Low Feed Rate Research Articles

Near-time optimal feedrate planning for the NURBS curve considering interpolation error constraints

Compared with general time-optimal robot feedrate planning, trajectory machining tasks require consideration of feedrate command constraints and the complexity of parameter spline curves. The interpolation error generated during the interpolation stage affects the command accuracy and contour accuracy of the trajectory. To ensure that the robot end-effector feedrate maintains consistency with the feedrate command and to improve the contour accuracy of the trajectory, this study proposes a two-stage method: near-time optimal feedrate planning for the NURBS curve considering interpolation error constraints. In the first stage, the end-effector velocity constraint under joint velocity constraint is calculated, and the feedrate command is corrected based on that constraint. Then, the corrected feedrate command is transformed into parameter form, and feedrate planning is carried out utilizing the direct transcription method. In the second stage, interpolation is carried out after feedrate planning, and interpolation error is calculated to detect any over-limit positions. If any over-limit positions are detected, the first over-limit position is recorded, and feedrate planning with reduced feedrate limit is carried out at that position. This process is repeated until the interpolation error constraint is satisfied. A series of simulations and experiments were conducted in this study. The simulation results show that the proposed method can consider feedrate command constraints and limit interpolation errors within specified constraints. The experimental results show that the proposed method can reduce contour errors, particularly at low feedrate command.

Measurement and Prediction of Sawing Characteristics Using Dental Reciprocating Saws: A Pilot Study on Fresh Bovine Scapula

Bone sawing is one of the most common operations during traditional dental and cranio-maxillofacial surgery and training systems based on virtual reality technology. It is necessary to predict and update conditions (including the sawing force, temperature and tool wear) in real time during VR surgical training and surgical simulation. All the specimens used in this study were fresh bovine scapula. The forces and temperatures were measured during the sawing process. Additionally, the thermal conductivity was measured via a laser flash instrument. Response surface methodology (RSM) was adopted to analyze and model the sawing force and sawing temperature. Meanwhile, tool wear was observed using a scanning electron microscope. The regression models of the sawing force and temperature rise under different experimental conditions were acquired. To obtain the minimum force within the recommended parameter ranges of commonly used medical reference parameters for bone sawing, a higher rotational speed combined with a lower feed rate were recommended. When considering the sawing force and temperature rise comprehensively, the rotational speed should not be extremely high (about 13,000 rpm is recommended). Meanwhile, abrasive wear is the main wear mode of saw blades. In order to avoid surgery failure, it is necessary to replace the saw blade in time. The experimental data were confirmed to be scientific and accurate for the predicted models of sawing conditions. To minimize the main cutting force, a feed rate of 40 mm/min combined with a rotational speed of 13,700 rpm is recommended. High cutting temperatures have the potential to cause irreversible tissue damage, so surgeons using dental reciprocating saws need to avoid excessively high-speed gears.

Effect of Different Litter Materials on Behavior, Stress and incidence of Mortality and Morbidity rate on Broiler Chickens

The goal of the current study was to find out effect of different litter materials on behavior, stress and incidence of mortality and morbidity rate on broiler chickens. The Poultry Unit of Livestock Farm Complex of the College of Veterinary Science and Animal Husbandry, ANDUAT Kumarganj, Ayodhya, UP, served as the study’s location. For a total of 42 days (6 weeks), the experiment was conducted on 240-day-old Vencobb400 straight run commercial broiler chicks. After being weighed, the chicks were divided at random into three treatment groups: Group 1 (Control – Rice husk) is denoted by (Tc), Group 2 (50 % Rice husk + 50 % Paddy straw) is denoted by (T1), and Group 3 (Wood saving) is denoted by (T2). Each treatment group consisted of two replicates, each with 40 chicks. The experiment’s findings indicate that T1, or the treatment groups that received both paddy straw and rice hulls, had lower feeding rates and duration. However, throughout the course of the weeks, there were no significant differences in the frequency or percentage of time spent engaging in certain behaviors across the three groups. At age 6, the H/L ratio was higher in the Tc group (0.37a ± 0.008) than in the T1 group (0.33b ± 0.456) or T2 group (0.35a ± 0.120). According to this study, birds in the T1 group experienced the least amount of stress compared to other treatment groups. The broiler chick mortality rate was 6.25% in the wood-saving litter (T2) and 3.75% in the T1 group, followed by 5% in the Tc group.

