Wyniki wyszukiwania - BazTech

1

Advanced methods of determination of friction coefficient in the machining process

Grzesik Wit

Mechanik

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2026

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R. 99, nr 1

8--13

EN

In this article, several possibilities for integrating AI methods with FEM-based modelling for coefficient of friction (COF) prediction are reviewed and discussed. In particular, the implementation of a Grey-Box model and selected regression testing methods is presented. Results of integrating a Python interface with the FEM DEFORM package for predicting componential cutting forces and cutting temperatures using estimated COF values are provided. The performance of different friction models implemented in FEM and SPH simulation packages is compared. New trends and future research directions are also outlined.

PL

W artykule omówiono możliwości integracji metod sztucznej inteligencji (AI) z modelowaniem metodą elementów skończonych (FEM) do prognozowania wartości współczynnika tarcia. W szczególności przedyskutowano zastosowanie tzw. modelu szarej skrzynki (Grey-Box) i kilku metod testowania regresyjnego, a podano wyniki integracji interfejsu Pythona z programem symulacyjnym DEFORM dotyczące sił skrawania i temperatury, wykorzystujące wyniki prognozy współczynnika tarcia. Porównano efekty zastosowania różnych modeli tarcia w metodach FEM i SPH. Omówiono przyszłościowe kierunki badań.

2

Wpływ metody/sposobu podawania PCS na aktywność czyszczenia CPŚ w procesie szlifowania powierzchni płaskich

Wójcik Ryszard

Journal of Engineering 360

|

2025

|

Vol. 1, Iss. 1/25

23--30

PL

W opracowaniu zaprezentowano cykl badań czyszczących czynną powierzchnię ściernicy konwencjonalnej z wykorzystaniem dwóch metod podawania płynu chłodząco-smarującego z minimalnym wydatkiem – MQL (Minimum Quantity Lubrication) i metodą zalewową WET (wet machining) – wodna emulsja olejowa, podczas procesu szlifowania powierzchni płaskich wgłębnie, współ/przeciwbieżnie. Do badania wykorzystano stal 1.4034 o twardości 55 HRC. Zaproponowano specjalne rozwiązanie konstrukcyjne ściernicy 38A60KV8 (Norton Polska), które pozwoliło obserwować zachowanie zanieczyszczeń oraz osadzania na powierzchni próbki. Opracowano metodykę gromadzenia zanieczyszczeń na powierzchni szlifowanego materiału. Ważono zanieczyszczenia z czynnej powierzchni ściernicy (CPS). Uzyskane wyniki pozwoliły ocenić skuteczność badanych metod podawania płynu chłodząco-smarującego (PCS). W szczególności stwierdzono, że prostopadłe podawanie PCS wspomaga proces smarowania powierzchni szlifowanego przedmiotu, korzystnie wpływa na siły skrawania poprzez zmniejszenie tarcia, a tym samym obniża temperaturę w strefie obróbki, co sprzyja uzyskaniu korzystniejszego rozkładu naprężeń ściskających w warstwie wierzchniej.

XX

The study presents a series of experiments focused on cleaning the active surface of a conventional grinding wheel using two methods of supplying the cooling and lubricating fluid with minimum consumption: MQL (Minimum Quantity Lubrication) and the flood method WET (wet machining) with an oil–water emulsion, during the process of plunge surface grinding in both up- and down-grinding modes. The tests were carried out on steel grade 1.4034 with a hardness of 55 HRC. A special design solution of the 38A60KV8 grinding wheel (Norton Poland) was proposed, which enabled observation of the behavior and deposition of contaminants on the sample surface. A methodology was developed for collecting contaminants on the surface of the ground material. The contaminants from the active surface of the grinding wheel (CPS) were weighed. The obtained results made it possible to assess the effectiveness of the investigated methods of supplying the cooling and lubricating fluid (PCS). In particular, it was found that perpendicular delivery of PCS supports the lubrication of the ground surface, positively affects the cutting forces by reducing friction, and consequently lowers the temperature in the machining zone, which in turn contributes to achieving a more favorable distribution of compressive stresses in the surface layer.”

