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1

A Comparative Analysis of the Two Electrolyte Flow Configurations in Electrode Tool to Improve Efficiency in Electrochemical Machining

Abdulwahhab Ahmed Basil, Abbas Ahmed Mohammed, Mohsein Zainab H.

Management Systems in Production Engineering

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2026

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nr 1 (34)

138--144

EN

Electrochemical machining (ECM) is defined as a non-conventional method of manufacturing that is greatly employed in processing of materials with complex geometry which are hard to be machined, providing high accuracy and excellent surface finish. ECM is influenced to higher extent by the configuration of the electrolyte flow and design of electrode tooling. In this work, two types of electrolyte flow configurations in electrode tooling are studied and compared: straight flow and side nozzle flushing flow. The effects of these configurations on material removal rate (MRR) and surface roughness were investigated both experimentally and numerically. The results emphasize the significance of the choice of electrolyte flow configuration in improving the uniformity of ion transport, flow turbulence during machining and quick heat dissipation. According to the findings, it is clear that the hollow electrode with straight flow has the best material removal rate with a percentage increase of 4.61 percent recording a rate of 0.4352 g/min, as compared to the rigid electrode with nozzle flushing flow which records 0.416 g/min. Also, the hollow electrode at straight flow showed the least extreme surface roughness, a percentage decrease of 28.52% with the least extreme of 2.030 μm and the robust electrode surface with the nozzle flow of 2.840 μm. These findings have fundamental implications for the improvement of ECM technologies with regards to productivity, energy consumption, and accuracy of machining processes. In regards to the finding, the research provides an insight into the impact customization of flow and tooling with regards to the processes in the electrochemical operation.

2

Multi-objective prediction and optimization of 3D-printed polymer properties using neural networks and desirability functions

Shakir Layth Fadhil, Ismael Hameed Sarhan, Abdullah Mostafa Adel, Huayier Abdullah Faraj, Ghazi Safaa Kadhim

Advances in Science and Technology. Research Journal

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2026

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Vol. 20, no. 1

288--300

EN

The industry uses Fused Deposition Modeling (FDM) in the manufacture of the final products through the additive manufacturing method (AM). Due to this approach, one can construct a prototype and other components with complicated geometry, which not only translates into the saving of expensive dollars but also makes the project more flexible. Printing and material type, as well as other processing settings, affect the nature of parts, in terms of mechanics as well as other aspects. This paper attempts to develop a model to predict the mechanical capabilities and surface quality of FDM-printed ABS objects based on Artificial Neural Networks. Taguchi design of experiments is applied with an L27 orthogonal array coupled with a two-layer Neural Network (NN) with 15 neurons. The impact of the characteristics of the layer height, the orientation angle, and the nozzle temperature on the strength and finish of parts was investigated by means of the analysis of variance (ANOVA). Layer thickness seemed to be the major variable in the analysis because it was identified to create over 43.67% variation in ultimate tensile strength and 46.38% variation in surface roughness. The predicted results by the model were just a little different compared with the actual results. The highest percent error in the tensile strength and the surface roughness are 2.346 and 1.876, respectively, which arises when comparing the experimental and predicted values as calculated using the ANN model. With such a model, different parameters selected are able to achieve the requirements of a particular application.

3

A validated framework for the development of low-cost aluminum dies through rapid investment casting

