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Data-driven chatter detection techniques avoid complex physical modeling and provide the basis for industrial applications of cutting process monitoring. Among them, feature extraction is the key step of chatter detection, which can compensate for the accuracy disadvantage of machine learning algorithms to some extent if the extracted features are highly correlated with the milling condition. However, the classification accuracy of the current feature extraction methods is not satisfactory, and a combination of multiple features is required to identify the chatter. This limits the development of unsupervised machine learning algorithms for chattering detection, which further affects the application in practical processing. In this paper, the fractal feature of the signal is extracted by structure function method (SFM) for the first time, which solves the problem that the features are easily affected by process parameters. Milling chatter is identified based on k-means algorithm, which avoids the complex process of training model, and the judgment method of milling chatter is also discussed. The proposed method can achieve 94.4% identification accuracy by using only one single signal feature, which is better than other feature extraction methods, and even better than some supervised machine learning algorithms. Moreover, experiments show that chatter will affect the distribution of cutting bending moment, and it is not reliable to monitor tool wear through the polar plot of the bending moment. This provides a theoretical basis for the application of unsupervised machine learning algorithms in chatter detection.
Runqiong Wang; Qinghua Song; Zhanqiang Liu; Haifeng Ma; Munish Kumar Gupta; Zhaojun Liu. A Novel Unsupervised Machine Learning-Based Method for Chatter Detection in the Milling of Thin-Walled Parts. Sensors 2021, 21, 5779 .
AMA StyleRunqiong Wang, Qinghua Song, Zhanqiang Liu, Haifeng Ma, Munish Kumar Gupta, Zhaojun Liu. A Novel Unsupervised Machine Learning-Based Method for Chatter Detection in the Milling of Thin-Walled Parts. Sensors. 2021; 21 (17):5779.
Chicago/Turabian StyleRunqiong Wang; Qinghua Song; Zhanqiang Liu; Haifeng Ma; Munish Kumar Gupta; Zhaojun Liu. 2021. "A Novel Unsupervised Machine Learning-Based Method for Chatter Detection in the Milling of Thin-Walled Parts." Sensors 21, no. 17: 5779.
Cutting fluid has cooling and lubricating properties and is an important part of the field of metal machining. Owing to harmful additives, base oils with poor biodegradability, defects in processing methods, and unreasonable emissions of waste cutting fluids, cutting fluids have serious pollution problems, which pose challenges to global carbon emissions laws and regulations. However, the current research on cutting fluid and its circulating purification technique lacks systematic review papers to provide scientific technical guidance for actual production. In this study, the key scientific issues in the research achievements of eco-friendly cutting fluid and waste fluid treatment are clarified. First, the preparation and mechanism of organic additives are summarized, and the influence of the physical and chemical properties of vegetable base oils on lubricating properties is analyzed. Then, the process characteristics of cutting fluid reduction supply methods are systematically evaluated. Second, the treatment of oil mist and miscellaneous oil, the removal mechanism and approach of microorganisms, and the design principles of integrated recycling equipment are outlined. The conclusion is concluded that the synergistic effect of organic additives, biodegradable vegetable base oils and recycling purification effectively reduces the environmental pollution of cutting fluids. Finally, in view of the limitations of the cutting fluid and its circulating purification technique, the prospects of amino acid additive development, self-adapting jet parameter supply system, matching mechanism between processing conditions and cutting fluid are put forward, which provides the basis and support for the engineering application and development of cutting fluid and its circulating purification.
Xifeng Wu; Changhe Li; Zongming Zhou; Xiaolin Nie; Yun Chen; Yanbin Zhang; Huajun Cao; Bo Liu; Naiqing Zhang; Zafar Said; Sujan Debnath; Muhammad Jamil; Hafiz Muhammad Ali; Shubham Sharma. Circulating purification of cutting fluid: an overview. The International Journal of Advanced Manufacturing Technology 2021, 1 -36.
AMA StyleXifeng Wu, Changhe Li, Zongming Zhou, Xiaolin Nie, Yun Chen, Yanbin Zhang, Huajun Cao, Bo Liu, Naiqing Zhang, Zafar Said, Sujan Debnath, Muhammad Jamil, Hafiz Muhammad Ali, Shubham Sharma. Circulating purification of cutting fluid: an overview. The International Journal of Advanced Manufacturing Technology. 2021; ():1-36.
Chicago/Turabian StyleXifeng Wu; Changhe Li; Zongming Zhou; Xiaolin Nie; Yun Chen; Yanbin Zhang; Huajun Cao; Bo Liu; Naiqing Zhang; Zafar Said; Sujan Debnath; Muhammad Jamil; Hafiz Muhammad Ali; Shubham Sharma. 2021. "Circulating purification of cutting fluid: an overview." The International Journal of Advanced Manufacturing Technology , no. : 1-36.
Belt grinding of flat surfaces of typical parts made of steel and alloys, such as grooves, shoulders, ends, and long workpieces, is a good alternative to milling. Several factors can influence the belt grinding process of flat surfaces of metals, such as cutting speed and pressure. In this work, the importance of pressure in the belt grinding was investigated in terms of technological and experimental aspects. The grinding experiments were performed on structural alloy steel 30KhGSN2/30KhGSNA, structural carbon steel AISI 1045, corrosion-resistant and heat-resistant stainless steel AISI 321, and heat-resistant nickel alloy KHN77TYuR. The performance of the grinding belt was investigated in terms of surface roughness, material removal rate (MRR), grinding belt wear, performance index. Estimated indicators of the belt grinding process were developed: cutting ability; reduced cutting ability for belt grinding of steels and heat-resistant alloy. It was found that with an increase in pressure p, the surface roughness of the processed surface Ra decreased while the tool wear
Nelli Vladimirovna Syreyshchikova; Danil Yurievich Pimenov; Munish Kumar Gupta; Krzysztof Nadolny; Khaled Giasin; Muhammad Aamir; Shubham Sharma. Relationship between Pressure and Output Parameters in Belt Grinding of Steels and Nickel Alloy. Materials 2021, 14, 4704 .