3

Application of low-cost dynamometer based on full octagonal ring for turning process monitoring

Susanto Agus, Setiyana Budi, Ismail Rifky, Wicaksana Ramadhana Eka

Archive of Mechanical Engineering

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2025

|

LXXII, nr 1

153--175

EN

This article discusses a low-cost dynamometer based on a novel full octagonal ringshaped transducer applied to measure the cutting forces and analyze them with the use of signal processing tools, in order determine their compatibility and the potential to monitoring machining conditions. The results showed that the performance of the developed dynamometer was in good agreement with cutting forces simulation. The cutting forces were about 30 N in stable cutting and 80 N in unstable cutting. In stable cutting, the spectrum showed the spindle frequency 𝑓𝑠 of 5.33 Hz, corresponding to 320 rpm of spindle speed, which was followed by its harmonic frequencies of 10.66, 16 and 21.33 Hz. Revealing of all characteristic frequencies during turning processes through the frequency spectrum showed the evidence that the developed dynamometer indeed functioned well measuring cutting forces in machining. Apart of the spindle frequency of 7.5 Hz and its harmonics, there also appeared the chatter frequency 𝑓𝑐 of 62 Hz in unstable cutting condition. By using the combination of signal processing tolls of the ensemble empirical mode decomposition with the shorttime Fourier transform (EEMD-STFT), the chatter frequency was clearly captured. The combination of cutting forces measured by the developed dynamometer with EEMD-STFT makes it easier for the operator to reveal the machining conditions within a relatively short time.

4

Prediction of tool wear based cutting forces during end milling of Inconel 718 using artificial neural networks

Felusiak-Czyryca Agata, Twardowski Paweł

Advances in Science and Technology. Research Journal

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2025

|

Vol. 19, no. 7

394--405

EN

During the research, correlation between the input parameters (cutting parameters and cutting forces measure like peak to peak, root mean square and root mean square of ripple) and the variables were searched for, and the sensitivity of the network to input parameters was determined. In this paper artificial neural networks (ANNs) to prediction of tool wear based on cutting forces were used. Multilayer perceptron (MLP) networks with backward error propagation were used. The research shows that for the tested material and in the tested range, the cutting parameters are not diagnostically significant for the prediction of VBC (band width of the corner wear). The authors of this article focus on simplifying the model and analyzing the influence of variables on the prediction error. Neural networks show a correlation of about 95% for test sets.

5

Cutting forces during milling of vertical thin-walled structures of aerospace alloys

Zagórski Krzysztof

Advances in Science and Technology. Research Journal

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2025

|

Vol. 19, no. 7

197--210

EN

The article presents the results of the experiment conducted under controlled cutting conditions with a constant material removal rate, an increased cross-section of the cutting layer was used, tested for use in finishing. The analysis examined the influence of input factors on the measured values. Samples with a thin wall in vertical orientation were made of two materials - titanium Ti6Al4V and nickel alloy Inconel 625, which were the first input factor. Additional variable factors adopted during machining were cutting tools (a general purpose tool, a tool for efficient machining, a tool for high-speed machining) and machining strategies (side face milling and cylindrical side milling). The prepared samples contain two machined surfaces - inputs and outputs. During machining, the signal of cutting force components was recorded for them, based on which their graphs were made. In the case of side face milling of nickel alloy, an approximately 50% increase in the Fx component and an approximately twofold increase in the Fy and Fz components is observed compared to their titanium alloy counterparts. When milling titanium alloy samples, the values of the cutting force components between the strategies were similar, whereas for nickel alloy samples, milling with general-purpose and performance tools resulted in the cutting force component Fx being half as large as for the frontal approach.

