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Machining and Machinability of Advanced Materials and Composites

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 April 2022) | Viewed by 20540

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Prof. Dr. Victor Songmene

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Ecole de technologie supérieure (ÉTS), University of Québec, Montreal, QC, Canada
Interests: materials and manufacturing; machinability, metals, and composites; machining conditions optimisation; clean machining; cutting tool performance evaluation
Special Issues, Collections and Topics in MDPI journals

Prof. Dr. Fawzy Hosny Samuel

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Guest Editor

Department of Applied Sciences (DSA), University of Québec in Chicoutimi, Saguenay, QC, Canada
Interests: materials structure, properties and testing; materials manufacturing processes; materials performance; metallurgy

Special Issue Information

Dear Colleagues,

There is continuous growing interest in the development and use of advanced metallic and non-metallic materials. Some of these materials contain hard reinforcing elements and phases that improve their mechanical and field properties but are not necessarily easy to machine. These new materials call for the use of advanced cutting tools (materials, geometry, and coatings) for which optimal, economical, and safe machining parameters and conditions are still to be developed for metal cutting industries. The part quality and surface integrity also need to be investigated to understand the impact of metal cutting on the machined part. This Special Issue, therefore, aims to publish new and novel research work on the machining and machinability of these advanced metallic materials and composites. All aspects of machinability are considered in this Special Issue: forces, power, tool wear and tool life, part quality and integrity, tool geometry and tool performance, chip formation, air quality, burr formation, edge finishing, etc. Predicting machinability as a function of workpiece material properties and microstructures, as well as developing quick-tool life and machinability testing methods, is welcome. We will consider traditional and non-traditional processes, finishing processes, polishing, grinding, hybrid processes, and articles using machinability data to improve or optimize the machining process conditions and parameters. Research works on the finishing of additive manufactured parts, as well as edge finishing, deburring, and tailoring the material design for improved machinability, will also be considered.

Prof. Dr. Victor Songmene
Prof. Dr. Fawzy Hosny Samuel
Guest Editors

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Keywords

metals, ceramics and composites (MMC, PMC, CMC, etc.)
powder metals, nanomaterials, granites and woods
special alloys and super alloys
recycled and recomposed materials
machining and machinability
advanced cutting tools (materials, geometry and coatings)
cutting-tool performance
lubricated (wet, semi-wet) and dry machining
sustainable and green machining
traditional processes (turning, milling, drilling), non-traditional machining processes (EDM, laser, electrochemical, etc.), abrasive processes and hybrid processes
process performance indicators: tool wear, tool life, cutting forces, part quality, productivity, cycle times, environmental impacts, occupational safety, performance prediction, data acquisition, machining 4.0

Published Papers (11 papers)

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Research

18 pages, 7003 KiB

Open AccessArticle

Characterization of Si and SiO₂ in Dust Emitted during Granite Polishing as a Function of Cutting Conditions

by Jules Kouam, Victor Songmene, Ali Bahloul and Agnes M. Samuel

Materials 2022, 15(11), 3965; https://doi.org/10.3390/ma15113965 - 02 Jun 2022

Cited by 2 | Viewed by 1356

Abstract

Particles emitted during manufacturing processes such as polishing can represent a serious danger for the environment and for occupational safety. The formation mechanisms responsible for these dust emissions include chip formation, friction at the tool/workpiece and chip/tool interfaces, shearing and cutting. These mechanisms thus depend on workpiece and tool properties, as well as the polishing conditions. In the case of granite polishing, particle emissions during polishing can contain chemical compounds such as silica, which represent harmful health risks for the worker. It is therefore important to characterize the particles emitted and to search for possible interactions between the particles (size and composition) and the machining conditions in order to find ways of reducing emissions at the source. In this study, an investigation was undertaken to characterize the particles emitted during granite polishing as a function of polishing conditions, type of granite, and abrasive grit sizes used. Scanning electron microscopy (SEM) was employed for particle morphology characterization and particle grain size and chemical composition were evaluated using X-ray diffraction (XRD) and energy dispersive X-ray (EDX) techniques, respectively. Results show that the influence of polishing speed and feed rate on particle emission depends mainly on the granite type used, providing useful information for controlling the polishing procedure, and thereby dust emission. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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19 pages, 9179 KiB

