Article
Automation & Control Systems
Qiang Xiong, Qiusheng Yan, Jiabin Lu, Jisheng Pan
Summary: The study investigates the formation of edge burrs in the forming grinding of a cemented carbide micro-drill, finding that they are mainly caused by material plastic flow and accumulation of deformation during grinding. Adjusting grinding parameters or the rotation direction of the grinding tool can effectively reduce the generation of edge burrs.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Engineering, Multidisciplinary
Qiang Xiong, Jiabin Lu, Qiusheng Yan, Jisheng Pan
Summary: The formation of edge burrs in cemented carbide micro-drills is mainly related to the actual grinding depth and the cutting angle of abrasive grains. Control methods include increasing the cutting angle of abrasive particles and changing the grinding direction.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2021)
Review
Engineering, Manufacturing
Kai Zeng, Xian Wu, Feng Jiang, Jianyun Shen, Laifa Zhu, Liang Li
Summary: This review offers an overview of the latest technological developments in the traditional cutting and abrasive machining processes of cemented carbide. It briefly presents the microstructure and development of cemented carbide materials, reviews and summarizes current research and achievements in cutting and abrasive machining, discusses the comparison and challenges in different machining processes, and proposes future research directions.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Article
Green & Sustainable Science & Technology
L. A. S. Carreira, A. Hassui, C. E. H. Ventura
Summary: Due to the high demand for electricity in the manufacturing industry and the efforts to reduce environmental impact, investigations to increase energy efficiency in machining processes have been increasingly carried out. However, information on the behavior of insert grinding process is rarely found.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Joerg Hartig, Benjamin Kirsch, Jan C. Aurich
Summary: Cutting edge preparation using elastic bonded superabrasive grinding wheels is highly flexible and achieves high accuracy and repeatability at small and medium cutting depths. The study investigates the impact of process kinematics and parameters on grinding wheel wear and preparation result. Experimental results show that a soft grinding wheel exhibits greater process stability and a hard grinding wheel has higher grinding ratios. Suitable dressing cycles allow for the preparation of a large number of cutting edges using one grinding wheel.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Materials Science, Multidisciplinary
Rohit Singh, Varun Sharma
Summary: In this study, a cemented carbide cutting insert with cobalt alloy variation was developed using microwave radiation processing technique. It was found that the toughness characteristic of the sintered sample increased with an increase in the percentage of binder, while the hardness decreased. The machining of duplex stainless steel using the sintered samples required a higher cutting force compared to the standard tool.
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS
(2022)
Article
Engineering, Chemical
Wang Guo, Xiahui Gui, Yaowen Xing, Hanbo Zhang, Ruofan Ma, Wenlong Meng, Mao Luo
Summary: The objective of this study was to establish a mathematical model to evaluate the unequal-probability comminution of minerals during the grinding process. The effect of grinding time, grinding media filling rate, and powder filling rate on grinding of lithium ore in a lab-scale ball mill was investigated. The results showed that the grinding process of lithium ore followed a non-first grinding kinetic equation and that the breakage rate decreased as particle size decreased. The heterogeneity of the feed, confirmed by differences in elemental content of each size interval of the grinding product, was mainly responsible for the non-first order breakage. The content of Li, Na, and K-bearing minerals for each size interval could be characterized by the change in characteristic element content. It was found that Li-bearing mineral retained larger particles while Na and K-bearing minerals, which tended to break, retained smaller particles during the grinding process. The difference in the relative change of cumulative grade oversize between Li and Na, K increased gradually with increasing grinding time. On the other hand, the difference decreased with increasing grinding media and powder filling rates during the grinding process.
