalId":51873,"journal":{"name":"Manufacturing Review","volume":null,"pages":null},"PeriodicalIF":2.5,"publicationDate":"2021-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"57964078","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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