International Journal of Machining and Machinability of Materials (9 papers in press)

Regular Issues

• Investigation on implementing CAD/CAM/CNC systems in machining operations with a focus on tool wear and the type of chips produced  
  by Gustavo Guilherme Dos Santos Costa, Luiz Leroy Thomé Vaughan, Feliciano Cangue, José Aécio Gomes De Sousa 
  Abstract: The manufacture of parts by machining has evolved with a focus on productivity and quality improvements. In this context, this study investigates tool wear and chip formation in cavity milling of VP50 steel using carbide ball-end inserts. Two interpolation types (linear and circular) and two tolerances (0.05 mm and 0.10 mm) were analysed. The results showed that flank wear was predominant, with circular interpolation at 0.05 mm tolerance providing better performance in terms of accuracy and stability. Tool life reached approximately 27 minutes, and chips were mainly arc-shaped and loose, with finer chips obtained under linear interpolation with 0.10 mm tolerance.
  Keywords: CAD/CAM systems; machining; tool wear; chip type.
  DOI: 10.1504/IJMMM.2025.10074911
   
  
• Quality optimisation by metaphor less algorithms: a case study of abrasive waterjet industry  
  by Paramjit Thakur, Mugdha Dongre, Ajinkya Naik, D.N. Raut 
  Abstract: Abrasive waterjet cutting is a non-traditional machining process which can cut almost every material. The major problem faced by this industry is the conflicting nature of their quality responses. In order to solve this problem, overall quality optimisation is done in this work. The quality responses considered in this work are depth of cut, depth of smooth zone, grit embedment, kerf width and roughness. Firstly, these responses are converted into a single value known as multi response performance index (MRPI) by TOPSIS. The nonlinear regression equations are framed for all the responses and MRPI and fed as input to five metaphor less algorithms (TLBO, Jaya, Rao1, Rao2 and Rao3). The optimal parameters obtained from all the five algorithms are compared and TLBO was found to be the best. Further, analysis of variance was applied to find the effect of most influential parameters given variation in responses and MRPI.
  Keywords: metaphor less algorithms; optimisation; abrasive waterjet cutting; Ti6Al4V alloy; multi-response performance index; MRPI.
  DOI: 10.1504/IJMMM.2025.10075011
   
  
• Optimisation of process parameters of electro discharge drilling for micro-hole drilling on Super Ni 276 alloy  
  by Saidulu Nakarkanti, Pappula Laxminarayana, Ashok Kumar Uppari, Karrolla Buschaiah 
  Abstract: Super Ni 276, a nickel-chromium-molybdenum alloy, is widely used in aerospace and turbine industries due to its exceptional corrosion resistance and high-temperature stability. Drilling precise micro-holes in this alloy presents significant challenges. In this study, electro discharge drilling (EDD) was employed to drill micro-holes (0.5 mm, 0.6 mm, 0.7 mm, and 0.8 mm) using copper and brass tubular tools, with process parameters such as pulse on time, pulse off time, peak current, and tool diameter varied, while voltage remained constant. An L16 orthogonal array was used for the experimental design. Key performance metrics, including tool wear rate (TWR), material removal rate (MRR), hole ovality, taper, and the heat-affected zone (HAZ), were measured to identify optimal process parameters. The results indicate that brass tools generally provide better precision with lower diameter deviations and smaller taper angles (0.0013 to 0.0113), compared to copper (0.0008 to 0.0213). However, brass tools also produce a larger HAZ due to their higher thermal conductivity, potentially increasing thermal damage to the workpiece. Copper tools, with their smaller HAZ, are more suitable for applications where thermal management is critical, while brass tools offer superior accuracy and are preferable for high-precision machining with minimal taper.
  Keywords: electro discharge drilling; EDD; heat affected zone; HAZ; material removal rate; MRR; Super Ni 276; tool wear rate; TWR.
  DOI: 10.1504/IJMMM.2025.10075135
   
