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Article
Publication date: 18 August 2022

Shailendra Chauhan, Rajeev Trehan and Ravi Pratap Singh

This work aims to describe the face milling analysis on Inconel X-750 superalloy using coated carbides. The formed chips and tool wear were further analyzed at different cutting…

Abstract

Purpose

This work aims to describe the face milling analysis on Inconel X-750 superalloy using coated carbides. The formed chips and tool wear were further analyzed at different cutting parameters. The various impact of cutting parameters on chip morphology was also analyzed. Superalloys, often referred to as heat-resistant alloys, have exceptional tensile, ductile and creep strength at high operating temperatures and good fatigue strength, and often better corrosion and oxidation resistance at extreme heat. Because of these qualities, these alloys account for more than half of the weight of sophisticated aviation, biomedical and thermal power plants today. Inconel X-750 is a high-temperature nickel-based superalloy that is hard to machine because of its extensive properties. At last, the discussion regarding the tool wear mechanism was analyzed and discussed in this article.

Design/methodology/approach

The machining parameters for the study are cutting speed, feed rate and depth of cut. One factor at a time approach was implemented to investigate the effect of cutting parameters on the cutting forces, surface roughness and material removal rate. The scatter plot was plotted between cutting parameters and target functions (cutting forces, surface roughness and material removal rate). The six levels of cutting speed, feed rate and depth of cut were taken as cutting parameters.

Findings

The cutting forces are primarily affected by the cutting parameters, tool geometry, work material etc. The maximum forces Fx were encountered at 10 mm/min cutting speed, 0.15 mm/rev feed rate and 0.4 mm depth of cut, further maximum forces Fy were attained at 10 mm/min cutting speed, 0.25 mm/rev feed rate and 0.4 mm depth of cut and maximum forces Fz were attained at 50 mm/min cutting speed, 0.05 mm/rev feed rate and 0.4 mm depth of cut. The maximum surface roughness value was observed at 40 mm/min cutting speed, 0.15 mm/rev feed rate and 0.5 mm depth of cut.

Originality/value

The effect of machining parameters on cutting forces, surface roughness, chip morphology and tool wear for milling of Inconel X-750 high-temperature superalloy is being less researched in the present literature. Therefore, this research paper will give a direction for researchers for further studies to be carried out in the domain of high-temperature superalloys. Furthermore, the different tool wear mechanisms at separate experimental trials have been explored to evaluate and validate the process performance by conducting scanning electron microscopy analysis. Chip morphology has also been evaluated and analyzed under the variation of selected process inputs at different levels.

Details

World Journal of Engineering, vol. 21 no. 1
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 26 September 2023

Talwinder Singh, Chandan Deep Singh and Rajdeep Singh

Because many cutting fluids contain hazardous chemical constituents, industries and researchers are looking for alternative methods to reduce the consumption of cutting fluids in…

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Abstract

Purpose

Because many cutting fluids contain hazardous chemical constituents, industries and researchers are looking for alternative methods to reduce the consumption of cutting fluids in machining operations due to growing awareness of ecological and health issues, government strict environmental regulations and economic pressures. Therefore, the purpose of this study is to raise awareness of the minimum quantity lubrication (MQL) technique as a potential substitute for environmental restricted wet (flooded) machining situations.

Design/methodology/approach

The methodology adopted for conducting a review in this study includes four sections: establishment of MQL technique and review of MQL machining performance comparison with dry and wet (flooded) environments; analysis of the past literature to examine MQL turning performance under mono nanofluids (M-NF); MQL turning performance evaluation under hybrid nanofluids (H-NF); and MQL milling, drilling and grinding performance assessment under M-NF and H-NF.

Findings

From the extensive review, it has been found that MQL results in lower cutting zone temperature, reduction in cutting forces, enhanced tool life and better machined surface quality compared to dry and wet cutting conditions. Also, MQL under H-NF discloses notably improved tribo-performance due to the synergistic effect caused by the physical encapsulation of spherical nanoparticles between the nanosheets of lamellar structured nanoparticles when compared with M-NF. The findings of this study recommend that MQL with nanofluids can replace dry and flood lubrication conditions for superior machining performance.