Article
Automation & Control Systems
Yanjie Du, Caixu Yue, Xiaochen Li, Xianli Liu, Steven Y. Liang
Summary: Titanium alloy Ti6Al4V is widely used in the manufacturing of aerospace industrial parts due to its high specific strength, good heat resistance, and strong corrosion resistance. However, in side milling of titanium alloy, issues such as high cutting area temperature and cutting edge breakage may arise. By simulating the tool damage failure mechanism, a theoretical basis can be provided for high-speed and high-efficiency milling of titanium alloy, tool breakage, and tool life.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Automation & Control Systems
Berend Denkena, Benjamin Bergmann, Mirko Theuer, Philipp Wolters
Summary: This paper introduces a novel tool grinding process for the production of high-quality cutting tools. It focuses on the geometric process design and develops a method to determine the necessary parameters for achieving the desired cutting edge geometry. Experimental results demonstrate the successful implementation of this method in practical production.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Ceramics
Jingfei Yin, Min Li, Jiuhua Xu, Wenfeng Ding, Honghua Su
Summary: Silicon carbide fiber-reinforced silicon carbide ceramic matrix composite (SiCf/SiC) shows great potential for manufacturing aero-engines due to its high-temperature resistance and lightweight properties. However, the machining process of SiCf/SiC is challenging due to the material's hardness and brittleness, which often results in uncontrolled damages such as edge chipping, cracks, and fiber breakage. This research focuses on studying the edge chipping characteristics of SiCf/SiC during single grain grinding. The study finds that the edge chipping in SiC matrix grinding is influenced by pre-existing defects, while the edge chipping in SiC fiber grinding is dependent on both fiber orientation and grinding speed. Grinding perpendicular to the fiber orientation results in larger edge chipping compared to grinding along with the fiber orientation, and higher grinding speeds also decrease the width of the edge chipping area. Therefore, increasing grinding speed can enhance material removal rate without enlarging edge chipping, which is crucial for achieving desired surface finish and damage control in the machining of SiCf/SiC.
CERAMICS INTERNATIONAL
(2022)
Article
Thermodynamics
Guangen Zhao, Yongchao Xu, Charles Ming Zheng, Xiao Tian, Chen Lin, QianTing Wang, Youji Zhan
Summary: By using a resin bonded diamond grinding wheel, this study investigated the influence of grinding conditions on the processing quality of ultrafine cemented carbides. Grinding experiments were conducted to study the effects of grinding wheel linear speed, feed speed, and grinding depth on the surface morphology, roughness, and residual stress of the carbides. The relationship between grinding conditions and machining quality was established, enabling the evaluation and prediction of surface quality through ternary regression analysis. Gray relational analysis was then used to optimize the multi-objective surface quality and find the optimal grinding process parameters. The results showed that increasing the grinding linear speed and reducing the feed speed and grinding depth improved the surface plastic removal ratio and reduced the surface roughness. The multi-objective optimization of the grinding process was achieved using gray relational analysis, resulting in the lowest residual stress and surface roughness, providing a theoretical basis for predicting and controlling the surface quality of cemented carbide in the grinding process.
ADVANCES IN MECHANICAL ENGINEERING
(2022)
Article
Chemistry, Physical
Lucas Degeneve, Samy Adjam, Daniele Mari
Summary: Cemented carbides, consisting of hard tungsten carbide grains and a ductile cobalt binder, are widely used in the cutting tools industry for their excellent mechanical properties. Understanding the evolution of the microstructure of the two phases is essential for their extreme conditions of use. Mechanical Spectroscopy reveals three mechanical loss peaks in the spectrum, with the second peak showing a transition in its Arrhenius plot at 1140 K.
JOURNAL OF ALLOYS AND COMPOUNDS
(2022)
Article
Materials Science, Multidisciplinary
W. Albano, S. M. Alves, M. Filgueira
Summary: Nowadays, there is a trend to reduce or eliminate the use of cutting fluid in machining operations. This study investigated the development of self-lubricating cutting tool materials by adding graphite in WC-10wt% Co cemented carbide and analyzed the effect of graphite addition on mechanical properties and wear behavior.
INTERNATIONAL JOURNAL OF REFRACTORY METALS & HARD MATERIALS
(2023)
Article
Engineering, Manufacturing
Jorg Hartig, Benjamin Kirsch, Marco Zimmermann, Jan C. Aurich
Summary: The study investigates the influence of the interaction between metalworking fluid and grinding wheels on cutting edge preparation. It found that the interaction leads to changes in the properties of the grinding wheels, resulting in significant alterations in the geometry of the prepared cutting edges. The effects of this interaction are more pronounced under elevated temperatures.
CIRP JOURNAL OF MANUFACTURING SCIENCE AND TECHNOLOGY
(2022)
Article
Chemistry, Analytical
Lanying Shao, Yu Zhou, Wei Fang, Jiahuan Wang, Xu Wang, Qianfa Deng, Binghai Lyu
Summary: Reasonable cutting edge preparation is crucial for improving the performance of cutting tools. In this study, a flexible fiber-assisted shear thickening polishing method was used to prepare cemented carbide insert cutting edges. The effects of polishing angle and speed on the preparation process were investigated, and the edge shape was evaluated using cutting edge radius and K-factor. The results showed that the polishing angle had a more significant influence on the cutting edge radius, while the polishing speed had a minor effect. The cutting edge shape and surface roughness can be controlled by adjusting the polishing angle.
