Optimizing end mill geometry is critical for improving performance and reducing costs in the high-volume manufacturing of tools, dies and molds. This study demonstrates a successful optimization framework for solid end mills machining 1.2379 cold-work tool steel, integrating Finite Element Analysis (FEA), Artificial Neural Networks (ANN), and Genetic Algorithms (GA). The optimized tool geometry, derived from four key design parameters, delivered substantial performance gains over an industrial reference (parent) tool. Our ANN-GA model achieved a remarkable predictive accuracy (R = 0.75–0.98) over the RSM model (R = 0.17–0.63) and identified an optimal design that reduced the resultant cutting force by approximately 11% (to 142.8 N) and improved surface roughness by 21% (to 0.1637 µm) compared to experimental baselines. Crucially, the new geometry halved the tool breakage rate from 50% to ~25%. Parameter analysis revealed the width of the land as the most influential geometric factor. This work provides a validated, high-performance tool design and a powerful modeling framework for advancing machining efficiency in tool, mold and die manufacturing.

The aim of the present study was to compare the root surface wear and roughness, resulted from the professional dental hygiene instruments, including ultrasonic dental scalers, rubber prophy cups, and nylon bristle brushes, on the extracted human mandibular incisor teeth. Teeth (n = 80) were randomly assigned into eight groups according to the applied scaler type (Ma = Magnetostrictive, Pi = Piezoelectric), degree of power (M = Medium, F = Full), and angulation (0° and 45°). In the second stage, the specimens (n = 40) were further divided into two groups according to the applied polishing device (nylon bristle brush or rubber prophy cup). Laser scanner and contact profilometer devices were used for the surface analysis. Both ultrasonic instruments tested in our study produced rougher surfaces when full power was used at a 0° angle (p < 0.01). The highest wear (0.82 ± 0.07 mm³) and roughness values (0.30 ± 0.01 µm) were detected in the PiF0 group. Polishing performed with a rubber prophy cup resulted in almost twice the wear as well as a smoother surface when compared to polishing performed with a nylon bristle brush (p < 0.001). Variations in the application parameters of ultrasonic scalers and the type of polishing instrument might lead to significantly different root-surface characteristics.

This study examined the drilling performance of five polymer composite systems: three natural fiber (jute, flax, hemp) composites with aluminum particle-reinforced epoxy, one glass fiber-reinforced composite with the same matrix, and an unreinforced aluminum particle-filled epoxy (Al–epoxy). Drilling experiments were performed at spindle speeds of 1500 and 3000 rpm with feed rates of 50, 75, and 100 mm/min in order to evaluate the effect of cutting parameters on the drilling performance. Cutting zone temperatures were measured using thermocouples embedded within the drill bit’s cooling channels, while thrust forces were recorded with a dynamometer. Additionally, hole exit damage and inner hole surface roughness were evaluated to assess machining quality. The results showed that increasing spindle speed reduces thrust forces due to thermal softening of the matrix, whereas natural fiber-reinforced composites generally exhibit higher thrust forces and slightly rougher inner hole surfaces compared to synthetic counterparts. During drilling, the measured thrust forces ranged from 320 to 693 N for the glass fiber-reinforced specimen and from 335 to 702 N for the Al–epoxy specimen, while for natural fiber-reinforced composites the thrust force values were 352–679 N for hemp, 241–719 N for jute, and 571–732 N for flax specimens. Synthetic specimens (glass fiber and Al–epoxy) exhibited comparable cutting temperature ranges (288–371 °C and 248–327 °C, respectively), whereas natural fiber-reinforced composites showed higher and broader temperature ranges of 311–389 °C for hemp, 368–374 °C for jute, and 307–379 °C for flax specimens. The overall results indicated that lower forces were generated during the drilling of synthetic glass fiber-reinforced composites, while among natural fiber-reinforced plastics, flax fiber-reinforced composites stood out by exhibiting a balanced machining response.

Bolts cannot be loaded axially according to real field conditions in assembly lines. The main reasons for this are that the loads cannot be applied centred due to the plate thickness and the holes are wider than the bolt. This creates a change in the...