Engineering › Mechanical Engineering

Advanced machining processes and optimization

Works Count: 95681

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Description

This cluster of papers focuses on advanced monitoring and optimization of machining operations, including topics such as surface integrity, tool wear, cutting parameters, chatter vibration, minimum quantity lubrication, and high speed machining. It also covers the machining of composite materials and the control of surface roughness in various machining processes.

Keywords

Machining; Surface Integrity; Tool Wear; Cutting Parameters; Metal Cutting; Chatter Vibration; Minimum Quantity Lubrication; Composite Materials; High Speed Machining; Surface Roughness

Mechanics of the Metal Cutting Process. II. Plasticity Conditions in Orthogonal Cutting

1945-06-01

M. Eugene Merchant

The analysis of the mechanics of orthogonal cutting with a type 2 chip as presented in the first paper of this series can be extended by introducing those physical properties … The analysis of the mechanics of orthogonal cutting with a type 2 chip as presented in the first paper of this series can be extended by introducing those physical properties of the work material which control its plastic behavior. One evident plasticity condition is the equality of the shear stress on the plane of shear to the shear strength of the metal. If it is also assumed that the shear strength of the work material is a constant and is the only quantity controlling its plastic behavior, then a very simple additional plasticity condition is obtained by application of the principle of minimum energy. This condition is 2φ+τ−α=90°, where φ is the shear angle, τ the friction angle, and α the rake angle. This condition, however, is found by experiment to be a poor approximation in the case of polycrystalline metals. A very good approximation is obtained, though, if use is made of the fact that the shear strength of the polycrystalline metal is actually a function of the compressive stress on the shear plane. The resulting plasticity condition is cot (2φ+τ−α)=k, where k is the slope of the linear curve relating shear strength and compressive stress, and is thus a constant of the work material. Such a plasticity condition establishes a relationship between the force system and the geometry of chip formation, so that, if k and the shear strength be known for a given material, all forces involved in cutting it can be calculated with reasonably good accuracy directly from measurements of chip geometry only, without use of a tool dynamometer. This is of importance in the analysis of practical machining operations.

Environmental friendly cutting fluids and cooling techniques in machining: a review

2014-08-12

Sujan Debnath , Moola Mohan Reddy , Qua Sok Yi

Theory of Self-Excited Machine-Tool Chatter: Contribution to Machine-Tool Chatter Research—1

1965-11-01

H. E. Merritt

Self-excited chatter, an instability of the cutting process in combination with the machine structure, is a basic performance limitation of a machine tool. A theory is developed which permits calculation … Self-excited chatter, an instability of the cutting process in combination with the machine structure, is a basic performance limitation of a machine tool. A theory is developed which permits calculation of borderlines of stability for a structure having n-degrees of freedom and assuming no dynamics in the cutting process. Harmonic solutions of the system characteristic equation are found using a special chart, and the resulting data are used to plot a stability chart. However, an infinite number of such stability charts exists for a given machine because the structure dynamics vary with cutting-force orientation. This fact makes a simpler index of chatter performance desirable. A simple stability criterion is proposed which states that the directional cutting stiffness must be less than one half the minimum directional dynamic stiffness of the structure for each force orientation to assure chatter-free performance at all spindle speeds. Thus chatter-free performance can be fundamentally identified with adequate structural dynamic stiffness for all cutting-force orientations. Such a broad requirement for dynamic stiffness is difficult to meet in the design stage since structural characteristics are not easily predicted and controlled. Machine testing with continual improvements in the structure to increase dynamic stiffness is currently the best way to combat chatter.

Metal cutting principles

1987-09-01

M. C. Shaw

Chatter Stability of Metal Cutting and Grinding

2004-01-01

Yusuf Altintaş , Manfred Weck

A review of mechanical drilling for composite laminates

2011-12-03

Defu Liu , Yongjun Tang , Weilong Cong

Machining of Composite Materials

2002-01-01

Roberto Teti

Heat generation and temperature prediction in metal cutting: A review and implications for high speed machining

2005-09-17

N A Abukhshim , Paul Mativenga , Mariam Sheikh

Application of Taguchi method in the optimization of end milling parameters

2003-10-30

Jaharah A. Ghani , Imtiaz Ahmed Choudhury , Hazrina Hassan

Advanced monitoring of machining operations

2010-01-01

Roberto Teti , Krzysztof Jemielniak , Garret E. O’Donnell +1 more

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Prediction of Milling Force Coefficients From Orthogonal Cutting Data

1996-05-01

Erhan Budak , Yusuf Altintaş , E.J.A. Armarego

The mechanistic and unified mechanics of cutting approaches to the prediction of forces in milling operations are briefly described and compared. The mechanistic approach is shown to depend on milling … The mechanistic and unified mechanics of cutting approaches to the prediction of forces in milling operations are briefly described and compared. The mechanistic approach is shown to depend on milling force coefficients determined from milling tests for each cutter geometry. By contrast the unified mechanics of cutting approach relies on an experimentally determined orthogonal cutting data base (i.e., shear angle, friction coefficient and shear stress), incorporating the tool geometrical variables, and milling models based on a generic oblique cutting analysis. It is shown that the milling force coefficients for all force components and cutter geometrical designs can be predicted from an orthogonal cutting data base and the generic oblique cutting analysis for use in the predictive mechanistic milling models. This method eliminates the need for the experimental calibration of each milling cutter geometry for the mechanistic approach to force prediction and can be applied to more complex cutter designs. This method of milling force coefficient prediction has been experimentally verified when milling Ti6Al4V titanium alloy for a range of chatter, eccentricity and run-out free cutting conditions and cutter geometrical specifications.

Key improvements in the machining of difficult-to-cut aerospace superalloys

2005-03-29

E. O. Ezugwu

Machinability of titanium alloys (Ti6Al4V and Ti555.3)

2008-06-23

P.J. Arrazola , A. Garay , Luis María Iriarte +3 more

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Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids

2012-02-17

Alborz Shokrani , Vimal Dhokia , Stephen T. Newman

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Chatter in machining processes: A review

2011-01-18

Guillem Quintana , Joaquim Ciurana

Analytical Prediction of Stability Lobes in Milling

1995-01-01

Yusuf Altintaş , Erhan Budak

Review of vibration-assisted machining

2007-08-23

David Edward Brehl , T. A. Dow

Some experimental investigations in the drilling of carbon fiber-reinforced plastic (CFRP) composite laminates

1997-08-01

Wen-Chou Chen

Mechanics of the Metal Cutting Process. I. Orthogonal Cutting and a Type 2 Chip

1945-05-01

M. Eugene Merchant

An analysis of the chip geometry and the force system found in the case of orthogonal cutting accompanied by a type 2 chip has yielded a collection of useful equations … An analysis of the chip geometry and the force system found in the case of orthogonal cutting accompanied by a type 2 chip has yielded a collection of useful equations which make possible the study of actual machining operations in terms of basic mechanical quantities. The shearing strain undergone by the metal during chip formation, and the velocities of shear and of chip flow are among the geometrical quantities which can be quantitatively determined. The force relationships permit calculation of such quantities as the various significant force components, stresses, the coefficient of friction between chip and cutting tool, and the work done in shearing the metal and in overcoming friction on the tool face. The experimental methods by which such analyses can be readily made are described. Observed and calculated values from typical tests are presented.

