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This study proposes a novel response surface methodology (RSM) that integrates the mayfly algorithm (MOMA) and multi-objective particle swarm optimization (MOPSO) to enhance the Hastelloy-B3 turning process using a coated carbide insert tool and minimal quantity lubrication. The RSM design was limited by corresponding force, tool wear, temperature, and surface roughness to plan the three turning parts: the cutting velocity, the feed rate, and the cooling strategy. This strategy comprises the external spray rake (MDT 1) and nose side (MDT 2) on the insert, as well as the internal flow top (MDT 3) and bottom (MDT 4). Hence, it established an association between the input variables and responded using the sequential sum of squares for the two-factor interaction (2FI) technique. In addition, it has trained and tested the proposed hybrid algorithm model using experimental data. The optimization results show that removing heat from the chip and tool area makes MDT 4 more important. Compared to RSM-MOMA, the highest improvement in force was 13.65%, temperature was 5.51%, roughness was 49.96%, and tool wear was 24.13%. Additionally, these optimal values improved microhardness at 9.1%, residual stress at 47.2%, and curled diameter at 7.9%. The proposed hybrid algorithm of RSM-MOMA could be used for other machining tasks. [ABSTRACT FROM AUTHOR]

In response to growing concerns about environmental sustainability and the need to reduce carbon emissions in manufacturing, this study investigates the optimization of turning process parameters with a focus on minimizing energy consumption. The research develops a comprehensive mathematical model to identify the optimal cutting conditions, considering specific cutting energy, tool wear, and the application of minimum quantity lubrication (MQL) using eco-friendly canola oil. Experiments conducted on AISI 1080 steel using an uncoated carbide tool under varying machining conditions reveal that lubrication and tool wear significantly influence energy consumption. The results demonstrate that MQL not only reduces friction and cutting forces but also prolongs tool life, thereby lowering the specific cutting energy required for machining. By identifying the optimal combination of cutting speed, feed rate, and depth of cut, the study provides a pathway to achieving more sustainable machining practices. The findings highlight the potential for substantial energy savings in turning operations, contributing to the reduction of the carbon footprint associated with manufacturing processes. [ABSTRACT FROM AUTHOR]

The basic material used for tools for machining wood and wood-based materials is WC-Co (Tungsten Carbide with Cobalt)-cemented carbide. The advantages of WC-Co carbides are significant resistance to high temperatures, high hardness, and wear resistance. Wood-based materials, such as particleboard, are particularly difficult to machine due to their considerable inhomogeneity and the presence of various types of hard particle inclusions, such as sand. In addition, unlike metals, wood has a low thermal conductivity, which means that most of the heat generated during milling is transferred to the tool. The consequence of this phenomenon is an increased tool temperature. In addition, the use of a coolant is not possible when machining wood-based materials. The durability of carbide blades is mainly influenced by grain size and cobalt content. When analysing WC-Co as a tool material, it is necessary to consider how it is obtained, as this can also significantly affect its properties. This paper presents the results of a durability study of cutting blades produced by the innovative Upgraded Field-Assisted Sintering Technology (U-FAST) sintering method during particleboard milling. The wear of the blades was measured until the wear value, i.e., the maximum loss at the contact surface VBmax, was 0.2 mm. Three groups of WC-Co carbides with different WC grain sizes were tested: 0.1, 0.4, and 0.8 µm. Three rotational speeds were used: 12,000, 15,000, and 18,000 rpm. In the machinability tests, blades with a WC grain size of 0.8 µm showed a twofold increase in tool life compared to commercial blades with a similar grain size gradation. [ABSTRACT FROM AUTHOR]

WC–Co cemented carbide has been widely used as machining tool material due to its good mechanical properties. Grinding is an important process in the manufacture of cemented carbide tools. When grinding tools, there are problems such as excessive grinding force, small chip space, and poor lubrication and cooling performance, which in turn contribute to surface defects such as burrs, burns, and even edge damage such as edge chipping. These problems constrain the use of carbide tools, so that the cutting force is unstable and the machining surface quality is poor when the tool is in service. In this paper, straight-line and wavy-texture patterns were designed and formed on the surface of WC–Co tools using a picosecond laser. Grinding experiments were conducted on the ablated tool using a resin-bonded diamond wheel, and surface morphology, roughness, grinding force, and cutting edge quality were evaluated. Finally, turning experiments were conducted to compare the cutting performance of the tools after conventional and laser-assisted grinding. The experimental results showed that the tools with wavy texture showed superior surface and cutting edge quality, with 53.7% and 51.2% reduction in normal and tangential grinding forces, respectively, and 66.6% maximum reduction in edge chipping for the wavy textured tools. Therefore, this study not only reveals the advantages of laser-assisted grinding in machining WC–Co cutting tools, but also provides a valuable theoretical basis for realizing high-efficiency and low-loss tool machining. [ABSTRACT FROM AUTHOR]

Improving the material removal rate (MRR) can significantly enhance the efficiency of the milling operations during machining. However, increasing MRR develops a larger degree of stress and eventual wear at the cutting edge, reducing the tool's lifetime, in particular for hard metals like stainless steel. Therefore, it is important to optimize the tool geometry to enhance the stress-carrying capacity under extreme cutting conditions. Considering a four-fluted tungsten carbide milling tool for cutting stainless steel, we propose in this study a procedure for reducing tool stresses by modifying the tool geometry. Using a systematic set of finite element simulations, we showed that the degree of stresses on the cutting edge can be reduced by optimizing three geometrical parameters, i.e., helix angle, rake angle, and cutting edge radius. To validate the simulation results, we manufactured 18 four-fluted milling tools with varying geometries and tested them by milling stainless steel 316 L under identical cutting conditions. The performance of each tool was ranked based on microscopic inspections of their cutting edges, showing a close agreement with the numerical simulation predictions. This study presents a procedure for modifying milling tool geometry to enhance performance under extreme machining conditions. [ABSTRACT FROM AUTHOR]