Article
Engineering, Manufacturing
Wei Li, Qidi Chen, Yinghui Ren, Yi Jiao, Ahmed Mohamed Mahmoud Ibrahim
Summary: The proposed hybrid micro-grinding process utilizes a chemical modification solution to soften the surface layer for manufacturing ultra-precision meso/micro components of monocrystalline silicon. Compared with the conventional micro-grinding process, this technique achieves superior machining quality and significantly reduces tool wear.
MATERIALS AND MANUFACTURING PROCESSES
(2021)
Article
Environmental Sciences
A. H. Elsheikh, T. Muthuramalingam, M. Abd Elaziz, A. M. M. Ibrahim, E. A. Showaib
Summary: This study successfully improved the kerf geometry quality and reduced emitted harmful fumes during CO2 laser cutting of PVC sheets through experimental investigation and optimization. By using Taguchi method for experimental design and genetic algorithm for optimization, a significant decrease in kerf volume was achieved, resulting in a reduction of emitted fumes by 39% to 61%.
INTERNATIONAL JOURNAL OF ENVIRONMENTAL SCIENCE AND TECHNOLOGY
(2022)
Article
Engineering, Multidisciplinary
Wei Li, Zhipeng Li, Jun Yang, Yinghui Ren, Yi Jiao, Hussien Hegab, Ahmed Mohamed Mahmoud Ibrahim
Summary: In recent years, micro-grinding of complex meso/micro-components of hard and brittle materials has gained significant attention. A theoretical model was established to analyze the material removal mechanism and an evaluation factor of edge chipping damage was proposed. The theoretical results were verified using nano-scratch test, proving the efficiency of the proposed evaluation factor in describing and predicting micro-grinding quality.
PRECISION ENGINEERING-JOURNAL OF THE INTERNATIONAL SOCIETIES FOR PRECISION ENGINEERING AND NANOTECHNOLOGY
(2021)
Review
Engineering, Manufacturing
Ammar H. Elsheikh, S. Shanmugan, T. Muthuramalingam, Amrit Kumar Thakur, F. A. Essa, Ahmed Mohamed Mahmoud Ibrahim, Ahmed O. Mosleh
Summary: Residual stresses induced during turning processes can affect the quality and performance of machined products, depending on various factors such as material, cutting-tool configuration, and process parameters. Different research conditions can lead to disagreements regarding the influences of these factors on residual stresses.
ADVANCES IN MANUFACTURING
(2022)
Article
Nanoscience & Nanotechnology
Shuoqing Yan, Wenchao Zhai, Jianhua Xiao, Wenzheng Zhai, Ahmed Mohamed Mahmoud Ibrahim
Summary: This study successfully fabricated GO-decorated Ni superalloys, which exhibit exceptional yield strength and tensile ductility. These superior properties are attributed to collective effects of specific microstructures, including good interfacial bonding, uniformly-distributed precipitates, and GO induced twin boundaries.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Engineering, Chemical
Wenzheng Zhai, Aidong Sun, Wenhan Zeng, Wenlong Lu, Xiaojun Liu, Liping Zhou, Jian Wang, Ahmed Mohamed Mahmoud Ibrahim
Summary: This study demonstrates the potential of the EB-PBF technique to develop alloys with high wear resistance, showing a correlation between wear resistance improvement and precipitate distribution.
Article
Materials Science, Multidisciplinary
Anshuman Das, Smita Padhan, Sudhansu Ranjan Das, Mohammad S. Alsoufi, Ahmed Mohamed Mahmoud Ibrahim, Ammar Elsheikh
Summary: Sustainable machining is a main branch of sustainable manufacturing, aiming to improve environmental conditions, reduce power consumption, and minimize machining costs. In this study, the performance of three sustainable machining techniques was compared during the turning of austenitic stainless steel, with minimum quantity lubrication outperforming the other techniques in terms of economic feasibility and technical viability.
