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1

The Influence of Machining Conditions and Burnishing on the Surface Properties of 41Cr4 Steel in the Context of Minimizing Environmental Impact

Chodór Jarosław, Kułakowska Agnieszka, Bohdal Łukasz, Olewińska Kinga

Rocznik Ochrona Środowiska

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2025

|

Tom 27

677--684

EN

This paper verifies the technological parameters of the sliding burnishing (SB) and turning processes. The sliding burnishing and turning processes are characterized, accounting for the effects of technological parameters on surface roughness Ra. Experimental studies of sliding burnishing and turning with established parameters are performed. The processes are analyzed and described in detail. Conclusions are drawn indicating the potential use of turning and sliding burnishing in finishing.

2

Influence of high cutting speed turning on surface and corrosion properties of 08Ch18N10T austenitic stainless steel from the perspective of operational safety of primary circuit of a nuclear power plant

Kudláč Marek, Dománková Maria, Bártová Katarína, Škrobáková Ivana Sára, Vopát Tomáš, Gavalec Matúš, Slnek David

Production Engineering Archives

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2025

|

Vol. 31, Iss. 3

376--385

EN

From the point of view of the safety of nuclear power plants, it is necessary to determine the properties of the manufactured material used. One of the possible risks is the use of inappropriate turning on the material, whose subsequent surface and thus corrosion properties in such an extreme environment are significantly stricken. In this work, high cutting speed (596 m⋅min−1) was used for turning austenitic stainless steel 08Ch18N10T using a CBN cutting tool. Such a high cutting speed significantly affected surface integrity and surface properties such as residual stresses, roughness, hardness and surface toughness (metallographically determined and analysed using X-ray tensometry and acoustic emission). The area that was turned contained deformed grains, which contained deformation twins and slip bands. All these factors can affect stress corrosion cracking susceptibility and corrosion resistance. For this reason, the sample was exposed in a MgCl2 solution according to the ASTM G36, while the surface crack density and the crack lengths or depths were determined. The effect of residual stresses on the direction and propagation of surface cracks has been proven. DL-EPR test recorded sensitization that did not occur at the grain boundaries but in the turning direction where pitting lines appeared. Exposure in a simulated primary circuit environment was performed in an autoclave, where no signs of stress corrosion cracking were confirmed.

3

Development of forced cooling technology using a DLC coating tool with a small through-hole and a communicating tube regarding the turning for difficult-to-machine material

Tanabe Ikuo, Isobe Hiromi

Journal of Machine Engineering

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2025

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Vol. 25, No. 1

45--56

EN

In turning, the insert tip is continuously covered with chips and the temperature at the tool tip is very high. Especially when difficult-to-machine materials are used as work material, the temperature is above the melting point and the insert tip melts. Forced cooling of tools in turning is necessary. On the other hand, environmentally friendly turning is also necessary. Therefore, in this research, the forced cooling technology using a DLC coating insert with a small through-hole and a communicating tube regarding the turning for difficult-to-machine material was developed and evaluated. A connecting tube is a system in which the hole in the insert and the bottom of the assistant tank are connected by a tube, which allows the cooling medium contained in it to flow freely, so that the height of the cooling medium in the hole in the insert and the height of the cooling medium in the assistant tank behave equally due to gravity. The communicating tube was used for supplying the cooling fluid without no-energy, and the cooling fluid using the strong alkaline water with pH 12.5 was used for environmentally friendly. This strongly alkaline water has a significant cooling capacity equivalent to that of tap water and, moreover, does not corrode metals other than copper and aluminum. The small through-hole was machined for the cooling function on the insert tip. To reduce cutting heat, the inserts are coated with a DLC coating with a small low coefficient of friction. The proposed method was finally evaluated using the difficult-to-machine material Ti6Al4V for the workpiece in several experiments; temperature rise on the insert tip, tool life, surface roughness on the workpiece after the turning. In addition, the machining time, the running cost and the CO2 emission were also evaluated. It is concluded from the result that: (1) the proposed forced cooling technology was very effective for the turning of a difficult-to-machine material, (2) in the proposed method, it is important to maintain the tool tip temperature below 500°C, (3) the proposed method was superior in terms of the machining time and the running cost.