A field bioassay for assessing ivermectin bio-efficacy in wild malaria vectors

BackgroundIvermectin (IVM) mass drug administration is a candidate complementary malaria vector control tool. Ingestion of blood from IVM treated hosts results in reduced survival in mosquitoes. Estimating bio-efficacy of IVM on wild-caught mosquitoes requires they ingest the drug in a blood meal either through a membrane or direct feeding on a treated host. The latter, has ethical implications, and the former results in low feeding rates. Therefore, there is a need to develop a safe and effective method for IVM bio-efficacy monitoring in wild mosquitoes.MethodsInsectary-reared Anopheles gambiae s.s. were exposed to four IVM doses: 85, 64, 43, 21 ng/ml, and control group (0 ng/ml) in three different solutions: (i) blood, (ii) 10% glucose, (iii) four ratios (1:1, 1:2, 1:4, 1:8) of blood in 10% glucose, and fed through filter paper. Wild-caught An. gambiae s.l. were exposed to 85, 43 and 21 ng/ml IVM in blood and 1:4 ratio of blood-10% glucose mixture. Survival was monitored for 28 days and a pool of mosquitoes from each cohort sacrificed immediately after feeding and weighed to determine mean weight of each meal type.ResultsWhen administered in glucose solution, mosquitocidal effect of IVM was not comparable to the observed effects when similar concentrations were administered in blood. Equal concentrations of IVM administered in blood resulted in pronounced reductions in mosquito survival compared to glucose solution only. However, by adding small amounts of blood to glucose solution, mosquito mortality rates increased resulting in similar effects to what was observed during blood feeding.ConclusionBio-efficacy of ivermectin is strongly dependent on mode of drug delivery to the mosquito and likely influenced by digestive processes. The assay developed in this study is a good candidate for field-based bio-efficacy monitoring: wild mosquitoes readily feed on the solution, the assay can be standardized using pre-selected concentrations and by not involving treated blood hosts (human or animal) variation in individual pharmacokinetic profiles as well as ethical issues are bypassed. Meal volumes did not explain the difference in the lethality of IVM across the different meal types necessitating further research on the underlying mechanisms.

Experimental and statistical investigation into surface characteristics in micro milling of bottom pouring/gravity stir cast Al6061 alloy

Micro milling offers the best way to create micro channels; however, the burr formation and surface roughness of the micro channel are difficult to control. Micro channel fabrication and their characterization of stir cast Al6061 are rarely investigated. In the present study, Al6061 alloy was processed by the bottom pouring stir casting method. The micro channels were fabricated on a base and stir cast Al6061 alloys using TiSIN-coated micro end mill tools. The influence of micromachining parameters such as spindle speed, feed rate, and depth of cut on burr formation, cutting force, burr size, and surface roughness was investigated. A comparison was made between the findings obtained from the micro milling of the base and stir cast Al6061 alloys. The surface morphology of fabricated micro channels was analysed and correlated with the roughness profile to understand the channel profile and burr formation. The top burr formation mechanism in stir cast Al6061 alloy was investigated in detail. Low feed rate, low depth of cut, and high spindle speed produced the micro channel with fewer burrs, low surface roughness, and low cutting forces. At the optimum parameter, stir cast Al6061 alloy showed an approximate 420%, 16%, and 300% increase in Fy, Fz, and Ra, respectively, as compared to the base Al6061 alloy. Adhesion wear, built-up edge, and microchipping were found to be the main tool wear mechanisms in micro machining of stir cast alloy. This study directs the choice of cutting parameters for the stir cast micro milling process.

