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This study aims to establish a thermally coupled two-dimensional orthogonal cutting model to further improve the modeling process for systematic evaluation of material damage, stiffness degradation, equivalent plastic strain and other material properties, along with cutting temperature distribution and cutting forces. This enhances modeling efficiency and accuracy.

A two-dimensional orthogonal cutting thermo-mechanical coupled finite element model is established in this study. The tanh material constitutive model is used to simulate the mechanical properties of the material. Velocity-dependent friction model between the workpiece and the tool is considered. Material characteristics such as material damage, stiffness degradation, equivalent plastic strain and temperature field during cutting are evaluated through computation. Contact pressure and shear stress on the tool surface are extracted for friction analysis.

Speed-dependent friction models predict cutting force errors as low as 8.6%. The prediction errors of various friction models increase with increasing cutting forces and depths of cut, and simulation results tend to be higher than experimental data.

The current research results provide insights into understanding and controlling tool-chip friction in metal cutting, offering practical recommendations for friction modeling and machining simulation work.

The originality of this research is guaranteed, as it has not been previously published in any journal or publication.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0162/

This study aims to further refine the model, explore the influence of cutting parameters on the machining process, and apply it to practical engineering to improve the efficiency and quality of titanium alloy machining.

This paper establishes a comprehensive thermo-mechanical fully coupled orthogonal cutting model. This paper aims to couple the modified Johnson–Cook constitutive model, damage model and contact model to construct a two-dimensional orthogonal cutting thermo-mechanical coupling model for high-speed cutting of Ti6Al4V. The model considers the evolution of microstructures such as plastic deformation, grain dislocation rearrangement, dynamic recrystallization, as well as stress softening and hardening occurring continuously in Ti6Al4V metal during high-speed cutting. Additionally, the model incorporates friction and contact between the tool and the workpiece. It can be used to predict parameters such as cutting process, cutting force, temperature distribution, stress and strain in titanium alloy machining. The study establishes the model and implements corresponding functions by writing Abaqus VUMAT and VFRICTION subroutines.

The use of different material constitutive models can significantly impact the prediction of the cutting process. Some models may more accurately describe the mechanical behavior of the material, thus providing more reliable prediction results, while other models may exhibit larger deviations. Compared to the Tanh model, the proposed model achieves a maximum improvement of 8.9% in the prediction of cutting force and a maximum improvement of 20.9% in the prediction of chip morphology parameters. Compared to experiments, the proposed model achieves a minimum prediction error of 2.8% for average cutting force and a minimum error of 0.57% for sawtooth parameters. This study provides a comprehensive theoretical foundation and practical guidance for orthogonal cutting of titanium alloys. The model not only helps engineers and researchers better understand various phenomena in the cutting process but also serves as an important reference for optimizing cutting processes.

The originality of this research is guaranteed, as it has not been previously published in any journal or publication.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2024-0168/

The aim of this paper is to review the literature on the prediction of cutting tool life. Tool life is typically estimated by predicting the time to reach the threshold flank wear width. The cutting tool is a crucial component in any machining process, and its failure affects the manufacturing process adversely. The prediction of cutting tool life by considering several factors that affect tool life is crucial to managing quality, cost, availability and waste in machining processes.

This study has undertaken the critical analysis and summarisation of various techniques used in the literature for predicting the life or remaining useful life (RUL) of the cutting tool through monitoring the tool wear, primarily flank wear. The experimental setups that comprise diversified machining processes, including turning, milling, drilling, boring and slotting, are covered in this review.

Cutting tool life is a stochastic variable. Tool failure depends on various factors, including the type and material of the cutting tool, work material, cutting conditions and machine tool. Thus, the life of the cutting tool for a particular experimental setup must be modelled by considering the cutting parameters.

This submission discusses tool life prediction comprehensively, from monitoring tool wear, primarily flank wear, to modelling tool life, and this type of comprehensive review on cutting tool life prediction has not been reported in the literature till now. The future suggestions provided in this review are expected to provide avenues to solve the unexplored challenges in this field.

Cutting force prediction is pretty important for manufacture management. Thus, the purpose of this paper is to obtain the cutting force of the machining process with high efficiency and low cost. A method based on the improved auto regressive moving average (ARMA) model is proposed for cutting force predictions in milling process.

First, classification and normalization are made for initial cutting force. Second, the cutting force sequences are compressed followed singular and valid value removed. At last, the improved ARMA model is used for cutting force fit and extrapolation considered the time domain characteristics.

