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Optimization and Simulation in Alloy Cutting Processes
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Optimization and Simulation in Alloy Cutting Processes

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

Deadline for manuscript submissions: closed (20 June 2022) | Viewed by 48423

Special Issue Editor

Prof. Wojciech Zębala

E-Mail Website
Guest Editor
Politechnika Krakowska, Krakow, Poland
Interests: production engineering;construction and operation of machines; physical aspects of the cutting process; precision machining; cutting of difficult-to-cut materials; modeling and simulation of machining processes; numerical calculation methods (FEM);CNC machine tools; CAD/CAM systems; measurements of the geometric surface structure and modern manufacturing techniques (HSC, HPC, Hard machining,3D printing).
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In the last few years, we have observed rapid development in the automation of manufacturing processes, especially in automatic control systems. Progress in cutting stimulates a significant increase in the metal removal rate and achievement of high dimensional and shape accuracy of machine parts. To meet today’s high demands concerning the accuracy and efficiency of the manufacturing, it is necessary to use computer methods for the design and optimization of technological processes. The construction of machining simulation models allows, for example, fast visualization of the chip formation process in a wide range of machining parameters.

Machining operations can be applied to metallic (mainly alloys) and non-metallic materials like ceramics, composites, polymer, and wood. New materials, which play a key role, are used to produce cutting tools. The aim of all work related to the chip-forming simulation research is, first of all, to specify the material model characterizing the physical properties of the tool and workpiece materials, the friction model between the chip and tool, and to describe the shape of the tool, and which geometry of the rake face significant influences on the formed chip.

This Special Issue aims to present recent advances in the optimization of cutting processes for modern manufacturing engineering, especially CNC machining, application of modern tools for machining of difficult-to-cut materials, modeling and computer simulation of machining, and analysis of physical phenomena existing in the decohesion zone of the machined material.

It is my pleasure to invite you to submit original, high-quality research papers, short communications and state-of-the-art reviews for this Special Issue.

Prof. Wojciech Zębala
Guest Editor

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • Machining
  • Simulation of cutting processes
  • Optimization of manufacturing
  • Physical phenomena during cutting
  • Material models
  • Difficult-to-cut materials

Published Papers (20 papers)

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Research

23 pages, 8866 KiB  
Article
Parametric Study and Optimization of End-Milling Operation of AISI 1522H Steel Using Definitive Screening Design and Multi-Criteria Decision-Making Approach
by Muhammad Abas, Mohammed Alkahtani, Qazi Salman Khalid, Ghulam Hussain, Mustufa Haider Abidi and Johannes Buhl
Materials 2022, 15(12), 4086; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15124086 - 08 Jun 2022
Cited by 9 | Viewed by 1600
Abstract
End-milling operation of steel grade material is a challenging task as it is hard-to-cut material. Proper selection of cutting tools, cutting conditions, and cutting process parameters is important to improve productivity, surface quality, and tool life. Therefore, the present study investigated the end-milling [...] Read more.
End-milling operation of steel grade material is a challenging task as it is hard-to-cut material. Proper selection of cutting tools, cutting conditions, and cutting process parameters is important to improve productivity, surface quality, and tool life. Therefore, the present study investigated the end-milling operation of AISI 1522H steel grade under minimum-quantity lubrication (MQL) conditions using a novel blend of vegetable oils, namely canola and olive oil. Cutting process parameters considered were spindle speed (s), feed rate (f), depth of cut (d), width of cut (w), and cutting conditions (c), while responses were average surface roughness (Ra), cutting forces (Fc), tool wear (TW), and material removal rate (MRR). Experimental runs were designed based on the definitive screening design (DSD) method. Analysis of variance (ANOVA) results show that feed rate significantly affects all considered responses. Nonlinear prediction models were developed for each response variable, and their validity was also verified. Finally, multi-response optimization was performed using the combinative distance-based assessment (CODAS) method coupled with criteria importance through inter-criteria correlation (CRITIC). The optimized parameters found were: s = 1200 rpm, f = 320 mm/min, d = 0.6 mm, w = 8 mm, and c = 100 mL/h. Further, it was compared with other existing multi-response optimization methods and induced good results. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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24 pages, 14664 KiB  
Article
A Numerical Model for Predicting the Effect of Tool Nose Radius on Machining Process Performance during Orthogonal Cutting of AISI 1045 Steel
by Zakaria Ahmed M. Tagiuri, Thien-My Dao, Agnes Marie Samuel and Victor Songmene
Materials 2022, 15(9), 3369; https://0-doi-org.brum.beds.ac.uk/10.3390/ma15093369 - 08 May 2022
Cited by 10 | Viewed by 1471
Abstract
This paper presents the development of a numerical model for predicting and studying the effects of tool nose geometries and its interactions with cutting parameters during orthogonal cutting of AISI 1045 steel. The process performance characteristics studied were cutting temperature, effective stress, cutting [...] Read more.