4

A Comparative Study of Tool Wear for Niobium Carbide and Tungsten Carbide-Based Cutting Materials in Dry Cylindrical Turning

Uhlmann Eckart, Schneider Christoph

Journal of Machine Engineering

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2025

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Vol. 25, No. 2

64--73

EN

Using niobium carbide (NbC) for cutting materials is a promising alternative to tungsten carbide (WC) based cutting materials for metal machining due to the inherent material properties of NbC. These include increased hot hardness and reduced chemical wear compared to WC. This study examines the application behaviour at varying cutting speeds of the cutting material composition NbC-12Ni4Mo4VC produced on a laboratory scale as well as an industrial reference cutting material based on the tungsten carbide WC-6Co. A series of measurements and analyses are conducted during the machining tests in order to evaluate the tool life, the growth of the flank wear, the cutting force and the achieved roughness of the machined surface. For NbC-12Ni4Mo4VC an increase in cutting speed correlates with an increase in tool life. As for higher cutting speeds a superior tool life of NbC-12Ni4Mo4VC is achieved compared to the industrial reference cutting tool material WC-6Co.

5

Unravelling microstructure evolution mechanism within machined subsurface during turning of laser powder bed fusion-manufactured Inconel 625

Lv Zhaoqi, Wang Guobin, Li Binxun, Sun Yujing, Xia Yan, Du Jin, Su Guosheng

Archives of Civil and Mechanical Engineering

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2025

|

Vol. 25, no. 1

art. no. e5, 2025

EN

Post-machining of metal additive-manufactured (AMed) nickel-based alloy components is one of the efficient approaches to reduce surface roughness and enhance surface quality. Although the white layer formed on the wrought nickel-based alloy surface after machining has been deeply investigated, the formation mechanism of the white and dark layers generated on AMed nickel-based alloy still faces challenges. In this study, the white and dark layer formation on laser powder bed fusion (LPBF)-fabricated Inconel 625 alloy surface after turning was determined. Then various material characterization techniques were adopted to comprehensively analyze the microstructure, texture and phase constituent concerning the white and dark layers. Obvious intragranular misorientation change, great concentration of high angle grain boundaries and grain refinement occurred beneath the machined surface. Strongly refined grains in nanometers and noticeable plastic deformation with slight grain division along with disappeared dense dislocations were revealed correspondingly within the white and dark layers. Phase transformation was absent from the machined surface despite cutting parameters. Dynamical crystallization (DRX) following shear deformation dominated the formation of the white layer while plastic deformation was responsible for dark layer formation. The findings were beneficial to understanding the occurrence of damages initiated from machined surfaces during service.

6

Specific cutting force in dry turning of Ti6Al4V ELI using different grades of carbide inserts

Struzikiewicz Grzegorz

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 10

94--105

EN

This paper presents the results of experimental studies on the influence of the turning process parameters on the values of specific cutting force kc. with the use of different grades of carbide inserts. Three variables were analyzed, i.e. cutting speeds vc, depth of cut ap and feed f, for dry turning of the difficult-to-cut titanium alloy Ti6Al4V ELI. In the cutting tests, two types of inserts were used and made of two different grades of cemented carbides, ie, H13A and 1115. To determine the specific cutting force (SCF), a measuring system was used to trace and record the circumferential cutting force Fc. According to the adopted research plan, a total of 36 test systems were determined, on the basis of which the values of the kc coefficient were determined. The significance of the influence of the machining parameters on the SCF values was analyzed. The tests showed that the specific cutting force kc depends primarily on the cross-sectional area of the cutting layer, that is, directly on the feed value and depth of cut. Furthermore, it has been shown that turning with coated inserts results in a lower specific cutting force, which can directly translate into an increase in tool life. The mean value of the kc coefficient for the use of a cutting insert without coating differed from a cutting insert with a coating of 282.7 MPa (1952.2 MPa compared to 2234.9 MPa). Furthermore, a higher tendency for surface hardening and built-up edge was observed in the cutting tests for uncoated tool turning. The obtained results allowed to present the recommended ranges of machining parameters for dry turning of the processed material. The presented results can provide practical guidelines for the selection of cutting parameters for the machine industry and contribute to the reduction of costs and the negative impact on the environment of machining with the use of cutting fluids. The obtained research results were analyzed and concluded according to the Taguchi method. Based on the desirability function and the response surface methodology, cutting speed vc = 80 m/min, depth of cut ap = 1.0 mm and feed f = 0.2 mm/rev were selected as optimal machining factors.