In this study, we investigated the combined effects of AlCrN coatings and micro-textures on enhancing the mechanical properties of coatings and the cutting performance of cemented carbide tools, which is critical for improving dry cutting applications. To achieve this, micro-textures were fabricated on the rake face of WC/Co-based cemented carbide tools, and AlCrN coatings were deposited on the surfaces of textured samples using vacuum cathode arc ion plating technology. The effects of micro-texture size and arrangement parameters on the mechanical properties of the AlCrN coating were analyzed, leading to the optimization and definition of the optimal range for these texture parameters on tool. Dry cutting experiments were conducted on TC4 titanium alloy using the micro-textured tools coated with AlCrN. The results indicated that, compared to coatings on non-textured substrates, the mechanical properties of coatings on textured substrates are improved. Proper texturing parameters can enhance the anti-adhesion properties in the tool/workpiece contact area. Tools coated with AlCrN micro-textures demonstrate significantly enhanced performance in dry cutting of TC4 titanium alloy. Relative to traditional non-textured coated tools, there is a slight reduction in cutting force, but both surface roughness and tool wear are significantly decreased. These research results provide theoretical guidance for the design and optimization of textured coatings on tool surfaces. [ABSTRACT FROM AUTHOR]

This study aims to determine the extent to which coating composition and workpiece properties impact machinability and tool selection when turning Compacted Graphite Iron (CGI) under extreme roughing conditions. Two CGI workpieces, differing in pearlite content and graphite nodularity, were machined at a cutting speed of 180 m/min, feed rate of 0.18 mm/rev, and depth of cut of 3 mm. To assess the impact of tool properties across a wide range of commercially available tools, four diverse multilayered cemented carbide tools were evaluated: Tool A and Tool B with a thin AlTiSiN PVD coating, Tool C with a thick Al2O3-TiCN CVD coating, and Tool D with a thin Al2O3-TiC PVD coating. The machinability of CGI and wear mechanisms were analyzed using pre-cutting characterization, in-process optical microscopy, and post-test SEM analysis. The results revealed that CGI microstructural variations only affected tool life for Tool A, with a 110% increase in tool life between machining CGI Grade B and Grade A, but that the effects were negligible for all other tools. Tool C had a 250% and 70% longer tool life compared to the next best performance (Tool A) for CGI Grade A and CGI Grade B, respectively. With its thick CVD-coating, Tool C consistently outperformed the others due to its superior protection of the flank face and cutting edge under high-stress conditions. The cutting-induced stresses played a more significant role in the tool wear process than minor differences in workpiece microstructure or tool properties, and a thick CVD coating was most effective in addressing the tool wear effects for the extreme roughing conditions. However, differences in tool life for Tool A showed that tool behavior cannot be predicted based on a single system parameter, even for extreme conditions. Instead, tool properties, workpiece properties, cutting conditions, and their interactions should be considered collectively to evaluate the extent that an individual parameter impacts machinability. This research demonstrates that a comprehensive approach such as this can allow for more effective tool selection and thus lead to significant cost savings and more efficient manufacturing operations. [ABSTRACT FROM AUTHOR]

The present research analyses the power consumption (Pc) and surface roughness (Ra) in hard turning of high‐strength low‐alloy (HSLA) grade AISI 4140 steel using a recently developed AlTiSiN‐coated carbide tool under different cooling‐lubrication conditions (dry, flooded, nanofluid‐MQL). The nanofluid was prepared by mixing the MWCNT nanoparticles with an eco‐friendly automotive radiator coolant (base fluid). The cooling‐lubrication performance is investigated briefly by comparing the machining responses like machined surface morphology, tool wear, cutting force and temperature. The experiments associated with 46 trials were performed by considering various machining variables, namely cutting speed, nose radius, depth of cut, feed and cooling‐lubrication methods. From the perspective of predictive modelling and multi‐response optimisation, response surface methodology has been employed to minimise power consumption and surface roughness. Thereafter, the predictive modelling and optimisation results are implemented for economic analysis and energy‐saving carbon footprint evaluation. This innovative research also addresses comparative environmental sustainability evaluation in hard turning under different cooling‐lubrication conditions using a life cycle assessment methodology for cleaner and safer production. Results indicate that cutting speed was the most influential item in power consumption enhancement. Furthermore, compared with dry and flooded turning, lower cutting force, reduced cutting temperature, shorter width of flank wear and better surface morphology were obtained under nanofluid‐MQL machining. It has been observed that nanofluid‐MQL machining outperformed sustainability improvement concerning techno‐economically viable societal acceptable and environmental friendliness. [ABSTRACT FROM AUTHOR]

In this study, an optimum drilling parameter for Titanium nitride coated tungsten carbide tool in micro drilling works is able to determine the best drilling parameters for nickel-based alloy, CM247. In this experiment were performed by drilling tool of 0.3 mm with varying parameters, like spindle speed, feed rate and depth of cut in three different levels. 1500, 2000 and 2500 rpm are chosen as a rotation of Spindle speed and 0.2, 0.4 and 0.6 mm/min is set as Feed rate. The material removed values and Machining times have been calculated individually to measure the influence of process and performance parameters of micro hole. The Scanning Electron Microscopy (SEM) was used to examined the properties of drilled surfaces and tool electrodes. The main aim of this study is to find out why the workload characteristics such as Material Removal Rate (MRR) and Machining time (Tm) affects response influence the reaction. [ABSTRACT FROM AUTHOR]

Turning is an often observed technique in the field of metal cutting. During CNC machining, a work material is rotated along its axis while cutting tools at the centre of its axis are used to remove excess material and create the desired component. The ultimate level of quality and accuracy of the end result depends on several factors. In this context, three crucial parameters stand out as key contributors: cutting speed, feed rate, and depth of cut. The specific input parameter chosen for the working material is EN 8, and the cutting tool used is a carbide insert. Observation of tool wear can be made by examining the effects of velocity, feed rate, and cutting depth under different conditions. EN8 steel is a type of steel that has a significant amount of carbon and has a stiffness of around 600 MPa. The displayed graphs obtained from the conducted CNC machining process research provide clear insights into the patterns that demonstrate how the progression of tool flank wear ultimately results in failure. Through the implementation of several experiments, we successfully examined the influence of input variables on both the Material Removal Rate and Tool Wear. [ABSTRACT FROM AUTHOR]

