Search results

Optimisation of grinding processes involves enhancing the surface quality and reducing the cost of manufacturing through reduction of power consumptions. Recent research works have indicated the minimum quantity lubrication (MQL) system is used to achieve near dry machining of alloys and hard materials. This study aims to provide an experimental analysis of the grinding process during machining of aluminium alloy (Al6061-T6). MQL nanofluid was used as the lubricant for the grinding operations. The lubricant was formed by suspending silicon dioxide nanoparticles in canola vegetable oil. The effect of input parameters (i.e. nanoparticle concentration, depth of cut, air pressure and feed rate) on the grinding forces and surface quality was studied. Adaptive neuro-fuzzy inference system (ANFIS) prediction modelling was used to predict the specific normal force, specific tangential force and surface quality, the ANFIS models were found to have prediction accuracies of 97.4, 96.6 and 98.5 per cent, respectively. Further study shows that both the specific grinding forces and surface roughness are inversely proportional to the nanofluid concentration. Also, the depth of cut and table feed rate were found to have a directly proportional relationship with both the grinding forces and surface roughness. Moreover, higher MQL air pressure was found to offer better delivery of the atomised nanofluid into the grinding region.

Grinding experiments were performed using MQL nanofluid as the lubricant. The lubricant was formed by suspending silicon dioxide nanoparticles in canola vegetable oil. The effect of input parameters (i.e. nanoparticle concentration, depth of cut, air pressure and feed rate) on the grinding forces and surface quality has been studied.

The grinding process parameters were optimised using Taguchi S/N ratio analysis, whereas the prediction of the response parameters was done using ANFIS modelling technique. The developed ANFIS models for predicting the specific normal force, specific tangential force and surface quality were found to have prediction accuracies of 97.4, 96.6 and 98.5 per cent, respectively. Further findings show that both the specific grinding forces and surface roughness are inversely proportional to the percentage of nanoparticle concentration in the lubricant. Also, the depth of cut and table feed rate were found to exhibit a direct proportional relationship with both the grinding forces and surface roughness, while high MQL air pressure was observed to offer more efficient delivery of the atomised nanofluid into the grinding region.

The work can applied into manufacturing industries to prevent unnecessary trials and material wastages.

The purpose of this study is to develop an artificial intelligent model for predicting the outcomes of MQL grinding of the aluminium alloy material using ANFIS modelling technique.

This paper aims that optimization parameters depending on machining processes examine to define for the milling process of AL 6061-T6 aluminum alloy used in the aviation industry.

The Taguchi method was used to study the optimal parameters. Furthermore, the effects of machining parameters on surface roughness were also evaluated by performing variance analysis. Optimum parameter levels were determined by Signal/Noise analysis.

It was determined that the parameter levels that optimize the surface roughness were “4000 rev/min for the rotational speed of the cutting tool, 0.4 mm for the cutting depth and the optimum value for the feedrate 500 mm/min.”

It is limited by the precision of the manufacturing processes, the desired geometry and the exactness of the measurement make the machine productivity valuable in the production of parts.

By improving the optimal production parameters, reducing part production costs and waste amount in aviation has been seen as an important gain.

Improving production methods and optimization parameters in production technologies will ensure the minimization of loss and waste. These developed parameters with optimizing the surface roughness will add value in this context.

It was determined that the parameter levels that optimize the surface roughness of aluminum considering manufacturing processes. Especially as process parameters, optimum feed rate has been developed for effective rotation speed and cutting depth for cutting tools.

The purpose of this paper is to find out the optimal level as well as the influence of end mill cutter geometrical and machining parameters while machining metal matrix composite. End milling is carried out on Al 356/SiC metal matrix composites (MMC) using high-speed steel (HSS) end mill cutter. The optimum level of input parameters such as helix angle, nose radius, rake angle, cutting speed, feed rate and depth of cut are calculated for minimum temperature rise.

L27 Taguchi orthogonal design, signal-to-noise (S/N) ratio, are applied for conducting experiments, and to find the optimal level of input parameters for minimum temperature rise, respectively. Analysis of variance (ANOVA) is used to analyze the significance of input parameters on temperature rise.

It is found that the optimal combination of helix angle 400, nose radius 0.8 mm, rake angle 80, cutting speed 30 m/min, feed rate 0.04 mm/rev and depth of cut 0.5 mm have generated minimum temperature rise. From ANOVA analysis, it is found that rake angle influence is more on output performance followed by cutting speed and nose radius compared with other machining and geometrical parameters.

The influence of geometrical parameters such as helix angle, nose radius and rake angle of end mill cutter on temperature rise while machining MMC has not been explored previously.

The purpose of this paper is to analyze the literature that is currently available and take a glance at minimum quantity lubrication (MQL) with nanofluids (NFs) as viable candidates to improve the efficiency of various milling operations on challenging materials.

The extensive literature review is carried through the existing literature, which shows the effect of various process parameters in the milling operation of challenging materials under NF-MQL conditions. The manuscript also deals with identifying the inferences and research gaps from the literature review. The role and potential of NF-MQL in milling challenging materials are identified in this work.

The conclusion has also derived some recommendations for future study from the prior research, which will be helpful for any further research in this area.

This research work is limited to milling operations in challenging materials.

NF-MQL applications in milling operations are comparatively underexplored and merit considerable research. The amount of effort industry practitioners put into sustainable manufacturing will surely be greatly reduced by thorough research on the milling of challenging materials under NF-MQL settings.

MQL system has a great potential to perform well in the experimental endeavor. Despite that fact, majority of the small and medium scale manufacturing industries are still using the conventional flood system for the machining of the workpieces because of the unaffordable initial cost and requirement of expertise involved as compared to the flooded lubrication. This issue might be solved when more works will be accomplished in industries for small as well as medium scale production.