Article
Materials Science, Multidisciplinary
Ammar H. Elsheikh, T. Muthuramalingam, S. Shanmugan, Ahmed Mohamed Mahmoud Ibrahim, B. Ramesh, Ahmed B. Khoshaim, Essam B. Moustafa, Badr Bedairi, Hitesh Panchal, Ravishankar Sathyamurthy
Summary: In this paper, hybrid machine learning models were developed to predict induced residual stresses during turning of Inconel 718 alloy. Traditional artificial neural network was fine-tuned with bioinspired optimizers to enhance prediction accuracy, outperforming traditional ANN. The effects of cutting conditions on induced residual stresses were investigated.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Chemistry, Physical
Smita Padhan, Sudhansu Ranjan Das, Anshuman Das, Mohammad S. Alsoufi, Ahmed Mohamed Mahmoud Ibrahim, Ammar Elsheikh
Summary: This study compares the performance of four cooling/lubrication techniques in machining nickel-based super alloys and finds that MQL technology can significantly reduce cutting force, improve surface quality, lower cutting temperature and white layer thickness, and provide longer tool life.
Article
Chemistry, Multidisciplinary
Navaneethakrishnan Gopal, Parameswaran Palaniyandi, Palanisamy Ramasamy, Hitesh Panchal, Ahmed Mohamed Mahmoud Ibrahim, Mohammad S. Alsoufi, Ammar H. Elsheikh
Summary: In this research, zinc was alloyed with other nutrient metals to make a guided bone regeneration material. The physical, chemical, and biological properties of the alloy were studied and discussed through various tests and analysis methods.
Article
Green & Sustainable Science & Technology
V. Tirupati Rao, Y. Raja Sekhar, Hari Mahesh, Anantha Krishnan Muraleedharan, Derik Charles, N. Aljuraide, Ahmed Mohamed Mahmoud Ibrahim, Mahmoud Helal, Ahmed M. Galal, Rokayya Sami, Jong Wan Hu, Seon Ki Hong, Anka Trajkovska Petkoska
Summary: Different energy solutions are needed to meet the energy demand of the growing global population. Photovoltaic Thermal systems (PVT) can provide real-time solutions for power generation. Life Cycle Analysis (LCA) is used to compare the environmental impact and energy production of different PVT modules. The results show that rooftop installations of PVT systems have lower CO2 emissions compared to open-field installations.
Article
Chemistry, Multidisciplinary
Suyog S. Patil, Anand K. Bewoor, Rajkumar B. Patil, Ravinder Kumar, Bulbul Ongar, Yerlan Sarsenbayev, Seepana PraveenKumar, Ahmed Mohamed Mahmoud Ibrahim, Mohammad S. Alsoufi, Ammar Elsheikh
Summary: Failure Modes, Effects, and Criticality Analysis is used to assess failure modes, causes, and effects of a system. To overcome the limitations of traditional methods, a new model integrating Multi-Criteria Decision-Making approaches and expert opinions is proposed. The model is effective and flexible in handling complex system data.
APPLIED SCIENCES-BASEL
(2022)
Review
Engineering, Aerospace
Ahmed Mohamed Mahmoud Ibrahim, Wei Li, Abdel-hamid Ismail Mourad, Mohamed A. e. Omer, Fadl A. Essa, Ahmed Mustafa Abd El-Naby, Mohammad S. Al Soufi, Muhammad F. Ezzat, Ammar Elsheikh
Summary: This paper provides a detailed overview of lubrication and cooling technologies used in grinding operations and evaluates their effectiveness based on machining outputs, environmental impact, and hygiene effects. It also analyzes the sustainability of different cooling/lubrication strategies. The research presented in this paper serves as a comprehensive compilation of knowledge for future scientists to understand the current advancements and potential future research directions in machining for sustainability.
CHINESE JOURNAL OF AERONAUTICS
(2023)
Article
Multidisciplinary Sciences
H. Gassour, Gamal El-Din Ali Abu El-Magd, Asaad Mazen, Ahmed Mohamed Mahmoud Ibrahim
Summary: This research investigates the mechanical properties improvement of reinforced Al6061 using powder metallurgy (PM) route. It utilizes the nanoparticles strengthening mechanism to enhance the prepared samples' mechanical properties. The experimental results revealed highest hardness values at 2 wt% AgNPs reinforced sample that was sintered at 600 degrees C, while the lowest was obtained at un-reinforced sample sintered at 550 degrees C. Furthermore, the compression strength of sample reinforced with 2 wt% AgNPs and sintered at 600 degrees C recorded an improvement of 25.8% of the maximum compression strength compared to the un-reinforced sample, as it reached 216 N/mm(2).
SCIENTIFIC REPORTS
(2023)
