Search

The use of aluminium in automotive and aerospace parts as well as low-pressure moulds are widely popular in the manufacturing industry. The good machinability of its alloy is one of the many reasons why aluminium is a default choice. In this study, aluminium 6061 alloy was chosen. However, studies were done on the cutting path strategies in machining especially for convex curved shape and their effects on the surface finish of the workpiece were not very informative. Five cutting strategies were involved and compared – parallel, morphed spiral, spiral, radial and circle. As industries are moving towards minimising the carbon footprint of their manufacturing processes, this study provided a good opportunity to include the investigation of the energy consumption of the cutting path strategy as well. Essentially, this study was aimed to investigate the effect of cutting path strategies on the workpiece's surface roughness, and the energy consumption of the machining process as well as to establish the optimum cutting parameters for the best cutting path strategy. Overall, the parallel cutting path strategy was found to be the most suitable cutting strategy to be used for convexly curved surface machining.

Anodising is a process of developing oxide coating on surface of metal electrolytically to improve its corrosion resistance. However, there has been inadequate research on the impact of the anodised surface characteristics on hydrophobicity or hydrophilicity. Surface roughness and porosity are often used to quantify surface characteristics, while each alone could not be enough to reflect all complexity of the surface. Hence, the fractal theory utilised to quantify the complexity of the anodised surface and decode its relation with the hydrophobicity or hydrophilicity of the surface. In this study, experiments of anodising for aluminium 6061 were carried out with three concentrations of electrolyte (3.5, 2.5 and 1.5 mol) and three current densities (1.0, 1.5 and 2.0 A/dm2). In addition, the surface characteristics after anodising was studied by using Scanning Electron Microscopy (SEM) analysis. Furthermore, surface roughness measurement was performed to obtain the surface roughness profile for fractal analysis. Moreover, a hydrophobicity test was implemented on anodised samples to obtain the contact angle between the water droplet and the surface. The outcomes showed that higher fractal dimension of anodised surface resulted in a smaller contact angle presenting a more hydrophilic surface. Furthermore, anodised samples with higher current density and concentration of electrolyte will result in higher fractal dimension and hence lower contact angle indicating the anodised surface will become more hydrophilic. Therefore, it is shown that measurement of fractal dimension is a reliable indicator for predication of surface wettability after anodising in order to improve the paint adhesion.

Nowadays, the manufacturing industry is focused on newer modern manufacturing methods, such as single point incremental forming (SPIF). The popularity of the SPIF process in the manufacturing industry is increasing due to its capability for rapid prototyping, forming complex geometry with simple steps, and customizing products for customers. This study investigates the effect of forming parameters (feed rate and step size) on the surface structure of the aluminum AA6061 sheet. We employ fractal theory to investigate the complexity of deformed surfaces. Accordingly, we study the relationship between the complexity and roughness of the deformed surface. The results show that the complexity and roughness of the deformed surface vary due to the changes in forming parameters. Fractal analysis can be further employed in other manufacturing processes to investigate the relation between the complexity and roughness of processed surfaces.

15‐5PH steel is a group of martensitic stainless steel which is strengthened by precipitation hardening. This paper is aimed to evaluate the effects of precipitation hardening on the machinability of 15–5PH. Machining was carried out at different feed rates and cutting speeds under heat treatment conditions H900 (meaning heat treatment at 900 °F) and H1150. The cutting force, work‐piece's surface roughness and tool wear were compared to the results of turning in solution condition. Scanning electron microscopy observation revealed that crater and flank wear were the main tool wear types in the turning of 15–5PH under the H900, solution and H1150 conditions. In addition, turning in the H900 condition causes defects such as "side flow" of the workpiece surface and "plowing" by the tool, compared to turning in the solution condition. The analysis of variance indicated that H1150 had the highest performance in reducing the cutting force, tool wear and surface roughness. The comparison between turning in H900 and solution conditions showed that the average cutting force and tool's flank wear in the H900 condition are 18 % and 11 % higher than solution condition, respectively. However, the mean roughness was 14 % lower under H900 than the solution condition. [ABSTRACT FROM AUTHOR]

