Search Results (531)

The study is motivated by the application of dry finish milling for post-build processing of additive Ti6Al4V blanks, since the use of neither lubricant nor coolants has been attracting increasing attention due to its environmental benefits, non-toxicity, and the elimination of the need for additional cleaning processes. For end mills, wear patterns were investigated upon finish milling of the SLM Ti6Al4V samples under various machining conditions (by varying the values of radial depth of cut and feed values at a constant level of axial depth of cut and cutting speed). When using all the applied milling modes, the identical tool wear mechanism was revealed. Built-up edges mainly developed on the leading surfaces, increasing the surface roughness on the SLM Ti6Al4V samples but protecting the cutting edges. However, abrasive wear was mainly characteristic of the flank surfaces that accelerated peeling of the protective coatings and increased wear of the end mills. The following milling parameters have been established as being close to rational ones: Vc = 60 m/min, Vf = 400 mm/min, a_p = 4 mm, and a_e = 0.4 mm. They affected the surface roughness of the SLM Ti6Al4V samples in the following way: max cutting thickness—8 μm; built-up edge at rake surface—50 ± 3 μm; max wear of flank surface—15 ± 1 μm; maximum adherence of workpiece. Mode III provided the maximum MRR value and negligible wear of the end mill, but its main disadvantage was the high average surface roughness on the SLM Ti6Al4V sample. Mode II was characterized by both the lowest average surface roughness and the lowest wear of the end mill, as well as an insufficient MRR value. Since these two modes differed only in their feed rates, their values should be optimized in the range from 200 to 400 mm/min. Full article

Recently, essential rose oils and rose products have gained increasing importance in both the cosmetic and food industries, as well as in the composition of medicinal products. We investigated the in vitro antiviral activity of essential oil and floral water from Rosa damascena Mill against herpes simplex virus type 1 (HSV-1) infection in rabbit retinal cells (RRCs). The composition of the main chemical components in the rose essential oil was determined by means of gas chromatographic analysis. The effect on the viral replication cycle was determined using the cytopathic effect (CPE) inhibition assay. The virucidal activity, the effect on the adsorption stage of the virus to the host cell, and the protective effect on healthy cells were evaluated using the endpoint dilution method. The effects were determined as deviation in the viral titer, Δlg, for the treated cells from the one for the untreated viral control. The identified main active components of rose oil are geraniol (28.73%), citronellol (21.50%), nonadecane (13.13%), nerol (5.51%), heneicosane (4.87%), nonadecene (3.93), heptadecane (2.29), farnesol (2.11%), tricosane (1.29%), eicosane (1.01%), and eugenol (0.85%). The results demonstrated that both rose products do not have a significant effect on the virus replication but directly affect the viral particles and reduce the viral titer by Δlg = 3.25 for floral water and by Δlg = 3.0 for essential oil. Significant inhibition of the viral adsorption stage was also observed, leading to a decrease in the viral titers by Δlg = 2.25 for floral water and by Δlg = 2.0 for essential oil. When pretreating healthy cells with rose products, both samples significantly protected them from subsequent infection with HSV-1. This protective effect was more pronounced for the oil (Δlg = 2.5) compared to the one for the floral water (Δlg = 2.0). We used the in silico molecular docking method to gain insight into the mechanism of hindrance of viral adsorption by the main rose oil compounds (geraniol, citronellol, nerol). These components targeted the HSV-1 gD interaction surface with nectin-1 and HVEM (Herpesvirus Entry Mediator) host cell receptors, at N-, C-ends, and N-end, respectively. These findings could provide a structural framework for further development of anti-HSV-1 therapeutics. Full article

Helical milling presents a promising alternative to conventional drilling for hole production, offering superior surface quality and improved production efficiency. While this technique has been extensively applied in the aerospace industry, its potential for machining common engineering materials, such as AISI 1045 steel, remains underexplored in the literature. This study addresses this gap by systematically evaluating the influence of key process parameters—cutting speed (V_c), axial depth of cut (a_p), and tool diameter (D_t)—on hole quality attributes, including surface roughness, burr formation, and nominal diameter accuracy. A full factorial experimental design (2³) was employed, coupled with analysis of variance (ANOVA), to quantify the effects and interactions of these parameters. The results reveal that, with a higher V_c, it is possible to reduce surface roughness (R_a) by 30% to 40%, while an increased a_p leads to a 50% increase in R_a. Additionally, D_t emerged as the most critical factor for nominal diameter accuracy, reducing geometrical errors by 1% with a larger D_t. Burr formation was predominantly observed at the lower end of the hole, highlighting challenges specific to this technique. These findings provide valuable insights into optimizing helical milling for low-carbon steels, offering a foundation for broader industrial adoption and further research. Full article

