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In the current study, analysis, modeling, and optimization of machining with nano-additives based minimum quantity lubrication (MQL) during turning Inconel 718 are presented and discussed. Multi-walled carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles were utilized as used nano-additives. The studied design variables include cutting speed, feed rate, and nano-additives percentage (wt. %). Three machining outputs were considered namely: flank wear, surface roughness, and energy consumption. The novelty here focuses on improving the MQL heat capacity by employing two different nano-fluids. The analysis of variance (ANOVA) technique was employed to investigate the influence of the design variables on the studied machining outputs. The results demonstrated that the usage of MQL-nanofluids improved the cutting process performance compared to the classical approach of MQL. It was found that 4 wt. % of added MWCNTs decreased the flank wear by 45.6% compared to the pure MQL. Similarly, it was found that 4 wt. % of added Al2O3 nanoparticles improved the tool wear by 37.2%. Besides, the nanotubes additives showed more improvements than Al2O3 nanoparticles in terms of tool wear, surface quality, and energy consumption. Regarding the modeling stage, artificial neural network (ANN), adaptive neuro-fuzzy inference system (ANFIS), and genetic programming (GP) are employed to model the measured outputs in terms of the studied parameters. These soft computing approaches provide various advantages through their self-learning capabilities, fuzzy principles, and evolutionary computational concept. In addition, a comparison among the developed models has been conducted to select the most accurate approach to present the machining characteristics. Finally, the non-dominated sorting genetic algorithm (NSGA-II) was utilized to optimize the studied cutting processes. Moreover, a comparison between the optimized results from different approaches is presented. The proposed methodology presented in this work can be further implemented in other machining cases to model, analyze as well as optimize the machining performance, especially for the hard-to-cut materials which are commonly used in different industries.
H. Hegab; A. Salem; S. Rahnamayan; H.A. Kishawy. Analysis, modeling, and multi-objective optimization of machining Inconel 718 with nano-additives based minimum quantity coolant. Applied Soft Computing 2021, 108, 107416 .
AMA StyleH. Hegab, A. Salem, S. Rahnamayan, H.A. Kishawy. Analysis, modeling, and multi-objective optimization of machining Inconel 718 with nano-additives based minimum quantity coolant. Applied Soft Computing. 2021; 108 ():107416.
Chicago/Turabian StyleH. Hegab; A. Salem; S. Rahnamayan; H.A. Kishawy. 2021. "Analysis, modeling, and multi-objective optimization of machining Inconel 718 with nano-additives based minimum quantity coolant." Applied Soft Computing 108, no. : 107416.
Tool failure detection is a crucial task for continuous safe machining operations. In this study, a novel approach is proposed to develop an accurate and simple tool condition classification model (TCCM) for early failure detection during machining processes. Signals from current, vibration, and acoustic emission sensors were preprocessed and used for feature extraction in both time and frequency domains, leading to a total of 152 features. Next, a feature reduction was carried out based on relative importance, computed using a fully-grown random forest, which reduced the number of features to 15. To find out the best combination of relevant signal features, a total of 32,767 optimized support vector classifiers were developed. The comparison between different candidate models was based on both accuracy and complexity. The results showed that a classification accuracy up to 0.911 is attainable for a process-independent classification model using only current sensors. Besides, developing an ensemble of material-dependent models showed a good potential for improvement, recording a classification accuracy up to 0.958 while using features extracted only from the current sensors. The novelty in the present study is in its focus on developing a single sensor-based high-accuracy TCCM. This opens the door for wider utilization of such technology, especially that all existing studies focused on increasing the accuracy using multi-sensor TCCMs, which increases the cost of this technology and makes it inaccessible, especially for small and medium enterprises.
Mohamed Abubakr; Muhammed A. Hassan; Grzegorz M. Krolczyk; Navneet Khanna; Hussien Hegab. Sensors selection for tool failure detection during machining processes: A simple accurate classification model. CIRP Journal of Manufacturing Science and Technology 2020, 32, 108 -119.
AMA StyleMohamed Abubakr, Muhammed A. Hassan, Grzegorz M. Krolczyk, Navneet Khanna, Hussien Hegab. Sensors selection for tool failure detection during machining processes: A simple accurate classification model. CIRP Journal of Manufacturing Science and Technology. 2020; 32 ():108-119.
Chicago/Turabian StyleMohamed Abubakr; Muhammed A. Hassan; Grzegorz M. Krolczyk; Navneet Khanna; Hussien Hegab. 2020. "Sensors selection for tool failure detection during machining processes: A simple accurate classification model." CIRP Journal of Manufacturing Science and Technology 32, no. : 108-119.
The hardened tool steel AISI O1 has increased strength, hardness, and wear resistance, which affects the complexity of the machining process. AISI O1 has also been classified as difficult to cut material hence optimum cutting parameters are required for the sustainable machining of the alloy. In this work, the effect of feed peer tooth (fz), cutting speed (vc), cutting of depth (ap) on surface roughness (Ra, Rt), cutting force (Fx, Fy), cutting power (Pc), machining cost (Ci), and carbon dioxide (Ene) were investigated during the slot milling process of AISI O1 hardened steel. A regression analysis was carried out on the obtained experimental results and the induction of nonlinear mathematical equations of surface roughness, cutting force, cutting power, and machining cost with a high coefficient of determination (R2 = 90.62–98.74%) were deduced. A sustainability assessment model is obtained for optimal and stable levels of design variables when slot milling AISI O1 tool steel. Stable indicators to ensure personal health and safety of operation, P1 values were set to “1” at a cutting speed of 20 m/min or 43.3 m/min and “2” at a cutting speed of 66.7 m/min or 90 m/min. It is revealed that for eco-benign machining of AISI O1, the optimum parameters of 0.01 mm/tooth, 20 m/min, and 0.1 mm should be adopted for feed rate, cutting speed, and depth of cut respectively.