6

The influence of PCBN inserts microgeometry on cutting forces, surface roughness, and tool wear when milling Inconel 718

Szpunar Marcin, Zwolak Marek, Ostrowski Robert

Advances in Mechanical and Materials Engineering

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2025

|

Vol. 42, nr 1

121--133

EN

This study investigates the effect of cutting edge microgeometry on the milling of Inconel 718, a superalloy widely used in aircraft engine components. Face milling tests were conducted using a Ø63 mm tool with unevenly distributed polycrystalline cubic boron nitride (PCBN) inserts, comparing inserts with a chamfered cutting edge (15° × 0.2 mm) and sharp cutting edges. The experiments examined cutting forces, surface roughness (parameters Ra and Rz), and tool wear at various cutting speeds (80–300 m/min). The results revealed that sharp inserts generated lower cutting forces compared to chamfered inserts, with the axial force being the greatest component for chamfered tools and the lowest for sharp ones. The dominant tool wear mechanism for both insert types was chipping; however, sharp inserts also exhibited built–up edge formation and, in one case, a significantly deeper crater compared to chamfered inserts which showed smaller crater depths. The study concludes that the cutting edge microgeometry significantly influences the machining performance in terms of cutting forces, surface quality, and tool wear when milling Inconel 718.

PL

W niniejszym badaniu zbadano wpływ mikrogeometrii ostrza na proces frezowania Inconelu 718, stopu wysokotemperaturowego powszechnie stosowanego w komponentach silników lotniczych. Przeprowadzono testy frezowania czołowego za pomocą narzędzia o średnicy Ø63 mm z nierównomiernie rozmieszczonymi płytkami PCBN, porównując płytki z fazowanym ostrzem (15° × 0.2 mm) i ostrymi krawędziami skrawającymi. Eksperymenty dotyczyły analizy sił skrawania, chropowatości powierzchni (parametry Ra i Rz) oraz zużycia narzędzia przy różnych prędkościach skrawania (80–300 m/min). Na podstawie wyników stwierdzono, że frezowanie z użyciem frezów ostrych generowało niższe siły skrawania w porównaniu do frezów z fazką, przy czym osiowa siła skrawania była największą składową dla narzędzi z fazką, a najmniejszą dla narzędzi ostrych. Dominującym mechanizmem zużycia narzędzia dla obu typów płytek było wykruszanie; jednakże frezy ostre wykazywały również tworzenie się narostu oraz, w jednym przypadku, znacznie głębszy krater w porównaniu do frezów z fazką, które charakteryzowały się mniejszymi głębokościami kraterów. Wyniki badań dowiodły, że mikrogeometria ostrza znacząco wpływa na parametry obróbki pod względem sił skrawania, jakości powierzchni i zużycia narzędzia podczas frezowania Inconelu 718.

7

Investigation of the effects of machining parameters on cutting conditions during orthogonal turning of austenite stainless steel

Kónya Gábor, Takács János, Miskolczi István, Kovács Zsolt F.

Production Engineering Archives

|

2024

|

Vol. 30, Iss. 1

86--93

EN

The 1.4306 austenite stainless steel has been prominently utilized as a material in the automotive and aerospace industry. Considerable interest has been garnered in the machinability of stainless steel owing to its high strength and poor thermal conductivity. The aim of this study is to ascertain the influential cutting parameters, specifically the cutting speed and feed rate, on cut-ting forces, cutting temperature, and chip evaluation. Thus, austenite stainless steel was subjected to free-cutting using a carbide recessing tool under dry conditions. The principle of measuring cutting temperature, a complex procedure due to varying thermal homogeneity, was elucidated. For the turning experiments in question, the standard Taguchi orthogonal array L9 (32 ), featuring two factors and three levels, was employed. The experimental results were analyzed using MiniTab 17 software. The findings reveal a substantial effect of feed rate on cutting force, cutting temperature, and chip evaluation. The highest cutting force and cutting temperature were observed at a feed rate of 0.15 mm/rev. Conversely, the cutting force was minimized at a cutting speed of 100 m/min, indicating potential for increasing the cutting speed. The augmentation of feed rate led to chip compression and discoloration, attributed to elevated cutting force and a larger chip cross-section that efficiently dissipates heat from the cutting zone

8

Investigation of the effects of machining parameters on cutting conditions during orthogonal turning of austenite stainless steel

Kónya Gábor, Takács János, Miskolczi István, Kovács Zsolt F.

