International Journal of Machining and Machinability of Materials (21 papers in press)

Regular Issues

• Effect of cutting edge geometry on surface and subsurface characteristics of a beta titanium alloy  
  by Reginaldo Silva, Andrea Kliauga, A.I.S. Antonialli, Carlos E. H. Ventura 
  Abstract: With the frequent use of titanium alloys in aerospace and medical industries, the demand for studies on their machinability has increased. One of the most important aspects to be assessed corresponds to surface integrity, which can be induced by different tool edge geometries. Therefore, this work presents experimental results regarding the surface roughness and the depth of affected zone of a beta-titanium alloy (Ti-15Mo) turned by CBN cutting inserts with different edge geometries prepared by grinding. Considering the applied cutting parameters, the results demonstrated that a tool with form factor K = 2.0 leads to the highest machining forces, roughness, and depth of affected zone. The lowest surface roughness was obtained by the tool with a form factor K = 0.5, while the lowest depth of affected zone was measured for the tool with a form factor K = 1.0.
  Keywords: turning; surface integrity; CBN; edge preparation.
  DOI: 10.1504/IJMMM.2025.10068143
   
  
• Influence of milling parameters on delamination damage of CFRP unidirectional plates  
  by YIWEI ZHANG, Mengke Yan, Guixin WANG, Yang Luo, Tianlong Wen 
  Abstract: In order to control delamination damage in carbon fibre-reinforced polymer/plastic (CFRP) milling, we analysed the mechanism of delamination damage through experiments with varying fibre cutting angles. A Box-Behnken design was used to simulate delamination damage and establish a prediction model for factors affecting delamination. We found that delamination primarily occurs within a fibre cutting angle range of 45
  Keywords: CFRP milling; delamination damage; milling parameters; prediction model; machining dynamics.
  DOI: 10.1504/IJMMM.2025.10068144
   
  
• Finite element analysis of material removal in AWJM using different material models and spatial distributions for garnet abrasives  
  by Yahya Abdelhameed, Ibrahem Maher, Jiwang Yan, Hassan El-Hofy, Mohsen A. Hassan 
  Abstract: Garnet, the most widely used abrasive material in abrasive waterjet machining (AWJM), presents challenges in modelling its behaviour. Therefore, a finite element (FE) model was proposed to analyse the effect of using different material models and spatial distributions for garnet on the erosion behaviour of Al 7075-T6. Three popular material models were considered for garnet, including rigid, linear elastic, and tensile failure models, in addition to the Johnson-Holmquist (JH2) model. These four models were tested and compared for single and multiple particle impact under different waterjet pressures, abrasive mesh sizes, and impact angles. Furthermore, the effect of particle spatial distribution within the jet pass was examined. The model results demonstrated that using different material models for garnet significantly controls the erosion behaviour in AWJM. In addition, the radial distribution of the abrasive particles critically affected the erosion process and kerf geometry, while the axial distribution insignificantly influenced the erosion rate.
  Keywords: abrasive waterjet; finite element simulation; garnet material model; spatial distribution of abrasive particles; material removal.
  DOI: 10.1504/IJMMM.2025.10068145
   
  
• Surface quality analysis of Abrasive Waterjet Cutting (AWJ) on AA5083 aluminium alloy.  
  by Thomas Felipe Zibetti, Mauricio Policena, Charles Leonardo Israel, Carlos Edmundo De Abreu e Lima Ipar, Emerson Dos Santos Passari 
  Abstract: This research scrutinizes the influence of abrasive waterjet cutting (AWJ) process parameters in the surface quality resultant from the cutting of the AA5083 aluminium alloy. The objective was to explore the influence of transverse speed (Vf), abrasive mass flow rate (?A), working pressure of the waterjet (P), and standoff distance (ds) (input variables) on various defects, including kerf width (kw), perpendicular deviation (u), initial zone (DIDR depth and WIDR width), and final damage zone (DFDR depth and WFDR width). X-ray micro-computed tomography analysed cut surface images. Average values obtained indicated an initial damage zone with a depth of 0.254 mm and a width of 0.242 mm, a final damage zone with a depth of 0.137 mm and a width of 0.245 mm, a perpendicular deviation of 0.318 mm, and a kerf width of 1.224 mm. ANOVA revealed that the distance parameter held the utmost significance in influencing defects.
  Keywords: abrasive waterjet cutting; AWJ; aluminium aa5083; machined surface; defect measurement; quality assessment.
  DOI: 10.1504/IJMMM.2025.10068146
   