7

Machinability investigation during turning of polyoxymethylene POM-C and optimization of cutting parameters using Pareto analysis, linear regression and genetic algorithm

Hakmi Tallal, Hamdi Amine, Touggui Youssef, Laouissi Aissa, Belhadi Salim, Yallese Mohamed A.

Archive of Mechanical Engineering

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2024

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LXXI, nr 1

47--71

EN

This paper presents a study on the dry turning of polyoxymethylene copolymer POM-C. The effect of five factors (cutting speed, feed rate, depth of cut, nose radius, and main cutting edge angle) on machinability is evaluated using four output parameters: surface roughness, tangential force, cutting power, and material removal rate. To do so, the study relies on three approaches: (i) Pareto statistical analysis, (ii) multiple linear regression modeling, and (iii) optimization using the genetic algorithm. To conduct the investigation, mathematical models are developed using response surface methodology based on the Taguchi 𝐿16 orthogonal array. The results indicate that feed rate, nose radius, and cutting edge angle significantly influence surface quality, while depth of cut, feed, and speed have a notable impact on other machinability parameters. The developed mathematical models have determination coefficients greater than or very close to 95%, making them very useful for the industry as they allow predicting response values based on the chosen cutting parameters. Finally, the optimization using the genetic algorithm proves to be promising and effective in determining the optimal cutting parameters to maximize productivity while improving surface quality.

8

Simulation of displacement of cutting tool holders used for turning

Mautner Viktor, Horvat Katarina, Stoić Marija, Stoić Antun

Technologia i Automatyzacja Montażu

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2023

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nr 2

41--49

EN

This paper gives a comparison of the deformation and deflection of two types of tool holders used in turning processes. Comparison of the deflection and stresses has been performed on the location where the highest value of deflection can be measured i.e. on the tip of the cutting insert. Selected tool holder types (TH1 and TH2) have rectangular and polygonal shank. Tool holders were 3D modelled in SolidWorks and Autodesk Inventor software packages and exposed to the loading with ANSYS structural analysis FEM software. In FEM analysis, two elements size of the network are selected (mesh size 5 and 1 mm). The simulation was carried out for five different loading values acting on the tool holder model. Obtained results confirm lower deflections on CAPTO tool holders.

PL

W artykule porównano odkształcenie i ugięcie dwóch typów oprawek narzędziowych stosowanych w procesach toczenia. Porównanie ugięcia i naprężeń wykonano w miejscu, w którym można zmierzyć największą wartość ugięcia, czyli na czubku płytki skrawającej. Wybrane typy oprawek narzędziowych (TH1 i TH2) mają chwyt prostokątny i wielokątny. Uchwyty narzędziowe zostały wymodelowane w 3D w pakietach oprogramowania SolidWorks i Autodesk Inventor i poddane obciążeniu za pomocą oprogramowania do analizy strukturalnej FEM ANSYS. W analizie MES wybierane są dwa rozmiary elementów sieci (rozmiar oczek 5 i 1 mm). Symulację przeprowadzono dla pięciu różnych wartości obciążeń działających na model oprawki. Uzyskane wyniki potwierdzają mniejsze naprężenia i ugięcia oprawek narzędziowych CAPTO.

9

Experimental Research on the Influence of Roughness of the Machined Surface of a Part on Galvanization

Ravai Nagy Sandor, Pop Alina Bianca, Nabiałek Marcin, Alexandru Costin, Țîțu Aurel Mihail

Archives of Metallurgy and Materials

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2023

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Vol. 68, iss. 4

1591--1595

EN

The purpose of this scientific paper is to follow the influence of thermal galvanizing, as a technological process on the quality of the galvanized surface. The galvanizing technology used and studied involves at the end of the process, the removal of excess zinc from the surface by centrifugation. The zinc layer will be lower than that of simple immersion galvanizing. The measurements were performed following the roughness of the machined surface on a five-Section specimen - each Section being processed with a different cutting regime. The results were analyzed after each operation. The first measurements were made after the turning operation, followed by measurements made after pickling and fluxing and then after thermal galvanizing. Based on the results obtained, the aim was to set up a range of best roughness at which the galvanized part should have a commercial appearance and be made with a cost-effective cutting regime in terms of costs.

