Article
Chemistry, Physical
Menderes Kam, Ufuk Kabasakaloglu
Summary: Cylindrical grinding operation is crucial for improving product surface quality, experimental work and statistical analysis contribute to enhancing the product quality of manufactured parts. The study aimed to analyze the surface roughness values of cryogenically treated and tempered steels in cylindrical grinding operation, significant improvements were observed in Ra values of the steels.
SURFACE REVIEW AND LETTERS
(2021)
Article
Engineering, Electrical & Electronic
Viktor Molnar
Summary: 3D surface roughness measurement is less mature than its 2D version, but this study introduces a method to minimize the evaluated surface area, which could help industrial applications in reducing measurement time and cost.
Article
Engineering, Electrical & Electronic
Fabio Isaac Ferreira, Paulo Roberto de Aguiar, Rosemar Batista da Silva, Mark James Jackson, Fabricio Guimaraes Baptista, Eduardo Carlos Bianchi
Summary: This paper introduces the application of electromechanical impedance (EMI) sensors in the metal-cutting industry. By attaching low-cost piezoelectric diaphragms to each workpiece, the correlation between EMI measurements and surface quality can be monitored and verified. The results show a significant correlation between EMI measurement and surface roughness, indicating the promising potential of this monitoring system.
IEEE SENSORS JOURNAL
(2022)
Article
Automation & Control Systems
Zhijian Tao, Shan Li, Lu Zhang, Junde Qi, Dinghua Zhang
Summary: This paper proposes a surface roughness prediction model based on non-deformed chip thickness and generalized regression neural network in robotic belt grinding, which has significant application value.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Chemistry, Physical
Arunachalam S. S. Balan, Kannan Chidambaram, Arun V. Kumar, Hariharan Krishnaswamy, Danil Yurievich Pimenov, Khaled Giasin, Krzysztof Nadolny
Summary: The research investigates the impact of post-processing grinding on surface integrity and fatigue life of additively manufactured materials, finding that cryogenic grinding significantly reduces surface roughness and increases fatigue life by about 170%.
Article
Engineering, Mechanical
Ergun Ekici, Gultekin Uzun
Summary: This study investigated the effects of processing parameters and cryogenic treatment on cutting force and surface roughness in milling of Ti6AI4V alloy. The effects of cutting speed, feed rate, and tool treatments were evaluated using the Taguchi method and grey relational analysis. It was observed that cutting force decreased with increased cutting speed but significantly increased with feed rate. Surface roughness was found to vary based on cutting parameters. The most influential parameter for cutting force was feed rate with a contribution rate of 81.9%, while for surface roughness, it was cutting speed with a contribution rate of 48.8%. The optimal machining conditions were determined as A(1)B(3)C(2) through grey relational analysis for both responses.
JOURNAL OF THE BRAZILIAN SOCIETY OF MECHANICAL SCIENCES AND ENGINEERING
(2022)
Article
Automation & Control Systems
Sisay Workineh Agebo, Mahaboob Patel, Mariusz Deja
Summary: In this study, the effects of wet and cryogenic machining on turning of AISI D2 steel samples were investigated using multi-response optimization. The results showed that the feed rate had the greatest influence on metal removal rate (46.67%), followed by spindle speed (46.65%). Surface roughness was mainly affected by feed rate (56.66%), cutting condition (26.04%), and spindle speed (11.7%). The predicted values were in good agreement with the experimental validation values.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Mechanical
Pankaj Kumar Singh, Santosh Kumar, Pramod Kumar Jain
Summary: Additive manufacturing has the potential to produce customized three-dimensional components directly, but surface roughness is a major challenge. An experimental investigation was conducted to examine the effect of cryogenic grinding on the surface characteristics of DMLS Ti-6Al-4V alloy. The results revealed that different grinding characteristics and environments had significant effects on the grinding forces, temperature, surface roughness, force ratio, microhardness, and surface quality of the components.
SURFACE TOPOGRAPHY-METROLOGY AND PROPERTIES
(2023)
Article
Crystallography
Arabinda Meher, Manas Mohan Mahapatra, Priyaranjan Samal, Pandu Ranga Vundavilli, Karthik Venkitraman Shankar
Summary: The current study focuses on the mathematical modeling of the machinability of an in-situ synthesized RZ5-8 wt.% TiB2 composite using Taguchi design and analysis of variance (ANOVA). The study reveals that the most influential parameter in machining the composite is the feed rate, followed by the depth of cut and cutting speed. Regression equations are established using ANOVA to estimate the cutting force and surface roughness under different parametric conditions. The regression model is validated and shows a maximum deviation of +/- 10%. The effects of machining parameters on the composite's machinability are analyzed using main effects plots and response surface plots. Chip morphology and tool wear are also analyzed under different machining conditions using FESEM.
Article
Chemistry, Physical
Wojciech Stachurski, Jacek Sawicki, Bartlomiej Januszewicz, Radoslaw Rosik
Summary: This study investigated the effect of abrasive machining conditions on 20MnCr5 steel, finding that using Minimum Quantity Lubrication (MQL) method for grinding fluid supply resulted in improved microhardness and residual stress values, as well as reduced surface roughness.