AMA StyleNelli Vladimirovna Syreyshchikova, Danil Yurievich Pimenov, Munish Kumar Gupta, Krzysztof Nadolny, Khaled Giasin, Muhammad Aamir, Shubham Sharma. Relationship between Pressure and Output Parameters in Belt Grinding of Steels and Nickel Alloy. Materials. 2021; 14 (16):4704.
Chicago/Turabian StyleNelli Vladimirovna Syreyshchikova; Danil Yurievich Pimenov; Munish Kumar Gupta; Krzysztof Nadolny; Khaled Giasin; Muhammad Aamir; Shubham Sharma. 2021. "Relationship between Pressure and Output Parameters in Belt Grinding of Steels and Nickel Alloy." Materials 14, no. 16: 4704.
Grain-scale modelling and simulation is of vital importance during the full lifecycle of crystalline material miniature parts, whose mechanical responses depend on the actual material microstructure, part geometry and their correlation. Unfortunately, current studies fail to comprehensively consider indispensable microstructure information, and lack the consideration regarding part geometry. Therefore, this paper proposes and implements a geometry-considered 3D pseudorandom grain-scale modelling method, which takes into account the necessary actual microstructure information, part geometry and their mutual relations to generate accurate and efficient microstructure-dependent crystal plasticity finite element (M−CPFE) models. Firstly, the 3D actual grain-scale microstructure was acquired efficiently by combining 2D actual microstructures. Then the geometry-considered grain-scale microstructure was created pseudorandomly based on the actual 3D grain size, orientation and misorientation distributions. On this basis, the M−CPFE model was constructed accurately. The proposed method has been proved to have higher accuracy and robustness than the Voronoi random method on macroscopic response prediction, microstructure generation and microstructure evolution prediction. Furthermore, the applicability in micro-manufacturing and service has been demonstrated by micro sheet bending and micro impeller rotation simulations. There is a great potential for the full lifecycle tracking of crystalline material miniature parts with the help of the proposed method.
Hansong Ji; Qinghua Song; Munish Kumar Gupta; Wentong Cai; Jiahao Shi; Zhanqiang Liu. Geometry-considered 3D pseudorandom grain-scale modelling for crystalline material miniature parts. Materials & Design 2021, 210, 110054 .
AMA StyleHansong Ji, Qinghua Song, Munish Kumar Gupta, Wentong Cai, Jiahao Shi, Zhanqiang Liu. Geometry-considered 3D pseudorandom grain-scale modelling for crystalline material miniature parts. Materials & Design. 2021; 210 ():110054.
Chicago/Turabian StyleHansong Ji; Qinghua Song; Munish Kumar Gupta; Wentong Cai; Jiahao Shi; Zhanqiang Liu. 2021. "Geometry-considered 3D pseudorandom grain-scale modelling for crystalline material miniature parts." Materials & Design 210, no. : 110054.
Advance cooling/lubrication (lubricooling) approaches are getting fame in industry and academia due to their excellent performance. A significant amount of work has been conducted to investigate the effect of various lubricooling approaches on the machinability of the hardened steel. However, sustainability-based performance evaluation of lubricooling assisted machining is missing. Thus, this paper presents 3E-based (Energy, Economics, Environment) analysis to compare the performance of various lubricooling approaches. Initially, preliminary experiments were performed to achieve optimal flow rates of various cutting fluids used in Minimum Quantity Lubrication (MQL), cryogenic cooling, and conventional emulsion (Flood) approaches. Later, optimal flow rates were used to achieve equal cutting-tool life under all machining environments. Results showed that with the same tool life method (STLM), Cryogenic-MQL(CryoMQL) could withstand aggressive cutting speeds and produce the highest productivity among all lubricooling approaches. In addition, it yielded 50% lower-priced specific production cost as compared to dry machining. However, 44.3% more specific-CO2 emitted in CryoMQL as compared with dry machining. In summary, the hybrid CryoMQL assisted machining process is sustainable economically but not environmentally. The outcomes of the present study provide useful information, and it can help machinist to enhance the process performance.
Aqib Mashood Khan; Mohammed Alkahtani; Shubham Sharma; Muhammad Jamil; Asif Iqbal; Ning He. Sustainability-based holistic assessment and determination of optimal resource consumption for energy-efficient machining of hardened steel. Journal of Cleaner Production 2021, 319, 128674 .
AMA StyleAqib Mashood Khan, Mohammed Alkahtani, Shubham Sharma, Muhammad Jamil, Asif Iqbal, Ning He. Sustainability-based holistic assessment and determination of optimal resource consumption for energy-efficient machining of hardened steel. Journal of Cleaner Production. 2021; 319 ():128674.
Chicago/Turabian StyleAqib Mashood Khan; Mohammed Alkahtani; Shubham Sharma; Muhammad Jamil; Asif Iqbal; Ning He. 2021. "Sustainability-based holistic assessment and determination of optimal resource consumption for energy-efficient machining of hardened steel." Journal of Cleaner Production 319, no. : 128674.