In this study, the effects of cutting speed and feed rate on the roughness parameters Ra, Rz, Rsk, Rku, Rpk, Rvk, and A2 were examined during machining with coated carbide tools in a dry environment. The authors introduced the Rvk/Rpk ratio, a coefficient that facilitates a simpler evaluation of surface wear resistance. Specifically, if this ratio is greater than 1, the surface is more wear-resistant, while values less than 1 indicate a higher tendency for surface wear. The Taguchi OA method was used to analyze and identify the significance of technological parameters on output characteristics. Based on the results, it was established that feed rate has the greatest impact on all output characteristics. The highest cutting force was measured at a cutting speed of 60 m/min and a feed rate of 0.15 mm/rev, attributed to the fact that at lower cutting speeds, the base material does not soften while the cross-sectional area of the chip increases. To achieve the lowest Ra and Rz surface roughness, a cutting speed of 100 m/min and a feed rate of 0.05 mm/rev are recommended. If the goal is to enhance surface wear resistance and improve oil retention capability, machining with a cutting speed of 80–100 m/min and a feed rate of 0.15 mm/rev is advisable, as the coarser machining increases both the Rvk/Rpk ratio and the oil-retaining pocket size, which together improve the wear resistance of the machined surface. [ABSTRACT FROM AUTHOR]

The machining of titanium alloys, particularly Ti6Al4V, presents a significant challenge in manufacturing engineering. Its high strength, low thermal conductivity and high chemical reactivity make Ti6Al4V a hard-to-machine material. However, the machining process is critical for aerospace and biomedical industries. The rapid wear and short lifetime of cutting tools are the main limitations in Ti6Al4V machining, leading to a large increase in manufacturing costs and compromising the surface quality of machined components. Faced with this problem, the texturing of cutting tools, especially through laser-based techniques, has gained considerable attention in the last decade due to improvement of the tribological properties of textured surfaces. Laser Surface Texturing (LST) has emerged as a promising technique to improve the tribological performance of cutting tools by enabling the creation of precise surface structures. Building on prior research, this review provides a comprehensive overview of the most recent research on this topic, summarizing key findings and outcomes from various investigations. [ABSTRACT FROM AUTHOR]

In the modern world of competitive manufacturing, turning is a basic and important process that needs to be optimized for the fast-evolving industrial nature. It has its application in various fields involving numerous materials. This research study deals with modeling with optimization on the turning process parameters of turning E2-BS970 mild steel with cryogenically treated tungsten carbide tool under NFMQL having SiC + MoS 2 nanofluid. The parameters considered as the input factors are spindle speed and depth of cut along with feed rate and lubrication condition. The design of the experiment is done based on Box–Behnken design for 27 trials in the response surface method. The Deep Neural Network (DBN) and the Coot optimization algorithm are employed using MATLAB software for the prediction modeling. The prediction model developed by the DBN sigmoid function gave minimal error with prediction regression values of 0.99988 for MRR, 0.99516 for Cutting temperature, and 0.99545 for Tool life. The optimized result by CO shows a value of 188.89 rpm for spindle speed, 0.2318 mm/rev for feed rate, Doc of 1.45 mm, and 0.5015 vol.% nanofluid MQL condition. The optimized values of MRR are 3.35 mm3/min, 2 4. 1 4 5 ∘ C cutting temperature, and 1543.12 s of tool life. The DBN model combined with the Coot algorithm shows minimal deviation compared to the experimental results validation and confirmatory analysis and is deemed suitable for efficient prediction. [ABSTRACT FROM AUTHOR]

Coating by sol–gel deposition to modify the tribological properties of K10 carbide cutting insert was performed. The study examines the thermal and tribological characteristics of uncoated cutting inserts and the cutting inserts coated with TiO2/8YSZ and TiO2/15YSZ layers respectively. The TiO2/8YSZ and TiO2/15YSZ coatings had a hardness of 1151.6 and 1678.9 HV, respectively, and the TiO2/8YSZ and TiO2/15YSZ coated inserts had scratch hardness of 2.73 and 22.98 GPa respectively. Among the uncoated and coated inserts, the TiO2/15YSZ coated inserts had the lowest coefficient of friction and rate of wear. The TiO2/8YSZ coated insert had a lower thermal conductivity when compared to TiO2/15YSZ coated insert and uncoated carbide cutting insert (10.3 vs. 14.1, and 41.8 W/m.K). The thermal expansion coefficients of the 8YSZ layers, 15YSZ layers, and carbide cutting tool were 3.66*10−6, 3.546*10−6 and 14*10−6 K−1, respectively. The reasons for the enhancement of the tribological properties of the carbide cutting tools by the ceramic coatings are discussed. [ABSTRACT FROM AUTHOR]

Tool wear in machining is inevitable, and determining the precise moment to change the tool is challenging, as the tool transitions from the steady wear phase to the rapid wear phase, where wear accelerates significantly. If the tool is not replaced correctly, it can result in poor machining performance. On the other hand, changing the tool too early can lead to unnecessary downtime and increased tooling costs. This makes it critical to closely monitor tool wear and utilize predictive maintenance strategies, such as tool condition monitoring systems, to optimize tool life and maintain machining efficiency. Acoustic emission (AE) is a widely used technique for indirect monitoring. This study investigated the use of Short-Time Fourier Transform (STFT) for real-time monitoring of tool wear in machining AISI 4340 steel using carbide tools. The research aimed to identify specific wear mechanisms, such as abrasive and adhesive ones, through AE signals, providing deeper insights into the temporal evolution of these phenomena. Machining tests were conducted at various cutting speeds, feed rates, and depths of cut, utilizing uncoated and AlCrN-coated carbide tools. AE signals were acquired and analyzed using STFT to isolate wear-related signals from those associated with material deformation. The results showed that STFT effectively identified key frequencies related to wear, such as abrasive between 200 and 1000 kHz and crack propagation between 350 and 550 kHz, enabling a precise characterization of wear mechanisms. Comparative analysis of uncoated and coated tools revealed that AlCrN coatings reduced tool wear extending tool life, demonstrating superior performance in severe cutting conditions. The findings highlight the potential of STFT as a robust tool for monitoring tool wear in machining operations, offering valuable information to optimize tool maintenance and enhance machining efficiency. [ABSTRACT FROM AUTHOR]