Open AccessArticle

Assessment of the Influence of Additives on the Mechanical Properties and Machinability of Al-11%Si Cast Alloys: Application of DOE and ANOVA Methods

by Yasser Zedan, Victor Songmene, Agnes M. Samuel, Fawzy H. Samuel and Herbert W. Doty

Materials 2022, 15(9), 3297; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15093297 - 04 May 2022

Cited by 1 | Viewed by 1276

Abstract

In the present study, the statistical design of experiments (DOE) method was applied to study and control the properties of near-eutectic Al-11%Si alloys. In this study, we developed regression equations between response variables, including hardness, yield stress, ultimate tensile stress, elongation, total cutting force, cutting power, and tool life, and varying factors which included the percentage of the alloying element in the composition and the modification level. These equations may be analyzed quantitatively to acquire an understating of the effects of the main variables and their interactions on the mechanical behavior and the machinability of the alloy under investigation. Analysis of variance (ANOVA) was performed to verify the fit and adequacy of the developed mathematical models. The results show that increasing the levels of Cu and Fe results in an increase in hardness, yield stress and ultimate tensile strength in both modified and non-modified alloys. On the other hand, both Cu and Fe appear to affect the elongation adversely, whereas the Sr level shows a positive effect on the elongation percentage. We found that the Sr level had the most significant effect on the cutting forces and cutting power, followed by Fe and Cu contents. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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22 pages, 11422 KiB

Open AccessArticle

MulTi-FAST: A Machinability Assessment of Functionally Graded Titanium Billets Produced from Multiple Alloy Powders

by Oliver Levano Blanch, Daniel Suárez Fernández, Alex Graves and Martin Jackson

Materials 2022, 15(9), 3237; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15093237 - 30 Apr 2022

Cited by 4 | Viewed by 1750

Abstract

Technological developments in the area of functionally graded multi-material manufacture are poised to disrupt the aerospace industry, providing the means for step-change improvements in performance through tailored component design. However, the challenges faced during the downstream processing, i.e., machining of such functionally graded multi-materials are unclear. In this study, the challenges involved when face-turning billets consisting of multiple alloys are assessed. To achieve this, a cylindrical billet consisting of Ti-64, Ti-6242, Ti-5553 and Beta C alloys was manufactured from powder feedstock using field-assisted sintering technique (FAST) and termed MulTi-FAST billets. A detailed study of the structural integrity during machining at the diffusion bond interfaces of multiple titanium alloy bond pairings in the MulTi-FAST billet was conducted. The machining forces were measured during face-turning to investigate the impact and behaviour of different alloy pairings during a continuous machining operation. The results showed the significant differences in force machining response, surface topography and the type of surface damage was dependent on the direction the titanium alloy graded pairings were machined in. In terms of subsurface microstructural damage, regardless of the machining direction, no critical damage was found in the vicinity of the bonded alloys. The findings provide an insight into the deformation characteristics and challenges faced in the machining of functionally graded components with multiple titanium alloys. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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16 pages, 13545 KiB

Open AccessArticle

Machinability Investigation of Nitronic 60 Steel Turning Using SiAlON Ceramic Tools under Different Cooling/Lubrication Conditions

by Smita Padhan, Sudhansu Ranjan Das, Anshuman Das, Mohammad S. Alsoufi, Ahmed Mohamed Mahmoud Ibrahim and Ammar Elsheikh

Materials 2022, 15(7), 2368; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15072368 - 23 Mar 2022

Cited by 23 | Viewed by 1964

Abstract

The machining of nickel-based super alloys is challenging, owing to the generation of high cutting temperatures, as well as difficulty in maintaining dimensional accuracy and minimizing surface roughness, which compels the use of cutting fluids for reducing these issues due to efficient cooling/lubrication strategies. The present work investigates the comparative performance of four cooling/lubrication techniques: dry cutting, wet, minimum quantity lubricant (MQL) and compressed-air modes in turning Nitronic 60 steel using a new-generation SiAlON ceramic inserts. Several machinability parameters were analyzed for performance evaluation. For this purpose, 16 cycles of turning trials were performed based on Taguchi’s L₁₆ orthogonal array experimental design by varying cutting conditions and lubrication modes. MQL exhibits beneficial effects as compared to the other lubrication conditions concerning low cutting force, improved surface finish, decreased cutting temperature, longer tool life, and lower white layer thickness on machined surface. Burr formation on the saw-tooth chip surface, as well as friction, greatly influenced the tool flank wear due to improper cooling and poor lubrication approach in dry, wet, and compressed-air-cooled machining environments in comparison to MQL-machining. From an economical perspective, the tool life in MQL machining improved by 11%, 72%, and 138% in the comparison with flooded, compressed-air, and dry conditions, respectively. The results of the study demonstrate that using the MQL system can help with heat extraction capability, and provide some promising outcomes. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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19 pages, 7589 KiB