This article reflects the main sources of risks for metallurgical enterprises in Russia, presenting the implementation of an innovative approach to increasing the competitiveness of an industrial enterprise, which is a typical representative of large enterprises of the metallurgical industry, based on the development of risk-oriented thinking when loading rolling mills with orders of intersecting assortment according to a new model. To reduce the emerging risks of a new model of the loading process of rolling mills of a metallurgical enterprise, it is proposed to take into account the risks in a complex way, taking into account their interactions with the use of integrated risk management (IRM). Practical development of the implemented approach was carried out by identifying the risks of the new improved loading process and their causes at each stage of the process. Risks were identified by analysis, qualitative and quantitative assessment of the likelihood of risks and the severity of consequences from their implementation with the establishment of events with a high potential hazard. Possible causes of hazardous events have been identified. To reduce the likelihood of unfavorable events, measures have been developed to influence significant risks and their effectiveness has been determined. The development of an innovative approach using risk-based thinking in a previously unexplored field of the application provides competitive advantages for enterprises of the metallurgical industry, increases income by reducing the cost of manufacturing products and production volumes by reducing time costs, achieving an economic efficiency of up to 10 million rubles per year. The practical significance of the dissemination of development results in similar industries is obvious and relevant for metallurgy as a whole.
Nelli Syreyshchikova; Danil Pimenov; Elena Yaroslavova; Munish Gupta; Muhammad Aamir; Khaled Giasin. Managing Risks in the Improved Model of Rolling Mill Loading: A Case Study. Journal of Risk and Financial Management 2021, 14, 359 .
AMA StyleNelli Syreyshchikova, Danil Pimenov, Elena Yaroslavova, Munish Gupta, Muhammad Aamir, Khaled Giasin. Managing Risks in the Improved Model of Rolling Mill Loading: A Case Study. Journal of Risk and Financial Management. 2021; 14 (8):359.
Chicago/Turabian StyleNelli Syreyshchikova; Danil Pimenov; Elena Yaroslavova; Munish Gupta; Muhammad Aamir; Khaled Giasin. 2021. "Managing Risks in the Improved Model of Rolling Mill Loading: A Case Study." Journal of Risk and Financial Management 14, no. 8: 359.
Building orientation is important in selective laser melting (SLM) processes. Current studies only focus on the horizontal and vertical building orientations without considering different modes of horizontal orientations. In fact, for horizontal orientation, different surfaces of the sample that contact the substrate will affect the heat transfer mode and efficiency, and in turn affect the microstructure and material properties. In this paper, the effect of two modes of horizontal building orientations on microstructure, mechanical and surface properties of SLM Ti6Al4V was studied. Current research about building orientation is deficient because the geometry of samples or test surfaces are not strictly defined, which seriously influences the results due to their different heat transfer efficiency and mode. Therefore, the geometry of the samples and test surfaces were clearly defined, and its necessity was proved in this study. To achieve the research goal, three test samples were prepared: sample SLM-PB-S with the building orientation parallel to the substrate and the shorter side L1 contacts it, sample SLM-PB-L with the building orientation parallel to the substrate and the longer side L2 contacts it and sample SLM-VB with the building orientation vertical to the substrate. Subsequently, the microstructure, grain information, densification, residual stress, micro-hardness, tensile properties and surface topography of different samples were analyzed and compared. In the results, SLM-PB-S exhibited denser microstructure and better mechanical properties than SLM-PB-L, including smaller grain size, stronger texture, higher density, micro-hardness, tensile strength, plasticity and better surface quality. It originates from a higher cooling rate and shorter scanning time between layers during SLM-PB-S fabrication, leading to finer grains, lower porosity and better interlayer metallurgical bonding, thus resulting in better material properties. This study can provide a reference to select the proper building orientation in SLM.
Wentong Cai; Qinghua Song; Hansong Ji; Munish Gupta. Multi-Perspective Analysis of Building Orientation Effects on Microstructure, Mechanical and Surface Properties of SLM Ti6Al4V with Specific Geometry. Materials 2021, 14, 4392 .
AMA StyleWentong Cai, Qinghua Song, Hansong Ji, Munish Gupta. Multi-Perspective Analysis of Building Orientation Effects on Microstructure, Mechanical and Surface Properties of SLM Ti6Al4V with Specific Geometry. Materials. 2021; 14 (16):4392.
Chicago/Turabian StyleWentong Cai; Qinghua Song; Hansong Ji; Munish Gupta. 2021. "Multi-Perspective Analysis of Building Orientation Effects on Microstructure, Mechanical and Surface Properties of SLM Ti6Al4V with Specific Geometry." Materials 14, no. 16: 4392.
Owing to the extreme heat generated during Inconel 718 machining, the application of a minimum quantity lubrication (MQL) strategy is restricted to mild cutting conditions. By incorporating vegetable-based cutting oils reinforced by nanoparticles as possible additives, the effectiveness of MQL can be improved in high-speed machining. In this study, hybrid nano-green oils were developed by combining graphene nanoparticles in various volume concentrations with sunflower oil. Subsequently, dispersion stability, thermal conductivity, viscosity, and wetting angle of nano-green oils were measured. An MQL device is used to disperse the smallest amount of nano-green oils throughout the machining area. Later, the experimentally optimized graphene-based green oil is used for milling experiments. Furthermore, hard machining experiments were conducted with cutting speed of 80 m/min, feed rate of 0.2 mm/rev, and depth of cut of 0.5 mm under four different lubricating mediums: dry, flooded, sunflower oil, and 0.7% graphene reinforced sunflower oil. Comparative results show that 0.7% graphene reinforced sunflower oil performs better and reduces surface roughness by 49%, cutting force by 25%, cutting temperature by 31%, and tool wear by 20% as compared to dry machining environment. Finally, elemental analysis of cutting insert reports that adhesion is the major wear mechanism in all mediums.