A series of cutting force with the spindle speed 595r/min is carried out in the research. It is showed that the mean absolute percentage error value of cutting force extrapolation results which is based on the improved model is smaller. The percentage value is approximately 5.80%. Then the root mean square error test value is only 72.49, which is smaller than that with other traditional method, such as hidden Markov model. The extrapolation results with the proposed model performed good consistency and accuracy in terms of peaks, valleys and volatility compared with the experiment results.

The proposed method that is based on the improved ARMA model can be used for cutting force predictions conveniently. And the predictions can be used for improving the qualities in milling process.

Sustainable manufacturing is one of the most important and most challenging issues in present industrial scenario. With the intention of diminish negative effects associated with cutting fluids, the machining industries are continuously developing technologies and systems for cooling/lubricating of the cutting zone while maintaining machining efficiency. In the present study, three regression based machine learning techniques, namely, polynomial regression (PR), support vector regression (SVR) and Gaussian process regression (GPR) were developed to predict machining force, cutting power and cutting pressure in the turning of AISI 1045. In the development of predictive models, machining parameters of cutting speed, depth of cut and feed rate were considered as control factors. Since cooling/lubricating techniques significantly affects the machining performance, prediction model development of quality characteristics was performed under minimum quantity lubrication (MQL) and high-pressure coolant (HPC) cutting conditions. The prediction accuracy of developed models was evaluated by statistical error analyzing methods. Results of regressions based machine learning techniques were also compared with probably one of the most frequently used machine learning method, namely artificial neural networks (ANN). Finally, a metaheuristic approach based on a neural network algorithm was utilized to perform an efficient multi-objective optimization of process parameters for both cutting environment.

Hexahedral meshing is one of the most important steps in performing an accurate simulation using the finite element analysis (FEA). However, the current hexahedral meshing method in the industry is a nonautomatic and inefficient method, i.e. manually decomposing the model into suitable blocks and obtaining the hexahedral mesh from these blocks by mapping or sweeping algorithms. The purpose of this paper is to propose an almost automatic decomposition algorithm based on the 3D frame field and model features to replace the traditional time-consuming and laborious manual decomposition method.

The proposed algorithm is based on the 3D frame field and features, where features are used to construct feature-cutting surfaces and the 3D frame field is used to construct singular-cutting surfaces. The feature-cutting surfaces constructed from concave features first reduce the complexity of the model and decompose it into some coarse blocks. Then, an improved 3D frame field algorithm is performed on these coarse blocks to extract the singular structure and construct singular-cutting surfaces to further decompose the coarse blocks. In most modeling examples, the proposed algorithm uses both types of cutting surfaces to decompose models fully automatically. In a few examples with special requirements for hexahedral meshes, the algorithm requires manual input of some user-defined cutting surfaces and constructs different singular-cutting surfaces to ensure the effectiveness of the decomposition.

Benefiting from the feature decomposition and the 3D frame field algorithm, the output blocks of the proposed algorithm have no inner singular structure and are suitable for the mapping or sweeping algorithm. The introduction of internal constraints makes 3D frame field generation more robust in this paper, and it can automatically correct some invalid 3–5 singular structures. In a few examples with special requirements, the proposed algorithm successfully generates valid blocks even though the singular structure of the model is modified by user-defined cutting surfaces.

The proposed algorithm takes the advantage of feature decomposition and the 3D frame field to generate suitable blocks for a mapping or sweeping algorithm, which saves a lot of simulation time and requires less experience. The user-defined cutting surfaces enable the creation of special hexahedral meshes, which was difficult with previous algorithms. An improved 3D frame field generation method is proposed to correct some invalid singular structures and improve the robustness of the previous methods.

To develop a new method for computer‐based 3D construction of garment basic cut on a computer generated body model.

The method has been developed on an example of a 3D garment basic cut construction on a virtual body model, determining the position of characteristic 3D points necessary for computer‐based definition of 3D cutting pattern contour segments. Contour segments modelling, as well as the modelling of 3D cut surfaces has been done using the NURBS objects.

A 3D garment cut has been constructed, such that matches physical characteristics of the body in question and offers the necessary comfort of the cut. The surface of the 3D cut has been divided into individual 3D cutting patterns.

The method has been developed on an example of a 3D garment basic cut construction of a single paper of clothing. However, the same principles can be applied and developed for any garment basic cut.

The 3D garment cut constructed can be further transformed into a network of polygons. Introducing fabric physical‐chemical properties fabric drape can be simulated, aiming at more realistic visualisation and further assessment of the garment fit. The 3D cutting patterns developed can be, applying computer‐based application of the mathematical models, transformed into 2D cutting patterns.