Open AccessArticle

Establishment of Analytical Model for CFRP Cutting Force Considering the Radius of the Edge Circle

by Haifeng Ning, Hualin Zheng and Guixin Wang

Materials 2022, 15(6), 2127; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15062127 - 14 Mar 2022

Cited by 2 | Viewed by 1526

Abstract

Carbon fiber-reinforced composite material (CFRP) has been widely applied in the aerospace industry, which places demanding requirements on the accuracy and quality of its processing. However, there remains a lack of clarity on the microscopic material removal process of CFRP, despite substantial relevant research. This paper aims to reveal the mechanism of material removal in the CFRP cutting process at different fiber cutting angles and to establish an analytical model for CFRP cutting force by considering the radius of the edge circle. Furthermore, the CFRP cutting force analytical model was established by considering the radius of the edge circle on the basis of the CFRP representative volume unit (RVE). According to the model, the cutting process was divided into three regions, the cutting slip zone, fiber fracture zone, and spring back zone, with consideration given to the effect of residual fibers on the cutter teeth. The CFRP cutting finite element model was defined using the software Abaqus, while the chip removal and single-fiber deformation processes were analyzed using the finite element model. As indicated by the experimental results, the analytical model is reliable and capable of providing cutting force values within a 15% deviation. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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21 pages, 3826 KiB

Open AccessArticle

Multi-Response Optimization of Al₂O₃ Nanopowder-Mixed Wire Electrical Discharge Machining Process Parameters of Nitinol Shape Memory Alloy

by Rakesh Chaudhari, Parth Prajapati, Sakshum Khanna, Jay Vora, Vivek K. Patel, Danil Yurievich Pimenov and Khaled Giasin

Materials 2022, 15(6), 2018; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15062018 - 09 Mar 2022

Cited by 21 | Viewed by 2336

Abstract

Shape memory alloy (SMA), particularly those having a nickel–titanium combination, can memorize and regain original shape after heating. The superior properties of these alloys, such as better corrosion resistance, inherent shape memory effect, better wear resistance, and adequate superelasticity, as well as biocompatibility, make them a preferable alloy to be used in automotive, aerospace, actuators, robotics, medical, and many other engineering fields. Precise machining of such materials requires inputs of intellectual machining approaches, such as wire electrical discharge machining (WEDM). Machining capabilities of the process can further be enhanced by the addition of Al₂O₃ nanopowder in the dielectric fluid. Selected input machining process parameters include the following: pulse-on time (T_on), pulse-off time (T_off), and Al₂O₃ nanopowder concentration. Surface roughness (SR), material removal rate (MRR), and recast layer thickness (RLT) were identified as the response variables. In this study, Taguchi’s three levels L₉ approach was used to conduct experimental trials. The analysis of variance (ANOVA) technique was implemented to reaffirm the significance and adequacy of the regression model. Al₂O₃ nanopowder was found to have the highest contributing effect of 76.13% contribution, T_on was found to be the highest contributing factor for SR and RLT having 91.88% and 88.3% contribution, respectively. Single-objective optimization analysis generated the lowest MRR value of 0.3228 g/min (at T_on of 90 µs, T_off of 5 µs, and powder concentration of 2 g/L), the lowest SR value of 3.13 µm, and the lowest RLT value of 10.24 (both responses at T_on of 30 µs, T_off of 25 µs, and powder concentration of 2 g/L). A specific multi-objective Teaching–Learning-Based Optimization (TLBO) algorithm was implemented to generate optimal points which highlight the non-dominant feasible solutions. The least error between predicted and actual values suggests the effectiveness of both the regression model and the TLBO algorithms. Confirmatory trials have shown an extremely close relation which shows the suitability of both the regression model and the TLBO algorithm for the machining of the nanopowder-mixed WEDM process for Nitinol SMA. A considerable reduction in surface defects owing to the addition of Al₂O₃ powder was observed in surface morphology analysis. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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12 pages, 1147 KiB