Mohd Danish; Munish Kumar Gupta; Saeed Rubaiee; Anas Ahmed; Murat Sarikaya. Influence of graphene reinforced sunflower oil on thermo-physical, tribological and machining characteristics of inconel 718. Journal of Materials Research and Technology 2021, 15, 135 -150.
AMA StyleMohd Danish, Munish Kumar Gupta, Saeed Rubaiee, Anas Ahmed, Murat Sarikaya. Influence of graphene reinforced sunflower oil on thermo-physical, tribological and machining characteristics of inconel 718. Journal of Materials Research and Technology. 2021; 15 ():135-150.
Chicago/Turabian StyleMohd Danish; Munish Kumar Gupta; Saeed Rubaiee; Anas Ahmed; Murat Sarikaya. 2021. "Influence of graphene reinforced sunflower oil on thermo-physical, tribological and machining characteristics of inconel 718." Journal of Materials Research and Technology 15, no. : 135-150.
In the aviation and structural industries, the requirement of smooth holes is an important safety problem. Since holes are a part of the joints made with fasteners, they affect the fatigue strength of the structure. Therefore, it is necessary to be very selective in terms of cutting parameters and cutting tools, especially in drilling metal/composite or composite/metal stacked materials. In this context, cutting conditions in conventional machining methods should be optimized or novel machining methods should be applied. In this context, this study minimized the limitations in machining of carbon fiber-reinforced composite (CFRP)/Ti6Al4V alloy stack material and the delamination problem that occurs especially in composite laminates. For this purpose, cutting conditions have been optimized for each of CFRP/Ti6Al4V alloy material, depending on the thrust force (Fz), surface roughness (Ra), and delamination factor (Fd) obtained by preliminary tests. The drilling tests were performed at the cutting speed of 60 m/min, the feed rate of 0.05 mm/rev for CFRP material, the cutting speed of 15 m/min, and the feed rate 0.05 mm/rev for Ti6Al4V material. The novel method for this study is that the tool was kept in the air for 1 min after each 4 mm drilling of Ti6Al4V alloy to cool the tool during the rebounds to the safe approach distance. Finally, according to the optimized cutting parameters, Fz, Ra, and Fd were assessed to evaluate the performances of cutting tools in the drilling of CFRP/Ti6Al4V stacked material. According to the experimental results and images of the digital camera and SEM device, flank wear and cracking as the wear type in the U-WC tool; flank wear, cracking, and BUE as the wear type in the TiAlN-coated tools; and outer corner wear and coating removal in diamond-coated tools. Moreover, when the tool performance is evaluated according to the cutting tool tip angle, the highest amount of wear was seen in cutting tools with 140° point angle.
Nafiz Yaşar; Mehmet Erdi Korkmaz; Munish Kumar Gupta; Mehmet Boy; Mustafa Günay. A novel method for improving drilling performance of CFRP/Ti6AL4V stacked materials. The International Journal of Advanced Manufacturing Technology 2021, 1 -21.
AMA StyleNafiz Yaşar, Mehmet Erdi Korkmaz, Munish Kumar Gupta, Mehmet Boy, Mustafa Günay. A novel method for improving drilling performance of CFRP/Ti6AL4V stacked materials. The International Journal of Advanced Manufacturing Technology. 2021; ():1-21.
Chicago/Turabian StyleNafiz Yaşar; Mehmet Erdi Korkmaz; Munish Kumar Gupta; Mehmet Boy; Mustafa Günay. 2021. "A novel method for improving drilling performance of CFRP/Ti6AL4V stacked materials." The International Journal of Advanced Manufacturing Technology , no. : 1-21.
Nickel based super alloys are considered as difficult to machine materials. These days, the sustainable cooling system are applied at the cutting zone for enhancing the machining performance of nickel based super alloys. Therefore, the present work focusses on the machining aspects of Nimonic 80A under different cooling conditions. Moreover, the turning experiments were performed under dry, minimum quantity lubrication (MQL different positions) and nano-MQL (different positions) conditions and the influence of nozzle position during MQL and nano-MQL were investigated. The tool wear, surface roughness, mechanism promoting tool wear, power consumption and chips morphology were investigated under these subjected conditions. The outcomes of this study state that the position of MQL nozzles plays an important role to improve the machining performance of Nimonic-80 alloy. The total tool wear is approximately 60% better for nano-MQL (mixed direction) than dry conditions. The results also stated that abrasion and adhesion are prompting tool wear mechanisms observed under dry conditions.
Mehmet Erdi Korkmaz; Munish Kumar Gupta; Mehmet Boy; Nafiz Yaşar; Grzegorz M. Krolczyk; Mustafa Günay. Influence of duplex jets MQL and nano-MQL cooling system on machining performance of Nimonic 80A. Journal of Manufacturing Processes 2021, 69, 112 -124.
AMA StyleMehmet Erdi Korkmaz, Munish Kumar Gupta, Mehmet Boy, Nafiz Yaşar, Grzegorz M. Krolczyk, Mustafa Günay. Influence of duplex jets MQL and nano-MQL cooling system on machining performance of Nimonic 80A. Journal of Manufacturing Processes. 2021; 69 ():112-124.
