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Open Access
Article
Publication date: 2 January 2024

Guillermo Guerrero-Vacas, Jaime Gómez-Castillo and Oscar Rodríguez-Alabanda

Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using…

Abstract

Purpose

Polyurethane (PUR) foam parts are traditionally manufactured using metallic molds, an unsuitable approach for prototyping purposes. Thus, rapid tooling of disposable molds using fused filament fabrication (FFF) with polylactic acid (PLA) and glycol-modified polyethylene terephthalate (PETG) is proposed as an economical, simpler and faster solution compared to traditional metallic molds or three-dimensional (3D) printing with other difficult-to-print thermoplastics, which are prone to shrinkage and delamination (acrylonitrile butadiene styrene, polypropilene-PP) or high-cost due to both material and printing equipment expenses (PEEK, polyamides or polycarbonate-PC). The purpose of this study has been to evaluate the ease of release of PUR foam on these materials in combination with release agents to facilitate the mulding/demoulding process.

Design/methodology/approach

PETG, PLA and hardenable polylactic acid (PLA 3D870) have been evaluated as mold materials in combination with aqueous and solvent-based release agents within a full design of experiments by three consecutive molding/demolding cycles.

Findings

PLA 3D870 has shown the best demoldability. A mold expressly designed to manufacture a foam cushion has been printed and the prototyping has been successfully achieved. The demolding of the part has been easier using a solvent-based release agent, meanwhile the quality has been better when using a water-based one.

Originality/value

The combination of PLA 3D870 and FFF, along with solvent-free water-based release agents, presents a compelling low-cost and eco-friendly alternative to traditional metallic molds and other 3D printing thermoplastics. This innovative approach serves as a viable option for rapid tooling in PUR foam molding.

Details

Rapid Prototyping Journal, vol. 30 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 10 January 2024

Zhaozhi Li, Changfu Zhang, Hairong Zhang, Haihui Liu, Zhao Zhu and Liucheng Wang

This study aims to apply an electrochemical grinding (ECG) technology to improve the material removal rate (MRR) under the premise of certain surface roughness in machining U71Mn…

Abstract

Purpose

This study aims to apply an electrochemical grinding (ECG) technology to improve the material removal rate (MRR) under the premise of certain surface roughness in machining U71Mn alloy.

Design/methodology/approach

The effects of machining parameters (electrolyte type, grinding wheel granularity, applied voltage, grinding wheel speed and machining time) on the MRR and surface roughness are investigated with experiments.

Findings

The experiment results show that an electroplated diamond grinding wheel of 46# and 15 Wt.% NaNO3 + 10 Wt.% NaCl electrolyte is more suitable to be applied in U71Mn ECG. And the MRR and surface roughness are affected by machining parameters such as applied voltage, grinding wheel speed and machining time. In addition, the maximum MRR of 0.194 g/min is obtained with the 15 Wt.% NaCl electrolyte, 17 V applied voltage, 1,500 rpm grinding wheel speed and 60 s machining time. The minimum surface roughness of Ra 0.312 µm is obtained by the 15 Wt.% NaNO3 + 10 Wt.% NaCl electrolyte, 13 V applied voltage, 2,000 rpm grinding wheel speed and 60 s machining time.

Originality/value

Under the electrolyte scouring effect, the products and the heat generated in the machining can be better discharged. ECG has the potential to improve MRR and reduce surface roughness in machining U71Mn.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2023-0341/

Details

Industrial Lubrication and Tribology, vol. 76 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 4 January 2024

Muhammet Uludag and Osman Ulkir

In this study, experimental studies were carried out using different process parameters of the soft pneumatic gripper (SPG) fabricated by the fused deposition modeling method. In…

Abstract

Purpose

In this study, experimental studies were carried out using different process parameters of the soft pneumatic gripper (SPG) fabricated by the fused deposition modeling method. In the experimental studies, the surface quality of the gripper was examined by determining four different levels and factors. The experiment was designed to estimate the surface roughness of the SPG.

Design/methodology/approach

The methodology consists of an experimental phase in which the SPG is fabricated and the surface roughness is measured. Thermoplastic polyurethane (TPU) flex filament material was used in the fabrication of SPG. The control factors used in the Taguchi L16 vertical array experimental design and their level values were determined. Analysis of variance (ANOVA) was performed to observe the effect of printing parameters on the surface quality. Finally, regression analysis was applied to mathematically model the surface roughness values obtained from the experimental measurements.

Findings

Based on the Taguchi signal-to-noise ratio and ANOVA, layer height is the most influential parameter for surface roughness. The best surface quality value was obtained with a surface roughness value of 18.752 µm using the combination of 100 µm layer height, 2 mm wall thickness, 200 °C nozzle temperature and 120 mm/s printing speed. The developed model predicted the surface roughness of SPG with 95% confidence intervals.

