Magnesium alloy AZ91D is used extensively in the automotive industry because of its high strength-to-weight ratio. Typically, components produced using are required to have good surface finish and contribute productivity but require long cutting times. Cryogenic cooling an environmentally friendly technology which has been proven improve tool life finish. This paper presents investigation on effects dry cryogenic conditions at a speed regime for milling magnesium alloy. study focused...

In the current investigation, additive friction stir-deposition (AFS-D) of as-cast hypoeutectic A356 Al alloy was conducted. The effect feeding speeds 3, 4, and 5 mm/min at a constant rotational speed 1200 rpm on macrostructure, microstructure, hardness manufacturing parts (AMPs) investigated. Various techniques (OM, SEM, XRD) were used to evaluate grain presence phases, intermetallics for material AMPs. results showed that stir deposition technique successfully produced sound manufactured...

In this work, three mathematical models for the heat generation during bobbin tool friction stir welding (BT-FSW) of aluminum using pin geometries have been proposed. The utilized and updated available conventional (CT-FSW). For validation models, BT-FSW experiments carried out alloy AA1050 different (cylindrical, square, triangular), at speeds 200, 400, 600, 800, 1000 mm/min a constant rotation speed 600 rpm. temperatures measured to be compared with that calculated from same parameters. It...

Hard turning is a precision machining process used to cut materials with hardnesses exceeding 45 HRC using single-point tools. It offers an efficient alternative traditional grinding for finishing operations in manufacturing. This paper explores the machinability of hardened AISI 4340 steel hard utilizing dry and cryogenic (Cryo) plus minimum quantity lubrication (MQL) (Cryo+MQL) techniques, focusing on critical aspects such as cutting force, surface roughness, tool life. The orthogonal was...

This study investigated the effect of friction stir welding rotation rate and speed on quality properties dissimilar joints between aluminum carbon steel. Plates 4 mm thickness from both AA2024 AISI 1018 were successfully butt welded at speeds 200, 250, 300 rpm 25, 50, 75 mm/min. The joint was along top surface transverse cross-sections. Further investigation using scanning electron microscopy conducted to assess intermetallic layers grain refining in zone. mechanical tensile testing for two...

This work investigates the feasibility of using friction stir welding (FSW) process as a groove filling technique to weld duplex stainless steel (DSS) that is extensively used by petroleum service companies and marine industries. For FSW experiments, three different geometries without root gap were designed machined in DSS plates 6.5 mm thick. carried out produce butt-joints at constant tool rotation rate 300 rpm, traverse speed 25 mm/min, tilt angle 3o tungsten carbide (WC) tool....

To curtail the negative effects of traditional flood machining, dry cutting using carbide tools has emerged as a prominent alternative for manufacturers, owing to its low cost and phenomenal surface qualities. In line with this view, high-speed machining high-strength AISI 4340 alloy steel was carried out multilayer Al2O3/TiCN-CVD TiAlN/AlCrN-PVD in environment. The experimental scheme adopted, per Taguchi’s L18 orthogonal array, investigate two most crucial machinability aspects, namely...

The relevance of three different techniques (Stylus Profiler (SP), Scanning White-Light Interferometry (SWLI) and Atomic Force Microscopy (AFM)) to characterise the topography aluminium hard steel surfaces, was investigated. Evolution roughness parameters (Ra Rt) analysed according evaluation length. Asymptotic Ra values showed good agreement between data measured by SP AFM. SWLI show important discrepancies with other instruments due their sensitivity surface morphologies. AFM is best...

This work evaluates the mechanical properties of glass fiber reinforced polymer (GFRP) material taken from an out service 100 KW power wind turbine blade which has been in life 20 years old. Investigated samples were two positions undamaged regions at 1.6 m and 5.4 rotor hub, respectively. Microstructure investigation lay-up analysis carried out. Fiber weight fraction investigated was ranging between 0.55–0.60. Tensile compression tests temperature range −10 °C to +50 on specimens machined...

Purpose This study aims to investigate the machining performance of CVD-coated carbide tools by considering most crucial machinability aspects: cutting force, tool life, surface roughness and chip morphology in high-speed hard turning AISI 4340 alloy steel under a sustainable minimum quantity lubrication (MQL) environment. Design/methodology/approach The purpose this is analyze coated MQL environment therefore, tests were performed accordance with Taguchi L9 orthogonal array, accommodating...

Traditionally, components of hardened steels, such as bearings, gears, shafts and rails, are finished by grinding process. In this study, Precision Hard Turning (PHT) is proposed an alternative finishing process to manufacture AISI 52100 bearing (60-62 HRC), because PHT improves surface integrity therefore increases the Rolling Contact Fatigue (RCF) life. An experimental design used, under dry condition using cubic Boron Nitride (c-BN) cutting tools, investigate effect parameters on...

Summary Precision hard turning is a process to improve the surface integrity of functional surfaces. Machining experiments are carried out on hardened AISI 52100 bearing steel under dry condition using c‐BN cutting tools. A full factorial experimental design used characterize effect parameters. As topography characterized by numerous roughness parameters, their relative relevance investigated statistical indices performance computed combining analysis variance, discriminant and bootstrap...

A three dimensional computational fluid dynamic (CFD) analysis was conducted to understand the hydrodynamic performance of a dimple texture produced using recently invented low-cost dynamic-assisted tooling (DAT) in machining process. Five different area ratios, α r 0%, 1.63%, 3.26%, 6.53%, and 9.80%, sliding speeds represented by Reynolds number, Re 10, 45, 80 were analyzed. From study, there existed an optimum ratio which generated up 290% higher load-carrying capacity compared fully...

Surface integrity induced by finishing processes significantly affects the functional performance of machined components. In this work, three kinds processes, i.e., precision hard turning, conventional grinding, and sequential grinding honing, were used for finish machining AISI 52100 bearing steel rings. The surface these was studied via SEM investigations residual stress measurements. To investigate rolling contact fatigue performance, tests performed on a twin-disc testing machine. As...

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Abstract This study investigates the effectiveness of CVD coated carbide inserts in turning hardened AISI 4340 steel at high-machining speed V = 300, 350 m min −1 under sustainable dry cutting environment. Experiments were executed accordance to Taguchi L 4 orthogonal array and crucial machinability aspects tool life, wear progression mechanism, force, surface roughness evaluated detail. The results this revealed that Al 2 O 3 /TiCN coating successfully inhibited faster low (300 ), feed rate...