  
• Prediction of heat removal rate and surface finish in MQL with coconut oil-based NCF for Inconel machining  
  by Subhash Khetre, Arunkumar Bongale, Satish Kumar 
  Abstract: The environment-friendly minimum quantity lubrication (MQL) technology is used to extend tool life at a low cost. The flow rate in MQL is lower and produces good results when compared to existing cooling techniques. The novel CBN TNMG TNMG cutting tool insert for MQL with coconut oil-based SiC-MWCNT nano cutting fluid is proposed in which cubic boron nitride (CBN) insert is used for machining of Inconel alloy 718 that has high resistance to wear, friction, and compressive stress thereby avoid the BUE formation in the workpiece and silicon carbide (SiC) and multi-walled carbon nano tubes (MWCNT) are added to coconut oil with an appropriate volume fraction for better heat removal rate from the workpiece, and tool during turning. The thermal properties of the proposed nano cutting fluid are compared with those of some existing nano MQL cutting fluids and it was found that the proposed MQL cutting fluid has a high heat removal rate and reduces friction and it improves the surface finish of the workpiece. The result obtained by the proposed model efficiently solved the existing problems with high thermal conductivity, less temperature gradient, and low surface roughness in the workpiece.
  Keywords: minimum quantity lubrication; MQL; CBN TNMG insert; Inconel 718 alloy; MATLAB Simulink; nano cutting; fluid; silicon carbide; SiC; multi-walled carbon nano tubes; MWCNT; nanoparticle; heat removal rate.
  DOI: 10.1504/IJMMM.2026.10076494
   
  
• Optimisation of wire EDM parameters for Ti-Ni SMA using multi-objective approach  
  by Rakesh Ramchandra Kolhapure, Duradundi Sawant Badkar 
  Abstract: This study investigates the optimisation of WEDM parameters of Ti-Ni SMAs for improved machining efficiency, surface integrity, and biocompatibility for biomedical implant use. Tool wear and unsatisfactory surface finish occur during conventional machining due to Ti-Ni SMA; hence, WEDM with Mo wire and deionised water was employed. A multi-objective optimisation strategy involving Taguchis L18 orthogonal array, ANOVA, and GRA was employed for the optimisation of four significant responses: MRR, SR, DD, and KW. The optimised parameter setting of 100 V, 80 us Ton, 10 us Toff, 4 A I, and 30 Hz WF improved the grey relational grade by 6.26%. SEM and EDS analysis confirmed that superior minimisation of microcracks, blowholes, and recast layer thickness (from 13.793-34.497 um to 5.306-10.959 um) took place with the retention of elemental biocompatibility. Supervised machine learning was leveraged for response prediction, with random forest (R2 = 0.59) being superior to XGBoost (R2 = 0.40). The optimised setting of 1.82% improved MRR and reduced SR by 5.01%, DD by 0.46%, and KW by 0.43%. A Ti-Ni SMA recon plate was successfully fabricated, with improved dimensional accuracy and mechanical reliability, confirming the process for biomedical implant application.
  Keywords: WEDM; shape memory alloy; SMA; Taguchi; GRA; ANOVA; SEM; EDS; supervised machine learning; SML.
  DOI: 10.1504/IJMMM.2026.10076729
   
  
• Investigation of nanoparticle-enhanced vegetable oils with minimum quantity lubrication on sustainable machining of titanium alloys  
  by Samir D. Jariwala, Shashank Thanki 
  Abstract: Titanium alloys require eco-friendly machining alternatives to hazardous conventional lubricants. This study investigates titanium machining using nanoparticle-enriched vegetable oils under minimum quantity lubrication. Cutting forces, surface roughness, and temperature are analysed with varying machining and lubrication parameters. Enhanced thermal conductivity and protective nanoparticle films promote efficient heat dissipation, reduced cutting temperature, smoother tool-workpiece interaction, and superior surface finish. Experimental results reveal cutting force initially rises with velocity due to work hardening, then decreases from thermal softening. Optimal lubrication pressure was 3 kg/cm2, while nozzle angle effects were nonlinear, peaking at 30 and minimising at 45. Nanofluid-assisted MQL reduced cutting temperature by 15%-20% and significantly improved surface finish, with palm oil + MWCNT achieving up to 52% roughness reduction. Depth of cut dominated machining response, followed by feed rate and pressure. These findings highlight that Sustainable machining can be achieved using nanoparticle-based MQL oils.
  Keywords: titanium alloys; minimum quantity lubrication; MQL; vegetable oils; nano particles.
  DOI: 10.1504/IJMMM.2026.10076730
   