Utilization of palm residues for biochar production using continuous flow pyrolysis unit

Biochar is a carbonaceous solid substance produced by heating biomass without using air. This research aimed to create and evaluate local carbonization pyrolysis using a screw conveyor and filtration equipment. Date palm frond (DPF) biochar was studied and tested at pyrolysis temperatures of 320, 390, and 460 °C, as well as feeding rates of 60, 90, and 120 kg/h. The physicochemical parameters of DPF biochar were evaluated using SEM and FTIR. When the pyrolysis temperature was raised from 320 to 450 °C, and the feed rates were reduced from 120 to 60 kg/h, the biochar yield of DPF and volatiles fell. At 460 °C and 60 kg/h, the maximum ash and fixed carbon content were 11.73 and 77.61 %, respectively. As the feed rate decreased and the temperature increased, the H and O values (1.96 and 2.62 %, respectively) of DPF biochar decreased considerably; the C and N values (83.60 and 0.24 %, respectively) trended inopposite directions. The BET surface area and pore volume increased as a result of the micropore surface area and volume at higher temperatures and lower feeding rates, but water holding capacity increased from 6.04 gwater/10 g at 320 °C to 6.78 gwater/10 g at 390 °C (60 kg/h). The results showed that the heating temperature increased and the feeding rate decreased; phosphorus) P(and magnesium (Mg) increased significantly, whereas the levels of potassium (K) and calcium (Ca) showed a non-significant increase. Furthermore, as the pyrolysis temperature increased, pH and EC increased from 7.90 to 10.96 and 2.91 to 4.25 dSm−1, respectively, while CEC declined; however, there were no significant changes in CEC. DPF biochar demonstrated enhanced macro porosity and surface area at 460 °C and 60 kg/h, making it acceptable for agricultural use as a soil supplement.

Compensatory growth and production economics of Silver pompano, Trachinotus blochii (Lacepede, 1801), fingerlings stunted by feed and space deprivation

The effect of stunting by feed and space deprivation on compensatory growth (CG) in Silver pompano,Trachinotus blochii, was investigated. A commercial pellet feed (45% protein and 10% fat) was fed two times a day, throughout the entire experiment. The 270-day experiment consisted of an initial 60-day stunting phase and a 60-day post-stunting phase carried out in 4 × 2 × 2 m3galvanized iron (GI) rectangular cages, and a 150-day grow-out phase carried out in 3-m diameter circular GI cages. During the stunting phase, the normal fish (in triplicates) were stocked at lower stocking density (17 fish/m3) and fed at 10% of body weight (BW), while stunted fish (one replication) were stocked at about three times higher stocking density (56 fish/m3) and fed at a three times lower feeding rate (3% of BW). The stunted and normal fish were reared in triplicates during the post-stunting phase, at uniform stocking density (15 fish/m3) with feeding at a higher rate (10% of BW) for stunted fish and normal feeding rate (8% of BW) was adopted for normal fish. During the grow-out stage, each replication from the post-stunting phase was shifted to 3-m circular cages with the same feeding rates. The lag in growth in stunted fish (5.56 g against 9.43 ± 0.13 g of normal) during the stunting phase was compensated during the post-stunting phase (36.88 ± 2.23 g against 38.13 ± 1.48 g of normal) by higher feeding rate. There were no significant (p> 0.05) differences in final harvest, biometry, morphometry, dressing yield, carcass nutritional composition, and serum biochemical markers at the end of grow-out stage. Because of the significant difference (p< 0.05) in the total feed provided (5.2 kg for stunted fish against 22.8 kg for normal fish) and the lesser unit cost for the production of stunted fingerling (USD 0.087 for stunted fish against USD 0.106 for normal), the farming of stunted fish brought about a higher net operational revenue and benefit:cost ratio.

