The Special Issue Machining—Recent Advances, Applications and Challenges is intended as a humble collection of some of the hottest topics in machining. The manufacturing industry is a varying and ...challenging environment where new advances emerge from one day to another. In recent years, new manufacturing procedures have retained increasing attention from the industrial and scientific community. However, machining still remains the key operation to achieve high productivity and precision for high-added value parts. Continuous research is performed, and new ideas are constantly considered. This Special Issue summarizes selected high-quality papers which were submitted, peer-reviewed, and recommended by experts. It covers some (but not only) of the following topics:
High performance operations for difficult-to-cut alloys, wrought and cast materials, light alloys, ceramics, etc.;
Cutting tools, grades, substrates and coatings. Wear damage;
Advanced cooling in machining: Minimum quantity of lubricant, dry or cryogenics;
Modelling, focused on the reduction of risks, the process outcome, and to maintain surface integrity;
Vibration problems in machines: Active and passive/predictive methods, sources, diagnosis and avoidance;
Influence of machining in new concepts of machine–tool, and machine static and dynamic behaviors;
Machinability of new composites, brittle and emerging materials;
Assisted machining processes by high-pressure, laser, US, and others;
Introduction of new analytics and decision making into machining programming.
We wish to thank the reviewers and staff from Materials for their comments, advice, suggestions and invaluable support during the development of this Special Issue.
•Need of hybrid micromachining.•Laser-based hybrid micromachining process classifications.•Hybrid micromachining principles and setup.•Current scenario of hybrid machining setup development.•Future ...scope to develop hybrid micromachining processes.
Laser beam micromachining is a prominent method for micromachining applications. But it has some drawbacks like thermal stresses, uncontrolled dimensions, burrs, and spatter. Similarly, non-conventional processes like ECM, EDM, and conventional machining processes, namely turning, drilling and milling, also have limitations due to slow process and tooling costs. Researchers are continuously seeking hybrid machining, like laser-based hybrid machining methods, to improve the product's quality characteristics. Researchers have thoroughly investigated the laser-based hybrid process mechanism in the last decade and have identified different issues and control strategies to improve its performance. This paper reviews laser-based hybrid micromachining processes (LHMMP) in which LBM is combined with conventional processes and non-conventional processes in an assisted or sequential manner. Also, other energy sources assisting the laser beam machining process, viz. vibration, magnetic field, electric field, fluids, and gases, are reviewed in the current work. This paper summarizes the work performed on metals, non-metals and ceramics in the area of the LHMMP to create 3D micro features. Theoretical and experimental studies, mechanisms of machining, machining setups, and the impact of process parameters on laser-based hybrid micromachining techniques are reviewed in detail. The hybrid processes elevate the process efficiency, surface quality, tooling cost and precision of fabricated parts. In the last section of this paper, future development efforts needed in this area of laser-based hybrid machining are suggested to multiply the process utility.
Machining of biocompatible materials: a review Saptaji, Kushendarsyah; Gebremariam, Mebrahitom Asmelash; Azhari, Mohd Azmir Bin Mohd
International journal of advanced manufacturing technology,
07/2018, Letnik:
97, Številka:
5-8
Journal Article
Recenzirano
The need for more effective and efficient manufacturing processes to transform the biocompatible materials into high standard artificial human body components (implants) is rapidly growing. Machining ...of biocompatible materials as one of the key processes in manufacturing of implants need to be improved due to the significant effects of machined surface quality to the compatibility and osseointegration with human organs such as tissues, bones, and environment of the human body. The challenges of machining biocompatible materials due to their applications as bio-implants in the human body and the nature of materials properties and microstructures have been explored and solved by various researchers. This article reviews the trends and developments of the machining of biocompatible materials. A range of possible machining technologies and strategies on various biocompatible materials using conventional (milling, turning and drilling) and non-conventional or advanced (abrasive water jet machining (AWJM), ultrasonic machining (USM), ion beam machining (IBM), laser beam machining (LBM), electrical discharge machining (EDM), and electron beam machining (EBM)) are presented and discussed. This review also examines the emerging new technologies such as additives manufacturing and hybrid processes as potential solutions and future research trends in order to fulfill the high standard requirements for a wider range of applications of the biomaterials.