Angelos P. Markopoulos; Nikolaos E. Karkalos; Mozammel Mia; Danil Yurievich Pimenov; Munish Kumar Gupta; Hussein Hegab; Navneet Khanna; Vincent Aizebeoje Balogun; Shubham Sharma. Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel. Metals 2020, 10, 1650 .
AMA StyleAngelos P. Markopoulos, Nikolaos E. Karkalos, Mozammel Mia, Danil Yurievich Pimenov, Munish Kumar Gupta, Hussein Hegab, Navneet Khanna, Vincent Aizebeoje Balogun, Shubham Sharma. Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel. Metals. 2020; 10 (12):1650.
Chicago/Turabian StyleAngelos P. Markopoulos; Nikolaos E. Karkalos; Mozammel Mia; Danil Yurievich Pimenov; Munish Kumar Gupta; Hussein Hegab; Navneet Khanna; Vincent Aizebeoje Balogun; Shubham Sharma. 2020. "Sustainability Assessment, Investigations, and Modelling of Slot Milling Characteristics in Eco-Benign Machining of Hardened Steel." Metals 10, no. 12: 1650.
This paper presents an experimental study into the comparative response of wiper and round-nose conventional carbide inserts coated with TiCN + AL2O3 + TiN when turning an AISI 4340 steel alloy. The optimal process parameters, as identified by pre-experiments, were used for both types of inserts to determine the machined surface quality, tool wear, and specific cutting energy for different cutting lengths. The wiper inserts provided a substantial improvement in the attainable surface quality compared with the results obtained using conventional inserts under optimal cutting conditions for the entire range of the machined lengths. In addition, the conventional inserts showed a dramatic increase in roughness with an increased length of the cut, while the wiper inserts showed only a minor increase for the same length of cut. A scanning electron microscope was used to examine the wear for both types of inserts. Conventional inserts showed higher trends for both the average and maximum flank wear with cutting length compared to the wiper inserts, except for lengths of 200–400 mm, where conventional inserts showed less average flank wear. A higher accumulation of deposited chips was observed on the flank face of the wiper inserts than the conventional inserts. The experimental results demonstrated that edge chipping was the chief tool wear mechanism on the rake face for both types of insert, with more edge chipping observed in the case of the conventional inserts than the wiper inserts, with negligible evidence of crater wear in either case. The wiper inserts were shown to have a higher specific cutting energy than those detected with conventional inserts. This was attributed to (i) the irregular nose feature of the wiper inserts differing from the simpler round nose geometry of the conventional inserts and (ii) a higher tendency of chip accumulation on the wiper inserts.
Adel T. Abbas; Saqib Anwar; Hussien Hegab; Faycal Benyahia; Hazem Ali; Ahmed Elkaseer. Comparative Evaluation of Surface Quality, Tool Wear, and Specific Cutting Energy for Wiper and Conventional Carbide Inserts in Hard Turning of AISI 4340 Alloy Steel. Materials 2020, 13, 5233 .
AMA StyleAdel T. Abbas, Saqib Anwar, Hussien Hegab, Faycal Benyahia, Hazem Ali, Ahmed Elkaseer. Comparative Evaluation of Surface Quality, Tool Wear, and Specific Cutting Energy for Wiper and Conventional Carbide Inserts in Hard Turning of AISI 4340 Alloy Steel. Materials. 2020; 13 (22):5233.
Chicago/Turabian StyleAdel T. Abbas; Saqib Anwar; Hussien Hegab; Faycal Benyahia; Hazem Ali; Ahmed Elkaseer. 2020. "Comparative Evaluation of Surface Quality, Tool Wear, and Specific Cutting Energy for Wiper and Conventional Carbide Inserts in Hard Turning of AISI 4340 Alloy Steel." Materials 13, no. 22: 5233.
Due to rising demands of replacing traditional cooling strategies with sustainable cooling strategies, the development of sustainable strategies such as minimum quantity lubrication (MQL) of nano-cutting fluids (NCFs) is on the rise. MQL of NCFs has received a lot of attention due to its positive impact on machining process efficiency. However, environmental and human health impacts of this strategy have not been fully investigated yet. This work aims to investigate the impacts of MQL of molybdenum disulfide (MoS2), multi-walled carbon nanotubes (MWCNTs), titanium dioxide (TiO2), and aluminum oxide (Al2O3) NCFs by employing a cradle-to-gate type of life cycle assessment (LCA). Besides, this paper provides a comparison of the impacts and machining performance when utilizing MQL of NCFs with other cooling strategies such as traditional flood cooling (TFC) of conventional cutting fluids and MQL of vegetable oils. It was found that NCFs have higher impacts than conventional cutting fluids and vegetable oils. The impacts of TiO2-NCF and MoS2-NCF were lower than the impacts of MWCNTs-NCF and Al2O3-NCF. MQL of NCFs presented higher impacts by 3.7% to 35.4% in comparison with the MQL of vegetable oils. TFC of conventional CFs displayed the lowest impact. However, TFC of conventional cutting fluids is contributing to severe health problems for operators. MQL of vegetable oils displayed higher impacts than TCFs of conventional cutting fluids. However, vegetable oils are considered to be environmentally friendly. According to the findings, the MQL of vegetable oils is the most sustainable strategy for machining processes with associated low/medium cutting temperatures. While MQL of TiO2 and MoS2 NCFs are the sustainable strategy for machining processes associated with high cutting temperatures.