Optimizing process for pulsed laser additive manufacturing of nickel-based single crystal superalloy

The relationship between pulsed laser processing parameters and epitaxial growth of alloy is essential to additive manufacturing technology in repairing and manufacturing nickel-based single crystal (SX) superalloys. In this paper, orthogonal experiments of Laser Direct Energy Deposition (DED-L) process have been designed to optimize the process for the epitaxial growth of the SX superalloy. The relationship between process parameters and epitaxial growth of SX superalloy is established in a radar map, which shows that low laser power, pulse width and powder feeding rate help epitaxial growth in the DED-L process. It is implied that increasing the powder feeding rate value in the process range decreases the epitaxial growth rate of the molten pool and increases manufacturing efficiency. The size of the cladding layer width is greatly influenced by laser power (reached 44%) and pulse width (reached 38%). The deposited heigh of the cladding layer is mainly influenced by pulse width (reached 45%) and powder feeding rate (reached 42%). The process parameters have a similar level (approximately 33%) of influence on the powder using efficiency.

Numerical simulation on melt pool and solidification in the direct energy deposition process of GH3536 powder superalloy

Rapid melting, solidification, and a highly powerful laser all contribute to complex heat transfer and flow phenomena during the directed energy deposition (DED) process. To investigate the impact of process parameters on the melt pool and solidification quality during the DED process, a three-dimensional finite element model (FEM) was established. The heat transfer, fluid flow, and solidification during the DED process were investigated. The correct input parameters for GH3536 superalloy were discovered by examining the effects of laser power, scanning speed, and feed rate on the shape of molten pool and interlayer fusion. To forecast the quality of the solidified structure at the cut-off point, temperature gradient and solidification rate discovered in transient thermal distribution were employed. The results shows that the melt pool will grow as a result of high laser power and low scanning speed or feed rate. Concentrating on the expansion of the melt pool is not the best solution because well-solidified microstructure frequently develops in the middle of the parameter set. The correlation between feed rate and laser power is insensitive. At a specific feed rate, the minimum threshold for scanning speed was discovered. When the scanning rate falls below the threshold, uneven solidification structures and anomalous melt pool morphology will take place. The undesirable and potentially fluctuating parameters were indicated, and the laser power and scanning speed range suited for the GH3536 superalloy were summarized. For the feed rate, the center of the parameter set is advised.

Grain Structure Evolution in 6013 Aluminum Alloy during High Heat-Input Friction-Stir Welding.

This work was undertaken to evaluate the influence of friction-stir welding (FSW) under a high-heat input condition on microstructural evolution. Given the extreme combination of deformation conditions associated with such an FSW regime (including the highest strain, temperature, and strain rate), it was expected to result in an unusual structural response. For this investigation, a commercial 6013 aluminum alloy was used as a program material, and FSW was conducted at a relatively high spindle rate of 1100 rpm and an extremely low feed rate of 13 mm/min; moreover, a Ti-6Al-4V backing plate was employed to reduce heat loss during welding. It was found that the high-heat-input FSW resulted in the formation of a pronounced fine-grained layer at the upper weld surface. This observation was attributed to the stirring action exerted by the shoulder of the FSW tool. Another important issue was the retardation of continuous recrystallization. This interesting phenomenon was explained in terms of a competition between recrystallization and recovery at high temperatures. Specifically, the activation of recovery should reduce dislocation density and thus retard the development of deformation-induced boundaries.

Study on surface quality of CNTs/2009Al composites in grinding process with a volume fraction ratio of 3%

Composite materials made of aluminum-based carbon nanotubes (CNTs/Al) are often employed in industries like aerospace and national defense that place a high priority on material processing accuracy at the material’s surface. The most popular machining technique for enhancing the surface quality of materials is grinding. This paper built a prediction model for the surface roughness of CNTs/2009Al composites and identified the process of micro-grinding. Using the ABAQUS software, a non-uniform finite element simulation model of the single abrasive grain grinding process of CNTs/2009AL composites was created. An electroplated diamond grinding rod with a diameter of 2 mm was used in the micro-grinding experiment on the CNTs/2009Al composite, and the impact of the grinding parameters on the quality of the machined surface was examined. According to the findings, the feed speed has the least impact on the material’s surface roughness, whereas the spindle speed and grinding depth both have a significant impact. The measurement of the minimal roughness is 0.117 m. A shallower grinding depth, a lower feed rate, and a correspondingly higher spindle speed should be used in order to provide a superior surface quality. According to the prediction model of micro-grinding surface roughness and laser confocal microscope scanning, the primary phenomena of CNTs in the grinding process include pull-out, fracture, and elastic deformation.

