Article
Engineering, Industrial
Berk Tekkaya, Markus Meurer, Michael Doelz, Markus Koenemann, Sebastian Muenstermann, Thomas Bergs
Summary: Surface integrity plays a crucial role in determining the performance of machined parts and is influenced by factors such as tool material, wear, chemical composition, microstructure of the workpiece material, and cutting parameters. The aggressive nature of the cutting process can lead to altered microstructure on the workpiece surface, resulting in the formation of a detrimental white layer. This paper presents a physics-based dislocation density-based model to predict the white layer formation and investigates the influence of cutting parameters on the white layer thickness for AISI 4140 grade steel.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
S. Fakher, M. Reihanian, S. M. Lari Baghal, Laleh Fatahi
Summary: The study focused on the deformation processing of a metal laminate with a cracked interlayer, utilizing a model material and finite element analysis to explore related mechanisms. Experimental and simulation results showed the direction of spread for discontinuities during the roll bonding process. Peeling test after single roll bonding revealed an increase in bond strength for the Al/Cr composite with cracked interlayer as thickness reduction and hard chrome layer decreased.
METALS AND MATERIALS INTERNATIONAL
(2021)
Article
Automation & Control Systems
Rafael Guerra-Silva, Uwe Teicher, Steffen Ihlenfeldt, Aristides Gonzalez-Zamora
Summary: Cellular metals are highly porous materials with unique properties. Cutting speed, depth of cut, and tool rake angle were found to influence chip formation and surface damage, with the stochastic nature of the cell structure making it difficult to identify optimal cutting parameters for surface quality.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Jimmy E. Campbell, Marcus Gaiser-Porter, Wenchen Gu, Steve Ooi, Max Burley, James Dean, Trevor William Clyne
Summary: This study applied profilometry-based indentation plastometry (PIP) to metals with very high hardness and successfully obtained reliable stress-strain curves, showing advantages over traditional uniaxial testing in terms of implementation ease and obtaining behavior information at high strains.
ADVANCED ENGINEERING MATERIALS
(2022)
Article
Biochemistry & Molecular Biology
Muhammad Imam Ammarullah, Rachmad Hartono, Toto Supriyono, Gatot Santoso, S. Sugiharto, Muki Satya Permana
Summary: In order to solve the problems caused by polymeric wear debris, metal ions, and brittle characteristic in total hip prosthesis bearing, new material options are needed. The present study confirms the potential of polycrystalline diamond (PCD) as a safe option for hard-on-hard bearing compared to metals and ceramics through von Mises stress investigations.
Article
Computer Science, Interdisciplinary Applications
Hyo-Jin Kim, Dong-Hwa Lee, Kyungho Yoon, Phill-Seung Lee
Summary: This study presents a multi-director continuum beam finite element for efficient analysis of multi-layer strand cables, which can handle complex geometries and material non-linearities with reduced degrees of freedom. The predictive ability of the proposed beam model is demonstrated through numerical examples.
COMPUTERS & STRUCTURES
(2021)
Article
Automation & Control Systems
Daniel Weber, Benjamin Kirsch, Christopher R. Chighizola, Christopher R. D'Elia, Barbara S. Linke, Michael R. Hill, Jan C. Aurich
Summary: This paper investigates the effect of machining on residual stresses in thin-walled monolithic aluminum workpieces and their repeatability. It was found that stable machining conditions lead to better repeatability of MIRS, while unstable machining conditions result in worse repeatability. The experiments show that more and/or deeper MIRS cause more distortion in the workpieces.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Biomedical
Jungil Choi, Shulin Chen, Yujun Deng, Yeguang Xue, Jonathan T. Reeder, Daniel Franklin, Yong Suk Oh, Jeffrey B. Model, Alexander J. Aranyosi, Stephen P. Lee, Roozbeh Ghaffari, Yonggang Huang, John A. Rogers
Summary: Eccrine sweat contains a rich blend of chemical components that can reflect hydration status and health conditions. Recent advancements in soft, skin-interfaced microfluidic systems allow for real-time measurement of local sweat loss and biomarker concentrations with various healthcare applications.
ADVANCED HEALTHCARE MATERIALS
(2021)
Article
Engineering, Mechanical
Muhammad Mubashir Munir, Khurram Hameed Mughal, Muhammad Asif Mahmood Qureshi, Asif Ali Qaiser, Fazal Ahmad Khalid
Summary: The study focuses on the design and analysis of modified ultrasonic horns for non-conventional machining techniques. The results show that the modified horns achieve higher amplitude ratio and lower stresses compared to the commercial horns. The higher amplitude ratio can improve cutting force and surface quality of hard and brittle materials.