Practical implications

Machining under the MQL regime provides a dry, clean, healthy and pollution-free working area, thereby resulting the machining of materials green and environmentally friendly.

Originality/value

This paper describes the suitability of MQL for different machining operations using M-NF and H-NF.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0131/

Details

Industrial Lubrication and Tribology, vol. 75 no. 9
Type: Research Article
ISSN: 0036-8792

Keywords

Open Access
Article
Publication date: 29 February 2024

Guanchen Liu, Dongdong Xu, Zifu Shen, Hongjie Xu and Liang Ding

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous…

Abstract

Purpose

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Design/methodology/approach

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

Findings

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

Originality/value

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

Details

Journal of Intelligent Manufacturing and Special Equipment, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2633-6596

Keywords

Article
Publication date: 14 August 2023

Abhishek Kansal, Akshay Dvivedi and Pradeep Kumar

The purpose of this study to investigate the organized porous network zinc (OPNZ) scaffolds. Their mechanical characteristics, surface roughness and fracture mechanism were…

Abstract

Purpose

The purpose of this study to investigate the organized porous network zinc (OPNZ) scaffolds. Their mechanical characteristics, surface roughness and fracture mechanism were assessed in relation to their structural properties. The prospects of fused deposition modeling (FDM) for printing metal scaffolds via rapid tooling have also been studied.

Design/methodology/approach

Zn scaffolds with different pore and strut sizes were manufactured via the rapid tooling method. This method is a multistep process that begins with the 3D printing of a polymer template. Later, a paraffin template was obtained from the prepared polymer template. Finally, this paraffin template was used to fabricate the Zn scaffold using microwave sintering. The characterization of prepared Zn samples involved structural characterization, microstructural study, surface roughness testing and compression testing. Moreover, based on the Gibson–Ashby model analysis, the model equations’ constant values were evaluated, which can help in predicting the mechanical properties of Zn scaffolds.

Findings

The scanning electron microscopy study confirmed that the fabricated sample pores were open and interconnected. The X-ray diffraction analysis revealed that the Zn scaffold contained hexagonal closed-packed Zn peaks related to the a-Zn phase, validating that scaffolds were free from contamination and impurity. The range for ultimate compressive strength, compressive modulus and plateau stresses for Zn samples were found to be 6.75–39 MPa, 0.14–3.51 GPa and 1.85–12.6 MPa by adjusting their porosity, which are comparable with the cancellous bones. The average roughness value for the Zn scaffolds was found to be 1.86 µm.

Originality/value

This research work can widen the scope for extrusion-based FDM printers for fabricating biocompatible and biodegradable metal Zn scaffolds. This study also revealed the effects of scaffold structural properties like porosity, pore and strut size effect on their mechanical characteristics in view of tissue engineering applications.

Details

Rapid Prototyping Journal, vol. 29 no. 9
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 13 December 2023

Nivin Vincent and Franklin Robert John

This study aims to understand the current production scenario emphasizing the significance of green manufacturing in achieving economic and environmental sustainability goals to…

Abstract

Purpose

This study aims to understand the current production scenario emphasizing the significance of green manufacturing in achieving economic and environmental sustainability goals to fulfil future needs; to determine the viability of particular strategies and actions performed to increase the process efficiency of electrical discharge machining; and to uphold the values of sustainability in the nonconventional manufacturing sector and to identify future works in this regard.

Design/methodology/approach

A thorough analysis of numerous experimental studies and findings is conducted. This prominent nontraditional machining process’s potential machinability and sustainability challenges are discussed, along with the current research to alleviate them. The focus is placed on modifications to the dielectric fluid, choosing affordable substitutes and treating consumable tool electrodes.

Findings

Trans-esterified vegetable oils, which are biodegradable and can be used as a substitute for conventional dielectric fluids, provide pollution-free machining with enhanced surface finish and material removal rates. Modifying the dielectric fluid with specific nanomaterials could increase the machining rate and demonstrate a decrease in machining flaws such as micropores, globules and microcracks. Tool electrodes subjected to cryogenic treatment have shown reduced tool metal consumption and downtime for the setup.