Amr Salem; Connor Hopkins; Mohamd Imad; Hussien Hegab; Basil Darras; Hossam Kishawy. Environmental Analysis of Sustainable and Traditional Cooling and Lubrication Strategies during Machining Processes. Sustainability 2020, 12, 8462 .
AMA StyleAmr Salem, Connor Hopkins, Mohamd Imad, Hussien Hegab, Basil Darras, Hossam Kishawy. Environmental Analysis of Sustainable and Traditional Cooling and Lubrication Strategies during Machining Processes. Sustainability. 2020; 12 (20):8462.
Chicago/Turabian StyleAmr Salem; Connor Hopkins; Mohamd Imad; Hussien Hegab; Basil Darras; Hossam Kishawy. 2020. "Environmental Analysis of Sustainable and Traditional Cooling and Lubrication Strategies during Machining Processes." Sustainability 12, no. 20: 8462.
Many techniques have been developed to improve the machinability of aeronautical materials titanium and nickel-based alloys such as ultrasonic-assisted turning, laser-assisted turning, and cryogenic-assisted turning. This collaborative scientific investigation presents the steps taken to gain insight into the phenomena of machining Nimonic 90 (a nickel-based alloy) alloy using ultrasonically assisted turning. The cutting speed, feed rate, depth of cut, and frequency are taken as input parameters and average surface roughness (Ra), power consumption (P), and chip formation are considered as output parameters. The experiments are carried out with the full factorial design. The UAT (ultrasonically assisted turning) process gives a significant improvement in average surface roughness and power consumption because of the intermittent cutting action of the cutting tool. UAT process shows a 70–80% reduction in average surface roughness (Ra) and a 6–15% reduction in power consumption as compared with CT (conventional turning) process. Ultrasonically assisted turning also resulted in the thin and smoother chips as compared with CT process which helps to achieve a more superior machining effect. Finite element modeling shows that the quasi-static nature of the stress induced in the UAT process leads to lower force and ultimately lower power generation. Moreover, a sustainability assessment model is implemented to investigate the effect of UAT in terms of machining performance as well as sustainability effectiveness in a single integrated approach. The novelty of this work lies in providing an integrated concept that combines experimental analysis and sustainability assessment when using ultrasonic vibrational energy during turning of Nimonic 90.
Jay Airao; Navneet Khanna; Anish Roy; Hussien Hegab. Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility. The International Journal of Advanced Manufacturing Technology 2020, 109, 1447 -1462.
AMA StyleJay Airao, Navneet Khanna, Anish Roy, Hussien Hegab. Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility. The International Journal of Advanced Manufacturing Technology. 2020; 109 (5-6):1447-1462.
Chicago/Turabian StyleJay Airao; Navneet Khanna; Anish Roy; Hussien Hegab. 2020. "Comprehensive experimental analysis and sustainability assessment of machining Nimonic 90 using ultrasonic-assisted turning facility." The International Journal of Advanced Manufacturing Technology 109, no. 5-6: 1447-1462.
The proper implementation of sustainable manufacturing processes is an effective step towards a clean environment. The modern cooling strategies applied in the manufacturing sector have presented promising solutions that enable economic growth and ecological environment. In machining operations, cryogenic cooling and minimum quantity lubrication (MQL) have been extensively utilized to replace conventional cooling techniques. Thus, this work offers a detailed review of major works focused on manufacturing processes that use some of these sustainable cooling/lubrication modes (i.e., MQL, nanocutting fluids, nanofluid-based MQL strategy, and other miscellaneous MQL upgrades). The main driver of this study is to create a bridge between the past and present studies related to MQL and MQL upgrades. In this way, a new guideline can be established to offer clear directions for a better economic vision and a cleaner manufacturing process. Thus, this review has mainly focused on the machining of the most commonly used materials under MQL-related methods in conventional operations including turning, milling, drilling, and grinding. Current work provides a detailed insight into the major benefits, limitations, as well as mechanisms of cooling strategies that directly affects the machinability performance from a sustainable point of view. In summary, further potential upgrades are indicated so that it will help to drive more sustainable approaches in terms of cooling and lubrication environment during machining processes.
GurRaj Singh; Munish Kumar Gupta; Hussein Hegab; Aqib Mashood Khan; Qinghua Song; Zhanqiang Liu; Mozammel Mia; Muhammed Jamil; Vishal S Sharma; Murat Sarikaya; Catalin Iulian Pruncu. Progress for sustainability in the mist assisted cooling techniques: a critical review. The International Journal of Advanced Manufacturing Technology 2020, 109, 345 -376.
AMA StyleGurRaj Singh, Munish Kumar Gupta, Hussein Hegab, Aqib Mashood Khan, Qinghua Song, Zhanqiang Liu, Mozammel Mia, Muhammed Jamil, Vishal S Sharma, Murat Sarikaya, Catalin Iulian Pruncu. Progress for sustainability in the mist assisted cooling techniques: a critical review. The International Journal of Advanced Manufacturing Technology. 2020; 109 (1-2):345-376.
Chicago/Turabian StyleGurRaj Singh; Munish Kumar Gupta; Hussein Hegab; Aqib Mashood Khan; Qinghua Song; Zhanqiang Liu; Mozammel Mia; Muhammed Jamil; Vishal S Sharma; Murat Sarikaya; Catalin Iulian Pruncu. 2020. "Progress for sustainability in the mist assisted cooling techniques: a critical review." The International Journal of Advanced Manufacturing Technology 109, no. 1-2: 345-376.
