Review
Engineering, Chemical
Rui Wang, Dayong Yang, Wei Wang, Furui Wei, Yuwei Lu, Yuqi Li
Summary: Nickel-based superalloys are widely used in aerospace, petrochemical, and marine fields due to their excellent oxidation resistance, corrosion resistance, stability, and reliability at various temperatures. However, during the cutting process, the interaction between the tool and the workpiece generates a large amount of cutting heat. The low thermal conductivity of the workpiece causes the cutting heat to accumulate at the contact point, resulting in severe tool wear, reduced tool life, and increased production cost. This paper discusses the tool wear mechanisms in the machining process of nickel-based superalloys and summarizes the research status of failure mechanisms and tool wear optimization. It highlights the importance of controlling heat and improving the tool environment to prolong the service life of tools. The development prospects of tool wear prevention measures in the field of nickel-based alloy machining are also described.
Article
Engineering, Mechanical
Vipul Agrawal, Kishor Kumar Gajrani, Rakesh G. Mote, Harish C. Barshilia, Suhas S. Joshi
Summary: This study presents a theoretical model to predict tool wear in drilling as a function of time and evaluates the tool life of different coated drills. The experimental results show that the coated drills have longer tool life compared to uncoated drills, and the corner of the drill has the highest wear-rate.
JOURNAL OF TRIBOLOGY-TRANSACTIONS OF THE ASME
(2022)
Article
Automation & Control Systems
Xiaofan Ma, Bin Yao, Zhiqin Cai, Zhengminqing Li
Summary: Previous models for predicting the surface topography of internal splines did not consider the correlation between tool and workpiece geometry and cutter edge wear. This study establishes a model for tooth topography of internal splines by considering the relationship between tool and workpiece geometry. A gear shaper wear model is also developed based on cutter edge wear and chip thickness accumulation. The validity of the model is confirmed through an internal spline shaping experiment, and a shaping process optimization algorithm is proposed to improve tooth topography and surface roughness.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
F. J. Amigo, G. Urbikain, L. N. Lopez de Lacalle, O. Pereira, P. Fernandez-Lucio, A. Fernandez-Valdivielso
Summary: The hottest parts of aerospace components often require machining of heat-resistant materials. New high-feed machining strategies have been introduced to improve productivity rates, but tracking tool wear is crucial for timely replacement. High pressure cooling and cryogenic techniques are used to assist the machining of aggressive materials while reducing environmental impact. This study presents a prediction cutting model for high feed turning of Nimonic (c) C-263 superalloy, considering tool wear and the benefits of reducing side cutting edge angle. The wear prediction model shows good agreement with experimental results and reveals the significant increase in tool life achieved by reducing the side cutting edge angle.
Article
Engineering, Mechanical
Xiang Li, Guangming Zheng, Jiwang Yan, Xiang Cheng, Yang Li, Enzhao Cui
Summary: In this work, the possibility of improving the machinability of cobalt-based superalloy GH605 by optimizing the LN2 injection temperature is demonstrated. It is found that reducing the LN2 injection temperature can delay tool wear, decrease surface roughness, enhance surface hardness and reduce residual stress. The results suggest that LN2 clean cutting using AlTiN coated tools is a promising method for improving the machining of cobalt-based superalloy.
Article
Engineering, Aerospace
Dehua Li, Yingguang Li, Changqing Liu
Summary: The condition of cutting tools directly affects machining quality and efficiency. This paper proposes a method for predicting the remaining useful life of cutting tools in variable cutting conditions based on the Gaussian process regression model and tool wear mechanism. By constraining the predicted values at adjacent moments to a linear relationship using the covariance matrix of the Gaussian model, it can model the wear process under continuous changing conditions. Furthermore, the prediction accuracy is improved by enhancing the input feature space and the model's output.
CHINESE JOURNAL OF AERONAUTICS
(2022)
Article
Engineering, Mechanical
Onur Ozbek
Summary: This article focuses on the use of different coolant/lubricant methods to work with the difficult superalloy Udimet 720. The study involves delivering Graphene and Multi-Walled Carbon Nanotubes nanopowders dispersed in vegetable oil to the cutting area using the minimum quantity lubrication (MQL) method. Experiments were conducted in different cutting environments with varied cutting speeds and feed rates. Compared to dry turning, the MQL method resulted in a decrease in cutting zone temperature, formation of an oil film through better penetration of the cutting tool-chip interface, and reduced cutting tool wear. As a result, the study found improvements of 30% in cutting zone temperature, 51.8% in tool wear, and 43.9% in surface roughness.