JOURNAL OF VIBRATION ENGINEERING & TECHNOLOGIES
(2023)
Article
Biology
Sarah Broyde, Matthew Dempsey, Linjie Wang, Philip G. Cox, Michael Fagan, Karl T. Bates
Summary: Biomechanical modelling is a useful tool for studying the evolution of functional performance in extinct animals, but reconstructions of soft tissue properties in current models face challenges. The qualitative and quantitative differences in reconstructions have a significant impact on predicting evolutionary patterns in macroevolutionary studies.
PROCEEDINGS OF THE ROYAL SOCIETY B-BIOLOGICAL SCIENCES
(2021)
Article
Mechanics
Farzam Dadgar-Rad, Mokarram Hossain
Summary: This study models the deformation of Hard-magnetic soft materials (HMSMs) under external magnetic stimuli using the micropolar continuum theory. The developed formulation successfully predicts the deformation of HMSMs under various loading and boundary conditions, as demonstrated through numerical simulations and examples.
INTERNATIONAL JOURNAL OF SOLIDS AND STRUCTURES
(2022)
Article
Engineering, Mechanical
Tian Xu, Dongfang Zeng, Liantao Lu, Gang Chen, Qiang Zou
Summary: The finite element model with phase transformation was used to study the formation of white etching layer (WEL) in HiSi wheel steel. Results showed that the higher austenitization temperature of HiSi steel at high heating rate leads to better resistance to WEL formation compared to ER8 wheel steel.
ENGINEERING FAILURE ANALYSIS
(2021)
Article
Mechanics
Jie Xu, Yi Deng, Chenxi Wang, Guiqiang Liang
Summary: By proposing an amended friction model, the numerical model was significantly improved in predicting cutting and thrust forces, as well as chip formation. It was demonstrated that the relationship between normal force and friction coefficient is nonlinear in tool-CFRP tangential contact, and the friction coefficient is not a constant value.
COMPOSITE STRUCTURES
(2021)
Article
Chemistry, Physical
Usama Umer, Syed Hammad Mian, Muneer Khan Mohammed, Mustufa Haider Abidi, Khaja Moiduddin, Hossam Kishawy
Summary: This study investigates the performance of self-propelled rotary tools in hard turning using 3D finite element models, and validates the models through experimental results. The effects of different process parameters were analyzed using FE models, and optimal process conditions were found through optimization methods.
Article
Mechanics
K. A. Hasim, A. Kefal
Summary: A new IsoGeometric formulation (IG-RZT) based on Refined Zigzag Theory has been proposed for static analysis of laminated plates with curvilinear fiber paths. This method accurately predicts in-plane displacement of composite materials with curved fibers, addressing the challenges of variable angle tow composites. The integration of IG-RZT with Non-Uniform Rational B-Splines (NURBS) functions ensures accuracy and efficiency in predicting displacement and stress distributions in VAT composite structures.
COMPOSITE STRUCTURES
(2021)
Article
Computer Science, Software Engineering
Paola Festa, Serena Fugaro, Francesca Guerriero
Summary: The paper discusses the algorithm for reoptimizing shortest paths in the scenario of multiple changes to the arc sets, and implements and compares it with the well-known Dijkstra's algorithm. The experimental results help distinguish situations where the reoptimization approach is efficient from those that should be solved from scratch.
OPTIMIZATION METHODS & SOFTWARE
(2022)
Article
Engineering, Manufacturing
B. Huang, Y. Kaynak, Y. Sun, M. K. Khraisheh, I. S. Jawahir
Summary: Burnishing is increasingly used to improve the surface integrity of manufactured components. Cryogenic burnishing can generate surface and subsurface layers with ultrafine grains, leading to improved surface integrity characteristics such as increased hardness and reduced roughness. The generation of compressive stresses within the refined layers also improves fatigue life and wear and corrosion resistance.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2022)
Article
Automation & Control Systems
Giovanna Rotella, Maria Rosaria Saffioti, Michela Sanguedolce, Domenico Umbrello
Summary: This paper presents a physics-based model able to simulate the flow stress behavior of the Ti6Al4V alloy during subsequent severe plastic deformation processes, such as turning and burnishing. The proposed numerical model was validated through turning and roller burnishing experiments, accurately predicting the evolution of grain size, dislocations, hardness, and residual stresses in the manufactured Ti6Al4V components. Different process combinations can lead to similar microstructures, and information on different contributions can be highlighted through physics-based modelling and simulated process combinations.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Guang Chen, James Caudill, Shi Chen, I. S. Jawahir
Summary: The study focuses on the influence of cutting edge radii and cooling/lubricating conditions on surface integrity of machined components. Experimental analysis shows that larger cutting edge radii lead to material compression into the machined surface, while changes in cooling/lubricating conditions also affect surface integrity. These findings can be applied to improve the service life and functional performance of machined parts.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Industrial
Domenico Umbrello, Maria Rosaria Saffioti, Stano Imbrogno
