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1

A digital twin-driven approach for process parameters selection in planarization technology

Piotrowski Norbert

Advances in Science and Technology. Research Journal

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2026

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Vol. 20, no. 5

213--222

EN

Planarization technologies such as lapping and chemical-mechanical polishing (CMP) are critical in achieving high-precision surface quality in various industrial applications. While predictive models of tool wear and material removal rate have been developed in previous studies, recent advances in digital twins open new possibilities for integrating physics-based and data-driven approaches into a comprehensive decision-making framework. This paper proposes a digital twin-driven methodology for selection of process parameters in planarization technology. The framework combines lapping kinematic models, tribological equations and machine learning methods into a dynamic, adaptive system capable of predicting tool wear, optimizing parameters, and supporting real-time control. Case studies demonstrate the integration of predictive models into the proposed framework. Potential applications, limitations, and future research directions are discussed.

2

The Evaluation of the Wear of Surface-set Diamond Drill Bits by Analysing the Rock Debris and Process Parameters

Bali Hudáková Mária, Kiovský Alexander, Krúpa Víťazoslav, Vavrek Pavol, Lazarová Edita, Ivaničová Lucia

Inżynieria Mineralna

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2025

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Vol. 3, no. 2

art. no. 17

EN

In this article, experimental research on rotary drilling into limestone and granodiorite samples, conducted on a horizontal drilling rig constructed at the Institute of Geotechnics of the Slovak Academy of Sciences, is described. Drilling into limestone and granodiorite was conducted using two surface set core diamond drill bits with diamonds of different sizes but identical drill bit contact areas. The purpose of the experiments was to obtain data on the wear of drilling tools, in particular by changing the type of the rock used in the drilling experiments. Initial drilling was conducted into limestone, and after drilling the length of 6.75 meters, the drilling was conducted into granodiorite, the rock with higher abrasivity. The findings observed with the use of granodiorite included more significant changes in the shape and abrasion degree of the diamonds embedded in the drilling tools. For the purpose of the assessment of the condition of the surface set diamond drill bits, the penetration depth and torque parameters were measured during experimental drilling, and subsequently used to calculate the values of specific energy. Rock debris generated by drilling was collected and subjected to a sieve analysis in a laboratory. Results of the sieve analysis were used to calculate the coarseness index (CI) in order to compare the changes in the rock debris particle size. It was examined whether the changes in the shapes and condition of the diamonds embedded in drill bits affected the process parameters and the rock debris particle size. The objective was to identify the effects of deterioration of the drilling elements of the surface set diamond drill bits on the values of the yield of rock debris of all fractions, as well as its effects on the penetration depth and specific energy values. It was observed that the tested drill bits exhibited comparable values of the yield of rock debris of all fractions after drilling into limestone to identical penetration depths. The difference in the calculated CI values observed for the drill bit with larger diamonds during the first conducted drilling into granodiorite was more significant that that observed with the use of the bit with smaller diamonds. The resulting comparison of the drilling tools, in particular the respective values of the penetration depth and the CI calculated based on the analysed rock debris, revealed that the surface set drill bit with smaller embedded diamonds was more suitable for drilling into limestone as well as granodiorite.

3

Investigation on Machining Parameters of Titanium Alloy in NMQL Environment

Shanmugasundaram S., Suresh R., Gopi B., Anandavelu K.

Archives of Metallurgy and Materials

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2025

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Vol. 70, iss. 1

359--365

EN

Vegetable oil-based nano particle is a realistic alternative lubrication used in standard cutting fluids. In this research, turning operations are done on titanium alloy utilizing cemented carbide inserts with nano minimum quantity lubrication (NMQL). A response surface methodology is employed to optimize the machining variables such as cutting speed, feed, and depth of cut to anticipate the ideal surface roughness, cutting forces, and tool tip temperature. Moreover, an experimental study is conducted to evaluate the performance of NMQL with the different machining factors. According to the findings, NMQL with nano aluminum oxide particles added with coconut oil is an effective lubricant which provides lowering cutting forces, surface roughness, and tool wear. The novelty of work is to analyze the machined surface using atomic force microscopy and tool wear patterns were analyzed by using SEM image. Result was compared with the experimental observations. The most ideal solution for the reduction of surface roughness, cutting force, and tool tip temperature was reached at cutting speed of 60 m/min, a feed rate of 0.04 mm/rev, and a depth of cut of 0.05 mm. The greatest roughness value of 1.62 microns obtained.