The nano-fluid system efficiency is mostly governed by the amount, structure, and characteristics of the nano-additives and the mechanism by which the nano-fluids are distributed and sprayed to the tool–workpiece interface zone. The utilization of nano-additive-based cutting fluid demonstrated significant improvement in the wear behavior of the cutting tool. They also provide excellent cooling capabilities when machining is carried out at high temperatures especially when cutting difficult-to-machine workpiece material. The present study offers an in-depth study aided with solid analysis and interpretation for the tribological phenomenon associated with the nano-cutting fluids. In the current study, a relative wear volume model has been proposed and validated for two nano-cutting fluid cases. The presented model reveals that nanotubes offer less induced abrasive wear in comparison with the nanoparticles (i.e., the ratio between the induced nanoparticles wear to the nanotubes wear ranges from 139 up to 360 when the applied forces ranges from 10 up to 3000 N, respectively). To validate the model findings, machining experiments were carried out on Inconel 718 under nano-cutting fluid minimum quantity lubrication (MQL) with different cutting parameters and nano-additive concentrations. Two nano-additives performance have been worked out with the MQL conditions, namely, alumina nanoparticles (Al2O3) and multi-walled carbon nanotubes (MWCNTs). The wear on the flank face is determined for each cutting run to evaluate the performance of both nano-cutting fluids. The model estimates found to be consistent with the experimental findings as as MWCNTs showed less tool wear compared with Al2O3 (i.e., varied from 2 up to 150% at different cutting speeds and feed rates).
H. Hegab; U. Umer; A. Esawi; H. A. Kishawy. Tribological mechanisms of nano-cutting fluid minimum quantity lubrication: a comparative performance analysis model. The International Journal of Advanced Manufacturing Technology 2020, 108, 3133 -3139.
AMA StyleH. Hegab, U. Umer, A. Esawi, H. A. Kishawy. Tribological mechanisms of nano-cutting fluid minimum quantity lubrication: a comparative performance analysis model. The International Journal of Advanced Manufacturing Technology. 2020; 108 (9):3133-3139.
Chicago/Turabian StyleH. Hegab; U. Umer; A. Esawi; H. A. Kishawy. 2020. "Tribological mechanisms of nano-cutting fluid minimum quantity lubrication: a comparative performance analysis model." The International Journal of Advanced Manufacturing Technology 108, no. 9: 3133-3139.
This paper aims to present the environmental issues associated with conventional cutting fluids strategy and find out alternative solutions in terms of environmentally friendly cooling and lubrication techniques with high machining performance. In this view, this paper analyses the cleaner cooling and lubrication techniques, namely dry, MQL, and cryogenic machining with conventional lubrication technique, namely wet machining to reduce the usage of non-renewable energy source and recycle process without losing the productivity. In this context, cutting force, co-efficient of friction (CoF), energy consumption, surface roughness parameters and chip reduction coefficient (CRC) are measured for dry, wet, MQL, and cryogenic machining of 15−5 Precipitation Hardened Stainless Steel (PHSS) with variation in cutting speed and feed rate. Also, a previously applied sustainability assessment algorithm has been implemented to study the effectiveness of these cooling and lubrication strategies. The sustainability assessment includes machining performance as well as sustainable indicators (i.e., waste management, environmental impact as well as operational health and safety) in a single integrated analysis to achieve a balance between the machining efficiency and sustainability effectiveness. At higher value of cutting speed (199 m/min) and feed rate (0.333 mm/rev), 29.26 %, 52.68 % and 53.33 % increment in the value of cutting force were observed in dry, wet and MQL machining in comparison with cryogenic machining respectively. The higher values of CoF and CRC found in dry machining suggest more friction and amount of plastic deformation respectively as compared to other cutting fluid strategies. The 6.27 % higher value of energy consumption was observed in dry machining as compared to other cutting environments. At higher cutting parameters, in cryogenic machining, 6.76 %, 1.8 % and 26.62 % lower surface roughness (Ra) were observed as compared to dry, wet and MQL machining, respectively.
Navneet Khanna; Prassan Shah; Radoslaw W. Maruda; Grzegorz M. Krolczyk; Hussien Hegab. Experimental investigation and sustainability assessment to evaluate environmentally clean machining of 15-5 PH stainless steel. Journal of Manufacturing Processes 2020, 56, 1027 -1038.
AMA StyleNavneet Khanna, Prassan Shah, Radoslaw W. Maruda, Grzegorz M. Krolczyk, Hussien Hegab. Experimental investigation and sustainability assessment to evaluate environmentally clean machining of 15-5 PH stainless steel. Journal of Manufacturing Processes. 2020; 56 ():1027-1038.
Chicago/Turabian StyleNavneet Khanna; Prassan Shah; Radoslaw W. Maruda; Grzegorz M. Krolczyk; Hussien Hegab. 2020. "Experimental investigation and sustainability assessment to evaluate environmentally clean machining of 15-5 PH stainless steel." Journal of Manufacturing Processes 56, no. : 1027-1038.
This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel.
Adel T. Abbas; Magdy M. El Rayes; Monis Luqman; Noha Naeim; Hussien Hegab; Ahmed Elkaseer. On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts. Materials 2020, 13, 2036 .
AMA StyleAdel T. Abbas, Magdy M. El Rayes, Monis Luqman, Noha Naeim, Hussien Hegab, Ahmed Elkaseer. On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts. Materials. 2020; 13 (9):2036.
Chicago/Turabian StyleAdel T. Abbas; Magdy M. El Rayes; Monis Luqman; Noha Naeim; Hussien Hegab; Ahmed Elkaseer. 2020. "On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts." Materials 13, no. 9: 2036.