Article
Materials Science, Multidisciplinary
Mike Olsson, Volodymyr Bushlya, Filip Lenrick, Jan-Eric Stahl
Summary: Tungsten is commonly used in various industries, including nuclear and research facilities, due to its unique properties. However, its poor machinability and brittleness present challenges for tooling solutions. In this study, various tool materials were tested for turning high purity tungsten, with only PCD and PVD coated cemented carbide showing sufficient performance. Wear mechanisms were analyzed, revealing abrasion, oxidation, and cracking for carbide tools, while PCD tools showed mainly abrasion and diffusional dissolution. Surface quality issues were attributed to factors such as cracking, porosity, and adhesion.
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS
(2021)
Article
Materials Science, Ceramics
Shuai Yan, Chibin Wei, Hongbo Zou, Jingyue Chen, Yining Li, Tong Shen, Anying Wang, Tianyi Sui, Bin Lin
Summary: Ceramics are widely used in tribology due to their superior properties, and surface texture machining using a nanosecond laser can improve their tribological performance. The study on dimples processed on different ceramic surfaces shows that the wear volume of ceramic balls can be significantly reduced by the existence of surface texture.
CERAMICS INTERNATIONAL
(2021)
Review
Engineering, Industrial
Alisson R. Machado, Leonardo R. R. da Silva, Felipe C. R. de Souza, Rahul Davis, Leandro C. Pereira, Wisley F. Sales, Wagner de Rossi, Emmanuel O. Ezugwu
Summary: This paper reviews recent research on the application of surface texturing in machining processes, highlighting the influencing parameters and common implementation methods to guide future related studies.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Engineering, Manufacturing
Bibeye Jahaziel Ronadson, Krishnaraj Vijayan, Sudhagar Sanmugam, Geetha Priyadarshini Badhirappan
Summary: This research compared different surface modification techniques on cutting tools and found that TiN-WS2 coated textured tool (T4) showed the best performance in dry machining of Ti-6Al-4V, reducing cutting force by 14% and increasing shear angle by 7.5% while decreasing coefficient of friction by 47%. The tool life of T4 tool was also improved by 43%. TiN-WS2 coatings, with its lubricity properties, nullified the effect of coating affinity and resulted in better machining characteristics when combined with surface textures.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Review
Materials Science, Multidisciplinary
Moganapriya Chinnasamy, Rajasekar Rathanasamy, Samir Kumar Pal, Sathish Kumar Palaniappan
Summary: Tool life is a crucial parameter in sustainable manufacturing, and extending the life of cutting tools is essential for reducing manufacturing costs. Cryogenic treatment, a sub-zero heat treatment, is an environmentally sustainable alternative that can enhance tool life and improve product quality through microstructure improvements.
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS
(2022)
Article
Automation & Control Systems
Sefika Kasman, Ibrahim Can Ucar, Sertan Ozan
Summary: The surface of the commercial CoCr28Mo alloy was textured using a 20W pulsed fiber laser with different beam scan strategies, resulting in a chaotic texture formation. The surface roughness ranged from 1 to 7 μm, while the surface topography significantly affected the wettability. The optimal parameters for the laser engraving process were determined using the Taguchi method.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Mechanical
Demofilo Maldonado-Cortes, Laura Pena-Paras, Natalia Rodriguez Martinez, Marcelo Posada Leal, Daniel Ivan Quintanilla Correa
Summary: Various techniques, including coatings, heat treatments, lubricants, additives, and laser surface texturing (LST), have been used to enhance the tribological properties of surfaces in contact and relative movement. Among different geometries studied for LST, circles, triangles, and lines have shown the most promising results in reducing coefficient of friction (COF) and wear. The study also compared the performance of different geometries under varying pressures, with circles showing the best performance at low pressures and S shape geometry showing the best performance at high pressures.