These are novel study approaches because there are so many variables that affect cutting efficiency; therefore, more research is required to assess and provide direction for the advancement of hard milling technology.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-01-2023-0010/

This work describes the fabrication of composite nanogrease based on carbon nanotubes (CNTs) as an additive at different volume concentrations 0, 0.5, 1, 2 and 3 Wt.% and investigates the correlation between CNTs and grease rheological behaviour. In addition, study the influence of shear thinning rate at various temperatures and investigates the thermal conductivity of nanogrease. The results demonstrated that grease behaves like a Newtonian viscoelastic material with a narrow linear domain. The thermal conductivity of nanogrease was enhanced by about 31.58 per cent, and the thermal and mechanical stabilities improved. Moreover, the apparent viscosity and dropping point increased by about 93 and 27 per cent, respectively.

Grease was dissolved in chloroform (10 Wt.%), at 25°C for 1 h. In parallel, functionalized CNTs with different volume concentrations (0.5, 1, 2 and 3 Wt.%) were dispersed in N,N-dimethylformamide; the dispersion was stirred for 15 min, and then sonicated (40 kHz, 150 W) for 30 min. Grease solution was then added to the CNTs. The nanofluid was magnetically stirred for 15 min and then sonicated for 2 h. This ensured uniform dispersion of nanoparticles in the base fluid.

Inexpensive and simple fabrication of nanogrease. Thermal conductivity of nanogrease was typically enhanced compared to other reported studies. Apparent viscosity and dropping point increases with the increase the volume concentration.

This work describes the inexpensive and simple fabrication of nanogrease for improving properties of lubricants, which improve power efficiency and extend lifetimes of mechanical equipment.

This paper seeks to provide an insight into the design and development of the thermal test model (TTM) of X‐Sat, a 120 kg class micro‐satellite, being developed at the Centre. This model was specifically constructed for carrying out a thermal balance test (TBT) in a 4 m diameter vertical thermal vacuum chamber.

The construction of the thermal model followed a structural mock‐up model which was modified thermally to suit the purpose. Specific and careful consideration was given to the geometry and, more importantly, thermal characteristics such as thermal mass, surface properties, etc. to mimic the actual satellite configuration as closely as possible. Test plans were devised to qualify the fabricated components to meet the out‐gassing and other thermal requirements for the model. Design and qualification of supporting frame and linkages for TBT are also covered.

It is possible to simulate the thermal characteristics of a micro‐satellite in orbit under a different mission scenario through proper scaling and using alternative material options while developing TTM.

The paper discusses in detail the simplified cost‐effective approach of constructing TTM and also outlines the various issues to be considered for a TBT. It provides valuable information needed for micro‐satellite designers.

The process of hydroforming is defined as the formation of parts into the internal mold design using internal pressure. This process can extensively reduce parts and secondary operations, and adoption to the loading path is one of its most essential points. The purpose of this paper is to address these issues.

A dynamic loading path was taken into account in the current study, and a drop hammer was employed for this purpose, decreasing the time and requiring less number of systems.

One of the main observations of this research is that selecting side punches with a smaller central hole radius is proportional to the kinetic energy and the amount of fluid. Moreover, it can be effective in achieving the optimal loading path.

In addition to experiments for numerical analyses, the finite element simulation model was provided via Abaqus software in which the Eulerian–Lagrangian coupling method was utilized for evaluating the tube forming process through repeating the fluid flow formation because of the effect. Moreover, the genetic programming model was efficient for determining the most suitable input parameters regarding prediction for the minimum thickness which examined the efficiency of the process and presented a mathematical relationship.

Al‐alumina interconnected phase composites were processed using the direct fused deposition process. These materials with tailored microstructures can find applications as structural materials with gradient properties.

In this process, feedstock material with fused silica as a starting material was compounded at a high shear mixer and then extruded as a filament using a single screw extruder. Extruded filaments were used with a commercial fused deposition modeler, FDM 1650, to process controlled porosity green ceramic structures. Porous green ceramic preforms were subjected to binder removal and sintering cycles in furnace air. Controlled porosity sintered ceramic structures were infiltrated with Al 5052 metal by pressureless reactive metal infiltration to form an in situ Al‐alumina structured composite.

The main advantage for this approach is to control distribution of both metal and ceramic phases in the composite. During metal infiltration good bonding was observed between the metal and the ceramic phases. Composites were tested under both quasi‐static and dynamic shock loading to evaluate their mechanical properties. Compression strength of these composites was 689±95 MPa.

This paper describes application of the direct fused deposition process for fabrication of ceramic/metal composites where both macrostructure as well as microstructure can be controlled simultaneously. The paper also focuses on one of the potential application area for 5052‐Al alloy.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

The purpose of the study is to fabricate a joint between two aluminium metal matrix composites using microwave hybrid heating (MHH).

Taguchi design of experiments was applied to conduct the experimental study. The mechanical properties such as ultimate tensile strength, micro-hardness and porosity were studied. Grey Relational Analysis was applied to understand the significance of fabrication parameters of best performing sample. The dominant factor of fabrication was analysed using ANOVA. The best performance sample was further characterised using X-ray diffraction and field emission scanning electron microscopy. Energy dispersive X-ray was used to analyse the elemental composition of the sample.

The Aluminium Metal Matrix Composite (AMMC) joint was successfully fabricated using MHH. The mechanical properties were mainly influenced by the fabrication factor of exposure time.

The formation of AMMC joint using MHH might explore the way for the industries in the field of joining.