This paper focuses primarily on the wear behavior observed in AISI4340 steel when machining with a multi-layered coated carbide tool. Numerical and experimental examination is processed out to predict the wear performance of AISI 4340 steel along with its cutting force and temperature. In this process, four layers of different coated material are bonded together to form a multi-layered coated carbide tool. The coated thickness is assessed with the assistance of a Scanning Electron Microscope (SEM). Experimental analysis takes place with a heavy duty lathe machine equipped with an infrared thermometer and force dynamometer. Simulation is performed using DEFORM-2D software to simulate cutting forces and interface temperature, and the output results obtained have been compared with the experimental work. With the help of the SEM image, maximum crater wear depth is evaluated and analyzed. Feed plays a crucial role in increasing the chip interface temperature and cutting force. For varied feed rates, the cutting tool edge radius, depth of cut, and cutting speed are taken as the input parameters. The proposed 2D finite element model provides effective parameter values for reducing wear. Results measured indicate that the output parameter values of interface temperature and cutting force obtained from simulation and experimental investigation match each other with high accuracy. Simulation results for temperature distribution around the tool tip show that a maximum temperature of 654 °C is formed at the feed rate of 0.4 mm/rev, leading to high heat flux. For the feed rate of 0.3 and 0.2 mm/rev, there is not much deviation in heat flux around the tool tip. The maximum temperature around the tool tip is near 527 °C for both 0.3 and 0.2 mm/rev. Simulation results show that the lowest tool wear of 0.001 23 mm was obtained for a feed rate of 0.2 mm/rev, followed by 0.004 25 (0.1 mm/rev), 0.005 09 mm (0.4 mm/rev), and 0.007 14 mm/rev. [ABSTRACT FROM AUTHOR]

The purpose of this study was to evaluate the possibility of using mechanical spectroscopy to determine the strength of tool coatings from their lifespan. Mechanical spectroscopy with the determination of the index tan δ (internal friction) was used as the research method. Samples were coated with lamellae composed of WC-6wt% Co cemented carbides. The specimens measured 1.0 mm, 3.0 mm, and 40.0 mm, created using a conventional industrial liquid phase sintering procedure. The original powder consisted of cobalt with traces of chromium and vanadium, and submicron WC grains. The tools tested included carbide cutting tools, and the workpieces were steel alloys. Comparative results showed that coated tools had significantly improved tool life and durability. The relationship between the coating and tool life was evident, providing a practical approach for predictive and non-destructive analyses of coatings on tool durability for composite and finely structured materials. [ABSTRACT FROM AUTHOR]

In the high-speed milling of titanium alloys, the combined application of surface texture and coatings can significantly enhance the performance of cemented carbide tools. Investigating the synergistic effect of surface texture and AlSiTiN coating on tool performance is crucial for advancing the development of their integrated preparation process. Therefore, in this study, a cemented carbide ball-end milling cutter is taken as the research object, and a surface-textured AlSiTiN coating is applied to the rake face. The effects of texture and coating parameters on the milling performance of titanium alloys are analyzed, and a regression model is developed to optimize the relevant parameters. The results indicate that the surface texture effectively reduces the actual contact area between the tool and the chip, serves as a storage space for chips, and enhances the wear resistance of the AlSiTiN coating. The coating thickness significantly affects milling force, milling temperature, and surface wear. An increase in coating thickness improves the hardness and integrity of the coating surface, and it also strengthens the adhesion of the texture to the coating. Additionally, precise control of the laser power plays a key role in reducing the milling temperature, while both the number of scans and the scanning speed significantly influence surface wear. Furthermore, maintaining an appropriate distance from the edge is crucial for enhancing the surface roughness of the workpiece. The optimized parameters for surface texture and coating preparation are as follows: coating thickness (h) = 3.0 µm, laser power (p) = 40 W, scanning speed (v) = 1590 µm/min, number of scans (n) = 6, texture diameter (d) = 42 µm, texture spacing (l) = 143 µm, and distance from the edge (l1) = 104 µm. The optimized milling performance of the milling cutter shows a significant improvement. [ABSTRACT FROM AUTHOR]

In recent years, the exponential growth of the machining industry and its needs has driven the development of new manufacturing technologies, more advanced cutting tool types, and new types of coatings to extend tool lifespan. New coating solutions have been studied and implemented for machining tools, which provide a low friction coefficient and lubrication, thus increasing tool lifespan. Following this line of reasoning, it is relevant to develop scientific work aimed at studying the behavior of cutting tools coated with thin films that promote low friction and high lubrication, as is the case with DLC (diamond-like carbon) coatings. These coatings promote good resistance to oxidation and allow high machining speeds, properties also exhibited by TiAlN (titanium aluminum nitride) coatings. In fact, there is a gap in the literature studying the performance of cemented carbide tools provided with multilayered coatings in milling operations of Cu–Be alloys, commonly used in inserts of plastic injection molds. This study's objective was to investigate the effect of a multilayer coating (TiAlN/DLC) on end-milling tools to analyze their cutting performance when milling a Cu–Be alloy known commercially as AMPCOLOY®83. The quality of the machined surface was evaluated, and the wear of the cutting tool was studied. A comparative analysis of milling parameters with respect to their effect on the condition of the surface after machining and the resulting wear on the tools, using coated and uncoated tools and different machining parameters, allowed us to verify a better quality of the machined surface and wear quantified in approximately half when used coated tools. [ABSTRACT FROM AUTHOR]

Purpose: This study aims to examine the cutting performance of a coated carbide tool during the boring of 1Cr17Ni2 martensitic stainless steel, with a focus on how the tool's structural parameters, particularly the nose radius, affect the wear patterns, wear volume and lifetime of the cutting tool, and related mechanisms. Design/methodology/approach: A full factorial boring experiment with three factors at two levels was conducted to analyze systematically the impact of cutting parameters on the tool wear behavior. The evolution of tool wear over the machining time was recorded, and the influences of the cutting parameters and nose radius on wear behavior of the tool were examined. Findings: The results show that higher cutting parameters lead to significant wear or plastic deformation at the tool nose. When the cutting depth is less than the nose radius, the tool wear tends to be minimized. Larger nose radius tools have weaker chip-breaking but greater strength and wear resistance. Higher cutting parameters reduce wear for the tools with larger nose radius, maintaining their integrity. Wear mechanisms are primarily abrasive, adhesive and diffusion wear. Furthermore, the full-factorial analysis of variance revealed that for the tool with rε = 0.4 mm and 0.8 mm, the factors contributing the most to tool wear were cutting speed (38.76%) and cutting depth (86.43%), respectively. Originality/value: This study is of great significance for selection of cutting tools and cutting parameters for boring 1Cr17Ni2 martensitic stainless-steel parts. Peer review: The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-07-2024-0266/ [ABSTRACT FROM AUTHOR]