Chicago/Turabian StyleMehmet Erdi Korkmaz; Munish Kumar Gupta; Mehmet Boy; Nafiz Yaşar; Grzegorz M. Krolczyk; Mustafa Günay. 2021. "Influence of duplex jets MQL and nano-MQL cooling system on machining performance of Nimonic 80A." Journal of Manufacturing Processes 69, no. : 112-124.
The recent step towards “Sustainable Manufacturing (SM)” and efforts to reduce the consumption of cutting fluids have become the hot topic of research these days. Various efforts and strategies have been employed in the modern manufacturing sector to control the environmental pollutions generated from the application of cutting fluids. Therefore, in this holistic work, one such effort of reducing the consumption of cutting fluid is employed with the application of minimum quantity lubrication (MQL) and tool texturing. The turning trials were made on titanium alloy:Ti3Al2.5V alloy under dry and MQL conditions using textured and non-textured tools. The tool life, average surface roughness, specific cutting energy, air quality, and chip morphology were studied with the aid of the above-subjected conditions. In the end, the socio-economic aspects of all cooling conditions were studied and analyzed in the context of sustainable manufacturing. The outcomes of this study reveal that the combination of textured tools and minimum quantity lubrication considerably enhance the machining and sustainability performance as contended with other conditions. However, the air quality factor, i.e., PM2.5 particle generation, was less in the case of a textured tool with MQL conditions. Overall, it is worthy to mention that the combination of tool texturing and MQL cooling conditions has been considered as one of the potential combinations in the area of green machining.
Rupinder Singh; Munish Kumar Gupta; Murat Sarikaya; Mozammel Mia; A. Garcia-Collado. Evaluation of machinability-based sustainability indicators in the eco-benign turning of Ti3Al2.5V alloy with textured tools. The International Journal of Advanced Manufacturing Technology 2021, 1 -11.
AMA StyleRupinder Singh, Munish Kumar Gupta, Murat Sarikaya, Mozammel Mia, A. Garcia-Collado. Evaluation of machinability-based sustainability indicators in the eco-benign turning of Ti3Al2.5V alloy with textured tools. The International Journal of Advanced Manufacturing Technology. 2021; ():1-11.
Chicago/Turabian StyleRupinder Singh; Munish Kumar Gupta; Murat Sarikaya; Mozammel Mia; A. Garcia-Collado. 2021. "Evaluation of machinability-based sustainability indicators in the eco-benign turning of Ti3Al2.5V alloy with textured tools." The International Journal of Advanced Manufacturing Technology , no. : 1-11.
Composites have excellent material properties such as lightness, rigidity, and strength with reinforcement of specialized materials to serve an extended field in engineering. Meanwhile, some restrictions due to the production process lead to poor machinability characteristics and show reduced surface quality, excessive cutting temperature, and tool wear. The principal aim in this study is to research the machinability characteristics of Cu matrix reinforced by B and ceramic CrC powders during dry turning operation. In addition to reinforcement ratio, cutting speed, feed rate, and depth of cut were taken into consideration according to Taguchi L8 orthogonal array in the experimental plan. Seemingly, reinforcement ratio is the governing factor over turning parameters on flank wear, surface roughness, and cutting temperatures. For the secondary effect, cutting speed and feed rate have contributing impact on cutting temperatures and surface roughness, respectively. Lastly, reinforcement ratio has significant impact on chip formation since deformation mechanism in the material is changed with cutting initiation. Accordingly, new additives reveal unique structure which is intriguing and need to be discovered for measuring the machinability behavior of metal matrix composites.
Üsame Ali Usca; Mahir Uzun; Mustafa Kuntoğlu; Emine Sap; Munish Kumar Gupta. Investigations on tool wear, surface roughness, cutting temperature, and chip formation in machining of Cu-B-CrC composites. The International Journal of Advanced Manufacturing Technology 2021, 1 -15.
AMA StyleÜsame Ali Usca, Mahir Uzun, Mustafa Kuntoğlu, Emine Sap, Munish Kumar Gupta. Investigations on tool wear, surface roughness, cutting temperature, and chip formation in machining of Cu-B-CrC composites. The International Journal of Advanced Manufacturing Technology. 2021; ():1-15.
Chicago/Turabian StyleÜsame Ali Usca; Mahir Uzun; Mustafa Kuntoğlu; Emine Sap; Munish Kumar Gupta. 2021. "Investigations on tool wear, surface roughness, cutting temperature, and chip formation in machining of Cu-B-CrC composites." The International Journal of Advanced Manufacturing Technology , no. : 1-15.
In this work, wire electrical discharge machining (WEDM) of aluminum (LM25) reinforced with fly ash and boron carbide (B4C) hybrid composites was performed to investigate the influence of reinforcement wt% and machining parameters on the performance characteristics. The hybrid composite specimens were fabricated through the stir casting process by varying the wt% of reinforcements from 3 to 9. In the machinability studies, the WEDM process control parameters such as gap voltage, pulse-on time, pulse-off time, and wire feed were varied to analyze their effects on machining performance including volume removal rate and surface roughness. The WEDM experiments were planned and conducted through the L27 orthogonal array approach of the Taguchi methodology, and the corresponding volume removal rate and surface roughness were measured. In addition, the multi-parametric ANOVA was performed to examine the statistical significance of the process control parameters on the volume removal rate and surface roughness. Furthermore, the spatial distribution of the parameter values for both the responses were statistically analyzed to confirm the selection of the range of the process control parameters. Finally, the quadratic multiple linear regression models (MLRMs) were formulated based on the correlation between the process control parameters and output responses. The Grass–Hooper Optimization (GHO) algorithm was proposed in this work to identify the optimal process control parameters through the MLRMs, in light of simultaneously maximizing the volume removal rate and minimizing the surface roughness. The effectiveness of the proposed GHO algorithm was tested against the results of the particle swarm optimization and moth-flame optimization algorithms. From the results, it was identified that the GHO algorithm outperformed the others in terms of maximizing volume removal rate and minimizing the surface roughness values. Furthermore, the confirmation experiment was also carried out to validate the optimal combination of process control parameters obtained through the GHO algorithm.
