Machined Aluminum Research Articles

Experimental Investigation on Surface Roughness and Metal Removal Rate of Aluminium 2024 Alloy

Abstract: The purpose of this work is to investigate experimentally the surface roughness and MRR while machining of aluminium 2024 alloy which is prepared by powder metallurgical technique. Aluminium 2024 alloy prepared with different composition such as Pure Al, 1.5 W% of Mg and 2-6 % of Cu powders. Powders are blended with ball milling machine according to the composition required and specimens are prepared in square shape die (25*25mm) by applying uniaxial load of 200Mpa. The sintering process was performed at 594 0C for 60 min and cooled at room temperature. SEM and XRD analysis was carried out to know various characteristics like green density, dimensional changes during sintering, sintering density, mechanical properties and microstructures. Finally the Surface roughness and MRR during machining with CNC milling machine at different depth of cuts was also evaluated. Keywords: Aluminium 2024 alloy, surface roughness, MRR, SEM and XRD analysis

Modeling and Optimization of Cut Quality Responses in Plasma Jet Cutting of Aluminium Alloy EN AW-5083.

The plasma jet cutting process has a high potential for the machining of aluminium and its alloys. Aluminium is well known as a highly thermally conductive and sensitive material, and because of that there exist uncertainties in defining process parameters values that lead to the best possible cut quality characteristics. Due to that, comprehensive analysis of process responses as well as defining optimal cutting conditions is necessary. In this study, the effects of three main process parameters—cutting speed, arc current, and cutting height—on the cut quality responses: top kerf width, bevel angle, surface roughness Ra, Rz, and material removal rate were analyzed. Experimentations were conducted on aluminium EN AW-5083. In order to model relations between input parameters and process responses and to conduct their optimization, a novel hybrid approach of response surface methodology (RSM) combined with desirability analysis was presented. Prediction accuracy of developed responses regression models was proved by comparison between experimental and predicted data. Significance of process parameters and their interactions was checked by analysis of variance (ANOVA). Desirability analysis was found as an effective way to conduct multi-response optimization and to define optimal cutting area. Due to its simplicity, the novel presented approach was demonstrated as a useful tool to predict and optimize cut quality responses in plasma jet cutting process of aluminium alloy.

Hybrid additive and subtractive manufacturing of multi-material objects

Purpose This study presents a method for fabricating multi-material objects using a hybrid additive and subtractive approach. By hybridizing the material composition in addition to the fabrication process, functional requirements can be met more effectively than through homogenous material parts produced using a single manufacturing process. Development of multi-material objects consisting of dissimilar materials that have been hampered by a lack of a structural interface compatible with in-envelope hybrid additive and subtractive manufacturing. Design/methodology/approach This research presents a novel method for producing multi-material components through in-envelope hybrid additive and subtractive manufacturing. This study attempts to address the absence of a metal-polymer interface by integrating polymer additive manufacturing into a five-axis mill. The ability of the polymer additive system to reproduce overhang geometries is assessed with different levels of cooling. The relationship between structural performance, cooling and material flow rate is evaluated for the deposited carbon fiber reinforced acrylonitrile butadiene styrene. Findings A mechanically interlocking root structure is developed to form an interface between a machined aluminum region and a polymer region of an object. The tensile strength of the metal-polymer object is measured and found to be on the same order of magnitude as the bulk three-dimensional printed polymer. Originality/value By targeting the material properties to the local functional requirements within a part and taking advantage of both additive and subtractive manufacturing processes, this study will enable broader design options and optimization of performance metrics.