Shehbaz Muhammad, Sajid Muhammad, Ali Muhammad Asad, Ahmad Wasim

Advances in Science and Technology. Research Journal

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2026

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Vol. 20, no. 1

104–-120

EN

The rising demand for agile, economical, and scalable manufacturing has driven the need for innovative approaches in tool and die development. Aluminum has emerged as a promising alternative to traditional die materials due to its low density, excellent castability, thermal conductivity, machinability, and recyclability. This study proposes and validates a structured framework for the development of low-cost aluminum dies using Rapid Investment Casting (RIC). The framework, grounded in an extensive review of existing practices, is implemented through a real-world case study focused on the development of a die for an automotive door handle. A CAD model was designed with a 3%-dimensional tolerance, and the die was fabricated using LM30 aluminum alloy via RIC. The die was then tested using polypropylene (PP) in an injection molding process to evaluate its dimensional accuracy and surface roughness. Results revealed that in contrast to certain features, which exhibited strong dimensional consistency—such as the circle diameter along the large pin, front lengths, and upper slope depth (with deviations within ±0.1 mm to ±0.2 mm) some geometries, particularly sloped features, showed notable discrepancies. Small slope length 1 demonstrated a significant reduction of 0.66 mm during casting, likely due to angular mold erosion or material pullback. Additionally, the small and large mounting pin lengths, handle length, and small slope length 1 recorded the highest dimensional deviations. Despite these variations, the aluminum die achieved a surface finish near the industrial standard of 3.2 µm, while the molded PP part exhibited improved surface quality. Economic considerations reveal the saving of time (~7 to 3 weeks) and cost ($720 to $180). The results demonstrate that the proposed RIC-based framework provides a cost-effective, efficient, and flexible solution for producing customized or low-volume dies, offering reduced tooling costs and faster production cycles while meeting the industry standards.

4

Physical properties of masking coating systems used in military technology

Michalski Marek, Radek Norbert

Zeszyty Naukowe Politechniki Morskiej w Szczecinie

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2025

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nr 82 (154)

69--79

EN

This paper presents the results of experimental tests on coating systems for military applications. The evaluation of properties is performed based on measurements of thickness, gloss, hardness, and surface roughness. The spectral characteristics of the tested systems and color parameters are presented. The tests are conducted for two-layer masking coating systems made in three variants: coating system (SP1), coating system modified with carbon nanotubes (SP2), and coating system modified with glass microspheres (SP3). Analysis of the obtained results reveals that these coating systems exhibit similar thickness, gloss, and spectral characteristics. The SP2 system is characterized by lower hardness, while the SP2 and SP3 systems have higher roughness.

5

Tribological Properties and Surface Roughness of Printed Ti-6Al-4v/PE-UHMW Friction Pair Elements

Musiał Janusz, Zasińska Katarzyna, Ligaj Bogdan, Kałaczyński Tomasz, Dykha Oleksandr

Tribologia

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2025

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nr 1

29--36

EN

The article presents tribological research on the cooperation of a kinematic pair composed of metallic and polymer biomaterials. In the sample tests, a material widely used in orthopaedics and dentistry was used (the medical titanium alloy Ti-6Al-4V obtained both by traditional manufacturing methods, i.e. casting, and the additive manufacturing method SLM/DLMS (3D printing)) and a counter sample (high-density polyethylene PE-UHMW). The friction pair selected in this way was subjected to tribological tests on a PT-3 tribometer under specific operating conditions. After the tribological tests, the change in tribological parameters, i.e. the coefficient of friction or abrasive wear on the surfaces of the tested biomaterials, was evaluated. The obtained results also enabled the assessment of the changes occurring in the geometric structure of the surface of the Ti-6Al-4V/ PE-UHMW friction pair for titanium samples obtained via drawn rod and 3D printing.

PL

W artykule przedstawiono badania tribologiczne dotyczące współpracy pary kinematycznej złożonej z biomateriałów metalicznych i polimerowych. W badaniach na próbki zastosowano materiał szeroko stosowany w ortopedii i stomatologii – medyczny stop tytanu Ti-6Al-4V otrzymany tradycyjną metodą wytwarzania, tj. odlewaniem oraz addytywną metodą wytwarzania SLM/DLMS (druku 3D), zaś na przeciwpróbkę – polietylen o wysokiej gęstości PE-UHMW. Tak dobraną parę cierną poddano badaniom tribologicznym na tribometrze PT-3 w określonych warunkach eksploatacyjnych. Po przeprowadzonych badaniach tribologicznych ocenie poddano zmianę parametrów tribologicznych, tj. współczynnik tarcia czy zużycia ściernego na powierzchniach badanych biomateriałów. Otrzymane wyniki pozwoliły również na ocenę zmian zachodzących w strukturze geometrycznej powierzchni pary ciernej Ti-6Al-4V/PE-UHMW dla próbek tytanowych otrzymanych w postaci pręta litego oraz druku 3D.