Analysis of drilling behavior of flax/PP composites

ABSTRACT The current research investigation aims to use and compare three different population-based optimization approaches to optimize the operating factors of drilling process to reduce thrust force (TF) and subsequently delamination in flax/PP laminates. Five different tool point geometries and three levels of spindle speed (SS) and feed rate (FR) were considered. Analysis of variance indicated that drill point geometry was most significant parameter affecting the TF, whereas SS had the most negligible impact. Moreover, the lowest and maximum TF and delamination factor (DF) were recorded for the U-shape drill bit and 135°- point angle twist drill bit, respectively. The outcome of the experimental investigation revealed that a low FR value (0.05 mm/rev) and medium-range SS value (1500–1800 RPM) were optimum parameters for each drill geometry. Although all optimization techniques provided almost the same optimum values, but TLBO (teaching learning-based optimization) technique’s convergence rate was fast compared to others.

Experimental studies on reflective finishing of aluminum sheet by CNC abrasive lapping

ABSTRACT This study focuses on improving the surface properties of Aluminum (Al) sheets for imaging and optical applications. To achieve high efficiency and low damage, novel CNC abrasive lapping (CNC AL) techniques were proposed and tested. The experiments investigated the impact of various parameters, such as spindle speed, feed rate, and depth of cut, using two types of abrasives (PCD and hybrid PCD with Al2O3) on the surface quality (Ra) and reflectance (R) of the Al sheets. Optimal parameters were determined using Taguchi L9 and (S/N) analysis, favoring low spindle speed, low feed rate, and high depth of cut. Surface roughness was measured with Surfcom1400G, while SEM EDX, AFM, and 3D profilometer were used to assess surface microstructures. Significant improvement of 35-96% was observed in the highly reflective Al sheets using UV-VIS spectrophotometry and texture analysis in MATLAB.

Effectiveness of coolant on sustainable drilling and hole quality of titanium alloy

The present research investigated the effects of input parameters such as feed rate, cutting speed and coolant type on sustainability and hole quality during the drilling of Ti-6Al-4V alloy. Several output parameters such as surface roughness, burr height, chip thickness ratio, thrust force, torque and peak power consumption were measured and analysed. Higher cutting speeds (2000 r/min) and lower feed rates (0.04 mm/rev) are recommended to be used to reduce drilling torque (0.77 Nm), thrust force (695 N) and power consumption (0.07 kW). However, it should be noted that increasing cutting speed (2000 r/min) can increase tool tip temperature which is detrimental, particularly for low thermal conductivity materials such as titanium alloys. In addition to that, the effect of tool wear also cannot be negated, as increased tool wear generates more heat in the cutting zone which was not effectively removed due to the poor thermal conductivity of titanium. Liquid nitrogen and chilled air had the greatest influence on temperature reduction at the cutting zone, however, its poor penetration and lubrication properties diminished hole quality. Minimum quantity lubrication conditions proved to strike a balance between good hole quality and enhancing sustainable machining by lowering torque, force and power consumption.

The Use of a Radial Basis Function Neural Network and Fuzzy Modelling in the Assessment of Surface Roughness in the MDF Milling Process.