Investigation and optimization of machining through hole by abrasive water jet machining in AA6063/Bagasseash/TiN hybrid composites

ABSTRACT This study aims to analyze the influence of parameters on Abrasive Water Jet Machining of aluminum (AA6063) composites reinforced with bagasse ash and titanium nitride particles. Bagasse ash and titanium nitride were reinforced in the aluminum alloy by the stir casting technique. Mathematical equations were derived by response surface methodology and the results were analyzed by ANOVA technique. The material removal rate and surface roughness were studied by varying the traverse speed, standoff distance, bagasse ash and titanium nitride. Characterizations of the machined surfaces were analyzed using scanning electron microscopy and atomic force microscopic study. Material removal rate and surface roughness are primarily influenced by standoff distance followed by traverse speed and titanium nitride particles. Microstructure reveals erosion mechanisms in the form of plowing, ridges, cavities, micro-cracks, tearing, deformation, etc. The abrasive machining results and optimization provides a database for various industrial applications.

Performance Investigation of the Effects of Nano-Additive-Lubricants with Cutting Parameters on Material Removal Rate of AL8112 Alloy for Advanced Manufacturing Application

The implementation of nano-additives in machining fluid is significant for manufacturers to attain a sustainable manufacturing process. The material removal rate (MRR) is a significant process of transforming solid raw materials into specific shapes and sizes. This process has many challenges due to friction, vibration, chip discontinuity when machining aluminum alloy, which has led to poor accuracy and affected the fatigue life of the developed material. It is worth noting that aluminum 8112 alloy is currently being applied in most engineering applications due to its lightweight-to-strength ratio compared to some other metals. This research aims to compare the effects of copra oil-based-titanium dioxide (TiO2)- and Multi-walled Carbon Nanotubes (MWCNTs)-nano-lubricant with cutting parameter interactions by conducting a study on MRR for advanced machining of aluminum 8112 alloys. The biodegradable nano-additive-lubricants were developed using two-step preparation techniques. The study employed a quadratic rotatable central composite design (QRCCD) to carry out the interaction study of the five machining parameters in the three lubrication environments on MRR. The results show that the copra-based-TiO2 nano-lubricant increases the MRR by 7.5% and 16% than the MWCNTs and copra-oil-lubrication machining environments, respectively. In conclusion, the eco-friendly nano-additive-lubricant TiO2-Copra oil-based should be applied to manufacture machine parts for high entropy applications for sustainable production systems.

Extraordinary Nanocrystalline Pb Whisker Growth from Bi-Mg-Pb Pools in Aluminum Alloy 6026 Moderated through Oriented Attachment.

The elucidation of spontaneous growth of metal whiskers from metal surfaces is still ongoing, with the mainstream research conducted on Sn whiskers. This work reports on the discovery of Pb whisker growth from Bi-Mg-Pb solid pools found in common machinable aluminum alloy. The whiskers and hillocks display unique morphologies and complex growth that have not been documented beforehand. In contrast to typical understanding of whisker growth, the presented Pb whiskers show a clear nanocrystalline induced growth mechanism, which is a novel concept. Furthermore, the investigated whiskers are also found to be completely composed of nanocrystals throughout their entire length. The performed research gives new insight into nucleation and growth of metal whiskers, which raises new theoretical questions and challenges current theories of spontaneous metal whisker growth. Additionally, this work provides the first microscopic confirmation of recrystallization growth theory of whiskers that relates to oriented attachment of nanocrystals formed within an amorphous metallic matrix. The impact of mechanical stress, generated through Bi oxidation within the pools, is theoretically discussed with relation to the observed whisker and hillock growth. The newly discovered nanocrystalline growth provides a new step towards understanding spontaneous metal whisker growth and possibility of developing nanostructures for potential usage in sensing and electronics applications.

Cyber-Physical System Implementation for Manufacturing With Analytics in the Cloud Layer

Abstract Effective and efficient modern manufacturing operations require the acceptance and incorporation of the fourth industrial revolution, also known as Industry 4.0. Traditional shop floors are evolving their production into smart factories. To continue this trend, a specific architecture for the cyber-physical system is required, as well as a systematic approach to automate the application of algorithms and transform the acquired data into useful information. This work makes use of an approach that distinguishes three layers that are part of the existing Industry 4.0 paradigm: edge, fog, and cloud. Each of the layers performs computational operations, transforming the data produced in the smart factory into useful information. Trained or untrained methods for data analytics can be incorporated into the architecture. A case study is presented in which a real-time statistical control process algorithm based on control charts was implemented. The algorithm automatically detects changes in the material being processed in a computerized numerical control (CNC) machine. The algorithm implemented in the proposed architecture yielded short response times. The performance was effective since it automatically adapted to the machining of aluminum and then detected when the material was switched to steel. The data were backed up in a database that would allow traceability to the line of g-code that performed the machining.

Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study

In this work, wire electrical discharge machining (WEDM) of aluminum (LM25) reinforced with fly ash and boron carbide (B4C) hybrid composites was performed to investigate the influence of reinforcement wt% and machining parameters on the performance characteristics. The hybrid composite specimens were fabricated through the stir casting process by varying the wt% of reinforcements from 3 to 9. In the machinability studies, the WEDM process control parameters such as gap voltage, pulse-on time, pulse-off time, and wire feed were varied to analyze their effects on machining performance including volume removal rate and surface roughness. The WEDM experiments were planned and conducted through the L27 orthogonal array approach of the Taguchi methodology, and the corresponding volume removal rate and surface roughness were measured. In addition, the multi-parametric ANOVA was performed to examine the statistical significance of the process control parameters on the volume removal rate and surface roughness. Furthermore, the spatial distribution of the parameter values for both the responses were statistically analyzed to confirm the selection of the range of the process control parameters. Finally, the quadratic multiple linear regression models (MLRMs) were formulated based on the correlation between the process control parameters and output responses. The Grass–Hooper Optimization (GHO) algorithm was proposed in this work to identify the optimal process control parameters through the MLRMs, in light of simultaneously maximizing the volume removal rate and minimizing the surface roughness. The effectiveness of the proposed GHO algorithm was tested against the results of the particle swarm optimization and moth-flame optimization algorithms. From the results, it was identified that the GHO algorithm outperformed the others in terms of maximizing volume removal rate and minimizing the surface roughness values. Furthermore, the confirmation experiment was also carried out to validate the optimal combination of process control parameters obtained through the GHO algorithm.

WITHDRAWN: Surface roughness modelling in wire EDM machining aluminium of Al6061 composite by ANFIS

Abstract This research aims to analyze the impact of wire electrical discharge machining factors on execution parameters to improve the usefulness with a higher surface finish of Al6061/SiC/Graphite composite by utilizing the artificial intelligent strategy. In this trial examination, the adaptive network based fuzzy inference system (ANFIS) model has been profoundly evolved and the multi-parametric improvement has been done to track down the ideal answer for the machining of Al6061/SiC/Graphite composite. Factors like heartbeat on schedule, beat off time, current and wire speed were chosen set up the exhibition qualities of WEDM like surface unpleasantness. Central composite Design (CCD) of response surface methodology (RSM) is utilized to dissect the impacts of huge machining parameters on the exhibition attributes. The surface finish was considered as output reactions. The effect on machining execution has been broke down by the ANFIS model and the created model was approved with the full factorial relapse models. The created models showed the base mean rate blunder and this technique showed the significant improvement simultaneously. The ANFIS model forecast made with Trapezoid participation type 1.67 % given the normal error rate. The qualities anticipated by the created model are contrasted and the trial esteems and it is uncovered that there is a relationship among the exploratory qualities and the anticipated qualities which are from the created ANFIS model. At last, it has additionally affirmed that the technique for crossover RSM and ANFIS approach is a viable answer for streamlining.

Some Experimental Investigations in the Performance of Electochemical Machining Process.(Dept.M)

A rigid abright drill provided the ratory motion for a brass disc employed as the tool having no embeded abrasive material, Sodium Chloride and Sodium Hydroxide having different concentrating rates between (10% - 50%) were employed as electrolytes covering the gab between the tool and workpieces. Mild steel, free machining -rass and pure aluminum in the as-received conditions were employed as workpieces. Material removal rates were found to be greater for smaller gap widths, higher speed of revolution, greater gap voltage, higher percentages of electrolyte conceration and greater electrolyte velocity for all workpiece materials especially when using sodium chloride. As the material removal rate increases, consequently workpiece surface temperature rises. Such temperature rises all-over the entire range did not exceed + 30°C. Workpiece surface finish were found to improve for higher rates of material removal for mild steel and free machining brass only. No such improvements were noted after aluminum machining except at high tool speeds. Deep scatered scratchs in aluminum specimens were noted at lower tool speeds.

