International Journal of Machining and Machinability of Materials (8 papers in press)

Regular Issues

• Research on micro cutting mechanism of CFRP oblique milling  
  by YIWEI ZHANG, Guixin WANG, Jiexiao Yang, Mengke Yan, Junjie Tang, Panpan Hu 
  Abstract: In order to investigate the material removal mechanism of carbon fiber-reinforced polymer/plastic (CFRP) during milling, a study on CFRP spiral milling was conducted. The milling process of CFRP is simplified as bevel cutting, and a three-dimensional finite element simulation model for microscopic-level bevel cutting is established. The accuracy of the model is validated through experimental verification. By defining the cutting side as the "cutting side" and the non-cutting side as the "non-cutting side" the material removal mechanism and damage mechanism during oblique cutting are observed. It has been discovered that when the fiber cutting angle is 0
  Keywords: CFRP milling; Oblique cutting; Mechanism research; simulation model.
  DOI: 10.1504/IJMMM.2024.10065726
   
  
• Machining of Aluminium 7075-T6 alloy under dry environment using DLC coated tool  
  by Kshitij Pandey, Nidhi Mishra 
  Abstract: Excellent strength-to-weight fraction of aluminium alloys (mainly series 2XXX, 6XXX and 7XXX) makes them perfect for use in aircraft industries. Among the aluminium alloys, 7075 is used for manufacturing of shafts, gears and machine fittings. The present study include the comparative analysis of DLC coated tungsten carbide (WC) insert and uncoated WC insert during the machining of AA 7075-T6 under dry environment. T6 stands for a specific heat treatment provided to 7075 alloy resulting in enhanced mechanical properties of 7075-T6 alloy compared to conventional 7075 alloy. The performance of both inserts is compared in respect of cutting force, tool-tip temperature and wear morphology of tool.
  Keywords: aluminium 7075-T6; heat treatment; DLC coated carbide inserts.
  DOI: 10.1504/IJMMM.2024.10065727
   
  
• Comparative experimental investigation on tool wear while dry turning of SS 304 and Ti6Al4V  
  by Uttakantha Dixit, Ramesh Kumar Guduru 
  Abstract: Stainless steel 304 and titanium alloys are used extensively in aerospace, biomedical, and automotive industries due to their exceptional mechanical strength, corrosion resistance, and biocompatibility. However, their machinability is hindered by high ductility, leading to challenges in chip formation, increased tool/workpiece heating, and poor surface quality. A comparative study was conducted on tungsten carbide tools for wear during dry cutting of SS 304 and Ti6Al4V alloys. Differently prepared tools, i.e., chemically textured inserts, MoS2 lubricant coated textured inserts, TiN coated and hBN+TiN coated inserts were evaluated for their performance in terms of wear on the flank face and nose radius. Results indicated that while machining SS 304, tool wear was more pronounced due to stiction issues, whereas Ti6Al4V showed better performance. Textured and TiN coated tools exhibited superior performance when machining Ti6Al4V. These studies suggest texturing of tools add to the advantage of enhanced tool life in the turning operations.
  Keywords: stainless steel; titanium alloy; surface texture; solid lubricant; tool wear; cutting dynamics.
  DOI: 10.1504/IJMMM.2024.10065730
   
  
• Experimental investigation and FEA implementation on drilling of graphene reinforced GF/epoxy polymer nano composite laminate using coated and uncoated carbide drills  
  by Bishnu Prasad Mishra, Debadutta Mishra, Pranabini Panda, Pragyan Senapati, Trupti Ranjan Mahapatra 
  Abstract: The current study aims to explore the drilling characteristics of graphene-reinforced GF/epoxy nanocomposites via experimentation, validated by finite element analysis (FEA). Experiments involved drilling a [0/90]40s 10 mm thick laminate using 8 mm diameter uncoated and coated (TiN, TiAlN) solid carbide drills (2 flute, cone angle: 118°). Effects of coating, cutting speed, and feed rate on thrust force, torque, entry, and exit hole size were analysed. Uncoated drills exhibited the highest average thrust force (78.6 N) and torque (0.61 Nm) compared to TiAlN and TiN coated drills. TiAlN produced maximum average value of thrust force and torque of 48.4 N and 0.44 Nm, while TiN yielded maximum average value of thrust force and torque of 44.70 N and 0.35 Nm, respectively. Uncoated drills showed 27%-38% higher thrust force than TiAlN and 34%-48% higher than TiN under various cutting conditions. TiN coated drills exhibited the lowest thrust force and torque. Lower feed rates with higher spindle speeds reduced thrust force, minimising drilling-induced damage, offering valuable guidelines for high-quality drilling operations. The FEA predictions showed a maximum 10% error compared to experimental results for thrust force and torque under different drilling settings.
  Keywords: drilling; nanocomposite; grapheme; thrust; torque; finite element analysis; FEA.
  DOI: 10.1504/IJMMM.2024.10064864
   