Wood-based composites are increasingly used in the industry not only because of the shortage of solid wood, but above all because of the better properties, such as high strength and aesthetic appearance compared to wood. Medium-density fiberboard (MDF) is a wood-based composite that is widely used in the furniture industry. In this work, an attempt was made to predict the surface roughness of the machined MDF in the milling process based on acceleration signals from an industrial piezoelectric sensor installed in the cutting zone. The surface roughness parameter Sq was adopted for the evaluation and measurement of surface roughness. The surface roughness prediction was performed using a radial basis function (RBF) artificial neural network (ANN) and a Takagi-Sugeno--Kang (TSK) fuzzy model with subtractive clustering. In the research, as inputs to the ANNs and fuzzy model, the kinematic parameters of the cutting process and selected measures of the acceleration signal were adopted. At the output, the values of the surface roughness parameter Sq were obtained. The results of the experiments show that the surface roughness is influenced not only by the kinematic parameters of the cutting, but also by the vibrations generated during the milling process. Therefore, by combining information on the cutting kinematics parameters and vibration, the accuracy of the surface roughness prediction in the milling process of MDF can be improved. The use of TSK fuzzy modelling based on the subtractive clustering method for integrating the information from many acceleration signal measurements in the examined range of cutting conditions meant the surface roughness was predicted with high accuracy and high reliability. With the help of two tested artificial intelligence tools, it is possible to estimate the surface roughness of the workpiece with only a small error. When using a radial neural network, the root mean square error for estimating the value of the Sq parameter was 0.379 μm, while the estimation error based on fuzzy logic was 0.198 μm. The surface of the sample made with the cutting parameters vc = 76 m/min and vf = 1200 mm/min is characterized by a less concentrated distribution of ordinate densities, compared to the surface of the sample cut with lower feed rates but at the same cutting speed. The most concentrated distribution of ordinate density (for the cutting speed vc = 76 m/min) is characterized by the surface, where the feed rate value was vf = 200 mm/min, with 90% of the material concentrated in the profile height of 28.2 μm. When using an RBF neural network, the RMSE of estimating the value of the Sq parameter was 0.379 μm, while the estimation error based on fuzzy logic was 0.198 μm.

An Experimental Study on Drilling Behavior of Silane-Treated Cotton/Bamboo Woven Hybrid Fiber Reinforced Epoxy Polymer Composites.

Machining is considered to be an important post-manufacturing process. Evaluation of machinability of natural-fiber-reinforced composites is important owing to its wide application spectrum. Current experiments focus on the drilling parameters of cotton/bamboo woven fabric reinforced epoxy composites laminates using a solid twist drill. Composites were manufactured with 45 wt.% cotton/bamboo woven fabric in epoxy resin using a compression molding method. Drilling experiments were carried out in pillar-type drilling machine and the drilling characteristics, such as thrust force, were analyzed using four process parameters like spindle speed, feed rate, drill diameter, and silane-treated fabric. Drilling experiments were carried out using the Box-Behnken Experimental Design, and the recommended drilling characteristics were analyzed using quadratic models based on response surface methodology. It was observed from the results that the thrust force is low with small drill-bit diameter, higher cutting speed, and lower feed rate, according to the response surface analysis. Surface morphology of the drilled hole suggested that a better quality of hole can be obtained at lower feed rates.

Energetic scope limits growth but not byssal thread production of two mytilid mussels

Anthropogenic warming of the ocean and atmosphere, concurrent with ocean acidification and deoxygenation, has made it even more pressing to quantify the link between environmental stressors and marine organism population dynamics. In marine environments, low food availability, low feeding rates, and/or increased metabolic costs can cause energetic limitation. Energetic limitation affects some functional traits, such as growth rates of body tissue and reproductive output. Other functional traits that are linked with short-term survival are often prioritized in conditions of energy limitation, despite their energetic cost. Mussels are ecosystem engineers in rocky shore ecosystems, and they produce byssal threads to attach to hard substrate and aquaculture line. Previous studies of mytilid mussel bioenergetics suggest tissue and shell growth are energetically-constrained, while production of byssal threads presents a fitness trade-off and could potentially be a fixed or ‘constitutive’ response regardless of energetic state. In this study, we conduct a field test with two congener mussel species, Mytilus trossulus and Mytilus galloprovincialis to determine whether an index of energetic availability, scope for growth (SFG), correlates with growth and byssal thread production, and the extent to which other potential stressors (hypoxia, low pH, low salinity and high temperature) modulate this response. We find a positive correlation between SFG and growth (both tissue and shell) but not the number of byssal threads produced. We also find low pH or low DO, two co-varying physiological stressors, negatively affect tissue growth of both species, but only marginally affect byssal thread production. We also observed mortality in the late summer/early autumn that coincides with the period of greater hypoxia and low pH. Overall, this work suggests that some functional traits, such as shell and tissue growth, are energetically-constrained while other functional traits, such as mussel byssal thread production, may be best described as a fitness trade-off.

