Surface Integrity in Machining describes the fundamentals and recent advances in the study of surface integrity in machining processes."Surface Integrity in Machining" gathers together research from ...international experts in the field. Topics covered include: the definition of surface integrity and its importance in functional performance, surface topography characterization and evaluation, microstructure modification and the mechanical properties of subsurface layers, residual stresses, surface integrity characterization methods, and surface integrity aspects in machining processes.A useful reference for researchers in tribology and materials, mechanical and materials engineers, and machining professionals, "Surface Integrity in Machining" can be also used as a textbook by advanced undergraduate and postgraduate students.
High speed machining is now acknowledged to be one of the key manufacturing technologies to ensure high productivity and throughput. Drilling of CFRP, though a challenging task, is being performed ...successfully at low spindle speeds. However high speed drilling in CFRP thin laminates has not been explored much. This paper reports an experimental investigation of a full factorial design performed on thin CFRP laminates using K20 carbide drill by varying the drilling parameters such as spindle speed and feed rate to determine optimum cutting conditions. The hole quality parameters analyzed include hole diameter, circularity, peel-up delamination and push-out delamination. Analysis of variance (ANOVA) was carried out for hole quality parameters and their contribution rates were determined. Genetic Algorithm (GA) methodology was used in the multiple objective optimization (using MATLAB R2010a software) to find the optimum cutting conditions for defect free drilling. Tool life of the K20 carbide drill was predicted at optimized cutting speed and feed.
In this paper is presented a new comprehensive approach to select cutting parameters for damage-free drilling in carbon fiber reinforced epoxy composite material. The approach is based on a ...combination of Taguchi’s techniques and on the analysis of variance (ANOVA). A plan of experiments, based on the techniques of Taguchi, was performed drilling with cutting parameters prefixed in an autoclave carbon fiber reinforced plastic (CFRP) laminate. The ANOVA is employed to investigate the cutting characteristics of CFRP’s using high speed steel (HSS) and Cemented Carbide (K10) drills. The objective was to establish a correlation between cutting velocity and feed rate with the delamination in a CFRP laminate. The correlation was obtained by multiple linear regression. Finally, confirmation tests were performed to make a comparison between the results foreseen from the mentioned correlation.
The correct choice of the drill and the cutting parameters is crucial in carbon fibre reinforced plastics (CFRPs) drilling quality. In this work, the influence of three distinct drill geometries and ...cutting parameters (feed rate and spindle speed) in the delamination was assessed through two delamination factors. A non-destructive method, based on processed images analyses of the drilled surfaces, was used to measure the delaminated area and the maximum diameter of damage zone. The best results were obtained with a SPUR drill. With this, the higher rate of production, without the occurrence of delamination, was obtained with a feed rate of 2025mm/min and a spindle speed of 6750rpm.
Hard machining is a recent technology that can be defined as a direct machining operation of workpieces that have hardness values typically in the 45-70HRc range using tools with ...geometrically-defined cutting edges. This operation always presents the challenge of selecting a cutting tool insert that facilitates an extended tool life and high-precision machining of the component. Hard machining presents several advantages when compared with the traditional methodology based on finish grinding operations after heat treatment of workpieces. This technology also offers a great contribution to sustainable manufacturing. Hard materials comprise hardened steels, high-speed steels, heat-treatable steels, tool steels, bearing steels and chilled/white cast irons. Inconnel, Hastelloy, cobalt alloys for biomedical applications and other special materials are also classified as hard materials. These materials are in constant use by the automotive industry for bearing production and for the machining of dies and moulds as well as other components for advanced industries. Machining of Hard Materials aims to provide the fundamentals and recent advances in the study of hard machining of materials. All chapters are written by international experts in this important field of research. Chapter 1 defines machining of hard materials and its application in industry. Chapter 2 is dedicated to advanced cutting tools used for the machining of hard materials. Chapter 3 describes the mechanics of the cutting and chip formation. Chapter 4 contains information on surface integrity. Chapter 5 is dedicated to finite element modelling and simulation. Finally, Chapter 6 is dedicated to computational methods and optimization. Machining of Hard Materials can serve as a useful reference for academics, manufacturing and materials researchers, manufacturing and mechanical engineers, and professionals in machining and related industries.
Material selection is a difficult and subtle task due to the immense number of different available materials. In choosing the right material, there is not always a single definite criterion of ...selection and the designers and engineers have to take into account a large number of material selection criteria. This paper presents a logical procedure for material selection for a given engineering design. The procedure is based on a combined TOPSIS and AHP method. The proposed material selection index helps to evaluate and rank the materials for a given engineering design. Two examples are included to illustrate the approach.
The present investigation is an attempt to study the effect of control factors i.e. the cutting speed, the feed rate, and the titanium alloys on response variables i.e. the cutting force, the feed ...force and the cutting tool temperature by using the Taguchi techniques. A number of experiments were conducted using the L18 orthogonal array on a CNC vertical machining center. The machining center was configured to act as a lathe with the tool oriented to produce an orthogonal cut. A combined technique using orthogonal array and analysis of variance was employed to investigate the contribution and effects of cutting speed, feed rate and different aerospace grade titanium alloys (Ti6Al4V, Ti54M and Ti10.2.3) on two force components and cutting tool temperature. The results revealed that the feed rate was the most influential factor which affects the cutting and feed forces, while the cutting speed had most significant effect on the cutting tool temperature. Thereafter, optimal control factors were obtained for minimum response variables.
This editorial presents insights into sustainable and intelligent manufacturing in line with the 2030 agenda for sustainable development. It begins by framing the concept of sustainable development ...and its objectives within the scope of the 2030 agenda. Then it explains the concept of sustainable and intelligent manufacturing in agreement with the latest developments in the industry. It finishes by envisioning the integration of Industry 5.0 in the 2030 agenda.
Drilling is a frequently practiced machining process in industry due to the need for component assembly in mechanical pieces and structures. Drilling of composite materials is significantly affected ...by damage tendency of these materials under action of cutting forces (thrust force and torque). So the aim of this paper is the study of the cutting parameters (cutting velocity and feed rate) under specific cutting pressure, thrust force, damage and surface roughness in Glass Fiber Reinforced Plastics (GFRP's). A plan of experiments, based on the techniques of Taguchi, was established considering drilling with prefixed cutting parameters in a hand lay-up GFRP material. The analysis of variance (ANOVA) was performed to investigate the cutting characteristics of GFRP's using Cemented Carbide (K10) drills with appropriate geometries. The objective was to establish a correlation between cutting velocity and feed rate with the specific cutting pressure, thrust force, damage factor and surface roughness, in a GFRP material.
The trend towards miniaturization has increased dramatically over the last decade, especially within the fields concerned with bioengineering, microelectronics, and aerospace. Micromillin8 is among ...the principal manu- facturing processes which have allowed the development of components possessing micrometric dimensions, being used to the manufacture of both forming tools and the final product. The aim of this work is to present the principal aspects related to this technology, with emphasis on the work material requirements, tool ma- terials and geometry, cutting forces and temperature, quality of the finished product, process modelling and monitoring and machine tool requirements. It can be noticed that size effect possesses a relevant role with regard to the selection of both work material （grain size） and tooling （edge radius）. Low forces and temper- ature are recorded during micromillin8, however, the specific cutting force may reach high values because of the ploughing effect observed as the uncut chip thickness is reduced. Finally, burr formation is the principal concern with regard to the quality of the finished part.