The use of aluminum honeycomb structures is fast expanding in advanced sectors such as the aeronautics, aerospace, marine, and automotive industries. However, processing these structures represents a major challenge for producing parts that meet the strict standards. To address this issue, an innovative manufacturing method using longitudinal ultrasonic vibration-assisted cutting, combined with a CDZ10 hybrid cutting tool, was developed to optimize the efficiency of traditional machining processes. To this end, a 3D numerical model was developed using the finite element method and Abaqus/Explicit 2017 software to simulate the complex interactions among the cutting tool and the thin walls of the structures. This model was validated by experimental tests, allowing the study of the influence of milling conditions such as feed rate, cutting angle, and vibration amplitude. The numerical results revealed that the hybrid technology significantly reduces the cutting force components, with a decrease ranging from 10% to 42%. In addition, it improves cutting quality by reducing plastic deformation and cell wall tearing, which prevents the formation of chips clumps on the tool edges, thus avoiding early wear of the tool. These outcomes offer new insights into optimizing industrial processes, particularly in fields with stringent precision and performance demands, like the aerospace sector. Full article

Ball-end milling cutters are normally used for complex surface machining. During the milling process, the tool posture and cutting parameters of the ball-end milling cutters have a significant impact on chip formations and morphological changes. Based on the Cutter Workpiece Engagement (CWE) model, this study establishes a chip flow model for ball-end milling cutters with consideration of the tool posture variation. The machining experiments of Ti-6Al-4V with a 15° inclined plane and different feed directions were carried out. The influence mechanism of time-varying tool posture on chip formation was systematically investigated. The results reveal an interaction between the chip flow direction and the cutting velocity direction. The included angle between the chip flow directions at the maximum and minimum contact points in the CWE area affects the degree of chip curling, with a smaller angle leading to weaker curling. This research provides a theoretical foundation for the optimization of posture parameters of ball-end milling cutters and expounds on the influence of the chip flow angle on chip deformation. Full article

During the service life of automotive panel stamping dies, the surface is often subjected to high loads and repeated friction, resulting in excessive wear. This leads to die failure, reduced machining accuracy, and decreased production efficiency. To enhance the anti-friction and wear-resistant performance of die steel surfaces, this study introduces the concept of biomimetic engineering in surface science. By mimicking microstructural configurations found in nature with outstanding wear resistance, biomimetic functional surfaces were designed and fabricated. Specifically, quadrilateral dimples inspired by the back of dung beetles, pentagonal scales from armadillo skin, and hexagonal scales from the belly of desert vipers were selected as biological prototypes. These surface textures were fabricated on Cr12MoV die steel using high-speed ball-end milling. Finite element simulations and dry sliding wear tests were conducted to systematically investigate the tribological behavior of surfaces with different dimple geometries. The results showed that the quadrilateral dimple surface derived from the dung beetle exhibited the best performance in reducing friction and wear. Furthermore, the milling parameters for this surface were optimized using response surface methodology. After optimization, the friction coefficient was reduced by 21.3%, and the wear volume decreased by 38.6% compared to a smooth surface. This study confirms the feasibility of fabricating biomimetic functional surfaces via high-speed ball-end milling and establishes an integrated surface engineering approach combining biomimetic design, efficient manufacturing, and parameter optimization. The results provide both theoretical and methodological support for improving the service life and surface performance of large automotive panel dies. Full article

End milling is a process that is widely used for producing components in aerospace applications, automobile applications, and many other fields. It is crucial to forecast a workpiece’s deformation behaviour during the machining process to choose the best process settings and maximize the part’s overall quality. Understanding the behaviour of each workpiece during the end-milling process through physical experiments is critical, but expensive. Hence, it is inevitable that a numerical study will be developed to estimate workpiece deformation with higher accuracy and less computational cost. The end-milling process on AISI 1045 is simulated in this work using a 3D finite element modelling technique. The ANSYS Workbench 2020 R1 is used to conduct an explicit dynamic analysis in the suggested model. The workpiece’s stress and deformation values throughout the machining process are estimated and examined. Full article