Nagarajan Lenin; Mahalingam Sivakumar; Gurusamy Selvakumar; Devaraj Rajamani; Vinothkumar Sivalingam; Munish Gupta; Tadeusz Mikolajczyk; Danil Pimenov. Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study. Metals 2021, 11, 1105 .
AMA StyleNagarajan Lenin, Mahalingam Sivakumar, Gurusamy Selvakumar, Devaraj Rajamani, Vinothkumar Sivalingam, Munish Gupta, Tadeusz Mikolajczyk, Danil Pimenov. Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study. Metals. 2021; 11 (7):1105.
Chicago/Turabian StyleNagarajan Lenin; Mahalingam Sivakumar; Gurusamy Selvakumar; Devaraj Rajamani; Vinothkumar Sivalingam; Munish Gupta; Tadeusz Mikolajczyk; Danil Pimenov. 2021. "Optimization of Process Control Parameters for WEDM of Al-LM25/Fly Ash/B4C Hybrid Composites Using Evolutionary Algorithms: A Comparative Study." Metals 11, no. 7: 1105.
The poor thermal conductivity of Inconel 718 leads to higher cutting temperatures and, as a consequence, rapid tool degradation is a common phenomenon. As a result, a hybrid lubri-cooling environment for turning Inconel 718 alloys is proposed, incorporating the theory of cryogenic cooling and minimum quantity lubrication (Cryo-MQL). For improved lubri-cooling effect, Cryo-MQL integrates the application of a minimum quantity of vegetable oil and liquid nitrogen from two distinct nozzles in the cutting zone. Surface roughness, cutting temperature, tool wear, chip morphology, and micro-structure of the machined surface were evaluated for different lubri-cooling mediums: dry, MQL, Cryogenic, and Cryo-MQL. In comparison to a dry medium, the Cryo-MQL environment decreases surface roughness, cutting temperature, and tool wear by 60.6%, 37%, and 19.5%, respectively. Adhesion and abrasion were patented to be common tool wear types, as per SEM micro-graphs. Eventually, in the Cryo-MQL environment, a spike in micro-hardness value has been reported. However, during processing with Cryo-MQL, the grain structure of the working material is found to be smaller as compared to other mediums.
Mohd Danish; Munish Kumar Gupta; Saeed Rubaiee; Anas Ahmed; Mehmet Erdi Korkmaz. Influence of hybrid Cryo-MQL lubri-cooling strategy on the machining and tribological characteristics of Inconel 718. Tribology International 2021, 163, 107178 .
AMA StyleMohd Danish, Munish Kumar Gupta, Saeed Rubaiee, Anas Ahmed, Mehmet Erdi Korkmaz. Influence of hybrid Cryo-MQL lubri-cooling strategy on the machining and tribological characteristics of Inconel 718. Tribology International. 2021; 163 ():107178.
Chicago/Turabian StyleMohd Danish; Munish Kumar Gupta; Saeed Rubaiee; Anas Ahmed; Mehmet Erdi Korkmaz. 2021. "Influence of hybrid Cryo-MQL lubri-cooling strategy on the machining and tribological characteristics of Inconel 718." Tribology International 163, no. : 107178.
Mustafa Kuntoğlu; Emin Salur; Munish Kumar Gupta; Murat Sarıkaya; Danil Yu. Pimenov. A state-of-the-art review on sensors and signal processing systems in mechanical machining processes. The International Journal of Advanced Manufacturing Technology 2021, 1 .
AMA StyleMustafa Kuntoğlu, Emin Salur, Munish Kumar Gupta, Murat Sarıkaya, Danil Yu. Pimenov. A state-of-the-art review on sensors and signal processing systems in mechanical machining processes. The International Journal of Advanced Manufacturing Technology. 2021; ():1.
Chicago/Turabian StyleMustafa Kuntoğlu; Emin Salur; Munish Kumar Gupta; Murat Sarıkaya; Danil Yu. Pimenov. 2021. "A state-of-the-art review on sensors and signal processing systems in mechanical machining processes." The International Journal of Advanced Manufacturing Technology , no. : 1.
Cryogenic machining is becoming a sustainable choice due to its extraordinary performance (such as non-toxic and environmentally friendly) superiority to other traditional coolants and lubricants to produce products with superior quality. This paper also critically reviews improvements in designing the cryogenic delivery setup used by researchers for machining low machinability materials like titanium alloys, nickel alloys, ferrous alloys, composites, and other difficult-to-cut materials. It also briefs the economic and sustainable perspective of this state-of-art technology. The aim is to maximize the usage of sustainable cryogenic and hybrid machining technologies in the global manufacturing industry by highlighting their advantages. An overview of in-house developed cryogenic and hybrid machining techniques is presented. Various challenges and future needs related to cryogenic and hybrid-machining techniques are also discussed in the articles. Although remarkable results are obtained with the available literature's delivery methods, there is still no consensus regarding the best cryogenic delivery methods for machining the aforementioned materials. In addition, further hybridization of cryogenic delivery techniques with near dry machining techniques such as minimum quantity lubrication (MQL), electrostatic-MQL (EMQL), and nanofluid based MQL (nMQL) can be beneficial for machinability improvements of difficult-to-machine materials.
