Search Results (162)

As manufacturing demands for challenging-to-machine metallic materials continue to evolve, the performance of cutting tools has emerged as a critical limiting factor. The synergistic application of micro-texture and coating in cutting tools can improve various properties. For the processing of existing micro-texture, because of the fast cooling and heating processing method of laser, there are defects such as remelted layer stacking and micro-cracks on the surface after processing. This study introduces a preheating-assisted technology aimed at optimizing the milling performance of textured coated tools. A milling test platform was established to evaluate the performance of these tools on titanium alloys under thermally assisted conditions. The face-centered cubic response surface methodology, as part of the central composite design (CCD) experimental framework, was employed to investigate the interaction effects of micro-texture preparation parameters and thermal assistance temperature on milling performance. The findings indicate a significant correlation between thermal assistance temperature and tool milling performance, suggesting that an appropriately selected thermal assistance temperature can enhance both the milling efficiency of the tool and the surface quality of the titanium alloy. Utilizing the response surface methodology, a multi-objective optimization of the textured coating tool-preparation process was conducted, resulting in the following optimized parameters: laser power of 45 W, scanning speed of 1576 mm/s, the number of scans was 7, micro-texture spacing of 130 μm, micro-texture diameter of 30 μm, and a heat-assisted temperature of 675.15 K. Finally, the experimental platform of optimization results is built, which proves that the optimization results are accurate and reliable, and provides theoretical basis and technical support for the preparation process of textured coating tools. It is of great significance to realize high-precision and high-quality machining of difficult-to-machine materials such as titanium alloy. Full article

Nickel-based superalloy Hastelloy C276 is widely used in high-performance industries due to its strength, corrosion resistance, and thermal stability. However, these same properties pose substantial challenges in machining, resulting in high tool wear, surface defects, and dimensional inaccuracies. This study investigates methods to enhance machining performance and surface quality by evaluating the tribological behavior of TiSiN/TiAlN-coated carbide inserts under six cooling and lubrication conditions: dry, MQL with coconut oil, Cryo-LN₂, Cryo-LCO₂, MQL–Cryo-LN₂, and MQL–Cryo-LCO₂. Open-slot finishing was performed at constant cutting parameters, and key indicators such as cutting zone temperature, tool wear, surface roughness, chip morphology, and microhardness were analyzed. The hybrid MQL–Cryo-LN₂ approach significantly outperformed other methods, reducing cutting zone temperature, tool wear, and surface roughness by 116.4%, 94.34%, and 76.11%, respectively, compared to dry machining. SEM and EDS analyses confirmed abrasive, oxidative, and adhesive wear as the dominant mechanisms. The MQL–Cryo-LN₂ strategy also lowered microhardness, in contrast to a 39.7% increase observed under dry conditions. These findings highlight the superior performance of hybrid MQL–Cryo-LN₂ in improving machinability, offering a promising solution for precision-driven applications. Full article

The effect of severe plastic deformation during milling and conventional and Spark Plasma Sintering (SPS) on the wt. % microstructural, structural, thermal, magnetic, and mechanical properties of the Al–16 wt. % Mn–7 wt. % Cu alloy was studied. A milling process for up to 24 h (A24) leads to microstructure refinement and the presence of Al, Mn, and Cu solid solutions. The energy dispersive spectroscopy (EDS) analysis reveals the existence of Cu–Al, Mn–Al, and Al–Mn enriched particles. The powders exhibit weak ferromagnetism and an exchange bias (EB) behaviour that decreases with increasing milling time. The Ms values fitted using the law of approach to saturation (LAS) are comparable to the experimental values. The exothermic and endothermic peaks that appear in the differential scanning calorimetry (DSC) scans in the 500–900 °C range on heating/cooling are related to different phase transformations. The crystal structure of the A24 powders heated up to 900 °C (A24_900 °C) consists of a dual-phase microstructure of Al₂₀Cu₂Mn₃ nanoprecipitates (~28%) and Al matrix (~72%). The sintering of the A24 powders at 500 °C for one hour (A24S) leads to the precipitation of Al₆Mn, Al₂Cu, and the Al₂₀Cu₂Mn₃ T-phase into the Al-enriched matrix. In contrast, the consolidation by SPS (A24SPS) leads to a mixture of an Al solid solution, Al₆Mn, T-phase, and α-Mn with an increased weight fraction of the T-phase and Al₆Mn. The sintered samples exhibit the coexistence of a significant PM/AFM contribution to the M-H curves, with increasing Hc and decreasing EB. A higher microhardness value of about 581 HV is achieved for the A24SPS sample compared to those of the A24 (68 HV) and A24S (80 HV) samples. Full article