4

Effect of Reinforcement Content and Cutting Parameters on Tool Wear in Machining of Aluminum Hybrid Composites

Sarpkaya İbrahim, Özer Emre, Zalaoğlu Demet, Übeyli Mustafa, Fedai Yusuf

Archives of Metallurgy and Materials

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2025

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Vol. 70, iss. 2

593--600

EN

The machinability of aluminum hybrid composites (AHCs) can be enhanced by utilization of optimum composition and cutting parameters. In this study, the machinability of AHCs containing micron-sized TiB2 and B4C particles was investigated using the face milling operation with a double coated cemented carbide tool. The composites, fabricated via cold pressing and microwave sintering, were subjected to the face milling experiments using a CNC milling machine. The influence of hybrid reinforcement content, feed rate and cutting speed on tool wear and surface roughness was examined during the milling of these composites. After the machinability tests, the worn surface of inserts was examined by a scanning electron microscope to see the wear types. The reinforcement content and cutting speed were obtained to have a much greater effect on the machinability and surface roughness of the hybrid composites compared to the feed rate. Either increasing the feed rate or decreasing the cutting speed provided a larger amount of chip removal until the wear limit. Moreover, the feed rate was obtained to be more effective on the tool wear at lower cutting speeds and higher amounts of hybrid reinforcement.

5

The influence of cutting parameters and tool wear on the quality of holes in package sheets used in heat exchangers

Wieczorek Łukasz, Józwik Jerzy, Niesłony Piotr, Moj Kevin

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 4

156--170

EN

The presented research aimed to obtain information on the effect of cutting parameters and tool wear on the quality of shaped holes in stainless steel package sheets. The testing was planned to allow evaluation of the impact of drilling technology. For this reason, verification tests were performed on a monolithic sheet of the same material grade and thickness equal to the package of four base sheets. It was noted that the double-insert drill is not qualified for use in this process, as it does not provide adequate hole quality (even 0.7 mm deviation in measured diameter from nominal value) and does not provide the expected tool life. Significantly better results were obtained for the monolithic and indexable head drills (IT8). In addition, it was observed that the burr formed when the drill exits the hole, in the case of the indexable double-insert drill, is also significantly larger (~1mm) than for the other tools (less than 0.1 mm). Preliminary tests carried out in this way made it possible to select the tool with the best cutting capability and quality of the generated holes. It was decided to use a drill with an interchangeable head. Tests have shown that it is possible to produce up to 1,000 holes with a diameter of 18.5 mm in a sheet package of 316Ti material with a thickness of 40 mm while maintaining the assumed effective speed of the process (n=1200 rpm, fn=0.18 mm/rev). In experimental testing, a significant effect of cutting speed on tool wear was noted. A correlation between coolant concentration and tool life was also identified - raising the concentration from 8% to 12% increased tool life by virtually 100%. Testing of hole roughness over a full tool life cycle showed that a drill bit with a completed break-in phase provides better hole roughness than a new drill bit. Measuring equipment and software were used for the research and processing of the results – Wenzel XO55, Hommel Etamic LV 17, WM Quartis R2021-1, Grapher 18.3.400, Autodsk Inventor Professional 2023.

6

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

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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.

7

Application of machine learning algorithms for recognizing the wear of the cutting tool during precision milling of hardened tool steel

Twardowski Paweł, Tabaszewski Maciej, Tabaszewski Mateusz, Czyżycki Jakub

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 2

365--382

EN

The paper presents extensive research on tool wear and the analysis of diagnostic measures for different cutting speeds (vc). The work is divided into two parts. The first part involves conducting an experiment on a machining center, measuring the tool wear index, and recording vibration acceleration signals, followed by analyzing the obtained results. In the second part, the authors focus on determining appropriate diagnostic signal measures and their selection and applying various machine learning methods. The machine learning pertains to classifying the tool condition as operational or non-operational. The best of the tested classifiers achieved an accuracy of 0.999. Thanks to the comparative analysis, it was possible to propose a condition monitoring method that is based only on vibration acceleration without taking into account the cutting speed parameter. Vibration measurement can be performed on the spindle. In this case, the weighted accuracy value determined on the test set was 0.993. The F1 coefficient characterizing both precision and accuracy was 0.982. The authors consider this result to be satisfactory in industrial conditions. Measurement on the spindle without the need to take into account the cutting speed is easy to use in industrial practice

8

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

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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.