A review of developments towards dry and high speed machining of Inconel 718 alloy

2003-12-10

D. Dudzinski , Arnaud Devillez , A. Moufki +3 more

Recent advances in modelling of metal machining processes

2013-01-01

P.J. Arrazola , Tuğrul Özel , Domenico Umbrello +2 more

Design optimization of cutting parameters for turning operations based on the Taguchi method

1998-12-01

Weihong Yang , Y.S. Tarng

Dry Machining and Minimum Quantity Lubrication

2004-01-01

Klaus Weinert , Ichiro INASAKI , John W. Sutherland +1 more

Dry machining: Machining of the future

2000-04-01

P. S. Sreejith , B. K. A. Ngoi

Machining induced surface integrity in titanium and nickel alloys: A review

2010-11-25

Durul Ulutan , Tuğrul Özel

A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V

2007-10-31

Madalina Calamaz , D. Coupard , F. Girot

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Cross-Coupled Biaxial Computer Control for Manufacturing Systems

1980-12-01

Yoram Koren

Biaxial control systems for generating predetermined paths under load disturbances, such as encountered in NC and CNC systems for machine tools, are conventionally designed such that the control of each … Biaxial control systems for generating predetermined paths under load disturbances, such as encountered in NC and CNC systems for machine tools, are conventionally designed such that the control of each axis is independent of the other. The present paper is concerned with providing cross-couplings for biaxial control systems, whereby an error in either axis affects the control loops of both axes. An algorithm for a cross-coupled control system is presented, and the performance of the cross-coupled system is mathematically analyzed and compared with the conventional CNC system having individual axis control. It is shown that cross-coupling between axes improves the contour accuracy while the velocity response of each axis is only slightly reduced. Although the proposed cross-coupled system requires additional hardware for implementation with an NC system, operation with a CNC-based system requires only software modifications to the system control program.

Tool Condition Monitoring (TCM) — The Status of Research and Industrial Application

1995-01-01

G. Byrne , David Dornfeld , Ichiro INASAKI +3 more

Application of Taguchi method in the optimization of cutting parameters for surface roughness in turning

2006-03-25

Muammer Nalbant , Hasan Gökkaya , Gökhan Sur

Machine tool feed drives

2011-01-01

Yusuf Altintaş , Alexander Verl , Christian Brecher +2 more

Sensor signals for tool-wear monitoring in metal cutting operations—a review of methods

2000-06-01

Eric Dimla

Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design

2001-09-01

Yusuf Altintaş , AA Ber

9R15. Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design. - Y Altintas (Manuf Autom Lab, Univ of British Columbia, Canada). Cambridge UP, Cambridge, UK. 2000. 286 pp. … 9R15. Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design. - Y Altintas (Manuf Autom Lab, Univ of British Columbia, Canada). Cambridge UP, Cambridge, UK. 2000. 286 pp. Softcover. ISBN 0-521-65973-6. $39.95.Reviewed by AA Ber (Dept of Mech Eng, Technion Israel Inst of Tech, Technion City, Haifa 32000, Israel).This reviewer wishes to congratulate the author for writing this book. This combination of the three subjects, Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design under one roof, is actually done for the first time. Furthermore, integration of these three subjects gives the readers, students (mostly graduates), design engineers, as well as practitioners, a better outlook on the subject dealt with in the book Manufacturing Automation. The book is well written, and the sequence of subjects is perfect. The author was aware that each of the major subjects can fill up a book by itself, and he mentioned it in the introduction. Inserting a Problem Section after each chapter, emphasizing the main points discussed in it, turns the work into a textbook. However, it can also serve as a reference book for engineers and practitioners. Chapter 1 is a general introduction to manufacturing and a short overview of what one will find in this book chapter by chapter. Chapter 2 presents the mechanics of cutting. It is introduced under the most classical approach and written in an orderly and systematic way, except for the section on Milling and Tool Breakage which introduces a refreshing modern approach. Most of the equations are brought in their final form, which is quite acceptable for graduate students, engineers, and practitioners. The nomenclature and symbols are sometimes confusing; the author mixes old American standards with the ISO standards and puts them together in the same equation. This reviewer suggests that in future editions only ISO standard 3002/I through IV be considered. In this chapter, this reviewer missed the roles of Surface Finish and Tolerances in the cutting operations. Tool life is defined geometrically and not in a modern way, namely “The tool terminates its life when it ceases to fulfill its function.” In other words, the tool life ends on reaching the geometrical life (as defined in the book), or when the Surface Finish exceeds the demand and or the part is out of the defined Tolerance. It is a pity that the author did not include a section dealing with tool materials in this chapter. The materials composing the tool play a major role in the mechanics of cutting. For example, the contact length between tool and chip is a function of the tool’s properties (primarily its thermal conductivity) and of other factors.In Chapter 3, the static and dynamic deformation in machining is treated in a very extensive and clear way that even this reviewer (whose field is not dynamics) could understand the factors and problems involved. The analysis presented emphasizes, by sample formulation, prediction of the magnitude and location of static deformation of bar turning and end milling. The section dealing with chatter is most impressively introduced. By introducing modal analysis techniques, the author shows how one can represent a complex machine tool structure using commonly used mathematical expressions and analyze the chatter as well as other sources of vibrations. In Chapter 4, the practical side of manufacturing is discussed. The author introduces the CNC technology and its principles of operation and leads the reader through NC programming of a part. The methodology of NC programming is well presented. All elements involved in CNC are discussed and theoretically supported. In the paragraph on Computer Assisted NC Part Programming, the author succeeded in showing in a compact and very clear form how complicated forms can be dealt with and successfully machined. The basics of Computer-Aided Manufacturing (CAM) is introduced. The author focuses on the teaching aspects of the subject. Chapter 5 contains conventional textbook material. The chapter is well written. The reader is led systematically through the various aspects of the CNC systems. A typical CNC machining center, including all necessary hardware, mechanical, electrical, and hydraulic and their combinations necessary to operate CNC systems, is well described. The various elements required, like machine tool drives, mechanical as well as electrical (and others), are described in detail and accompanied by the relevant formulation on which they are based upon. The mathematical modeling of drive systems is covered both in the time and frequency domain. The author directs some attention to the accuracy of the system. At the end of the chapter, the author presents an example of a design of an Electro-Hydraulic CNC Press Brake. The design contains the various elements of the system and may serve as a guide to the inexperienced reader (mostly students) while dealing with any CNC design. Chapter 6 is mostly an abstract of the author’s research works in the area of Sensor Related Machining. This chapter is based on material published by the author in various publications. The dominant direction is the one established by Prof Tlusty. It might have been more fruitful if the author had discussed other approaches as well. Basic principles and techniques appear in Chapters 7 and 8. Chapter 7 contains the Laplace and z Transforms and includes several examples. In Chapter 8, the author introduces Off-Line and On-Line Parameters Estimation with Least Squares. At the end of the book, one can find a very extensive bibliography covering all aspects of the subjects discussed in the book. This reviewer recommends Manufacturing Automation: Metal Cutting Mechanics, Machine Tool Vibrations, and CNC Design as a textbook for students, undergraduate as well as graduate. It can also serve as an excellent reference book for those engaged in manufacturing, ie, engineers, technicians, and other practitioners.