Originality/value

It is essential to examine the surface quality of parts fabricated in additive manufacturing using different variables. In the literature, surface roughness has been examined using different factors and levels. However, the surface roughness of a soft gripper fabricated with TPU material has not been examined previously. The surface quality of parts fabricated using flexible materials is very important.

Details

Multidiscipline Modeling in Materials and Structures, vol. 20 no. 1
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 2 February 2024

Ferhat Ceritbinmez and Ali Günen

This study aims to comparatively analyze the cut parts obtained as a result of cutting the Ni-based Inconel 625 alloy, which is widely used in the aerospace industry, with the…

Abstract

Purpose

This study aims to comparatively analyze the cut parts obtained as a result of cutting the Ni-based Inconel 625 alloy, which is widely used in the aerospace industry, with the wire electro-discharge machining (WEDM) and abrasive water jet machining (AWJM) methods in terms of macro- and microanalyses.

Design/methodology/approach

In this study, calipers, Mitutoyo SJ-210, Nikon SMZ 745 T, scanning electron microscope and energy dispersive X-ray were used to determine kerf, surface roughness and macro- and microanalyses.

Findings

Considering the applications in the turbine industry, it has been determined that the WEDM method is suitable to meet the standards for the machinability of Inconel 625 alloy. In contrast, the AWJM method does not meet the standards. Namely, while the kerf angle was formed because the hole entrance diameters of the holes obtained with AWJM were larger than the hole exit diameters, the equalization of the hole entry and exit dimensions, thanks to the perpendicularity and tension sensitivity of the wire electrode used in the holes drilled with WEDM ensured that the kerf angle was not formed.

Originality/value

It is known that the surface roughness of the parts used in the turbine industry is accepted at Ra = 0.8 µm. In this study, the average roughness value obtained from the successful drilling of Inconel 625 alloy with the WEDM method was 0.799 µm, and the kerf angle was obtained as zero. In the cuts made with the AWJM method, thermal effects such as debris, microcracks and melted materials were not observed; an average surface roughness of 2.293 µm and a kerf of 0.976° were obtained.

Details

Aircraft Engineering and Aerospace Technology, vol. 96 no. 2
Type: Research Article
ISSN: 1748-8842

Keywords

Article
Publication date: 12 September 2023

Yuzhu Han, Jieshi Chen, Shuye Zhang and Zhishui Yu

This paper aims to investigate the effect of solder composition and roughness on early wetting behavior and interfacial reaction under atmospheric conditions.

Abstract

Purpose

This paper aims to investigate the effect of solder composition and roughness on early wetting behavior and interfacial reaction under atmospheric conditions.

Design/methodology/approach

High-speed photography is used to observe the early wetting and spreading process of the solder on the substrate in real time. The morphology of intermetallic compounds (IMCs) was observed by scanning electron microscopy, and the composition of IMCs micro bumps was determined by energy dispersive spectroscopy.

Findings

With a roughness range of 0.320–0.539 µm, the solder is distributed in an elliptical trilinear pattern along the grinding direction. With a roughness range of 0.029–0.031 µm, the solder spreads in the direction of grinding and perpendicular, forming a perfect circle (except in the case of Sn63Pb37 solder). The effect of three types of solder on early wettability is Sn63Pb37 > Sn96.5Ag3Cu0.5 > Sn. The wetting behavior is consistent with the Rn∼t model. The rapid spreading stage (Stage I) is controlled by the interfacial reaction with n1 values between 2.4 and 4. The slow spreading stage (stage II) is controlled by diffusion with n2 values between 4 and 6.7. The size of Cu6Sn5 formed on a rough substrate is greater than that produced on a smooth substrate.

Originality/value

Investigating the effect of solder composition and roughness on early wettability. This will provide a powerful guide in the field of soft brazing.

Details

Soldering & Surface Mount Technology, vol. 35 no. 5
Type: Research Article
ISSN: 0954-0911

Keywords

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: 20 November 2023

Reddy K. Prasanth Kumar, Nageswara Rao Boggarapu and S.V.S. Narayana Murty

This paper adopts a modified Taguchi approach to develop empirical relationships to the performance characteristics (output responses) in terms of process variables and…

Abstract

Purpose

This paper adopts a modified Taguchi approach to develop empirical relationships to the performance characteristics (output responses) in terms of process variables and demonstrated their validity through comparison of test data. The method suggests a few tests as per the orthogonal array and provides complete information for all combinations of levels and process variables. This method also provides the estimated range of output responses so that the scatter in the repeated tests can be assessed prior to the tests.