Navneet Khanna; Chetan Agrawal; Danil Yu Pimenov; Anil Kumar Singla; Alisson Rocha Machado; Leonardo Rosa Ribeiro da Silva; Munish Kumar Gupta; Murat Sarikaya; Grzegorz M. Krolczyk. Review on design and development of cryogenic machining setups for heat resistant alloys and composites. Journal of Manufacturing Processes 2021, 68, 398 -422.
AMA StyleNavneet Khanna, Chetan Agrawal, Danil Yu Pimenov, Anil Kumar Singla, Alisson Rocha Machado, Leonardo Rosa Ribeiro da Silva, Munish Kumar Gupta, Murat Sarikaya, Grzegorz M. Krolczyk. Review on design and development of cryogenic machining setups for heat resistant alloys and composites. Journal of Manufacturing Processes. 2021; 68 ():398-422.
Chicago/Turabian StyleNavneet Khanna; Chetan Agrawal; Danil Yu Pimenov; Anil Kumar Singla; Alisson Rocha Machado; Leonardo Rosa Ribeiro da Silva; Munish Kumar Gupta; Murat Sarikaya; Grzegorz M. Krolczyk. 2021. "Review on design and development of cryogenic machining setups for heat resistant alloys and composites." Journal of Manufacturing Processes 68, no. : 398-422.
Recent burgeoning development in nanotechnology unfold an avenue in the manufacturing industry. Owing to the superior heat transfer potential of nanoadditives mentioned recently, it could be interesting to improve the heat transfer and tribological capability of metal cutting fluids by mixing nanofluids in emulsions properly. In order to attain high-performance cutting of difficult-to-cut alloys, hybrid nanofluids assisted Minimum Quantity Lubrication (MQL) system is applied with the anticipation of efficient lubrication and heat transfer. Taguchi based L16(43) orthogonal array is used involving nanofluids concentrations of alumina-multiwalled carbon nanotubes (Al2O3-MWCNTs) air pressure and cooling flow rate at constant cutting conditions in the milling of Ti-6Al-4V. The resultant cutting force (FR), cutting temperature (T), and surface roughness (Ra) is considered as key machining responses. Besides, tool wear, chip analysis, and surface topography are also analyzed under the effect of hybrid nanofluids. Findings have shown the minimum resultant force, cutting temperature and surface roughness of 24.3N, 148.7oC, and 0.67µm respectively at nanofluids concentration of 0.24vol%, 120ml/h of flow rate at 0.6MPa of air pressure. The microscopic analysis of the end-mill depicted minor thermal damage, chip-welding, and coating peeling. Also, chip analysis depicts the clean back surface and less melting of saw-tooth chip edges. The surface topography confirms the less micro-adhesion of chips and material debris. The summary showed that appropriately chosen MQL parameters have improved the lubrication/cooling performance by providing oil film and enhancing the milling performance measures. The outcomes of the proposed study are useful for the manufacturing industry for the enhancement of process performance.
Muhammad Jamil; Ning He; Wei Zhao; Aqib Mashood Khan; Munish Kumar Gupta. Tribological and Machinability Performance of Hybrid Al2O3 -MWCNTs MQL for Milling Ti-6Al-4V. 2021, 1 .
AMA StyleMuhammad Jamil, Ning He, Wei Zhao, Aqib Mashood Khan, Munish Kumar Gupta. Tribological and Machinability Performance of Hybrid Al2O3 -MWCNTs MQL for Milling Ti-6Al-4V. . 2021; ():1.
Chicago/Turabian StyleMuhammad Jamil; Ning He; Wei Zhao; Aqib Mashood Khan; Munish Kumar Gupta. 2021. "Tribological and Machinability Performance of Hybrid Al2O3 -MWCNTs MQL for Milling Ti-6Al-4V." , no. : 1.
With the development of ideas such as green and sustainable processing, recently evolved lubrication methods are commonly used to resolve the disadvantages of the flood lubrication approach. In the minimum quantity lubrication (MQL) technology, a small lubricant mist is inserted into the tool-workpiece interface to achieve better lubrication. The present study, therefore, explored the viability of alumina-reinforced palm oil as a lubricant in the MQL environment. A diverse volume fraction of aluminium (0-1.4%) was mixed with palm oil, and the optimal concentration of nanoparticles (0.8%) was chosen through spectroscopic analysis. Subsequently, twenty-seven milling operations were carried out on Inconel 690 material under the best lubricating medium. Statistical analysis of the machining values was conducted using the main effect plot (MEP), empiric cumulative distribution (ECD), and analysis of variance (ANOVA). Besides, Response surface methodology (RSM) was used to create a mathematical equation between input and machining responses. Finally, the Particle Swarm Optimization (PSO) approach was applied to achieve an optimal machining environment: cutting speed = 88.348 m/min, feed rate = 0.108 mm/tooth, and depth of cut = 1 mm. The optimal machining conditions were confirmed by functional experimentation, which has shown that the mean error between the experimental and the predictive outputs is minimal (less than 2%).