Advancing Cutting Technology

2003-01-01

G. Byrne , David Dornfeld , Berend Denkena

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Analytical Prediction of Chatter Stability in Milling—Part I: General Formulation

1998-03-01

Erhan Budak , Yusuf Altintaş

A new analytical method of chatter stability prediction in milling is presented. A general formulation for the dynamic milling system is developed by modeling the cutter and workpiece as multi-degree-of-freedom … A new analytical method of chatter stability prediction in milling is presented. A general formulation for the dynamic milling system is developed by modeling the cutter and workpiece as multi-degree-of-freedom structures. The dynamic interaction between the milling cutter and workpiece is modeled considering the varying dynamics in the axial direction. The dynamic milling forces are governed by a system of periodic differential equations with delay whose stability analysis leads to an analytical relation for chatter stability limit in milling. The model can be used to determine the chatter free axial and radial depth of cuts without resorting to time domain simulations.

Investigation of micro-cutting operations

2005-08-03

Ji-Yong Chae , Simon S. Park , Theodor Freiheit

Application of response surface methodology in describing the performance of coated carbide tools when turning AISI 1045 steel

2003-10-09

M.Y. Noordin , V.C. Venkatesh , Safian Sharif +2 more

Predicting surface roughness in machining: a review

2003-04-24

Panorios Benardos , George-Christopher Vosniakos

Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks

2004-11-04

Tuğrul Özel , Yiğit Karpat

Recent Advances in Mechanical Micromachining

2006-01-01

D. A. Dornfeld , Sangkee Min , Yoshimi TAKEUCHI

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State-of-the-art in surface integrity in machining of nickel-based super alloys

2015-10-21

Ajay D. Thakur , S. Gangopadhyay

Chatter suppression techniques in metal cutting

2016-01-01

Jokin Muñoa , Xavier Beudaert , Zoltán Dombóvári +4 more

Review of ultrasonic vibration-assisted machining in advanced materials

2020-07-10

Zhichao Yang , Lida Zhu , Guixiang Zhang +2 more

The Theory of Plasticity Applied to a Problem of Machining

1951-12-01

E. H. Lee , Bernard W. Shaffer

Abstract The recently developed methods of analyzing stress and strain distributions in the plane plastic flow of an ideally plastic material are applied to the problem of machining. It is … Abstract The recently developed methods of analyzing stress and strain distributions in the plane plastic flow of an ideally plastic material are applied to the problem of machining. It is shown that the idealized stress-strain relationship involves justifiable assumptions for this application. Analytical expressions are obtained for orthogonal machining which give the machining force, the chip thickness, and the chip deformation in terms of the tool geometry, the relevant coefficients of friction, and the appropriate yield stress of the work. With increasing friction at the tool face or decreasing rake angle the development of a built-up nose arises naturally as a consequence of the analysis. The theory includes this phenomenon. The results of this theory are compared with published experimental results, and with other theoretical analyses. Satisfactory agreement with experiment is obtained.

Dry Cutting

1997-01-01

Fritz Klocke , Gerrit Eisenblätter

Metal cutting principles

1985-02-01

M. C. Shaw , J.O. Cookson

Quantitative analysis of milling chatter severity based on image-signal multi-modal data fusion

2025-06-25

Xinpeng Sun , Haifeng Ma , Bo Wang +3 more | Journal of Manufacturing Processes

DIRECT INCREASING OF EFFICIENCY IN TOOTH GRINDING BY COPYING METHOD BASED ON SYSTEM ANALYSIS

2025-06-25

Nariman Rasulov , Mursal Alakbarov | Elmi Əsərlər

The grinding by copying of working surfaces of gear teeth is of particular importance in ensuring their high production and operational qualities. The article presents a general concept developed for … The grinding by copying of working surfaces of gear teeth is of particular importance in ensuring their high production and operational qualities. The article presents a general concept developed for designing highly efficient mechanical processing technological operations, based on the system analysis of tooth grinding through copying method. It also outlines the directions for directly increasing efficiency, determined by examining the functional relationships of mechanical processing specific to the output parameters of tooth grinding. The essence of directly increasing the efficiency of shaped and gear surfaces and the possible sources to achieve this are explained. The theoretical basis for directly increasing efficiency by reducing the number of working passes in tooth grinding without decreasing the accepted allowance and actual cutting depth is provided, along with the results of experimental trials. The developed methodology is recommended for use in increasing the efficiency of mechanical processing operations.

A tool path planning method of continuous variable-axis plunge milling for titanium alloy thin-walled curved slots

2025-06-25

Jian-wei Ma , Zhichao Liu , Song-hong-ze Wang +2 more | The International Journal of Advanced Manufacturing Technology

Characterization and wear performance of advanced AlTiSiN-based coated cutting tools in dry machining of Ti-6Al-4V alloy

2025-06-25

Prasenjit Sharma , Sarvesh Kumar Mishra , J. Ramkumar | Journal of Manufacturing Processes

Mechanism of lubrication enhancement in drilling with MWCNTs nanocapsules cutting fluid

2025-06-24

Niankai He , Kecheng Gu , Jiju Guan +1 more | Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture

Insufficient micro-lubricant supply during drilling operations results in inadequate heat dissipation and ineffective friction reduction at elevated temperatures, thereby limiting machining efficiency. This study addresses the issue by preparing nanocapsules … Insufficient micro-lubricant supply during drilling operations results in inadequate heat dissipation and ineffective friction reduction at elevated temperatures, thereby limiting machining efficiency. This study addresses the issue by preparing nanocapsules via a wet chemical method. Chlorinated paraffin (T301), a lubricating agent, was encapsulated within carbon nanotubes (CNTs) to form nanocapsules, which were subsequently used as additives in nanofluids. During drilling, these nanocapsules release T301, enabling a self-lubricating effect that enhances penetration and retention in the cutting zone, thereby improving both cooling and lubrication performance. The mechanical and thermodynamic properties of the nanofluids were characterized, and a series of drilling tests were conducted using these enhanced fluids. The study also analyzed heat transfer in the drilling area and the formation of a lubrication layer influenced by the nanofluids. The nanocapsules demonstrated excellent thermal conductivity and dispersion stability. When drilling 45 steel, the inclusion of nanocapsules resulted in significant improvements: torque was reduced by 35.6%, drilling temperature by 19.3%, surface roughness of the inner hole by 22.7%, and tool wear by 25.5%, compared to the use of commercial emulsions. Surface composition analysis of the drill bit revealed that the self-lubricating effect was due to the rupture of multi-walled carbon nanotubes (MWCNTs) during metal cutting and drilling, which released the T301 lubricant directly into the drilling zone.

Nanotechnology Mechanistic Techniques and Ideas for Mechatronics

2025-06-24

Aditi Singhal , Mansi Verma , Sanjay Kumar Singh | CRC Press eBooks

Development and Evaluation of Modified Rotor–Stator Knives for Enhanced Fine Grinding of Chicken Meat–Bone Raw Material in Colloid Mill

2025-06-24

Zhanibek Yessimbekov , Rasul Turagulov , Айтбек Какимов +3 more | Applied Sciences