6

Application of the Tensile Bending Test to Determine the Tribological Behavior of DC01 Steel Sheets

Szewczyk Marek, Szwajka Krzysztof, Trzepieciński Tomasz, Zielińska-Szwajka Joanna, Barlak Marek

Tribologia

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2025

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nr 1

67--76

EN

The article presents the results of the analysis of changes in the coefficient of friction occurring on the edge of the punch during sheet metal plastic processing. Experimental studies were conducted using the friction method in bending and stretching. A tribometer developed by the authors was used. The research material consisted of 0.8 mm thick DC01 low-carbon steel sheets. The evolution of changes in the coefficient of friction during friction tests was studied in dry friction conditions and lubrication of the sheet metal surface with S100 Plus and S300 oil (Naftochem). Countersamples made of 145Cr6 tool steel, and additionally modified by applying anti-wear coatings were used. The obtained results showed that the coefficient of friction depended on the coating used, and the nature of this change depended on the friction conditions. In the analyzed friction conditions, a decrease in the values of the Sa and Ssk parameters was observed, and an increase in the Sku parameter in relation to the sheet metal in the delivery state.

PL

W artykule przedstawiono wyniki analizy zmian współczynnika tarcia zachodzących na krawędzi stempla w procesach obróbki plastycznej blachy. Badania eksperymentalne przeprowadzono metodą tarcia przy zginaniu i rozciąganiu. Zastosowano opracowany przez autorów tribometer. Materiał badawczy stanowiły blachy ze stali niskowęglowej DC01 o grubości 0,8 mm. Badano ewolucję zmian współczynnika tarcia podczas badań tarcia w warunkach tarcia suchego i smarowania powierzchni blachy olejem S100 Plus i S300 (Naftochem). Zastosowano przeciwpróbki wykonane ze stali narzędziowej 145Cr6, które zostały dodatkowo zmodyfikowane poprzez naniesienie powłok przeciwzużyciowych. Uzyskane wyniki wykazały zależność wartości współczynnika tarcia od zastosowanej powłoki, a charakter tej zmiany zależy od warunków tarcia. W analizowanych warunkach tarcia zaobserwowano zmniejszenie wartości parametrów Sa i Ssk oraz zwiększenie parametru Sku w stosunku do blachy w stanie dostawy.

7

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

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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.

8

Analysis of Connecting Rod Bearing Wear

Sienkiewicz Judyta, Lipiński Hubert

Problemy Mechatroniki : uzbrojenie, lotnictwo, inżynieria bezpieczeństwa

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2025

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Vol. 16, Nr 2 (60)

27--44

EN

This paper analyses the wear mechanisms occurring in connecting rod bearings, which are exposed to various mechanical failures, such as incorrect assembly, high loads, extreme temperatures, unsuitable operating conditions, or loss of lubrication. The investigation was conducted on previously collected post-service samples, each evaluated for factors contributing to their wear or damage. The samples came from eight engines belonging to two groups- four- and six-cylinder BMW units installed in vehicles produced during the same time period. Advanced research techniques, such as optical microscopy, surface profilometry, and hardness measurements, were employed for the bearing analysis. Several wear mechanisms were identified, including sliding wear, fatigue wear (characterised by visible cracks and material pull-out), surface discolouration, as well as two-body and three-body abrasive wear (evidenced by friction marks). The research enabled a detailed characterisation of bearing wear mechanisms and improved understanding of the factors influencing their durability under various operating conditions.