  
• Comparative Evaluation of Cut Quality between Abrasive Water Jet Machining and Laser Beam Machining of Ti6Al4V  
  by Sandesh Phalke, P. Dinesh Babu 
  Abstract: Titanium alloy, grade five (Ti6Al4V) has been in massive demand in the aerospace, automobile, and marine industries. Manufacturers use different non-conventional machining techniques like abrasive waterjet machining (AWJM), laser beam machining (LBM), and a few others to process this alloy. These processes ease the machining process, reduce the cost and enhance the machining qualities thus optimizing the machining parameters to obtain these desirable characteristics. This paper identifies the impact of different machining parameters of AWJM and LBM on the cut quality of Ti6Al4V on a 5mm thick plate. Further, compares the cut quality between the two-machining process. Although both the machining processes have different operation principles, comparing the final cut quality becomes highly relevant as both the non-conventional processes are suitable substitutes for each other. The study stands novel in stating the optimized machining parameters and comparing the relevant machining process in a real-time environment.
  Keywords: Ti6Al4V; cut quality; AWJM; LBM; optimization; comparison.
  DOI: 10.1504/IJMMM.2025.10068692
   
  
• Sustainable Machining of Inconel Alloy X-750 with carbide tool: Unveiling Trends through Bibliometric lens  
  by Manjeet Bohat, Neeraj Sharma, Vishal Ahlawat 
  Abstract: Inconel X-750 (nickel-chromium superalloy) presents challenging machining as a result of its exceptional strength and work-hardening properties. Future materials will be made of aluminum alloys like Inconel Alloy X-750. The foremost focus of this investigation is to conduct a bibliometric investigation using 2683 research papers retrieved from Scopus and published between 2013 and 2023. Biblioshiny on R Studio, M.S. Excel, and VoS Viewer were used in associated investigations about network graphical representation, intellectual geography, and bibliometric evaluation of sustainable machining of Alloy (Inconel) using carbide tools. The research emphasizes research patterns, publications with significant citations, significant journals, influential authors, co-occurrence analyses, and prolific nations. In order to present scholars with a more inclusive comprehension of the research related to “sustainable machining of Inconel Alloy X-750 with carbide tools,” the paper finishes by highlighting potential avenues for further and future investigations.
  Keywords: Bibliometric Analysis; Alloy X-750; Biblioshiny; Coated Carbide Tools; VoS Viewer; Sustainable Machining; Material Science.
  DOI: 10.1504/IJMMM.2025.10069319
   
  
• Cutting performance of various CNC drilling cycles at diverse cutting speeds concerning hole dimension error, surface roughness, and cutting time  
  by Sutopo Sutopo, Sentot Wijanarka, Aris Eko Wibowo, Achmad Arifin, Yu-Ren Wu 
  Abstract: Many drilling cycles with various characteristics are available in CNC machining. This study empirically verified the distinctive drilling cycles with different cutting speeds to evaluate their cutting performance. The simple/spot drilling (G81 and G82) and peck drilling (G73 and G83) were operated at various cutting speeds on the ST-37 workpiece using the HSS drill bit. The drilled-hole dimension error, surface roughness, and drilling time were measured. The results confirmed that the peck drilling achieved lower dimension error and produced smoother surfaces than the simple/spot drilling. They revealed that G73 exhibited the slightest diameter error, and G83 achieved the finest surface roughness. Further, the results demonstrated that the diameter error decreased with increasing cutting speed. Still, the high cutting speed caused rapid wear on the cutting edge of the drill bit, resulting in a rougher drilled surface. In addition, various cutting speeds did not affect the drilling time required. However, it significantly impacted the diameter error and the surface roughness.
  Keywords: CNC machining; cutting parameter; drilling canned cycle; hole dimension error; cutting time; surface roughness.
  DOI: 10.1504/IJMMM.2025.10069320
   