Design/methodology/approach

In order to obtain defect-free products meeting the required specifications, researchers have conducted extensive experiments using powder bed fusion (PBF) process measuring the performance indicators (namely, relative density, surface roughness and hardness) to specify a set of printing parameters (namely, laser power, scanning speed and hatch spacing). A simple and reliable multi-objective optimization method is considered in this paper for specifying a set of optimal process parameters with SS316 L powder. It was reported that test samples printed even with optimal set of input variables revealed irregular shaped, microscopic porosities and improper melt pool formation.

Findings

Finally, based on detailed analysis, it is concluded that it is impossible to express the performance indicators, explicitly in terms of equivalent energy density (E_0ˆ*), which is a combination of multiple sets of selective laser melting (SLM) process parameters, with different performance indicators. Empirical relations for the performance indicators are developed in terms of SLM process parameters. Test data are within/close to the expected range.

Practical implications

Based on extensive analysis of the SS316 L data using modified Taguchi approach, the optimized process parameters are laser power = 298 W, scanning speed = 900 mm/s and hatch distance = 0.075 mm, for which the results of surface roughness = 2.77 Ra, relative density = 99.24%, hardness = 334 Hv and equivalent energy density is 4.062. The estimated data for the same are surface roughness is 3.733 Ra, relative density is 99.926%, hardness is 213.64 Hv and equivalent energy density is 3.677.

Originality/value

Even though equivalent energy density represents the energy input to the process, the findings of this paper conclude that energy density should no longer be considered as a dependent process parameter, as it provides multiple results for the specified energy density. This aspect has been successfully demonstrated in this paper using test data.

Details

Multidiscipline Modeling in Materials and Structures, vol. 20 no. 1
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 25 January 2024

Talwinder Singh

The purpose of this paper, an experimental study, is to investigate the optimal machining parameters for turning of nickel-based superalloy Inconel 718 under eco-friendly…

Abstract

Purpose

The purpose of this paper, an experimental study, is to investigate the optimal machining parameters for turning of nickel-based superalloy Inconel 718 under eco-friendly nanofluid minimum quantity lubrication (NMQL) environment to minimize cutting tool flank wear (Vb) and machined surface roughness (Ra).

Design/methodology/approach

The central composite rotatable design approach under response surface methodology (RSM) is adopted to prepare a design of experiments plan for conducting turning experiments.

Findings

The optimum value of input turning parameters: cutting speed (A), feed rate (B) and depth of cut (C) is found as 79.88 m/min, 0.1 mm/rev and 0.2 mm, respectively, with optimal output response parameters: Vb = 138.633 µm and Ra = 0.462 µm at the desirability level of 0.766. Feed rate: B and cutting speed: A2 are the leading model variables affecting Vb, with a percentage contribution rate of 12.06% and 43.69%, respectively, while cutting speed: A and feed rate: B are the significant factors for Ra, having a percentage contribution of 38.25% and 18.03%, respectively. Results of validation experiments confirm that the error between RSM predicted and experimental observed values for Vb and Ra is 3.28% and 3.75%, respectively, which is less than 5%, thus validating that the formed RSM models have a high degree of conformity with the obtained experimental results.

Practical implications

The outcomes of this research can be used as a reference machining database for various metal cutting industries to establish eco-friendly NMQL practices during the turning of superalloy Inconel 718 to enhance cutting tool performance and machined surface integrity.

Originality/value

No study has been communicated till now on the turning of Inconel 718 under NMQL conditions using olive oil blended with multi-walled carbon nanotubes-based nanofluid.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2023-0317/

Details

Industrial Lubrication and Tribology, vol. 76 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 6 September 2023

Aiman Yahaya, Syahrullail Samion and Mohd Kameil Abdul Hamid

The purpose of this study is to investigate the use of micro-pits technology to the problem of tribological performance in a sliding motion.

Abstract

Purpose

The purpose of this study is to investigate the use of micro-pits technology to the problem of tribological performance in a sliding motion.

Design/methodology/approach

Vegetable oil is a sustainable and economically viable alternative to both mineral and synthetic oils, offering significant savings in both the cost of research and manufacturing. To solve the depriving issue and boost lubrication film thickness, the micro-pits on the surface may function as reservoirs that provide the oil to the contact inlet area. In this research, an aluminium block is used as the workpiece material in an evaluation of a through pin-on-disc tribotester. Lubricating oil in the form of super olein (SO) was used in the experiment.

Findings

The results show that the friction performance during a rubbing process between a hemispherical pin and an aluminium block lubricated with SO using aluminium alloy materials, AA5083, was significantly improved.

Originality/value

In this study, a material that breaks down called SO, which is derived from the fractionation of palm olein, was used to use a modified aluminium micro-pit sample that will serve as a lubricant reservoir in pin-on-disc tribotester.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2023-0200/

Details

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

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

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