10

Analysis of segmental coordination in the lower extremity using vector coding: a pilot return-to-play study of acute ankle sprain

Yang Xiaoyi, Jiang Hanhui, Yu Peimin, Mei Qichang, Fernandez Justin, Gu Yaodong

Acta of Bioengineering and Biomechanics

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2023

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Vol. 25, no. 4

23--34

EN

Background: Acute ankle sprain may affect ankle function during sport and daily activities. This study aimed to use vector coding technique to analyze the difference over time between injured and healthy lower limb during the first week of acute ankle sprain phase (P1) and post a 1-month recovery phase (P2) to understand the return-to-play coordination strategy in the lower extremity. Methods: Six females attended the gait experiments with attached 40 reflective markers using eight camera Vicon motion capture system. All participants walked barefoot while turning in four directions (T0°, T45°, T90°, T135°) at their self-selected speed. Coordination patterns were classified as in-phase, anti-phase, proximal or distal dominancy between lower limb joints involving hip, knee, ankle, subtalar, metatarsophalangeal (MTP) joint and tarsometatarsal (TMT) joint. Results: P1 showed more proximal joint dominant in Hip-Knee coupling angles but P2 displayed more distal joint dominant in Knee-Ankle joint coordination pattern and mainly distal joint dominant in Ankle-MTP coupling angle mapping. The Ankle-TMT1 and Ankle-TMT5 coordination patterns matched best in straight walking but worst in T135 walking. Conclusions: Investigating inter-segmental coordination in different turning movements could provide insights into gait changes from acute ankle sprain from one-month return-to-play recovery. Knowledge of lower limb coordination pattern may provide clinical implications to improve dynamic balance and gait stability for individuals with acute ankle sprain.

11

Analysis of the influence of turning parameters of CuZn39Pb3 and AW 6060 materials on surface roughness

Tomczewski Leszek, Muszyńska-Pałys Jagoda

Technologia i Automatyzacja Montażu

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2022

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nr 2

8--14

EN

The article presents an analysis of the turning parameters of two non-ferrous materials. The tested materials were: brass CuZn39Pb3 and aluminum alloy AW 6060. A Kyocera turning knife and a WNMG 080404 AH plate were used to make the samples. Three parameters were tested: rotational speed, feed and depth of cut at three levels of variability. The roughness parameters Ra and Rz were selected for the analysis. On the basis of the obtained results, it was shown that the feed used during machining has the greatest influence on roughness, while the change of depth or cutting speed does not cause significant differences in roughness.

PL

W artykule przedstawiono analizę parametrów toczenia dwóch materiałów nieżelaznych. Materiałami poddanymi badaniom były: mosiądz CuZn39 Pb3 i stop aluminium AW 6060. Do wykonania próbek użyto noża tokarskiego firmy Kyocera i płytki WNMG080404AH tej firmy. Badaniom poddano trzy parametry: prędkość obrotową, posuw i głębokość skrawania na trzech poziomach zmienności. Do analizy wybrano parametr chropowatości Ra i Rz. Na podstawie uzyskanych wyników wykazano, że największy wpływ na chropowatość ma posuw stosowany podczas obróbki, natomiast zmiana głębokości czy tez prędkości skrawania nie powoduje znaczących różnić w chropowatości.

12

Wpływ geometrii płytek skrawających na chropowatość powierzchni w obróbce wykończeniowej

Osak Mateusz, Żyłka Wojciech

Obróbka Metalu

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2022

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nr 1

32--36

PL

W artykule przedstawiono badania wpływu geometrii płytek tokarskich na chropowatość powierzchni. Obróbce toczeniem poddano dwa rodzaje stali: 1.0503 (C45) oraz 1.6582 (34CrNiMo6) w formie wałka o średnicy Ø 50. Badano otrzymaną chropowatość powierzchni toczonych trzema rodzajami płytek DCET 11T3005R (z geometrią ostrza Wiper), WNMG080404, VBMT160404. Wyniki badań jednoznacznie wykazały, że powierzchnie obrobione płytkami typu Wiper charakteryzują się mniejszymi wartościami parametrów chropowatości niż obrobione płytkami o geometrii standardowej.