This paper presents the development of a numerical model for predicting and studying the effects of tool nose geometries and its interactions with cutting parameters during orthogonal cutting of AISI 1045 steel. The process performance characteristics studied were cutting temperature, effective stress, cutting forces and tool wear. The cutting simulations were done using the commercial DEFORM-2D R V 11.3 software, based on the finite element method (FEM). The cutting tool used had a round nose with various nose radii (0.01–0.9 mm), while the machining parameters tested were the feed rate (0.1–0.3 mm/rev), the cutting speed (100–500 m/min) and the rake angle (–5° to +10°). The interactions between the tool nose radius and the cutting parameters (speed, feed) were found to affect mostly the cutting stress and, slightly, the tool wear rate. These interactions did not much influence the cutting temperature, that was found to be high when the tool nose radius and/or the cutting speed were high. The maximum temperature was found to occur at the middle of the tool-chip contact length and at the interaction of nose radius and flank face of the tool. Except for some fluctuations, there was no significant difference in tool wear rate between small and large nose radius scales. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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21 pages, 11027 KiB  
Article
Surface Roughness Analysis and Prediction with an Artificial Neural Network Model for Dry Milling of Co–Cr Biomedical Alloys
by Manuela-Roxana Dijmărescu, Bogdan Felician Abaza, Ionelia Voiculescu, Maria-Cristina Dijmărescu and Ion Ciocan
Materials 2021, 14(21), 6361; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14216361 - 24 Oct 2021
Cited by 13 | Viewed by 1914
Abstract
The aim of this paper is to conduct an experimental study in order to obtain a roughness (Ra) prediction model for dry end-milling (with an AlTiCrSiN PVD-coated tool) of the Co–28Cr–6Mo and Co–20Cr–15W–10Ni biomedical alloys, a model that can contribute to more quickly [...] Read more.
The aim of this paper is to conduct an experimental study in order to obtain a roughness (Ra) prediction model for dry end-milling (with an AlTiCrSiN PVD-coated tool) of the Co–28Cr–6Mo and Co–20Cr–15W–10Ni biomedical alloys, a model that can contribute to more quickly obtaining the desired surface quality and shortening the manufacturing process time. An experimental plan based on the central composite design method was adopted to determine the influence of the axial depth of cut, feed per tooth and cutting speed process parameters (input variables) on the Ra surface roughness (response variable) which was recorded after machining for both alloys. To develop the prediction models, statistical techniques were used first and three prediction equations were obtained for each alloy, the best results being achieved using response surface methodology. However, for obtaining a higher accuracy of prediction, ANN models were developed with the help of an application made in LabView for roughness (Ra) prediction. The primary results of this research consist of the Co–28Cr–6Mo and Co–20Cr–15W–10Ni prediction models and the developed application. The modeling results show that the ANN model can predict the surface roughness with high accuracy for the considered Co–Cr alloys. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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15 pages, 3117 KiB  
Article
Analysis and Optimization of Machining Hardened Steel AISI 4140 with Self-Propelled Rotary Tools
by Waleed Ahmed, Hussien Hegab, Atef Mohany and Hossam Kishawy
Materials 2021, 14(20), 6106; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14206106 - 15 Oct 2021
Cited by 5 | Viewed by 1492
Abstract
It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. [...] Read more.
It is necessary to improve the machinability of difficult-to-cut materials such as hardened steel, nickel-based alloys, and titanium alloys as these materials offer superior properties such as chemical stability, corrosion resistance, and high strength to weight ratio, making them indispensable for many applications. Machining with self-propelled rotary tools (SPRT) is considered one of the promising techniques used to provide proper tool life even under dry conditions. In this work, an attempt has been performed to analyze, model, and optimize the machining process of AISI 4140 hardened steel using self-propelled rotary tools. Experimental analysis has been offered to (a) compare the fixed and rotary tools performance and (b) study the effect of the inclination angle on the surface quality and tool wear. Moreover, the current study implemented some artificial intelligence-based approaches (i.e., genetic programming and NSGA-II) to model and optimize the machining process of AISI 4140 hardened steel with self-propelled rotary tools. The feed rate, cutting velocity, and inclination angle were the selected design variables, while the tool wear, surface roughness, and material removal rate (MRR) were the studied outputs. The optimal surface roughness was obtained at a cutting speed of 240 m/min, an inclination angle of 20°, and a feed rate of 0.1 mm/rev. In addition, the minimum flank tool wear was observed at a cutting speed of 70 m/min, an inclination angle of 10°, and a feed rate of 0.15 mm/rev. Moreover, different weights have been assigned for the three studied outputs to offer different optimized solutions based on the designer’s interest (equal-weighted, finishing, and productivity scenarios). It should be stated that the findings of the current work offer valuable recommendations to select the optimized cutting conditions when machining hardened steel AISI 4140 within the selected ranges. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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20 pages, 8551 KiB  
Article
Experimental-Analytical Method for Temperature Determination in the Cutting Zone during Orthogonal Turning of GRADE 2 Titanium Alloy
by Łukasz Ślusarczyk
Materials 2021, 14(15), 4328; https://0-doi-org.brum.beds.ac.uk/10.3390/ma14154328 - 03 Aug 2021
Cited by 5 | Viewed by 1754
Abstract
The paper presents an experimental-analytical method for determination of temperature in the cutting zone during the orthogonal turning of GRADE 2 titanium alloy. A cutting insert with a complex rake geometry was used in the experiments. The experimental part of the method involved [...] Read more.