The rapid growth of the machining market and advancements in additive manufacturing (AM) present new opportunities for innovative tool designs. This preliminary study proposes a design for additive manufacturing (DfAM) approach to redesign a milling cutter head in 17-4 PH stainless steel by integrating topology optimization (TO) and internal coolant channel optimization, enabled by laser powder bed fusion (LPBF). An industrial eight-insert milling cutting tool was reimagined with conformal cooling channels and a lightweight topology-optimized structure. The design process considered LPBF constraints and was iteratively refined using computational fluid dynamics (CFD) and finite element analysis (FEA) to validate fluid flow and structural performance. The optimized milling head achieved approximately 10% weight reduction while improving stiffness (reducing maximum deformation under load from 160 μm to 151 μm) and providing enhanced coolant distribution to the cutting inserts. The results demonstrate that combining TO with internal channel design can yield a high-performance and lightweight milling tool that leverages the freedom of additive manufacturing. As proof of concept, this integrated CFD–FEA validation approach under DfAM guidelines highlights a promising pathway toward superior cutting tool designs for industrial applications. Full article

Additive manufacturing (AM) stands out for its variable applications in terms of material, quality, and geometry. Wire Arc Additive Manufacturing (WAAM) is remarkable for producing large parts in reduced times when compared to other AM methods. The possibility of producing a part with a near-net shape not only enhances productivity but also reduces resources usage. However, parts produced by WAAM may need post-processing by machining to achieve functional surface requirements. Therefore, it is important that machining, even if minimized, does not lead to a significant environmental impact. In this sense, this work evaluates the effect of using compressed air, dry cut, and synthetic biodegradable cutting fluid at varying nozzle positions and flow rates on the surface quality of ER70S-6 steel produced by WAAM, after milling with TiAlN-coated carbide tools. To analyze the surface roughness, parameters Ra, Rq, and Rz were measured and microscopy was used to further evaluate the surfaces. The surface hardness was also evaluated. The results showed that a flow rate of 10 L/min promotes better surface quality, which can be further improved using compressed air, leading to a surface quality 50% better when compared to dry cutting. Dry cut was not suitable for machining ER70S-6 WAAM material as it resulted in rough surface texture with an Rz = 4.02 µm. Compressed air was the best overall condition evaluated, achieving a 36% Ra reduction compared to dry cutting, the second-lowest hardness deviation at 6.51%, and improved sustainability by eliminating the need for cutting fluid. Full article

This article explores how alloy composition, hardness, and machining parameters can affect the cutting forces encountered in aluminum–lithium (Al-Li)-based alloys. By analyzing Cu and Cu with Sc additions to Al-Li alloys and exposing them to various heat treatments to modify their hardness, this research was designed to evaluate milling performance under various feed rates, cutting speeds, and cooling conditions. The findings indicate that increased hardness leads to higher cutting forces, with Al-Li-Cu-Sc exhibiting the greatest resistance due to scandium’s grain-refining effect and the formation of stable precipitates. Statistical analyses identify the feed rate as the main parameter controlling cutting force, along with hardness and cooling conditions. Notably, wet machining consistently reduces cutting forces, especially in Al-Li-Cu-Sc alloys, enhancing machinability when using high cutting speeds. This work underscores the significance of selecting optimal machining parameters tailored to specific alloy compositions. These findings contribute to improved process efficiency, reduced tool wear, and enhanced productivity. Given the attractive characteristics of these alloys, i.e., their low weight and high strength, the insights from this study are particularly beneficial for aerospace applications where machining performance directly impacts component quality, cost, and overall operational efficiency. Full article