The friction at the cutting wedge has a significant influence on tool wear. Due to the strong local variance of temperatures and stresses at the cutting wedge, the friction conditions differ ...significantly locally. In this work, a method is presented with which normal stresses, tangential stresses and local friction coefficients at the cutting wedge can be determined based on experimental investigations. For this purpose, high-speed recordings and force measurements are conducted on a planing test rig. In addition to dry cutting processes, investigations are carried out on the test rig using emulsion and oil as metal working fluid. The results show a reduction of the coefficients of friction when oil is used as metal working fluid. However, when emulsion is used as metal working fluid, the coefficient of friction changes only slightly compared to dry machining. This can be attributed to low film-forming ability of the emulsion. Keywords Machining, load stresses, cooling lubricant, tribometry, coefficient of friction, emulsion Die Reibung am Schneidkeil beeinflusst massgeblich das Verschleissverhalten in der Zerspanung. Aufgrund der starken ortlichen Varianz von Temperaturen und Spannungen am Schneidkeil unterscheiden sich die Reibverhaltnisse lokal signifikant. In dieser Arbeit wird eine Methode vorgestellt, mit der Normalspannungen, Tangentialspannungen und lokale Reibkoeffizienten am Schneidkeil auf Basis experimenteller Untersuchungen bestimmt werden konnen. Zu diesem Zweck werden Hochgeschwindigkeitsaufnahmen und Kraftmessungen an einem Hobelprufstand erstellt. Neben trockenen Zerspanprozessen werden an dem Prufstand Untersuchungen mit Emulsion und Ol als Kuhlschmierstoff durchgefuhrt. Die Ergebnisse zeigen einen Abfall der Reibkoeffizienten beim Einsatz von Ol als Kuhlschmierstoff. Beim Einsatz von Emulsion als Kuhlschmierstoff verandert sich der Reibkoeffizient gegenuber der trockenen Zerspanung jedoch nur geringfugig. Dies kann auf geringe Fahigkeit der Emulsion zur Filmbildung zuruckgefuhrt werden. Schlusselworter Zerspanung, Lastspannungen, Kuhlschmierstoff, Tribometrie, Reibkoeffizient, Emulsion
This paper offers a comprehensive literature review of the conventional machining processes along with optimization methods used in metal matrix composites (MMCs), such as turning, milling, drilling, ...and grinding machining processes. The tool wear mechanism and machinability of MMCs along with surface quality are discussed in the number of different manufacturing processes and examined thoroughly. Additionally, the manufacturing of MMC products through nonconventional machining processes such as electrical discharge machining (EDM), wire electrical discharge machining (WEDM), laser machining, electrochemical machining, ultra- sonic machining (USM), and high-speed machining are investigated and considered, in connection with MMC processing are discussed, as alternatives to the aforementioned processes. Moreover, this review focuses on the modeling of the machining process, finite element modeling, and simulation and optimization of soft computing methods in MMCs. The study will emphasize on the most generally used methods, namely, response surface methodology, artificial neural network, Taguchi method, and fuzzy logic as soft computing optimization methods. Finally, the comprehensive open issues and conclusions have drawn on the machining and optimization of particle-reinforced MMCs.
Non-Traditional and Advanced Machining Technologies covers the technologies, machine tools, and operations of non-traditional machining processes and assisted machining technologies. Two separate ...chapters deal with the machining techniques of difficult-to-cut materials, such as stainless, super alloys, ceramics, and composites. Design for machining, accuracy and surface integrity of machined parts, environment-friendly machine tools and operations, and hexapods are also presented. The topics covered throughout reflect the rapid and significant advances that have occurred in various areas in machining technologies and are organized and described in such a manner to draw the interest of the reader. The treatments are aimed at motiving and challenging the reader to explore viable solutions to a variety of questions regarding product design and optimum selection of machining operations for a given task. The book will be useful to professionals, students, and companies in the areas of industrial, manufacturing, mechanical, materials, and production engineering fields.
Cutting fluids can be used to cool workpieces at high cutting speeds and remove chips from cutting zones. The effectiveness of cutting fluids may be improved with the addition of hybrid nanoparticle ...dispersion. This study evaluates the effectiveness of an Alsub.2Osub.3-TiOsub.2 hybrid as a cutting fluid in turning operations. The Alsub.2Osub.3-TiOsub.2 hybrid nano-cutting fluid was prepared using a one-step method in computer numerical control (CNC) coolant with concentrations of up to 4%. Utilizing air-assisted nano-cutting fluids injected through a minimum quantity lubrication (MQL) setup, the effectiveness of turning cutting performance, cutting temperature (°C), average surface roughness (Ra), and tool wear (%) were evaluated. Then, the response surface method (RSM) was utilized as the design of experiment (DOE) to optimize the turning cutting performance parameters. The combination of 4% hybrid nano-cutting fluid concentration, 0.1 mm/rev feed rate, and 0.55 mm depth of cut yielded the lowest cutting temperature, surface roughness, and tool wear values of 25.3 °C, 0.480 µm, and 0.0104%, respectively. The 4% concentration of Alsub.2Osub.3/TiOsub.2 hybrid nano-cutting fluid inclusion achieved the highest surface roughness reduction that led to better surface finish and the lowest tool-wear reduction led to longer tool life. Therefore, Alsub.2Osub.3/TiOsub.2 hybrid nano-cutting fluids were strongly recommended in turning operations for CNC lathes.
Micro-structured functional surfaces have achieved widespread applications in various advanced scientific, technological, industrial, and engineered fields due to their excellent performances, which ...are vitally limited by their feasible fabrication. Currently, ultra-precision machining, typically including ultra-precision diamond turning, ultra-precision diamond milling, ultra-precision diamond scratching, ultra-precision grinding, and ultra-precision polishing, is developed as a very-promising solution for the micro-structured functional surface fabrication with high quality, high efficiency, high flexibility, and low cost. Therefore, this paper aims to briefly review the current state of the art in the investigation into ultra-precision machining characteristics of micro-structured functional surfaces with a focus on their typical advanced applications as the significant achievements of their ultra-precision machining fabrication, discuss the key challenges, and further provide new insights into ultra-precision machining of micro-structured functional surfaces for the future research and their further advanced applications.
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•Applications of micro-structured functional surfaces of UPM are surveyed.•UPM capability of micro-structured functional surfaces is reviewed.•It is highly feasible to fabricate micro-structured functional surfaces.•The challenges and opportunities with some speculations are proposed.
Analysis of Oversize of Engine Compressor Disk Zhang, Lili; Zhao, Yuan; Tao, Lin ...
IOP conference series. Materials Science and Engineering,
10/2019, Letnik:
612, Številka:
3
Journal Article
Recenzirano
Odprti dostop
In order to solve the problem of the extreme axial position of the engine compressor during the process of machining, three kinds of calculation States were selected according to the extreme ...difference, and the influence of the excess on the stress and deformation of the compressor was determined.
![Performance of Al[sub.2]O[s...](http://api.summon.serialssolutions.com/2.0.0/image/issn/XR4PS5YY4K/2075-4442/small "Performance of Al[sub.2]O[sub.3]/TiO[sub.2] Hybrid Nano-Cutting Fluid in MQL Turning Operation via RSM Approach")
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