Performance evaluation of surface texturing on carbide tool under minimum quantity lubrication turning of aluminium alloy Al6061 using canola oil

Turning operation is considered an important material removal process and its performance depends largely on the machining parameters. This study presents the analysis of the effect of surface texturing on tool during MQL turning of Aluminium alloy Al6061 using canola oil. Minimum quantity lubrication possesses the benefits of flood lubrication as well as dry machining. Canola oil used in this study possesses good lubrication properties and its kinematic viscosity is 41 mm2/s at 40 °C. Tool texturing is in growing trend in the manufacturing industry and it has gained the attention of many researchers in the past few years. In this study parallel textured pattern is used in which the grooves are perpendicular to chip flow direction. Average surface roughness (Ra) and tangential cutting forces (Ft) are the responses measured. Chip patterns are also examined under different conditions. It is concluded that high spindle speed of 160 m/min along with low feeding rate of 0.2 mm/rev with MQL system using textured tool generates better results for tangential cutting force as well as average surface roughness in contrast with other machining conditions.

Characterising surface roughness of Ti-6Al-4V alloy machined using coated and uncoated carbide tools with variable nose radius by machine learning

A rich literature explores how cutting parameters influence surface roughness in machining different materials using two- or three-dimensional visualisations. Research on Ti-6Al-4V alloy, an important but difficult-to-machine material, is relatively nascent. This research conducts real-life turning operations for Ti-6Al-4V alloy using coated and uncoated carbide inserts with different nose radii and subsequently applies ML techniques to simulate and characterise surface roughness (Ra) for varying cutting parameters — cutting speed (v), feed rate (f), depth of cut (d). Additionally, it presents an innovative visualisation of all three machining parameters’ influences on the surface roughness for Ti-6Al-4V alloy. The results identify Support Vector Machine (SVM) with RBF kernel as a highly potential ML approach to characterise the impact compared to SVM with linear kernel, Random Forest, Deep Learning, and ensemble approaches. The results also demonstrate, for a low feed rate and cutting speed, the surface roughness is better irrespective of the depth of cut and cutting tool materials. For coated carbide with a 0.40 mm nose radius and feed rate of 0.10 mm/rev, for example, Ra values stay within the range of 0.68 to 1.16 mμ for all experimented cutting speeds ranging from 50 m/min to 250 m/min. A similar outcome occurs for other cutting tools. The surface roughness tends to be higher for a higher feed rate. However, the Ra values can decrease even for a high feed rate if the cutting speed exceeds 200 m/min. Overall, the visualisation indicates a nonlinear relationship between machining parameters and surface roughness.

Investigation of the effects of MQL and material hardness on energy consumption, vibration, and surface roughness in hard turning of AISI 52100 steel for a sustainable manufacturing

Turning hardened steels is more advantageous than cylindrical grinding. However, the machinability of hardened steel is difficult. Therefore, in this experimental study, two different AISI52100 steels with 45 and 50 HRC were machined with varying cutting parameters (feed rate: 0.15, 0.25, 0.35 mm/rev; cutting speed: 140, 155, 170 m/minute; depth of cut: 0.08, 0.12, 0.16 mm) under three different cooling conditions (dry, coolant, and MQL). According to the experimental result the lowest surface roughness, vibration, and energy consumption were obtained in cutting with MQL. With increasing feed rate and depth of cut, vibration, power consumption, and surface roughness increased, while energy consumption decreased because the machining time was shortened. With increasing cutting speed, surface roughness, tool vibration, and energy consumption decreased, while instantaneous power consumption and chuck vibration increased. For the lowest energy consumption, surface roughness, vibration, and highest machine tool performance for the ideal cutting condition, high hardness (50 HRC) using MQL, high cutting speed (145 m/minute), low feed rate (0.1 mm/rev), and high depth of cut (0.3 mm) should be preferred. Thus, 3.88% energy consumption, 58.25% surface roughness value, 10.06% chuck vibration value, and 28.80% tool vibration have decreased according to the average cutting conditions.