Abstract Micro-milling of cemented carbides is a challenging task due to their high hardness, low toughness and wear resistance. Ensuring good surface quality dimensional accuracy crucial for extending parts service life, which in turn enhances economical environmental sustainability. This paper mainly focused on evaluating formation mechanisms, scale effects, fracture behaviour chip using distinct carbide micro-milling tools with multi-layer diamond HF-CVD. In order achieve higher precision...

In recent years, promising solutions have emerged to address the need reduce structural weight in modern transportation (aeronautical and automotive) industry, namely multi-material assemblies combining fibre-reinforced polymers aluminium alloys. Given distinct mechanical thermal characteristics of each component, drilling process, fundamental for creating holes riveted or bolted assemblies, presents significant challenges achieving damage-free with precise tolerances. This is due defects...

The automotive industry encounters daily challenges as it navigates through new design trends and technological developments, which drive companies to rapidly develop models. This scenario paves the way for manufacturing approaches such additive (AM) is transforming by enabling production of complex geometries while minimizing material usage. Regarding cutting tools sector, AM enables resource-efficient generation shapes features that are not possible with conventional subtractive processes....

Machining processes of Ni-based alloys typically lead to very high wear rates and significant heat generation, even when small material removal are considered. Despite the increasing usage PCBN tools in machining superalloys, further research is required order better understand associated benefits. In this work, machinability Inconel 718 two different delivered strength conditions has been evaluated using through instrumented turning operations. Tool-life explored linked cutting force...

Abstract Metal additive manufacturing (MAM) currently allows the production of mechanical components with technical specifications suitable for structural applications a high level complexity. Despite most recent technological developments, additively manufactured parts may still lack geometrical and dimensional accuracy as well surface integrity required precision assemblies system reliability. These requirements often lead to post-processing operations through machining technologies. The...

Multi-Component Molding (MCM) enables the combination of different materials and components in a single manufacturing process, allowing creation complex functional products. Still, inherent challenges related with distinct physical mechanical properties tend to arise, namely adhesion involved materials. The development strategies improve polymer-polymer polymer-metal is great importance ensure integrity final parts. In this work, an experimental campaign covering operational conditions that...

The international safety regulations are pushing the manufacturers of water systems and equipment to remove lead from material compositions due potential human hazard absorption. usage green lead-free brass alloys is becoming mandatory in many important markets, demanding quickly adapt their production techniques both casting machining this new reality. Regarding machining, has been used facilitate chip control, working as a natural breaker reducing tool wear. Therefore, reduction...

Fibre metal laminates (FML) are significantly adopted in the aviation industry due to their convenient combination of specific strength, impact resistance and ductility. Drilling such materials is a regular pre-requisite which enables assembly operations, typically through rivet joining. However, hole-making operation increased complexity dissimilarity involved materials, often resulting defects (i.e., material interface delamination), can compromise otherwise excellent fatigue strength....

Inconel 718 is used in many industry sectors, particularly, the aerospace, automotive and energy industries. This alloy selected due to its excellent mechanical properties stability at high temperatures. However, this material considered difficult machine. Its high-strength, low thermal conductivity, tendency work-hardening, makes machining of quite challenging, generally causing amounts tool-wear. To surpass these processing problems, usually, coated tungsten carbide tools are for 718,...

The sharp growth that additive manufacturing has been showing recently broadened its application field and resulted in more varied demand of high-volume parts as well a general increase part series. current focus on productivity enhancement imposed the implementation multiple-laser systems with larger scan fields. Its usage, combined adequate layer thickness laser power selection, makes less challenging to obtain. This paper focuses understanding influence using multiple-scan fields for...

This paper focuses on the machinability of additively manufactured steel alloys (316L stainless and 18Ni300 Maraging steel) by reference to their conventional metallurgical conditions. The both conditions has been evaluated longitudinal turning tests under laboratory using two different cutting tool geometries (flat rake face chip-breaker geometry) covering speeds, depths cut feed values. Cutting forces, chip morphology surface roughness were investigated as indicators. influence process...

A thorough control of the machining operations is essential to ensure successful post-processing additively manufactured components, which can be assessed through machinability tests endowed with numerical simulation metal cutting process. However, accurately depict complex mechanism, it not only necessary develop robust models but also properly characterize material behavior, a long-winded process, especially for state-of-stress sensitive materials. In this paper, an efficient mechanical...

The present paper proposes a combined tribo-mechanical methodology for assessing friction under conditions representative of metal cutting, without resorting to machining process monitoring. purpose is withdraw the size effect’s contribution due tool edge radius well-known overestimation coefficient. Comparative numerical analysis several tribological tests led us conclude that ring compression test one most suitable reproducing frictional at chip–tool interface. Two distinct metallic alloys...

Abstract Nowadays, Western rigid inflatable boat (RIB) manufacturers are facing increased competition from Asian and Middle East producers the need to push modularization of their product architecture. Many techniques have been developed support this effort, being Modular Function Deployment a well-established multi-stage technique with applications in several industries. Despite reported literature, challenges learnings application focused on large organizations complex systems. In paper,...

Inconel 718 is a highly valued material in the aerospace and nuclear industries due to fact of its exceptional properties. However, processing this quite difficult, especially through machining processes. Machining results rapid tool wear, even when low removal rates are considered. In study, instrumented turning experiments were employed evaluate machinability alloy using PCBN tools while assessing usage two distinct binder phases, TiN TiC, for those cutting tools. It was found that life...

Achieving a mirror-like finish surface quality in plastic injection molds and dies is necessary for the manufacture of optical components automotive industry. Any defects present on mold will be evidenced injected part, compromising functionality final product. Moreover, typically employed finishing techniques (milling polishing) mould steels can excessively time-consuming. The identification machining polishing combinations that meet demanding requirements while minimizing time material...

Due to the high abrasiveness and anisotropic nature of composites, along with need machine different materials at same time, drilling multi-materials is a difficult task, usually results in material damage, such as uncut fibres delamination, hindering hole functionality reliability. Image processing analysis algorithms can be developed effectively assess allowing for calculation delamination factors essential quality control inspection composite materials. In this study, digital image...

Machining in ductile mode is usually applied for finishing precision parts of hard materials, such as cemented carbide parts, medical ceramic components or glass material applications. Thus, the study cutting brittle materials has been attracting more and efforts. The possibility applying predominant plastic-flow (ductile mode), using ultra-precision machines, hard/brittle previously linked to careful selection operational conditions, regarding brittle-to-ductile threshold. This threshold,...