Open AccessArticle

Optimizing Friction Stir Welding of Dissimilar Grades of Aluminum Alloy Using WASPAS

by Pinnavasal Venukrishnan Rajesh, Krishna Kumar Gupta, Robert Čep, Manickam Ramachandran, Karel Kouřil and Kanak Kalita

Materials 2022, 15(5), 1715; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15051715 - 24 Feb 2022

Cited by 8 | Viewed by 1389

Abstract

Aluminum is a widely popular material due to its low cost, low weight, good formability and capability to be machined easily. When a non-metal such as ceramic is added to aluminum alloy, it forms a composite. Metal Matrix Composites (MMCs) are emerging as alternatives to conventional metals due to their ability to withstand heavy load, excellent resistance to corrosion and wear, and comparatively high hardness and toughness. Aluminum Matrix Composites (AMCs), the most popular category in MMCs, have innumerable applications in various fields such as scientific research, structural, automobile, marine, aerospace, domestic and construction. Their attractive properties such as high strength-to-weight ratio, high hardness, high impact strength and superior tribological behavior enable them to be used in automobile components, aviation structures and parts of ships. Thus, in this research work an attempt has been made to fabricate Aluminum Alloys and Aluminum Matrix Composites (AMCs) using the popular synthesis technique called stir casting and join them by friction stir welding (FSW). Dissimilar grades of aluminum alloy, i.e., Al 6061 and Al 1100, are used for the experimental work. Alumina and Silicon Carbide are used as reinforcement with the aluminum matrix. Mechanical and corrosion properties are experimentally evaluated. The FSW process is analyzed by experimentally comparing the welded alloys and welded composites. Finally, the best suitable FSW combination is selected with the help of a Multi-Attribute Decision Making (MADM)-based numerical optimization technique called Weighted Aggregated Sum Product Assessment (WASPAS). Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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20 pages, 7908 KiB

Open AccessArticle

Milling Al520-MMC Reinforced with SiC Particles and Additive Elements Bi and Sn

by Mahmoud Alipour Sougavabar, Seyed Ali Niknam, Behnam Davoodi and Victor Songmene

Materials 2022, 15(4), 1533; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15041533 - 18 Feb 2022

Cited by 2 | Viewed by 1734

Abstract

In recent years and due to advanced fabrication techniques of composites, many of these functional materials have been brought to the forefront with more benefits. Amongst composites, special attention has been paid to metal matrix composites (MMCs). Reinforced aluminum MMCs with nanoparticles are among the new MMCs with a wide range of industry applications. The combination of aluminum as a soft, lightweight, and low-strength material with silicon carbide (SiC), bismuth (Bi), and tin (Sn) particles, which are hard and high-strength materials, may lead to the generation of high-strength and lightweight material, which can be classified as difficult to cut material. According to literature, limited studies have been reported on the effects of various reinforcing elements on the machinability of Al-MMC, in principle tool wear morphology and size and surface quality. According to statistical analysis, the effect of cutting parameters and reinforcing particles on the surface quality attributes is not statistically significant. In contrast, the effect of cutting parameters and reinforcing particles on the tool flank wear is significant and reliable. In addition, it is observed that the reinforcing particles and cutting speed have the most significant effects, and the lubrication mode has a minor impact on the tool flank wear. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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21 pages, 6301 KiB

Open AccessArticle

Predictive Analytical Modeling of Thermo-Mechanical Effects in Orthogonal Machining

by Alliche Mohamed-Amine, Djennane Mohamed, Djebara Abdelhakim and Victor Songmene

Materials 2021, 14(24), 7876; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14247876 - 19 Dec 2021