Hardox 500 is a special low-alloy, martensitic steel possessing extraordinary wear resistance, high hardness, and high ductility; thus, it has been widely used in many industrial applications. Nevertheless, this type of steel has a low machinability and is grouped among the difficult-to-machine materials. Hence, this paper’s objective was to study its hard milling performance under minimum quantity cooling lubrication (MQCL) conditions using an Al₂O₃/MoS₂ hybrid nano cutting oil. The Box–Behnken response surface methodology was used to investigate the effects of the nanoparticle concentration (NC), cutting speed (v), and feed rate (f) on the total cutting force F and cutting force coefficient F_y/F_z. The obtained results indicate that the cutting efficiency of Hardox 500 steel was improved thanks to the enhancement in cooling lubrication from the MQCL using the Al₂O₃/MoS₂ hybrid nano cutting oil. The applicability of vegetable oil and coated carbide inserts is thus extended to the hard milling of difficult-to-cut materials. Moreover, the provision of the appropriate ranges and optimal set of investigated variables obtained in this paper will be useful guides for technologists and further studies. Concretely, NC = 0.5–0.7%, v = 110–115 m/min, and f = 0.08–0.10 mm/tooth are the optimal set for the total cutting force F, while NC = 0.5%, v = 138–140 m/min, and f = 0.08–0.09 mm/tooth are suggested for the cutting force coefficient F_y/F_z. Full article

Hastelloy is widely used in the manufacturing of high-temperature components in the aerospace industry because of its high strength and corrosion-resistant physical properties, as well as its ability to maintain excellent mechanical properties at high temperatures. However, with developments in science and technology, the amount of available components for use in high-temperature and corrosive environments is increasing, their structures are becoming more complex and varied, and requirements with regard to the surface quality of the components has also become more stringent. The integration of cold plasma (CP) and nano-lubricant minimum quantity lubrication (NMQL), within a multi-physics coupling-assisted micro-grinding process (CPNMQL), presents a promising strategy to overcome this bottleneck. In this paper, micro-grinding of Hastelloy C-276 was performed under dry, CP, NMQL, and CPNMQL conditions, respectively. Contact angle testing, X-ray photoelectron spectroscopy (XPS) analysis, and nano-scratch experiments were used to investigate the mechanism of CPNMQL and to compare the micro-milling performance under different cooling and lubrication conditions employing various characteristics such as grinding temperature, surface roughness, and 3D surface profile. The results showed that at different micro-grinding depths, the micro-grinding temperature and surface roughness were significantly reduced under CP, NMQL, and CPNMQL conditions compared to dry friction. Among them, CPNMQL showed the best performance, with 53.4% and 54.7% reductions in temperature and surface roughness, respectively, compared to the dry condition. Full article

This study examines the impact of PVD coatings on cutting tool wear during the milling of 316L stainless steel under air cooling conditions. In the experiment, a carbide milling cutter coated with a nanocomposite nACo3 (AlTiSiN) coating was used. The coating was deposited using a next-generation device, the PLATIT π411PLUS, which features one central and three lateral rotating cathodes. The nanocomposite nACo3 coating obtained with this method exhibits exceptionally high structural density and excellent mechanical properties. The new generation of the nACo3 coating demonstrates improved surface properties and a lower friction coefficient compared to previous generations. The findings indicate that PVD nACo3 coatings significantly enhance wear resistance, extending tool life while maintaining acceptable surface quality. The optimal cutting time was determined to be approximately 90 min, after which a sharp increase in surface roughness and tool wear was observed. After 120 min of machining, substantial deterioration of surface quality parameters was recorded, suggesting increasing cutting forces and cutting edge degradation. SEM and EDS analyses revealed the presence of adhered material on the tool and sulfide inclusions in the microstructure of 316L stainless steel, which influenced the machining process. The nACo3 coating demonstrated high thermal and wear resistance, making it an effective solution for machining difficult-to-cut materials. This study suggests that selecting appropriate cutting parameters, tool geometry, protective coatings, and cooling strategies can significantly affect tool longevity and machining quality. The novelty of this research lies in the application of innovative nanocomposite PVD coatings during the milling of 316L stainless steel under air cooling conditions. These studies indicate potential future research directions, such as the use of minimum quantity lubrication (MQL) or cryogenic cooling as methods to reduce tool wear and improve post-machining surface quality. Full article

