Thermoplastic materials hold great promise for next-generation engineered and sustainable plastics and composites. However, due to their thermoplastic nature and viscoplastic material response, it is difficult to predict the properties of surfaces generated by machining. This is especially problematic in micro-channel machining, where burr formation and excessive surface roughness lead to poor component-surface integrity. This study attempts to model the influence of size effects, which occur due to the finite sharpness of any cutting tool, on surface finish and burr formation during micro-milling of an important thermoplastic material, polycarbonate. Experimental results show that the depth of cut does not affect either surface finish or burr formation. A proposed new sideflow model shows the dominant effect of cutting-edge radius and feed rate on surface finish, while tool edge roughness, coating and feed rate have the most pronounced influence on burr formation. Overall, a good agreement between the experimental data and the proposed size effect model for the machining of thermoplastic material was found. Based on these results, tool geometry and process parameters may be optimized for improved surface integrity of machined thermoplastic components.

Gamma titanium aluminide (γ-TiAl) is considered a high-performance, low-density replacement for nickel-based superalloys in the aerospace industry due to its high specific strength, which is retained at temperatures above 800 °C. However, low damage tolerance, i.e., brittle material behavior with a propensity to rapid crack propagation, has limited the application of γ-TiAl. Any cracks introduced during manufacturing would dramatically lower the useful (fatigue) life of γ-TiAl components, making the workpiece surface’s quality from finish machining a critical component to product quality and performance. To address this issue and enable more widespread use of γ-TiAl, this research aims to develop a real-time non-destructive evaluation (NDE) quality monitoring technique based on acoustic emission (AE) signals, wavelet transform, and deep neural networks (DNN). Previous efforts have opted for traditional approaches to AE signal analysis, using statistical feature extraction and classification, which face challenges such as the extraction of good/relevant features and low classification accuracy. Hence, this work proposes a novel AI-enabled method that uses a convolutional neural network (CNN) to extract rich and relevant features from a two-dimensional image representation of 1D time-domain AE signals (known as scalograms), subsequently classifying the AE signature based on pedigreed experimental data and finally predicting the process-induced surface quality. The results of the present work show good classification accuracy of 80.83% using scalogram images, in-situ experimental data, and a VGG-19 pre-trained neural network, establishing the significant potential for real-time quality monitoring in manufacturing processes.

The chief objective of manufacturing process improvement efforts is to significantly minimize process resources such as time, cost, waste, and consumed energy while improving product quality and process productivity. This paper presents a novel physics-informed optimization approach based on artificial intelligence (AI) to generate digital process twins (DPTs). The utility of the DPT approach is demonstrated in the case of finish machining of aerospace components made from gamma titanium aluminide alloy (γ-TiAl). This particular component has been plagued with persistent quality defects, including surface and sub-surface cracks, which adversely affect resource efficiency. Previous process improvement efforts have been restricted to anecdotal post-mortem investigation and empirical modeling, which fail to address the fundamental issue of how and when cracks occur during cutting. In this work, the integration of in-situ process characterization with modular physics-based models is presented, and machine learning algorithms are used to create a DPT capable of reducing environmental and energy impacts while significantly increasing yield and profitability. Based on the preliminary results presented here, an improvement in the overall embodied energy efficiency of over 84%, 93% in process queuing time, 2% in scrap cost, and 93% in queuing cost has been realized for γ-TiAl machining using our novel approach.