  
• Analysis of the surface integrity and cutting parameters of turning Ti-6Al-4V alloy using design of experiments and a vapour compression cooling system  
  by Luis Henrique D. Araujo, Carlos Augusto N. Oliveira, Tiago L. Rolim, Rogério P. Araújo, Cezar H. Gonzalez, Edval G. Araújo 
  Abstract: This study evaluates the surface roughness in longitudinal turning of Ti-6Al-4V using pressurised cutting fluid and two design of experiments (DOE) approaches. Five input parameters were analysed: cutting speed, feed rate, depth of cut, fluid temperature, and tool radius, each at three levels. A cooling system was integrated into a CNC lathe to stabilise fluid temperature and reduce tool wear. Roughness parameters (Ra and Rz) were measured, and uncertainty analysis was applied to identify significant parameters and interactions. Feed rate had the strongest influence on both responses, while cutting speed and fluid temperature affected tool wear progression. A quadratic model best predicted Ra, with a mean absolute percentage error of 6.9%, whereas a linear model predicted Rz with an error of 3.8%. All models exhibited reliability above 95%. The results demonstrate that combining DOE with controlled cooling improves surface integrity and supports optimisation of machining parameters for Ti-6Al-4V.
  Keywords: Ti-6Al-4V alloy; design of experiments; DOE; refrigeration system; surface roughness; CNC turning.
  DOI: 10.1504/IJMMM.2026.10076920
   
  
• Experimental investigation and optimisation of machining parameters in CNC end milling of 17-4PH stainless steel  
  by Aamir Khan, Nilesh P. Ghongade, Mahesh S. Kavre 
  Abstract: This study examines the effects of cutting speed, feed rate, and depth of cut on material removal rate (MRR) and surface roughness during CNC end milling of 17-4PH (AISI 630) stainless steel using TiAlN-coated solid carbide end mills. Experiments were designed using the Taguchi L9 orthogonal array, and analysis of variance (ANOVA) identified depth of cut as the dominant factor for MRR, while cutting speed most significantly influenced surface roughness. Linear regression models were developed to predict performance, achieving prediction errors within 10% in confirmation tests. The results demonstrate that proper selection of machining parameters can simultaneously enhance productivity and surface quality. This work also addresses a notable research gap, as CNC end milling of 17-4PH stainless steel with TiAlN-coated carbide tools has received limited attention. The findings provide practical guidelines for optimising machining of precipitation-hardening stainless steels in high-precision manufacturing.
  Keywords: surface roughness; CNC end-milling; optimisation; 17-4PH stainless steel; Taguchi method; analysis of variance; ANOVA.
  DOI: 10.1504/IJMMM.2026.10077548
   
  
• Parametric analysis and multi-response optimisation of drilling of CFRP laminates  
  by K. Shunmugesh, Brijesh Paul, Partha Protim Das, Shankar Chakraborty 
  Abstract: Due to superior mechanical performance of carbon fibre-reinforced polymers (CFRPs), like higher strength-to-weight ratio, fatigue strength, temperature and corrosion resistance; they are replacing metals in many of the manufacturing industries. However, because of their poor machinability, rigorous process optimisation is required for efficient mass production and waste minimisation. This paper proposes optimisation of drilling of CFRP laminates using multi-criteria decision making (MCDM) techniques. While drilling quasi-isotropic CFRP laminates using tungsten carbide twist drills, it studies the effects of spindle speed, feed rate and drill diameter on material removal rate, and delamination factor, circularity and cylindricity of the drilled holes. The said drilling process is optimised employing four MCDM methods, i.e., weighted aggregated sum product assessment (WASPAS), combined compromise solution (CoCoSo), mixed aggregation by comprehensive normalisation technique (MACONT) and alternative ranking order method accounting for two-step normalisation (AROMAN). Criteria importance through intercriteria correlation (CRITIC) is employed for measuring the importance of the responses. It is noticed that almost all the MCDM techniques suggest higher spindle speed and drill diameter, and lower feed rate for having the desired response values. These methods appear to be quite robust against changing values of the response weights, providing almost accurate ranking results.
  Keywords: carbon fibre-reinforced polymer; CFRP; drilling; optimisation; multi-criteria decision making; hybrid.
  DOI: 10.1504/IJMMM.2026.10077690