This study aimed to examine the possibility of using insulin orally with gelatin encapsulation to enhance the usefulness of the drug and increase the lifespan of insulin in the body using polylactic-co-glycolic acid (PLGA) nanoparticles alongside gelatin encapsulation. In this regard, PLGA was synthesized via ring opening polymerization, and PLGA/insulin nanoparticles were prepared by a modified emulsification–diffusion process. The resulting nanoparticles with various amounts of insulin were fully characterized using FTIR, DSC, DLS, zeta potential, SEM, and glucose uptake methods, with results indicating the interaction between the insulin and PLGA. The process efficiency of encapsulation was higher than 92%, while the encapsulation efficiency of nanoparticles, based on an insulin content of 20 to 40%, was optimized at 93%. According to the thermal studies, the PLGA encapsulation increases the thermal stability of the insulin. The morphological studies showed the fine dispersion of insulin in the PLGA matrix, which we further confirmed by the Kjeldahl method. According to the release studies and kinetics, in-vitro degradation, and particle size analysis, the sample loaded with 30% insulin showed optimum overall properties, and thus it was encapsulated with gelatin followed by coating with aqueous methacrylate coating. Release studies at pH values of 3 and 7.4, alongside the Kjeldahl method and standard dissolution test at pH 5.5, and glucose uptake assay tests clearly showed the capsules featured 3–4 h biodegradation resistance at a lower pH along with the sustained release, making these gelatin-encapsulated nanoparticles promising alternatives for oral applications. [ABSTRACT FROM AUTHOR]

Long tool life and high material removal rate (MRR) are the two essential requirements in rough cutting of materials. The rapid rate of the flank wear propagation in machining of nickel-based superalloys has induced the utilization of low cutting parameters when the goal was set to maximize the tool life based on the machining time or cutting length. However, this method may not provide an effective rate for the material being cut. This work presents two mathematical models to find the optimum cutting parameters results for the minimum flank wear and maximum MRR. Experimental tests were carried out based on the central composite design (CCD) in rough cutting of Inconel 625 by using TiAlN-coated insert. Maximum flank wear was measured to determine the tool wear propagation. The wear mechanisms which contribute in the tool wear were analyzed by using scanning electron microscope (SEM) to evaluate the effects of cutting parameters on the flank wear propagation. The results showed that cutting speed and depth of cut had the most significant effect on the tool wear. However, optimum cutting condition was achieved by reducing the cutting speed when feed rate and depth of cut maintained at the highest level. This was associated to the interaction of cutting speed and depth of cut, and predominant of abrasion and notching at their highest levels, respectively. [ABSTRACT FROM AUTHOR]

It is known that geometry of cutting tool affects the cutting forces in machining operations. In addition, the value of cutting forces changes during machining operations and creates a chaotic time series (signal). In this paper, we analyze the variations of the complex structure of cutting force signal in rough end milling operation using fractal theory. In fact, we analyze the variations of cutting force signal due to variations of tool geometry (square end mill versus serrated end mill). In case of each type of end mill, we did the machining operation in wet and dry conditions. Based on the results, the fractal structure of cutting force signal changes based on the type of milling tool. We also did the complexity analysis using approximate entropy to check the variations of the complexity of cutting force signal, where the similar behavior of variations between different conditions was obtained. The method of analysis that was used in this research can be applied to other machining operations to study the influence of different machining parameters on variations of fractal structure of cutting force. [ABSTRACT FROM AUTHOR]