The paper presents an experimental-analytical method for determination of temperature in the cutting zone during the orthogonal turning of GRADE 2 titanium alloy. A cutting insert with a complex rake geometry was used in the experiments. The experimental part of the method involved orthogonal turning tests during which the cutting forces and the chip forming process were recorded for two different insert rake faces. The analytical part used a relationship between the cutting forces and the temperature in the Primary Shear Zone (PSZ) and the Secondary Shear Zone (SSZ), which are described by the Johnson-Cook (J-C) constitutive model and the chip forming model according to the Oxley’s theory. The temperature in the PSZ and SSZ was determined by finding the minimum difference between the shear flow stress determined in the J-C model and the Oxley’s model. Finally, using the described method, the relationship between the temperature in the PSZ and SSZ and the rake face geometry was determined. In addition, the temperature in the cutting zone was measured during the experimental tests with the use of a thermovision camera. The temperature distribution results determined experimentally with a thermovision camera were compared with the results obtained with the described method. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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17 pages, 5285 KiB  
Article
Numerical Modeling and Analysis of Ti6Al4V Alloy Chip for Biomedical Applications
by Waqas Saleem, Bashir Salah, Xavier Velay, Rafiq Ahmad, Razaullah Khan and Catalin I. Pruncu
Materials 2020, 13(22), 5236; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13225236 - 19 Nov 2020
Cited by 8 | Viewed by 1784
Abstract
The influence of cutting forces during the machining of titanium alloys has attained prime attention in selecting the optimal cutting conditions to improve the surface integrity of medical implants and biomedical devices. So far, it has not been easy to explain the chip [...] Read more.
The influence of cutting forces during the machining of titanium alloys has attained prime attention in selecting the optimal cutting conditions to improve the surface integrity of medical implants and biomedical devices. So far, it has not been easy to explain the chip morphology of Ti6Al4V and the thermo-mechanical interactions involved during the cutting process. This paper investigates the chip configuration of the Ti6Al4V alloy under dry milling conditions at a macro and micro scale by employing the Johnson-Cook material damage model. 2D modeling, numerical milling simulations, and post-processing were conducted using the Abaqus/Explicit commercial software. The uncut chip geometry was modeled with variable thicknesses to accomplish the macro to micro-scale cutting by adapting a trochoidal path. Numerical results, predicted for the cutting reaction forces and shearing zone temperatures, were found in close approximation to experimental ones with minor deviations. Further analyses evaluated the influence of cutting speeds and contact friction coefficients over the chip flow stress, equivalent plastic strain, and chip morphology. The methodology developed can be implemented in resolving the industrial problems in the biomedical sector for predicting the chip morphology of the Ti6Al4V alloy, fracture mechanisms of hard-to-cut materials, and the effects of different cutting parameters on workpiece integrity. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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16 pages, 7298 KiB  
Article
Evaluation of Self-Propelled Rotary Tool in the Machining of Hardened Steel Using Finite Element Models
by Usama Umer, Hossam Kishawy, Mustufa Haider Abidi, Syed Hammad Mian and Khaja Moiduddin
Materials 2020, 13(22), 5092; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13225092 - 11 Nov 2020
Cited by 6 | Viewed by 1538
Abstract
This paper presents a model for assessing the performance of self-propelled rotary tool during the processing of hardened steel. A finite element (FE) model has been proposed in this analysis to study the hard turning of AISI 51200 hardened steel using a self-propelled [...] Read more.