PL

W niniejszej pracy przeprowadzono analizę mechanizmów zużycia występujących w panewkach korbowodowych, które są narażone na różnorodne awarie inżynieryjne, takie jak nieprawidłowy montaż, duże obciążenia, ekstremalne temperatury, nieodpowiednie warunki pracy czy utrata smarności. Badania przeprowadzono na wcześniej zgromadzonych próbkach po eksploatacji, z których każda została poddana ocenie pod kątem czynników przyczyniających się do jej zużycia lub uszkodzenia. Próbki pochodziły z ośmiu egzemplarzy silników dwóch grup - cztero- i sześciocylindrowych jednostek BMW, montowanych w pojazdach produkowanych w zbliżonym okresie. Do analizy panewek wykorzystano zaawansowane techniki badawcze, takie jak mikroskopia optyczna, profilometria powierzchni oraz pomiary twardości. Zidentyfikowano różne mechanizmy zużycia, w tym zużycie ślizgowe, zużycie zmęczeniowe z widocznymi pęknięciami i wyrwanym materiałem, przebarwienia powierzchni oraz zużycie ścierne o charakterze dwu- i trójpłaszczyznowym (ślady tarcia). Przeprowadzone badania pozwoliły na scharakteryzowanie mechanizmów zużycia panewek oraz zrozumienie czynników wpływających na ich trwałość w różnych warunkach eksploatacyjnych

9

Accuracy and surface characterization of 3D printed samples fabricated from thermoplastic and photopolymer resin

Rębisz Sylwia, Wojnarowska Wiktoria

Physics for Economy

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2025

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Vol. 7

21-39

EN

With a growing interest in 3D printing in medicine, it is essential to understand the properties of materials that allow accurate reproduction of anatomical structures. This study evaluated common materials used in Fused Deposition Modeling (FDM) and Stereolithography (SLA) 3D printing technologies in terms of dimensional accuracy and surface quality. The samples were analyzed using a Keyence VHX-X1 digital microscope. Dimensional accuracy was assessed through automatic 2D image measurements, while surface roughness was evaluated using 3D imaging. Polylactic Acid (PLA) and Polyethylene Terephthalate Glycol (PET-G) exhibited the highest accuracy (deviations <0.5%), with PLA showing exceptional stability (<0.3%). Acrylonitrile Butadiene Styrene (ABS) and medical ABS demonstrated greater variability, and ABS was prone to warping. Acrylonitrile Styrene Acrylate (ASA) showed high surface roughness. SLA samples printed with BioMed Clear resin had smooth, uniform, and transparent surfaces, advantageous for medical visualization. The results support the selection of materials in accord ance with medical application requirements.

PL

W dobie rosnącego zainteresowania drukiem 3D w medycynie, kluczowe jest poznanie właściwości materiałów umożliwiających dobre odwzorowanie struktur anatomicznych. W badaniu oceniono popularne materiały stosowane w druku 3D w technologiach FDM i SLA pod kątem dokładności wymiarowej i jakości powierzchni. Próbki analizowano za pomocą mikroskopu cyfrowego Keyence VHX-X1. Dokładność wymiarową oceniono na podstawie automatycznych pomiarów 2D, a chropowatość powierzchni określono z użyciem obrazów 3D. PLA i PET-G wykazały najwyższą dokładność (od chylenia <0,5%), z wyjątkową stabilnością PLA (<0,3%). ABS i medyczny ABS były bardziej zmienne, a ABS podatny na wypaczanie. ASA charakteryzowała się wysoką chropowatością. Próbki SLA z żywicy BioMed Clear miały gładką, jednolitą i przezroczystą powierzchnię, korzystną dla wizualizacji medycznych. Wyniki wspierają dobór materiałów zgodnie z wymaganiami zastosowań medycznych.