As compared to the methods developed by some previous investigations, the newly developed method offers the construction of garment 3D cut on a computer‐generated body model, granting the necessary comfort of the cut, which also means garment fitted to individual body characteristics. The 3D cut constructed can also be used as a starting point to define 2D cutting patterns in the following step, which will be matched to the physical characteristics of the model body, in the same way as the initial 3D cut.

The present study spotlights the single and multicriteria decision-making (MCDM) methods to determine the optimal machining conditions and the predictive modeling for surface roughness (Ra) and cutting tool flank wear (VB) while hard turning of AISI 4340 steel (35 HRC) under dry environment.

In this study, Taguchi L16 design of experiments methodology was chosen. The experiments were performed under dry machining conditions using TiSiN-TiAlN nanolaminate PVD-coated cutting tool on which Taguchi and responses surface methodology (RSM) for single objective optimization and MCDM methods like the multi-objective optimization by ratio analysis (MOORA) were applied to attain optimal set of machining parameters. The predictive models for each response and multiresponse were developed using RSM-based regression analysis. S/N ratios, analysis of variance (ANOVA), Pareto diagram, Tukey's HSD test were carried out on experimental data for profound analysis.

Optimal set of machining parameters were obtained as cutting speed: at 180 m/min., feed rate: 0.05 mm/rev., and depth of cut: 0.15 mm; cutting speed: 145 m/min., feed rate: 0.20 mm/rev. and depth of cut: 0.1 mm for Ra and VB, respectively. ANOVA showed feed rate (96.97%) and cutting speed (58.9%) are dominant factors for Ra and VB, respectively. A remarkable improvement observed in Ra (64.05%) and VB (69.94%) after conducting confirmation tests. The results obtained through the MOORA method showed the optimal set of machining parameters (cutting speed = 180 m/min, feed rate = 0.15 mm/rev and depth of cut = 0.25 mm) for minimizing the Ra and VB.

This work contributes to realistic application for manufacturing industries those dealing with AISI 4340 steel of 35 HRC. The research contribution of present work including the predictive models will provide some useful guidelines in the field of manufacturing, in particular, manufacturing of gear shafts for power transmission, turbine shafts, fasteners, etc.

To establish a method of transforming the 3D cutting patterns constructed and modelled into 2D patterns, excluding the fabric parameters.

Three methods have been developed for transforming 3D cutting part segments into 2D segments. They are based on the computer‐based application of the mathematical models developed. The mathematical models differ in their concepts and the application in a particular manner of transforming the 3D segments. Complex spatial matrix transformations have also been developed and used to further transform the 2D segments into the plane of chained 2D cutting pattern segments.

Two‐dimensional cutting patterns have been defined for the 3D garment model, initially constructed on a computer‐generated body model.

The method has been developed on an example of a 3D garment basic cut construction of a single article of clothing. However, the same principles can be applied and developed for any garment basic cut.

The mathematical models developed can be used in a new computer‐based application for the 3D garment construction and the development of the 2D cutting patterns, matched to individual physical characteristics.

The most outstanding property of the method developed is the possibility of gradual transformation of 3D cuts into 2D ones, with no need to define physical‐mechanical properties of the fabric used and no need to introduce fabric drape. The newly created 2D cutting patterns are of outstanding quality and preciseness.

This study was conducted to analyze the effects of machining parameters on the specific energy consumption in the computerized numerical control lathe turning operation of a hardened alloy steel roll at low cutting speeds. The aim was to minimize its consumption.

The design matrix was based on three variable factors at three levels. Response surface methodology was used for the analysis of experimental results. Optimization was carried out by using the desirability function and genetic algorithm. A multiple regression model was used for relationship build-up.

According to desirability function, genetic algorithm and multiple regression analysis, optimal machining parameters were cutting speed 40 m/min, feed 0.2 mm/rev and depth of cut 0.50 mm, which resulted in minimal specific energy consumption of 0.78, 0.772 and 0.78 kJ/mm³, respectively. Correlation analysis and multiple regression model found a quadratic relationship between specific energy consumption with power consumption and material removal rate.

In the past, many researchers have developed mathematical models for specific energy consumption, but these models were developed at high cutting speed, and a majority of the models were based on the material removal rate as the independent variable. This research work developed a mathematical model based on the machining parameters as an independent variable at low cutting speeds, for a new type of large-sized hardened alloy steel roll. A multiple regression model was developed to build a quadratic relationship of specific energy consumption with power consumption and material removal rate. This work has a practical application in hot rolling industry.