Article
Materials Science, Multidisciplinary
Rustem Binali, Havva Demirpolat, Mustafa Kuntoglu, Emin Salur
Summary: Machining AISI 304 stainless steel is difficult due to its structure and low thermal conductivity. Cooling and lubricating techniques have been developed to overcome this challenge. This study evaluated different turning conditions of AISI 304 stainless steel under dry and minimum quantity lubrication (MQL) environments. Cutting parameters and the cutting medium significantly affected the surface roughness and cutting force.
Article
Materials Science, Multidisciplinary
Arabinda Meher, Manas Mohan Mahapatra
Summary: Machinability analysis is essential for achieving better surface finish and minimum cutting force in the machining of materials used in automobile and aerospace industries. This study compared the machinability of RZ5 alloy and RZ5/8 wt.% TiB2 composite and analyzed the effects of cutting speed, feed rate, and depth of cut on cutting force, surface roughness, chip morphology, and tool wear. The results showed that machining RZ5 alloy required higher cutting force due to the formation of built-up edge, while abrasive tool wear was observed in the machining of RZ5/8 wt.% TiB2 composite. Additionally, the surface roughness increased with increasing feed rate and depth of cut for both materials.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(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
Materials Science, Multidisciplinary
Serhat Sap, Mahir Uzun, Usame Ali Usca, Danil Yu Pimenov, Khaled Giasin, Szymon Wojciechowski
Summary: Metal matrix composites (MMCs) are widely used due to their high specific strength, but their machinability presents challenges. The machinability of Cu composites reinforced with Ti-B-SiC powder particles at different ratios was studied, and the effects of cutting parameters on surface roughness, flank wear, and cutting temperature were investigated.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Engineering, Mechanical
Kamil Leksycki, Radoslaw W. Maruda, Eugene Feldshtein, Szymon Wojciechowski, Witold Habrat, M. K. Gupta, Grzegorz M. Krolczyk
Summary: This study evaluates the tribological interactions and machinability of Ti6Al4V titanium alloy in finish turning, identifying the influence of cooling/lubricating conditions on tool wear, cutting forces, and chip thickness ratios.
TRIBOLOGY INTERNATIONAL
(2023)
Article
Automation & Control Systems
Haidong Yang, Yusong Wu, Junsheng Zhang, Huohong Tang, Weijie Chang, Juchen Zhang, Shunhua Chen
Summary: In this study, the cutting characteristics of Zr57Cu20Al10Ni8Ti5 (at.%) bulk metallic glass (Zr57 BMG) were compared with industrial pure zirconium (Zr702) during high-speed machining (100-350 m/min). It was found that despite the higher strength of Zr57 BMG, there was no significant difference in the main cutting forces between the two materials, which was attributed to the thermal softening of Zr57 BMG during machining. Furthermore, the surface characteristics and chip morphology changed as the cutting speed increased, with the worst surface quality obtained at a speed of 250 m/min.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Reza Abedinzadeh, Ehsan Norouzi, Davood Toghraie
Summary: The research focuses on the laser-assisted machining of aluminum based hybrid nanocomposites, investigating the effects of process parameters on surface roughness, cutting force and temperature. It was found that cutting speed and depth of cut have significant impacts on surface roughness and cutting force, respectively, with optimal cutting conditions identified at specific laser power, cutting speed, and cutting depth.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Chemistry, Physical
Naresh Kumar Wagri, Neelesh Kumar Jain, Anand Petare, Sudhansu Ranjan Das, Mohammed Y. Y. Tharwan, Abdulkarim Alansari, Bader Alqahtani, Majed Fattouh, Ammar Elsheikh
Summary: The hardness of materials greatly affects their machinability, which in turn affects power consumption, cutting tool life, and surface quality during component machining. In this study, annealed AISI 4340 alloy steel was machined using a coated carbide tool in a dry environment. The microhardness of annealed and non-annealed workpieces was compared, and a significant reduction was found in the microhardness of annealed samples. The microstructure examination revealed the formation of coarse pearlite in the annealed sample, indicating a reduction in hardness and improved ductility. A commercially available CVD multilayer coated carbide cutting tool was used to evaluate the surface quality, machining forces, flank wear, and chip morphology during the turning of quenched and tempered AISI 4340 alloy steel, with the machining speed, rate of feed, and depth of cut varied. The findings showed that the feed rate had a high impact on surface finish, followed by cutting speed. The study concludes that annealing is a cost-effective and economical process to enhance the machinability of alloy steel.
