Pub Date : 2022-01-01DOI: 10.1504/ijmmm.2022.10050995
Rajul Singh, A. Narayan
{"title":"Parametric study of indigenously developed electrochemical diamond cut-off grinding set-up using INCONEL925","authors":"Rajul Singh, A. Narayan","doi":"10.1504/ijmmm.2022.10050995","DOIUrl":"https://doi.org/10.1504/ijmmm.2022.10050995","url":null,"abstract":"","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":"1 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"66739364","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 : 2022-01-01DOI: 10.1504/ijmmm.2022.10044696
Ravi Kumar Panthangi, B. R. Kumar, M. Reddy, G. K. Rao, M. V. Ramana
{"title":"Optimization and impact of process parameters on tool-chip interaction while turning of A286 Iron based Nickel super alloy","authors":"Ravi Kumar Panthangi, B. R. Kumar, M. Reddy, G. K. Rao, M. V. Ramana","doi":"10.1504/ijmmm.2022.10044696","DOIUrl":"https://doi.org/10.1504/ijmmm.2022.10044696","url":null,"abstract":"","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":"1 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2022-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"66739474","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 : 2021-09-16DOI: 10.1504/ijmmm.2021.117662
Meinam Annebushan Singh, Koushik Das, D. K. Sarma
Proper identification of the effect of various process parameters in wire-electrical discharge machining process is a very important area that needs a thorough analysis. Also, advancement in techno...
{"title":"Development and experimental validation of numerical formulations of a heuristic model in WEDM of H13 tool steel","authors":"Meinam Annebushan Singh, Koushik Das, D. K. Sarma","doi":"10.1504/ijmmm.2021.117662","DOIUrl":"https://doi.org/10.1504/ijmmm.2021.117662","url":null,"abstract":"Proper identification of the effect of various process parameters in wire-electrical discharge machining process is a very important area that needs a thorough analysis. Also, advancement in techno...","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":" ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2021-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47937185","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 : 2021-09-16DOI: 10.1504/ijmmm.2021.117661
Amrita Maddamasetty, Kamesh Bodduru, R. S. Revuru
Cutting fluids are commonly used for cooling and lubrication in machining but are unsafe to the environment and cause health problems in workers. Though dry machining can be used to eliminate this ...
{"title":"Preparation, characterisation and testing of graphene self-lubricated tungsten carbide tools for sustainable turning","authors":"Amrita Maddamasetty, Kamesh Bodduru, R. S. Revuru","doi":"10.1504/ijmmm.2021.117661","DOIUrl":"https://doi.org/10.1504/ijmmm.2021.117661","url":null,"abstract":"Cutting fluids are commonly used for cooling and lubrication in machining but are unsafe to the environment and cause health problems in workers. Though dry machining can be used to eliminate this ...","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":" ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2021-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45173890","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 : 2021-09-16DOI: 10.1504/ijmmm.2021.117660
A. Okafor, Theodore Obumselu Nwoguh
Inconel 718 use in aerospace and nuclear industries has gained wide interest due to the need to improve its machinability. This paper presents the results of experimental investigation of the effects of face milling methods and cutting speed on machinability of Inconel 718 with carbide inserts under conventional emulsion flood-cooling strategy (CEF-CS) as a benchmark for comparing alternative vegetable-oil-based MQL cooling strategy (VO-MQL-CS). The machinability parameters investigated are cutting force components, tool wear, burr formation, surface roughness, and tool life, under up and down-milling at cutting speeds of 30, 40, and 50 m/min and constant chip load. Lower cutting forces, tool wear, burr formation, surface roughness, and significant improvement in tool life and volume of material removed are achieved in down-milling over up-milling by 1,677%, 2,150% and 1,004% at 30, 40, and 50 m/min respectively. Down-milling at 40 m/min cutting speed under CEF-CS with coated carbide inserts is recommended as benchmark.
{"title":"Effects of cutting speed and milling method on cutting forces, tool wear, tool life, and surface roughness in high-speed shell milling of Inconel 718 with coated carbide insert under emulsion flood cooling strategy","authors":"A. Okafor, Theodore Obumselu Nwoguh","doi":"10.1504/ijmmm.2021.117660","DOIUrl":"https://doi.org/10.1504/ijmmm.2021.117660","url":null,"abstract":"Inconel 718 use in aerospace and nuclear industries has gained wide interest due to the need to improve its machinability. This paper presents the results of experimental investigation of the effects of face milling methods and cutting speed on machinability of Inconel 718 with carbide inserts under conventional emulsion flood-cooling strategy (CEF-CS) as a benchmark for comparing alternative vegetable-oil-based MQL cooling strategy (VO-MQL-CS). The machinability parameters investigated are cutting force components, tool wear, burr formation, surface roughness, and tool life, under up and down-milling at cutting speeds of 30, 40, and 50 m/min and constant chip load. Lower cutting forces, tool wear, burr formation, surface roughness, and significant improvement in tool life and volume of material removed are achieved in down-milling over up-milling by 1,677%, 2,150% and 1,004% at 30, 40, and 50 m/min respectively. Down-milling at 40 m/min cutting speed under CEF-CS with coated carbide inserts is recommended as benchmark.","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":" ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2021-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"47024725","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 : 2021-09-16DOI: 10.1504/ijmmm.2021.10041173
M. Ali, A. Eltawil, H. El-Hofy
Recently, an ultrasonic vibration-assisted technique has been utilised to improve the hole-making process of aerospace materials. However, there was a lack in discussing the effect of applying ultr...