10

Corrosion resistance of masking coating systems used in military technology

Michalski Marek, Łabęcka Paulina, Kozieł Tomasz

Ochrona przed Korozją

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2025

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nr 5

138--143

PL

Przedstawiono wyniki badań eksperymentalnych systemów powłokowych do zastosowań militarnych. Ocenę właściwości przeprowadzono na podstawie badań przyspieszonego starzenia w komorze solnej oraz badań odporności korozyjnej metodą potencjodynamiczną i impedancyjną. Badania przeprowadzono dla maskujących dwuwarstwowych systemów powłokowych wykonanych w trzech wariantach: system powłokowy (SP1), system powłokowy modyfikowany nanorurkami węglowymi (SP2) i system powłokowy modyfikowany mikrosferami szklanymi (SP3). Analiza uzyskanych wyników wykazała, że systemy powłokowe charakteryzowały się podobną odpornością korozyjną. System SP3 charakteryzował się najmniejszym rozwarstwieniem i korozją wokół zarysowania.

EN

The results of experimental tests of coating systems for military applications were presented. The assessment of properties was carried out on the basis of accelerated ageing tests in a salt spray chamber and in corrosion resistance tests using the potentiodynamic method and impedance studies. The tests were carried out for masking twolayer coating systems made in three variants: coating system (SP1), coating system modified with carbon nanotubes (SP2) and coating system modified with glass microspheres (SP3). Analysis of the results showed that the above coating systems were characterized by similar corrosion resistance. The SP3 system was characterized by the smallest delamination and corrosion around the scratch

11

Analysis of the influence of the dressing feed rate of a grinding wheel with sintered corundum on the surface roughness of AMS6308 steel after carburising in plunge grinding

Habrat Witold, Sałata Marcin, Ordon Tomasz

Mechanik

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2025

|

R. 98, nr 8-9

6--9

EN

The influence of the grinding wheel dressing speed on the surface roughness of AMS6308 steel after carburising during plunge grinding was investigated. A single-grain CVD diamond dresser and a grinding wheel with a 50% admixture of sintered corundum were applied. An increase in the dressing feed rate resulted in an increase in the surface roughness parameters after grinding.

PL

Badano wpływ prędkości obciągania ściernicy na chropowatość szlifowanej powierzchni stali AMS6308 po nawęglaniu podczas szlifowania wgłębnego. Zastosowano jednoziarnisty obciągacz słupkowy z diamentu CVD oraz ściernicę z 50% domieszką korundu spiekanego. Wzrost posuwu obciągania powodował wzrost parametrów chropowatości powierzchni po szlifowaniu.

12

Investigation of burr formation and surface integrity in micro-milling of aluminum alloy LF21 slot

Wu Chao, Li Weimin, Tang Zhaoqing, Feng Shuai, Liang Jixiang, Li Jiahui

Materials Science Poland

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2025

|

Vol. 43, No. 2

1--22

EN

Due to the nature of LF21 aluminum alloy material, it is difficult to process and easily prone to plastic deformation; hence, micro-milling process is prone to produce larger burrs and rougher surface. Currently, there are fewer investigations on LF21 slot micro-milling. So, this article uses a combination of finite element simulation and experimentation to analyze the effects of different cutting parameters on the LF21 slot exit, top burr size, and the surface quality of the bottom of the slot. The results of the investigation show that the top burr and exit burr sizes as well as the surface roughness at the bottom of the groove show a monotonically decreasing trend as the spindle speed increases, especially on the up-milling side where the burr size is significantly smaller than that on the down-milling side. Variation in feed rate plays a pivotal role in burr size and groove bottom roughness. The smallest burr size, along with the best surface quality, is achieved when the feed per tooth is close to the tool edge radius. Furthermore, as the cutting depth increases, both the burr size and surface roughness also increase. This effect becomes particularly pronounced at larger cutting depths, where surface valleys are markedly higher and grooves become significantly deeper. The results of this investigation are instructive for practical micro-milling of aluminum alloy LF21, which is important for improving machining efficiency.