Production Engineering Archives

|

2024

|

Vol. 30, Iss. 2

251--258

EN

The 1.4306 austenite stainless steel has been prominently utilized as a material in the automotive and aerospace industry. Considerable interest has been garnered in the machinability of stainless steel owing to its high strength and poor thermal conductivity. The aim of this study is to ascertain the influential cutting parameters, specifically the cutting speed and feed rate, on cutting forces, cutting temperature, and chip evaluation. Thus, austenite stainless steel was subjected to free-cutting using a carbide recessing tool under dry conditions. The principle of measuring cutting temperature, a complex procedure due to varying thermal homogeneity, was elucidated. For the turning experiments in ques-tion, the standard Taguchi orthogonal array L9 (32), featuring two factors and three levels, was employed. The experimental results were analyzed using MiniTab 17 software. The findings reveal a substantial effect of feed rate on cutting force, cutting temperature, and chip evaluation. The highest cutting force and cutting temperature were observed at a feed rate of 0.15 mm/rev. Conversely, the cutting force was minimized at a cutting speed of 100 m/min, indicating potential for increasing the cutting speed. The augmentation of feed rate led to chip compression and discoloration, attributed to elevated cutting force and a larger chip cross-section that efficiently dissipates heat from the cutting zone.

9

Simulation and Experimental Study of the Termo-Mechanical Effect of the Milling Process of 7075 Aluminium Alloy

Habrat W., Lisowicz Joanna, Tymczyszyn Jarosław, Skroban Anna

Advances in Science and Technology. Research Journal

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2024

|

Vol. 18, no. 3

58--66

EN

This study combined simulation and experimental tests to analyse the cutting performance of three solid carbide end mills with distinct geometries during the milling of the 7075 aluminium alloy. For the tests, three uncoated end mills were employed, which differed in rake angle, clearance angle, and helical pitch. Simulation tests revealed temperature distributions and the resultant cutting forces. The machining with a milling cutter with a higher blade angle was shown to cause an increase in the temperature in the cutting zone. However, during machining with a sharper blade of cutting tool, a decrease of cutting forces was not observed. The simulated temperature distribution on the cutting edge of the cutting tool may justify significant differences in the dynamics of changes in the cutting force components during the period of operational wear.

10

Empirical Study on the Effect of Tungsten Carbide Grain Size on Wear Resistance, Cutting Temperature, Cutting Forces and Surface Finish in the Milling Process of 316L Stainless Steel

Franczyk Emilia, Małek Marcin

Advances in Science and Technology. Research Journal

|

2023

|

Vol. 17, no. 6

367--377

EN

Cutting tools made of the WC-Co sintered carbides are now very popular and are widely used in machining of materials. However, there are numerous problems in this area which require more research and need to be studied further. This paper presents the results of an experimental study aimed at discovering the impact of the microstructure, particularly of the tool substrate grain size, on the quality of the machined surface, cutting forces and temperature in the cutting zone, as well as the tool life. In addition, the impact of the feed was considered. The machining process involved side milling of a cuboidal block made of the AISI 316L steel which, due to its specific properties, is widely used in many industries. The tools used in the tests had different WC phase grain size: 0.18, 0.28 and 0.31 μm, respectively, and moreover the middle specimen had also a non-homogeneous structure and an increased content of the Co matrix. The tests proved a significant impact of the tool microstructure on the tool life and the roughness parameters Ra and Rz of the machined surface. The impact of the studied factors on the forces and the temperature in the cutting zone was not as strong, because it did not exceed 20%. The value and the novel character of the paper results from the fact that it concerns a specific case: side milling of the 316L steel with the use of the WC-Co sintered carbide tools, and consequently provides a contribution to solve a practical industrial issue.