This paper presents the design and validation of a novel specialized fixture device for machining inclined planes with barrel cutters on 3-axis CNC machine tools. Barrel milling, also known as Parabolic Performance Cutting (PPC), is extensively used on 5-axis machines to enhance the efficiency of machining complex surfaces. While significant research has focused on optimizing barrel milling for aspects such as surface roughness and cutting forces, implementing this technique on 3-axis machines poses a challenge due to limitations in tool orientation. To overcome this, an innovative adaptable device was designed, enabling precise workpiece orientation relative to the barrel cutter. To overcome this limitation, an adaptable device was designed that enables precise workpiece orientation relative to the barrel cutter. The device utilizes interchangeable locating elements for different cutter programming angles (such as 18°, 20°, and 42.5°), thereby ensuring correct workpiece positioning. Rigid workpiece clamping is provided by the device’s mechanism to maintain precise workpiece positioning during machining, and probing surfaces are integrated into the device to facilitate the definition of the coordinate system necessary for CNC machine programming. Device control was performed using a Hexagon RA-7312 3D measuring arm. Inspection results indicated minimal dimensional deviations (e.g., surface flatness between 0.002 mm and 0.012 mm) and high angular accuracy (e.g., angular non-closure of 0.006°). The designed device enables the effective and precise use of barrel cutters on 3-axis CNC machines, offering a previously unavailable practical and economical solution for cutting tool tests and cutting regime studies. Full article

Olive mill wastewater is a by-product of olive oil extraction, characterized by a high concentration of organic matter, which presents a significant environmental challenge if not properly managed. This study was aimed at valorizing olive mill wastewater through selective fermentations to produce acetic beverages with low or no alcohol content. Olive mill wastewaters at three different dilutions (100%, 75% and 50%) were inoculated with Saccharomyces cerevisiae UMCC 855 for alcoholic fermentation. The resulting alcoholic product, with 75% olive mill wastewater, was then used as a substrate for acetic acid fermentation by Acetobacter pasteurianus UMCC 1754, employing both static and submerged acetification systems. The results showed that, at the end of the static acetification process, no residual ethanol was detected and that high concentrations of acetic and gluconic acid (46.85 and 44.87 g/L, respectively) were observed. In the submerged fermentation system, the final ethanol concentration was 24.74 g/L; the produced organic acids content reached 31.63 g/L of acetic acid and 39.90 g/L of gluconic acid. Furthermore, chemical analyses revealed that fermentation enhanced the antioxidant activity of olive mill wastewater. These results suggest promising insights for the valorization of olive mill wastewater. Full article

Face milling with end-mill tools represents a solution for woodworking applications on small-scale or complex surfaces, but information regarding the surface quality per specific tool type, wood material, and processing parameters is still limited. Therefore, this study examined the surface quality of tangential oak and maple CNC face-milled with two end-mill tools—straight-edged and helical—for three values of stepover (5, 7, 9 mm) and two cutting depths (1 and 3 mm). The surface quality was analyzed with roughness parameters, roughness profiles, and stereomicroscopic images and was referenced to that of very smooth surfaces obtained by super finishing. The helical end mill caused significant fiber tearing in maple and disrupted vessel outlines, while prominent tool marks such as regular ridges across the grain were noticed in oak. The best surface roughness was obtained in the case of the straight-edged tool and minimum stepover and depth of cut, which came closest to the quality of the shaved surfaces. An increase in the cutting depth generally increased the core surface roughness and fuzziness, for both tools, and this trend increased with an increase in the stepover value. The species-dependent machining quality implies that the selection of tool geometry and process parameters must be tailored per species. Full article

Antistatic and anti-flame biodegradable polymer composites were developed by melt-blending polybutylene succinate (PBS) with epoxy resin, polybutylene adipate-co-terephthalate (PBAT), and MgO particles. The composite films were prepared using a two-roll mill and an extrusion-blown film machine. Plasma and sparking techniques were used to improve the antistatic properties of the composites. The PBS/E1/PBAT/MgO 15% composite exhibited an improvement in V-1 rating of flame retardancy, indicating an enhancement in the flame retardancy of biodegradable composite films. The tensile strength of the PBS/PBAT blend increased from 19 MPa to 25 MPa with the addition of 1% epoxy due to the epoxy reaction increasing compatibility between PBS and PBAT. The PBS/E1/PBAT and PBS/E1/PBAT blends with MgO 0, 0.5, and 1% showed increases in the contact angle to 80.9°, 83.0°, and 85.7°, respectively, because the epoxy improved the reaction between PBS and PBAT via the MgO catalyst effect. Fourier-transform infrared spectroscopy confirmed the reaction between the epoxy groups of the epoxy resin and the carboxyl end groups of PBS and PBAT by new peaks at 1246 and 1249 cm⁻¹. Plasma technology (sputtering) presents better antistatic properties than the sparking process because of the high consistency of the metal nanoparticles on the surface. This composite can be applied for electronic devices as sustainable packaging. Full article