Summary: This paper analyzes the surface changes and biocompatibility of Zr-702 additively manufactured bars. The samples were machined under different conditions, and the adhesion and proliferation of MC3T3-E1 osteoblast cells on the printed and machined surfaces were observed. The study establishes a connection between surface characteristics and cell behavior, and evaluates the potential of machining processes to modulate the biocompatibility of the investigated material.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Industrial
Alborz Shokrani, Joseph Betts, I. S. Jawahir
Summary: This paper presents the results of end milling Inconel 718 using a newly designed and manufactured minimum quantity lubrication (MQL) delivery system. The system sprays electrically charged tungsten disulphide (WS2) nano particles dispersed in vegetable oil through pressurized air as a coolant/lubricant. The method improves cooling and lubrication during machining. Tool life, surface integrity, and cutting forces are compared with conventional flood and MQL cooling/lubrication. The electrically charged WS2 nanofluid extends tool life by 10% and significantly improves surface integrity.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Serafino Caruso, Domenico Umbrello
Summary: Residual stresses and strains, distortions, heat-affected zone (HAZ), grain size changes, and hardness variation are important aspects to study and control during the gas metal arc welding (GMAW) process. Numerical simulations using finite element method (FEM) software were used to model the GMAW process of AISI 441. The results showed that the predicted thermal phenomena and mechanical properties agreed with experimental findings, demonstrating the reliability of the simulation codes.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Shu Yang, Domenico Umbrello, Oscar W. Dillon, Ibrahim S. Jawahir
Summary: This paper demonstrates the development of a finite element method model to simulate the dynamic recrystallization-induced microstructural evolution of Co-Cr-Mo biomaterial during cryogenic burnishing. The effects of cryogenic cooling were incorporated using a heat exchange window. The Johnson-Cook model was modified to account for flow stress softening and grain refinement due to the DRX mechanism. The predicted grain size showed good agreement with experimental data.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2022)
Article
Engineering, Environmental
Buddhika M. Hapuwatte, Fazleena Badurdeen, Adib Bagh, I. S. Jawahir
Summary: The increasing frequency of new product introductions hinders closed-loop resource management, affecting sustainable manufacturing and circular economy transition. Optimizing component commonality can improve product sustainability performance.
RESOURCES CONSERVATION AND RECYCLING
(2022)
Article
Engineering, Manufacturing
Domenico Umbrello, Takashi Matsumura, Pedro J. Arrazola, Guenael Germain, Cedric Courbon
Summary: This paper reports on the state of the art in the experimental and numerical investigations of cutting and machining processes, highlighting the contributions published on ESAFORM Conferences. It emphasizes the crucial role played by the minisymposium on Machining and Cutting in this field.
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2022)
Review
Materials Science, Multidisciplinary
Hung Dang Nguyen, A. Pramanik, A. K. Basak, Y. Dong, C. Prakash, S. Debnath, S. Shankar, I. S. Jawahir, Saurav Dixit, Dharam Buddhi
Summary: This investigation compares electron beam melting (EBM), selective laser melting (SLM), and directed energy deposition (DED) as additive manufacturing (AM) techniques for producing titanium alloy parts. The study examines the differences in microstructure, tensile properties, porosity, surface roughness, and residual stress among these methods. It concludes that the choice of AM process affects the material's characteristics, and additional treatments such as annealing and stress relief can improve the performance of AM-fabricated parts.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Engineering, Industrial
Buddhika M. Hapuwatte, K. Daniel Seevers, I. S. Jawahir
Summary: This paper proposes a metrics-based framework to evaluate and forecast product sustainability performance during the design stage, considering dynamic variations in demand forecast, closed-loop resource constraints, and end-of-use resource allocations. A numerical application demonstrates that product sustainability performance significantly varies with changes in demand curve, even with constant product design.
JOURNAL OF MANUFACTURING SYSTEMS
(2022)
Article
Engineering, Manufacturing
Arjun Nagaraj, Alper Uysal, Suhasini Gururaja, I. S. Jawahir
Summary: This study investigated the machining performance of drilling CFRP composite material under cryogenic, minimum quantity lubrication, and hybrid conditions, and compared the performance with dry drilling. The results showed that using coolant/lubricant outperformed dry drilling in terms of producing better quality parts, and varying the feed rate proved to be advantageous.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Manufacturing
Guang Chen, James Caudill, Chengzu Ren, I. S. Jawahir
Summary: Numerical modeling is an effective method to study the cutting process. The JCM-ms model characterizes the effect of grain refinement on cutting. An energy density-based failure law controls chip formation and material removal mechanisms. The finite element simulation results are validated by experimental measurements.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