Oil-in-water emulsions (O/W emulsions) are generally used to lubricate the cold rolling process of low-carbon steel. In addition to the obvious advantages of efficient lubrication and cooling of the process, there are also some disadvantages, mainly related to emulsion bath maintenance, subsequent production steps and waste disposal. In some application areas, Oil-Free Lubricants (OFL’s) have been shown to be at least equally effective in decreasing friction and wear as conventional oil-based lubricants, while resulting in benefits related to waste disposal. In 2023, a project named “Transfer of aqueous oil free lubricants into steel cold rolling practice” (acronym ‘RollOilFreeII’) began, with it receiving funding from the Research Fund for Coal and Steel (RFCS). This project aims at an industrial application of Oil-Free Lubricants in the steel cold rolling process. The project builds on the work of the ‘RollOilFree’ project (also carried out in the RFCS-framework). This article briefly recapitulates the findings in the RollOilFree project and describes the objectives, benefits, activities and first results of the RollOilFreeII project. Notably, a pilot mill trial at high speed has been carried out, showing a good performance of the investigated OFLs. Back-calculated friction values were equal to, or even slightly lower than, reference O/W emulsions. The strip cleanliness with OFLs is much better than it is with the reference O/W emulsions. Only for a very thin product, as is the case in tinplate rolling, does the direct application of a conventional O/W dispersion (a high-particle-sized O/W emulsion) give a better performance than the investigated OFLs. Further development of OFLs should focus on this aspect. Full article

Hydrogen prereduction of two manganese ores fines was investigated under varied operating conditions in a fluidized bed. The manganese ores used in this study are the Zambian ore and the South African Nchwaneng ore from the Kalahari region. The samples were milled and sized before they were characterized with regard to sphericity, Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES) chemical analyses, X-ray diffraction (XRD) analyses and Scanning Electrons Microscope (SEM) analyses. Prereduction experiments were conducted in a laboratory scale fluidized bed with the parameters of interest being minimum fluidization velocity, terminal velocity, elutriation, average bed voidage, residence time, temperature, intrinsic ore properties and cohesive adhesion. Experiments for the determination of fluidization velocity and terminal velocity were conducted at both ambient temperature and elevated temperature ($500 °$C, $550 °$C, $600 °$C, $700 °$C, $800 °$C and $900 °$C), and for varied sample masses (100 g, 300 g and 700 g) and varied particle-size ranges (200–$300 \mathrm{\mu }$m, 300–$425 \mathrm{\mu }$m, 425–$500 \mathrm{\mu }$m and 500–$600 \mathrm{\mu }$m). The experimentally observed minimum fluidization velocities for particles size groupings of [+106–$200 \mathrm{\mu }$m], [+200–$300 \mathrm{\mu }$m], [+300–$425 \mathrm{\mu }$m], [+425–$500 \mathrm{\mu }$m] and [+500–$600 \mathrm{\mu }$m] as well as the mix (20 wt% of each) was comparable with the theoretical minimum fluidization velocity. The fluidized bed was heated to a desired temperature at a rate of $10 °$C/min under argon whilst logging the pressure drop across the bed with increasing temperature. The convectional cooling during the introduction of cold hydrogen as well as the net energy of endothermic and exothermic chemical reactions were observed to result in a temperature drop in the order of 100 to $250 °$C. Thermal mineral transformation under argon was observed to yield iron manganese oxide in the order of 15 to 30 wt/wt%. Prereduction was conducted using hydrogen gas at a desired temperature and terminal velocity. Reduction extent was observed to increase with the increasing temperature and residence time. Increasing reduction temperature beyond $700 °$C was not observed to improve reduction, whereas longer residence time (of up to 40 min) was observed to favor the formation of iron manganese oxide, iron manganese and manganosite. For hydrogen prereduction experiment conducted at $900 °$C, the reactor was observed to be brittle after the experiment. Cohesive adhesion was observed to be more pronounced at $900 °$C. Full article

This paper presents a study on the ring formation phenomenon in lime kilns using simulation. The research focuses on the chemical recovery cycle integrated into the pulp production process at a pulp mill, with particular emphasis on the calcium cycle within the lime kilns. Lime kilns are critical components, as their unavailability can significantly impact the overall cost-effectiveness of the facility. The calcination of lime sludge occurs in a rotary kiln, where calcium carbonate in the lime sludge is converted into calcium oxide (lime). Under certain conditions, material can progressively accumulate, leading to ring formation and eventual kiln clogging, resulting in operational downtime. To investigate this issue, the authors developed a physics-based model using a finite-dimensional, one-dimensional approach that considers only longitudinal variation. Several approximations were made to maintain a reasonable simulation time without compromising accuracy. Simulations based on real operational data identified fluctuations in fuel flow rate and sulfur content from non-condensable gases as key contributors to ring formation. The results showed that these fluctuations caused instability in the temperature profiles of the solids and gas beds, leading to periods of cooling before the lime sludge reaches the outlet to the coolers. This cooling promotes the recarbonation of lime and, consequently, the formation of rings. The findings highlight that stabilizing fuel flow and managing sulfur content could mitigate ring formation and improve kiln efficiency. The developed model provides a valuable tool for predictive analysis and process optimization, potentially supporting the development of a digital twin to enhance real-time monitoring and operational control. Full article

