Browse Topic: Turning

Items (53)

Evaluating the Applicability of Advanced Physical Vapor Deposition Coatings through Characterization and Dry Machining

8/18/2026

This study investigates the characterization and dry machining performance of advanced physical vapor deposition (PVD) aluminum titanium nitride (AlTiN) and aluminum chromium titanium nitride (AlCrTiN) coatings deposited using three techniques: cathodic arc evaporation (CAE), high-power impulse magnetron sputtering (HiPIMS), and scalable pulse power plasma (S3p). The coatings were evaluated for thickness, microstructure, surface roughness, coefficient of friction (CoF), adhesion strength, and microhardness. Among the tested coatings, the S3p-deposited AlCrTiN showed the best performance, exhibiting the highest microhardness (40 GPa), the strongest adhesion (108 N), and the lowest CoF (0.25), along with a defect-free microstructure. Under the selected dry turning condition of 150 m/min cutting speed, 0.15 mm/rev feed rate, and 0.7 mm depth of cut, the S3p-deposited AlCrTiN coating achieved a maximum tool life of 10,800 mm, nearly three times higher than the CAE-deposited AlTiN coating. In contrast, CAE coatings showed comparatively lower hardness and weaker adhesion, with minimum values of 25 GPa and 68 N for C1, along with higher CoF values of 0.58–0.60. Furthermore, AlCrTiN coatings produced by HiPIMS and S3p provided 20–30% longer tool life than AlTiN coatings under identical cutting conditions, highlighting the importance of deposition technique.

Dinkar Sonawane, Gaurav

Predictive Model and Analysis of the Resultant Force in the Dry Machining of Mg-4Zn/Si ₃ N ₄ Nanocomposites

2026-26-0762

6/1/2026

The development of lightweight materials for use in aerospace and automotive applications is extremely significant. Magnesium (Mg)-based alloys and composites are good candidate materials from the perspective of low density, good specific strength, and abundance. The Mg-4Zn alloy is one such alloy, which is a lightweight, biocompatible, and eco-friendly Mg-based alloy. In spite of these advantages, there is a strong need and scope to improve its wear resistance and mechanical properties. Mg-4Zn nanocomposites with Si3N4 reinforcements (a biocompatible bioceramic) are hypothesized to possess superior properties. Microstructural analysis of the vacuum stir-cast nanocomposites confirms grain refinement and a consequent increase in microhardness with an increase in Si3N4 reinforcement wt.%. The addition of Si3N4 reinforcement to improve the properties of the Mg-4Zn alloy could introduce challenges in machining. To make products from the nanocomposites, machining them with minimal subsurface defects with minimal energy consumption under sustainable conditions is necessary. The resultant machining force (Fr) is a good indicator of subsurface quality and energy consumption in machining. To investigate the effect of reinforcement wt.% and machining parameters on the resultant machining force, dry turning experiments on the vacuum stir-cast Mg-4Zn/Si3N4 nanocomposites were carried out based on the response surface methodology-based Box-Behnken design. It is observed that the regression model for Fr is influenced by the reinforcement wt.%, cutting speed, feed rate, and depth of cut and also their squares and their mutual interactions. Increase in microhardness, variation in porosity, thermal softening, and strain hardening contribute to the variation in Fr. Minimal Fr and hence better subsurface quality and lower energy consumption are obtained at mid values of Si3N4 reinforcement wt.% and cutting speed and low values of feed rate and depth of cut. The developed model is an excellent fit, with R2 and adjusted R2 values of 0.9907 and 0.9799, respectively.

N, Anand, Shaju, Tony M, G, Nagamalleswara Rao, D, Bijulal, K, Jayaprakash Reddy, K, Vijayan, Chaman, Joji J

Mixed Aggregation by Comprehensive Normalization Technique–Based Parametric Optimization of Turning of Ti-6Al-4V Alloy in Minimum Quantity Lubrication Environment