13

Effect of Hybrid Composite Electrode (Cu/Cr/Wc/Ag) on Surface Integrity of Stainless Steel 304l Machined by EDM

Abdulwahhab Ahmed Basil, Ibrahim Abbas F.

Management Systems in Production Engineering

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2025

|

nr 1 (33)

136--143

EN

Electrical Discharge Machining (EDM) is a modern technique extensively utilized across various industries to eliminate material using electrical discharges. Within the realm of EDM, a key obstacle involves identifying appropriate electrode materials capable of withstanding elevated temperatures and effectively eroding material from workpieces. Composite electrodes are becoming more commonly employed to tackle this issue, as a result of their exceptional electrical and thermal properties. The performance of a composite electrode that has been specifically improvement with (Cu-3%Cr-0.5%WC-1%Ag) is evaluated in this study using the stir casting technique. The investigation utilized stainless steel 304L as the workpiece material, and the performance of the composite electrode was evaluated against traditional pure copper electrodes. The results indicate that composite electrodes can decrease electrode wear and increase machining efficiency. The tool wear rate (TWR) for the composite electrode decreased to 0.0398 gm/min with a current of 10 A and a pulse-on time of 50 µs, along with a pulse-off time of 50 µs. In contrast, under the same conditions, the copper tool exhibited a TWR of 0.514 gm/min. The composite electrode achieved the highest material removal rate (MRR) at 59.7917 mm3/min, surpassing the copper electrode which had the lowest MRR at 54.5588 mm3/min. Additionally, the Surface Roughness (SR) of the composite electrode was measured at 3.253 μm, lower than the 3.967 μm of the pure copper electrode. These findings suggest that composite electrodes could serve as a viable substitute for conventional EDM electrodes.

14

The influence of construction parameters and the type of substrate on the conductivity value of multilayer structures made of NiFe and SiO2

Wilczyńska Aleksandra

International Journal of Electronics and Telecommunications

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2025

|

Vol. 71, No. 1

123-129

EN

This article presents a method of obtaining multilayer NiFe-SiO2 nanocomposites by non-reactive magnetron sputtering. Structures with different numbers and thicknesses of layers were made on two different types of dielectric substrates. Electrical parameters were tested in the frequency range from 4 Hz to 8 MHz, as well as measurements of the surface roughness of the substrates. Based on the results, the influence of design parameters and the aging effect on the AC properties of the structures was determined.

15

Parametric analysis and optimization of Wire EDM for improved surface roughness of D2 tool steel usingresponse surface methodology

Kharat D. P., Nawathe M. P.

International Journal of Applied Mechanics and Engineering

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2025

|

Vol. 30, no. 4

67--85

EN

This study presents a systematic investigation into the optimization of Wire Electrical Discharge Machining (WEDM) parameters for improving the surface finish of D2 tool steel. Utilizing Response Surface Methodology (RSM) integrated with Central Composite Design (CCD), the research aims to minimize surface roughness (Ra) through the controlled variation of critical process parameters: wire feed rate, pulse-on time, pulse-off time, peak current, and sensitivity. The optimal parameter configuration comprising a wire feed rate of 60 mm/min, pulse-on time of 32 µs, pulse-off time of 7 µs, peak current of 4 A, and sensitivity level of 5 resulted in a minimum surface roughness of approximately 3.7309 µm. These conditions enhanced process stability, facilitated efficient material removal, and reduced thermal damage, thereby preserving surface integrity. The developed regression model demonstrated high predictive accuracy, supported by a composite desirability index of 0.582. Experimental validation confirmed the reliability and repeatability of the optimized parameter set. The findings underscore the significance of multi-parameter optimization in achieving high-precision surface characteristics, offering practical insights for advanced machining applications in tool and die manufacturing.

16

Optimising surface roughness, dimensional accuracy and printing time of FDM PETG parts using statistical methods and artificial neural network

El Omari A., Ouballouch A., Nassraoui M.