Article
Engineering, Mechanical
M. Conradi, A. Kocijan, D. Klobcar, B. Podgornik
Summary: The study found that under different sliding conditions, dimples defined by nanosecond laser exhibited the lowest steady-state coefficient of friction, while in Hank's solution, lines and crosshatching showed better frictional characteristics after running-in and the removal of bulges around the laser textures. In terms of wear resistance, low-density lines pattern and particularly dimples were the most promising in contact situations likely to occur during starved/dry-lubrication conditions.
TRIBOLOGY INTERNATIONAL
(2021)
Article
Engineering, Mechanical
A. Ajithram, J. T. Winowlin Jappes, I Siva, N. C. Brintha
Summary: This research focused on evaluating the mechanical strength, absorption, characterization, thermal degradation, and stability of aquatic wastewater hyacinth plant long fiber reinforced with epoxy polymer composite. The study demonstrated the conversion of biological waste into a zero waste and useful product concept by using a new mechanical extraction method. The hyacinth long fiber composite showed high mechanical strength, absorption properties, and is recommended for profit-oriented products.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2022)
Article
Materials Science, Textiles
Ajithram Arivendan, Winowlin Jappes, Siva Irulapasamy, Adamkhan, Brintha Chrish
Summary: The utilization of fibers from aquatic natural plants, specifically water hyacinth, is explored in this paper. The study focuses on the applications of water hyacinth plant powder, ash, and fibers as reinforcement in composite materials. The results show that these materials have good mechanical properties and can be used as a lightweight alternative for bio-composites or fiber-reinforced polymer composites in various commercial applications.
JOURNAL OF NATURAL FIBERS
(2022)
Article
Engineering, Multidisciplinary
J. T. Winowlin Jappes, N. C. Brintha, M. Adam Khan
Summary: This study found that the use of a mechanical deflector during coating can enhance the mechanical properties of Electroless Ni-P deposits, resulting in improved crystallinity and conversion into phosphides.
JOURNAL OF ENGINEERING RESEARCH
(2022)
Article
Energy & Fuels
Sudhakar Uppalapati, Stanly Premila Jani, Mahaboob Basha Adam Khan, Manjunathan Alagarsamy, Mathankumar Manoharan, Hitesh Panchal, Kishor Kumar Sadasivuni
Summary: This study focuses on the challenges posed by energy crisis and climate change in biodiesel production. By analyzing the life cycle balance of biodiesel produced from different feedstock sources, it is found that biodiesel produced from Jatropha and Calophyllum inophyllum feedstocks are viable options that can overcome greenhouse gas emissions challenges without compromising energy balance.
ENERGY SOURCES PART A-RECOVERY UTILIZATION AND ENVIRONMENTAL EFFECTS
(2022)
Article
Polymer Science
S. P. Jani, A. Sujin Jose, C. Rajaganapathy, M. Adam Khan
Summary: This study explores the possibility of using natural fillers in fiber-reinforced polymer (FRP) systems and finds that coconut shell fillers can be used as reliable structural materials in FRPs. The inclusion of coconut fillers improves the flexural stiffness and toughness of FRP without compromising its performance.
IRANIAN POLYMER JOURNAL
(2022)
Article
Materials Science, Multidisciplinary
S. Vignesh, J. T. Winowlin Jappes, S. Nagaveena, R. Krishna Sharma, M. Adam Khan, Chaitali V. More
Summary: This article focuses on the preparation of novel in-situ layered polymer composites for irradiation shielding applications. The distinct layers of B4C and PbO were formed in the epoxy matrix, creating a continuous interface. XRD and FTIR tests confirmed the presence of particle reinforcements and chemical stability in the prepared samples. The results of gamma irradiation shielding studies indicated that the composite material exhibited superior efficiency in shielding gamma irradiation at lower energy doses.
Article
Engineering, Manufacturing
Roshan Kuruvila, S. Thirumalai Kumaran, M. Uthayakumar, M. Adam Khan, Farooq Ahmed
Summary: This study focuses on coating nichrome on duplex stainless steel using atmospheric plasma spray method (APS) and detonation gun method (DGun) to minimize erosion. The results indicate that the DGun coating outperforms the APS coating in terms of erosion resistance.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Article
Chemistry, Physical
Sujeet Kumar Chaubey, Kapil Gupta
Summary: This paper examines the surface quality of a miniature cylindrical titanium rod/bar (MCTB) after being turned by the wire electrical discharge turning (WEDT) process. The mean roughness depth was used as the key parameter to evaluate the surface quality. Through a Box-Behnken design and grey relational analysis optimization, the optimum combination of WEDT's variable parameters was determined, resulting in a 37% reduction in surface roughness and favorable tribological characteristics. The findings of this study are significant for the micro-turning of difficult-to-machine cylindrical bars.