Introduction: Friction drilling is an innovative method in hole-making for sheet metal applications, thin sheets of conventional structural alloy materials like copper, titanium, steel etc., even though there are other methods, such as thermal distortion for thewelding of nuts, riveting of nuts, and threading. For the last hundred years, researchers have focused on studying the development of this technique to maintain strength, hole roughness, hole geometry, hardness etc. It is interested in finding solutions for wear, tool life, and plastic deformation. Method: Friction drilling is also called a green hole-making process because this process uses the friction between the rotating tool and the workpiece. In this research, instead of regular HSS and Tungsten Carbide tools, the H13 tool steel is used, because the H13 steel tool has unique chemical compositions like chromium and molybdenum, which give high toughness, hot hardness, and wear resistance. Diamond-like-carbon (DLC) coating has been used in this research to enhance tool life and AZ31B magnesium alloy is used as the work material. Initially, in this research, the wear stability of the DLC-coated H13 tool was investigated, and later, the tool surface roughness and hole quality were verified. Results and Discussion: The material loss observed for the DLC-coated H13 steel tool in the pin-on-disk test was 0.05 g. This investigation used two different diameter tools, namely 3 and 7 mm. Research has concluded that the 7mmtool is better for friction drilling by seeing the roughness and hole quality. However, the conditions were that the spindle should rotate at 4,000 rpm and the feed rate of the tool to be at 200 mm/rev. [ABSTRACT FROM AUTHOR]

This work investigates the effects of high-current pulsed electron beam (HCPEB) irradiation on multi-layered TiN/TiCN/Al2O3 coatings deposited via chemical vapor deposition onto cemented carbide substrates. The study focuses on analyzing the impact of irradiation pulses on the phase composition, microstructure, mechanical properties, and cutting performance of these coatings. The results demonstrate that the multilayered TiN/TiCN/Al2O3 coatings exhibit a smooth surface with enhanced mechanical performance after HCPEB irradiation. Notably, the coating irradiated with 5 pulses achieves a maximum hardness of approximately 28.48 GPa, displaying improved wear resistance and cutting performance. These improvements can be primarily attributed to the enhancements in hardness and elastic modulus, along with the generation of residual compressive stress in the 5-pulse irradiated coating. [ABSTRACT FROM AUTHOR]

The friction/adhesion between the tool and chip is generally large in metal cutting, and it causes many problems such as high cutting energy/rough surface finish. To suppress this, cutting fluid and tool coating are used in practice, but they are high in energy/cost and environmentally unfriendly. Therefore, this paper investigates the extraordinarily high-speed cutting (EHS cutting) mechanics of mainly soft and highly heat-conductive materials and proposes their application to solve the friction/adhesion problem in an environmentally friendly manner. In order to clarify the EHS cutting mechanics, a simple analytical model is constructed and experiments are conducted with measurement of the cutting temperature and forces. As a result, the following points are clarified/found: (1) heat softening at the secondary plastic deformation zone rather than the primary plastic deformation zone, (2) friction coefficient drop to 0.170 in EHS cutting, and (3) gradually increasing trend of cutting temperature in EHS cutting. Finally, EHS cutting is applied to dry cutting of aluminum alloys with a non-coated carbide tool and compared to conventional wet cutting with a DLC-coated carbide tool, and it is shown that a coating/coolant can be omitted in this region to achieve environmentally friendly cutting. [ABSTRACT FROM AUTHOR]

The performance of the final part of the turning process, a topic of practical importance, heavily depends on the cutting parameters. Surface quality, a crucial product attribute in manufacturing, often tops consumer demands during machining due to its significant influence on product functionality. This paper assesses the correlation between the detected vibration signal, statistical parameters (Crest, Kurtosis and I-kaz3D coefficient) and surface roughness and provides valuable insights for practical applications. When the tool experiences vibrations during material removal, these oscillations leave a ripple effect on the surface of the workpiece. We aim to determine the impact of cutting parameters on surface roughness while turning 42CrMo4 steel using a carbide tool insert. Cutting parameters, such as spindle speed, feed, and depth of cut, were used. Signal processing is carried out using different techniques to identify the effect of the cutting parameters on vibration signals. Finally, we delve into the interaction effects between the cutting parameters, vibration signals and surface roughness, offering a comprehensive understanding of real-world manufacturing scenarios. Higher I-kaz3D coefficients correspond to higher surface roughness values. The I-kaz3D coefficient decreases as the surface roughness measurements decrease, indicating that the I-kaz3D technique can accurately indicate an increase or decrease in surface roughness. On the other hand, the cutting force Fc was the component most strongly correlated with surface roughness (Ra), yielding the best results across all indices (adjusted R²adj = 95.1%, er=.8 ± 2.3%). [ABSTRACT FROM AUTHOR]

The present study focuses on the elimination of delamination during the drilling of a linen-based biocomposite material in epoxy resin used for the manufacture of sports kayaks, depending on the tool material, cutting conditions, and the use of additional wooden support plates. In the present study, HSS (high-speed steel) and Carbide cutting tools without coatings, with the same geometry and two types of cutting conditions (n = 1500 rpm, fn = 0.05 and 0.1 mm/rev) were used. A Sololite-type wooden backing plate was used to aid in reducing delamination. The results show that the additional support plates significantly reduced delamination by up to 80% both at the material inlet and especially at the drill hole outlet. In this study, the use of a lower feed rate (fn = 0.05 mm/rev) per tooth was shown to have a significant effect on reducing the delamination of biocomposite materials with flax fibers, which are generally known to be difficult to machine. The Carbide cutting tool shows significantly better results both in terms of its wear and in terms of delamination of the biocomposite material. The highest delamination was obtained without the use of a backing board at the tool exit after 50 drilled holes of 3509 µm. With the use of a backing board, this delamination decreased to 693 µm after 50 drilled holes. [ABSTRACT FROM AUTHOR]

The current work presents an approach for the optimization of machining parameters on the turning of Al7075-T6 aerospace alloy. The alloy was turned on a lathe machine equipped with four different metalworking fluid (MF) setups: minimum quantity lubrication (MQL), Ranque–Hilsch vortex tube (RHVT), compressed air, and dry cutting using coated carbide tools. Taguchi technique was considered for the design of the L16 experimental array with three variable factors and four levels, and S/N ratios were obtained. The turning parameters feed rate and cutting speed are optimized in the experiment, taking into account responses such as surface roughness and tool wear. ANOVA determined the significant parameters that majorly influenced the responses. The results demonstrated that the condition of machining (<99% probability) was the most influential parameter followed by cutting speed (<95% probability) which affects the surface roughness and tool wear. Moreover, turning with MQL at a low cutting speed represented the optimum machining setup for reducing surface roughness and tool wear of this alloy. It was due to the fact that MQL decreases the friction between the tool and the workpiece which reduce the mechanical and thermal stresses on the cutting tool, resulting in lessened tool flank wear and effectively improving the surface quality. [ABSTRACT FROM AUTHOR]

