International Journal of Machining and Machinability of Materials (11 papers in press)

Regular Issues

• Characterisation and machinability study of green cutting fluid developed from used edible oils as a cutting fluid in CNC machining of AISI D3 steel under MQL condition  
  by Sunil S. Jamdade, Sharad D. Patil, Udaysinh S. Bhapkar 
  Abstract: The search for biodegradable alternative has become essential because of excessive use of petroleum-based cutting fluids and their environmental impacts. This study developed bio-based cutting fluids from waste cooking oil with 65% additives and evaluated their performance in CNC turning of AISI-D3 steel under minimum quantity lubrication (MQL). The cutting oils were formulated using rust inhibitors, emulsifiers, antioxidants, non-ionic surfactants, biocides, anti-foaming agents, and polyglycols according to IS-1115 standards. The developed oils exhibited alkaline pH values (8.33-9.33) and significantly higher thermal conductivity (0.6875-0.870 W/m K) than mono-ethylene glycol (0.2467 W/m-K). Palm oil showed the highest thermal conductivity (0.870 W/m-K) and the lowest primary cutting force (108.357 N). Sunflower oil achieved the lowest tool wear (0.1162 mm) and best surface finish (0.425 m), while cottonseed oil exhibited the highest viscosity (0.004282 Pa-s), indicating superior lubrication. The developed oils were highly bio-degradable, and sustainable alternatives to conventional cutting fluids.
  Keywords: viscosity; tool wear; machining; additives; waste cooking oil; WCO; sustainable manufacturing; minimum quantity lubrication; MQL.
  DOI: 10.1504/IJMMM.2026.10080633
   
  
• Optimisation of CNC milling parameters for SS316L using bio-based MWCNT nanolubricants through Taguchi and TOPSIS approach  
  by Pavan Bhadange, Satypal Warghat, Sachin Solanke, Chinnarao Kurangi, Prashant Renushe, Ajinkya Lale 
  Abstract: The present study investigates the role of bio-based nanolubricants in the machining of SS316L stainless steel during industrial CNC milling. Performed experiments were designed using L9 Taguchi orthogonal array considering lubrication type, cutting speed, and depth of cut as input parameters. Three lubrication environments were evaluated like conventional soluble cutting oil, palm oil reinforced with MWCNT and neem oil reinforced with MWCNT. The machining performance investigated in terms of material removal rate and surface roughness. Experimental results indicate that cutting speed and depth of cut significantly influence MRR, lubrication type mostly affects surface roughness. Statistical analysis using Taguchi signal-to-noise ratios and ANOVA confirmed the significance of the selected parameters. TOPSIS was used to evaluate overall machining performance. Results demonstrate the potential of novel bio-based nanolubricants as sustainable alternatives to regular conventional cutting fluids for high performance machining of SS316L.
  Keywords: SS316L; nanolubrication; CNC milling; Taguchi optimisation; TOPSIS; multi-walled carbon nanotubes; MWCNTs.
  DOI: 10.1504/IJMMM.2026.10080864
   
  
• Performance Analysis of Gear Hobbing in terms of Accuracy, Productivity and Sustainability of Spur Gears Produced under Flooded and MQL Conditions  
  by Arif Pathan, Dhananjay Dolas, Munjadas Kadam 
  Abstract: The frequent operation of one-phase loads in three-phase systems and the growing demand for nonlinear demands are major contributors to grid-connected systems power quality issues. It consequently results in an undesired power quality issue that is characterised by changes in the electrical systems waveforms, voltage levels, and current. Compared to power quality issues connected to current, normal voltage-related issues cause a major interruption in the network. Through a sequential process, the integrated series active pass filter provides the grid with the required voltage while efficiently reducing the harmonics caused by nonlinear demands that are connected to the grid. This project focuses on the creation of an adaptive neuro-fuzzy inference system for the controller. The purpose of this controller is to minimise the active filter rate while producing the reference voltage signals. The MATLAB 2020b/Simulink platform was used for the simulation analysis.
  Keywords: microgeometric deviations; flooded; MQL; sustainability; cutting oil; performance characteristics; MRR.
  DOI: 10.1504/IJMMM.2026.10081059
   