The growing demand for cost-effective, high-quality protein ingredients in the meat industry highlights the need for advanced processing methods capable of producing uniform, functional meat–bone pastes from poultry by-products. This … The growing demand for cost-effective, high-quality protein ingredients in the meat industry highlights the need for advanced processing methods capable of producing uniform, functional meat–bone pastes from poultry by-products. This study investigates the optimization of colloid milling parameters for the fine grinding of chicken meat–bone by-products, with a focus on improving particle size distribution, rheological properties, and processing efficiency. A modified rotor–stator system with teeth inclined at 20° and a reduced pitch (0.5 mm) was compared to a conventional configuration (45° inclination, 1.5 mm pitch). Experiments were conducted at rotor speeds ranging from 1000 to 4000 rpm, with a fixed clearance of 0.1 mm. The results showed that the modified design significantly enhanced grinding efficiency, reducing the proportion of bone fragments > 1 mm and yielding over 70% of particles under 0.1 mm at 3000 rpm. Viscosity and shear stress measurements indicated that grinding at 3000 rpm yielded a dynamic viscosity of 71,507 Pa·s and a shear stress of 43,531 mPa·s, values that were significantly lower (p < 0.05) than those observed at other tested speeds, thereby producing a paste consistency with the most favorable balance of elasticity and flowability. At 4000 rpm, the temperature rise (up to 32 °C) led to partial denaturation of muscle proteins, accompanied by emulsion destabilization and disruption of the protein gel matrix, resulting in reductions in the viscosity and water-binding capacity of the paste. Comparative analysis confirmed that tool geometry and rotor speed have critical effects on grinding quality, energy use, and thermal load. The optimal operating parameters, 3000 rpm with modified rotor–stator teeth, achieve the finest, most homogeneous bone paste while preserving protein functionality and minimizing energy losses. These findings support the development of energy-efficient grinding equipment for the valorization of poultry by-products in emulsified meat formulations.

Surface Integrity Investigation into Longitudinal-Torsional Ultrasonic Vibration Side Milling for a TC18 Titanium Alloy—Part II: Effects of Ultrasonic Amplitude on Cutting Force and Surface Integrity

2025-06-24

Weibo Xie , Yan Jie , Yuanhao Tie +1 more | Journal of Vibration Engineering & Technologies

Surrogated based optimization of stress concentration in Al-2024 T3 pate with elliptical cutout under uniaxial loading

2025-06-24

Ramli Abdullah , Omar Jumaah , Yogesh Jaluria | Al-Qadisiyah Journal for Engineering Sciences

Metal plates with different cutout shapes are commonly used in various engineering applications. Cutouts are unavoidable in structural design as they are needed for practical reasons, such as reducing the … Metal plates with different cutout shapes are commonly used in various engineering applications. Cutouts are unavoidable in structural design as they are needed for practical reasons, such as reducing the structure’s weight and providing access to other parts. This paper investigates the stress concentration induced in Al-2024 T3 plate with an elliptical cutout under a tensile load, experimentally and numerically. Practical tensile test and strain gauge results measure the generated stress concentration in Al-2024 T3 plate. A finite element model is created to analyze the stress concentration factor (SCF) in Al 2024 T3 plate under uniaxial loading. The numerical model is validated against the experimental and analytical results. The influence of the elliptical cutout orientation angle (φ) on SCF was investigated. The results showed that SCF increases with increasing elliptical cutout orientation angle (φ = 0°) to (φ = 90°). However, adding auxiliary holes around the central elliptical cutout enhances the stress distribution and reduces SCF in the range (1.9 to 25 %). Surrogated-based optimization is used to build response surface models for predicting optimal SCF and removal mass (RM). Multi-objective optimization is formulated to minimize SCF and maximize RM. The results show that increasing AH diameter leads to minimizing SCF and maximizing RM for the plate with an elliptical cutout that is restrained to be greater than or equal to 45 (φ ≥ 45°). Pareto frontier offers reliable, optimal solutions of SCF and RM based on input design parameters, including the orientation angle and auxiliary hole diameters.

Acoustic mechanism analysis of milling process through workpiece and spindle vibrations

2025-06-24

Lei Yang , Guochao Li , Da Xie +4 more | Journal of Vibration and Control

Acoustic signals possess significant potential for online monitoring of tool wear conditions. However, the acoustic mechanism of milling remains unclear, posing significant challenges in the collection and noise reduction of … Acoustic signals possess significant potential for online monitoring of tool wear conditions. However, the acoustic mechanism of milling remains unclear, posing significant challenges in the collection and noise reduction of acoustic signals, thereby reducing prediction accuracy. A comprehensive understanding of the mechanism underlying milling sound generation is essential. This paper designs a synchronous acquisition system for milling sound and vibration, analyzing the influence of workpiece and spindle vibrations on milling sound. A milling dynamic model and milling acoustic sound field model are developed to elucidate the relationship between workpiece vibration and milling sound. The results reveal that intermittent milling sound generation originates primarily from forced vibrations induced by periodic tool-workpiece interactions, exhibiting strong spectral correlations with tool tooth passing frequency and its harmonics. These findings provide critical theoretical foundations for optimizing acoustic-based tool condition monitoring systems through targeted signal denoising and frequency-domain feature extraction.

Noise analysis of grinding machine in the material cutting process

2025-06-24

Rini Dharmastiti , Andreas Remmy Tan Wijaya , Fitri Kurniasari | Jurnal Teknosains

The handheld grinding machine used for cutting materials has generated noise that may affect the operator and individuals nearby. The noise produced by this machine needs to be analyzed to … The handheld grinding machine used for cutting materials has generated noise that may affect the operator and individuals nearby. The noise produced by this machine needs to be analyzed to prevent potential health impacts. This study aims to measure the noise levels the handheld grinding machine generates while cutting materials such as ceramic, metal, and natural stone. Noise measurements were taken at the noise source and distances of 2 meters, 3 meters, and 4 meters from the source. A sound level meter was used for the noise measurements. The study's results indicate that the type of material being cut using the handheld grinder does not significantly affect the noise level produced. The highest noise level was recorded when cutting the plate, with an equivalent continuous sound level (Leq) of 91.6 dB at the source. The lowest noise level was recorded when cutting ceramic material, with a Leq of 89.7 dB. Statistical tests on the distance and measurement locations at 2 meters, 3 meters, and 4 meters from the source showed that the distance does not significantly affect the noise level. At distances of 2 meters and 3 meters, the average Leq for all materials was the same, ata 94.2 dB, while at 4 meters, the average Leq was slightly lower, at 93.9 dB.

Tool wear prediction through a physics-assisted method using few-sensor monitoring data

2025-06-24

Zhuang Mao , Ming Luo , Dinghua Zhang | The International Journal of Advanced Manufacturing Technology

Cross-parameter grinding disc wear condition monitoring via weighted multi-source deep subdomain adversarial adaptation network

2025-06-24

Jiacheng Li , Rongqiang Shen , Yanling Xu +2 more | Journal of Manufacturing Processes

Estimating the radii of rounded cutting edges in milling tools using measured ploughing force

2025-06-24

Shao-Cong Linghu , Min Wan , Dan-Yang Wen +1 more | Journal of Manufacturing Processes

Change of the machined hole wall surface roughness, microstructure and microhardness of low alloy steel caused by drill-guide-pads during BTA deep hole drilling

2025-06-24

Binghao Li , Chuanzhen Huang , Zhen Chen +6 more | The International Journal of Advanced Manufacturing Technology

Experimental investigation on performance of cryogenic, MQL and Nano-Coolant machining environment in turning of inconel 718

2025-06-24

Satya Prasad Somayajula , Priyadarsini Morampudi , S. Sudhakar Babu +4 more | Industrial Lubrication and Tribology

