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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.

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.

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.

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.

Investigates the effects of the most influential cutting parameters (cutting speed, feed rate, depth of cut, tool nose radius, tool length and work piece length) on surface roughness quality and on the formation of built‐up edge in a lathe dry turning process of mild carbon steel samples. A full factorial design (384 experiments), taking into account the three‐level interactions between the independent variables has been conducted. The results show that the following three‐level interactions: feed rate × cutting speed × depth of cut, feed rate × cutting speed × tool nose radius and tool nose radius × depth of cut × tool length have significant effects on surface roughness in this type of machining operation. Shows that the analysis of main effects alone and even two‐level interactions could lead to a false interpretation of the results. The analysis of variance revealed that the best surface roughness is achieved with a low feed rate, a large tool nose radius and a high cutting speed. The results also show that the depth of cut has no significant effect on surface roughness when operating at cutting speeds higher than 160m/min. Furthermore, it is shown that built‐up edge formation deteriorates surface roughness when machining mild carbon steel at specific feed rate, tool nose radius and cutting speed levels. Proposes a new model for evaluating the limiting cutting speed to avoid the built‐up edge formation. Finally, shows through experimentation that an increase in depth of cut would lead to improved surface roughness when tool vibration is increased.

The purpose of this paper is to evaluate surface integrity of quenched steel 1045 ground drily by the brazed cubic boron nitride (CBN) grinding wheel and the black SiC wheel, respectively. Surface integrity, including surface roughness, sub-surface hardness, residual stresses and surface morphology, was investigated in detail, and the surface quality of samples ground by two grinding wheels was compared.

In the present work, surface integrity of quenched steel 1045 machined by the CBN grinding wheel and the SiC wheel was investigated systematically. All the specimens were machined with a single pass in the down-cutting mode of dry condition. Surface morphology of the ground specimen was observed by using OLYMPUS BX51M optical microscopy. Surface roughness of seven points was measured by using a surface roughness tester at a cut-off length of 1.8 mm and the measurement traces were perpendicular to the grinding direction. Sub-surface micro-hardness was measured by using HVS-1000 digital micro-hardness tester after the cross-section surface was polished. The residual stress was tested by using X-350A X-ray stress analyzer.

When the cut depth is increased from 0.01 to 0.07 mm, the steel surface machined by the CBN wheel remains clear grinding mark, lower roughness, higher micro-hardness and higher magnitude of compressive stress and fine microstructure, while the surface machined by the SiC grinding wheel becomes worse with increasing of cut depth. The value of micro-hardness decreases, and the surface roughness increases, and the surface compressive stress turns into tensile stress. Some micro-cracks and voids occur when the sample is processed by the SiC grinding wheel with cut depth 0.07 mm.

In this paper, the specimens of quenched steel 1045 were machined by the CBN grinding wheel and the SiC wheel with various cutting depths. The processing quality resulted from the CBN grinding wheel is better than that resulted from the SiC grinding wheel.

This study aims to reveal the influence of milling process parameters on the surface roughness and morphology of superalloy GH4145.The groove milling mechanism and surface quality influence factors of superalloy GH4145 were studied experimentally.

This paper provides investigations on three-dimensional finite element model (FEM) and simulation of milling process for GH4145.The milling experiment uses Taguchi L16 experimental design and single factor experimental design. The surface morphology of the workpiece was observed by scanning electron microscopy, and the influence mechanism of milling parameters on surface quality is expounded.

The results show that the cutting force increases by 133% with the increase in milling depth. The measured minimum surface roughness is 0.035 µm. With the change in milling depth, the surface roughness increases by 249%. With the change in cutting speed, the surface roughness increased by 54.8%. As the feed rate increases, the surface roughness increases by a maximum of 91.1%. The milling experiment verifies that the error between the predicted surface roughness and the actual value is less than 8%.

The milling experiment uses a Taguchi L16 experimental design and a single-factor experimental design. Mathematical models can be used in research as a contribution to current research. In addition, the milling cutter can be changed to further test this experiment. Reveal the influence of milling process parameters on the surface roughness and morphology of superalloy GH4145.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2024-0080/

The purpose of this paper is to measure the effect of rake angle on cutting forces on the rake face of single point cutting tool with two cutting conditions. The experimental setup has been developed to measure the cutting forces. The study aims to put forward the optimum cutting condition, which improves the product quality, surface finish, productivity and tool life.

The load cell-based tool dynamometer has been developed to measure the cutting forces. The experiments have performed on the mild steel bar of hardness 60 BHN. The friction and the normal forces have measured in dry cutting condition and with rust-X cutting fluids. The cutting forces for these two cutting conditions have calculated with constant depth of cut, speed and feed with different rake angles in the range of degrees 6, 7, 8, 9, 10, 11, 12, 15 and 20.

The experimental observations shows the variations of friction and normal forces with different cutting conditions and parameters. It shows the friction force on rake face increase and the normal force on the rake face decreases with increase the rake angle.

The observations has done only for mild steel of hardness 60 BHN. It can also be perform on different materials and for different cutting conditions.

The experimental setup developed in this research can be used in the manufacturing industry. It can help to decide and maintain the optimum cutting conditions.

The observations have been made on an experimental setup, which fulfills the actual working/cutting conditions as per the use in industries.

The Finite Element Method and Response Surface Method are used to find the effect of milling parameters (Cutting speed, Feedrate and Axial depth) on plastic strain when milling Hastelloy C‐22HS. This simulation gain more understanding of the strain distribution in metal cutting. Response surface method (RSM) has been used to minimize the number of simulation. The contour plot from the RSM shows the relationship between variables (cutting speed, feedrate and axial depth) and response (plastic strain ‐ rate).The friction interaction along the tool‐chip interface is modeled with Coulomb friction law.