  
• Experimental study of high quality small hole fabrications in superalloy  
  by Mingze Tang, Xiang Cheng, Jiankun Liang, Enzhao Cui, Junfeng Zhang, Huanbao Liu 
  Abstract: Superalloy is a typical difficult-to-cut material and small hole fabrication on it is even more challenging. To identify the suitable cutting process and optimise high-quality small hole fabrication on superalloys, this paper experimentally studies the quality defects occurring in small hole machining of nickel-based superalloy GH4169. Firstly, comparative analyses by drilling and helical milling processes have been conducted based on the selected key evaluation indicators as the exit burr height H, diameter deviation D and taper . Secondly, RSM experiments have been conducted to explore the relationships between evaluation indicators with critical experimental parameters (spindle speed n, tangential feed per tooth fzt, axial depth of cut ap) of the helical milling process. Optimal parameter combinations have been identified. At last, comparative experiments have been conducted to make validations. It turns out that the key indices H, D, have been reduced by 64.39%, 51.45% and 63.75%, respectively.
  Keywords: nickel-based superalloy; helical milling; drilling; burr height; diameter deviation; taper.
  DOI: 10.1504/IJMMM.2026.10081480
   
  
• Geometry dependent surface integrity in semi-circular ball nose milling of ultra-high molecular weight polyethylene  
  by Shukri Zakaria, Mahamad Hisyam Mahamad Basri, Mohamad Irwan Yahaya, Wan Nor Shela Ezwane Wan Jusoh 
  Abstract: This study investigates geometry-dependent surface roughness and dimensional accuracy during semi-circular ball nose milling of ultra-high molecular weight polyethylene (UHMWPE). Using response surface methodology (RSM) and central composite design (CCD), the effects of spindle speed, feed rate, and depth of cut were evaluated. Surface roughness and CMM-based circularity analyses revealed that continuously varying cutter engagement significantly dictates the machining responses. The developed regression model (R2 = 0.928) identified spindle speed as the dominant parameter. Higher spindle speeds successfully compensated for reduced effective cutting speeds along the curved profile, mitigating localised viscoelastic rubbing and promoting stable chip formation. Ultimately, this integrated evaluation proves that dynamic geometric changes strictly govern surface integrity, providing a fundamental mechanism-based framework for optimising the machining of highly compliant polymers.
  Keywords: UHMWPE; ball nose milling; semi-circular milling; surface integrity; response surface methodology; RSM; circularity; dimensional accuracy; polymer machining.
  DOI: 10.1504/IJMMM.2026.10081651
   
  
• Drilling performance on flax/PP composite via microwave power: a parametric study  
  by Pankaj Kumar, P. Sudhakar Rao, Rampal, Nishant Verma 
  Abstract: In the present study, MwD of flax-reinforced polypropylene composites (FRPCs) was experimentally investigated using a CNC-controlled modified microwave system. The effects of microwave power (180720 W) and concentrator feed rate (100130 mm/min) on hole quality characteristics material removal rate (MRR), tool wear rate (TWR), heat affected zone (HAZ), taper angle, circularity error, and overcut were systematically analyzed. Experimental results showed that microwave power significantly governs plasma stability and hole geometry, while feed rate primarily influences thermal damage and dimensional accuracy. Multi-criteria decision-making (MCDM) using TOPSIS combined with equal weight, entropy, and CRITIC methods identified an optimal condition of 720 W microwave power and 110 mm/min feed rate, yielding minimum HAZ, overcut, circularity error, and taper with maximum MRR. The study establishes MwD as an effective drilling technique for FRPCs and provides optimised process parameters for improved hole quality.
  Keywords: composites machining; microwave power assisted machining; drilling; process optimisation; material removal rate; MRR; natural fibre.
  DOI: 10.1504/IJMMM.2026.10081963
   