Cited by 1 | Viewed by 2064

Abstract

Factor relationships in a machining system do not work in pairs. Varying the cutting parameters, materials machined, or volumes produced will influence many machining characteristics. For this reason, we are attempting to better understand the effect of the Johnson-Cook (J-C) law of behavior on cutting temperature prediction. Thus, the objective of the present study is to investigate, experimentally and theoretically, the tool/material interactions and their effects on dust emission during orthogonal cutting. The proposed approach is built on three steps. First, we established an experimental design to analyze, experimentally, the cutting conditions effects on the cutting temperature under dry condition. The empirical model which is based on the response surface methodology was used to generate a large amount of data depending on the machining conditions. Through this step, we were able to analyze the sensitivity of the cutting temperature to different cutting parameters. It was found that cutting speed, tool tip radius, rake angle, and the interaction between the cutting speed and the rake angle explain more than 84.66% of the cutting temperature variation. The cutting temperature will be considered as a reference to validate the analytical model. Hence, a temperature prediction model is important as a second step. The modeling of orthogonal machining using the J-C plasticity model showed a good correlation between the predicted cutting temperature and that obtained by the proposed empirical model. The calculated deviations for the different cutting conditions tested are relatively acceptable (with a less than 10% error). Finally, the established analytical model was then applied to the machining processes in order to optimize the cutting parameters and, at the same time, minimize the generated dust. The evaluation of the dust generation revealed that the dust emission is closely related to the variation of the cutting temperature. We also noticed that the dust generation can indicate different phenomena of fine and ultrafine particles generation during the cutting process, related to the heat source or temperature during orthogonal machining. Finally, the effective strategy to limit dust emissions at the source is to avoid the critical temperature zone. For this purpose, the two-sided values can be seen as combinations to limit dust emissions at the source. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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23 pages, 29813 KiB

Open AccessArticle

CNC Edge Finishing of Granite: Effect of Machining Conditions on Part Quality, Cutting Forces, and Particle Emissions

by Haithem Bahri, Victor Songmene, Jules Kouam, Agnes Marie Samuel and Fawzy Hosny Samuel

Materials 2021, 14(21), 6496; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14216496 - 29 Oct 2021

Cited by 3 | Viewed by 1974

Abstract

Edge finishing is a shaping process that is extremely important in the granite and marble processing industries. It does not only shape the edge but also makes it shiny and durable. However, this process generates dust (fine and ultrafine particles) that can have a significant impact on air quality in the workshop and can put workers’ health at risk. While environmental requirements and occupational health and safety regulations are becoming increasingly stringent, at the same time, industries must continue to produce quality parts at competitive prices. The purpose of this study was to examine the surface quality, the cutting forces, and the emission of fine (FP) and ultrafine (UFP) particles during wet and dry edge finishing of granite edges as a function of the machining parameters and abrasive grit sizes. Three machining operations were investigated: roughing, semi-finishing, and finishing, using diamond abrasives (with grit sizes 45, 150, 300, 600, 1500, and 3000). The experiments were carried out on two granites, one being black and the other white. The tested spindle speeds ranged from 1500 rpm to 3500 rpm and the feed rates from 500–1500 mm/min. It was found that roughing operations produce more fine particles while finishing operations produce more ultrafine particles. These particle emissions, as well as the part quality and the cutting forces are strongly dependent on cutting speed and on the grit size of the abrasive used. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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24 pages, 4540 KiB

Open AccessArticle

Experimental Investigation on Dry Routing of CFRP Composite: Temperature, Forces, Tool Wear, and Fine Dust Emission

by Tarek Elgnemi, Victor Songmene, Jules Kouam, Martin B.G. Jun and Agnes Marie Samuel

Materials 2021, 14(19), 5697; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14195697 - 30 Sep 2021

Cited by 11 | Viewed by 1503

Abstract

This article presents the influence of machining conditions on typical process performance indicators, namely cutting force, specific cutting energy, cutting temperature, tool wear, and fine dust emission during dry milling of CFRPs. The main goal is to determine the machining process window for obtaining quality parts with acceptable tool performance and limited dust emission. For achieving this, the cutting temperature was examined using analytical and empirical models, and systematic cutting experiments were conducted to assess the reliability of the theoretical predictions. A full factorial design was used for the experimental design. The experiments were conducted on a CNC milling machine with cutting speeds of 10,000, 15,000, and 20,000 rpm and feed rates of 2, 4, and 6 µm/tooth. Based on the results, it was ascertained that spindle speed significantly affects the cutting temperature and fine particle emission while cutting force, specific cutting energy, and tool wear are influenced by the feed rate. The optimal conditions for cutting force and tool wear were observed at a cutting speed of 10,000 rpm. The cutting temperature did not exceed the glass transition temperature for the cutting speeds tested and feed rates used. The fine particles emitted ranged from 0.5 to 10 µm aerodynamic diameters with a maximum concentration of 2776.6 particles for those of 0.5 µm diameters. Finally, results of the experimental optimization are presented, and the model is validated. The results obtained may be used to better understand specific phenomena associated with the milling of CFRPs and provide the means to select effective milling parameters to improve the technology and economics of the process. Full article

(This article belongs to the Special Issue Machining and Machinability of Advanced Materials and Composites)

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