Article
Engineering, Mechanical
Qinqiang Wang, Zhuji Jin, Yong Zhao, Lin Niu, Jiang Guo
Summary: This study investigated the cutting performance of different cutting tool materials in turning of tungsten heavy alloys under oil lubrication condition. The TiAlN-coated carbide cutting tool exhibited the best cutting performance in terms of tool life.
Article
Chemistry, Analytical
Xian Wu, Yu Zhou, Congfu Fang, Laifa Zhu, Feng Jiang, Ke Sun, Yuan Li, Yiyang Lin
Summary: This study investigates the effects of magnetic-field-assisted turning on the metal-cutting process. The experimental results show that the magnetic field can improve the cutting force, chip morphology, and surface quality. Magnetic-field assisted turning increases the cutting force due to the induced Lorentz force, while reducing the cutting-force ratio and friction coefficient on the rake surface. Additionally, it results in smaller chip-compression ratio and continuous side morphology. Magnetic-field assisted turning has a positive impact on metal machinability and surface quality.
Article
Automation & Control Systems
Muhammad Jamil, Ning He, Wei Zhao, Aqib Mashood Khan, Rashid Ali Laghari
Summary: The recent advancement in nanotechnology has opened up new opportunities in the manufacturing industry, particularly in enhancing heat transfer and tribological capabilities of metal cutting fluids through the proper mixing of nanofluids. A hybrid nanofluids-assisted minimum quantity lubrication system has been successfully applied to achieve high heat transfer performance in cutting difficult-to-cut alloys. Under specific cutting conditions, the use of alumina-multiwalled carbon nanotubes nanofluids has resulted in significant improvements in cutting force, temperature, and surface roughness, showcasing the potential for enhanced machining performance.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Engineering, Mechanical
Wei Cai, Yuanhui Zhang, Li Li, Tao Peng, Kee-hung Lai, Marian Wiercigroch
Summary: This study proposes a new approach called forward-and-reverse multidirectional turning (MDT) to overcome deficiencies of tool wear, low processing efficiency, and chip breakage using conventional turning. The mechanism and fundamentals of MDT are illustrated through dynamics analysis. A thermomechanical coupling simulation model is established to analyze the mechanical properties of MDT. The optimal machining scheme is selected based on the analysis of cutting force, temperature, stress, and chip morphology characteristics.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2023)
Article
Engineering, Manufacturing
Bangfu Wu, Minxiu Zhang, Biao Zhao, Wenfeng Ding, Guoliang Liu
Summary: Cutting fluid is widely used in the metal cutting industry for its cooling and lubrication properties. However, excessive use can result in environmental issues and higher costs. Ultrasonic atomization-based cutting fluid (UACF) spray has shown superior performance in cooling and lubrication, but its management and impact on machining performance require further understanding.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Automation & Control Systems
Emine Sap, Usame Ali Usca, Munish Kumar Gupta, Mustafa Kuntoglu
Summary: The study investigated the effects of different machining parameters on Cu/Mo-SiCp composites during turning, finding that the particle additive ratio was the most important parameter affecting surface roughness, tool wear, and cutting temperature. It was also observed that chip types and wear types changed with increasing reinforcement rates.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Haidong Yang, Xu Wang, Junsheng Zhang, Huohong Tang, Zhenhua Qing, Shunhua Chen
Summary: Refractory high entropy alloys (RHEAs) have potential applications in aerospace and nuclear fusion fields. The study shows that RHEA has good thermal stability and smaller variations in cutting forces and surface roughness compared to conventional alloys. However, RHEA has higher cutting forces and produces serrated chips. The cutting parameters and corner radius have a comprehensive effect on the chip parameters. Adhesive wear is the main tool wear behavior in RHEA machining.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Paul Stavroulakis, Anagnostis I. Toulfatzis, George A. Pantazopoulos, Alkiviadis S. Paipetis
Summary: This paper reviews the innovative and sustainable material solutions in the manufacturing industry, in line with environmental regulations, by highlighting smart alloy design practices and promoting new approaches for material selection and process optimization. The processing, structure, and machinability aspects of leaded brasses are analyzed, and the major guidelines and research methodologies required to overcome technical challenges and improve the mechanical properties and machinability of lead-free brass alloys are outlined.