Purpose This study aims to investigate the effect of various advanced cooling techniques on the machinability of Inconel 718, a nickel-based superalloy known for its high strength, poor thermal conductivity, … Purpose This study aims to investigate the effect of various advanced cooling techniques on the machinability of Inconel 718, a nickel-based superalloy known for its high strength, poor thermal conductivity, work hardening and rapid tool wear which make it difficult to machine especially under dry or conventional cooling conditions. The objective is to compare dry machining, minimum quantity lubrication (MQL), cryogenic cooling, nanofluids and their hybrids – particularly cryogenic-nanofluid MQL (cryo-nMQL) – to identify the most effective strategy for enhancing machining performance. Design/methodology/approach Nanofluids containing carbon nanotubes (CNT) and aluminum oxide (Al2O3) were prepared using a three-step dispersion method. Turning tests were conducted on Inconel 718 at a constant cutting speed of 70?m/min, 0.1?mm/rev feed and 0.3?mm depth of cut under 16 different cooling conditions. Tool-chip temperature, surface roughness (Ra) and flank wear were measured using an infrared camera, profilometer and optical microscope for machining performance evaluation. SEM and EDX analyses were used to study wear mechanisms. Findings Cryo-nMQL with 0.5 vol% CNT nanofluid yielded superior performance, reducing tool-chip interface temperature by 59.3%, surface roughness by 42.8% and tool wear by 66.5% compared to dry machining. CNT-based nanofluids performed better than Al2O3 due to higher thermal conductivity and a ball-bearing effect. Higher nanoparticle concentration increased viscosity, reducing effectiveness. SEM confirmed adhesion, notch wear and chipping as dominant wear mechanisms. Originality/value The novelty of this study lies in demonstrating the effectiveness of cryo-nMQL with CNT nanofluids for significantly enhancing the machining of difficult-to-machine materials like Inconel 718, offering a sustainable and efficient cooling strategy. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2025-0096/

Knowledge and data dual-driven cyber-physics system for intelligent monitoring and compensation of machine tool dynamic coupling error

2025-06-24

Chengyi Wu , Shijun Ji , Ji Zhao | Engineering Applications of Artificial Intelligence

Method for Determining Contact Temperature of Tool Rake Face During Orthogonal Turning of Ti-6Al-4V Alloy

2025-06-24

Łukasz Ślusarczyk , A. Twardowska | Materials

This paper proposes a method for determining the contact temperature in the secondary shear zone. The input data include the results of the experimental tests of the orthogonal turning of … This paper proposes a method for determining the contact temperature in the secondary shear zone. The input data include the results of the experimental tests of the orthogonal turning of a Ti-6Al-4V titanium workpiece using uncoated WC-Co tools with a flat rake face. The cutting force components were recorded using a piezoelectric dynamometer, a thermovision camera was used to record the temperature in the cutting zone, and a high-speed camera was used to record the chip-forming process. The independent variables included machining parameters, feed rate, cutting speed, and rake angle. A dual-zone thermomechanical cutting process model that accounted for the sticking and sliding areas was adapted for the identification of the heat flux in the chip–rake face contact zone. Then, based on the Shaw approach, the partition coefficients were determined for the contact temperature on the chip–tool tip contact. In addition, the results of the experimental tests allowed the determination of the relationship among the process parameters, friction coefficients, and the length of the contact of the chip with the tool rake face. A graphical visualization of the temperature distribution on the tool rake face was performed using the MATLAB PDE 3.9 software package. Although the application of the dual-zone model has been well presented in the literature, the results provided in this paper may be helpful in analyzing and modeling thermal phenomena in the secondary shear zone.

Study on Cutting Performance and Wear Resistance of Biomimetic Micro-Textured Composite Cutting Tools

2025-06-23

Youzheng Cui , Dongyang Wang , Minli Zheng +7 more | Metals

During the dry machining of 6061 aluminum alloy, cemented carbide tools often suffer from severe wear and built-up edge (BUE) formation, which significantly shortens tool life. Inspired by the non-smooth … During the dry machining of 6061 aluminum alloy, cemented carbide tools often suffer from severe wear and built-up edge (BUE) formation, which significantly shortens tool life. Inspired by the non-smooth surface structure of dung beetles, this study proposes an elliptical dimple–groove composite bionic micro-texture, applied to the rake face of cemented carbide tools to enhance their cutting performance. Four types of tools with different surface textures were designed: non-textured (NT), single-groove texture (PT), circular dimple–groove composite texture (AKGC), and elliptical dimple–groove composite texture (TYGC). The cutting performance of these tools was analyzed through three-dimensional finite element simulations using the Deform-3D (version 11.0, Scientific Forming Technologies Corporation, Columbus, OH, USA) software program. The results showed that, compared to the NT tool, the TYGC tool exhibited the best performance, with a reduction in the main cutting force of approximately 30%, decreased tool wear, and significantly improved chip-breaking behavior. Based on the simulation results, a response surface model was constructed to optimize key texture parameters, and the optimal texture configuration was obtained. In addition, a theoretical model was developed to reveal the mechanism by which the micro-texture reduces interfacial friction and temperature rises by shortening the effective contact length. To verify the accuracy of the simulation and theoretical analysis, cutting experiments were further conducted. The experimental results were consistent with the simulation trends, and the TYGC tool demonstrated superior performance in terms of cutting force reduction, smaller adhesion area, and more stable cutting behavior, validating both the simulation model and the proposed texture design. This study provides a theoretical foundation for the structural optimization of bionic micro-textured cutting tools and offers an in-depth exploration of their friction-reducing and wear-resistant mechanisms, showing promising potential for practical engineering applications.

Modelling breakage during drying of organomineral fertilizer using XDEM and Xception-LSTM

2025-06-23

Cem KORKMAZ , İlyas KACAR | Computational Particle Mechanics

Abstract This study presents a novel approach for detecting grain breakages in industrial production environments using a hybrid deep learning architecture combining the Xception convolutional neural network (CNN) with a … Abstract This study presents a novel approach for detecting grain breakages in industrial production environments using a hybrid deep learning architecture combining the Xception convolutional neural network (CNN) with a long short-term memory (LSTM) network. The proposed method leverages the feature extraction capabilities of Xception to process data and integrates temporal sequence modelling via LSTM to enhance predictive accuracy. The model is trained and tested on a specialized dataset comprising various stages of breakage. Results demonstrate that the Xception-LSTM model significantly outperforms traditional CNN architectures in terms of accuracy, precision, and recall. Notably, the hybrid model achieved an accuracy of 98.7%, with a marked improvement in sensitivity to minor and early stage breakages. The study underscores the model’s robustness in real-time applications, indicating its potential for deployment in automated monitoring systems to prevent costly downtimes and ensure production continuity. The findings contribute to the field by offering a scalable and efficient solution that bridges advanced modelling with time-series analysis for industrial fault detection.

Dynamic modeling and stability prediction of dry hobbing considering the coupling of hob and workpiece

2025-06-23

Benjie Li , Huangshuai Li , Xiao Yang +2 more | The International Journal of Advanced Manufacturing Technology

A Dual-Mean Statistical and Multivariate Framework for Machinability Evaluation in CNC Turning: Gradient and Stiffness Analysis Across Five Materials

2025-06-22

Mohammad S. Alsoufi | Materials

This study proposes a dual-statistical and gradient-based framework to evaluate the machinability of five engineering alloys under CNC turning. Cutting force and surface deformation were measured across five machining zones. … This study proposes a dual-statistical and gradient-based framework to evaluate the machinability of five engineering alloys under CNC turning. Cutting force and surface deformation were measured across five machining zones. Finite difference-based gradients revealed spatial variations in material response. Stainless Steel 304 showed the highest cutting force (328 N), while Aluminum 6061 had the highest deformation (0.0164 mm). Carbon Steel 1020 exhibited the highest force-to-deformation efficiency (>97,000 N/mm). Arithmetic and harmonic means highlighted statistical sensitivities, while principal component analysis (PCA) identified clustering among materials and reduced dimensionality. A composite machinability score, integrating stiffness variation, efficiency gradients, and multivariate features, ranked Aluminum 6061 highest, followed by Brass C26000 and Bronze C51000. This methodology enables interpretable benchmarking and informed material selection in precision manufacturing.