Effectivity of homecare and professional biofilm removal procedures on initial supragingival biofilm on laser-microtextured implant surfaces in an ex vivo model

BackgroundThe aim of the current study was the evaluation of initial biofilm adhesion and development on laser-microtextured implant collar surfaces and the examination of effectivity of different biofilm management methods.MethodsInitial biofilm formation was investigated on hydrophobic machined and laser-microtextured (Laser-Lok) titanium surfaces and hydrophobic machined and laser-microtextured (Laser-Lok) titanium aluminium vanadium surfaces and compared to hydrophobic smooth pickled titanium surfaces, hydrophilic smooth and acid etched titanium surfaces, hydrophobic sandblasted large grid and acid etched titanium surfaces (titanium Promote) via erythrosine staining and subsequent histomorphometrical analysis and scanning electron microscopic investigations. After decontamination procedures, performed via tooth brushing and glycine powder blasting, clean implant surface was detected via histomorphometrical analysis.ResultsAfter 24 h mean initial plaque area was detected in the following descending order: smooth pickled titanium > titanium Promote > hydrophilic smooth and acid etched titanium > Laser-Lok titanium > Laser-Lok titanium aluminium vanadium. The same order was determined after 48 h of biofilm formation. After glycine powder blasting all samples depicted almost 100% clean implant surface. After tooth brushing, Laser-Lok titanium (67.19%) and Laser-Lok titanium aluminium vanadium (69.80%) showed significantly more clean implant surface than the other structured surfaces, hydrophilic smooth and acid etched titanium (50.34%) and titanium Promote (33.89%). Smooth pickled titanium showed almost complete clean implant surface (98.84%) after tooth brushing.ConclusionsBoth Laser-Lok surfaces showed less initial biofilm formation after 24 and 48 h than the other implant surfaces. In combination with the significant higher clean implant surfaces after domestic decontamination procedure via tooth brushing, both Laser-Lok surfaces could be a candidate for modified implant and abutment designs, especially in transmucosal areas.

Researching of the Efficiency on the Application for Complex Processing in Obtaining the Different Types of Surfaces

The influence of the effect of combining different types of processing based on the physical force acting on the surface of conductive materials and the electrochemical active action of electrolytes acting as a cutting fluid is considered. The experiments carried out and show a significant effect of these types of processing on the surface quality and the provision of the initial various physical and mechanical properties of the processed materials. The article presents various dependencies of qualitative parameters for the implementation of shaping processes using such blade processing operations as turning, threading in holes of small diameter and expanding the holes. With combined processing methods, the process of forming the finish surface is due to the combined action of the cutting tool and the anodic dissolution of the metal under the influence of an electric current in the electrolyte solution. The application of this method allows obtain higher quality parameters when machining aluminum and copper alloys, the surface formed during processing, including the preservation of such special characteristics of certain materials, such as porosity.

Optimization of EDM Process Parameters on Machining Characteristics of SiC and Graphene Reinforced Al 6061-T6nano-Composites

Aluminum composites play an important role in various applications due to their low weight to strength ratio, high corrosive resistance, etc. As reinforcement materials, Graphene and SiCnano particles were used. Since, they havea high melting point, young modules, strong electrical and thermal properties etc. Electrical Discharge Machining (EDM) is one of the non-conventional machining techniques widely used for the machining of hard materials such as composites. The aim of current work is to evaluate the influence of EDM process parameters such as peak current, pulse on-time, voltage and flushing pressure on machining of Aluminium 6061 reinforced with 0.5 wt% SiC and 0.5 wt% Graphene nanoparticles. Al-based Metal Matrix Composite was casted by using liquid processing technique i.e. Stir Casting. Taguchi’s Design of Experiments was used to evaluate the effect of process parameters on machining characteristics i.e. Material Removal Rate (MRR) and Tool Wear Rate (TWR) of developed composite. From the results it was observed that peak current is the most influencing factor on MRR and TWR followed by other parameters.

