Article
Engineering, Manufacturing
Shoichi Tamura, Takashi Matsumura, Atsushi Ezura, Kazuo Mori
Summary: This paper investigates the cutting force in the milling of maraging steel using selective laser melting as an additive manufacturing process. The study demonstrates the influence of material anisotropy on cutting forces through experiments and analysis on workpieces with repeated laser scanning at 0/90 degrees and 45/-45 degrees. The changes in cutting forces with feed direction are discussed, and a force model is proposed to associate anisotropy with shear stress on the shear plane.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2022)
Article
Materials Science, Multidisciplinary
Nana Kwabena Adomako, Sung Hoon Kim, Ji Hong Yoon, Se-Hwan Lee, Jeoung Han Kim
Summary: The study focused on predicting residual stress distribution during the deposition of 17-4PH stainless steel on Ti-6Al-4V alloy, revealing a sharp stress gradient at the joint interface attributed to the large difference in coefficients of thermal expansion. Engineers can use this study to understand residual stress development in 17-4PH and Ti-6Al-4V joints fabricated with additive manufacturing.
Article
Materials Science, Multidisciplinary
Nimel Sworna Ross, Munish Kumar Gupta, Peter Madindwa Mashinini, M. Belsam Jeba Ananth, Grzegorz M. Krolczyk
Summary: Additive manufacturing (AM) has advantages over conventional manufacturing techniques, but the mechanical and tribological qualities of AMed parts are different. This study investigates the impact of four environmental regimes on the metal cutting of AMed stainless steel specimens, and finds that N-MQL lubrication offers enhanced machining performance and surface quality.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Materials Science, Multidisciplinary
Eun-Jung Kim, Choon-Man Lee, Dong-Hyeon Kim
Summary: Metal additive manufacturing is an innovative method for fabricating products used in various industries. Post-processing methods such as conventional machining and induction-assisted machining can improve the cutting force, surface roughness, hardness, and microstructure of fabricated metal products.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Engineering, Manufacturing
Seyed Mohammad Ebrahimi, Mohammadjafar Hadad, Alireza Araee
Summary: This study simulated the cutting process of hardened AISI630 stainless steel and conducted hot turning experiments to demonstrate the effectiveness of the process. The results showed that hot turning at 300 degrees Celsius can reduce cutting forces and tool wear, as well as decrease machined surface roughness.
MACHINING SCIENCE AND TECHNOLOGY
(2021)
Article
Engineering, Mechanical
S. M. Basha, M. R. Sankar, N. Venkaiah
Summary: Additive manufacturing of metallic parts often results in surface defects, which require post-processing. Abrasive flow finishing is commonly used, and in this study, it was found that using abrasive medium with bimodal particle distribution can improve the surface finish of selectively laser melted 18Ni300 steel.
Article
Green & Sustainable Science & Technology
M. J. Jackson, G. M. Robinson, M. D. Whitt, R. B. da Silva, M. B. da Silva, A. R. Machado
Summary: This study investigates the wear mechanisms of cutting tools coated with functional graded nanostructured coatings in subtractive manufacturing processes using advanced measurement techniques such as x-ray fluorescence technology. The results show that commercially-available coated tools can reduce chemical species diffusion and create an effective chemical barrier during machining. It is also found that the thermal properties of coatings do not correlate with tool wear. Additionally, flank wear as a function of machining duration is a reliable method for assessing the transition of wear stages during clean machining operations.
JOURNAL OF CLEANER PRODUCTION
(2023)
Article
Materials Science, Multidisciplinary
Seong-Gyu Kim, Choon-Man Lee, Dong-Hyeon Kim
Summary: This study explores conventional machining (CM) and plasma-assisted machining (PAM) of 304 stainless steel (SS) manufactured using wire arc additive manufacturing (WAAM). The experimental results were evaluated, machining conditions for PAM were selected via thermal analysis, and the post-machining effect was analyzed to compare the performance of these two machining methods in material processing.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Green & Sustainable Science & Technology
Munish Kumar Gupta, Mehmet Erdi Korkmaz
Summary: Sustainability assessment is a set of practices for guiding planning and decision-making towards sustainable development. Current techniques are criticized for lacking interdependence, consistency, subjectivity, and financial biases. This study applies a conceptual framework to evaluate the sustainability performance of machining with MQL and hBN-enriched nano-MQL cooling/lubrication. The findings support the claim that nano-MQL improves sustainability and machining performance.