9

The role of lead in the machinability of copper alloys used for drinking water installations

Krawczyk Janusz, Skoda Philipp, Chaczyk Agnieszka

Advances in Materials Science

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2025

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Vol. 25, nr 3(85)

53--66

EN

The machinability of two copper alloys with lead: CuZn40Pb2 and CuSn5Zn5Pb2, was assessed. Turning tests were performed based on the selection of parameters that will result in the tool being worn out after 1 minute. Tool wear was assessed by observing dimensional and microstructural changes in the blade. When assessing machinability, power consumption, chip shape, changes in the surface layer and surface roughness were taken into account. The research aims to determine the custom machinability index of materials used in SANHA Polska. A publicly available index must be adapted to a given application, and such adaptation is often quite time-consuming. Therefore, a 1-minute test was carried out as a quick and cheap alternative to a large fleet of machines with various machining properties. The developed methodology and the results obtained are the basis for further research conducted as part of the implementation doctorate, the aim of which is to implement the production of well-machinable lead-free materials for drinking water installations, characterized by good solderability and corrosion resistance. As a result of the conducted research, the role of lead in the machining of copper alloys was identified, which is important due to European restrictions on the elimination of this element and its replacement in a way that allows for precise removal processing.

10

The Influence of Deep Drawing Parameters on Stresses and Strains in Drawing Tools in the Context of their Durability and Process Load

Kałduński Paweł

Rocznik Ochrona Środowiska

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2024

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Tom 26

616--628

EN

This publication presents the influence of selected parameters in the deep drawing process on the energy consumption of the entire process. It was analysed how die clearance and the radius of the rounded working edge of the die affect drawing force and work. Modifying these parameters does not directly affect the geometry of the finished stamped product. In addition, it was analysed how modifying the clearance and the radius of the rounding of the working edge of the die affects the magnitudes of stresses and strains in the tools, i.e. the punch and the die. The study was carried out numerically using Ansys Ls-Dyna software. An elastic-plastic model with isotropic hardening was used to model the tools without considering strain rate. This approach makes it possible to assess how a given process will affect the abrasive wear of the working surfaces of the die and punches when the yield stress in the tool material is exceeded. A significant increase in tool life was observed through a reduction in plastic deformation when using clearances greater than the thickness of the sheet metal. Using a larger die edge rounding radius also positively affected tool life, maximum drawing force, and total work.

11

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

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2024

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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

12

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

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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.

13

Machinability of steels used for drinking water installation fittings

Chaczyk Agnieszka, Skoda Philipp, Krawczyk Janusz

Inżynieria Materiałowa

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2024

|

Vol. 45, nr 1

6--11

EN

The machinability of two steels was assessed: 11SMnPb37 with reduced lead content and lead-free 11SMn30 steel. Turning tests were performed based on the selection of parameters, as a result of which the tool will be worn after 1 minute. The evaluation took into account power consumption, chip shape, changes in the surface layer and surface roughness. The tests are aimed at determining the own index of machinability of materials used in SANHA Polska. The generally available machinability index has to be adapted to each application [1]. This adaption is often pretty time and cost consuming. Therefor we are looking for a fast and cheap alternative for the rich machine park with various machining properties. The developed methodology and the obtained results are the basis for further research conducted as part of the implementation doctorate, the aim of which is to implement the production of well-machinable lead-free materials for drinking water installation, characterized by good solderability and corrosion resistance.

PL

Przeprowadzono ocenę skrawalności dwóch stali: 11SMnPb37 z obniżoną zawartością ołowiu i bezołowiowej stali 11SMn30. Próby toczenia wykonano w oparciu o dobór parametrów, w wyniku których narzędzie zostało zużyte po czasie 1 min. Przy ocenie wzięto pod uwagę pobór mocy, kształt wióra, zmiany w warstwie wierzchniej materiału i chropowatość powierzchni. Badania miały na celu wyznaczenie własnego indeksu skrawalności materiałów stosowanych w SANHA Polska. Ogólnie dostępny wskaźnik skrawalności musi być dostosowany do danego zastosowania [1]. Taka adaptacja jest często dość czasochłonna i kosztowna. Dlatego przeprowadzono 1-minutowy test jako szybką i tanią alternatywę dla bogatego parku maszynowego o różnych właściwościach obróbczych. Opracowana metodyka i otrzymane wyniki stanowią podstawę do dalszych badań prowadzonych w ramach doktoratu wdrożeniowego, którego celem jest wdrożenie do produkcji dobrze skrawalnych materiałów bezołowiowych przeznaczonych do instalacji wody pitnej, charakteryzujących się dobrą lutownością i odpornością na korozję.

