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
   
  
• Sustainable machining practices adopted during milling process: A review  
  by Sandeep Kumar Bhaskar, Manoj Kumar Sain, Praveen Saraswat 
  Abstract: Traditional machining processes have a significant contribution in the production of various structural and machine components. In this era of competitiveness and globalisation, environmental and sustainability aspects are key concern for almost all the areas including machining processes. However various non-traditional machining processes have been developed so far but traditional processes like milling are still relevant. The only requirement is to enhance these processes to achieve sustainability. This review article focuses on different aspects of adoption of various sustainable practices in milling process. During the study of literature, it was observed that researchers focused on incorporating ecological elements such as reducing cutting fluid consumption through automatic and variable flood cooling, minimum quantity and hybrid lubrication, cryogenics, etc. Improvement in the cutting tool life through tool modifications are also needed to be explored critically. These techniques may be taken up as the projecting domain of further exploration and research.
  Keywords: sustainable manufacturing; sustainable milling practices; cooling techniques.
  DOI: 10.1504/IJMMM.2024.10067458
   
  
• Experimental investigation of turning cutting-tool performance with low-cost material cutting-edge under various cutting conditions  
  by Thomas Sukardi, Paryanto Paryanto, Van-Quyet Tran, Achmad Arifin 
  Abstract: Discovering low-cost materials is still required to obtain cutting tools with better wear resistance and achieve the desired surface roughness. This study evaluated the tool performance, which utilized HASE, LASE, and HSS tip materials under different cutting conditions. The tool tips were applied to cut mild steel and S45C workpieces at various feed rates and depths of cut in turning. Then, the surface roughness and tool wear were measured to assess the tool performance. The results denoted that, for the turning on mild steel, the tool with the HASE tip had superior wear resistance and better surface roughness, particularly in thicker cuts, compared to those with HSS and LASE tips. Accordingly, the HASE tool is excellently suited for roughing work, mainly when dealing with larger depths of cut and higher feed rates. However, for the turning process on S45C, a cutting tool with a LASE tip is preferable. LASE utilization could improve the general productivity of the turning process due to its increased wear resistance.
  Keywords: Cutting tool tip; cutting conditions; cutting tool performance; surface roughness; tool wear.
  DOI: 10.1504/IJMMM.2024.10067459
   
  
• 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