{"title":"Cutting force, torque, and hole quality in vibration-assisted helical milling of AA7075","authors":"M. Ali, A. Eltawil, H. El-Hofy","doi":"10.1504/ijmmm.2021.10041173","DOIUrl":"https://doi.org/10.1504/ijmmm.2021.10041173","url":null,"abstract":"Recently, an ultrasonic vibration-assisted technique has been utilised to improve the hole-making process of aerospace materials. However, there was a lack in discussing the effect of applying ultr...","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":" ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2021-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"45817542","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 : 2021-05-20DOI: 10.1504/IJMMM.2021.10038116
J. L. Ramdatti, A. V. Gohil, V. Jain, K. Dave
The current experimental research is being carried out to investigate the correlation between the process parameter of the electrical discharge machine (EDM) with the composite electrode (Cu-W-Si) produced through the process of powder metallurgy (P/M). The experiments on P20+Ni die steel were planned and performed using the rotatable second-order central composite design (CCD). The mathematical response model was obtained through response surface methodology. MRR, TWR and SR have been studied on the significance of compaction pressure (Cp), peak current (Ip), pulse-on time (Ton) and duty cycle (τ). ANOVA was conducted to investigate the contribution percentage of the parameters. The optimal set of process parameters was obtained using a multi-objective optimisation technique called 'composite desirability'. The predicted results of responses were confirmed with the experimental results. The reasonable agreements between predicted and experimental results of MRR and TWR have been obtained with error lying within 5.19% and −3.33% respectively.
{"title":"Performance evaluation of Cu-W-Si green P/M composite electrode for surface modification of P20+Ni steel using electrical discharge machine","authors":"J. L. Ramdatti, A. V. Gohil, V. Jain, K. Dave","doi":"10.1504/IJMMM.2021.10038116","DOIUrl":"https://doi.org/10.1504/IJMMM.2021.10038116","url":null,"abstract":"The current experimental research is being carried out to investigate the correlation between the process parameter of the electrical discharge machine (EDM) with the composite electrode (Cu-W-Si) produced through the process of powder metallurgy (P/M). The experiments on P20+Ni die steel were planned and performed using the rotatable second-order central composite design (CCD). The mathematical response model was obtained through response surface methodology. MRR, TWR and SR have been studied on the significance of compaction pressure (Cp), peak current (Ip), pulse-on time (Ton) and duty cycle (τ). ANOVA was conducted to investigate the contribution percentage of the parameters. The optimal set of process parameters was obtained using a multi-objective optimisation technique called 'composite desirability'. The predicted results of responses were confirmed with the experimental results. The reasonable agreements between predicted and experimental results of MRR and TWR have been obtained with error lying within 5.19% and −3.33% respectively.","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":" ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2021-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"44919013","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 : 2021-05-20DOI: 10.1504/IJMMM.2021.10038104
K. Chatterjee, Jian Zhang, U. S. Dixit
Surface roughness prediction in a turning process is of paramount importance. However, there is hardly any physics-based model that can predict it accurately. Recently, thanks to advancements in information technology, there are an ample amount of data in the industry. This article proposes a methodology to estimate surface roughness in turning based on industrial big data. An attempt has been made to extract and preserve the concise, useful information to reduce the burden on data storage. The proposed methodology predicts the lower, upper and most likely estimates of the surface roughness. A case study containing 35,000 datasets is simulated using a virtual lathe to demonstrate the efficacy of the methodology. The whole region of data is divided into 81 cells, and model fitting is carried out in each cell. The developed model based on industrial big data provides reasonable prediction of surface roughness.