This study describes the cutting performance of Monel 400 alloy using a cryo-treated AlTiN carbide tool. The AlTiN carbide tool was cryo-treated at −196°C for 24 h of soaking at a cooling rate of 0.5°C/min and then tempered at 200°C for 2 h at a heating rate of 0.5°C/min. In this work, we evaluate and compare the hardness, composition, and phases of untreated and cryo-treated AlTiN-coated carbide inserts and also the turning performance of Monel 400 alloy. The machinability characteristics of cutting temperature, turning force, roughness parameter (Ra), form of chip, and SEM-EDS analysis of turned inserts are evaluated and then compared. It was found that the cryo-treated (CT) inserts offered a higher hardness value by 1.5% than the untreated (UT) ones, due to the formation of a new hard surface coating with cryogenic treatment. Cryo-treated AlTiN coated carbide inserts provided the following benefits over untreated ones: lower the cutting temperature at the cutting zone by a maximum of 10%; decreased the cutting force by 6–14%; reduced the Ra values in the turned surface by a maximum of 83%; a reduction in the size of the serrated form of chip; a reduced rate of insert wear; and lower deposition of work material constituents in the turned insert. The reason is enhanced resistance to wear due to an increase in hardness and the formation of a new hard surface coating with cryo-treated AlTiN coated carbide inserts, which was confirmed by analyses of hardness, SEM coupled with EDS, and X-ray diffraction. From the comparison of the characterisation and machinability indices of untreated and cryo-treated AlTiN coated carbide inserts, it was found that the cryo-treated AlTiN-coated carbide inserts provided the favourable turning performance of Monel 400 alloy. [ABSTRACT FROM AUTHOR]

Surface roughness as a machinability index is very important parameter for getting a quality product in manufacturing industry because of affecting the fatique and fracture behaviour of any type of materials. Aim of the study is to generate statistical models in surface finish when machining AISI 1040 hardened mild steels with coated carbides including two different geometries of triangle and square under different conditions. The machining test was carried out at different cutting parameters of cutting speeds (65-76.5-90-104-119) m/min, feed rates (0.11-0.132-0.15-0.173-0.198) mm/rev. and depth of cuts (0.36-0.425-0.50-0.575-0.66) mm. The tools for experiment were coated carbide cutting tools that are formed by chemical vapour deposition while material used for the study was a mild steel, which is the generally used material for manufacturing industry. Furthermore, analysis of variance was used for determining the main factors/interactions. These results are compared and predicted through response surface methodology (RSM) and artificial neural network (ANN). Both approaches indicated that feed rate was dominant while others were not significant. Further, ANN's predicion ability was higher than RSM because coefficients of determination were equalled to 0.995 and 0.925 for ANN and RSM, respectively, which were associated with mean squared errors of 0.00056 and 0.0088 for ANN and RSM, respectively. Moreover, percentage errors for square-shaped inserts in randomly selected test was 6.66% and 1.50% for RSM and ANN, respectively. Hence, two models are good at predicting surface roughness, which in turn can provide a very valuable tool for design and manufacturing of engineering applications, but ANN spends less time and gives more accuracy. [ABSTRACT FROM AUTHOR]

Cemented carbide is a composite material of hard WC and soft Co, and has been widely used as a tool material because of its excellent balance of hardness and toughness. Among them, superfine cemented carbide with WC grain size of less than 1 μm is widely used as a base material for cutting tools and wear-resistant tools because it can achieve both high hardness and high strength. When using superfine cemented carbide as a cutting tool, it is essential to adopt the finer WC particles with higher Co dispersibility, in addition to the appropriate addition of grain growth inhibitors. If the WC particles can be finer, the hardness and transverse rupture strength of the alloy can be expected to improve. In addition, if Co particles, which are softer than WC particles, can be distributed more finely and homogeneously in the mixed powder, the mechanical properties of the alloy may be further improved. In this paper, we report on the improvement of Co dispersibility and the development of new ultra-fine WC, and introduce the cutting performance of the developed practical tools using above the WC powder. [ABSTRACT FROM AUTHOR]

This study was intended to investigate the mechanical property and cutting performance of AlTiBN coating for machining of exotic materials such as heat-resistant alloys and Titanium alloys, which has been increasing for aerospace, energy and medical industries. In conventional PVD coatings for cutting tools, Cr and Si has often been added to AlTiN in order to increase hardness and heat resistance, achieving high wear resistance. However, these methods increase hardness as well as Young's modulus, which reduces toughness of coating. In exotic materials milling, coatings with a high Young's modulus tends to develop internal cracks, leading to early destruction of the coatings. In this research, optimizing B content of AlTiBN coating, we realized low Young's modulus while maintaining high hardness. This is probably because the pure AlTiN changed to a mixed crystal structure of cubic and hexagonal by the addition of B. When the cutting performance of this AlTiBN coating was evaluated in milling for Inconel 718, it was found that internal cracks were suppressed at the initial stage of processing. As a result, cemented carbide tool with the AlTiBN coating achieved approximately 1.6 times longer tool life than that with B-free AlTiN coating. [ABSTRACT FROM AUTHOR]

The Ti-5Al-5V-5Mo-3Cr alloy is utilized in the aerospace, biomedical, and military industries for its exceptional thermomechanical properties. However, its comparatively higher strength and toughness render it more difficult-to-cut than traditionally employed Ti alloys such as Ti-64. Despite its growing demand, a noticeable gap concerning the finish turning of Ti-5553 using coated carbide tools was identified. This paper aims to address this gap by conducting a comprehensive investigation of the tool life and micromechanical performance of novel mono/bi-layered PVD-coated WC tools under high-speed finish turning and wet conditions. A commercial AlTiN-based coating serves as the baseline reference layer and was compared with mono-layered ta-C (diamond-like carbon, DLC), AlCrN, and TiAlSiN coatings deposited atop the AlTiN base on three separate cutting tools. The study focused on evaluating the tool life and surface finish results of all the coatings. Demonstrating that the AlTiN/AlCrN coated tool exhibited the longest tool life, improvement of ~ 9.02% with reference to the baseline, while imparting the smoothest surface finish, an improvement of ~ 31.81%, on the workpiece material due to its optimal micromechanical properties and conducive oxide formation. The results obtained offer valuable insight into understanding the relationship between machining performance and coating properties, consequently allowing the industrial sector to refine its selection criteria to aid with productivity and quality assurance. [ABSTRACT FROM AUTHOR]

