Abstract The additive manufacturing technique of material extrusion has challenge excessive process defects and not achieving the desired mechanical properties. industry is trying to develop certification better control variations in attributes. current study a progress towards understanding evolution processing correlation behavior with parameters. Modeling 3D printing parameters such as layer thickness, speed, temperature carried out through L27 orthogonal array using Taguchi approach. In...

The superior engineering properties and excellent biocompatibility of titanium alloy (Ti6Al4V) stimulate applications in biomedical industries. Electric discharge machining, a widely used process advanced applications, is an attractive option that simultaneously offers machining surface modification. In this study, comprehensive list roughening levels variables such as pulse current, ON time, OFF polarity, along with four tool electrodes graphite, copper, brass, aluminum are evaluated...

Abstract Aluminium 6061 (Al6061) is a widely used material for various industrial applications due to low density and high strength. Nevertheless, the conventional machining operations are not best choice purposes. Therefore, amongst all non-conventional operations, electric discharge (EDM) opted carry out research its wide ability cut materials. But electrode wear rate (EWR) dimensional inaccuracy or overcut (OC) of EDM limit usage. Consequently, nanopowder added dielectric medium address...

The requirement for materials possessing both high strength and low density has garnered significant attention from industries researchers in recent times. Among these materials, aluminum 6061 (Al6061) exhibits the desired properties. However, due to its diverse machining capabilities, powder-mixed electric discharge (PMEDM) emerged as a viable option cutting such materials. This method been criticized energy consumption limited efficiency. Furthermore, conventional dielectric (kerosene)...

Surface modification is given vital importance in the biomedical industry to cope with surface tissue growth problems. Conventionally, basic treatment methods are used which include physical and chemical deposition. The major drawbacks associated these excessive cost poor adhesion of coating implant material. To generate a bioactive on an implant, electric discharge machining (EDM) promising emerging technology simultaneously serves as technique. Besides topology, material plays very...

Fibre Metal Laminates are structures used primarily in aerospace applications because of their principal advantages such as high strength, lower density, and impact resistance. In the present work, a systematic assessment has been made to evaluate two different stacking sequences FMLs (Type – I (AA 6061/Carbon Fibre/AA 6061), Type II (Carbon Fibre)) against pure carbon composite - III) baseline for improvement. The investigations enhanced resistance, improved tensile increased flexural...

The aeronautical industry constantly strives for efficient technologies to facilitate hole-making in CFRP/Ti6Al4V structural components. prime challenge this direction is excessive tool wear because of the different engineering properties both materials. Nanofluid minimum quantity lubrication (NF-MQL) latest technology provide synergistic improvement tribological and function during machining. In current study, an MoS2-based NF-MQL system was applied helical milling using a FIREX-coated...

Among recent developments in manufacturing industries, the laser-powder bed fusion process (L-PBF) is gaining attention for complex and functional parts through selective melting of powders. However, post-processing required to improve further quality L-PBF which corresponds machinability challenges. In this study, stainless steel grade SS 316L manufactured subjected high-speed turning explore influence variables. The cutting speed, CS (125 m/min, 175 , 225 m/min), depth cut, DOC (0.45 0.90...

In this modern era where Industry 4.0, plays a crucial role in enhancing productivity, quality, and resource utilization by digitalizing providing smart operation to industrial systems. Therefore, there is need establish framework that enhances productivity quality of work achieve the net-zero from industry. study, comprehensive generic analytical has been established mitigate or lessen research technological gap manufacturing sector. addition that, key stages involved artificial...

Abstract The aeronautical industry relies on high-performance equipment that demands materials with exceptional engineering attributes, such as the Ti6Al4V alloy. However, complexity of parts used in these applications presents challenges related to stack-up tolerances during assembly. Therefore, conventional machining processes are not economically viable due their two-step nature solution (machining and surface treatment) inability achieve required accuracy level, particularly given...

Hybrid aluminium matrix composites (HAMCs) are highly valued in manufacturing sectors but difficult to machine conventionally due reinforcements' inherent hardness and abrasiveness. This research finds high-speed wire electric discharge machining (WEDM) be a potent solution for stir-squeeze-casted HAMC (AA2024 with ceramic nanoparticles: Al2O3, SiC, Si3N4, BN) creating complex profiles superior erosion characteristics. The performance has been assessed terms of material removal rate (MRR)...

Abstract The need for materials with low density and high strength has drawn a lot of interest from researchers industry in the last few years. Aluminum 6061 (Al6061) is one these that required qualities. However, powder-mixed electric discharge machining (PMEDM) become practical choice cutting such because its versatile capabilities. This technique's excessive energy usage poor efficiency have criticism. Furthermore, there are serious health environmental risks associated typical dielectric...

Great biocompatibility and superior mechanical properties of titanium alloys (Ti6Al4V) stimulate the use this material frequently in biomedical, defence, aeronautical industries. In these applications, end parts generally have complex curved profiles. Through conventional means machining, profiles with high dimensional accuracy are not easily achievable due to difficult-to-cut nature Ti6Al4V. Wire Electric Discharge Machining (WEDM) is a promising alternative cut features like angular...

The study employs nonionic liquids with cryogenically treated tool electrodes to investigate micro-machining errors. An extensive Full Factorial-based experimental campaign is executed involving unmodified process: 12 experiments (kerosene dielectric as baseline for improvement) and modified 108 experiments. In process, three distinct liquid types, their concentration, electrodes, pulse ON:OFF time are used. All the liquid-mixed dielectrics have shown noticeable improvement in terms of...

Abstract The requirement of cost-effective and ecological production systems is crucial in the competitive market. In this regard, focus shifted towards sustainable cleaner machining processes. Besides clean technologies, effective parametric control required for materials (such as High Strength Low Alloy Steels) specifically designed high strength applications having superior physio-chemical properties. Therefore, machinability complexities require optimized solutions to reduce temperature...

One of the sustainability goals in aeronautical industry includes developing cost-effective, high-performance engine components possessing complex curved geometries with excellent dimensional precision and surface quality. In this regard, several developments wire electric discharge machining have been reported, but influence flushing attributes is not thoroughly investigated thus studied herein. The four process variables, namely servo voltage, pressure, nozzle diameter, nozzle-workpiece...

Abstract Over the years, machinists have been exploring hard part turning of AISI D2 steels. Initially, cylindrical grinding was used for this purpose, but it later replaced by single-point due to its advantages such as high material removal, low cost, and greater flexibility. Conventional inserts are in turning, they reported large radial forces, notch wear, poor surface finish. Therefore, multi-radii wiper were designed overcome these machining issues, their use restricted shallower depths...

Abstract The inflammation around poorly osseointegrated bioimplant is one of the root causes its failure. Therefore, biomedical industry constantly strives for new ways to develop bioactive surfaces in permanent implants enhance service life. In this regard, implant surface modification at micro/nanoscales carried out enrich substrate with higher engineering attributes and biocompatibility. Considering complexities post-processing implants, study evaluates potentiality an integrated process...

The surface integrity of machined components is considered to be an important part the quality matrix for high-performance applications in aviation industry. Therefore, close attention given made up hard-to-cut materials such as Ti6Al4V, which face processability challenges. In this regard, among non-conventional machining processes, electric discharge widely preferred cutting Ti6Al4V. study, potentiality cryogenic-treated tool electrodes (graphite and aluminum) with unmodified (kerosene)...