The objective of this research is focused on the design of a new hybrid composite as well as to analyse the optimum turning conditions to minimise the surface roughness and work piece surface temperature, thereby increasing the productivity.

Mechanical properties such as hardness and tensile strength of Al-Si10Mg alloy reinforced with 3, 6 and 9 wt.% of alumina along with 3 wt.% of graphite prepared by stir casting method have been evaluated. The present study addresses the machinability parameter optimisation of Al alloy-9 per cent alumina-3 per centgraphite. Experiments were conducted based on the Taguchi parameter design by varying the feed (0.1, 0.15 and 0.2 mm/rev), cutting speed (200, 250 and 300 m/min) and depth of cut (0.5, 1.0 and 1.5 mm). The results were then analysed using analysis of variance (ANOVA).

Mechanical properties of the hybrid composite increases with reinforcement content. The surface roughness decreases with increasing cutting speed and conversely increases with increasing feed and depth of cut. The work piece surface temperature increases as cutting speed, feed and depth of cut increases. The ANOVA result reveals that feed plays a major role in minimising both surface roughness and surface temperature of work piece. The cutting speed and depth of cut follow feed in the order of importance, respectively.

The vibration of the machine tool is a factor which may contribute to poor quality characteristics. This factor has not taken been into account in this analysis since major vibrations in the machine are induced due to the machining process.

Design and development of new hybrid metal matrix composites (HMMCs) with a detailed analysis on machining conditions. The findings could help in the production of composite with a higher degree of surface finish. This will enable the adoption of HMMCs as industrial product for mass scale production.

Good quality characteristics were achieved using optimum machining conditions arrived using a statistical modelling.

The purpose of this paper is to develop a mathematical model for the surface delamination through response surface methodology (RSM) and analyse the influences of the entire individual input machining parameters (cutting speed, feed rate and depth of cut) on the responses in milling of carbon fibre reinforced polymer (CFRP) composites with solid carbide end mill cutter coated with polycrystalline diamond.

Three factors, three level face-centered central composite design in RSM was employed to carry out the experimental investigation. The “Design Expert 8.0” software was used for regression and graphical analysis of the data collected. The optimum values of the selected variables were obtained by solving the regression equation and by analyzing the response surface contour plots. Analysis of variance was used to check the validity of the model and for finding the significant parameters.

The developed second-order response surface model is used to calculate the delamination of the machined surfaces at different cutting conditions with the chosen range with 95 per cent confidence intervals. Using such model, one can obtain remarkable savings in time and cost.

The effect of machining parameters on surface delamination during milling of CFRP composites using RSM has not been previously analysed.

The purpose of this paper is to develop a mathematical model for delamination through response surface methodology (RSM) and analyse the influences of the entire individual input machining parameters (cutting speed, depth of cut and feed rate) on the responses in milling of glass fibre reinforced plastics (GFRP) composites with solid carbide end mill cutter coated with polycrystalline diamond (PCD).

Three factors, three levels face-centered central composite design matrix in RSM is employed to carry out the experimental investigation. Shop microscope is used to examine the delamination of GFRP composites. The “Design Expert 8.0” software was used for regression and graphical analysis of the data collected. Analysis of variance is used to check the validity of the model and for finding the significant parameters.

The developed second-order response surface model is used to calculate the delamination of the machined surfaces at different cutting conditions with the chosen range of 95 per cent confidence intervals. Analysis of the influences of the entire individual input machining parameters on the delamination has been carried out using RSM.

Influence of solid carbide end mill coated with PCD on delamination of bi-directional GFRP composite during milling has not been analysed yet using RSM.

Molecular dynamics is an emerging simulation technique in the field of machining in recent years. Many researchers have tried to simulate different processing methods of various materials with the theory of molecular dynamics (MD), and some preliminary conclusions have been obtained. However, the application of MD simulation is more limited compared with traditional finite element model (FEM) simulation technique due to the complex modeling approach and long computation time. Therefore, more studies on the MD simulations are required to provide a reliable theoretical basis for the nanoscale interpretation of grinding process. This study investigates the crystal structures, dislocations, force, temperature and subsurface damage (SSD) in the grinding of iron-nickel alloy using MD analysis.

In this study the simulation model is established on the basis of the workpiece and single cubic boron nitride (CBN) grit with embedded atom method and Morse potentials describing the forces and energies between different atoms. The effects of grinding parameters on the material microstructure are studied based on the simulation results.

When CBN grit goes through one of the grains, the arrangement of atoms within the grain will be disordered, but other grains will not be easily deformed due to the protection of the grain boundaries. Higher grinding speed and larger cutting depth can cause greater impact of grit on the atoms, and more body-centered cubic (BCC) structures will be destroyed. The dislocations will appear in grain boundaries due to the rearrangement of atoms in grinding. The increase of grinding speed results in the more transformation from BCC to amorphous structures.

This study is aimed to study the grinding of Fe-Ni alloy (maraging steel) with single grit through MD simulation method, and to reveal the microstructure evolution within the affected range of SSD layer in the workpiece. The simulation model of polycrystalline structure of Fe-Ni maraging steel and grinding process of single CBN grit is constructed based on the Voronoi algorithm. The atomic accumulation, transformation of crystal structures, evolution of dislocations as well as the generation of SSD are discussed according to the simulation results.