Sustainable manufacturing philosophy strives for energy-efficient, high quality, and productivity as critical characteristics of a milling process. Hence, an attempt was made to limit the energy consumption, and tool wear in the face milling of hard-to-cut titanium alloy without compromising product quality and productivity. For that, a strong influence of hybrid alumina and multiwalled carbon nanotube (Al2O3-MWCNT) nanoadditive-based minimum quantity lubrication (MQL) was investigated on key machining characteristics. The simultaneous influence of control factors on machining characteristics was evaluated through mathematical modeling and the most straightforward multi-objective optimization. Based on the multi-objective decision approach, the energy consumption of Ec = 829.78 W, surface roughness Ra = 0.549 μm, and material removal rate MRR = 303.9 mm3/min were attained at cutting speed N = 3800 rpm, feed f = 0.012 mm/tooth, depth of cut ap = 0.40 mm, and width of cut ae = 3.6 mm respectively. Despite the trade-off among energy consumption, surface roughness, and material removal rate, the desirability function tried to strike a balanced operating level to achieve less energy consumption, better surface quality, and higher materials removal rate. Additionally, tool wear, chip analysis, and surface topography as key characteristics of the milling process were considered to analyze the wear behavior, chip sliding, and machined surface characteristics under hybrid nanoadditive-based MQL machining. The novelty of this experimental work lies in considering important milling characteristics of hard-to-cut Ti–6Al–4V alloy under hybrid nanofluid-assisted MQL machining. Regarding sustainable green cutting technology, clean cutting of titanium alloy was implemented by nanoadditive-assisted MQL technique.
Muhammad Jamil; Aqib Mashood Khan; Hussien Hegab; Munish Kumar Gupta; Mozammel Mia; Ning He; Guolong Zhao; Qinghua Song; Zhanqiang Liu. Milling of Ti–6Al–4V under hybrid Al2O3-MWCNT nanofluids considering energy consumption, surface quality, and tool wear: a sustainable machining. The International Journal of Advanced Manufacturing Technology 2020, 107, 4141 -4157.
AMA StyleMuhammad Jamil, Aqib Mashood Khan, Hussien Hegab, Munish Kumar Gupta, Mozammel Mia, Ning He, Guolong Zhao, Qinghua Song, Zhanqiang Liu. Milling of Ti–6Al–4V under hybrid Al2O3-MWCNT nanofluids considering energy consumption, surface quality, and tool wear: a sustainable machining. The International Journal of Advanced Manufacturing Technology. 2020; 107 (9-10):4141-4157.
Chicago/Turabian StyleMuhammad Jamil; Aqib Mashood Khan; Hussien Hegab; Munish Kumar Gupta; Mozammel Mia; Ning He; Guolong Zhao; Qinghua Song; Zhanqiang Liu. 2020. "Milling of Ti–6Al–4V under hybrid Al2O3-MWCNT nanofluids considering energy consumption, surface quality, and tool wear: a sustainable machining." The International Journal of Advanced Manufacturing Technology 107, no. 9-10: 4141-4157.
The surface modification is a pivotal step in the field of the biomedical implant in order to improve its biomedical characteristics. A number of methods can be adopted to improve surface characteristics like coating, evaporation, sputtering, and ion implantation. The surface of any material can also be improved by machining. In the present work, an electric discharge drilling (EDD) was used for the development of quality holes on any conductive material regardless of its hardness. In the present research, commercially pure titanium (CPTi) was drilled for the development of microhole using the EDD. The effect of microholes on the apatite formation and weight gain was determined. The apatite formation was measured in the presence of simulated body fluid (SBF) after 7, 14, and 21 days of immersion. The temperature and pH during the apatite formation were 37 °C and 7.4, respectively. It was found that after the development of microholes, the quantity of apatite formation increases. On the contrary side on the normal CPTi material (without drilling), an insignificant apatite formation was observed. However, after drilling, the elements of calcium and phosphate were observed ever after 4 days of immersion in SBF. The surface area of the apatite formation increases by 24% after the development of microholes. Scanning electron microscopy (SEM) revealed the microstructure of the drilled surface before and after the immersion of CPTi in SBF. In addition, it was observed that with the increase in the number of holes and immersion period, the apatite formation increases.
Neeraj Ahuja; Neeraj Sharma; Hussien Hegab; Rajesh Khanna; Aqib Mashood Khan. Bioactivity measurement of commercially pure titanium processed by micro-electric discharge drilling. The International Journal of Advanced Manufacturing Technology 2020, 107, 2797 -2805.
AMA StyleNeeraj Ahuja, Neeraj Sharma, Hussien Hegab, Rajesh Khanna, Aqib Mashood Khan. Bioactivity measurement of commercially pure titanium processed by micro-electric discharge drilling. The International Journal of Advanced Manufacturing Technology. 2020; 107 (5-6):2797-2805.
Chicago/Turabian StyleNeeraj Ahuja; Neeraj Sharma; Hussien Hegab; Rajesh Khanna; Aqib Mashood Khan. 2020. "Bioactivity measurement of commercially pure titanium processed by micro-electric discharge drilling." The International Journal of Advanced Manufacturing Technology 107, no. 5-6: 2797-2805.