14

Investigation of coated and uncoated carbide cutting tool wear in dry turning of en aw 2007 aluminum alloy

Leksycki Kamil, Patil Gauravkumar Himmatrao, Małecka Joanna, Cagan Cinar Suleyman, Dąbrowski Karol

International Journal of Applied Mechanics and Engineering

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2024

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Vol. 29, no. 3

69--81

EN

The automotive, aerospace and marine industries make extensive use of aluminum and its alloys to produce a wide variety of components. This prompts research work related to improving manufacturing processes using these materials. One of the main problems in this area is the durability of cutting tools. This article describes the results of tests on wear of the coated and uncoated carbide cutting tools during turning of EN AW 2007 aluminum alloy. The tests were carried out under dry conditions and at higher cutting speeds. On the face rake, the VBB indicator (average width of the flank wear) and on the rake face, the KB indicator (crater width on the rake face) were evaluated. Only for the uncoated insert, the break-in period, steady-state wear region and intensive wear were observed and the limited alue of the VBB indicator was obtained after 36 minutes of the tool life. The TiAlN+TiN coated insert, as well as TiCN achieved very short tool life periods of 16 and 24 minutes, respectively. Compared to the uncoated and the TiCN coated insert, a VBB increase of about 170% was obtained for the TiAlN+TiN coated insert after 16 minutes. In contrast, an increase in the VBB of almost 60% was obtained for the TiCN coated insert after 24 minutes, compared to the uncoated insert. Compared to the uncoated insert, an increase of 12.1% in the KB value was obtained for the TiCN coated insert, and 18.2% for the TiAlN+TiN coated insert. The main wear mechanism of the tested cutting inserts was the phenomenon of adhesion. Abrasion wear is observed on the surfaces of the TiAlN+TiN and TiCN coated inserts. The TiCN coated insert also showed coating delamination. The build-up edge (BUE) phenomenon is observed on the surfaces of the TiAlN+TiN coated and uncoated inserts.

15

Influence of Aluminium Oxide Nanoparticles Mass Concentrations on the Tool Wear Values During Turning of Titanium Alloy Under Minimum Quantity Lubrication Conditions

Szczotkarz Natalia, Adamczuk Krzysztof, Dębowski Daniel, Gupta Munish Kumar

Advances in Science and Technology. Research Journal

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2024

|

Vol. 18, no. 1

76--88

EN

Recently, environmental consciousness has led to the quest for ways to minimise negative elements in machining operations that threaten operator health and the environment. Titanium alloys are hard to cut, thus cooling the cutting zone is essential to reduce tool wear. Variations in Al2O3 nanoparticle concentrations supplied to the MQL cutting fluid affect cutting wedge wear during Ti6Al4V alloy turning. A diameter of 15 nm nanoparticles were utilised at 0.25, 0.5, 0.75, and 1 wt% mass concentrations. In the experiments, the flank face wear band width VBB and crater width KB were measured. Comparisons were also made using dry-cutting tools and the MQL approach without nanoparticles. X-ray microanalysis was used to quantify and qualitatively assess the chemical composition of chosen rake surface micro-areas. Studies showed that Al2O3 nanoparticle mass concentration affects tool wear when turning a hard-to-cut alloy. 0.5 and 0.75 wt% mass concentrations had the lowest flank and rake wear of the four mass concentrations. The SEM examination showed that 0.5 wt% mass concentration decreased adhesive wear the most.

16

A comparative study of CNN, LSTM, BiLSTM, AND GRU architectures for tool wear prediction in milling processes

Zegarra Fabio C., Vargas-Machuca Juan, Coronado Alberto M.

Journal of Machine Engineering

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2023

|

Vol. 23, No. 4

122--136

EN

Accurately predicting machine tool wear requires models capable of capturing complex, nonlinear interactions in multivariate time series inputs. Recurrent neural networks (RNNs) are well-suited to this task, owing to their memory mechanisms and capacity to construct highly complex models. In particular, LSTM, BiLSTM, and GRU architectures have shown promise in wear prediction. This study demonstrates that RNNs can automatically extract relevant information from time series data, resulting in highly precise wear models with minimal feature engineering. Notably, this approach avoids the need for excessively large window sizes of data points during model training, which would increase model complexity and processing time. Instead, this study proposes a procedure that achieves low prediction errors with window sizes as small as 100 data points. By employing Bayesian hyperparameter optimization and two preprocessing techniques (detrend and offset), RMSE errors consistently fall below 10. A key difference in this study is the use of boxplots to provide a better representation of result variability, as opposed to solely reporting the best values. The proposed approach matches more complex state of-the-art. methods and offers a powerful tool for wear prediction in engineering applications.