Archives of Materials Science and Engineering

|

2025

|

Vol. 133, nr 1

5--17

EN

Purpose: The purpose of the paper is to optimise key quality characteristics of FDM PETG parts—surface roughness, dimensional accuracy, and printing time—by investigating the effects of critical process parameters. It further seeks to develop and compare predictive models using both statistical methods and artificial neural networks (ANN) to enhance the process efficiency and applicability of FDM technology. Design/methodology/approach: An experimental framework based on a Taguchi L25 orthogonal array was employed to analyse parameter combinations systematically. PETG specimens were modelled in SolidWorks, converted to G-code, printed, and evaluated. Statistical techniques, including ANOVA and regression analysis, were applied for parameter optimisation. Additionally, ANN models were developed to predict the output responses. The dual-methodology approach ensures robust modelling and validation of the results. Findings: The results demonstrate that both regression and ANN models effectively predict the responses of FDM PETG parts with high accuracy. However, the ANN models significantly outperformed the statistical methods, achieving superior predictive accuracy, particularly for surface roughness (R² = 0.9944). Multi-objective optimisation identified optimal parameter settings that minimise surface roughness, dimensional errors, and printing time simultaneously. Research limitations/implications: The study is limited to PETG material, and the findings may not be directly generalisable to other thermoplastics. Future research could include other parameters and mechanical properties that define the overall bearing capacity of the material, as well as investigate the effects of post-processing techniques. Practical implications: The research offers practical insights for manufacturing high-quality PETG parts with enhanced surface finish and dimensional accuracy, achieved in a reduced printing time. The developed models offer valuable guidance for optimising FDM processes in industrial applications. Originality/value: The research presents a novel integration of statistical methods and artificial neural networks for the multi-objective optimisation of FDM PETG parts. The study demonstrates the superior predictive capability of ANN modelling in capturing complex parameter-response relationships, while providing validated optimal processing parameters that simultaneously enhance surface quality, dimensional accuracy, and manufacturing efficiency. The work establishes a comprehensive framework for intelligent process optimisation in industrial additive manufacturing applications.

17

Study of the effect of process factors on the wear rate and surface integrity in incremental point forming of AA6061 aluminum alloy

Mughir Walaa Amer, Jasim Hussein Hatem

Advances in Science and Technology. Research Journal

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2025

|

Vol. 19, no. 3

84--95

EN

Incremental point forming is a contemporary method employed in sheet metal forming to achieve great flexibility in fabrication of intricate forms, eliminating the requirement for specific mold. According to its exceptional mechanical characteristics and low weight, this method is particularly employed in the production of aluminium alloys. The essential aim of this research is to examine the deformation mechanisms and discuss the mechanical properties of aluminium during the incremental forming process. The aim was to examine how various process parameters influence the surface properties, hardness, and wear resistance of the workpieces using aluminium alloy type AA6061. The parameters under investigation are increment step down size, feed rate, and spindle rotational speed. Furthermore, the impact of these factors on the forming process was investigated using several methodologies, including the Taguchi method for parameter optimization and surface analysis. The findings of this study demonstrate that spindle rotation speed exerted a substantial influence on both surface roughness and hardness, accounting for 63.41% for hardness and 52.19% for roughness. In terms of wear rate, the step size had the most significant impact, accounting for 48.53%.

