International Journal of Machining and Machinability of Materials (10 papers in press)

Regular Issues

• ANALYSES OF CHIP MORPHOLOGY AND CUTTING FORCE IN THE THREADING OF AUSTENITIC STAINLESS STEEL  
  by Carlos Costa, Milton Polli, Adriano Lara 
  Abstract: Chip formation and cutting force behaviour in the threading of austenitic stainless steels are important aspects that influence the performance of the process. The present paper analyses the impact of different infeed methods on the chip morphology and main cutting force in the threading of AISI 304L stainless steel. The results showed that long helical chips were predominant for the three infeed methods. The saw-tooth profile along the edges was present in the microscopic morphology of the chip, which is a characteristic of serrated chips. Flank and incremental infeed methods resulted in better chip generation and less restriction to chip flow when compared to the radial infeed. The main cutting force increased with the number of machined workpieces due to the progressive tool wear and the consequent changes in tool geometry. Radial infeed resulted in higher main cutting force than the other methods due to the V-shaped chip formation and higher stress concentration at the tool nose that accelerated tool wear.
  Keywords: threading; stainless steel; infeed method; chip morphology; cutting force.
  DOI: 10.1504/IJMMM.2024.10067460
   
  
• Productivity Improvement in Hard Turning of AISI 4340 with Response Surface Methodology and Machine Learning  
  by Armansyah Ginting, Rotama Sidabutar, Feby Pranata, Kemal Syam, Suryadi Situmorang, Topan Fikriawan 
  Abstract: This study aims to optimise the hard turning of AISI 4340 steel to improve productivity using response surface methodology (RSM) and machine learning (ML) techniques. The novelty lies in integrating these methods to enhance material removal rate (MRR) while maintaining surface roughness (Ra) quality. Experiments were conducted with an uncoated carbide tool under dry and minimum quantity lubrication (MQL) conditions, varying cutting speed, feed, and depth of cut. RSM identified feed as the most significant factor affecting Ra, while ML, specifically linear regression (LR), predicted optimal cutting conditions. Key findings include achieving an optimum MRR of 5.2 cm3/min under dry and 7.2 cm3/min under MQL conditions, with Ra within the acceptable range (1.6
  Keywords: surface roughness; Ra; material removal rate; MRR; linear regression; LR; minimum quantity lubrication; MQL.
  DOI: 10.1504/IJMMM.2024.10067461
   
  
• Experimental investigations into surface crack density and micro hole dimensions during ultrashort pulse laser ablation  
  by Deepu P, T. Jagadesh 
  Abstract: In this work, an attempt has been made to understand the nested concentric and Z-path laser scanning paths interaction with thermal barrier coating (TBC) titanium alloy using ultrashort pulse laser. Ablation threshold is evaluated at various repetition rates (RR) and laser fluence for nested concentric and Z-path movement. Detailed investigations have been conducted to study the influence of RR, pulse overlap (PO), laser fluence, and the number of laser scans on surface crack density (SCD), hole diameter and depth. It is inferred that ablation threshold saturation is obtained after a critical RR of 20 kHz and 10 kHz for nested concentric and Z-path, respectively. Micro hole diameter and depth are highest at critical RR. Nested concentric scanning path movement provides better hole morphology than Z-path movement at 2.29 J/cm2, however, the Z-path increased the hole depth by 25
  Keywords: ultrashort pulse laser; surface crack density; SCD; laser ablation; hole diameter; hole depth; ablation threshold; thermal barrier coating; TBC.
  DOI: 10.1504/IJMMM.2024.10067462
   
  
• 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
   
  
• Study on tearing defects in high-speed milling of aluminum honeycomb core  
  by Hualin Zheng, Haoran ZHANG, Chen Huan 
  Abstract: In order to study the tearing defects formed during high-speed milling of aluminum honeycomb cores, a finite element model for cutting a single honeycomb wall was established The influence of main processing parameters on tearing defects was explored, and the variation law between tearing defects and cutting forces under different processing parameters was further analyzed The results show that when the entrance angle is in regions I and III, the force F? parallel to the honeycomb wall is the main reason for the formation of tearing defects When the entrance angle is in region II, the force F? perpendicular to the honeycomb wall has a great influence on the tearing defect The degree of tearing defects is positively correlated with the force F? parallel to the honeycomb wall in general, and the influence on tearing defects follows that the entrance angle > feed speed > cutting speed.
  Keywords: aluminum honeycomb core; finite element simulation; cutting force ; tearing defect ; milling parameter.
  DOI: 10.1504/IJMMM.2025.10068693
   
  
• Optimizing the parameters in AWJT process using a modified multiobjective DE algorithm  
  by Ishan Gawai, D.I. Lalwani 
  Abstract: This paper presents a novel multiobjective optimization algorithm for predicting the optimal control parameters of a radial abrasive water jet turning (AWJT) method. The objective is to maximize the material removal rate (MRR) and minimize the surface roughness (Ra) of the turned surface. The control parameters include water pressure, jet feed speed, abrasive flow rate, surface speed, and nozzle tilted angle. The proposed algorithm, called multiobjective amended differential evolution algorithm (MADEA), is a rank-based differential evolution (DE) algorithm that uses non-dominated sorting and crowding distance to select and update the solutions. The performance of MADEA is compared with six state-of-the-art multiobjective evolutionary algorithms on a set of benchmark test problems and the AWJT problem. The results show that MADEA can find better Pareto optimal solutions than the other algorithms.
  Keywords: Multiobjective optimization; ADEA; AWJT; Turning; ENS; Evolutionary algorithms.
  DOI: 10.1504/IJMMM.2025.10068694