11

Studying the Behavior of the C45 Material when Changing the Tool Geometry Using the Finite Element Method

Pop Alina Bianca, Sandu Andrei Victor, Sachelarie Adrian, Țîțu Aurel Mihail

Archives of Metallurgy and Materials

|

2022

|

Vol. 67, iss. 2

653--659

EN

Machining with tool that have cutting edge radius provides components with high fatigue strength, microhardness of a large surface layer and plastic deformation. Finite element simulations of the cutting process give a better knowledge of the chip generation phenomenon, heat generation in the machining area, stress and temperature field results. This study emphasizes the true importance of the mathematical model that underlies the shape of the tool in the pre-processing steps of finite element analysis. The argument is that its achievement and definition depend on the network difficulty. This research purpose is to perform simulations series of orthogonal machining with different radius and depth of cut. In this way, conclusions on the impact of these variations on the whole cutting process were drawn. The finite element application used is Deform 2D, the Lagrange incremental method and the Johnson-Cook material model. The temperature distribution, stress distribution, von Mises stress distribution, effects on specific tool pressure and wear, and fluctuations in the cutting resistance of the tool tip and C45 workpiece were analyzed.

12

Machinability Studies on the Turning of Magnesium Metal Matrix Composites

Gobivel K., Vijay Sekar K.S.

Archives of Metallurgy and Materials

|

2022

|

Vol. 67, iss. 3

939--948

EN

Magnesium-based MMCs are widely used in structural-based applications due to their lightweight, high hardness, corrosion and wear resistance. Also, machining is an important manufacturing process that is necessary to ensure dimensional accuracy and produce intricate shapes. In this context, the machining of Magnesium based metal matrix composites is undertaken to study the impact of the cutting parameters on the machinability behaviour. In this work, turning of pure Mg/SiCp on a Lathe is done and an in-depth assessment on the machining forces, machined surface quality, chip microstructure, and tool morphology has been carried out using TiAlN coated tooling insert. The analysis revealed that the thrust force decreased due to the thermal softening of the matrix meanwhile the feed force also followed the similar trend at higher cutting speeds because of the minimized built-up edge and cutting depth whereas principal cutting force was inconsistent at higher cutting speeds. The surface finish was better at high cutting speed - low feed combination. The chip microstructure revealed that gross fracture propagation at the free surface and variations in the shear bands have occurred at different cutting speeds. Tool studies using SEM analysis revealed wear modes like chipping and built-up edge at low cutting speeds, but with a reduced impact at intermediate cutting conditions, whereas abrasion wear was observed predominantly in the tool nose at higher cutting speeds.

13

Experimental Investigations of Tool Wear in Vibration-Assisted Turning of Inconel 718

Dodla Srihari

Archives of Metallurgy and Materials

|

2022

|

Vol. 67, iss. 3

949--953

EN

In the current paper, the effect of tool wear for a constant period of time (360 s) during conventional and ultrasonic assisted machining of Inconel 718 is investigated in terms of cutting forces, temperature, and deviation measurements. For fixed process parameters turning experiments have been performed with and without the application of tangential vibration. Ultrasonic assisted turning (UAT) experiments have been compared with conventional turning (CT). The experimental results reveal that cutting forces and temperature increase linearly in the case of UAT whereas remaining constant in CT for a constant period of time. Besides the tool wear rate in the case of UAT is more than that in the CT.

14

Analysis and prediction of the impact of technological parameters on cutting force components in rough milling of AZ31 magnesium alloy

Kulisz M., Zagórski I., Weremczuk A., Rusinek R., Korpysa J.

Archives of Civil and Mechanical Engineering

|

2022

|

Vol. 22, no. 1

art. no. e1, 2022

EN

This paper presents the results of experimental study of the AZ31 magnesium alloy milling process. Dry milling was carried out under high-speed machining conditions. First, a stability lobe diagram was determined using CutPro software. Next, experimental studies were carried out to verify the stability lobe diagram. The tests were carried out for different feed per tooth and cutting speed values using two types of tools. During the experimental investigations, cutting forces in three directions were recorded. The obtained time series were subjected to general analysis and analysis using composite multiscale entropy. Modelling and prediction were performed using Statistica Neural Network software, in which two types of neural networks were applied: multi-layered perceptron and radial basis function. It was observed that milling with high cutting speed values allows for component values of cutting force to be lowered as a result of the transition into the high-speed machining conditions range. In most cases, the highest values for the analysed parameters were recorded for the component Fx, whereas the lowest were recorded for Fy. Additionally, the paper shows that a prediction (with the use of artificial neural networks) of the components of cutting force can be made, both for the amplitudes of components of cutting force Famp and for root mean square Frms.