Axial ultrasonic vibration-assisted micro-milling (UVAM) has emerged as an advanced technique that can be tailored to improve the machinability of difficult-to-machine materials such as 316L stainless steel. This article sets out to meticulously compare and analyze the cutting performance of conventional milling (CM) and UVAM techniques in the side milling of 316L stainless steel. The cutting separation characteristics of UVAM of 316L stainless steel are elucidated, and the air-cutting ratio in UVAM is introduced. The relationship between the air cutting ratio and spindle speed is also derived. Based on theory, the finite element simulation and experiments are compared under both milling conditions. An analysis of the results for these two sections is presented to validate the theoretical derivation. The results show that the trend and analysis of the experimental cutting forces are aligned with those in the simulation. The cutting forces also confirm the reliability of the simulation results. Due to factors such as tool wear, there is a deviation of 5–20% between the experimental values and the simulation results. A chip variation analysis in the simulation also corresponds to the trend in cutting temperature. An evaluation of the surface morphology and roughness of the experimental samples reveals that the surface quality and smoothness under UVAM are superior to those under CM. Tool wear analysis indicates that the carbide tool undergoes severe wear in the side milling of 316L stainless steel. In summary, the simulation and experiments convincingly demonstrate the advantages of UVAM technology and provide a reference for optimizing the milling process of challenging materials. [ABSTRACT FROM AUTHOR]

Milling difficult-to-machine metals like titanium alloys requires a precise surface finish at the nanoscale levels. This examines the surface properties of the Ti-6Al-4V alloy when milled in a tungsten carbide tool coated with TiAlN. With the latest technological improvements, more awareness is being developed to utilize the field of Machine learning. This research is focused on different Machine learning algorithms such as Neural networks (NN), Linear Regression analysis (LR), and Hyperplane based Support Vector Regression (SVR) are being employed to predict the accuracy of the cutting force and Surface finish (Ra) model during milling of Titanium alloy machining. The cutting force is simulated using the AdvantEdge software and compared the results with experimental values using a PVD-coated cemented tungsten carbide tool coated with TiAlN. Taguchi analysis was applied to the milling process in dry conditions using various cutting speeds (120-180 m/min), feed rates (0.05-0.1 mm/tooth), and depths of cut (0.5-1 mm) while applying TOPSIS multi-criterion decision making to get the optimum process parameters for cutting forces. According to the TOPSIS multi-criterion technique, cutting speed has the biggest contribution (64.17%) when compared to the feed rate (18.12 %). Milling cutting force is analyzed using the Deep learning model and compared the results with experiments and error percentile are calculated to obtain the most optimum model for the prediction. The productivity of the manufacturing product is improved by using simulation software to predict the cutting force and surface roughness and implementing intelligent machine learning tools. The polynomial regression model was used to predict the cutting force on milling Ti alloy and found that linear regression prediction was 220.21 whereas polynomial regression prediction was 222.98 at depth of cut 0.5 mm which is more accurate and the curve is fitted properly with most of the data points. [ABSTRACT FROM AUTHOR]

Tool wear is a key issue for the manufacturing performance of refill friction stir spot welding in high-volume manufacturing environments. As such, the aim of this study is to examine conditions in which tungsten carbide with a cobalt binder can succeed as a tool material in the spot welding of 2029 aluminum for a sustained lifetime. Critical factors are shown herein to include cleanliness and thermal management. The life of a WC-Co toolset is demonstrated to be approximately 2998 welds, which is of the same scale as conventional steel tooling. With a WC-Co shoulder and probe, the H13 clamp showed the only significant wear. [ABSTRACT FROM AUTHOR]

The surface roughness and surface residual stresses are affected by the coating thickness of physical vapor deposition (PVD) TiAlN tools, which could alter the service performance of machined components. However, the relationships among the tool coating thickness, the machined surface roughness, the surface residual stress, and the fatigue life are still not sufficiently illustrated. In this research, PVD TiAlN coatings with several thicknesses of 1.6 μm, 2 μm, 2.5 μm, and 3 μm were deposited on carbide tools. Turning experiments using Inconel 718 were conducted with uncoated and various TiAlN tools under flood cooling conditions. The surface roughness could be improved with the selection of thin PVD TiAlN coating thicknesses of 1.6 μm and 2 μm compared to that of uncoated tools. The tensile residual stresses at the machined surface in the directions of cutting speed and feed rate linearly decreased by 148.67% and exponentially decreased by 92.24% when the TiAlN coating thickness was increased from 0 μm to 3 μm. The values of the low-cycle fatigue life of machined Inconel 718 linearly increased by 15.60% with the increase in TiAlN coating thickness from 0 μm to 3 μm, which was mainly due to the improvement of surface residual stresses. The results could provide guidance for the selection of suitable TiAlN coating thicknesses for wet machining Inconel 718 based on the part service conditions. [ABSTRACT FROM AUTHOR]

It is currently known that in certain circumstances pre-rounding of cutting blades can significantly increase tool life. Despite many data on the beneficial effect of drag-finishing on the durability of metalworking tools, it is not entirely clear whether similar benefits appear when machining wood-based panels. The results of some pilot study are quite promising but the real impact of cutting blades pre-rounding (it is about blades made of various standard cemented carbides), on tool life in particleboard milling are very rarely studied. The study aims to fill this gap in the knowledge system. The experimental research was carried out using a CNC milling machine equipped with a single-blade milling head with replaceable blades. It turned out that the positive effect of the drag-finishing of cutting blades on tool life in particleboard machining depends on the structure and hardness of carbide. A significant extension of the tool life (about 50%) was observed only in the case of particularly hard carbide (2240 HV10). There was no significant advantage for the softer type of carbide (1800 HV10). [ABSTRACT FROM AUTHOR]