Practical implications

The findings suggested eco-friendly machining techniques and optimized control settings that reduce energy consumption, lowering operating expenses and carbon footprints. Using eco-friendly dielectrics, including vegetable oils or biodegradable dielectric fluids, might lessen the adverse effects of the electrical discharge machine operations on the environment. Adopting sustainable practices might enhance a business’s reputation with the public, shareholders and clients because sustainability is becoming increasingly significant across various industries.

Originality/value

A detailed general review of green nontraditional electrical discharge machining process is provided, from high-quality indexed journals. The findings and results contemplated in this review paper can lead the research community to collectively apply it in sustainable techniques to enhance machinability and reduce environmental effects.

Details

World Journal of Engineering, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 5 January 2024

Shucai Yang, Dawei Wang and Zhanjun Xiao

The purpose is to explore the improvement mechanism of coating and laser micro-texture on the surface properties of cemented carbide, so as to give full play to the technical…

Abstract

Purpose

The purpose is to explore the improvement mechanism of coating and laser micro-texture on the surface properties of cemented carbide, so as to give full play to the technical advantages of both and improve the overall surface properties of the material.

Design/methodology/approach

The surface hardness of the coating was measured by a microhardness tester, the surface element composition of the coating was tested by an energy spectrum analyzer and the phase was measured by an X-ray diffractometer to observe the surface morphology after the friction and wear experiment.

Findings

Laser will generate new oxide and nitride films on the surface of the coating, which will improve the hardness of the coating surface and the bonding strength between the coating and the substrate. The surface micro-texture can collect wear debris during the friction process, reduce abrasive wear and play a good role in inhibiting the expansion of the coating failure zone.

Originality/value

Most of the research on traditional laser coating is to process micro-texture first and then coating. This study is the opposite. In this paper, the modification effect of laser on the coating surface is explored, and the parameters of laser and coating are optimized, which paves the way for the subsequent milling experiments of textured coating tools.

Details

Industrial Lubrication and Tribology, vol. 76 no. 1
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 21 December 2022

Ravinder Kumar and Sahendra Pal Sharma

This experimental study aims to deal with the improvement of process performance of electric discharge drilling (EDD) for fabricating true blind holes in titanium alloy Ti6Al4V…

Abstract

Purpose

This experimental study aims to deal with the improvement of process performance of electric discharge drilling (EDD) for fabricating true blind holes in titanium alloy Ti6Al4V. Micro EDD was performed on Ti6Al4V and blind holes were drilled into the workpiece.

Design/methodology/approach

The effects of input parameters (i.e. voltage, capacitance and spindle speed) on responses (i.e. material removal rate, tool wear rate and surface roughness [SR]) were evaluated through response surface methodology. The data was analyzed using analysis of variance and multi-optimization was performed for the optimized set of parameters. The optimized process parameters were then used to drill deeper blind holes.

Findings

Blind holes have few characteristics such as SR, taper angle and corner radius. The value of corner radius reflects the quality of the hole produced as well as the amount of tool roundness. The optimized process parameters suggested by the current experimental study lower down the response values (i.e. SR, taper angle and corner radius). The process is found very effective in producing finished blind holes.

Originality/value

This experimental study establishes EDD as a feasible process for the fabrication of truly blind holes in Ti6Al4V.

Details

World Journal of Engineering, vol. 21 no. 2
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 7 December 2023

Murat Isik, Isa Emami Tabrizi, Raja Muhammad Awais Khan, Mehmet Yildiz, Eda Aydogan and Bahattin Koc

In recent years, additive manufacturing (AM) has started to be used for manufacturing real functional parts and assemblies for critical applications in aerospace, automotive, and…

Abstract

Purpose

In recent years, additive manufacturing (AM) has started to be used for manufacturing real functional parts and assemblies for critical applications in aerospace, automotive, and machinery industries. Most complex or assembled parts require internal features (IF) such as holes, channels, slots, or guides for locational and mating requirements. Therefore, it is critical to understand and compare the structural and mechanical properties of additively manufactured and conventionally machined IFs.