Experimental Study on Surface Integrity of Nickel-Based Superalloy in Ultrasonic Elliptical Vibration Cutting

2025-06-22

Gaofeng Hu , Yanjie Lu , Shengming Zhou +4 more | Micromachines

Nickel-based superalloys, renowned for their exceptional high-temperature strength, oxidation resistance, and corrosion resistance, have become essential materials in the aerospace, defense, and nuclear industries. However, due to their poor machinability, … Nickel-based superalloys, renowned for their exceptional high-temperature strength, oxidation resistance, and corrosion resistance, have become essential materials in the aerospace, defense, and nuclear industries. However, due to their poor machinability, common cutting processes often result in poor surface quality, difficulties in chip breaking, and significant tool wear. This study investigates the surface integrity of nickel-based superalloys during ultrasonic elliptical vibration cutting. The effects of various process parameters on the surface roughness, residual stress, and microhardness are systematically analyzed. The results indicate that under ultrasonic elliptical vibration cutting conditions, the surface roughness of the workpiece increases with the ultrasonic amplitude, cutting depth, and feed rate. It initially decreases and then increases with cutting speed, and decreases with an increase in the tool tip radius. The post-cutting residual stress in the nickel-based superalloy decreases with higher cutting speed and ultrasonic amplitude, but increases with greater cutting depth and tool tip radius. The surface microhardness increases with the cutting speed up to a point, after which it decreases, while it significantly increases with a higher ultrasonic amplitude, feed rate, and cutting depth. A comparative experiment was conducted between ultrasonic elliptical vibration and conventional cutting. The research results showed that when the cutting depth was 2 µm, the surface roughness and wear decreased by 19% and 53%, respectively, and the residual compressive stress and microhardness increased by 44% and 21%, respectively. This further verified the significant advantages of ultrasonic elliptical vibration cutting in optimizing machining performance.

Drilling Performance of AISI 430 Stainless Steel Using Al-Ti-N Coated and Uncoated HSS Drill Bits

2025-06-21

Abdul Haris Nasution | Engineering and Technology Journal

This study investigates the influence of tool coating and cutting parameters on the surface integrity and dimensional accuracy during drilling of ferritic stainless steel AISI 430. Using both Al-Ti-N coated … This study investigates the influence of tool coating and cutting parameters on the surface integrity and dimensional accuracy during drilling of ferritic stainless steel AISI 430. Using both Al-Ti-N coated and uncoated HSS drill bits, experiments were performed under dry conditions with varying spindle speeds (800–1200 rpm) and feed rates (0.1–0.2 mm/rev). Results show that coated tools consistently yielded lower surface roughness (Ra), reduced diameter error, improved hole roundness (ovality), and better perpendicularity. The Al-Ti-N coating significantly mitigated tool wear and thermal effects, enhancing process stability and microhardness near the drilled surface. Optimal drilling performance was observed at lower feed rates and moderate spindle speeds when using coated tools. These findings highlight the critical role of tool coatings and parameter optimization in machining ferritic stainless steels for high-precision applications.

High-performance milling of Ti-6Al-4V through rotary ultrasonic elliptical milling with anticlockwise elliptical vibration

2025-06-21

Lianxing Liu , Xinggang Jiang , Enze Yingam +2 more | Journal of Zhejiang University. Science A

The Development and Performance Assessment of Palm Kernel Nut Oil as a Cutting Fluid for the Turning of AA6061

2025-06-21

Omolayo M. Ikumapayi , Opeyeolu Timothy Laseinde , Rasaq A. Kazeem +2 more | Lubricants

This study focuses on investigating the manufacturing, characterization, and assessment of palm kernel nut oil as a cutting fluid (CF) in the machining of aluminium 6061 alloy. Cutting fluids are … This study focuses on investigating the manufacturing, characterization, and assessment of palm kernel nut oil as a cutting fluid (CF) in the machining of aluminium 6061 alloy. Cutting fluids are vital in machining operations as they reduce friction, dissipate heat, and prolong the lifespan of tools. Palm kernel nut oil, derived from the fruit of a palm kernel, has attracted attention due to its environmentally friendly and readily biodegradable characteristics. This study involved the extraction, refinement, and characterization of palm kernel nut oil for its potential application as a cutting fluid. An experimental investigation was conducted to evaluate the performance of palm kernel nut oil (PKNO) as a CF through turning operations on aluminium 6061 alloy. The experimental parameters included the cutting speed, feed rate, and depth of cut, while the effectiveness of the CF was assessed based on key performance indicators such as surface roughness and cutting temperature. The findings demonstrated that the PKNO-CF exhibited favourable physical properties, including optimal viscosity, density, and pH levels. Furthermore, a detailed chemical analysis confirmed the absence of hazardous components, establishing palm kernel nut oil as a safer and more environmentally friendly alternative to conventional cutting fluids. This study aligns with United Nations Sustainable Development Goal (SDG) 12: Responsible Consumption and Production as it promotes the use of an environmentally friendly and biodegradable cutting fluid, reducing reliance on conventional, potentially hazardous cutting fluids and reducing environmental pollution. By utilizing palm kernel nut oil as a sustainable alternative, this research supports eco-friendly manufacturing practices and minimizes environmental impact in machining operations

Long-term performance analysis of polycrystalline diamond (PCD) tools in the milling of aluminium alloy components in a manufacturing context

2025-06-21

Jesús David Chaux , P. Aristimuño , Mikel Etxanojauregi +2 more | The International Journal of Advanced Manufacturing Technology

High-quality laser trepan drilling of carbon/carbon composites by modelling and analyzing process parameters

2025-06-21

Song-hong-ze Wang , Jian-wei Ma , Chunguang Zhang +4 more | Optics & Laser Technology

A hybrid modeling approach for Ti-6Al-4 V turning under a high-pressure CO2 cryogenic cooling jet

2025-06-20

Libin Zhu , Shuaishuai Nie , Haihong Huang +2 more | The International Journal of Advanced Manufacturing Technology

Toward digital twins for intelligence manufacturing: Self-adaptive control in assisted equipment through multi-sensor fusion smart tool real-time machine condition monitoring

2025-06-20

Jin Zhang , Chengchao Li , Chenjie Deng +5 more | Journal of Manufacturing Systems

Dual-method approach of tool condition monitoring using sensor-based deep learning with vision-based image processing

2025-06-20

Ahmed Abdeltawab , Xi Zhang , Zhang Longjia | Journal of Manufacturing Processes

Research on the main cutting force of ultrasonic elliptical vibration cutting SiCp/Al composite materials

2025-06-20

Zhaopeng Hao , Huihui Zhang , YiHang Fan | Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture

To predict the dynamic principal cutting force of aluminum-based silicon carbide composites (SiCp/Al) during ultrasonic elliptical vibration cutting (UEVC), the resistance acting on the PCD tool was divided into four … To predict the dynamic principal cutting force of aluminum-based silicon carbide composites (SiCp/Al) during ultrasonic elliptical vibration cutting (UEVC), the resistance acting on the PCD tool was divided into four parts according to the different force deformation zones: shear deformation zone, tool rake face-chip interface friction deformation zone, plow force and SiC-reinforced particle fracture force deformation zone, and side-workpiece interface friction deformation zone. Considering the parameters such as shear angle, shear flow strength and uncut deformation thickness, the main cutting force model of the interaction between the tool and the machined material was established by applying the maximum shear stress criterion, the minimum energy principle, the three-phase friction principle shear band model and other related knowledge. Finally, the cutting parameters are determined by the three-factor three-level orthogonal UEVC experiment, and the accuracy of the theoretical mathematical model of the main cutting force is verified. The experimental results show that the maximum relative error between the measured value of the main cutting force and the predicted value calculated by the main cutting force model is 15.28%, and the average relative error is 8.07%, and the accuracy of the main cutting force model is fully proven.