The necessity for decreasing the negative impact of the manufacturing industry has recently increased. This is getting recognized as a global challenge due to the rapid increase in life quality standards, demand, and the decrease in available resources. Thus, manufacturing, as a core of the product provision system and a fundamental pillar of civilized existence, is significantly influenced by sustainability issues. Furthermore, current manufacturing modeling and assessment criteria require intensive revisions and upgrades to keep up with these new challenges. Nearly all current manufacturing models are based on the old paradigm, which was proven to be inadequate. Therefore, manufacturing technology, along with culture and economy, are held responsible for providing new tools and opportunities for building novel resolutions towards a sustainable manufacturing concept. One of such tools is sustainability assessment measures. Revising and updating such tools is a core responsibility of the manufacturing sector to efficiently evaluate and enhance sustainable manufacturing performance. These measures should be adequate to respond to the growing sustainability concerns in pursuit of an integrated sustainability concept. The triple bottom line (TBL) that includes environment, economic, and social dimensions has usually been used to evaluate sustainability. However, there is a lack of standard sets of sustainable manufacturing performance measures. In addition to the sustainability concept, a new concept of smart manufacturing is emerging. The smart manufacturing concept takes advantage of the recent technological leap in Artificial Intelligent (AI), Cloud Computing (CC), and the Internet of Things (IoT). Although this concept offers an important step to boost the current production capabilities to meet the growing need, it is still not clear whether the two concepts of smart manufacturing and sustainability will constructively or destructively interact. Therefore, the current study aims to integrate the sustainable smart manufacturing performance by incorporating sustainable manufacturing measures and discussing current and future challenges that are faced by the manufacturing sector. In addition, the opportunities for future research incorporating sustainable smart manufacturing are also presented.
Mohamed Abubakr; Adel T. Abbas; Italo Tomaz; Mahmoud S. Soliman; Monis Luqman; Hussien Hegab. Sustainable and Smart Manufacturing: An Integrated Approach. Sustainability 2020, 12, 2280 .
AMA StyleMohamed Abubakr, Adel T. Abbas, Italo Tomaz, Mahmoud S. Soliman, Monis Luqman, Hussien Hegab. Sustainable and Smart Manufacturing: An Integrated Approach. Sustainability. 2020; 12 (6):2280.
Chicago/Turabian StyleMohamed Abubakr; Adel T. Abbas; Italo Tomaz; Mahmoud S. Soliman; Monis Luqman; Hussien Hegab. 2020. "Sustainable and Smart Manufacturing: An Integrated Approach." Sustainability 12, no. 6: 2280.
Titanium alloys are widely used in various applications including biomedicine, aerospace, marine, energy, and chemical industries because of their superior characteristics such as high hot strength and hardness, low density, and superior fracture toughness and corrosion resistance. However, there are different challenges when machining titanium alloys because of the high heat generated during cutting processes which adversely affects the product quality and process performance in general. Thus, optimization of the machining conditions while machining such alloys is necessary. In this work, an experimental investigation into the influence of different cutting parameters (i.e., depth of cut, cutting length, feed rate, and cutting speed) on surface roughness (Rz), flank wear (VB), power consumption as well as the material removal rate (MRR) during high-speed turning of Ti-6Al-4V alloy is presented and discussed. In addition, a backpropagation neural network (BPNN) along with the technique for order of preference by similarity to ideal solution (TOPSIS)-fuzzy integrated approach was employed to model and optimize the overall cutting performance. It should be stated that the predicted values for all machining outputs demonstrated excellent agreement with the experimental values at the selected optimal solution. In addition, the selected optimal solution did not provide the best performance for each measured output, but it achieved a balance among all studied responses.
Adel T. Abbas; Neeraj Sharma; Saqib Anwar; Monis Luqman; Italo Tomaz; Hussien Hegab. Multi-Response Optimization in High-Speed Machining of Ti-6Al-4V Using TOPSIS-Fuzzy Integrated Approach. Materials 2020, 13, 1104 .
AMA StyleAdel T. Abbas, Neeraj Sharma, Saqib Anwar, Monis Luqman, Italo Tomaz, Hussien Hegab. Multi-Response Optimization in High-Speed Machining of Ti-6Al-4V Using TOPSIS-Fuzzy Integrated Approach. Materials. 2020; 13 (5):1104.
Chicago/Turabian StyleAdel T. Abbas; Neeraj Sharma; Saqib Anwar; Monis Luqman; Italo Tomaz; Hussien Hegab. 2020. "Multi-Response Optimization in High-Speed Machining of Ti-6Al-4V Using TOPSIS-Fuzzy Integrated Approach." Materials 13, no. 5: 1104.
The need of a cost-effective production system is indispensable, especially in the current competitive manufacturing market. To the same extent, special attention should be focused on the sustainable and clean machining processes. Several studies have focused on the machining of hard-to-cut materials using sustainable and clean cutting technologies. However, there is a need to establish a detailed and reliable cost-energy model for sustainable machining processes. In this research, empirical models have been developed for cost and energy consumption to define the system boundaries under different cooling conditions. Mono and hybrid nanofluids have been synthesized and their performance is evaluated by analyzing viscosity, thermal conductivity, and coefficient of friction. Moreover, a holistic sustainability assessment has been performed for the measured results. The surface roughness, power and energy consumption, tool life and cost per part are determined and the results are compared with those obtained in classical MQL process. It should be noted that the study findings offer guidelines which can be easily implemented in any metal processing industry to enhance the process’s performance measures. Furthermore, this work is the first of its kind that proposes hybrid Energy-Cost models and their experimental validations.
Aqib Mashood Khan; Munish Kumar Gupta; Hussein Hegab; Muhammad Jamil; Mozammel Mia; Ning He; Qinghua Song; Zhanqiang Liu; Catalin Iulian Pruncu. Energy-based cost integrated modelling and sustainability assessment of Al-GnP hybrid nanofluid assisted turning of AISI52100 steel. Journal of Cleaner Production 2020, 257, 120502 .
AMA StyleAqib Mashood Khan, Munish Kumar Gupta, Hussein Hegab, Muhammad Jamil, Mozammel Mia, Ning He, Qinghua Song, Zhanqiang Liu, Catalin Iulian Pruncu. Energy-based cost integrated modelling and sustainability assessment of Al-GnP hybrid nanofluid assisted turning of AISI52100 steel. Journal of Cleaner Production. 2020; 257 ():120502.