This paper presents a model for assessing the performance of self-propelled rotary tool during the processing of hardened steel. A finite element (FE) model has been proposed in this analysis to study the hard turning of AISI 51200 hardened steel using a self-propelled rotary cutting tool. The model is developed by utilizing the explicit coupled temperature displacement analysis in the presence of realistic boundary conditions. This model does not take into account any assumptions regarding the heat partitioning and the tool-workpiece contact area. The model can predict the cutting forces, chip flow, induced stresses, and the generated temperature on the cutting tool and the workpiece. The nodal temperatures and heat flux data from the chip formation analysis are used to achieve steady-state temperatures on the cutting tool in the heat transfer analysis. The model outcomes are compared with reported experimental data and a good agreement has been found. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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21 pages, 3091 KiB  
Article
Experimental Investigation and Statistical Evaluation of Optimized Cutting Process Parameters and Cutting Conditions to Minimize Cutting Forces and Shape Deviations in Al6026-T9
by Muhammad Abas, Bashir Salah, Qazi Salman Khalid, Iftikhar Hussain, Abdur Rehman Babar, Rashid Nawaz, Razaullah Khan and Waqas Saleem
Materials 2020, 13(19), 4327; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13194327 - 29 Sep 2020
Cited by 16 | Viewed by 3026
Abstract
Precise, economical and sustainable cutting operations are highly desirable in the advanced manufacturing environment. For this aim, the present study investigated the influence of cutting parameters (i.e., the cutting speed (c), feed rate (f), depth of cut (d [...] Read more.
Precise, economical and sustainable cutting operations are highly desirable in the advanced manufacturing environment. For this aim, the present study investigated the influence of cutting parameters (i.e., the cutting speed (c), feed rate (f), depth of cut (d) and positive rake angle (p)) and sustainable cutting conditions (dry and minimum quantity lubricant (MQL)) on cutting forces (i.e., feed force (Ff), tangential forces (Ft), radial force (Fr) and resultant cutting forces (Fc) and shape deviations (i.e., circularity and cylindricity) of a 6026-T9 aluminum alloy. The type of lubricant and insert used are virgin olive oil and uncoated tungsten carbide tool. Turning experiments were performed on a TAKISAWA TC-1 CNC lathe machine and cutting forces were measured with the help of a Kistler 9257B dynamometer. Shape deviations were evaluated by means of a Tesa Micro-Hite 3D DCC 474 coordinate measuring machine (CMM). Experimental runs were planned based on Taguchi mixture orthogonal array design L16. Analysis of variance (ANOVA) was performed to study the statistical significance of cutting parameters. Taguchi based signal to noise (S/N) ratios are applied for optimization of single response, while for optimization of multiple responses Taguchi based signal to noise (S/N) ratios coupled with multi-objective optimization on the basis of ratio analysis (MOORA) and criteria importance through inter-criteria correlation (CRITIC) are employed. ANOVA results revealed that feed rate, followed by a depth of cut, are the most influencing and contributing factors for all components of cutting forces (Ff, Ft, Fr, and Fc) and shape deviations (circularity and cylindricity). The optimized cutting parameters obtained for multi responses are c = 600 m/min, f = 0.1 mm/rev, d = 1 mm and p = 25°, while for cutting conditions, MQL is optimal. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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23 pages, 10468 KiB  
Article
Prediction and Analysis of Multi-Response Characteristics on Plasma Arc Cutting of Monel 400™ Alloy Using Mamdani-Fuzzy Logic System and Sensitivity Analysis
by Rajamani Devaraj, Emad Abouel Nasr, Balasubramanian Esakki, Ananthakumar Kasi and Hussein Mohamed
Materials 2020, 13(16), 3558; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13163558 - 12 Aug 2020
Cited by 12 | Viewed by 2517
Abstract
Nickel-based alloys, especially Monel 400™, is gaining its significance in diverse applications owing to its superior mechanical properties and high corrosion resistance. Machining of these materials is extremely difficult through the traditional manufacturing process because of their affinity to rapid work hardening and [...] Read more.