Key manufacturing process technologies of fluid connectors in liquid cooling systems

2025-06-20

Yikang Sun | Advances in Engineering Innovation

With the rapid development of industries such as artificial intelligence and big data, the demand for liquid cooling in data centers is continuously increasing. Among various technologies, cold plate liquid … With the rapid development of industries such as artificial intelligence and big data, the demand for liquid cooling in data centers is continuously increasing. Among various technologies, cold plate liquid cooling has become one of the most widely applied methods. The performance and quality of components in the cooling system directly affect its operational and maintenance costs. This paper focuses on fluid connectors in liquid cooling systems, exploring key technical factors influencing their performance. It introduces process methods covering the entire production cycle from part machining to assembly and testing, and elaborates on critical control points at each manufacturing stage. The aim is to improve the technological level of fluid connectors. Finally, the paper briefly introduces new materials and technologies applied to fluid connectors and presents prospects for the future development of the liquid cooling industry.

Evolution of heat fluxes into Ti6Al4V machined surface due to tool wear

2025-06-20

Rayen Hanna , Gérard Poulachon , Frédéric Rossi +1 more | CIRP journal of manufacturing science and technology

A mutual cross-attention fusion network for surface roughness prediction in robotic machining process using internal and external signals

2025-06-20

Zhiqi Wang , Dong Gao , Yong Lu +4 more | Journal of Manufacturing Systems

An Authoritative Mathematical Procedure for Vibration Investigation of FG Saturated Porous Curved Microbeams Based on Modified Strain Gradient Theory

2025-06-20

Yijun Yan | International Journal of Structural Stability and Dynamics

Experimental Study of Effects of Machining Parameters on Cast Iron by Slot Milling Operation

2025-06-19

B. Suresh Kumar , G. Navaneethakrishnan , R. Palanisamy +2 more | Research Square (Research Square)

<title>Abstract</title> Precision machining processes like milling are crucial for achieving close tolerances in machine tool design. While several processes contribute, T-slot milling, utilizing rotating cutters to remove excess material, remains … <title>Abstract</title> Precision machining processes like milling are crucial for achieving close tolerances in machine tool design. While several processes contribute, T-slot milling, utilizing rotating cutters to remove excess material, remains a prevalent technique. However, high cutting forces and limited stability often restrict productivity. This study investigates the influence of key machining parameters on T-slot milling performance. The design of experiments facilitated the execution of a comprehensive study, enabling the generation of empirical models via regression analysis. Response surface plots were employed to visualize the impact of individual and combined parameter effects. Statistical analysis using ANOVA further elucidated each parameter's significance and interactions. The developed models provide valuable insights for optimizing T-slot milling conditions, fostering improved productivity and material removal rates within the constraints of stability and process limitations.

Advances in Surface Finishing Technology for Wind Turbine Gears: A Comprehensive Review

2025-06-19

Lijun Cheng , Wenhui Li , Xiuhong Li +7 more | Precision Engineering

Acoustic emission sensor-based in-process characterizations for surface morphology of mechanical-based machining at the nanoscale

2025-06-19

Xinchen Wang , Mohammad Alshoul , Jia Deng +1 more | Journal of Manufacturing Science and Engineering

Abstract Real-time monitoring of nanometric level morphology and structure is essential for the quality inspection and mechanism exploration of the nanofabrication process, which has not been fully studied based on … Abstract Real-time monitoring of nanometric level morphology and structure is essential for the quality inspection and mechanism exploration of the nanofabrication process, which has not been fully studied based on previous research. The acoustic emission (AE) sensor signals are induced with real-time information of the underlying processes, which allows immediate anomaly detection and diagnosis of potential quality issues in manufacturing. However, the micro/nano-level time domain signal cannot distinguish the various cutting conditions due to the weak signal energy and the high-level noises from the surroundings, which may adversely impact the accuracy and effectiveness of information extraction from monitored sensor signals. This paper reports an in situ characterization of the nanoscale surface morphology using AE sensor signals. It links the AE spectral responses to the material removals under different cutting conditions: the AE spectral energy from various cutting conditions shows different patterns highly related to nanofabrication. The selected AE spectral responses can be used to effectively predict the in situ nanomachined surface characteristics while the precision of the process remains under sub-10 nanometers. Using the significant AE spectral features, the predictive model can obtain an overall accuracy of 82% in R-squared value to estimate the achieved surface characteristics. Therefore, the presented AE sensor-based monitoring scheme may open up an avenue to allow real-time characterizations and quality inspection for surface characteristics during machining under the nanoscale.

An adaptive disturbance compensation method for force-sensorless control systems applied to robotic milling

2025-06-19

Han-Hao Tsai , Jen-Yuan Chang | Robotics and Computer-Integrated Manufacturing

Effect of cooling medium on clean milling mechanism and surface integrity in hard milling process

2025-06-19

Chengli Jing , Guangming Zheng , Wenfeng Yang +3 more | The International Journal of Advanced Manufacturing Technology

Investigation of the drill temperature distributions in high-throughput dry drilling of compacted graphite iron

2025-06-19

Zhaoju Zhu , Albert J. Shih , Lei Chen | Journal of Manufacturing Processes

Investigation of edge damage of the hole and adhesive wear of the tool in ultrasonically assisted step drilling of SiCp/Al composites

2025-06-19

Haohui Shi , Tao Chen , Xinlong Pan +2 more | Journal of Manufacturing Processes

Dynamic Model of Ultrasonic Milling for Aluminum Alloy with Unequal Helix Angle Milling Cutter and Chatter Suppression

2025-06-19

Hao Wu , Yuxiang Song , Li Dong +7 more | Research Square (Research Square)

<title>Abstract</title> With the global trend towards lightweight new energy vehicles, the processing demand for weak-rigidity components such as vehicle frames has been increasing. Milling, as an indispensable method for machining … <title>Abstract</title> With the global trend towards lightweight new energy vehicles, the processing demand for weak-rigidity components such as vehicle frames has been increasing. Milling, as an indispensable method for machining such thin-walled structural parts, faces a major bottleneck: machining deformation caused by chatter during processing has become a significant challenge. Unequal-helix-angle milling cutters and ultrasonic-assisted machining have been proven effective in suppressing chatter. However, research on the milling dynamics model and chatter suppression based on ultrasonic-assisted unequal-helix-angle milling cutters remains incomplete. Based on this, this study established a dynamic model for milling aluminum alloy 6061 using an ultrasonic unequal-helix-angle milling cutter. Firstly, based on the instantaneous milling force model, the time-varying characteristics of cutting thickness caused by the tool's motion trajectory under ultrasonic vibration and the variation in cutting time difference between adjacent cutting edges due to the unequal-helix-angle cutter were considered. Furthermore, both the workpiece and the tool for machining thin-walled parts were regarded as flexible bodies. Combined with the dynamic response of the machine tool system, a modal parameter-based milling dynamics model was established. Based on the closed-loop control system of milling dynamics, the stability of the milling system was determined by solving eigenvalues, and a solution for calculating the limiting cutting depth and spindle speed was obtained. Modal parameters were acquired through modal hammering experiments. Numerical analysis of the lobe diagram shows that the limiting cutting depth increases with rising spindle speed and ultrasonic frequency. At different spindle speeds, the stability of the lobe diagram for unequal-helix-angle ultrasonic milling is significantly higher than that of both conventional milling and ultrasonic milling. Compared with conventional milling, the limiting cutting depth for unequal-helix-angle ultrasonic milling is 3.2 mm, representing a 113% improvement. Finally, in milling experiments, the stability of the milling process was analyzed from both time-domain and frequency-domain perspectives by performing a fast Fourier transform on the force time-domain signal. This verifies that the coupling effect of ultrasonic vibration and unequal-helix-angle milling cutters can effectively suppress chatter when milling thin-walled workpieces.