Chicago/Turabian StyleAqib Mashood Khan; Munish Kumar Gupta; Hussein Hegab; Muhammad Jamil; Mozammel Mia; Ning He; Qinghua Song; Zhanqiang Liu; Catalin Iulian Pruncu. 2020. "Energy-based cost integrated modelling and sustainability assessment of Al-GnP hybrid nanofluid assisted turning of AISI52100 steel." Journal of Cleaner Production 257, no. : 120502.
To improve the machinability of Inconel 718, a lot of work has been done in the past decade by modifying tools and machining processes. However, a recently developed cryogenic-ultrasonic assisted turning (CUAT) process influencing the machinability of Inconel 718 as compared to the conventional turning process (CT) has not been conspicuously presented. This paper analyzes the machinability of Inconel 718 using indigenously developed ultrasonic assisted turning (UAT) and CUAT facilities. The influence of the UAT process of Inconel 718 on cutting parameters recommended by the industry has been investigated. Surface roughness (Ra) and power consumption are measured under the UAT process and then compared with the CT process. Particle swarm optimization (PSO) algorithm is used to identify the optimum cutting parameters to achieve minimum Ra and power consumption for UAT and CT processes. The optimized parameters are considered to confirm the usefulness of CUAT as compared to UAT and CT processes. Experimental results of this research work endorse positive effects of the CUAT process over UAT and CT processes in terms of Ra and chip morphology. Ra values under the CUAT process are reduced significantly in comparison to UAT and CT processes, respectively. UAT and CUAT processes resulted in discontinuous chips having smaller chip thickness in comparison to the CT process. The results are being shared with the local SMEs, and the industry is anticipated to be benefited in terms of improving cutting performance using CUAT and UAT. Moreover, a sustainability assessment model is implemented to investigate the effect of CUAT in terms of machining performance as well as sustainability effectiveness in a single integrated approach.
Navneet Khanna; Prassan Shah; Chetan Agrawal; Franci Pusavec; Hussien Hegab. Inconel 718 machining performance evaluation using indigenously developed hybrid machining facilities: experimental investigation and sustainability assessment. The International Journal of Advanced Manufacturing Technology 2020, 106, 4987 -4999.
AMA StyleNavneet Khanna, Prassan Shah, Chetan Agrawal, Franci Pusavec, Hussien Hegab. Inconel 718 machining performance evaluation using indigenously developed hybrid machining facilities: experimental investigation and sustainability assessment. The International Journal of Advanced Manufacturing Technology. 2020; 106 (11-12):4987-4999.
Chicago/Turabian StyleNavneet Khanna; Prassan Shah; Chetan Agrawal; Franci Pusavec; Hussien Hegab. 2020. "Inconel 718 machining performance evaluation using indigenously developed hybrid machining facilities: experimental investigation and sustainability assessment." The International Journal of Advanced Manufacturing Technology 106, no. 11-12: 4987-4999.
In the present research, a bio-composite material was initially designed and developed as per the requirement of prosthesis implants. Hydroxyapatite (HA) is considered as one of mostly used biomaterial due their unique characteristics of similarity in the composition of human bone and its bioactivity. Ti–6Al–4V is one of the foremost used materials in bio-implants due to their strength, wear resistance, corrosion resistance and bio-compatibility. The addition of HA in Ti alloy substantially improves its bioactivity and biocompatibility. However, at the same time, the wear rate of bio-composite increases. In the present work, Ti–6Al–4V/hydroxyapatite composite was developed by powder metallurgy method. To evaluate the real-time tribological characterization, the biocomposite was processed against the Al2O3 counter-surface in the presence of phosphate buffered saline (PBS) as a lubricant. In terms of characterization, the pin-on-disk tribometer was used for the evaluation of wear rate and friction coefficients in the range of 5 N–30 N of load. Scanning electron microscopy (SEM) micrographs revealed that plastic deformation and the abrasion are the main mechanisms of biocomposite/Al2O3 system. The pull-out material from the biocomposite plays a negative role on the friction coefficient and wear rate.
Gurpreet Singh; Neeraj Sharma; Deepak Kumar; Hussien Hegab. Design, development and tribological characterization of Ti–6Al–4V/hydroxyapatite composite for bio-implant applications. Materials Chemistry and Physics 2020, 243, 122662 .
AMA StyleGurpreet Singh, Neeraj Sharma, Deepak Kumar, Hussien Hegab. Design, development and tribological characterization of Ti–6Al–4V/hydroxyapatite composite for bio-implant applications. Materials Chemistry and Physics. 2020; 243 ():122662.
Chicago/Turabian StyleGurpreet Singh; Neeraj Sharma; Deepak Kumar; Hussien Hegab. 2020. "Design, development and tribological characterization of Ti–6Al–4V/hydroxyapatite composite for bio-implant applications." Materials Chemistry and Physics 243, no. : 122662.
Nowadays, titanium alloys are achieving a significant interest in the field of aerospace, biomedical, automobile industries especially due to their extremely high strength to weight ratio, corrosive resistance, and ability to withstand higher temperatures. However, titanium alloys are well known for their higher chemical reactive and low thermal conductive nature which, in turn, makes it more difficult to machine especially at high cutting speeds. Hence, optimization of high-speed machining responses of Ti–6Al–4V has been investigated in the present study using a hybrid approach of multi-objective optimization based on ratio analysis (MOORA) integrated with regression and particle swarm approach (PSO). This optimization approach is employed to offer a balance between achieving better surface quality with maintaining an acceptable material removal rate level. The position of global best suggested by the hybrid optimization approach was: Cutting speed 194 m/min, depth of cut of 0.1 mm, feed rate of 0.15 mm/rev, and cutting length of 120 mm. It should be stated that this solution strikes a balance between achieving lower surface roughness in terms of Ra and Rq, with reaching the highest possible material removal rate. Finally, an investigation of the tool wear mechanisms for three studied cases (i.e., surface roughness based, productivity-based, optimized case) is presented to discuss the effectiveness of each scenario from the tool wear perspective.