Article
Chemistry, Multidisciplinary
Nectarios Vidakis, Markos Petousis, Nikolaos Michailidis, Sotirios Grammatikos, Constantine N. David, Nikolaos Mountakis, Apostolos Argyros, Orsa Boura
Summary: This study prepared and fully characterized nanocomposites of medical-grade polyamide 12 with incorporated copper oxide. The results showed that the nanocomposites with 2.0 wt.% loading exhibited the best overall performance, while loadings ranging from 0.5 wt.% to 4.0 wt.% showed discrete improvements in either mechanical, thermal, or antibacterial properties.
Article
Materials Science, Multidisciplinary
Athanasios Vazdirvanidis, Andreas Rikos, Anagnostis Toulfatzis, George A. Pantazopoulos
Summary: This paper investigates the microstructure and texture of two machinable lead-free brass alloys and evaluates their properties in different conditions. The results demonstrate that the crystallographic properties have a significant influence on the fracture resistance of the alloys, and grain boundary engineering plays a vital role in designing the mechanical behavior of new alloys.
Article
Polymer Science
Markos Petousis, Nectarios Vidakis, Nikolaos Mountakis, Sotirios Grammatikos, Vassilis Papadakis, Constantine N. David, Amalia Moutsopoulou, Subrata C. Das
Summary: The effect of silicon carbide as a boosting agent of the mechanical response of polycarbonate polymer was investigated. The study aimed to fabricate nanocomposites with improved mechanical performance and expand the utilization of 3D printing. The results showed that silicon carbide can enhance the mechanical performance of polycarbonate thermoplastic.
Article
Polymer Science
Nectarios Vidakis, Markos Petousis, Nikolaos Mountakis, Constantine N. David, Dimitrios Sagris, Subrata C. Das
Summary: Sustainability is crucial in today's world due to the rising usage of polymers. Mechanical recycling of polymers, involving grinding/shredding and thermal extrusion, can negatively impact the mechanical performance and introduce contamination. This study investigates the response of Thermoplastic Polyurethane (TPU) in material extrusion (MEX) 3D printing after multiple recycling cycles. The results show that TPU mechanical recycling is a viable option, with the highest tensile strength observed in the sixth repetition of thermal reprocessing.
POLYMER DEGRADATION AND STABILITY
(2023)
Article
Engineering, Manufacturing
Nectarios Vidakis, Markos Petousis, Constantine N. David, Dimitrios Sagris, Nikolaos Mountakis, Emmanuel Karapidakis
Summary: This paper investigates the impact of seven control parameters on the energy consumption and compressive performance of polycarbonates in material extrusion additive manufacturing. The study identifies the most significant factors affecting energy consumption and compressive strength, and establishes quadratic regression models for each response metric.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Materials Science, Multidisciplinary
Peter Pavol Monka, Katarina Monkova, George A. A. Pantazopoulos, Anagnostis I. I. Toulfatzis
Summary: This research aims to study the frequency response of the machining system to different values of tool wear and cutting speed, as well as the effect of artificial wear and cutting speed on vibration and chip shape characteristics. The experimental results showed that brass alloys CW510L and CW614N have lower vibration damping compared to CW724R, while relatively good chip formation was observed in the evaluated machining conditions without a chip breaker. The problematic chip shape only occurred in some cases with CW510L and CW724R, and cannot be generalized.