  
• Investigation of sustainable strategies with metaheuristic algorithm on surface roughness, cutting temperature, and chip morphology during machining of Ti6Al4V alloy  
  by Sutanu Misra, Yogesh Kumar, Goutam Paul, Buddhadeb Pradhan 
  Abstract: This research work explores the effects of dry, liquid N2-based cryogenic cooling and cryogenic plus MQL hybrid strategy on surface roughness, rake surface temperature, principal cutting-edge temperature, auxiliary cutting-edge temperature, and chip morphology to understand the machinability of Ti-6Al-4V alloy using sustainable manufacturing techniques. Here, a metaheuristic algorithm approach has been introduced to determine the experimental data's accuracy, which is approximately 75% for further investigation. Logistic regression and support vector machine provided higher accuracy and best fitted with the dataset and problem formulation. During this work, it has been observed that chip morphology is influenced by cutting parameters and lubrication strategy. The cryogenic plus MQL hybrid approach is the best method over cryogenic cooling by decreasing the heat by 12% and giving 8% better surface quality.
  Keywords: metaheuristic algorithm; chip morphology; turning; cryogenic; MQL.
  DOI: 10.1504/IJMMM.2024.10065729
   
  
• Machinability investigation of S32750 super duplex stainless steel using magnetorheological fluid-assisted nano polished cemented carbide tool inserts  
  by M. Thiyagu, J. Elanchezhian, G. Anbuchezhiyan, S.K. Narendranathan, Paneerselvam Purushothaman 
  Abstract: This study investigates the nano polishing of cemented carbide tool insert surfaces using a magnetorheological fluid (MRF) assisted with diamond abrasives to improve tribological properties in the tool chip contact zone. The unique MRF assisted tool finishing process resulted in a tool insert surface roughness of less than 22.3 nm on the flank and less than 37.4 nm on the rake face. The machinability characteristics of the nano-finished inserts were investigated in the dry turning of S32750 super duplex stainless steel. Compared to unprocessed tools, MRF-assisted nano-finished tools demonstrated up to 30% longer tool life spans. The average tool life for the nano polished inserts was 27 min, compared to 19 min for the unprocessed inserts. Turning an S32750 super duplex stainless steel material resulted in an 18% reduction in cutting forces owing to the use of nano polished inserts, which also provided excellent lubricity. The results showed that nano polished inserts performed better than conventional inserts in terms of cutting force, flank wear, and surface roughness.
  Keywords: tool texturing; magnetorheological fluid; MRF; diamond abrasives; surface roughness; cutting force; rake face; flank surface.
  DOI: 10.1504/IJMMM.2024.10064862
   
  
• Influence of high magnetic field on surface roughness and temperature of Inconel 718 in dry turning operation with SiAlON ceramic cutting tool.  
  by Sukhdev B. Waghmode, Anupama N. Kallol, Rajendra L. Doiphode, Deepak M. Shinde 
  Abstract: In this research work, the high magnetic field is applied on a single-point silicon aluminium oxynitride (SiAlON) ceramic cutting tool during the turning process of Inconel 718 (In718) to check its effect on surface roughness, tool temperature, and tool wear at different cutting speeds. A neodymium magnet is used to apply the magnetic field. The machining parameters selected for experimentations are speed - 5 levels, and magnetic field - 11 levels. In the experiment, Lorentz force is developed which helps for improvement of surface roughness. The experimental results showed that tool marks caused by the tool vibration are highly reduced, resulting in improvements in surface roughness. Moreover, because of the magnetic field fine particles are removed from the cutting zone resulting in decreased tool wear. Magnetic field affected on thermal conductivity of In718 which causes tool temperature is decreased but in the case without magnetic field machining temperature is increased as speed increases.
  Keywords: Inconel 718; turning; magnetic field; surface roughness; tool wear.
  DOI: 10.1504/IJMMM.2024.10064863
   
  
• A comprehensive experimental analysis of vibration-assisted electrical discharge machining of Bohler K110 steel  
  by Mahmoud Assem, Magdy Samuel, Sara A. El-Bahloul 
  Abstract: Vibrations assisted electrical discharge machining (V-EDM) has emerged as a potent machining methodology capable of surmounting the inherent strength or hardness limitations encountered in the processing of diverse materials. Despite the well-recognised versatility of EDM, its pervasive utilisation has been impeded by constraints pertaining to lower material removal rate (MRR) and protracted machining time (MT). This study addresses this prevailing industrial challenge by endeavouring to augment the efficiency of EDM through the strategic incorporation of vibrations into the machining of Bohler K110 Steel. The investigation conducted herein systematically explores the ramifications of applying vibrations to both the dielectric fluid (DF) and the WP. The empirical findings unequivocally establish that the integration of vibrations engenders a substantial enhancement in MRR. Moreover, an elevated vibration frequency (VF) emerges as a particularly efficacious parameter, manifesting a noteworthy escalation in MRR and, consequently, a commensurate reduction in MT. Concurrently, this innovative approach exerts a discernible influence on surface roughness (SR), thereby underscoring a comprehensive amelioration in the overall quality of machining outcomes. This experimental validation substantiates the viability and practicality of V-EDM, thereby offering a promising avenue for addressing the efficiency constraints historically associated with conventional EDM methodologies.
  Keywords: V-EDM; Bohler K110 steel; vibration frequency; VF; material removal rate; MRR; machining time; MT; surface roughness; SR.
  DOI: 10.1504/IJMMM.2024.10065728