  
• Machinability study of hybrid epoxy/ (BaTiO3 + CaCu3Ti4O12) composite in abrasive jet machining  
  by Ajit Kumar Behera, Punyapriya Mishra, Trupti Ranjan Mahapatra, Punyatoya Mishra, Debadutta Mishra 
  Abstract: This study investigates the machinability characteristics of epoxy composites reinforced with barium titanate (BT: BaTiO3) and calcium copper titanate (CCT: CaCu3Ti4O12) using the abrasive jet machining (AJM) process. Various proportions of BT and CCT (BT:CCT=100:0, 40:60, 50:50, 60:40, 0:100) were mixed with epoxy resin matrix in a 20:80 ratio, forming requisite composite samples via compression molding. The density, microhardness, tensile, flexural, and impact strengths of the samples were measured according to ASTM standards. While density decreased as BT was replaced by CCT, the hybridization of BT and CCT exhibited improved mechanical properties. Subsequently, the machinability of these epoxy-ceramic hybrid composites was then examined using AJM with 150 mesh size silicon carbide abrasive particles. The rate of material removal (RMR) and surface roughness (Ra) were measured according to the Taguchi design of experiments, and the significance of control factors (BT and CCT proportions, pressure, and stand-off distance) was determined through ANOVA. Optimal settings of these factors for individual responses were identified, and grey relational analysis (GRA) was used for simultaneous optimization of performance characteristics.
  Keywords: Epoxy-ceramic composite; BT; CCT; Taguchi methodology; Abrasive Jet Machining; GRA.
  DOI: 10.1504/IJMMM.2025.10069321
   
  
• Experimental investigation towards achieving optimized responses of Inconel 800 by high speed dry turning  
  by SUMIT DHAR, Subhash Chandra Panja, Sovan Sahoo 
  Abstract: Inconel 800, widely used in defense, aviation, and oil refineries, is difficult to machine due to its toughness and work-hardening nature. This study examines the hard turning of Inconel 800, focusing on the impact of cutting speed, feed rate, depth of cut, and tool nose radius on key outcomes like surface roughness (SR), material removal rate (MRR), and cutting power (CP). Experiments were conducted using the Taguchi L9 orthogonal array, with analysis of variance (ANOVA) applied to determine the most significant factors. Grey Relational Analysis (GRA) was also used for multi-objective optimization. Results indicated that feed rate had the largest influence, followed by tool nose radius, cutting speed, and depth of cut. The optimal machining parameters were a cutting speed of 182 m/min, a feed rate of 0.180 mm/rev, a depth of cut of 1 mm, and a tool nose radius of 1.2 mm.
  Keywords: Inconel 800; Taguchi Method; ANOVA; Material removal rate (MRR); Surface Roughness (SR); Cutting Power (CP); Grey Relational Analysis (GRA).
  DOI: 10.1504/IJMMM.2025.10069848
   
  
• Soft Computing Based Comparative Analysis of Al/Gr/Cp5 MMC WEDM.  
  by MANGESH PHATE, Shraddha Toney, Sarang Toney 
  Abstract: The work looks at how surface roughness is predicted for an alloy based on aluminium, Al/Gr/Cp5, which is made of aluminium and graphite, during wire electro-discharge machining (WEDM).The WEDM performance of the composite was examined using methods such as artificial neural networks (ANN) and response surface-based modeling (RSM). Using Taguchi's L27 OAs and process variables such as material pulse-on-time, pulse-off-time, wire feed rate, and input current, the study examined surface properties. Significant factors influencing surface properties were found using ANOVA. The results showed that the RSM and ANN approaches were the most successful, with correlation coefficients of 0.9859 and 0.99201, respectively.
  Keywords: RSM; ANN; ANOVA; Taguchi; Surface roughness; Al/Gr/CP5.
  DOI: 10.1504/IJMMM.2025.10069849
   
  
• IMPROVEMENT OF EDM MACHINING PERFORMANCE BY BRASS COATED COPPER ELECTRODE  
  by Sivasankar Arumugam, Balamurugan Gopalakrishanan, Sivakumar Ganesan, Vivek Chandrasekaran 
  Abstract: The main objective of this work is to improve the selected output responses of EDM machining PH15-5 stainless steel material with brass coated copper electrode by controlling various process parameters such as voltage (V), current (Amp), Pulse on duration (
  Keywords: EDM; Electrode Material; Coated electrode; Brass coated copper; PH 15-5 Stainless steel.
  DOI: 10.1504/IJMMM.2025.10069850
   