05-19-03-0022

12/19/2025

Although Ti-6Al-4V alloy offers high strength-to-weight ratio, corrosion resistance, and biocompatibility properties, its machining is challenging due to low thermal conductivity, high hardness, and chemical reactivity. This study examines turning of Ti-6Al-4V under minimum quantity lubrication (soybean oil). Cutting speed (CS), feed rate (FR), and depth of cut (DOC) are considered as the input parameters. On the other hand, material removal rate (MRR), tool wear rate (TWR), surface roughness (SR), and cutting force (Fc) are treated as the responses. Optimization of the said process is carried out using the mixed aggregation by comprehensive normalization technique (MACONT), a recently developed multi-criteria decision-making (MCDM) method. The optimal parameters are identified as CS = 72.26 m/min, FR = 0.022 mm/rev, and DOC = 0.2 mm, achieving high MRR with low TWR, SR, and Fc. The effects of different turning parameters on the responses are also investigated. Sensitivity analysis confirms robustness, and comparative evaluation with other MCDM tools validates accuracy of the adopted approach. The results demonstrate MACONT’s effectiveness in optimizing turning of hard-to-machine alloys, supporting greener and sustainable machining practices.

Das, Partha Protim, Sharma, Saurabh, Chakraborty, Shankar

A Research on Path Planning of Kelp Harvesting Vessel Based on Reciprocal Traversal

2025-99-0407

12/10/2025

min

Wang, Jie, Yang, Yue, Chen, Xin, Cui, Jiaxing

Predictive Modeling of Surface Roughness, Tool Wear, and Cutting Temperature in High-Speed Turning under Sustainable Machining Environments

05-19-01-0007

5/24/2025

The utilization of Inconel 718 is increasing daily in stringent operating conditions such as aircraft engine parts, space vehicles, chemical tanks, and the like due to its physical properties such as maintaining strength and corrosion resistance at higher temperature conditions. Besides, Inconel 718 is one of the difficult materials for machining because of maintaining its strength at elevated temperature, which generates higher cutting force leading to observed multiple tool wear mechanisms that affect the surface quality; lower thermal conductivity of materials produces high temperature generation that impacts the tool performance by reducing tool life. In addition, the presence of carbides and high hardness of IN 718 affects the machining performance. Therefore, in this view, this article describes the effect of cutting environments and machining parameters on the machining of Inconel 718 and optimizes the cutting conditions for sustainable machining. Three input parameters namely cutting speed, feed rate, and depth of cut as well as three cutting environments such as flood cooling, MQL (minimum quantity lubrication), and NMQL (nano minimum quantity lubrication) were considered for the experimentation. Experimental runs were designed based on the Taguchi method, which had a total of 27 runs performed on the CNC turning. TiAlN-coated triangular-shaped cutting inserts were used for all experimental runs. This research study addresses three output parameters namely surface roughness, tool wear, and cutting temperature. Finally, the cutting condition was optimized by using the Taguchi method and predicting the relationship between the input parameters and the output parameter using the RSM method. Experimental results observed that the NMQL cutting environment shows better machining performance than the MQL and flood cooling due to the presence of nanoparticles in the base fluid, which act as heat carriers. Whereas minimal surface roughness 0.4 μm and lower cutting temperature (85°C) were observed at low cutting speed, feed rate, and depth of cut (78.54 mm/min, 0.1 mm/rev, 0.1 mm) combination and minimum tool wear was found in moderate cutting speed conditions (117.81 mm/min, 0.1 mm/rev, 0.1 mm). Whereas highest cutting temperature and tool wear such as 130°C and 0.3 mm, respectively, observed in flood cooling environment at the cutting speed (157.08 mm/min, 0.3 mm/rev, 0.3 mm). Using the Taguchi method optimum condition was found in the NMQL cutting environment, at the combination of cutting speed 78.54 m/min, feed 0.1 mm/rev, and depth of cut 0.1 mm. From the ANOVA results, develop the predictive model whose results match with the experimental result. Finally, regression model was developed between the response variable and input parameters.

Mane, Pravin Ashok, Dhawale, Pravin A., Nipanikar, Suresh, Khadtare, Avinash N.