18

Optimization of fused deposition modeling parameters to enhance tensile strength and surface roughness of polyethylene terephthalate glycol

Shabeeb Alaa Hassan, Abdulwahhab Ahmed Basil, Ismael Hameed S., Ghazi Safaa Kadhim

Advances in Science and Technology. Research Journal

|

2025

|

Vol. 19, no. 8

345--358

EN

The wide examination of FDM as an industrial additive manufacturing technique appears because it provides design freedom alongside improved material efficiency and reasonable cost. This study's main objective is to investigate the relationship of Fused Deposition Modeling (FDM) process parameters with the tensile properties and surface roughness of Polyethylene terephthalate glycol (PETG) parts. A response surface methodology (RSM) utilizing Box–Behnken design methodology studied three essential parameters consisting of infill density and layer height, together with plate temperature. The analysis demonstrated that layer height proved to be the main element affecting tensile strength because it contributed 80.9% of the experimental variations, while infill density stood out as the leading determinant of surface roughness, which was responsible for 78% of the contribution. Experimental testing proved that the predictive model showed accurate results when validated through measurements of tensile strength, which produced maximum errors of 1.28%, and surface roughness, which yielded maximum errors of 6.54%. A desirability analysis indicated that the ideal parameters of the roughness and tensile strength of the printed parts included an infill density of 64.24% combined with a layer height of 0.1813 mm and plate temperature of 51.46°C. These outcomes provide a comprehensive understanding of process parameter effects that result in quality PETG parts with mechanical performance. The two-axis optimization methodology for PETG also enhances its use in functional engineering systems that require simultaneous mechanical durability and manufacturing accuracy.

19

Enhancing surface integrity of 316 SS with ecofriendly electrolyte in electrochemical machining

Najm Vian Nihad, Abdulrazaq Mustafa Mohammed, Ahmed Athraa Mohammed Salih

Advances in Science and Technology. Research Journal

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2025

|

Vol. 19, no. 12

109--119

EN

Electrochemical machining (ECM) is an advanced technology that enables the efficient and precise machining of difficult metal materials without affecting their mechanical properties or causing thermal stress. In this research, ECM was used for machining 316 stainless steel; it is recognized for its high corrosion resistance, tolerance to harsh chemical environments, and biological stability, making it ideal for use in surgical instruments, sutures, and implants. The development of eco-friendly electrolytes has the potential to impact the safety and performance of electrochemical devices. the development of eco-friendly electrolytes remains a challenging task for well operability. In this research, the possibility of using eco-friendly acidic sodium nitrate solution electrolyte in the ECM of SS316 was investigated. The experimental results manifested that using ECM with SS316 achieves effective results in terms of material removal rate and surface roughness. The results showed that the voltage was the sturdiest affecting parameter, followed by acidified sodium nitrate concentration on MRR as well as for the surface roughness (SR). As it was found that higher MRR (0.0823) was achieved with voltage of (30 V), electrolyte concentration of (100), and gap of (0.2 mm). besides the lowest SR (0.1881 µm) was achieved with voltage of (30 V), electrolyte concentration of (125), and gap of (0.3 mm).

20

Enhancing laser cutting quality of stainless steel 201 by controlling dross formation and surface roughness using multi-factor experimental design

Zabon Anwar Hassan, Abbas Tahseen Fadhil, Bedan Aqeel Sabree

Advances in Science and Technology. Research Journal

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2025

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Vol. 19, no. 7

458--470

EN

A better process and products are thought to require characterization, evaluation of effects, and understanding of the damage extension caused by the Laser Cutting (LC) process on the surface integrity of the cut workpieces, given its many benefits and applications in the industry. In this work, 32-run CCD was used under Response Surface Methodology (RSM) to examine the laser cutting of stainless steel 201 (SST 201) utilizing a 32-run experimental design. Laser power (Pu), cutting speed (V), frequency (F), focal position (FP), and gas pressure (P) are chosen as parameters for the input process, where the surface roughness and dross formation are taken into account as response variables in this process. Each parameter's relevance and impact was evaluated by a thorough statistical analysis that included Analysis of Variance (ANOVA), counters plots, main effect plots, and residual plots. The ANOVA results for surface roughness (Ra) and dross generated area (DA) are closely related since both are influenced by process parameters. While improving assist gas pressure enhances the surface quality and lowers the accumulation, increasing the laser power and cutting speed decreases both roughness and dross.