Nickel-based alloys, especially Monel 400™, is gaining its significance in diverse applications owing to its superior mechanical properties and high corrosion resistance. Machining of these materials is extremely difficult through the traditional manufacturing process because of their affinity to rapid work hardening and deprived thermal conductivity. Owing to these difficulties a well-established disruptive metal cutting process namely plasma arc cutting (PAC) can be widely used to cut the sheet metals with intricate profiles. The present work focuses on an intelligent modeling of the PAC process and investigation on the multi-quality characteristics of PAC parameters using the fuzzy logic approach. The Box-Behnken response surface methodology is incorporated to design and conduct the experiments, and to establish the relationship between PAC parameters such as cutting speed, gas pressure, arc current, and stand-off distance and responses which include the material removal rate (MRR), kerf taper (KT), and heat affected zone (HAZ). The quadratic regression models are developed and their performances are assessed using the analysis of variance (ANOVA). Fuzzy set theory-based models are formulated to predict various responses using the Mamdani approach. Fuzzy logic and regression results are compared with the experimental data. A comparative evaluation predicted an average error of 0.04% for MRR, 0.48% for KT, and 0.46% for HAZ, respectively. The effect of variations in PAC process parameters on selected responses are estimated through performing the sensitivity analysis. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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12 pages, 4522 KiB  
Article
Drilling Burr Minimization by Changing Drill Geometry
by Emilia Franczyk, Łukasz Ślusarczyk and Wojciech Zębala
Materials 2020, 13(14), 3207; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13143207 - 18 Jul 2020
Cited by 12 | Viewed by 3260
Abstract
This article presents an attempt to solve the problem of the formation of burrs and drilling caps in the process of drilling in difficult-to-cut materials, specifically in the titanium alloy Ti-6Al-4V. In order to eliminate these phenomena, a chamfer of specific length and [...] Read more.
This article presents an attempt to solve the problem of the formation of burrs and drilling caps in the process of drilling in difficult-to-cut materials, specifically in the titanium alloy Ti-6Al-4V. In order to eliminate these phenomena, a chamfer of specific length and angle was made on FANAR drill’s margin. Taguchi and ANOVA methods were used to plan and analyze the experiment aimed at determining the optimal geometry of the modified drill. Chamfer with a length of 2 mm and an angle of 10° was selected. In the next stage of research, the values of cutting forces and burr heights obtained during drilling with the original and modified drill were compared for three different feed rate values. It turned out that the introduced changes significantly reduced both the axial cutting force (22–23%) and the height of burrs (10–22%) and caused the complete elimination of the presence of drilling caps. Additionally, a positive correlation between the cutting force and the burr size was found. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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22 pages, 8728 KiB  
Article
The Effect of Abrasive Waterjet Machining Parameters on the Condition of Al-Si Alloy
by Monika Kulisz, Ireneusz Zagórski and Jarosław Korpysa
Materials 2020, 13(14), 3122; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13143122 - 13 Jul 2020
Cited by 14 | Viewed by 2499
Abstract
This paper analyses the effect of the abrasive waterjet cutting parameters’ modification on the condition of the workpiece surface layer. The post-machined surface of casting aluminium alloys, AlSi10Mg and AlSi21CuNi, was characterised in terms of surface roughness and irregularities, chamfering, and microhardness in [...] Read more.
This paper analyses the effect of the abrasive waterjet cutting parameters’ modification on the condition of the workpiece surface layer. The post-machined surface of casting aluminium alloys, AlSi10Mg and AlSi21CuNi, was characterised in terms of surface roughness and irregularities, chamfering, and microhardness in order to reveal the effect that variable jet feed rate, abrasive flow rate, and sample height (thickness of the cut material) have on the quality of surface finish. From the analysis of the results, it emerges that the surface roughness remains largely unaffected by changes in the sample height h or the abrasive flow rate ma, whereas it is highly susceptible to the increase in the jet feed rate vf. It has been shown that, in principle, the machining does not produce the strengthening effect, that is, an increase in microhardness. Owing to the irregularities that are typically found on the workpieces cut with higher jet feed rates vf, additional surface finish operations may prove necessary. In addition, chamfering was found to occur throughout the entire range of speeds vf. The statistical significance of individual variables on the 2D surface roughness parameters, Ra/Rz/RSm, was determined using factorial analysis of variance (ANOVA). The results were verified by means of artificial neural network (ANN) modelling (radial basis function and multi-layered perceptron), which was employed to predict the surface roughness parameters under consideration. The obtained correlation coefficients show that ANNs exhibit satisfying predictive capacity, and are thus a suitable tool for the prediction of surface roughness parameters in abrasive waterjet (AWJ) technology. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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16 pages, 6896 KiB  
Article
Laser-Machining of Microchannels in NiTi-Based Shape-Memory Alloys: Experimental Analysis and Process Optimization
by Muneer Khan Mohammed and Abdulrahman Al-Ahmari
Materials 2020, 13(13), 2945; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13132945 - 01 Jul 2020
Cited by 13 | Viewed by 1932
Abstract
Nickel–Titanium (NiTi)-based shape-memory alloys (SMA) are utilized in automotive, biomedical, microsystem applications because of their excellent shape memory effect, biocompatibility and super elastic properties. These alloys are considered difficult to cut—especially with conventional technologies because of the work hardening and residual stresses. Laser-machining [...] Read more.