Experimental Investigation of Minimum Quantity Lubrication Strategy during Machining of Ti6Al4V Alloy

05-18-03-0022

3/3/2025

The experimental investigation analyzed the performance of three machining conditions: dry machining, cryogenic machining, and cryogenic machining with minimum quantity lubrication (MQL) on tool wear, cutting forces, material removal rate, and microhardness. The outcome of this study presents valuable knowledge regarding optimizing conditions of turning operations for Ti6Al4V and understanding the machinability under cryogenic-based cooling strategies. Based on the experimentation, cryogenic machining with MQL is the most beneficial approach, as it reduces cutting force and flank wear with a required material removal rate. This strategy significantly enhances the machining efficiency and quality of Ti6Al4V under variable feed rates (0.05 mm/rev, 0.1 mm/rev, 0.15 mm/rev, 0.2 mm/rev, 0.25 mm/rev) where cutting velocity (120 m/min) and depth of cut (1 mm) are constant. The effects of the main cutting force, feed force, thrust force, material removal mechanism, flank wear, and microhardness on machining performance have been analyzed in this research work. It has been observed that higher cutting forces result in greater energy transferred to the workpiece material, leading to more effective material removal, and chip thickness is reduced in cryogenic plus MQL conditions compared to dry and cryogenic machining due to the excellent cushioning effect and reduced adhesion.

Misra, Sutanu, Kumar, Yogesh, Paul, Goutam, Forouhandeh, Fariborz

A Machine Learning Approach for the Prediction of Surface Roughness Using the Tool Vibration Data in Turning Operation

2025-28-0152

2/7/2025

Surface roughness is a key factor in different machining processes and plays an important role in ergonomics, assembly process, wear and fatigue life of components. Other factors like functionality, performance and durability of parts are also affected by surface roughness. Although maintaining an optimum surface roughness is a major challenge in many manufacturing industries. Surface roughness during machining depends upon machining parameters such as tool geometry, feed rate, depth of cut, rotational speed, lubrication, tool wear, etc. Tool vibrations during machining also have significant influence in surface roughness. In this work an attempt is made to predict the surface roughness of machined components made by the turning process by using machine learning of tool vibration signals. By varying different machining parameters and keeping other tooling and material properties same, a range of surface roughness values can be obtained. For each condition, corresponding tool vibration signals were recorded. Our experimental setup involves a vibration data collector which is used for recording vibration signals generated during the turning operation. The collected data preprocessed and categorized into training and test sets. Various machine learning regression techniques including Linear Regression, Ridge Regression, Support Vector Regression (SVR), Decision Tree Regression, Random Forest Regression, Gradient Boosting Regression, K-Nearest Neighbors Regression (KNN), and Neural Network Regression were used to predict the surface roughness. The study highlights the importance of feature extraction and model selection in achieving accurate and reliable surface roughness predictions, ultimately contributing to enhanced machining process control and product quality.

S S, Safeer, Sadique, Anwar, D, Navaneeth

Comparative Investigations of Tool Wear and Cutting Force for Wet and Dry Turning of Super Duplex Stainless Steels 2507

05-18-02-0012

11/7/2024

Super Duplex Stainless Steels (SDSS) are attracting attentions of the manufacturing industries due to the excellent corrosion resistance to critical corrosion. But SDSS2507 is the hardest to machine with lowest machinability index among DSS family. Moreover, formation of built-up layer (BUL) and work hardening tendency makes it further difficult to machine. Researchers have the conflict in opinions on using wet machining or dry machining using tool coatings. In this investigation SDSS2507 machining is carried out using uncoated and PVD–TiAlSiN-coated tools. The wet and dry machining environment are compared for increase in cutting speed from 170 m/min to 230 m/min. Excellent properties of PVD–TiAlSiN coatings exhibited microhardness of 39 GPa and adhesion strength of 88 N, which outperformed the uncoated tools. Tool life exhibited by coated tools was four times higher than uncoated tools. Wet machining was found to be ineffective when PVD-coated tools are used, exhibiting the same performance as that of dry machining. Dry machining can be preferred for the machining SDSS2507 with PVD–TiAlSiN-coated tools, eliminating the cost of cutting fluids with enhanced productivity.