  
• EFFECT OF COOLED COMPRESSED AIR ON THE MACHINING FORCE AND SURFACE ROUGHNESS GENERATED BY FACE MILLING OF CW50/PEEK  
  by Carlos Aita, André Souza, Émerson Passari, Arnaldo Gonzalez, Guilherme Schirmer, Jeferson Jesus 
  Abstract: This study examines the effect of cooled compressed air (CCA) at -60
  Keywords: Face milling; CW50/PEEK; Machining force; Surface roughness; Box-Behnken Design; Abbott-Firestone Curve; Probability Density Function; SEM.
  DOI: 10.1504/IJMMM.2025.10069852
   
  
• Optimizing Tool Flank Wear in Turning Operations Using Non-Edible Vegetable Oil-Based Cutting Fluids  
  by Balwan Singh, Tushar Gupta, Pankaj Kumar Singh, Narender Singh, Gurpreet Singh Saini 
  Abstract: The study assessed the efficacy of cutting fluids derived from non-edible vegetable oils, focusing on flood cooling during mild steel turning. Karanja and neem oils were blended in varying ratios, and MIRANDA S-400 high-speed steel tools measured flank wear during machining. The Taguchi method, employing an L9 orthogonal array, analysed the impact of cutting fluid on tool flank wear, correlating variables like cutting speed, cutting feed, and depth of cut. Statistical techniques including S/N ratio and Analysis of Variance were utilized, with Minitab 18 software for analysis. Optimal machining parameters (v1-f2-d1-CF1) were identified, resulting in a 48.30% reduction in tool flank wear. This research provides valuable insights into minimizing wear on tool flanks during machining processes.
  Keywords: Taguchi Method; Tool Flank Wear; Lathe Turning; Cutting Fluid; Karanja; Neem.
  DOI: 10.1504/IJMMM.2025.10070427
   
  
• Effect of deep cryogenic treatment on different graphite electrodes for EDM performance  
  by Israa Dheyaa Khalaf Alrubaye, Gualtiero Fantoni, Davide Melis, Massimo Arcion, Dario Clori, Francesco Grazzi, Leonardo Del Rosso 
  Abstract: In the present investigation, cryogenic treatment (CT) has been used to enhance the efficiency of electrical discharge machining (EDM). Different cylindrical electrodes, made of high-quality (QG) and standard (SG) graphite have been cryogenically treated at temperatures of 185 C and 196 C with varying soaking durations using liquid nitrogen and helium gas as a cooling system. Raman spectroscopy has been employed to monitor the microstructural changes in the graphite material. The impact of cryogenic treatment on the graphite electrode microstructure has been investigated using a scanning electron microscope (SEM). While the microstructure of the machined workpiece has been investigated using optical microscopy (OM). The EDM experiments showed that cryogenically treated standard graphite electrode for 24 h (liquid nitrogen system) reduced the total machining time by 45% and machined surface roughness by 15%, compared to untreated electrode. These findings highlight the benefits of cryogenic treatment for enhancing EDM performance when using graphite electrodes.
  Keywords: deep cryogenic treatment; electrical discharge machining; EDM; graphite electrode; cooling system; Raman spectroscopy; machined surface roughness.
  DOI: 10.1504/IJMMM.2025.10070925
   
  
• Investigation on machinability characterisation of Al7075-fly ash composite using Taguchi approach  
  by Ankit Verma, Pardeep Kumar Sood, Sant Ram Chauhan, Kali Dass 
  Abstract: In this research investigation, stir casting was used to fabricate metal matrix composites (MMCs) using (150 um) fly ash particulates as reinforcement and Al7075 aluminium alloy as the matrix. Machining tests were performed on a CNC turning machine with cermet tool insert. The addition of fly ash improved tensile strength and hardness. Microstructural analysis shows a uniform dispersion of particles. The effects of process parameters on main cutting force, power consumption and surface roughness were investigated using a L9 orthogonal array and ANOVA. Main cutting force, power consumption and surface roughness were compared to cutting speed, feed rate and depth of cut. The results showed straight proportionality with cutting speed (100180 m/min), feed rate (0.100.16 mm/rev), depth of cut (0.10.3 mm) and increased with reinforcement (2.57.5 wt. %). Microstructure, chip formation and tool wear were analysis using scanning electron microscopy.
  Keywords: metal matrix composite; Al7075; fly ash; cutting force; power consumption; surface roughness; chip formation; tool wear.
  DOI: 10.1504/IJMMM.2025.10070926
   