15

Cutting Mechanics when Turning Powder Metallurgy Produced Nickel-Cobalt Base Alloy with a Cubic Boron Nitride Insert

Daź Waldemar, Habrat Witold, Tymczyszyn Jarosław, Krupa Krzysztof

Advances in Science and Technology. Research Journal

|

2022

|

Vol. 16, no. 4

163--175

EN

For the critical aero-engine parts it’s important to understand influence of cutting tools, cutting parameters, tool ware etc. on near surface condition which highly affect fatigue strength and at the same part life-time. New material implemented for the latest designs of aero-engines parts generate challenges for machining processes to fulfil strict requirements of aviation standards. Finish machining is the most important stage of process influencing fatigue strength. cBN tool are often used for final stage of machining. The objective of this study was analysis of cutting mechanics during finish turning of modern nickel-cobalt based alloy with cBN insert. Observations of cutting tool wear and cutting parameters influence on the components of cutting force, surface roughness and residual stress are presented in this paper.

16

Determination of Coal Cutting Forces Using the Cutting Head of POU-BW/01-WAP Device

Biały Witold, Fries Jiri, Galecki Greg

Multidisciplinary Aspects of Production Engineering

|

2021

|

Vol. 4, Iss. 1

281--289

EN

The paper presents a method for measuring and recording the forces involved in the coal cutting process. Moreover, a method for visualization of all forces involved in the cutting process was described. In the following part, the construction and principle of operation of a device for determination of forces involved in the cutting process (coal mining), referred to by the author as POU-BW/01-WAP, are presented. Resistance extensometry was used to measure the forces. This is the only device in the world that determines two of three force components that take part in the cutting process. For this purpose, two independent measuring blocks were used, which are strain gauges of force: cutting (Fs) and knife pressure (Fd). In order to register these forces, a real mining knife used in longwall shearer drums was applied – i.e. tangential-rotary. The equipment has the ATEX certificate allowing for operation in real conditions as a device intended for use in potentially explosive atmospheres – in accordance with the directive 94/9/EC. It has received many awards at world fairs for inventions and innovative solutions.

17

A review of the recent investigations regarding texturized cutting tools

Jarosz Krzysztof

Mechanik

|

2021

|

R. 94, nr 4

6--9

EN

This paper presents some important, recently performed investigations on the laser texturing technology applied to the PCD and PCBN cutting tools and some resulting process outputs including cutting forces, tool wear indexes concerning both rake and flank tool faces. It was documented that the properly texturized tool faces results in a substantial reduction of cutting forces, elimination of the adhesion interaction between the tool and the chip, and reduction of abrasive and diffusion tool wear. The role of additional lubrication supply to the cutting zone with modified contact properties is discussed.

PL

W artykule przedstawiono kilka ważnych, niedawno przeprowadzonych badań nad technologią teksturowania laserowego zastosowaną w narzędziach skrawających z PCD i PCBN oraz niektóre wynikające z tego procesu wyniki odnośnie do siły skrawania, wskaźników zużycia narzędzia, dotyczące zarówno powierzchni natarcia, jak i powierzchni bocznej narzędzia. Udokumentowano, że odpowiednio teksturowane powierzchnie narzędzi powodują znaczne zmniejszenie sił skrawania, eliminację interakcji adhezyjnej między narzędziem a wiórem oraz zmniejszenie zużycia ściernego i dyfuzyjnego narzędzia. Omówiono rolę dodatkowego doprowadzania smaru do strefy skrawania o zmodyfikowanych właściwościach stykowych.