Nickel–Titanium (NiTi)-based shape-memory alloys (SMA) are utilized in automotive, biomedical, microsystem applications because of their excellent shape memory effect, biocompatibility and super elastic properties. These alloys are considered difficult to cut—especially with conventional technologies because of the work hardening and residual stresses. Laser-machining is one of the most effective tools for processing of these alloys especially for microsystem applications. In this work, a thorough investigation of effect of process parameters on machining of microchannels in NiTi SMA is presented. In addition, a multi-objective optimization is carried out in order to find the optimal input parameter settings for the desired output performances. The results show that the quality of microchannels is significantly affected by input parameters. Layer thickness was found to have a significant effect on taper angle of the microchannel. Scan speed, layer thickness and scan strategy were found to have significant effects on both spatter thickness and top-width error, but in opposite directions. The multi-objective optimization-minimizing taper angle and spatter thickness revealed an optimal solution that was characterized by high frequency, moderate speed and low layer-thickness and track displacement. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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18 pages, 4641 KiB  
Article
Reduction of Power Consumption by Chip Breakability Control in Ti6Al4V Titanium Alloy Turning
by Wojciech Zębala, Grzegorz Struzikiewicz and Bogdan Słodki
Materials 2020, 13(11), 2642; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13112642 - 10 Jun 2020
Cited by 10 | Viewed by 2278
Abstract
The paper concerns the problem of energy savings in turning of titanium alloy Ti6Al4V. Since this alloy belongs to difficult to cut materials, there is a problem with chip forming and breaking. The turning process is often supported by implementing a high-pressure cooling [...] Read more.
The paper concerns the problem of energy savings in turning of titanium alloy Ti6Al4V. Since this alloy belongs to difficult to cut materials, there is a problem with chip forming and breaking. The turning process is often supported by implementing a high-pressure cooling (HPC) system. Based on the observations and the adopted chip classification method, the authors proved that it is not necessary to use this method in roughing operations, however it helps with the chips breaking process in finishing operations. A general algorithm for machining optimization due to the chip geometry is presented and described. In the presented case, it was shown that the acceptable chip geometry could be obtained with a reduced power consumption by approximately Pc = 0.5 kW. The authors concluded that it was not necessary to apply cutting data and a coolant system to achieve perfect chip geometry. An acceptable form was often sufficient, while requiring less energy. An additional factor resulting from the operation of systems supporting the cutting process, such as an HPC device, should be taken into account in the formula concerning the energy consumption (EC) of a computerized numerical control (CNC) machine tool. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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22 pages, 8298 KiB  
Article
Optimization of Cutting Data and Tool Inclination Angles During Hard Milling with CBN Tools, Based on Force Predictions and Surface Roughness Measurements
by Andrzej Matras and Wojciech Zębala
Materials 2020, 13(5), 1109; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13051109 - 02 Mar 2020
Cited by 8 | Viewed by 3211
Abstract
This work deals with technological considerations required to optimize the cutting data and tool path pattern for finishing the milling of free-form surfaces made of steel in a hardened state. In terms of technological considerations, factors such as feed rate, workpiece geometry, tool [...] Read more.
This work deals with technological considerations required to optimize the cutting data and tool path pattern for finishing the milling of free-form surfaces made of steel in a hardened state. In terms of technological considerations, factors such as feed rate, workpiece geometry, tool inclination angles (lead and tilt angles) and surface roughness are taken into account. The proposed method is based on calculations of the cutting force components and surface roughness measurements. A case study presented in the paper is based on the AISI H13 steel, with hardness 50 HRC and milling with a cubic boron nitride (CBN) tool. The results of the research showed that by modifications of the feed value based on the currently machined cross-sectional area, it is possible to control the cutting force components and surface roughness. During the process optimization, the 9% and 15% increase in the machining process efficiency and the required surface roughness were obtained according to the tool inclination angle and feed rate optimization procedure, respectively. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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14 pages, 3346 KiB  
Article
Analysis of the Machinability of Copper Alloy Ampcoloy by WEDM
by Katerina Mouralova, Libor Benes, Tomas Prokes, Josef Bednar, Radim Zahradnicek, Robert Jankovych, Jiri Fries and Jakub Vontor
Materials 2020, 13(4), 893; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13040893 - 17 Feb 2020
Cited by 7 | Viewed by 2147
Abstract
The unconventional technology of wire electrical discharge machining is widely used in all areas of industry. For this reason, there is always an effort for efficient machining at the lowest possible cost. For this purpose, the following comprehensive study has been carried out [...] Read more.