EN

In this paper investigates how the geometry of turning plates affects the surface roughness were described. Two steel types were machined: 1. 0503 (C45) and 1. 6582 (34CrNiMo6) in the form of a shaft with a diameter of Ø50. The resulting surface roughness was investigated with three plate types DCET 11T3005R (with Wiper geometry), WNMG080 404, VBMT160 404. The test results clearly showed that surfaces treated with Wiper geometry plates have lower roughness parameters than plates with standard geometry.

13

Vibration analysis of a turning tool with passive damping

Klamczyński Kamil

Mechanik

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2022

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R. 95, nr 10

40--46

EN

Mechanical vibrations generated during machining can cause many problems in production processes. Vibrations can cause high dynamic loads leading to damage of the machine spindle, the cutting tool or the workpiece. Another unwanted effect of the existence of vibration during the machining process can be a deterioration in the quality of the machined surface. In this paper, a comparative analysis was carried out based on studies of the face turning process with conventional knives and those equipped with passive vibration damping systems. The results show the influence of the implemented vibration damper on the cutting process.

PL

Drgania mechaniczne pojawiające się podczas obróbki skrawaniem mogą być przyczyną występowania wielu problemów w procesach produkcyjnych. Drgania mogą powodować duże obciążenia dynamiczne prowadzące do uszkodzenia wrzeciona obrabiarki, narzędzia skrawającego lub przedmiotu obrabianego. Innym niepożądanym efektem występowania drgań w czasie procesu obróbki mechanicznej może być pogorszenie jakości obrabianej powierzchni. W niniejszej pracy przeprowadzono analizę porównawczą na podstawie badań procesu toczenia czołowego powierzchni nożami konwencjonalnymi i wyposażonymi w pasywne systemy tłumienia drgań. Wyniki badań przedstawiają wpływ zastosowanego tłumika drgań na przebieg procesu skrawania.

14

Performance optimisation of the turning process along with multi-surface heating process

Sathish Kumar D., Thanigaivelan R., Natarajan N.

Materials Science Poland

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2022

|

Vol. 40, No. 4

1--13

EN

Materials that are difficult to cut possess excellent qualities and machinability, though conventional machining techniques require additional energy to circumvent the problems associated with the turning process. In this study, heat-assisted turning of duplex stainless steel (SS) was carried out. Various heating techniques such as infrared (IR)-, ultraviolet (UV)- and hot air(HA)-assisted heating were adopted. The experiment used an L16 orthogonal array with the most significant parameters such as heating method, feed rate in millimetres per revolution (mm/rev), depth of cut (millimetres [mm]) and cutting speed (metres per minute [m/min])on the cutting force and surface roughness. The technique for order performance by similarity to ideal solution (TOPSIS) and grey relational analysis (GRA), were used to optimise the output performance. The results of TOPSIS showed that the 16th experimental combination, i.e., the HA heating method, with feed rate = 0.175 mm/rev, depth of cut = 0.1 mm and cutting speed = 150 m/min, required a smaller cutting force and resulted in lower surface roughness. In case of the GRA method, the best output performance was observed for the 15th experimental combination, that is, the HA heating method, with feed rate = 0.15 mm/rev, depth of cut = 0.2 mm and cutting speed = 200 m/min. Compared to the non-heat-assisted turning process, the HA- and UV-assisted processes required 10.25% and 7.69% lesser cutting force, respectively, and the surface roughness in case of the HA method was 15.13% lesser.