18

Analysis of the OCHN3MFA steel in terms of cutting forces and cutting material flank wear mechanisms in hard turning processes

Majerík Jozef, Barényi Igor, Pokorný Zdenek, Sedlák Josef, Neumann Vlastimil, David Dobrocký, Jaroš Aleš, Krbata Michal, Jambor Jaroslav, Kusenda Roman, Sagan Miroslav, Procházka Jiri

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2021

|

Vol. 69, nr 6

art. no. e139203

EN

This article deals with the effect of selected machining parameter values in hard turning of tested OCHN3MFA steel in terms of SEM microstructural analysis of workpiece material, cutting forces, long-term tests, and SEM observations of flank wear VB and crater wear KT of used changeable coated cemented carbide cutting inserts in the processes of performed experiments. OCHN3MFA steel was selected as an experimental (workpiece) material. The selected experimental steel was analyzed prior to hard turning tests to check the initial microstructure of bulk material and subsurface microstructure after hard turning and chemical composition. Study of workpiece material’s microstructure and worn cemented carbide cutting inserts was performed with Tescan Vega TS 5135 scanning electron microscope (SEM) with the X-Ray microanalyzer Noran Six/300. The chemical composition of workpiece material was analyzed with Tasman Q4 surface analyzer. All hard turning experiments of the used specimens were performed under the selected machining parameters in the SU 50A machine tool with the 8th selected individual geometry of coated cementite carbide cutting inserts clamped in the appropriate DCLNR 2525M12-M type of cutting tool holder. During the hard turning technological process of the individual tested samples made of OCHN3MFA steel, cutting forces were measured with a Kistler 9257B piezoelectric dynamometer, with their subsequent evaluation using Dynoware software. After the long-term testing, other experiments and results were also realized, evaluating the influence of selected machining parameters with different cutting insert geometry on the achieved surface quality.

19

Multiobjective Performance Investigation of CNT Coated HSS Tool Under the Response Surface Methodology Platform

Chandru Manivannan, Selladurai Velappan, Venkatesh Chenrayan

Archives of Metallurgy and Materials

|

2021

|

Vol. 66, iss. 2

627--635

EN

The present research employs the statistical tool of response surface methodology (RSM) to evaluate the machining characteristics of carbon nanotubes (CNTs) coated high-speed steel (HSS) tools. The methodology used for depositing carbon nanotubes was Plasma-Enhanced Chemical Vapor Deposition (PECVD). Cutting speed, thickness of cut, and feed rate were chosen as machining factors, and cutting forces, cutting tooltip temperature, tool wear, and surface roughness were included as machining responses. Three-level of cutting conditions were followed. The face-centered, Central Composite Design (CCD) was followed to conduct twenty number of experiments. The speed of cutting and rate of feed have been identified as the most influential variables over the responses considered, followed by the thickness of cut. The model reveals the optimized level of cutting parameters to achieve the required objectives. The confirmation experiments were also carried out to validate the acceptable degree of variations between the experimental results and the predicted one.

20

The decisive impact of microstructure on the machinability of pure copper

Sun Xiaoxiang, Ebrahimi Mahmoud, Attarilar Shokouh

Archives of Civil and Mechanical Engineering

|

2021

|

Vol. 21, no. 3

852--860

EN

Ultrafine-grained (UFG) materials have been of great attention due to their considerable behavior compared to coarse-grained counterparts. Also, the machinability of these UFG materials is of great importance because of the machining significance in manufacturing the final shape of industrial components. Hence, this study dealt with machinability in relation to the microstructure and mechanical properties of the UFG pure copper processed by the twist extrusion. The remarkable microstructure evolution through the dynamic recrystallization mechanisms improved the tensile strengths and hardness of the twist extrusion processed pure copper. Also, the reduction of ductility in the UFG copper compared to the initial state was related to the change of tensile fractography mechanism in which the large and deep dimples transformed into the combined small and shallow dimples with some cleavage planes in the UFG copper. Furthermore, the enhanced machinability of the processed sample was related to its lower thermal conductivity and the development of strain localization within the narrow shear bands which lead to the production of discontinuous short chips. Hence, the formation of the UFG structure is a suitable option to attain the enhanced machinability behavior of copper as one of the most used metals.