Binayak Sen; Syed Abou Iltaf Hussain; Munish Kumar Gupta; Mozammel Mia; Uttam Kumar Mandal. Swarm intelligence based selection of optimal end-milling parameters under minimum quantity nano-green lubricating environment. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science 2021, 1 .
AMA StyleBinayak Sen, Syed Abou Iltaf Hussain, Munish Kumar Gupta, Mozammel Mia, Uttam Kumar Mandal. Swarm intelligence based selection of optimal end-milling parameters under minimum quantity nano-green lubricating environment. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science. 2021; ():1.
Chicago/Turabian StyleBinayak Sen; Syed Abou Iltaf Hussain; Munish Kumar Gupta; Mozammel Mia; Uttam Kumar Mandal. 2021. "Swarm intelligence based selection of optimal end-milling parameters under minimum quantity nano-green lubricating environment." Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science , no. : 1.
Titanium, being a structural material, undergoes drilling process frequently for its engineering applications. The superior mechanical properties of titanium alloys make hole-making a highly unsustainable process. The process is marred by high cutting forces, intense tool damage, high energy consumption, poor hole quality, and high process cost. The work presents an approach for viable and cleaner drilling of the difficult-to-cut material by investigating the effects of micro-lubrication and the following two options of cryogenic cooling: (1) evaporative cooling using liquid nitrogen and (2) throttle cooling using compressed carbon dioxide gas. Additionally, the effects of cutting speed and pecking – a technique actualized by rapidly retracting the twist drill by 2 mm at two levels of depth during thru-cutting of the holes – are also quantified. Pecking is not found to be favorable to any of the evaluated sustainability measures. Of the three cutting fluids testes, throttle cryogenic cooling yielded the most advantageous results. The coolant, because of its effective heat dissipation capability, yielded superior outcomes with respect to all the sustainability measures except surface quality. Micro-lubrication proved to be beneficial, at the low level of cutting speed, to specific cutting energy, surface quality, and process cost. Evaporative cryogenic cooling did not yield promising results. The runs employing evaporative coolant or the high level of cutting speed experienced thicker tool adhesions whereas those utilizing pecking showed signs of intense progressive wear. Moreover, the thrust force data indicated occurrence of thermal softening of the work material as the drills progressed through the hole-cutting process. From the holistic perspective of sustainability, it is recommended to adopt throttle cryogenic cooling, a medium-to-high level of cutting speed, and no-pecking for hole-making in the titanium alloy.
Asif Iqbal; Guolong Zhao; Juliana Zaini; Ning He; Malik M. Nauman; Muhammad Jamil; Hazwani Suhaimi. Sustainable hole-making in a titanium alloy using throttle and evaporative cryogenic cooling and micro-lubrication. Journal of Manufacturing Processes 2021, 67, 212 -225.
AMA StyleAsif Iqbal, Guolong Zhao, Juliana Zaini, Ning He, Malik M. Nauman, Muhammad Jamil, Hazwani Suhaimi. Sustainable hole-making in a titanium alloy using throttle and evaporative cryogenic cooling and micro-lubrication. Journal of Manufacturing Processes. 2021; 67 ():212-225.
Chicago/Turabian StyleAsif Iqbal; Guolong Zhao; Juliana Zaini; Ning He; Malik M. Nauman; Muhammad Jamil; Hazwani Suhaimi. 2021. "Sustainable hole-making in a titanium alloy using throttle and evaporative cryogenic cooling and micro-lubrication." Journal of Manufacturing Processes 67, no. : 212-225.
Being one of the most important staple crops of the world, rice has played a vital role in slaking the calorie requirements of the masses in all the inhabitable continents of our planet. Regardless of this fact, there are many environmental concerns related to the rice production systems across the globe. One of the major worries is the emission of lethal greenhouse gases as a result of the different steps and procedures concerned with rice production and their contribution towards global warming. This study presents the status quo of the rice straw burning practice across the globe. It focuses on the greenhouse gas emissions as a result of the open field burning of rice residues and its direct effect on the environment, eventually contributing towards climate change. The study evidently shortlists the most profound regions contributing towards the open burning dilemma and the socio-political reasons associated with it. The study additionally discusses the different alternatives to straw burning with a clear-cut motive of throwing light on the opportunities that lie in the efficacious and sustainable utilization of homogeneous agricultural wastes. Different in-field straw management techniques related to the farmers and off-field methods related to the industry have been discussed. Predicated upon a survey of the life cycle assessment (LCA) studies across the globe, it is concluded that soil incorporation and electricity generation are the most environment friendly alternatives with an enormous scope of improvement in the coming future.
GurRaj Singh; Munish Kumar Gupta; Santan Chaurasiya; Vishal S. Sharma; Danil Yu Pimenov. Rice straw burning: a review on its global prevalence and the sustainable alternatives for its effective mitigation. Environmental Science and Pollution Research 2021, 28, 32125 -32155.
AMA StyleGurRaj Singh, Munish Kumar Gupta, Santan Chaurasiya, Vishal S. Sharma, Danil Yu Pimenov. Rice straw burning: a review on its global prevalence and the sustainable alternatives for its effective mitigation. Environmental Science and Pollution Research. 2021; 28 (25):32125-32155.
Chicago/Turabian StyleGurRaj Singh; Munish Kumar Gupta; Santan Chaurasiya; Vishal S. Sharma; Danil Yu Pimenov. 2021. "Rice straw burning: a review on its global prevalence and the sustainable alternatives for its effective mitigation." Environmental Science and Pollution Research 28, no. 25: 32125-32155.