15

A simplistic regression-based genetic algorithm optimization of tool-work interface temperature

Utkarsh, Kumar Saumya, Kumar Saaransh, Kiran G. Uday, Mukhopadhyay Arkadeb, Barman Manik

Engineering Transactions

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2022

|

Vol. 70, iss. 2

141--156

EN

This work aims to investigate the average tool-work interface temperature for the HSS tool and AISI 1040 steel pair. A tool-work thermocouple is proposed for the measurement of temperature because of its simple construction in addition to the low cost. The machining process of AISI 1040 steel is considered due to its extensive application, including industry usage. The changes in cutting temperature are studied for combinations of cutting speed, feed and the depth of cut during turning operation. The orthogonal array L9 by Taguchi is adopted for designing the experiments within a restricted set of runs. The average cutting temperature shows an increasing curve with functions of speed versus depth of cut and speed versus feed. But no clear trend is observed for a combination of feed versus depth of cut. A second-order regression equation with reasonable accuracy (R 2 = 0.99) is fitted using the data. Analysis of variance (ANOVA) reveals the highest contribution from cutting speed, which influences average temperature at the interface of tool and work. Further, the genetic algorithm predicts an optimal combination of parameters, which is 82.542 m/min cutting speed, 0.276 mm/rev feed rate and 0.2 mm depth.

16

Experimental study of the wear behaviour of a metal carbide tool in turning by dimensionless analysis

Amier F.D., Belarifi F., Noureddine R.

Archives of Materials Science and Engineering

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2022

|

Vol. 114, nr 1

5--12

EN

Purpose: In this article, we present the experimental results with a dimensionless analysis of the wear behavior of a metal carbide tool in a turning operation. Design/methodology/approach: The highlighting of the dimensional input and output parameters of the experimental tests to bring out the different adimensional parameters. Regarding the input parameters, we have the rotational velocity (N), the feed (f), the depth of cut (ap), the machining time (t). The output parameters are defined by the flow rate (DC), the volume of the used tip (VU), the face wear (VB), as well as the cutting power (PC) and that of the machine (PM). Findings: The dimensionless approach allowed us to find the desired cutting conditions as well as the possibility of working in ranges of cutting conditions for known wear, which is not possible with a dimensional analysis. It should be noted that the appropriate choice of these parameters was essential to achieve these results. Research limitations/implications: The existence of a working range proposed by this analysis leads us to the proposal of a model and a numerical optimization. Practical implications: This work offers the desired compromise of adequate cutting conditions during machining. Originality/value: Deduction of adequate cutting conditions with minimum wear. Among other things, we can extrapolate the results to offer us compromises in the choice of ranges of cutting conditions.

17

To decrease the turning-induced pitting susceptibility of laser-cladded Fe–Cr–Ni layer by low plasticity burnishing

Zhang Peirong, Hu Shunrui, Lv Tao, Du Jin, Su Guosheng, Liu Zhanqiang, Xu Chonghai

Archives of Civil and Mechanical Engineering

|

2022

|

Vol. 22, no. 4

art. no. e179, 2022

EN

Corrosion resistance of machined surface and its correlation with surface roughness have been the important concerns for sustainability of the final products. However, the pitting corrosion of laser-cladded Fe–Cr–Ni layers by turning exhibits susceptibility to surface roughness characteristics. In present study, the generation mechanism of pitting susceptibility by turning and the effect of burnishing on decreasing the pitting susceptibility were explored. To this end, a theoretical model of the potential difference between roughness peaks and valleys was established with considering the functional parameters of the surface roughness. Then, the correlations between the potential difference and pitting characteristics including pitting depth, width and area were analyzed in order to reveal the generation mechanism of pitting susceptibility. The occurrence of pitting corrosion could be predicted by the local potential difference, which was higher at the location where pitting corrosion would occur while lower where pitting corrosion did not occur. Finally, the influence of each functional parameter of surface roughness on the potential difference was analyzed using the proposed model, with which the machining schematics were discussed. On the basis of this research, it was expected to improve the corrosion resistance of the claddings by turning and subsequent burnishing process chain.