Article
Engineering, Manufacturing
N. E. Arun Kumar, M. Subramanian, A. Suresh Babu, R. Elakkiyadasan
Summary: WEDM is a specialized thermo electric cutting process that reduces the use of conventional machining methods for precise machining of materials with varied hardness and complex geometries. This study investigates the effects of different machining variables on the Surface Roughness (SR) and Material Removal Rate (MRR) of Monel 400 alloy. Untreated and deep cryogenic treated brass wires are used as the tool, and the results show that cryogenically treated wire provides better surface finish and smaller kerf width than untreated wire. Experimental results confirm the effectiveness of this approach.
MATERIALS AND MANUFACTURING PROCESSES
(2023)
Article
Materials Science, Multidisciplinary
Bin Luo, Qiusheng Yan, Jisheng Pan, Jiabin Lu, Zhanliang Huang
Summary: The wear processes on a metal-bonded diamond grinding wheel during surface grinding of monocrystal sapphire were investigated through single-factor grinding experiments. The results revealed that the wear process of the grinding wheel consists of four stages, and the wear from the grinding wheel rises with the increase of the grinding depth during the grinding of sapphire wafers.
DIAMOND AND RELATED MATERIALS
(2021)
Article
Engineering, Mechanical
Raphael Lima de Paiva, Deborah de Oliveira, Rodrigo de Souza Ruzzi, Mark James Jackson, Rogerio Valentim Gelamo, Alexandre Mendes Abra, Rosemar Batista da Silva
Summary: Bearings are widely used in various industries with different quality requirements. Grinding is a viable option to achieve the desired combination of low surface roughness and tight dimensional deviations. However, heat generated in the grinding wheel-workpiece interface can lead to surface finish deterioration and thermal damages, reducing the component's life. Various cooling-lubrication techniques, including adding solid particles, have been tested to enhance grinding efficiency. This study evaluated the roughness and surface morphology of bearing steel after grinding with multilayer graphene platelets dispersed in different cutting fluids, and found that the fluid type significantly affected grinding performance.
Article
Engineering, Mechanical
Menderes Kam
Summary: This study investigated the effects of Deep Cryogenic Treatment (DCT) on machinability, hardness, and microstructure in dry turning process of AISI 4140 tempered steels. The experiments showed that the DCTT36 sample had the lowest Ra value and highest hardness values compared to other samples. The study suggested that lower Ra values can be achieved with ceramic cutting tools in dry turning experiments, making DCT a cost-effective alternative to cylindrical grinding.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2021)
Article
Engineering, Electrical & Electronic
Guojun Zhang, Changyuan Liu, Kang Min, Hong Liu, Fenglei Ni
Summary: This paper proposes a roughness measurement method based on GAN and BP neural network, which learns image features through training GAN to improve measurement accuracy.
Article
Materials Science, Composites
Khaled Giasin, Antigoni Barouni, Hom Nath Dhakal, Carol Featherson, Zitoune Redouane, Sezer Morkavuk, Ugur Koklu
Summary: A new environmentally friendly cryogenic cooling technique was used for drilling S2/FM94 glass fibre reinforced epoxy composite in a liquid nitrogen bath. The study aimed to investigate the effects of drilling parameters and cryogenic cooling on cutting forces, surface roughness, hardness, and delamination factor at hole entry and exit sides. The results showed that spindle speed and cryogenic cooling had the most significant influence on cutting forces and surface roughness, while cryogenic cooling had the most significant influence on increasing hardness and delamination size at the hole entry and exit sides.
JOURNAL OF REINFORCED PLASTICS AND COMPOSITES
(2021)
Article
Materials Science, Multidisciplinary
Ugur Koklu, Husnu Kayhanlar
Summary: The study conducted experiments on milling AZ31 magnesium alloy using cryogenic cooling approach, and found that it improved surface quality, reduced chip formation, and decreased milling forces compared to dry cutting conditions. The experimental results provide valuable information for industrial production processes.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2022)
Article
Engineering, Mechanical
Ugur Koklu, Oguz Kocar, Sezer Morkavuk, Khaled Giasin, Onder Ayer
Summary: This study investigates the effect of different extrusion ratios on the drilling machinability of AZ31 magnesium alloy. The results show that thrust force and borehole quality are influenced by the extrusion ratio and cutting parameters. The highest thrust force and surface roughness occur when drilling AZ31 alloy produced with the highest extrusion ratio, while the sample produced with an intermediate extrusion ratio has the best hole edge quality and least burr formation.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2022)
Article
Polymer Science
Khaled Giasin, Hom N. Dhakal, Carol A. Featheroson, Danil Yurievich Pimenov, Colin Lupton, Chulin Jiang, Antigoni Barouni, Ugur Koklu
Summary: This study investigates the impact-induced damage of aerospace glass fiber epoxy composites under different fiber orientations and incident energy levels. Experimental and numerical analysis show that fiber orientation and energy level have significant effects on the impact resistance and damage modes. The results provide guidance for the design of glass composites in aerospace applications.