The unconventional technology of wire electrical discharge machining is widely used in all areas of industry. For this reason, there is always an effort for efficient machining at the lowest possible cost. For this purpose, the following comprehensive study has been carried out to optimize the machining of the copper alloy Ampcoloy 35, which is particularly useful in plastic injection moulds. Within the study, a half-factor experiment of 25-1 with 10 axial points and seven central points of a total of 33 rounds was carried out, which was focused on the response monitoring of the input factors in the form of the machine parameters setup: gap voltage, pulse on time, pulse off time, discharge current, and wire speed. Based on the study of the response in the form of cutting speed and surface topography, their statistical models were created, while the optimal setting of machine parameters was determined to maximize the cutting speed and minimize the topography parameters. Further, a detailed cross-sectional analysis of surface and subsurface layer morphology was performed using electron microscopy including chemical composition analysis. In order to study microstructural changes in the material at the atomic level, a lamella was created, which was then studied using a transmission electron microscope. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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16 pages, 4845 KiB  
Article
Optimization and Modeling of Process Parameters in Multi-Hole Simultaneous Drilling Using Taguchi Method and Fuzzy Logic Approach
by Muhammad Aamir, Shanshan Tu, Majid Tolouei-Rad, Khaled Giasin and Ana Vafadar
Materials 2020, 13(3), 680; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13030680 - 03 Feb 2020
Cited by 54 | Viewed by 4010
Abstract
In industries such as aerospace and automotive, drilling many holes is commonly required to assemble different structures where machined holes need to comply with tight geometric tolerances. Multi-spindle drilling using a poly-drill head is an industrial hole-making approach that allows drilling several holes [...] Read more.
In industries such as aerospace and automotive, drilling many holes is commonly required to assemble different structures where machined holes need to comply with tight geometric tolerances. Multi-spindle drilling using a poly-drill head is an industrial hole-making approach that allows drilling several holes simultaneously. Optimizing process parameters also improves machining processes. This work focuses on the optimization of drilling parameters and two drilling processes—namely, one-shot drilling and multi-hole drilling—using the Taguchi method. Analysis of variance and regression analysis was implemented to indicate the significance of drilling parameters and their impact on the measured responses i.e., surface roughness and hole size. From the Taguchi optimization, optimal drilling parameters were found to occur at a low cutting speed and feed rate using a poly-drill head. Furthermore, a fuzzy logic approach was employed to predict the surface roughness and hole size. It was found that the fuzzy measured values were in good agreement with the experimental values; therefore, the developed models can be effectively used to predict the surface roughness and hole size in multi-hole drilling. Moreover, confirmation tests were performed to validate that the Taguchi optimized levels and fuzzy developed models effectively represent the surface roughness and hole size. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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13 pages, 4673 KiB  
Article
The Effect of the Feed Direction on the Micro- and Macro Accuracy of 3D Ball-end Milling of Chromium-Molybdenum Alloy Steel
by Balázs Mikó, Bálint Varga and Wojciech Zębala
Materials 2019, 12(24), 4038; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12244038 - 04 Dec 2019
Cited by 3 | Viewed by 2374
Abstract
The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness [...] Read more.
The machining of free form surfaces is one of the most challenging problems in the field of metal cutting technology. The produced part and machining process should satisfy the working, accuracy, and financial requirements. The accuracy can describe dimensional, geometrical, and surface roughness parameters. In the current article, three of them are investigated in the case of the ball-end milling of a convex and concave cylindrical surface form 42CrMo4 steel alloy. The effect of the tool path direction is investigated and the other cutting parameters are constant. The surface roughness and the geometric error are measured by contact methods. Based on the results, the surface roughness, dimensional error, and the geometrical error mean different aspects of the accuracy, but they are not independent from each other. The investigated input parameters have a similar effect on them. The regression analyses result a very good liner regression for geometric errors and shows the importance of surface roughness. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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18 pages, 13991 KiB  
Article
Impact of Process Parameters on the Quality of Deep Holes Drilled in Inconel 718 Using EDD
by Magdalena Machno
Materials 2019, 12(14), 2298; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12142298 - 18 Jul 2019
Cited by 17 | Viewed by 2901
Abstract
Advanced engineering materials (e.g., nickel or titanium alloy) are being increasingly applied to produce parts of gas turbines in the aerospace industry. To improve the durability of these parts, many holes, with a length-to-diameter aspect ratio greater than 20:1, are created in their [...] Read more.