Sonawane, Gaurav Dinkar, Bachhav, Radhey

Optimizing Cutting Parameters for Effective Turning of EN-31 Steel by Utilizing Vegetable-Based Cutting Fluids as a Coolant

05-18-01-0006

10/12/2024

The primary objective of this article is to study the improvement of machining efficiency of EN-31 steel by optimizing turning parameters using newly developed cutting fluids with different proportions of aloe vera gel and coconut oil, utilizing the Taguchi technique. Furthermore, performance metrics including material removal rate (MRR), surface roughness, and tool wear rate (TWR) were assessed. Analysis of variance (ANOVA) suggested that as cutting speed and feed increase, the MRR is positively influenced, but likewise tool wear is intensified. The surface roughness exhibited a positive correlation with cutting speed, and a negative correlation with increasing both cutting speed and feed. It was found that the maximum MRR value was attained at a cutting speed of 275 m/min, a feed rate of 1.00 mm/rev, and a cutting fluid composition of 30% aloe vera and 70% coconut oil. For the best surface smoothness, it is advisable to adjust the cutting speed to 350 m/min and the feed rate to 0.075 mm/rev. A cutting speed of 275 m/min and a feed rate of 1.00 mm/rev led to a lower TWR. The results suggest that the combined use of coconut oil and aloe vera as cutting fluids improves the turning quality of EN-31 steel, particularly when employing a combination of 30% aloe vera and 70% coconut oil. As a possible solution for performance problems in achieving desired results during the turning of EN-31 steels, these recommendations may be used in industries to enhance turning performance.

Premkumar, R., Ramesh Babu, R., Saiyathibrahim, A., Murali Krishnan, R., Vivek, R., Jatti, Vijaykumar S., Rane, Vivek S., Balaji, K.

Multi Response Optimization of Machining Heat Treated Aluminium Alloy Using Desirability Approach

2023-01-5186

2/23/2024

Aluminium alloys enrolled their applications in automobile sectors, agricultural equipment, machine tools and aerospace because of their weight-to-strength ratio. Aluminium alloy 7075-T651 is an inevitable material used in engineering sectors. Turning is a metal removal process, to obtain net geometrical aspects and better surface finish of the products. The machinability of the turning operation is based on different factors; however, turning factors and material of tool plays a significant position in the turning process. To identify the truthful cutting parameters to achieve multi-responses in turning operation, the experiment was designed via Response Surface Methodology (RSM) Central Composite Design (CCD) and the experimental results are analyzed under the desirability approach. By trialing 26 interpretations in the desirability approach; the optimal cutting parameter settings of speed 800 rpm, feed rate 0.140315 mm/rev and depth of cut 0.3501 mm have been revealed to enhance surface roughness (SR) and metal removal rate (MRR).The confirmation test addresses better agreement with the predicted value of responses, the result of the investigation directed to the industries for the variant aluminium alloy parts manufacturing.

Sundarrajan, D., Senthil Kumaar, J. S., Muthiah, A., Manikandan, A., Sivakumar, N. S.

Characterization of Enhanced Magnetorheological Fluid Damper and Its Influence on Sustainable Hard Turning of SS410

2023-01-5133

2/23/2024

Sustainable manufacturing, a term that has been used in the recent past on numerous occasions. A primary reason for it being in limelight, is that it does not cause any damage to the environment and also to the personal involved. Additionally, another important parameter of concern is the energy consumed during the machining process. One major reason for higher energy consumption is because of the presence of tool vibration. There have been several attempts made to reduce vibration and though they have been proved to be effective, they could be not classified under sustainable manufacturing. When used as a semi-active damper in metal cutting, magnetorheological fluid (MRF) has proven to be successful in vibration suppression. MRF is an intelligent non-Newtonian fluid that can change its viscosity instantly when a magnetic field is applied to it. They've utilised it as a damper in a number of areas because of this quality and its toughness. One significant drawback is the settling of magnetic particles floating in a non-magnetic fluid. When the current provided to the coil is increased, the settling rate becomes much worse. Increased current increases the amount of heat created in the coil, which heats the non-magnetic fluid and reduces its viscosity. Stabilizers are added to MRF to address this issue, and particle size has an immediate impact on settling. In this study, activated carbon and titanium were used as stabilisers, and the size of the magnetic particles was adjusted to see how it affected the viscosity of MRF. The testing results showed that adding stabilisers to MRF enhanced the viscosity and thus the cutting capability of SS410 steel during dry hard turning.

Ajay Vasanth, X., Sam Paul, P., Lawrance, G., Rajkumar, V., Senthilkumar, K.