SUSTAINABLE MATERIALS AND TECHNOLOGIES
(2023)
Article
Green & Sustainable Science & Technology
P. Nieslony, S. Wojciechowski, M. K. Gupta, R. Chudy, J. B. Krolczyk, R. Maruda, G. M. Krolczyk
Summary: This study investigates the relationship between energy consumption and surface integrity in the electrical discharge machining (EDM) of hot work die steel (1.2344). Surface topography, power spectral density analysis, and surface roughness were measured using advanced instruments. Energy consumption data was analyzed using Labview software, and the relationship between the two factors was established and compared with different process parameters. The results showed a direct relationship between energy consumption and surface integrity, with the highest pulse voltage (U = 200 V) resulting in the lowest Sa and Sz values, 34% and 44% lower than the lowest pulse voltage (U = 80 V).
SUSTAINABLE MATERIALS AND TECHNOLOGIES
(2023)
Article
Automation & Control Systems
Lhoucine Boutrih, Lanouar Ben Ayed, Mohammed Nouari
Summary: Structures involving assembled materials such as titanium/composite are commonly used in the aeronautical industry due to their high mechanical properties, but machining difficulties are often encountered due to their poor machinability. A numerical model considering different phases of the assembly has been developed, which revealed that the cutting sequence is crucial in preventing interface delamination. The study also found two levels of cutting forces related to the ductile behavior of the titanium phase and the brittle behavior of the composite phase during the orthogonal cutting process.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Aerospace
Zhengyang XU, Yudi WANG
Summary: Electrochemical machining (ECM) has become a viable method for machining components in various industrial applications due to its advantages such as no tool wear, independence on material properties, and high efficiency. Recent studies have focused on key factors of ECM like electrochemical dissolution characteristics, numerical simulation, tool design, flow field simulation, and innovation in machining methods for difficult-to-cut materials in aero-engine manufacturing.
CHINESE JOURNAL OF AERONAUTICS
(2021)
Article
Engineering, Mechanical
Kazem Malekipour, Mohsen Badrossamay, Mohammad Mashayekhi
Summary: Damage growth and load-carrying capacity of specimens produced by LPBF under various triaxial stresses were evaluated using the damage mechanics approach. The effects of stress triaxiality, external HCF loading, and micro-pore geometric parameters size on damage growth and coalescence of two-void cluster embedded in RVE were investigated. The results showed that increasing triaxial stress leads to a decrease in load carrying capacity and eventual void coalescence, and two-void clusters with a relative distance of less than 10 can be considered as crack initiating sites in LPBF microstructures under HCF loading.
ENGINEERING FAILURE ANALYSIS
(2023)
Article
Engineering, Mechanical
Himanshu Singh, Rajanish Chandra, Prateek Saxena, Yogesh M. Puri
Summary: This study addresses the challenges of machining high-strength alloys like EN19 steel by investigating the use of cryogenically cooled electrode materials in electric discharge machining (EDM). Through experimental data and simulation results, it is demonstrated that cryogenic treatment of copper electrodes significantly improves material removal rates, reduces electrode wear rates and surface roughness, thereby enhancing machining efficiency and electrode longevity.
PROCEEDINGS OF THE INSTITUTION OF MECHANICAL ENGINEERS PART E-JOURNAL OF PROCESS MECHANICAL ENGINEERING
(2023)
Article
Construction & Building Technology
Haider K. Ammash, Safa S. Kadhim, Mohammed K. Dhahir
Summary: In this paper, a repairing system for flat slabs suffering from punching shear stresses was implemented. The system successfully repaired the damaged slabs and showed improvements in punching shear strength and deformation capacity. Increasing the concrete compressive strength and flexural reinforcement ratios had positive effects on the shear capacity.