Design/methodology/approach

In this study, mechanical and microstructural properties of Inconel 718 (Inc718) alloy internal features, manufactured either as-built with AM or machining of additively manufactured (AMed) part thereafter were investigated.

Findings

The results showed that the average ultimate tensile strength (UTS) of additively manufactured center internal feature (AM-IF) is almost analogous to the machined internal feature (M-IF). However, the yield strength of M-IF is greater than that of AM-IF due the greater surface roughness of the internal feature in AM-IF, which is deemed to surpass the effect of microstructure on the mechanical performance. The results of digital image correlation (DIC) analysis suggest that AM-IF and M-IF conditions have similar strain values under the same stress levels but the specimens with as built IF have a more locally ductile region around their IF, which is confirmed by hardness test results. But this does not change global elongation behavior. The microstructural evolution starting from as-built (AB) and heat-treated (HT) samples to specimens with IF are examined. The microstructure of HT specimens has bimodal grain structure with d phase while the AB specimens display a very fine dendritic microstructure with the presence of carbides. Although they both have close values, machined specimens have a higher frequency of finer grains based on SEM images.

Originality/value

It was shown that the concurrent creation of the IF during AM can provide a final part with a preserved ultimate tensile strength and elongation but a decreased yield strength. The variation in UTS of AM-IF increases due to the surface roughness near the internal feature as compared to smooth internal surfaces in M-IF. Hence, the outcomes of this study are believed to be valuable for the industry in terms of determining the appropriate production strategy of parts with IF using AM and postprocessing processes.

Details

Rapid Prototyping Journal, vol. 30 no. 2
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 14 August 2023

Usman Tariq, Ranjit Joy, Sung-Heng Wu, Muhammad Arif Mahmood, Asad Waqar Malik and Frank Liou

This study aims to discuss the state-of-the-art digital factory (DF) development combining digital twins (DTs), sensing devices, laser additive manufacturing (LAM) and subtractive…

Abstract

Purpose

This study aims to discuss the state-of-the-art digital factory (DF) development combining digital twins (DTs), sensing devices, laser additive manufacturing (LAM) and subtractive manufacturing (SM) processes. The current shortcomings and outlook of the DF also have been highlighted. A DF is a state-of-the-art manufacturing facility that uses innovative technologies, including automation, artificial intelligence (AI), the Internet of Things, additive manufacturing (AM), SM, hybrid manufacturing (HM), sensors for real-time feedback and control, and a DT, to streamline and improve manufacturing operations.

Design/methodology/approach

This study presents a novel perspective on DF development using laser-based AM, SM, sensors and DTs. Recent developments in laser-based AM, SM, sensors and DTs have been compiled. This study has been developed using systematic reviews and meta-analyses (PRISMA) guidelines, discussing literature on the DTs for laser-based AM, particularly laser powder bed fusion and direct energy deposition, in-situ monitoring and control equipment, SM and HM. The principal goal of this study is to highlight the aspects of DF and its development using existing techniques.

Findings

A comprehensive literature review finds a substantial lack of complete techniques that incorporate cyber-physical systems, advanced data analytics, AI, standardized interoperability, human–machine cooperation and scalable adaptability. The suggested DF effectively fills this void by integrating cyber-physical system components, including DT, AM, SM and sensors into the manufacturing process. Using sophisticated data analytics and AI algorithms, the DF facilitates real-time data analysis, predictive maintenance, quality control and optimal resource allocation. In addition, the suggested DF ensures interoperability between diverse devices and systems by emphasizing standardized communication protocols and interfaces. The modular and adaptable architecture of the DF enables scalability and adaptation, allowing for rapid reaction to market conditions.

Originality/value

Based on the need of DF, this review presents a comprehensive approach to DF development using DTs, sensing devices, LAM and SM processes and provides current progress in this domain.

Open Access
Article
Publication date: 19 March 2024

Zhenlong Peng, Aowei Han, Chenlin Wang, Hongru Jin and Xiangyu Zhang

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC…

Abstract

Purpose

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.

Design/methodology/approach

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.

Findings

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.

Originality/value

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.

Details

Journal of Intelligent Manufacturing and Special Equipment, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 2633-6596

Keywords

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