Analysis of Influence on Machining Characteristics of Nimonic 80

2023-01-5173

2/23/2024

The quality of the finished product depends on the contribution of many factors along with the complex process involved to move forward towards the new product development. Many operations like turning, drilling, milling in metal machining deserves the quality as a predominant measurement. The tool and work piece plays a vital role in machining process which depends on machining parameters such as spindle speed, feed rate, depth of cut, approach angle. In the present work the turning operation was carried out on Nickel alloy (Nimonic 80) as a work piece and the carbide insert was used as a tool for performing the machining operations. The cutting parameters were optimized using Taguchi based grey relational analysis. Provided that, the ANOVA analysis to find the predominant factors that affects the quality were also determined. The experimental results were compared with the predicted results and found to be a promising agreement between the factors and responses.

Jashwanth, S., Rajaparthiban, J., Ganesamoorthy, R., Balaji, N., Padmavathi, K.R.

Application of Desirability Approach to Determine Optimal Turning Parameters

2024-01-5022

2/20/2024

Aluminum alloys are employed in agricultural equipment, aerospace sectors, medical instruments, machinery, automobiles, etc. due to their physical and mechanical characteristics. The geometrical shape and size of the parts are modified in turning operation by using a single-point cutting tool. A356 aluminum alloy is widely used in various engineering sectors, hence there is a necessity to produce A-356 components with quality. The inappropriate cutting parameters used in turning operation entail high production costs and reduce tool life. Box–Behnken design (BBD) based on response surface methodology (RSM) was used to design the experiments such that the experiment trials were conducted by varying cutting parameters like N-spindle speed (rpm), f-feed rate (mm/rev), and d-depth of cut (mm). The multi-objective responses, such as surface roughness (SR) and metal removal rate (MRR) were analyzed with the desirability method. The analysis of variance (ANOVA) represents the significant factor for each response, whereas the desirability approach focuses on a single optimal cutting parameter setting to achieve both responses with a better level of accuracy. The most favorable turning parameters N: 713.563 rpm (715 rpm), f: 1 mm/rev, and d: 1 mm was determined in the desirability approach to enhance results of SF: 2.511 μm and MRR 25.145 gm/min. The validation test was executed with predicted factors, such that the experiment results form a better agreement with the predicted results. The determined cutting parameters settings are advisable to machine the liquid metallurgical A-356 aluminum alloy castings.

Arunbharathi, R., Arish, R., Girith Chandru, S., Bhavandharshan, K., Gowthamprasath, A. D., Hari, K.

Modeling and Optimization of Process Variables in Turning of Inconel 617 through Criteria Importance through Inter-Criteria and Weighted Aggregated Sum Product Assessment Methodology

2022-28-0524

12/23/2022

Inconel 617 is found in industrial sectors, including chemical, petrochemical, and nuclear. This work mainly concentrates on the analysis and the input-parameters optimization that minimizes the surface roughness, tool wear, and force in turning Inconel 617. Then, the chip and inserts are morphologically characterized using optical images. The residual plots showed that the accomplished investigational data are reliable and suitable for further study. Abrasion is accountable for tool wear mechanisms, and a rise in cutting speed affects the tool wear profile. Chip burr adhering to the flank surface is responsible for the surface roughness increase. Optimum cutting parameters are determined as 0.3mm depth of cut, 0.1mm/rev feed rate, and 220m/min cutting speed. Feed rate is the most influential parameter for process variables through Criteria Importance through Inter Criteria and weighted aggregated sum product assessment methodology.

Sundararajan, Devendiran

Optimization of Machining Parameters in Turning of Hastelloy C-276 by Considering Machinability and Chip Morphology Characteristics

