Metal additive manufacturing (AM) is capable of producing complex parts, using a wide range of functional metals that are otherwise very difficult to make and involve multiple manufacturing processes. However, because of the involvement of thermal energy in the fabrication of metallic AM parts, residual stress remains one of the major concerns in metal AM. This residual stress has negative effects on part quality, dimensional accuracy, and part performance. This study aims to carry out a comprehensive review and analysis of different aspects of residual stress, including the causes and mechanisms behind the generation of residual stress during metal AM, the state-of-the-art measurement techniques for measuring residual stress, various factors influencing residual stress, its effect on part quality and performance, and ways of minimizing or overcoming residual stress in metal AM parts. Residual stress formation mechanisms vary, based on the layer-by-layer deposition mechanism of the 3D printing process. For example, the residual stress formation for wire-arc additive manufacturing is different from that of selective laser sintering, direct energy deposition, and powder bed fusion processes. Residual stress formation mechanisms also vary based on the scale (i.e., macro, micro, etc.) at which the printing is performed. In addition, there are correlations between printing parameters and the formation of residual stress. For example, the printing direction, layer thickness, internal structure, etc., influence both the formation mechanism and quantitative values of residual stress. The major effect residual stress has on the quality of a printed part is in the distortion of the part. In addition, the dimensional accuracy, surface finish, and fatigue performance of printed parts are influenced by residual stress. This review paper provides a qualitative and quantitative analysis of the formation, distribution, and evolution of residual stress for different metal AM processes. This paper also discusses and analyzes both in situ and ex situ measurement techniques for measuring residual stress. Microstructural evolution and its effect on the formation of residual stress are analyzed. Various pre- and post-processing techniques used to countermeasure residual stress are discussed in detail. Finally, this study aims to present both a qualitative and quantitative analysis of the existing data and techniques in the literature related to residual stress, as well as to provide a critical analysis and guidelines for future research directions, to prevent or overcome residual stress formation in metal AM processes.

Advances in sensing technologies are increasingly transforming cutting operations by enabling data-driven condition monitoring, predictive maintenance, and process optimization. This review surveys recent developments in sensing modalities for cutting systems, including vibration sensors, acoustic emission sensors, optical and vision-based systems, eddy-current sensors, force sensors, and emerging hybrid/multi-modal sensing frameworks. Each sensing approach offers unique advantages in capturing mechanical, acoustic, geometric, or electromagnetic signatures related to tool wear, process instability, and fault development, while also showing modality-specific limitations such as noise sensitivity, environmental robustness, and integration complexity. Recent trends show a growing shift toward hybrid and multi-modal sensor fusion, where data from multiple sensors are combined using advanced data analytics and machine learning to improve diagnostic accuracy and reliability under changing cutting conditions. The review also discusses how artificial intelligence, Internet of Things connectivity, and edge computing enable scalable, real-time monitoring solutions, along with the challenges related to data needs, computational costs, and system integration. Future directions highlight the importance of robust fusion architectures, physics-informed and explainable models, digital twin integration, and cost-effective sensor deployment to accelerate adoption across various manufacturing environments. Overall, these advancements position advanced sensing and hybrid monitoring strategies as key drivers of intelligent, Industry 4.0-oriented cutting processes.

The effect of the grinding process for weld flash removal on the surface integrity of the welded joint has not been researched. The surface integrity of the welded joint is essential for the bandsaw blade life and to prevent any premature failure at the weld joint due to fatigue loading (a band saw blade undergoes mainly cyclic bending fatigue during its service). In this study, the effects of using different cutting fluid combinations on the grinding of weld flash in medium carbon alloy steel were carried out. The use of compressed air (CA) as a sustainable solution for grinding weld flash was explored. An experimental investigation of four different cutting fluid applications (dry/no cutting fluid, compressed air, minimum quantity lubricant using vegetable oil, and minimum quantity coolant using water-soluble oil) was carried out. The surface roughness, sub-surface residual stresses, and microhardness of the ground region were measured. This is a first-of-the-kind study on the effect of the flash removal process on the surface integrity of the welded joint. The results show that the surface integrity of the welded joint is significantly influenced by the cutting fluid application used during the grinding process of the flash. Dry grinding, the current industry standard for grinding weld flash in band saw blades, produced surface tensile residual stresses (24.82 MPa), lowest sub-surface microhardness (43.28 HRc), and the highest surface roughness (3.40 µm). In comparison, the air application had the highest surface compressive residual stresses (−289.57 MPa), highest sub-surface microhardness (48.67 HRc), and relatively low surface roughness (1.61 µm). This study provides the road map for selecting the cutting fluid application for grinding weld flash produced by the resistance welding process in the band sawing industry.

Cutting fluids used in machining have received a lot of attention due to their adverse environmental and economic effects. Researchers have studied cutting fluid usage in traditional machining processes such as turning, facing, milling, etc. However, few studies focused on the cutting fluid used in band sawing applications. This study reports a literature review of the usage of the cutting fluid in band sawing and their sustainable and economic aspects. A review of the literature and industrial data has shown that the majority of band saw blades use high-speed steel as the cutting tool material for cutting metal. This study presents a metric-based sustainability assessment and a detailed analysis of recent economic factors such as the cost of the cutting fluids used in band sawing through industrial case studies. A global survey of the cutting fluid usage in the bandsawing application has shown that the majority of the industry is employing flood coolant application. The flood coolant application cost can be as high as 8% of the total consumables cost of the band sawing process.