Rapid tool wear is one of the major machinability aspects of nickel-based super alloys. In this article, the effect of cutting parameters on material removal rate and tool wear of a whisker ceramic insert in turning of Inconel 625 was examined. Optical microscope and scanning electron microscope were applied to measure and study tool wear mechanism. Response surface method was used to develop a mathematical model which confirmed by experimental tests. The statistical analysis done by analysis of variance showed that depth of cut is the most effective factor on the tool wear. Experiments showed that increment of feed rate had an insignificant effect on the progress of flank wear, and it is an important controlling factor when material removal rate is considered as a desired output. Finally, optimized cutting condition is presented in this work. [ABSTRACT FROM AUTHOR]

Applying cutting tool with longer functioning time is a vital issue in machining of the nickel-based super alloys. However, the experimental analysis of this problem is quite expensive. Thus, three-dimensional numerical simulation of tool wear propagation in turning of Inconel 625 super alloy is taken into account, in this study. The cutting insert with complex geometry is modeled by using a reverse engineering method. Based on the cutting tool and workpiece material, Usui wear rate model is exerted to estimate the tool wear rate. In the first section, characterization of TiAlN-coated carbide tool, which is suggested by catalogue, on wear resistance is evaluated and then simulation results are validated with experiments. As a result, increment of depth of cut is the most effective factor on the generation of temperature and stresses on the tool faces resulting in wear rate acceleration. In the second section, different commercial coatings with multicompositions are applied in the simulation to find the best performance against wear. Finally, TiCN coating outperformed other coatings in turning of Inconel 625. [ABSTRACT FROM AUTHOR]

The needs to rapid manufacture of automotive components have led to the extensive uses of high-speed drilling in hole-making operation. However, issues such as uncontrollable thrust force and hole quality need to be addressed effectively in order to have full benefit of high-speed machining. Modeling the effect of drilling parameters on the machining responses can be a useful approach in controlling the thrust force and surface quality of the hole. This article reports on the development of mathematical models for thrust force (Ft) and surface roughness (Ra) during high-speed drilling of Al–Si alloy using uncoated carbide tools. Central composite design coupled with response surface methodology was used to predict the Ft and Ra values in relation to the primary machining variables such as cutting speed and feed rate. Second-order polynomial models were developed for both responses, and the adequacy of models was verified by analysis of variance. Results show the goodness of response surface methodology in the development of mathematical models in explaining the variation of thrust force and surface roughness by relating them to the variations of cutting parameters. In the developed models, linear effects of cutting parameters have the highest contribution to the thrust force model, while their quadratic effects are the significant terms influencing the surface roughness. Consequently, the optimum cutting condition was predicted at the high and low levels of cutting speed and feed rate, respectively. [ABSTRACT FROM PUBLISHER]

Nowadays, the manufacturing industry is focused on newer modern manufacturing methods, such as single point incremental forming (SPIF). The popularity of the SPIF process in the manufacturing industry is increasing due to its capability for rapid prototyping, forming complex geometry with simple steps, and customizing products for customers. This study investigates the effect of forming parameters (feed rate and step size) on the surface structure of the aluminum AA6061 sheet. We employ fractal theory to investigate the complexity of deformed surfaces. Accordingly, we study the relationship between the complexity and roughness of the deformed surface. The results show that the complexity and roughness of the deformed surface vary due to the changes in forming parameters. Fractal analysis can be further employed in other manufacturing processes to investigate the relation between the complexity and roughness of processed surfaces. [ABSTRACT FROM AUTHOR]

The curvature correction factor is an important parameter in the stress calculation formulation of a helical extension spring, which describes the effect of spring wire curvature on the stress increase towards its inner radius. In this study, the parameters affecting the curvature correction factor were investigated through theoretical and numerical methods. Several finite element (FE) models of an extension spring were generated to obtain the distribution of the tensile stress in the spring. In this investigation, the hook orientation and the number of coils of the extension spring showed significant effects on the curvature correction factor. These parameters were not considered in the theoretical model for the calculation of the curvature correction factor, causing a deviation between the results of the FE model and the theoretical approach. A set of equations is proposed for the curvature correction factor, which relates both the spring index and the number of coils. These equations can be applied directly to the design of extension springs with a higher safety factor. [ABSTRACT FROM AUTHOR]