Article
Materials Science, Multidisciplinary
Nectarios Vidakis, Constantine David, Markos Petousis, Dimitrios Sagris, Nikolaos Mountakis
Summary: Additive Manufacturing (AM) is a cost-effective manufacturing process that offers high flexibility and the capability to fabricate complex geometries. This study investigates the impact of six 3D printing control parameters on the quality of printed parts, and provides predictive equations for optimizing these parameters and improving printing quality.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Chemistry, Physical
Katarina Monkova, Peter Pavol Monka, George A. Pantazopoulos, Anagnostis I. Toulfatzis, Anna Smeringaiova, Jozef Torok, Sofia Papadopoulou
Summary: The development of additive technologies brings new possibilities and challenges, particularly in the use of regular cellular materials to fully utilize the potential of porous structures. This article focuses on investigating the mechanical properties of porous structures made by Direct Metal Laser Sintering (DMLS) of Inconel 718. Two types of basic cell topology, mono-structure Gyroid (G) and double-structure Gyroid + Gyroid (GG), were studied at different material volume ratios. The results show that the mono-structure Gyroid at 10% displayed the best behavior under compression load.
Article
Polymer Science
Markos Petousis, Ioannis Ntintakis, Constantine David, Dimitrios Sagris, Nektarios K. Nasikas, Apostolos Korlos, Amalia Moutsopoulou, Nectarios Vidakis
Summary: In this study, we quantitatively assessed the impact of varying compressive loading rates on the mechanical behavior of four thermoplastic polymers used in material-extrusion-based (MEX) 3D printing. The results showed that the compressive strength and stiffness increased with the increase in strain rate in all polymers tested, with PC exhibiting the highest strain rate sensitivity. These findings are valuable for design optimization in various industrial engineering applications involving these materials.
Article
Materials Science, Multidisciplinary
George A. Pantazopoulos
Article
Chemistry, Multidisciplinary
Constantine David, Dimitrios Sagris, Markos Petousis, Nektarios K. Nasikas, Amalia Moutsopoulou, Evangelos Sfakiotakis, Nikolaos Mountakis, Chrysa Charou, Nectarios Vidakis
Summary: This study aims to predict and optimize the compressive strength and energy consumption in the material extrusion 3D printing process with Polyamide 6 polymer. The effects of seven control variables on energy demands and compressive responses were examined. The study provides an optimal compromise between mechanical strength and energy efficiency, with significant technological and economic benefits.
APPLIED SCIENCES-BASEL
(2023)
Article
Engineering, Industrial
Nectarios Vidakis, Constantine David, Markos Petousis, Dimitrios Sagris, Nikolaos Mountakis, Amalia Moutsopoulou
Summary: This study investigates the effect of 6 control parameters on critical quality indicators in material extrusion additive manufacturing technology. Experimental data and regression models are used to optimize the quality of 3D printed parts and provide insights for control parameter ranking and optimization.
ADVANCES IN INDUSTRIAL AND MANUFACTURING ENGINEERING
(2022)
Article
Engineering, Multidisciplinary
Markos Petousis, Nectarios Vidakis, Emmanuel Velidakis, John D. Kechagias, Constantine N. David, Stefanos Papadakis, Nikolaos Mountakis
Summary: This study investigates the use of Cuprous Oxide (Cu2O) as a filler in a commercial resin for 3D printing to induce biocidal properties. The nanocomposites showed antibacterial performance and mechanical enhancement, suggesting a potential application in engineering and medical fields.