International Journal of Machining and Machinability of Materials (6 papers in press)

Regular Issues

• Machinability study, machining performance optimization and sustainability assessment in laser micro-drilling of CNT/Epoxy nanocomposite  
  by Lipsamayee Mishra, Trupti Ranjan Mahapatra, Debadutta Mishra, Soumya Ranjan Parimanik 
  Abstract: Precision drilling of carbon nanotube (CNT)-based polymer matrix composite (PMC) is a demanding operation owing to their promising application. Laser beam machining is possibly a viable alternative to overcome the delamination, burr development, fiber pull-out, and poor surface quality problems associated with traditional drilling processes. The effectiveness of the Nd:YAG laser machining system on CNT/epoxy-based PMC is investigated in this article. The planned research aims to determine the best process parameter settings for obtaining the minimum taper and minimum heat affected zone for quality holes. The experimental investigation is performed utilizing a Box-Behnken design-based response surface methodology (BRSM) and the influence of numerous input parameters (pulse frequency, cutting speed, lamp current, and air pressure) have been discussed by various surface plots and contour plots. The whale optimization algorithm (WOA) is implemented to optimize the process parameters. Finally, confirmation tests are conducted to compare the experimental and optimal findings produced using the proposed methodology. The confirmation results prove that the WOA algorithm can be used for optimizing the machining parameters with utmost supremacy.
  Keywords: CNT polymer composite; laser micro-drilling; taper; HAZ; BRSM; WOA; Sustainability.
  DOI: 10.1504/IJMMM.2023.10052717
   
  
• High-Speed Machining of Inconel 718: Cutting Parameters Optimization Using RSM-GA Approach  
  by A.K.M. Nurul Amin, A. N. M. Amanullah Tomal, Kazi Sami Al-Jabir, Nusrat Jahan, Washima Zaman 
  Abstract: This research aims at finding suitable combination of cutting parameters for high-speed machining (HSM) of Inconel 718
  Keywords: Surface Roughness; Tool Wear; High Speed Machining; Response Surface Methodology (RSM); Genetic Algorithm (GA); Scanning Electron Microscope (SEM); Inconel 718.
  DOI: 10.1504/IJMMM.2023.10054206
   
  
• Sensor based process control of abrasive waterjet machining: a review  
  by Paramjit Mahesh Thakur, Dadarao Niwrutti Raut 
  Abstract: Abrasive waterjet technology can machine ductile, brittle, and composite materials without producing any heat-affected zone. In the competitive manufacturing field, the main goal of the manufacturer is to produce products with high quality, low cost, and in less time. All these goals can be attained by the automation of a complete abrasive waterjet system. Hence, this paper presents a review of online process monitoring of abrasive waterjet technology. Here, the overall methodology of process monitoring in abrasive waterjet technology is elaborated. The methodology involved sensor selection, signal processing, feature generation and selection, and the application of modelling techniques for prediction of responses. This review will provide the researchers with a complete source of information for online process monitoring of abrasive waterjet technology.
  Keywords: abrasive waterjet; monitoring; sensor; signal; feature selection.
  DOI: 10.1504/IJMMM.2023.10054849
   
  
• Minimization of Specific Cutting Energy consumption in the turning of Al 6063 alloy through optimization by TOPSIS approach  
  by Kannan A, N.M. Sivaram 
  Abstract: Parametric optimisation of the turning process parameters was carried out for Al 6063 alloy machined with tungsten carbide uncoated inserts using the TOPSIS approach. All experiments were performed in line with Taguchi L27 orthogonal array. Two machining characteristics namely specific cutting energy (SCE) and surface roughness were measured during the turning experiments. The optimum parameter combination was obtained for minimising SCE. By comparing the initial parameter settings with the optimum parameters, SCE consumed decreased by 84.53%. Meanwhile, an increase in surface roughness was noticed by 40.33% using a multi-response index (MRI). From the mean response value of MRI, it was found that the critical turning parameter that influences output performance is cutting speed, followed by feed rate and depth of cut. The SCE of Al 6063 alloy at the optimal parameter is 0.71 J/mm3.
  Keywords: sustainable machining; specific cutting energy; SCE; Al 6063 alloy; optimisation; TOPSIS; multi-response index; MRI.
  DOI: 10.1504/IJMMM.2023.10055395
   
  
• Machining Zinc-Aluminium alloy reinforced with SiCp composites and determination of machinability properties using commercial cutting tools  
  by Rajaneesh N. Marigoudar  
  Abstract: This paper highlights the cutting force variation during the turning trials on zinc aluminium alloy impregnated by silicon carbide particles-based composites. The necessary composite specimen with the prescribed composition is fabricated following the conventional stir-casting technique. Three different ranges of composites are fabricated containing SiC volume fractions 5%, 10% and 15%. The fabricated composite specimen is subjected to a dry turning process by employing uncoated (SNMG 090308) and coated tungsten carbide tools (SNMG 090308) under a specified set of machining variables. During each experimental machining trial, the cutting force acting on the cutting tool is measured. The impact of machining variables and composite composition on cutting force development is analysed and results are recorded. By observing the overall results of the experiment, it is observed that increased depth of cut, feed, size of the reinforcement particle and quantity of reinforcement presence in the composite cause increase in the force on the tool, on the contrary decline in the cutting force upon increasing cutting speed is observed. Coated carbide tools posed lower cutting force values in comparison with uncoated carbide tools during experimentation.
  Keywords: metal composites; zinc-aluminium; SiC; carbide tools; coatings; cutting force.
  DOI: 10.1504/IJMMM.2023.10055728
   
  
• CuO Nanoparticle Size effect on Inconel-718 turning with nanofluid minimum quantity lubrication  
  by Pravin Mane, Anupama N. Kallol, Rajendra L. Doiphode, Avinash Khadtare 
  Abstract: This study examined effect of nanofluid minimum quantity lubrication (NF-MQL) with CuO nanoparticles on Inconel 718 machinability. During turning process tribological properties (surface roughness and tool wear) and chip morphology were analysed. Minimum quantity lubrication (MQL) setup was used during turning process. L18 orthogonal array was used to conduct experimental trial. Nanoparticle size, flow rate, weight % and cutting speed used to analyse tribological properties along with chip morphology. Experimental results shows that cutting speed, particles size and flow rate are significant variable for a surface roughness and tool wear. Abrasive and chipping off wear mechanism was observed. For surface roughness 78.54 m/min cutting speed, 23 nm particle size, 0.3 wt. percentage and 160 ml/hr flow rate are the optimum conditions whereas for tool wear 78.54 m/min cutting speed, 8 nm particle size, 0.2 wt. percentage and 120 ml/hr flow rate are the optimum conditions.
  Keywords: Inconel-718; CuO; nanoparticles; roughness; wear; chip; morphology; NF-MQL.
  DOI: 10.1504/IJMMM.2023.10055979