Article
Chemistry, Analytical
Itemogeng Bernatt Babe, Kapil Gupta, Sujeet Kumar Chaubey
Summary: This paper investigates the turning of stainless steel 316 using microwave-treated cutting tool inserts. The results show that a 20-minute microwave treatment improves the tool hardness and metallurgical characteristics. By varying the cutting speed, feed rate, and depth of cut, the study finds that tool flank wear increases with all three parameters, while surface roughness decreases. The optimal machining parameters determined by the grey relational analysis technique are a cutting speed of 170 m/min, a feed rate of 0.2 mm/rev, and a depth of cut of 1 mm.
Article
Materials Science, Multidisciplinary
Sujeet Kumar Chaubey, Kapil Gupta
Summary: This article presents an experimental study on wire spark erosion turning of Titanium grade 5 miniature cylindrical bars, focusing on roundness deviation and material erosion rate as the main output parameters. Through Grey relational analysis, the optimum process parameters of WSET were determined and the best values of roundness deviation and material erosion rate were obtained. The results show that the work presented in this article is better than previous studies and has further practical application value in the fabrication of miniature products from difficult-to-machine materials like Titanium.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Manufacturing
N. Ganesh Rajkumar, M. Adam Khan, S. Rajesh, J. T. Winowlin Jappes, S. P. Jani
Summary: The aim of this study is to design a new humidifier that meets ISO standards, is compact, cost-effective, and can achieve 99% humidity. By comparing existing samples, conducting CFD analysis, developing a prototype, and establishing testing and validation guidelines, the researchers have identified optimal specifications for the humidification chamber.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Review
Chemistry, Analytical
Pudhupalayam Muthukutti Gopal, Vijayananth Kavimani, Kapil Gupta, Dragan Marinkovic
Summary: Ceramics are widely used in various industries, but conventional processes for fabrication and machining are difficult due to their hardness. Laser-based processes offer high precision, reduced thermal damage, and the ability to work with complex geometries. This paper explores different laser-based ceramic processing techniques and focuses on optimizing process parameters to improve output quality, providing knowledge for researchers in the field.
Article
Engineering, Manufacturing
S. R. Stalin, M. Adam Khan, J. T. Winowlin Jappes, N. C. Brintha
Summary: Micro cutting was performed on a hard nickel alloy using a short-pulsed laser machining process. The quality of the micro profile was studied by varying input process parameters such as laser power, laser scan speed, and laser beam frequency. Scanning electron microscopy was used to measure the dimensional quality of the micro profile. The influence of input process parameters was analyzed using statistical techniques and the optimal process conditions were found using an evolutionary search algorithm.
INTERNATIONAL JOURNAL OF INTERACTIVE DESIGN AND MANUFACTURING - IJIDEM
(2023)
Proceedings Paper
Green & Sustainable Science & Technology
Thobadingoe Craven Phokane, Kapil Gupta
Summary: This paper presents the optimization of wire-EDM parameters using Fuzzy-TOPSIS integrated hybrid multi-criteria decision making technique, aiming to improve gear quality and process productivity simultaneously. After conducting a series of experiments, the optimal combination of voltage, pulse-on time, pulse-off time, and wire feed rate has been identified to achieve the desired outcomes. The results of this study provide practical wire-EDM parameters for manufacturing high-quality gears with good productivity.
SMART TECHNOLOGIES IN URBAN ENGINEERING, STUE-2022
(2023)
Proceedings Paper
Materials Science, Multidisciplinary
M. Adam Khan, J. T. Winowlin Jappes, P. S. Samuel Ratna Kumar, P. M. Mashinini
Summary: In this study, the shape memory alloy was processed using electrical discharge machining, and the material removal rate was evaluated by varying the voltage, pulse off time, and on time. The results showed that the pulse on duration caused spark and diffusion, while variations in pulse off time led to improved conductivity and surface damage.
MATERIALS TODAY-PROCEEDINGS
(2022)