CASE STUDIES IN CONSTRUCTION MATERIALS
(2022)
Review
Engineering, Manufacturing
Deborah De Oliveira, Milla Caroline Gomes, Aline Goncalves Dos Santos, Kandice Suane Barros Ribeiro, Iago Jose Vasques, Reginaldo Teixeira Coelho, Marcio Bacci Da Silva, Nguyen Wayne Hung
Summary: This paper reviews the working principles of metal additive manufacturing (MAM) processes and summarizes the current post-processing techniques for surface finish improvement. It discusses various finishing techniques and their limitations, as well as enhancement techniques using magnetism, ultrasonic, and pulsed current. The post-processing not only reduces surface roughness, but also improves dimensional and form tolerances, and increases the fatigue and creep life of AM metals.
PROGRESS IN ADDITIVE MANUFACTURING
(2023)
Article
Automation & Control Systems
Alcione dos Reis, Leonardo Rosa Ribeiro da Silva, Aline Elias da Silva, Lucas Melo Queiroz Barbosa, Alisson Rocha Machado, Cassio Luiz Francisco de Andrade, Wilson Luiz Guesser
Summary: Gray cast irons are commonly used in machine tool bases and applications with noise restrictions. The graphite, sulfide, and ferrite/pearlite ratio are crucial parameters in determining the machinability of gray cast irons. This study evaluated the machinability of high-resistance gray cast irons in two versions, with the addition of molybdenum and with refined graphite and molybdenum, compared to commonly used materials. The results showed that using harder materials could enhance durability and efficiency, although they have shorter tool life and different performances under extreme cutting conditions.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Mayara Fernanda Pereira, Bruno Souza Abrao, Amanda Souza Abrao, Alisson Rocha Machado, Mark James Jackson, Amauri Hassui, Rosemar Batista Da Silva
Summary: In the aeronautical industry, abrasive machining processes are used to ensure surface integrity of components. However, machining titanium alloys like the Ti-6Al-4V alloy is challenging due to its properties. Therefore, this study aimed to evaluate the effects of different dressing conditions for a SiC grinding wheel on the surface integrity of the Ti-6Al-4V alloy.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Automation & Control Systems
Pedro Henrique Pires Franca, Lucas Melo Queiroz Barbosa, Gustavo Henrique Nazareno Fernandes, Leonardo Rosa Ribeiro da Silva, Alisson Rocha Machado, Paulo Sergio Martins, Marcio Bacci da Silva
Summary: Due to environmental degradation, industries are seeking less harmful manufacturing methods. This study focuses on a proposed cooling technique for machining, called internally cooled tool (ICT), which utilizes cutting tool and tool holders with internal cooling channels. The ICT technique reduces temperatures and thermal gradients in the cutting tool and has the potential to eliminate the use of cutting fluids. Experimental results showed a temperature reduction of up to 21.52% at the chip-tool interface compared to dry machining.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Multidisciplinary
Lucas Costa Brito, Milla Caroline Gomes, Deborah de Oliveira, Marcio Bacci da Silva, Marcus Antonio Viana Duarte
Summary: Monitoring the vibration signal features of micromachining process is crucial for ensuring surface quality. This study investigates the correlation between vibration signals and surface roughness in end micromilling operation, and identifies features that are directly correlated with roughness, providing the potential for indirect monitoring of the process.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2023)
Review
Green & Sustainable Science & Technology
Vitor Baldin, Leonardo Rosa Ribeiro da Silva, Alisson Rocha Machado, Celso Ferraz Houck
Summary: This article introduces the application of new technologies such as biodegradable cutting fluids and nanolubricants in cutting processes. The use of Minimum Quantity Lubrication (MQL) improves the machinability of metal alloys by reducing cutting forces, cutting temperature, tool wear, and workpiece surface roughness. Additionally, the addition of nanoparticles enhances the lubricating and cooling properties of cutting fluids, leading to reduced cutting forces, cutting temperature, workpiece surface roughness, coefficient of friction, and tool wear. These research findings are important for improving the environmental friendliness of the metal-mechanic industry.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Gustavo Henrique Nazareno Fernandes, Victor Tallis Bazon, Lucas Melo Queiroz Barbosa, Pedro Henrique Pires Franca, Marcio Bacci da Silva, Mohammad Uddin, Paulo Sergio Martins, Alisson Rocha Machado
