The manufacturing of parts from nickel-based superalloy, such as Inconel-800 alloy, represents a challenging task for industrial sites. Their performances can be enhanced by using a smart cutting fluid approach considered a sustainable alternative. Further, to innovate the cooling strategy, the researchers proposed an improved strategy based on the minimum quantity lubrication (MQL). It has an advantage over flood cooling because it allows better control of its parameters (i.e., compressed air, cutting fluid). In this study, the machinability of superalloy Inconel-800 has been investigated by performing different turning tests under MQL conditions, where no previous data are available. To reduce the numerous numbers of tests, a target objective was applied. This was used in combination with the response surface methodology (RSM) while assuming the cutting force input (F_c), potential of tool wear (VB_max), surface roughness (Ra), and the length of tool–chip contact (L) as responses. Thereafter, the analysis of variance (ANOVA) strategy was embedded to detect the significance of the proposed model and to understand the influence of each process parameter. To optimize other input parameters (i.e., cutting speed of machining, feed rate, and the side cutting edge angle (cutting tool angle)), two advanced optimization algorithms were introduced (i.e., particle swarm optimization (PSO) along with the teaching learning-based optimization (TLBO) approach). Both algorithms proved to be highly effective for predicting the machining responses, with the PSO being concluded as the best amongst the two. Also, a comparison amongst the cooling methods was made, and MQL was found to be a better cooling technique when compared to the dry and the flood cooling.

In this paper, the selected results of measurements and analysis of the active surfaces of a new generation of coated abrasive tools obtained by the use of focus-variation microscopy (FVM) are presented and discussed. The origin of this technique, as well as its general metrological characteristics is briefly described. Additionally, information regarding the focus variation microscope used in the experiments - InfiniteFocus^® IF G4 produced by Alicona Imaging, is also given. The measurements were carried out on microfinishing films (IMFF), abrasive portable belts with Cubitron™ II grains, and single-layer abrasive discs with Trizact™ grains. The obtained results were processed and analyzed employing TalyMap 4.0 software in the form of maps and profiles, surface microtopographies, Abbott- Firestone curves, and calculated values of selected areal parameters. This allowed us to describe the active surfaces of the coated abrasive tools, as well as to assess the possibility of applying the FVM technique in such kinds of measurements.

The following article presents the current state of knowledge about technologies connected with microcrystalline sintered corundum against the backdrop of present abrasive products and the contemporary grains market. The complementary presentation of issues related to the microcrystalline sintered corundum abrasive grains, which constitute an important group of abrasives used in modern grinding technology, was given. The most important stages in the development of sintered corundum grains production technology, from the 1960s to current developments (nanocrystalline sintered corundum) in this field, were presented in chronological order. The production technology, properties, working conditions, wear phenomena and most important areas of application of such abrasive grains were described. Particular attention was paid to the wear phenomena of microcrystalline sintered corundum abrasive grains occurring during the grinding process. The collection of phenomena affecting the extension of the life of these types of grain in comparison with the white fused alumina grains were described. Moreover, forecasts concerning the development of abrasive grains of micro- and nanocrystalline sintered corundum were presented.

The mechanical, physical and interfacial properties of aluminum alloys are improved by reinforcing the silicon carbide particles (SiC_p). Machinability of such alloys by traditional methods is challenging due to higher tool wear and surface roughness. The objective of research is to investigate the machinability of SiC_p reinforced Al6061 composite by Wire-Electrical Discharge Machining (wire-EDM). The effect of wire-EDM parameters namely current (I), pulse-on time (T_on), wire-speed (W_s), voltage (I_v) and pulse-off time (T_off) on material removal rate (MRR) is investigated and their settings are optimized for achieving the high MRR. The experiments are designed by using Taguchi L₁₆ orthogonal arrays. The MRR obtained at different experiments are analyzed using statistical tools. It is observed that all the chosen process parameters showed significant influence of on the MRR with contribution of 27.39%, 22.08%, 21.32%, 15.76% and 12.94% by I, I_v, T_off, T_on and W_s, respectively. At optimum settings, the Wire-EDM resulted in MRR of 65.21 mg/min and 62.41 mg/min for samples with 4% and 8% SiC_p. The results also indicated reinforcing SiC_p upto 8% showed marginally low influence on MRR. Microstructural investigation of the cut surface revealed the presence of craters with wave pattern on its surface. The top surface of the crater is featured by the recast layers connecting adjacent craters. Further, the statistical model is developed using linear regression to predict the MRR (R²—73.65%) and its predicting accuracy is verified by the confirmation trials. The statistical model is useful for predicting the MRR for different settings of the process parameters. The optimized settings can be used to improve the machining productivity by increasing the MRR while machining of Al6061-SiC_p (upto 8 wt. %) alloy by wire-EDM industries.

This article presents the results from a traverse internal cylindrical grinding process conducted using grinding wheels with sol–gel alumina abrasive grains and varying volumes of glass–ceramic vitrified bond. The aim was to determine how changing the bond volume within the range of V _b = 11.5–14.5 % influenced the wear phenomenon of the microcrystalline sintered corundum abrasive grains and the ceramic bond bridges with glass-crystalline structure. The paper presents grinding wheels with conic chamfer and the most important wear phenomena of the grinding wheel components occurring in the area of contact between the tool and the workpiece material. The work includes the methodology of the experimental tests on the traverse internal cylindrical grinding of bearing rings made from steel 100Cr6 (62 ± 2 HRC). A wide range of test results were analyzed, including machined surface roughness parameters (Ra, Rz, Sm, Δa), grinding power, grinding wheel volumetric wear V _s , material removal V _w , G-ratio, root-mean–square roundness deviation from mean circle (Δ, rms), grinding wheel edge wear, grinding wheel microtopography parameters (Sa, St, Sdr, Sds), and SEM images of the wear marks on the grinding wheel active surface. The dominant wear phenomena of the grinding wheels with conic chamfer and the influence of the bond volume share on its intensity were experimentally determined. The results show that the decrease in bond volume from V _b = 14.5 to 11.5 % increases the grinding wheel life by twofold. This was due to a decrease in abrasive wear and plastic flow phenomena and to a greater fracture wear (mostly fatigue and thermal-fatigue). These events led to a periodic shedding of the oxide layer and the plastically deformed grain layer and also revealed the crystals’ sharp edges, located below the plastically deformed surface layer.