{"title":"Estimation of surface roughness in a turning operation using industrial big data","authors":"K. Chatterjee, Jian Zhang, U. S. Dixit","doi":"10.1504/IJMMM.2021.10038104","DOIUrl":"https://doi.org/10.1504/IJMMM.2021.10038104","url":null,"abstract":"Surface roughness prediction in a turning process is of paramount importance. However, there is hardly any physics-based model that can predict it accurately. Recently, thanks to advancements in information technology, there are an ample amount of data in the industry. This article proposes a methodology to estimate surface roughness in turning based on industrial big data. An attempt has been made to extract and preserve the concise, useful information to reduce the burden on data storage. The proposed methodology predicts the lower, upper and most likely estimates of the surface roughness. A case study containing 35,000 datasets is simulated using a virtual lathe to demonstrate the efficacy of the methodology. The whole region of data is divided into 81 cells, and model fitting is carried out in each cell. The developed model based on industrial big data provides reasonable prediction of surface roughness.","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":" ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2021-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"48105908","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 : 2021-05-20DOI: 10.1504/IJMMM.2021.10038107
J. Hartig, B. Kirsch, J. Aurich
In general, the performance of cutting tools is determined by its cutting material specification, macrogeometrical shape, cutting edge design and coating. The cutting edge geometry can be considered as one of the most important factors for optimising cutting tools. By using cutting edge preparation, tools can be tailored to the machining task. A homogeneous preparation is either applied to resist high loads in the machining process or to optimise the resulting surface. Inhomogeneous cutting edge preparations can individually be designed to the machining task to match both target criteria simultaneously. In the following article, the cutting edges of tungsten carbide indexable inserts were prepared homogeneously and inhomogeneously. Tool wear and machining results during turning and drilling austempered ductile iron (ADI) 900 were investigated.
{"title":"Machining austempered ductile iron - impact of the cutting edge geometry on tool wear and surface quality","authors":"J. Hartig, B. Kirsch, J. Aurich","doi":"10.1504/IJMMM.2021.10038107","DOIUrl":"https://doi.org/10.1504/IJMMM.2021.10038107","url":null,"abstract":"In general, the performance of cutting tools is determined by its cutting material specification, macrogeometrical shape, cutting edge design and coating. The cutting edge geometry can be considered as one of the most important factors for optimising cutting tools. By using cutting edge preparation, tools can be tailored to the machining task. A homogeneous preparation is either applied to resist high loads in the machining process or to optimise the resulting surface. Inhomogeneous cutting edge preparations can individually be designed to the machining task to match both target criteria simultaneously. In the following article, the cutting edges of tungsten carbide indexable inserts were prepared homogeneously and inhomogeneously. Tool wear and machining results during turning and drilling austempered ductile iron (ADI) 900 were investigated.","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":"1 1","pages":""},"PeriodicalIF":0.0,"publicationDate":"2021-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"41537305","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 : 2021-05-20DOI: 10.1504/IJMMM.2021.10038106
R. N. Marigoudar, P. Shashidhar, Sadashivappa Kanakuppi, B. V. Dharmendra, T. S. Manjunatha
The effect of graphite addition to conventional composites and making it hybrid for better machinability is the motto behind this work. Here, ZA43+SiC mono composite and ZA43+SiC+graphite hybrid composite are machined under dry condition. Machining is executed using commercially available coated carbide SNMG 090308 tool. Cutting variables viz. machining speed, feed rate and depth of machining are varied and for each machining trial fresh cutting edge is used. Tool damage is measured while machining both the categories of materials and are compared. It is noticed that the hybrid composite causes less damage in comparison with mono composite. The reason may be due to powdered graphite present in the composite which is responsible for reduction in the friction. Graphite being solid lubricant prevents tools getting abraded by the hard workpiece and promotes easy machinability. Statistical analysis done on the results gives the details about most influencing variable to the machining process. The tool wear during composite machining is greatly influenced by machining speed and feed. Optimum machining parameters can be drawn considering material composition for less tool wear condition.
{"title":"Study of tool wear characteristics while machining mono and graphite reinforced hybrid zinc - aluminium-based MMCs","authors":"R. N. Marigoudar, P. Shashidhar, Sadashivappa Kanakuppi, B. V. Dharmendra, T. S. Manjunatha","doi":"10.1504/IJMMM.2021.10038106","DOIUrl":"https://doi.org/10.1504/IJMMM.2021.10038106","url":null,"abstract":"The effect of graphite addition to conventional composites and making it hybrid for better machinability is the motto behind this work. Here, ZA43+SiC mono composite and ZA43+SiC+graphite hybrid composite are machined under dry condition. Machining is executed using commercially available coated carbide SNMG 090308 tool. Cutting variables viz. machining speed, feed rate and depth of machining are varied and for each machining trial fresh cutting edge is used. Tool damage is measured while machining both the categories of materials and are compared. It is noticed that the hybrid composite causes less damage in comparison with mono composite. The reason may be due to powdered graphite present in the composite which is responsible for reduction in the friction. Graphite being solid lubricant prevents tools getting abraded by the hard workpiece and promotes easy machinability. Statistical analysis done on the results gives the details about most influencing variable to the machining process. The tool wear during composite machining is greatly influenced by machining speed and feed. Optimum machining parameters can be drawn considering material composition for less tool wear condition.","PeriodicalId":55894,"journal":{"name":"International Journal of Machining and Machinability of Materials","volume":" ","pages":""},"PeriodicalIF":0.0,"publicationDate":"2021-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"46370338","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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