Defect Analysis through the Implementation Statistical Quality Control Tools on VMC Machined Aluminium Component

Defect Analysis through the Implementation Statistical Quality Control Tools on VMC Machined Aluminium Component

Assessment of Tool Wear and Surface Integrity in Ductile Cutting Using a Developed Tool

Machined parts of aluminum alloys are used in a wide range of engineering applications, such as automobile parts. Many types of tool wear may occur during machining of these alloys, which reduces tool life. Therefore, it is beneficial to undertake comprehensive studies to improve tool life (reduce tool wear) in machining aluminum alloys. In the present study, the micro-textured cutting tool's performance is compared to the non-textured tool with chip breaker (and without chip breaker) when used cutting fluid under different cooling-lubrication methods. A literature review denoted that no experimental work is available for a comparison study between texture and chip breaker performance. Scanning electron microscope (SEM) images and energy-dispersive X-ray spectroscopy (EDX) were utilized to analyze the workpiece's surface. Although many scholars have stated that the chip breaker has a good effect on cutting performance, this research showed that the chip breaker has no positive effect on reducing tool wear in aluminum machining. Nonetheless, the SEM images denote a maximum of 30% and 36% improvement in surface quality and tool life, respectively, a considerable decrease in adhesion, abrasion, and breakage wear, and a drastic reduction in the density of defective regions in the workpiece surface when the optimum micro-textured tool was used.

WITHDRAWN: Cryogenic treatment effect on tool tip temperature during milling process

Abstract The cutting tool industry is striving towards making low cost, but high performance tools available to the industry, which gives good finish and dimensional accuracy that can eliminate subsequent operations like grinding. One such tool is found to be molybdenum based M2 HSS tool, which has been widely used in the industry. Added to this, cryo treatment of this tool has been found to improve the toughness of this tool and increase the productivity, which in turn can bring economic benefits. With this background, the authors in previous publication have compared the machining parameters machining force, machining power and surface roughness and their optimization while machining aluminum AL6351 using deep cryo-treated Molybdenum M2 tool. Considering very little is reported on the effect of the cryo-treated tool on tool tip temperature this paper presents this aspect along with micro-structural analysis of the machined material. Obtained results have been analyzed by statistical method to authenticate the findings. While the tool tip temperature showed that the tip temperature for the treated tool was about 10% lower than that of the untreated tool, machining operation at higher speeds, higher feed and higher depth of cut compared to those with untreated tool without losing surface finish.

Study on roughness and form errors linked with tool wear in the drilling process of an Al-Si alloy under high cutting speed using coated diamond-like carbon high-speed steel drill bits

• High cutting speed can reduce cycle time, but it can increase cutting tool wear. • High-speed steel is used in machining processes, having cutting speed limitations. • Aluminum alloys are used in mechanical parts it requires high cutting parameters. • DLC application is an alternative to reduce cutting tool wear at high cutting speed. • Process parameters are essential to ensure product quality, roughness and form errors. Materials engineering development has led to steel and cast iron replacement by Aluminum-Silicon – Al-Si alloys in various applications due to the adequate good strength-to-weight ratio and corrosion resistance. These features of Al-Si are extremely relevant for the performance improvement of many products by applying this alloy instead of the usual materials. However, studies have shown that the machinability of these materials presents multiple negative aspects, such as adhesion and abrasion. Therefore, optime cutting parameters and tools need to be selected to combine tool life with product quality. Using hard coatings with high chemical inertia, such as Diamond-Like Carbon (DLC), has shown promising results when machining aluminum alloys. Generally, in drilling, roughness, deviations in diameter, circularity and cylindricity represent the quality of a hole. Cutting speed directly influences tool wear and hole quality. Thus, this study aimed to evaluate the quality of holes machined using high-speed steel tools in an Al-Si alloy on the influence of cutting speed and the use of DLC coating. Tools with brazed Polycrystalline Diamond (PCD) are usually chosen for machining aluminum alloys, which can absorb high cutting speeds. In this paper, the replacement of brazed PCD is studied for high-speed steel coated with a thin film that can guarantee the same performance. The tests were carried out varying the cutting speed (V) in 340, 360, and 430 m/min, comparing DLC coated with uncoated tools. Flank wear was analyzed after each machining run using Scanning Electron Microscopy (SEM). The results showed that cutting speed directly influences the roughness, diameter variation, and flank wear. DLC coating did not show hole quality improvements as it presented adhesion problems on the high-speed steel substrate.