Bidirectionally Coupled FE-CFD Simulation Study on MQL Machining Process of Ti-6Al-4V Alloy

2025-06-19

Xiaorong Zhou , Lin He , Sen Yuan +5 more | Lubricants

In the context of sustainable manufacturing practices, minimum quantity lubrication (MQL) has been extensively employed in machining operations involving hard-to-cut materials. While substantial experimental and numerical investigations on MQL-assisted machining … In the context of sustainable manufacturing practices, minimum quantity lubrication (MQL) has been extensively employed in machining operations involving hard-to-cut materials. While substantial experimental and numerical investigations on MQL-assisted machining have been conducted, existing simulation approaches remain inadequate for modeling the dynamic flow field variations inherent to MQL processes, significantly compromising the predictive reliability of current models. This study introduced an innovative bidirectional iterative coupling framework integrating finite element (FE) analysis and computational fluid dynamics (CFD) to enhance simulation accuracy. Since fluid flow characteristics critically influence tribological and thermal management at the tool–workpiece interface during machining, CFD simulations were initially performed to evaluate how MQL parameters govern fluid flow behavior. Subsequently, an integrated FE-CFD modeling approach was developed to simulate Ti-6Al-4V alloy turning under MQL conditions with varying feed rates. The novel methodology involved transferring thermal flux data from FE simulations to CFD’s heat source domain, followed by incorporating CFD-derived convective heat transfer coefficients back into FE computations. This repetitive feedback process continued until the thermal exchange parameters reached convergence. Validation experiments demonstrated that the proposed method achieved improved alignment between the simulated and experimental results for both cutting temperature profiles and principal force components across different feed conditions, confirming the enhanced predictive capability of this coupled simulation strategy.

CFRP surface roughness prediction in machining by acoustic emission: a reliable machine learning study

2025-06-19

Thiago Luiz Lara Oliveira , M.I.L.L. Oliveira , Matheus Brendon Francisco +4 more | Research Square (Research Square)

<title>Abstract</title> Composite materials such as polymer-reinforced carbon fiber have been increasingly used in various sectors due to their reduced mass and high mechanical strength. The aeronautical sector, for example, has … <title>Abstract</title> Composite materials such as polymer-reinforced carbon fiber have been increasingly used in various sectors due to their reduced mass and high mechanical strength. The aeronautical sector, for example, has shown that manufacturing the Boeing 787 with 50% of its structure using this type of material led to fuel savings of 25%. However, when using these materials, machining is used as a secondary manufacturing process for geometry adjustments and can represent considerable costs for the manufacturing of components. Developing tools that can assist in real-time control of the surface quality of these machined parts is essential to understand, control, and optimize the machining process. Few studies have been found successfully associating some machine learning models with surface roughness, and the vast majority are focused on metals and using the own machining parameters. This study investigates whether considering also the acoustic emission signal emitted during the machining process would help or not to improve the surface roughness prediction. For that, this study applies a set of more than twenty machine learning models tuned by Bayesian optimization to a dataset constructed using Optimal Design of Experiments for the milling of polymer-reinforced carbon fiber under four machining variables (cutting speed, tool condition, milling direction, and carbon fiber) and fifteen input parameters from acoustic emission analysis. Our studies show that it is possible to successfully predict surface roughness with these parameters, show the best machine learning algorithm and its hyperparameters for this purpose, and the six most relevant features out of nineteen.

A hybrid model to analyze stress distributions at the tool and workpiece interface during drilling of thick cfrp laminates considering thermal effects

2025-06-18

Fahim Shariar , Umut Karagüzel , Yiğit Karpat | The International Journal of Advanced Manufacturing Technology

Abstract Drilling is employed as a machining method to meet the demands for producing functional CFRP structures without compromising their unique and desirable material properties. Because of its intrinsic material … Abstract Drilling is employed as a machining method to meet the demands for producing functional CFRP structures without compromising their unique and desirable material properties. Because of its intrinsic material properties and drill-induced damages, drilling CFRP remains an ambitious task. This study investigates the stress distributions at the tool-workpiece interface during the CFRP dry drilling process. A better understanding of contact pressure and tangential stress distribution on the cutting edge of drills is necessary for a better selection of process parameters. The drill margin region, which directly affects the hole wall quality, has been included in the analysis. Drilling experiments were conducted to measure thrust force, torque, and temperature for different cutting parameter configurations. Finite element-based thermal models have been utilized to estimate the hole wall surface temperature during drilling. The analytical cutting force model is coupled with the temperature distribution from the FE model to analyze the variation of contact pressure and tangential stress distributions along the tip of the drill, together with the thermal effects on contact pressure during drilling.

Single-Step Drilling Using Novel Modified Drill Bits Under Dry, Water, and Kerosene Conditions and Optimization of Process Parameters via MOGA-ANN and RSM

2025-06-18

Sumitava Paul , Barun Haldar , Hillol Joardar +3 more | Lubricants

The burr removal and finishing of drilled hole walls typically require multiple post-processing steps. This experimental study introduces a novel single-step drilling approach using modified drill bits for simultaneous burr … The burr removal and finishing of drilled hole walls typically require multiple post-processing steps. This experimental study introduces a novel single-step drilling approach using modified drill bits for simultaneous burr removal and surface finishing in aluminum 6061-T6. The odified-1 drill, equipped with a deburring micro-insert, achieved superior results, with a chamfer height of −2.829 mm, drilling temperature of 40.28 ◦C, and surface roughness of 0.082 µm under optimal conditions. Multi-objective optimization using the RSM and MOGA-ANN identified the optimal drilling parameters for the Modified-1 drill at 3000 rpm under water lubrication as compared to dry conditions and kerosene. Experimental validation confirmed the high prediction accuracy, with deviations under 6%. These results establish the Modified-1 twist drill bit with a deburring micro-insert as a highly effective tool for burr-free high-quality drilling in a single operation. This innovative drill design presents an efficient, single-step solution for burr elimination, chamfer formation, and surface finishing in drilling operations.

Digital twin with dynamic mechanistic simulation core for milling tool wear prediction

2025-06-18

Zhaoqing Han , Xiaojun Liang , Weichao Luo +5 more | Journal of Manufacturing Processes

Surface integrity of superalloys during ultrasonic vibration-assisted milling processes: research status and challenges

2025-06-18

Qianxi He , Xin Wang , Shiyu Ma +4 more | The International Journal of Advanced Manufacturing Technology