  
• Optimisation of surface roughness and tool wear in high-speed milling machining of INCONEL 718 using uncoated tools  
  by A.K.M. Nurul Amin, Sinthea Khatun, Tasfia Saba, Mashiat Iqbal, Md Jalal Uddin Rumi 
  Abstract: The current study investigates the application of high-speed milling techniques on INCONEL 718 using uncoated tools. The study employed nano-MQL (NMQL), incorporating a combination of palm oil and AlO at different concentrations. The effects of various control parameters, including cutting speed, feed rate, and nano-powder concentration, on surface roughness and tool wear were examined. The investigation focused on evaluating different combinations of process parameters using the design of experiments (DoE) with a central composite design (CCD) tool. The goal was to identify the most effective parameter combinations for optimal results. Mathematical models for surface roughness (Ra, Rt), tool nose wear, and flank wear were developed using ANOVA. Genetic algorithm (GA) was employed to implement an alternative optimisation approach based on the results of response surface methodology (RSM) analysis. The graphs generated through DoE were used to analyse the individual impact of parameters on responses. Surface characteristics were assessed using scanning electron microscopy (SEM).
  Keywords: surface roughness; tool nose wear; tool flank wear; response surface methodology; RSM; central composite design; CCD; genetic algorithm; GA; scanning electron microscopy; SEM; carbide tools; nano-MQL; Al2O3 nano-powder.
  DOI: 10.1504/IJMMM.2025.10071053
   
  
• Evaluation of machining parameters on specific cutting energy consumption in the turning of Al 7075 alloy in dry conditions using Taguchi and desirability approach  
  by A. Kannan, N.M. Sivaram 
  Abstract: In the present study, Al 7075 alloy was turned using an uncoated tungsten carbide cutting tool. The number of experiments conducted was 27, as per the Taguchi L27 OA design plan. Turning operation was performed without the presence of cutting fluid, which makes it to be the most sustainable form of machining. Evaluating the specific cutting energy (SCE) required to remove the unit volume of material is the novelty of the present study. Responses considered were SCE and surface roughness (Ra). Optimisation of the input parameters was executed for individual cases using the Taguchi approach, and simultaneous optimisation was carried out using the desirability approach (DA). The 100 m/min cutting speed, 0.1 mm/rev feed rate, and 1 mm depth of cut combination produces the optimal value for SCE, and the 200 m/min cutting speed, 0.05 mm/rev feed rate, and 1 mm depth of cut combination makes the optimal value for Ra, considering the individual response optimisation. This study optimised the turning of Al 7075 alloy using a tungsten carbide tool in a dry, sustainable process. Through 27 Taguchi designed experiments, optimal parameters for minimising specific cutting energy (SCE) and surface roughness (Ra) were identified. The best combined setting (200 m/min speed, 0.075 mm/rev feed, 1 mm depth) reduced SCE by 88.31% and Ra by 14.48%, achieving a low SCE of 0.166 J/mm
  Keywords: machining; Al 7075 alloy; specific cutting energy; SCE; Taguchi method; composite desirability; CD; sustainability.
  DOI: 10.1504/IJMMM.2025.10071074
   
  
• Investigating the feasibility of utilising cactus oil as a minimum quantity lubrication eco-friendly coolant for machining 42CrMo4 steel  
  by Nada K. Elbadawy, Mohamed A. Daha, Galal Ali Nassef, Ibrahem Maher 
  Abstract: Lubricants are essential in machining, serving as coolants and cutting fluids. Traditionally, petroleum-based oils were used, but their environmental impact has led to a shift towards eco-friendly options. This research investigated soluble and non-edible cactus oils as cutting fluids in minimum quantity lubrication for turning 42CrMo4 steel with cemented carbide inserts. Minitab software, Taguchi L9 orthogonal array design, and ANOVA were utilised to evaluate the effects of cutting fluid and depth of cut on surface roughness and flank tool wear. The study aimed to enhance surface roughness and tool wear. Results indicated that surface roughness decreased by 17% with soluble oil and 28% with cactus oil at a 1 mm cutting depth compared to dry conditions. Flank tool wear was reduced by 8% with soluble oil and 16% with cactus oil. Cactus oil improved surface roughness by 13% and tool wear by 9% over soluble oil at the same depth.
  Keywords: eco-friendly coolant; dry machining; cactus oil; MQL; surface roughness; flank tool wear; contact angle; dynamic viscosity; viscosity index; rheology; wettability; 42CrMo4.
  DOI: 10.1504/IJMMM.2025.10071129
   