Summary: High heat generation in machining processes affects tool life and workpiece quality. Conventional cutting fluid cooling has environmental hazards and high manufacturing costs. This study evaluates the performance of a novel internally cooled tool for machining grey cast iron, which effectively removes heat from the interface. The results show that the internally cooled tool reduces surface roughness and increases microhardness and machining performance, indicating its potential as an eco-friendly and efficient technique.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Automation & Control Systems
Victor Hugo Serafim Rubin, Leonardo Rosa Ribeiro da Silva, Kenji Fabiano avila Okada, Felipe Chagas Rodrigues de Souza, Danil Yurievich Pimenov, Marcio Tadeu Gravalos, Alisson Rocha Machado
Summary: This work implements artificial neural networks to monitor tool wear during turning of AISI D6 steel. The goal is to detect wear, prevent tool breakage, and enhance productivity. Experimental tests involve using polycrystalline cubic boron nitride tools to turn AISI D6 steel, measuring wear and surface roughness. ANNs are trained with machining forces, electric current, and acoustic emission data. The findings show that cutting and machining forces, along with motor current, increase as the wear progresses. The ANN achieves satisfactory results in wear estimation but has limited predictive capability beyond the training range.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Mechanical
Gabriel de Paiva Silva, Marcio Bacci da Silva, Deborah de Oliveira
Summary: Micromilling is a difficult and time-consuming process due to the need for microscopy operations, but measuring tool wear can be simplified by using the dimensions of the microslot produced. However, burrs may affect the accuracy of this method. This study evaluates the impact of abrasive deburring on tool wear measurement in precision features of Inconel 718 and found that deburring significantly reduces burr heights and improves the accuracy of tool wear measurement through slot geometry.
JOURNAL OF THE BRAZILIAN SOCIETY OF MECHANICAL SCIENCES AND ENGINEERING
(2023)
Article
Engineering, Mechanical
Vitor Baldin, Leonardo Rosa Ribeiro da Silva, Rahul Davis, Mark James Jackson, Fred Lacerda Amorim, Celso Ferraz Houck, Alisson Rocha Machado
Summary: The use of vegetal-based cutting fluids as an alternative to mineral-based fluids can help reduce environmental impact. The minimum quantity of lubricant (MQL) method has proven advantageous compared to dry cutting in milling processes. This study compares the performance of two vegetable-based and one mineral-based oils using the MQL method and analyzes the machining parameters and tool wear mechanisms.
Article
Automation & Control Systems
Gustavo Henrique Nazareno Fernandes, Lucas Melo Queiroz Barbosa, Pedro Henrique Pedro Franca, Paulo Sergio Martins, alisson Rocha Machado
Summary: This study introduces and evaluates the performance of an internally cooled tool system for machining Inconel 718. The internally cooled tools outperform cutting fluids, showing higher material removal rate and cutting forces compared to both cutting fluids and dry machining.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Green & Sustainable Science & Technology
M. J. Jackson, G. M. Robinson, M. D. Whitt, R. B. da Silva, M. B. da Silva, A. R. Machado
Summary: This study investigates the wear mechanisms of cutting tools coated with functional graded nanostructured coatings in subtractive manufacturing processes using advanced measurement techniques such as x-ray fluorescence technology. The results show that commercially-available coated tools can reduce chemical species diffusion and create an effective chemical barrier during machining. It is also found that the thermal properties of coatings do not correlate with tool wear. Additionally, flank wear as a function of machining duration is a reliable method for assessing the transition of wear stages during clean machining operations.
JOURNAL OF CLEANER PRODUCTION
(2023)
Article
Engineering, Manufacturing
Lucas Melo Queiroz Barbosa, Pedro Henrique Pires Franca, Gustavo Henrique Nazareno Fernandes, Eder Silva Costa, Marcio Bacci da Silva, Paulo Sergio Martins, Alisson Rocha Machado
Summary: Machining, a widely used manufacturing process, generates high temperatures that can cause tool wear and other issues. This study proposes a more sustainable approach using an internally cooled tool (ICT) system, which effectively reduces temperature, extends tool life, and improves cutting forces and surface roughness.
JOURNAL OF MANUFACTURING PROCESSES
(2023)