18

Study on Chip Breakability Index During Longitudinal Turning of Cast and DMLS Additively Manufactured AlSi10Mg Aluminum Alloy

Struzikiewicz Grzegorz, Słodki Bogdan, Zębala Wojciech, Franczyk Emilia

Advances in Science and Technology. Research Journal

|

2022

|

Vol. 16, no. 1

28--35

EN

The article presents selected issues related to the process of turning samples made of the AlSi10Mg alloy with the use of various manufacturing technologies, i.e. casting and DMLS (Direct Metal Laser Sintering). Machining processes of cylindrical surfaces of samples made with these two methods were subjected to a comparative analysis. The main idea behind the research was to develop guidelines for turning parts obtained using laser powder sintering. Study on the influence of cutting parameters on the value of breakability index Cin. as well as the type, shape and form of chips produced during longitudinal turning is presented. The chips were also measured and the results of the microscopic analysis of the chips form are described. Results showed that the values of Cin index for turning of the cast AlSi10MG alloy depend mainly on the value of feed f. According to adopted chip classification for the feed value of f > 0.1 mm/rev the chips had a favorable, short form. In the case of turning the sample obtained by the DMLS method, the values of the chip breakability index Cin are not significantly dependent on the adopted ranges of cutting parameters. The Taguchi method was used to develop the conclusions obtained on the basis of the research results.

19

Analysis of the Impact of Wiper Geometry Insert on Surface Roughness and Chips in Machining Materials Used in the Aviation Industry

Szablewski Piotr, Smak Krzysztof, Krawczyk Bartłomiej

Advances in Science and Technology. Research Journal

|

2022

|

Vol. 16, no. 1

203--212

EN

Nowadays, great emphasis is placed on increasing the efficiency of machining processes. However, this cannot be done at the expense of quality worsening of the machined surface. In this paper the influence of Wiper geometry on Ra and Rz surface roughness parameters is described when finishing turning of materials used in the aviation industry: austenitic stainless steel XCrNiNb18-9, low alloy steel 14NiCr14 and aluminum alloy A356, as well as the chips generated in the cutting process in terms of shape were assessed. It was found that for the lowest tested feed rate during turning with a Wiper insert, the values of Ra and Rz parameters do not differ significantly from the roughness parameters obtained during machining with a conventional insert. The beneficial effect of feed rate on surface roughness for the Wiper insert is clearly visible above f ≥ 0.12 mm/rev. The biggest difference in roughness parameters was recorded for the highest value of the applied feed f = 0.28 mm/rev. Using conventional insert, Ra and Rz values are almost three times bigger than for Wiper insert. The influence of the cutting speed on the Ra and Rz parameters depends on the type of material being processed. Increasing cutting speed from vc =120 m/min to vc = 200 m/min for stainless steel, Ra and Rz values decrease about 35%. Similar situation noticed for aluminum alloy, but increasing cutting speed decrease Ra and Rz values only about 18%. The situation is different for low alloy steel. Increasing the cutting speed increases the Ra and Rz parameters by about 37%. Rz/Ra ratio shows that for feed rate f ≤ 0.12 mm/rev. cutting process is unstable, because the values are between 5.5–7.5, but should oscillate around 4. Increasing feed rate value to f = 0.2 mm/rev allows to stabilize the process and the ratio value is close to 4. Wiper insert create the same form chips as a conventional insert, using the same value of feed rate.

20

Optimization of process parameters in turning of magnesium AZ91D alloy for better surface finish using genetic algorithm

Pradeep Kumar Madhesan, Venkatesan Rajamanickam, Manimurugan Manickam

Acta Innovations

|

2022

|

no. 43

54--62

EN

This research examined at the optimum cutting parameters for producing minimum surface roughness and maximum Material Removal Rate (MRR) when turning magnesium alloy AZ91D. Cutting speed (m/min), feed (mm/rev), and cut depth (mm) have all been considered in the experimental study. To find the best cutting parameters, Taguchi's technique and Response Surface Methodology (RSM), an evolutionary optimization techniques Genetic Algorithm (GA) and Non-dominated Sorting Genetic Algorithm-II (NSGA-II) were employed. GA gives better results of 34.04% lesser surface roughness and 15.2% higher MRR values when compared with Taguchi method. The most optimal values of surface roughness and MRR is received in multi objective optimization NSGA-II were 0.7341 µm and 9460 mm3/min for the cutting parameters cutting speed at 140.73m/min, feed rate at 0.06mm/min and 0.99mm depth of cut. Multi objective NSGA-II optimization provides several non-dominated points on Pareto Front model that can be utilized as decision making for choice among objectives.