In hard milling, there has been a significant surge in demand for sustainable machining techniques. Research indicates that the Minimum Quantity Lubrication (MQL) method is a promising approach to achieving sustainability in milling processes due to its eco-friendly characteristics, as well as its cost-effectiveness and improved cooling efficiency compared to conventional flood cooling. This study investigates the end milling of AISI H11 die steel, utilizing a cooling system that involves a mixture of graphene nanoparticles (Gnps) and sesame oil for MQL. The experimental framework is based on a Taguchi L36 orthogonal array, with key parameters including feed rate, cutting speed, cooling condition, and air pressure. The resulting outcomes for cutting zone temperature and surface roughness were analyzed using the Taguchi Signal-to-Noise ratio and Analysis of Variance (ANOVA). Additionally, an Adaptive Neuro-Fuzzy Inference System (ANFIS) prediction model was developed to assess the impact of process parameters on cutting temperature and surface quality. The optimal cutting parameters were found to be a cutting speed of 40 m/min, a feed rate of 0.01 mm/rev, a jet pressure of 4 bar, and a nano-based MQL cooling environment. The adoption of these optimal parameters resulted in a substantial 62.5% reduction in cutting temperature and a 68.6% decrease in surface roughness. Furthermore, the ANFIS models demonstrated high accuracy, with 97.4% accuracy in predicting cutting temperature and 92.6% accuracy in predicting surface roughness, highlighting their effectiveness in providing precise forecasts for the machining process. Full article

Ti-6Al-4V is a titanium-based alloy that is widely used in a diverse range of applications, especially in industries such as biomedical and aerospace. Several lubricooling techniques have been introduced to enhance the machinability of these materials. Among them, environmentally friendly strategies are gaining in importance, with sustainability trends rising in manufacturing. The present research investigates the effect of two eco-friendly lubricooling techniques (minimum quantity lubrication and cryogenic cooling), along with other cutting parameters (cutting speed and feed per tooth), on the surface roughness and microhardness of the machined surfaces, which are identified as one of the most frequently implemented indicators of surface integrity in the ball-end milling of the Ti-6Al-4V alloy. In addition, the total electrical energy consumption of the machine tools under different cooling/lubrication conditions was also analyzed. The results obtained showed that cryogenic cooling enhanced milling performance as compared to MQL. Moreover, a multi-objective parameter optimization model integrating the machining responses (surface roughness, microhardness, energy consumption, and productivity) and sustainability metrics (environmental impact, operator’s health and safety, and waste management) was introduced. It was found that cryogenic cooling outperformed the MQL method in terms of both machining performance and environmental impact. An analysis of variance (ANOVA) was carried out to evaluate the significance of each process parameter on the multiple performance index. The results indicate that feed per tooth, cooling method, and cutting speed were significant, with respective contributions of 39.4%, 36.8%, and 22.9%. Finally, the optimal parameter setting was verified through a confirmation test and the results reveal that an improvement was observed in the machining responses and multiple performance index. Full article

In this study, the correlations between milling conditions—namely, the cutting tool feed direction relative to the rolling direction, the milling type, the coolant application, as well as the cutting speed—and the surface residual stress of a selected aluminum alloy (2024 T351) were investigated. Determining the type and magnitude of residual stress is of paramount importance as this stress is among the primary causes of post-machining strain of thin-walled components. On the basis of the experimental results, it was found that all factors analyzed significantly affect the residual stress state. Specifically, milling in the parallel direction induces lower residual tensile stress compared to milling in the perpendicular direction. Analogously, up-milling yields lower tensile residual stress than down-milling, and flood cooling leads to lower tensile residual stress than MQL. It was clearly confirmed that as cutting speed increases, tensile residual stress also increases, but only up to a certain threshold; once the high-speed cutting regime is reached, tensile residual stress begins to decrease. Consequently, the proper selection of milling parameters is a crucial consideration for optimizing machining processes and minimizing machining-induced residual stress. Full article