Adel T. Abbas; Neeraj Sharma; Saqib Anwar; Faraz H. Hashmi; Muhammad Jamil; Hussien Hegab. Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V. Materials 2019, 12, 3749 .
AMA StyleAdel T. Abbas, Neeraj Sharma, Saqib Anwar, Faraz H. Hashmi, Muhammad Jamil, Hussien Hegab. Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V. Materials. 2019; 12 (22):3749.
Chicago/Turabian StyleAdel T. Abbas; Neeraj Sharma; Saqib Anwar; Faraz H. Hashmi; Muhammad Jamil; Hussien Hegab. 2019. "Towards Optimization of Surface Roughness and Productivity Aspects during High-Speed Machining of Ti–6Al–4V." Materials 12, no. 22: 3749.
In bone fixation, frictional heat effect in orthopedic surgery has a potentially hazardous for soft tissues. Saline water irrigation has frequently been practiced preventing the thermal damage and limiting the applied cutting forces in high-speed orthopedic drilling. The application of excessive cutting fluids limits the heat and applied forces; however, it isn’t an environmentally friendly solution. In this work, a novel micro-irrigation system was developed to provide a mixture of air and saline water, having a small quantity of cooling spray (SQCS) at higher pressure into the cutting zone. This SQCS limits the frictional heat and providing lubrication and near to dry clean operative zone through a superior cooling effect compared to conventional irrigation. The carbide drills were used to make a hole in the fresh calf tibia bone. In addition, response surface methodology (RSM) was used to design the experiments. The regression models were developed between the input design parameters and performance measures to explore the relation under proposed micro-irrigation and facilitate the multi-objective optimization. Besides, cost analysis for the process has been performed. Thus, this work offers an integrated analysis to purely study and understand the bone drilling process under employing micro-cooling spray.
Muhammad Jamil; Aqib Mashood Khan; Hussien Hegab; Mozammel Mia; Munish Kumar Gupta. Modeling, multi-objective optimization and cost estimation of bone drilling under micro-cooling spray technique: an integrated analysis. International Journal on Interactive Design and Manufacturing (IJIDeM) 2019, 14, 435 -450.
AMA StyleMuhammad Jamil, Aqib Mashood Khan, Hussien Hegab, Mozammel Mia, Munish Kumar Gupta. Modeling, multi-objective optimization and cost estimation of bone drilling under micro-cooling spray technique: an integrated analysis. International Journal on Interactive Design and Manufacturing (IJIDeM). 2019; 14 (2):435-450.
Chicago/Turabian StyleMuhammad Jamil; Aqib Mashood Khan; Hussien Hegab; Mozammel Mia; Munish Kumar Gupta. 2019. "Modeling, multi-objective optimization and cost estimation of bone drilling under micro-cooling spray technique: an integrated analysis." International Journal on Interactive Design and Manufacturing (IJIDeM) 14, no. 2: 435-450.
In this work, an extensive analysis has been presented and discussed to study the effectiveness of using different cooling and lubrication techniques when turning AISI 1045 steel. Three different approaches have been employed, namely dry, flood, and minimum quantity lubrication based nanofluid (MQL-nanofluid). In addition, three multi-objective optimization models have been employed to select the optimal cutting conditions. These cases include machining performance, sustainability effectiveness, and an integrated model which covers both machining outputs (i.e., surface roughness and power consumption) and sustainability aspects (carbon dioxide emissions and total machining cost). The results provided in this work offer a clear guideline to select the optimal cutting conditions based on different scenarios. It should be stated that MQL-nanofluid offered promising results through the three studied cases compared to dry and flood approaches. When considering both sustainability aspects and machining outputs, it is found that the optimal cutting conditions are cutting speed of 147 m/min, depth of cut of 0.28 mm and feed rate of 0.06 mm/rev using MQL-nanofluid. The three studied multi-objective optimization models obtained in this work provide flexibility to the decision maker(s) to select the appropriate cooling/lubrication strategy based on the desired objectives and targets, whether these targets are focused on machining performance, sustainability effectiveness, or both. Thus, this work offers a promising attempt in the open literature to optimize the machining process from the performance–sustainability point of view.
Adel T. Abbas; Faycal Benyahia; Magdy M. El Rayes; Catalin Pruncu; Mohamed A. Taha; Hussien Hegab. Towards Optimization of Machining Performance and Sustainability Aspects when Turning AISI 1045 Steel under Different Cooling and Lubrication Strategies. Materials 2019, 12, 3023 .
AMA StyleAdel T. Abbas, Faycal Benyahia, Magdy M. El Rayes, Catalin Pruncu, Mohamed A. Taha, Hussien Hegab. Towards Optimization of Machining Performance and Sustainability Aspects when Turning AISI 1045 Steel under Different Cooling and Lubrication Strategies. Materials. 2019; 12 (18):3023.
Chicago/Turabian StyleAdel T. Abbas; Faycal Benyahia; Magdy M. El Rayes; Catalin Pruncu; Mohamed A. Taha; Hussien Hegab. 2019. "Towards Optimization of Machining Performance and Sustainability Aspects when Turning AISI 1045 Steel under Different Cooling and Lubrication Strategies." Materials 12, no. 18: 3023.