The problem of reducing electric power consumption is critical to ferrous metallurgy as it is a very energy-intensive industry. Significant energy savings can be achieved by increasing the efficiency of high-power electric drives of rolling mills. Experiments with the 5000 plate mill showed that the deterioration of energy efficiency can be caused by the misalignment of loads between the upper and lower roller main electric drive motors (upper main drive/UMD and lower main drive/LMD, respectively) caused by the misalignment of roller motor speeds. Experiments showed that when the speed misalignment reaches 5%, the motor torques differ by two times. Various UMD and LMD speeds can be set to bend the front end of the workpiece (form a “ski”). The installed load division controller (LDC) option fails to provide load alignment due to a low response rate and late startup. This article’s contribution consists of the development of a forced UMD and LMD speed and torque alignment method. To implement this method, a load-division controller with a switching structure has been developed. The authors also developed an efficiency and electric loss monitor and provided an experimental assessment of electric losses per one-pass and per sheet batch rolling cycle. The prospects of this research include the optimization of high-speed and high-load electric drive modes to reduce the energy costs of rolling and the development of an LDC based on fuzzy logic algorithms. Full article

To address the issues of high cutting speeds and low surface precision during milling, this study investigates the effects of front and back cutting face microstructures on ball-end milling cutters processing 304 stainless steel. Firstly, a theoretical energy model for front and back cutting face microstructures is established to verify the feasibility of embedding microstructures. Then, finite element analyses are conducted on cutters with varying microstructure parameters on front and back cutting faces to determine reasonable parameter ranges. Parameter combinations are subsequently used to manufacture front/back microstructured cutters, which undergo FEA validation. Finally, milling experiments are designed with milling forces, tool wear, and workpiece surface roughness as evaluation metrics. The results demonstrate that front/back microstructured cutters reduce milling forces by 19.4%, cutting temperatures by 19%, and workpiece surface roughness (Sa) by 43% compared to non-microstructured cutters, while significantly mitigating tool wear. Full article

The resistance to erosion of stainless steel-based plasma transferred arc (PTA)-cladded hardfacings reinforced with ex-situ-synthesized TiC is compared to those reinforced using in-situ-synthesized TiC (formed from TiO₂ and graphite). The PTA cladding was performed under an optimized torch linear velocity of 0.7 m/s and cladding current of 115 A. The microstructure of the cladded overlay was analyzed using scanning electron microscopy (SEM), and the phase composition was determined using X-ray diffraction (XRD). Vickers macrohardness measurements were made at representative areas at the surface of the overlays. An erosive wear test was conducted with impact angles of 30° and 90° and impact velocities of 20, 50, and 80 m/s. The formation of TiC from TiO₂ and graphite started during ball milling and ended during the cladding stage. The final TiC content in the hardfacings was below nominal, which is likely due to carbide segregation occurring during the cladding process. The highest hardness was 2.4 times that of stainless steel, which was observed in the deposit containing 60 vol.% ex-situ-synthesized TiC. Both ex-situ and in-situ TiC reinforcement improved resistance to erosion, providing up to 1.5 times better resistance under the 30° impact angle and up to 6.3 times under the 90° impact angle than that of stainless steel. However, ex-situ TiC showed a slightly larger improvement. At the 30° impact angle, the primary wear mechanism is micro-ploughing, but at the 90° impact angle it is surface fatigue. Both mechanisms appeared at both angles under 80 m/s impact velocity. Full article

The present work intends to assess the impact of trochoidal toolpath rounding radius loop adjustments on surface roughness, nose radius wear, and resultant cutting force during end milling of AISI D3 steel. Twenty experimental trials have been performed utilizing a face-centered central composite design through a response surface approach. Artificial Neural Network (ANN) models were built to forecast outcomes, utilizing four distinct learning algorithms: the Batch Back Propagation Algorithm (BBP), Quick Propagation Algorithm (QP), Incremental Back Propagation Algorithm (IBP), and Levenberg–Marquardt Back Propagation Algorithm (LMBP). The efficacy of these models was evaluated using RMSE, revealing that the LMBP model yielded the lowest RMSE for surface roughness (Ra), nose radius wear, and resultant cutting force, hence demonstrating superior predictive capability within the trained dataset. Additionally, a Genetic Algorithm (GA) was employed to ascertain the optimal machining settings, revealing that the ideal parameters include a cutting speed of 85 m/min, a feed rate of 0.07 mm/tooth, and a rounding radius of 7 mm. Moreover, the detachment of the coating layer resulted in alterations to the tooltip cutting edge on the machined surface as the circular loop distance increased. The initial arc radius fluctuated by 33.82% owing to tooltip defects that alter the edge micro-geometry of machining. The measured and expected values of the surface roughness, resultant cutting force, and nose radius wear exhibited discrepancies of 6.49%, 4.26%, and 4.1%, respectively. The morphologies of the machined surfaces exhibited scratches along with laces, and side flow markings. The back surface of the chip structure appears rough and jagged due to the shearing action. Full article