Article
Engineering, Mechanical
Sezer Morkavuk, Ugur Koklu, Kubilay Aslantas
Summary: This study experimentally investigated the drilling machinability of flat, convex, and concave curved carbon fiber reinforced plastics, with results showing that the least thrust force and damage occurred when drilling the concave curved surface, while the largest thrust force and damage occurred when drilling the flat surface.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART C-JOURNAL OF MECHANICAL ENGINEERING SCIENCE
(2022)
Article
Engineering, Mechanical
Emrah Dagtekin, Muammer Gavas, Ugur Koklu
Summary: Deep drawing is a commonly used sheet metal forming process, but it often faces limitations such as increasing sheet thickness, ironing, and wrinkling. In this study, the drawing height was increased by machining the edges of the blank material at certain angles.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2023)
Article
Materials Science, Composites
Sezer Morkavuk, Ugur Koklu, Kubilay Aslantas
Summary: This study compares the drilling machinability of CFRP tubes and CFRP plates produced by different methods. Experimental results show that the plate generates more force and damage during drilling compared to the tubes, making it more difficult to machine. The filament wound tube exhibits higher thrust force and damage compared to the roll wrapped tube. Additionally, the use of support does not increase the thrust force in composite tubes, but significantly improves drilling-induced delamination damage behavior. The plate provides better borehole surface quality compared to the tubes, but more dust chip formation is observed.
JOURNAL OF REINFORCED PLASTICS AND COMPOSITES
(2023)
Article
Mechanics
Mehmet Aydin, Ugur Koklu
Summary: This paper investigates the cutting forces for flat-end milling with tool runout through experimental study and mechanistic prediction. The results show that the cutting force coefficients decrease with an increase in spindle speed and are affected by the workpiece material and helix angle.
MECHANICS BASED DESIGN OF STRUCTURES AND MACHINES
(2022)
Article
Chemistry, Physical
Shahryar Manzoor, Israr Ud Din, Khaled Giasin, Ugur Koklu, Kamran A. Khan, Stephane Panier
Summary: Considering the challenges in machining composites, this study numerically evaluated the effects of cutting parameters on thrust force and torque during drilling of glass-fiber-reinforced polymers. A developed model accurately predicted the thrust force and torque profiles, providing useful guidelines for drilling operations to minimize drilling-induced damage. The study also investigated the effect of coefficient of friction and found that higher friction reduced the thrust force.
Review
Materials Science, Multidisciplinary
Erhan Baysal, Oguz Kocar, Engin Kocaman, Ugur Koklu
Summary: Research on ultra-fine grain materials has gained attention in recent years, with a focus on improving material properties and decreasing costs. Severe plastic deformation methods have emerged as a good alternative, resulting in materials with grain sizes below 1 μm and positively affecting the mechanical properties.
Article
Automation & Control Systems
Khaled Giasin, Muhammad Atif, Yuan Ma, Chulin Jiang, Ugur Koklu, Jos Sinke
Summary: This study investigated the effect of ultrasonic-assisted drilling (UAD) on GLARE laminates. The results showed that UAD resulted in a significant reduction in thrust force without affecting surface roughness metrics. Scanning electron microscopy (SEM) analysis revealed irregular and fuzzy surfaces in the holes machined using UAD.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Mechanical
A. S. Guldibi, U. Koklu, O. Kocar, E. Kocaman, S. Morkavuk
Summary: Corrax is a maraging steel that is widely used in various industries due to its high strength, hardness, and corrosion resistance. However, these specifications can present challenges in manufacturing operations. Therefore, it is important to study the effects of heat treatment on the material's properties and behavior.
EXPERIMENTAL TECHNIQUES
(2023)
Article
Engineering, Mechanical
Ragavanantham Shanmugam, Satish Shenoy Baloor, Ugur Koklu, Ashwin Polishetty, Gururaj Bolar
Summary: The study evaluates the use of helical milling in hole processing for titanium alloys. The results show that helical milling can reduce machining temperature, improve surface roughness, and decrease the size of exit burrs compared to traditional drilling. However, helical-milled holes exhibit higher subsurface microhardness than conventionally drilled holes. The process variables have a significant impact on machining temperature.
Article
Materials Science, Composites
Caglar Betgul, Ugur Koklu, Sezer Morkavuk
Summary: This study experimentally investigated the effect of using support plates of different thicknesses on drilling carbon fiber reinforced plastics (CFRP). The results showed that increasing the support plate thickness increased the thrust force and reduced the severity of delamination damage.
JOURNAL OF REINFORCED PLASTICS AND COMPOSITES
(2023)
Article
Materials Science, Characterization & Testing
Mehmet Akif Erden, Ugur Koklu, Ahmet Serdar Guldibi, Muhammed Elitas
Summary: This study evaluated the effect of compaction pressure on the properties of AISI 316L and its machining performance. Increasing compaction pressure resulted in smaller grain sizes, increased hardness, and higher tensile strength. Higher compaction pressure led to higher thrust force and torque, while lower compaction pressure improved hole surface quality and reduced chip length.