Reaction screening in multiwell plates: high-throughput optimization of a Buchwald-Hartwig amination.

Chemical space is vast, and chemical reactions involve the complex interplay of multiple variables. As a consequence, reactions can fail for subtle reasons, necessitating screening of conditions. High-throughput experimentation (HTE) techniques enable a more comprehensive array of data to be obtained in a relatively short amount of time. Although HTE can be most efficiently achieved with automated robotic dispensing equipment, the benefits of running reaction microarrays can be accessed in any regularly equipped laboratory using inexpensive consumables. Herein, we present a cost-efficient approach to HTE, examining a Buchwald-Hartwig amination as our model reaction. Experiments are carried out in a machined aluminum 96-well plate, taking advantage of solid transfer scoops and pipettes to facilitate rapid reagent transfer. Reaction vials are simultaneously heated and mixed, using a magnetic stirrer, and worked up in parallel, using a plastic filter plate. Analysis by gas chromatography provides the chemist with 96 data points with minimal commitment of time and resources. The best-performing experiment can be selected for scale-up and isolation, or the data can be used for designing future optimization experiments.

The recent trends of EDM applications and its relevance in the machining of aluminium MMCs: A comprehensive review

In the recent few years, owing to the versatility of electro discharge machining, its use hasn’t just been limited to the usual precision material removal process but also extended to the areas of micro machining, micro impressions, machining of difficult-to-machine materials etc. With the development of high hardness advanced materials like metal matrix composites, there is also an increasing research interest developed among the researchers across the globe in non-conventional machining process like EDM (Electro Discharge Machining) on such materials. In this review work, the recent exploration of EDM in various fields of research such as medical implants, food industry, super-alloys, etc. are being discussed and reviewed the process control parameters for EDM machining of aluminium based MMCs (metal matrix composites), reported by some of the researchers across the globe.

Comparative performance analysis of cemented carbide, TiN, TiAlN, and PCD coated inserts in dry machining of Al 2024 alloy

Dry machining of aluminum (Al) 2024 alloy has been performed with four different cutting inserts (cemented carbide, titanium nitride (TiN) coated, titanium aluminum nitride (TiAlN) coated, and polycrystalline diamond (PCD) coated), and their performance is assessed for tool wear and workpiece surface roughness. Design of experiments and response surface methodology (RSM) was performed to optimize the cutting parameters. TiAlN coated inserts presented an average ≈ 21%, ≈ 36%, and ≈ 58% less tool wear than the uncoated cemented carbide, TiN and PCD coated inserts, respectively. While TiN coated inserts exhibited an average ≈ 17%, ≈ 37%, and ≈ 42% less workpiece surface roughness than the uncoated cemented carbide, TiAlN, and PCD coated inserts, respectively. PCD coated inserts have greater mechanical properties, but due to the poor adhesion strength of the coating, it performed worst regarding tool wear and workpiece surface roughness. Energy dispersive X-ray spectroscopy (EDX) analysis of the chips validated our findings that the adhesion of coated tools is also very important for the evaluation of machining performance other than mechanical properties. It is concluded that the mechanical properties and adhesion of the coated tools are both important in assessing the tool wear and workpiece surface roughness. Also, the research community and industry need to consider adhesion strength of the coated tools for better machining performance.