17

Advances in friction stir welding of Ti6Al4V alloy complex geometries: T-butt joint with complete penetration

Ambrosio Danilo, Wagner Vincent, Vivas Javier, Dessein Gilles, Aldanondo Egoitz, Cahuc Olivier

Archives of Civil and Mechanical Engineering

|

2023

|

Vol. 23, no. 3

art. no. e182, 2023

EN

In this work, the friction stir weldability of Ti6Al4V T-joints has been investigated. Its aims are: (i) to study the influence of tool and welding parameters on weld quality, (ii) to assess the joints’ mechanical strength to foresee future applications, and (iii) to characterize Co-based FSW tools’ wear by following the wear during the tests. Welds’ defectivity is studied by cross-section macrographies analysis. Independently from welding parameters and tools, internal voids are avoided, and a suitable weldability window is identified. Microstructure observations have corroborated temperatures below the -transus point even in the nugget zone, guaranteeing joints’ maximum mechanical strengths at 96% and 87% of the base material for UTS and Y, respectively. Contrarily, elongation at break is very low, without reaching 20% of the base material. The failure is linked to section thinning and kissing bond defects at the joints’ corners. Additionally, tool wear proved to be a critical issue while friction stir welding Ti6Al4V. The inner part of the shoulder is the most sensitive to wear. The consequent high wear rate might be a problem for mass production. The work established the pertinence of assembling complex geometries of Ti6Al4V using friction stir welding, considering weld quality and the mechanical strength achieved. However, critical factors such as section thinning, kissing bond, and tool wear must be carefully addressed to avoid joints’ low elongation at break and to guarantee their mechanical strength.

18

A review on machinability in the milling processes

Demirpolat Havva, Kuntoğlu Mustafa, Binali Rüstem

Sustainable Production, Instrumentation and Engineering Sciences

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2022

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vol. 1, nr 1

27--36

EN

This review paper focuses on the up-to-date machinability characteristics of milling processes such as cutting forces, surface roughness and tool wear and their impacts on the cutting mechanism. The methodology pur-sued in this paper is to analyze the previous research articles published between 2019–2022 classifying them into the subcategoriesthat usemill-ing operation as manufacturing strategy. As known, milling is one of the most used machining processes in industry and often applied for academic studiesforawide range of materials. Therefore, used sensor systems, main aim and the preferred methodology were summarized in the context of this paper. Seemingly, a great number of machinability papers have been published recently which focuses on the several types of engineering ma-terials and utilized various types of sensor system to improve the surface roughness and tool life. In addition, the investigation showed that optimi-zation approaches have been applied broadly to detect the best machining conditions. Also, it was observed that several modeling approaches such as finite element analysis is a good alternative to analyze the process.

19

Determination of twist drill bits wear: the effect of the composition and structure of the steels

Prałat Karol, Krupińska Andżelika, Ochowiak Marek, Włodarczak Sylwia, Matuszak Magdalena, Ciemnicka Justyna, Koper Artur, Wójcicka Karolina

Polish Journal of Chemical Technology

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2022

|

Vol. 24, nr 3

8--13

EN

The aim of the study was to relate the infl uence of the chemical composition, structure, and basic properties as hardness of the tested drill bits on resistance to their wear. The chemical composition of the drill bit was investigated using the electric excitation emission spectrometry method and EDS microanalysis. Metallographic specimens were prepared and observed to determine the structure of each tool. Hardness tests were carried out on the shank and the working part of the tools. Material wear tests were carried out on the basis of measuring the wear of the drill bit flank. It has been shown that the appropriate selection of the chemical composition and heat treatment has a signifi cant impact on the wear resistance of cutting tools, which directly translates into their quality.

20

Progress in structured and textured cutting tools. Part 2. Influence of structured and textured cutting tools on the process performance

Grzesik Wit

Mechanik

|

2022

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R. 95, nr 7

6--10

EN

This paper presents the possible influence of structured and textured cutting tools made of different cutting tool materials. Some recently published data concerning research works in the influence on the cutting mechanics (componential cutting forces and chip formation mechanism), heat generation and transfer, interface contact conditions and lubrication, interface friction and tool wear are discussed.

PL

W artykule przedstawiono możliwy wpływ strukturyzowanych i teksturyzowanych ostrzy skrawających wykonanych z różnych materiałów narzędziowych na przebieg procesu skrawania. Omówiono wnioski z ostatnio opublikowanych prac badawczych na temat czynników mających wpływ na mechanikę procesu (składowych siły skrawania i procesu tworzenia wiórów), generowania oraz rozpływu ciepła, warunków kontaktu i smarowania, tarcia i zużycia ostrza.