Advanced engineering materials (e.g., nickel or titanium alloy) are being increasingly applied to produce parts of gas turbines in the aerospace industry. To improve the durability of these parts, many holes, with a length-to-diameter aspect ratio greater than 20:1, are created in their structure. The quality of the holes significantly affects the cooling process of the elements. However, it is challenging to machine materials by conventional methods. When machining a hole with a high aspect ratio, the major problem is effective flushing of the machining area, which can improve the hole’s surface integrity and dimensional accuracy. Consequently, the electro-discharge drilling (EDD) process is good alternative for this application. This paper presents the results of an analysis of the EDD of Inconel 718 alloy. An experiment was conducted to evaluate the impact of process parameters (pulse time, current amplitude, and discharge voltage) on the process’s performance (linear tool wear, taper angle, drilling speed, the hole’s aspect ratio, and surface roughness (Ra and Rz)). The results show that EDD provides us with the possibility to drill holes with an aspect ratio greater than 10:1. The results also demonstrate that holes with an aspect ratio greater than 10:1 and a small taper angle value have a significantly decreased quality of internal surface, especially at the bottom of the hole. This indicates that an insufficient amount of debris is removed from the bottom of the hole. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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17 pages, 8004 KiB  
Article
A Methodology to Systematically Investigate the Diffusion Degradation of Cemented Carbide during Machining of a Titanium Alloy
by Sara Saketi, Jonas Östby, Ulf Bexell and Mikael Olsson
Materials 2019, 12(14), 2271; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12142271 - 15 Jul 2019
Cited by 9 | Viewed by 2890
Abstract
Using Ti6Al4V as a work material, a methodology to systematically investigate the diffusion degradation of cemented carbide during machining is proposed. The methodology includes surface characterization of as-tested worn inserts, wet etched worn inserts, metallographic cross-sectioned worn inserts as well as the back-side [...] Read more.
Using Ti6Al4V as a work material, a methodology to systematically investigate the diffusion degradation of cemented carbide during machining is proposed. The methodology includes surface characterization of as-tested worn inserts, wet etched worn inserts, metallographic cross-sectioned worn inserts as well as the back-side of the produced chips. Characterization techniques used include scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDS), Auger electron spectroscopy (AES) and time of flight secondary ion mass spectroscopy (ToF-SIMS). The results show that the characterization of wet etched worn inserts gives quick and useful information regarding the diffusion degradation of cemented carbide, in the present work the formation of a fine crystalline W layer (carbon depleted WC layer) at the tool-work material interface. The present study also illuminates the potential of AES analysis when it comes to analyzing the degradation of cemented carbide in contact with the work material during machining. The high surface sensitivity in combination with high lateral resolution makes it possible to analyze the worn cemented carbide surface on a sub-µm level. Especially AES sputter depth profiling, resulting in detailed information of variations in chemical composition across interfaces, is a powerful tool when it comes to understanding diffusion wear. Finally, the present work illustrates the importance of analyzing not only the worn tool but also the produced chips. An accurate characterization of the back-side of the chips will give important information regarding the wear mechanisms taking place at the tool rake face–chip interface. Surface analysis techniques such as AES and ToF-SIMS are well suited for this type of surface characterization. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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14 pages, 3257 KiB  
Article
Study on ASJ Cutting of TC18, Based upon Multivariate Nonlinear Regression and SA-BP-AGA
by Jie Lin, Xin Zhou, Hui Zhang, Fengchao Wang, Qiwen Xu and Chuwen Guo
Materials 2019, 12(12), 1902; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12121902 - 13 Jun 2019
Cited by 3 | Viewed by 2284
Abstract
TC18 titanium alloy has been widely applied, but is considered as a difficult machining material. Taking the kerf angle as the quality criterion, this paper studied the cutting performance of TC18 by the use of an abrasive slurry jet (ASJ), based upon multivariate [...] Read more.
TC18 titanium alloy has been widely applied, but is considered as a difficult machining material. Taking the kerf angle as the quality criterion, this paper studied the cutting performance of TC18 by the use of an abrasive slurry jet (ASJ), based upon multivariate nonlinear regression and SA-BP-AGA. Cutting experiments were carried out according to the Taguchi orthogonal method. The experimental factors included traverse speed, standoff distance, pressure and slurry concentration, with five levels set, respectively. Meanwhile, a characterization method of the major influencing factors was proposed. A multiple nonlinear regression model and a back propagation artificial neural network (BP) prediction model, based on adaptive genetic algorithm (AGA), were established. The reliability was verified by statistics equations for the 22 groups of the fitting or training model and the three groups of experimental results. The BP-AGA and Simulated annealing algorithm (SA) were used to form a set of prediction optimization systems, called integrated SA-BP-AGA. Finally, the results showed that the main factor influencing the kerf angle is the slurry concentration. BP-AGA is easier to model, offers better robustness and is more accurate than a multivariate nonlinear regression model. The best kerf angle can be predicted by the integration system. The study results can improve the performance for the machining of TC18 by ASJ. Full article
(This article belongs to the Special Issue Optimization and Simulation in Alloy Cutting Processes)
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