  
• A smart swarm-based optimisation framework for computing the optimal surface finish value for machining Ti-alloy  
  by K. Srinivasulu, G. Krishna Mohan Rao 
  Abstract: High corrosion and wear resistance makes Ti-alloys the best choice for manufacturing aerospace, automobile and power plant machinery parts. Surface roughness (SR) in Ti-alloy can arise from machining processes. This paper focuses on computing the optimal value of cutting speed, feed rate, depth of cut for minimising SR of Ti-alloy under different machining conditions by uncoated, chemical vapour deposition (CVD) and physical vapour deposition (PVD) based carbide tools. For this purpose, artificial neural network (ANN) is employed to model the SR. With the help of optimal ANN parameters, the objective functions are developed which are then optimised by particle swarm optimisation (PSO) method. The result obtained from the PSO method is validated by performing a confirmatory experiment. On comparison the absolute percentage error varied in the range of 1%6% for dry, synthetic and mineral oil machining by uncoated, PVD and CVD coated carbide tools.
  Keywords: Ti-alloys; surface roughness; artificial neural network; ANN; objective functions; particle swarm optimisation; PSO.
  DOI: 10.1504/IJMMM.2025.10071383
   
  
• Machinability analysis of carbon nanotubes reinforced PMMA composites: a comparative study  
  by Prabhat Kumar Nanda, Narasingh Deep, Punyapriya Mishra, Trupti Ranjan Mahapatra, Punyatoya Mishra 
  Abstract: This study investigates the machinability criteria of carbon nanotube (CNT)-reinforced polymethyl methacrylate (PMMA) composites using ultrasonic machining (USM) and abrasive jet machining (AJM) processes. The composite materials were fabricated with varying weight percentages of CNTs, and their density, hardness, and impact strengths were acquired. The hardness improved progressively, whereas the impact strength diminished with the wt.% of CNT reinforcement. Subsequently, machining operations were carried out considering the material removal rate (MRR) and the surface roughness as the response indicators. The micrographs of the machined surfaces were also studied. The comparative analysis revealed significant differences in the machining behaviour of the CNT reinforced PMMA composites under USM and AJM. AJM exhibited higher MRRs, whereas lower surface roughness is achieved in USM.
  Keywords: carbon nanotube; CNT; PMMA composites; machinability; ultrasonic machining; USM; abrasive jet machining; AJM.
  DOI: 10.1504/IJMMM.2025.10071555
   
  
• Multi-criteria decision making approach for selecting the best Ti alloy turning parameters by analysing the influence of cutting force on surface finish under different conditions  
  by K. Srinivasulu, G. Krishna Mohan Rao 
  Abstract: Ti-alloys are known for their supreme physical properties and high industrial applications. The surface finish of the Ti-alloy is compromised when the high material removal rate desired. Hence, computing the best turning parameter of Ti-alloy is a multi-criteria decision making (MCDM) problem. Therefore, a risk minimisation based MCDM model is developed to determine the best turning parameter of Ti-alloy. The weight of the criteria is determined by the entropy method. The proposed model determined that the machining speed (MS) of 52 mm/min, feed 0.245 mm/rev, depth of cut (DOC) is 0.6 mm with synthetic oil as lubricant is the best for turning Ti-alloy by uncoated carbide tool. Whereas, MC of 96 mm/min, feed 0.29 mm/rev, DOC 0.6 mm with synthetic oil as lubricant used best for turning Ti-alloy by chemical and physical vapour deposited carbide tool. Finally, a sensitivity analysis is conducted to test the stability of the model.
  Keywords: Ti-alloy; surface finish; multi-criteria decision making; MCDM; cutting forces; surface roughness; sensitivity analysis.
  DOI: 10.1504/IJMMM.2025.10071587