Friction surfacing is a solid-state coating process that uses plastic deformation to improve the efficiency of the core metallic pattern, resulting in fine-grained coatings with superior wear and corrosion properties. This article focuses on the development of inherently homogeneous, non-diluted coating of AISI316Ti stainless steel above EN8 and also encloses the empirical relationship for the prediction of bond strength (B_s), coating thickness (C_t), and coating width (C_w). The key individualities for bonding geometry were believed to be the process parameters such as rotational speed (rpm), traverse speed (mm/s), and axial load (kN). The effect of input parameters on the bond’s external dimensions and strength was investigated using a multi-objective optimization approach through experimentation. The bond’s strength improved as the coating thickness was reduced and the coating width was increased. The grain-refined coatings superimposing martensitic microstructure with no deposition of carbide particles added value to the metallurgical study using the scanning electron microscope.

During the machining of deep hole drilling in industries, Micro-Electrical Discharge machines are frequently exposed to pulse on time and high current, reducing tool life, micro-hole efficiency, machining accuracy, and production rate. As a result of this research, a ground-breaking strategy for overcoming the aforementioned industry problems has been discovered. In this analysis, nickel was coated on the brass electrode with a wall thickness of 2 µm to control the secondary reaction in the machining phase. Current, Voltage, Pulse-on time, and Capacitance parameters were investigated on the micro-coated tool in micro EDM. This article proposed the morphology wear behavior of the tool electrode by the Taguchi (L9 Orthogonal Array) design approach. Micro-holes are drilled with an aspect ratio of 20 on D2 steel using this technique. The coated tool will minimize tool wear and increase the material’s rate of removal and compromises the surface quality according to experimental results. Since a large taper angle was observed in the machining process by the Video Measuring Machine (VMM). The consistency of micro-holes on AISI D2 Steel has suffered, which is analyzed by Optical Microscope. In this research work the size of Crater wear discussed with SEM (Scanning Electron Microscope) images.

WEDM is regarded as a specialized thermo electric cutting process for precise machining in a wide range of materials with varied hardness and complex geometries that curtails utilization of conventional machining methods. The technology of WEDM process requires electricity to penetrate through a material with a thin conductive wire electrode as the tool. In this study, an untreated and deep cryogenic treated (196°C) brass wires are used to experiment with different machining variables such as peak current (IP), tension in the wire, pulse on time (T_ON), servo feed rate (SF), and pulse off time (T_OFF). Monel 400 alloy, a work material that has high mechanical strength and corrosion-resistant properties, for which the output responses such as Surface Roughness (SR) and Material Removal Rate (MRR) are investigated. Taguchi L27 orthogonal array was selected to formulate the design of experiments and to inquire the response of each variable from the output responses. The most influencing parameters such as pulse-on time on MRR, pulse-off time as contributing parameter in surface roughness and wire tension playing a vital role in kerf width were determined by the analysis of variance. MRR is greater with untreated brass wire than cryogenic treated brass wire. Cryogenically treated brass wire provides leverage over untreated brass wire in Surface Roughness and Kerf width. Surface morphological study proves that workpiece machined by deep cryogenic treated wire electrode provides better surface finish over untreated wire electrode which has large pores, voids, and unevenly distributed re-solidified particles. Experimental results are provided to verify this approach, and conclusion is to be drawn on the wire electrode with most phenomenal aspects.

The traditional way to machine hybrid composites is hard because they tend to break, have a high retraction, have a high service temperature, and have an uneven surface irregularity. For high-strength fiber/metal composite constructions, alternative machining methods have drawn interest as a solution to these problems. Current research focuses on enhancing the Abrasive Water Jet Machining process by optimizing its variables using a composite material of epoxy reinforced with silicon carbide, stainless steel wire mesh, and Kevlar. The variables assessed are the Nozzle-to-substrate gap (S), the Abrasive discharge molding and different percentages of silicon carbide (SiC) filler (0%, 3%, and 6% by weight), three different types of hybrid laminates (H1, H2, and H3) were produced. The response surface method (RSM) was utilized in this learning, specifically on a central composite design, to calculate and optimize machining variables based on the Kerf convergence ratio (K_t) and Surface irregularity (R_a) as responses. According to the results, the traverse feed velocity, Abrasive discharge proportion, and Nozzle-to-substrate gap are the critical factors in determining Surface irregularity and Kerf convergence width (H1 laminate) for a fiber/metal laminate with 0%, 3% and 6% weight fraction. In the case of a 3% weight fraction H2 laminate, the traverse feed velocity was identified as the primary factor affecting the Kerf convergence ratio. In contrast, traverse feed velocity and Nozzle-to-substrate gap had the most significant influence on Surface irregularity. The findings also indicated that S, followed by Abrasive discharge proportion and traverse feed velocity, are the variables that have the most significant influence when cutting 6 wt% SiC filler particle fiber/metal laminate (H3 laminate). For Surface irregularity, the combination of traverse feed velocity and Nozzle-to-substrate gap had the most significant impact. To validate the optimization results, confirmatory tests was conducted, and the findings were very similar to the experimental values, indicating the accuracy and effectiveness of the optimization process. To better understand the manufacturing processes, a scanning electron microscope was used to examine the morphological features of the machined surfaces, such as delamination, fibre breakage, and fibre pull-out.

The AM60B magnesium alloy remains a pivotal player in the pursuit of lighter, biodegradable and more sustainable solutions for various biomedical implants because of its excellent machinability, exceptional strength and resistance to degradation. However, AM60B magnesium alloys exhibit poor machinability when machined by conventional methods, since they are susceptible to deformation and degradation at elevated temperatures. The current work focused on multiresponse optimization for AM60B magnesium alloys for wire electrical discharge machining (WEDM), where multiple output variables including the machining rate, surface irregularity, and microindentation hardness, were considered simultaneously. Response surface methodology (RSM) along with artificial neural network (ANN) were utilized to investigate the effect of these parameters on the control of these output characteristics. The findings demonstrated the best combination of input specifications, with a discharge duration of 112.743 µs, a spark gap time of 57.6532 µs, a discharge voltage of 6.63 V and a wire advance rate of 5.39357 mm/min which yielded the best surface irregularity, microindentation hardness, and machining rate from the RSM. ANN and RSM models were effective in simulating the experiments, with predicted values closely aligning with the experimental results. An optimally trained network model exhibited good agreement with a mean error less than 5%. Additionally, the condition of the machined surface, including any cracks, voids, or other flaws, was examined using scanning electron microscope (SEM).

Developments in the evolution of manufacturing processes have directed their focus toward machining sustainability. A majority of manufacturing processes utilize a huge quantity of coolant to attain the desired surface finish. The process of grinding is a procedural example that requires a large amount of water to be mixed with the oil in order to produce an emulsion. Furthermore, grinding procedures such as centerless grinding necessitate a high rate of coolant flow to maintain workpiece quality. Minimum quantity lubrication (MQL) is an alternate fluid reduction method used in machining that reduces lubricant quantities to a higher extent. It also facilitates the nonspreading of cutting fluids around the work area, thus resulting a cleaner workplace. This work explicits the analysis of surface finish and roundness of EN19 steel grinding with three different machining conditions, namely, dry, wet, and MQL conditions. The results showed that by using MQL, the surface finish is closer to wet machining with reduced coolant usage and has a cleaner workplace.