  
• Optimisation of EDM parameters for 6061-T6 aluminium alloy using AHP-TOPSIS framework and ANOVA validation  
  by Alaa M. Ubaid, Shukry H. Aghdeab, Shakir M. Mousa 
  Abstract: This study aims to determine the optimal EDM conditions for machining 6061-T6 aluminium alloy using a copper electrode and to identify the statistical significance of the principal machining parameters. A structured optimisation framework integrating design of experiments (DoE), the analytic hierarchy process (AHP), the technique for order preference by similarity to ideal solution (TOPSIS), and analysis of variance (ANOVA) was applied. Three input parameters, current, pulse-on time, and pulse-off time, were examined against three performance measures: material removal rate (MRR), electrode wear rate (EWR), and microhardness (MH). Based on an L27 orthogonal array and multi-criteria ranking, the optimal parameter combination was 20 A current, 150 μs pulse-on time, and 50 μs pulse-off time, yielding 5.5125 g/min MRR, 1.24% EWR, and 107.76 HV microhardness. ANOVA results confirmed current as the most influential factor, pulse-on time as a secondary factor with borderline significance, and pulse-off time as statistically negligible.
  Keywords: electrical discharge machining; EDM; optimisation; analytic hierarchy process; AHP; technique for order preference by similarity to ideal solution; TOPSIS; analysis of variance; ANOVA; 6061-T6 aluminium alloy.
  DOI: 10.1504/IJMMM.2026.10080206
   
  
• 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
   
  
• 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 optimisation and cutting tool performance analysis in turning of AISI 301 stainless steel  
  by M. Venkata Ramana, G. Krishna Mohana Rao, D. Mansingh 
  Abstract: AISI 301 stainless steel is used for applications demanding good ductility, strength, and corrosion resistance, excelling in automotive, aircraft parts, etc. The plan of this work is to examine the optimum of process parameters and effect of parameters in turning of AISI 301 stainless steel through experimental work on cutting force and surface roughness. Trials are conducted by employing PVD coated and uncoated tools under minimum quantity lubrication (MQLn), dry, and nano MQLn environments using analysis of mean and analysis of variance (ANOVA). Investigational results indicated that the PVD coated tool reduced the cutting force in MQLn with nano cutting fluid condition. The uncoated tool minimised the surface roughness under MQLn conditions. Based on the ANOVA results, the depth of cut is the important process parameter influencing more on cutting force. The feed is highly substantial process parameter contributing to surface roughness under dry and MQLn machining environments.
  Keywords: Taguchi's optimisation; uncoated tools; PVD coated tools; AISI 301 stainless steel; dry machining; minimum quantity lubrication machining; nano MQLn machining.
  DOI: 10.1504/IJMMM.2026.10079283
   
  
• Statistical texture analysis of hydrophobic microstructures fabricated on CFRP using reverse μ-EDM  
  by Suresh Pratap, Pradyut Anand, Somak Datta 
  Abstract: This study fabricates and statistically evaluates hydrophobic micro-dimple, groove, and cross-hatched textures on T300 CFRP using reverse μ-EDM. Surface characterisation via microscopy, profilometry, and contact angle measurements was paired with ISO 25178 areal parameters and statistical descriptors (skewness, kurtosis). Process fidelity was high, with errors < 3% and variation < 10%. While the mean dimensions matched the designs, skewness and kurtosis revealed distributional asymmetries. Regression showed that contact angles (132°-152°) were strongly correlated with statistical descriptors, such as skewness (R² = 087), outperforming simple geometric descriptors. Statistical texture analysis is thus a robust tool for predicting hydrophobicity and ensuring reproducibility in scalable aerospace CFRP fabrication.
  Keywords: reverse μ-EDM; hydrophobic microtextures; statistical surface analysis; CFRP machining; micromachining.
  DOI: 10.1504/IJMMM.2026.10079964