In modern industrial production, noise can reflect the cutting state of the workpiece and tool to a certain extent, and the noise collection method cannot interfere with the complex processing environment. To further improve the cutting performance of coated cemented carbide micro-textured tools, this paper builds a friction and wear test platform for micro-textured cemented carbide pins with AlSiTiN-AlCrN coating and titanium alloy discs. Based on the test noise signal, the relationship between friction and wear and the noise of the workpiece was studied by the Hilbert–Huang transform (HHT). Through the change of noise in different periods, the micro-texture and coating life of cemented carbide pin under other processing parameters were analyzed. Based on the influence of the interaction between processing parameters and micro-texture diameter on the test results, the test parameters were optimized. The results show that the change of noise signal during the test presents a "V" curve with the grinding process, which mainly affects the noise through the shift of pin-disc friction form and the anti-wear effect of micro-texture. The interaction mainly affects the test results by affecting the micro-texture diameter, laser energy concentration, and the roughness of the inner wall of the pit. The optimized micro-texture geometry and preparation parameters are as follows: scanning times is 8, micro-texture diameter is 50 μm, scanning speed is 1500 mm/s, micro-texture spacing is 170 μm, and laser power is 40 W. The research content of this paper provides a reference for improving the surface properties of cemented carbide. [ABSTRACT FROM AUTHOR]

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Vanadis 8 steel is a tool steel manufactured by powder metallurgic processing. Its main alloy elements are V, Cr and Mo. By implementing an experimental design with five factors—all of them are related to the thermal processing of this steel and with ionic nitriding—the effects of said factors on adhesive wear resistance and corrosion resistance were studied. For this purpose, Pin-on-Disc wear tests and lineal polarization resistance tests were carried out using an aqueous solution with 3.5% NaCl by weight. The main aim was to increase this steel use in more aggressive environmental conditions, such as in coastal environments. By means of XRD, the percentage of retained austenite was determined, and by SEM-EDX, the microstructure was revealed. The conclusion is that adhesive wear resistance is improved if thermal processing parameters are at such levels that increase austenite destabilization and reduce retained austenite content. This means to destabilize austenite at 1180 °C during 1 h, with oil quenching, tempering at 520 °C during 2 h and ionic nitriding at 520 °C during 2 h. Corrosion resistance is highly improved with ionic nitriding. At the same time, to compensate for the negative effect on corrosion resistance of a high density of primary and secondary carbides, it is essential to carry out the ionic nitriding treatment. The harmful effect of electrochemical microcells that appear in the carbide/matrix interface is compensated by the passivating effect generated by the nitrided surface. [ABSTRACT FROM AUTHOR]

The tool wear characteristics and mechanisms were investigated during interrupted-cutting Zr-based bulk metallic glass (BMG). The effect of tool wear on the cutting forces, chip morphology, and machined surface quality was also analyzed. The increase in cutting speed significantly affected the transformation of tool wear behavior. The cutting tool failure form was mainly characterized with adhesive wear and edge chipping. The enhancement of cyclic mechanical impact, caused by the increase of cutting speed in interrupted-cutting, was the main reason for the tool wear behavior transition and life reduction. Furthermore, oxidation wear led to serious boundary wear. The tool wear drastically altered the chip morphology, and the free surface serrated feature disappeared, which was replaced by flaky droplets with the increase of cutting speed. Moreover, it also led to various surface defects on the machined surface, among which the plastic side flow showed the most significant impact on surface roughness. [ABSTRACT FROM AUTHOR]

Inconel 657, also known as 50Cr-50Ni, is a high-temp, corrosion-resistant Ni-Cr alloy with excellent fuel-ash corrosion resistance against sulfur and vanadium. To make components from Inconel 657, it undergoes casting and machining for dimensional accuracy and surface finish. This study explores the effect of cutting speed on tool wear in turning Inconel 657, focusing on carbide and CBN tools. Higher cutting speeds led to increased flank wear for both tools. Carbide tool wear rose by 16% and 25% at 60 and 120 m/min compared to 30 m/min. CBN tool wear increased by 15%, 29%, and 66% at 120, 250, and 400 m/min compared to 60 m/min. CBN inserts showed 39% less wear than the carbide tool at 60 m/min and 35% less at 120 m/min. Therefore, the carbide tool suits low-speed turning, while the CBN tool is ideal for high-speed machining operations. [ABSTRACT FROM AUTHOR]

This study examines the process of optimising machining parameters in the turning of EN8 steel. The PROMETHEE-II multicriteria decision-making technique is utilised for this purpose. The analysed machining variables consist of Material Removal Rate (MRR), Surface Roughness (SR), Acceleration (Ac), and Tool Wear (TW). These variables are influenced by the cutting speed (Vc), Feed Rate (FR), and Depth of Cut (DoC) which serve as input parameters. The experimental trials were performed utilizing Taguchi's L27 orthogonal array on a CNC lathe. The ANOVA analysis showed that Vc had the most substantial effect on MRR, SR, and Ac, whereas FR had the greatest influence on TW. The PROMETHEE-II approach determined that the most favourable machining settings are a cutting speed (Vc) of 200 m/min, an FR of 0.08 mm/rev, and a DoC of 0.2 mm. Given these circumstances, the MRR achieved a value of 2.887 cubic millimetres per second, the SR was minimized to 0.744 micrometres, the Ac was decreased to 0.026 meters per second squared, and the TW was restricted to 0.026 millimetres. The study finds that PROMETHEE-II is a highly successful method for optimizing multiple machining reactions, resulting in substantial enhancements in machining performance. [ABSTRACT FROM AUTHOR]

In the present study, Experimental investigation of the effects of various cutting parameters on the response parameters so as cutting zone temperature (T) and material removal rate (MRR) in the turning of EN AW 1350 Aluminum Alloy by coated carbide tool. The input control parameters selected for the present work were the cutting speed, feed rate and depth of cut. The objective of the present work is to examine the cutting zone temperature and material removal rate for better productivity. The design of experiments was done with the help of Taguchi L27 orthogonal array. Analysis of variance (ANOVA) was used to find out the significance of the input parameters on the response parameters. Percentage contribution for each control parameter was calculated using ANOVA with 95 % confidence interval. From results, it was observed that cutting speed is the most dominant factor for temperature and the depth of cut is the most significant control parameter for material removal rate. Finally, the multiple response optimization of cutting zone temperature and material removal rate was carried out using the desirability function approach. [ABSTRACT FROM AUTHOR]