2022-28-0526

12/23/2022

The present paper mainly focuses on the analysis and multi-factor optimization of cutting process parameters in turning Hastelloy C-276 using an integrated approach of Weighted Aggregated Sum Product Assessment (WASPAS) and criteria importance through inter-criteria correlation (CRITIC). To achieve this objective, a design of experiment (DoE) is employed for the three control parameters: cutting speed, feed rate, and cutting depth. The insert used for turning is a coated carbide insert (PVD: Ti-Al-N). Different responses are recorded: force, tool wear, and surface roughness in machining attributes, chip structure, chip thickness, chip thickness ration, shear angle, and friction coefficient in chip-tool interface indices. Uncertainty probabilistic study depends on Monte Carlo (MC) method applied. From the experimental results, the most impactful processing variable for force is cutting depth, surface roughness, and chip-tool interface indices are feed rate while cutting velocity for tool wear. The optimized results are a cutting speed of 70m/min, a feed rate of 0.10mm/rev, and a depth of cut of 0.4mm. Abrasive wear, micro-chipping, thermal spots, and notch wear are the leading causes of tool wear at 292μm with a roughness value of 2.25 μm. Also, the confirmation test showed 10% in predicting error in determining optimal parameters. This paper’s originality to the works is integrating the machinability and chip-morphology indices for process optimization through CRITIC and WASPAS methodology for the first time.

Kannan, Venkatesan, Sundararajan, Devendiran

Influence of Various Parameters of Turning Low Carbon Steel with M2 HSS Tool Using Minimum Quantity Lubrication

2022-28-0533

12/23/2022

Turning is a widely used manufacturing process in mechanical machining industries, while the cost associated with this process is high due to the cost involved in changing tools or tool regrinding. All the parameters of turning, like feed rate, cutting speed, and depth of cut, substantially impact the tool wear, which subsequently reduces tool life. Cooling methods like flooding, Minimum Quantity Lubrication (MQL), etc., are incorporated to minimise these effects on the tool and workpiece interface. When using these cooling techniques, the process parameters involved play vital roles in increasing the effectiveness. This paper focuses on the effects of machining parameters on the tool and the workpiece quality. Experiments were conducted to study the impact of various input parameters of the turning process on the tool tip temperature, cutting forces, and tool wear, ultimately affecting the tool's life. The average cutting forces are reduced by 60 N, a 30 % reduction in the forces is seen. The average surface roughness has a 2.02 μm reduction, which is a 30 % reduction when compared. These results emphasise the need for a tradeoff between the cooling and lubrication rates when using cooling techniques.

Sundaram Sundararajan, Anuj Srivathsa, B, Muralidharan

Tiny Quantum Sensors See Materials Transform Under Pressure

TBMG-40580

1/1/2022

Diamond anvil cells have made it possible for scientists to recreate extreme phenomena, such as the crushing pressures deep inside the Earth’s mantle, or to enable chemical reactions that can only be triggered by intense pressure, all within the confines of a laboratory apparatus. To develop new, high-performance materials, scientists need to understand how useful properties, such as magnetism and strength, change under such harsh conditions. But often, measuring these properties with enough sensitivity requires a sensor that can withstand the crushing forces inside a diamond anvil cell. By turning natural atomic flaws inside the diamond anvils into tiny quantum sensors, scientists have developed a tool that opens the door to a wide range of experiments inaccessible to conventional sensors.

Cross-Training Made Possible by Common Control Platform

TBMG-345796/1/2019

EMAG L.L.C. is the U.S. subsidiary of a major German machine tool builder that specializes in machine tools for the production of automotive, off-highway, agricultural, and oil field components. The company’s equipment ranges from basic round part turning centers to large-workpiece, five-axis machining centers; gear hobbing machines; and alternative equipment such as laser welding and electrochemical machining centers. This wide variety of machine tools requires an assortment of control technologies to power and manage the motion. For one customer requirement where a major agricultural equipment builder needed grinding, turning, and turn-grind machines, EMAG looked to Siemens for a standardized CNC solution.

Parametric Study, the Process Benefits, Optimization and Chip Morphology Study of Machining Parameter on Turning of Inconel 718 Using CVD Coated Tool and Nd: YAG Laser

2018-28-0029

7/9/2018

This paper presents the parametric study, process benefits, optimization and chip appearance of machining parameters on turning of the Inconel 718 using Nd: YAG laser source. To analyze the mentioned above effect on alloy 718, the cutting inserts of chemical vapor disposition coated (CVD) TiN/TICN/Al2O3 are used to turn at the time of machining. To evaluate the linear (mean effect plots) and interaction effect (3D surface plots) of laser parameters on the force, roughness and tool wear to keep the minimal, experiments of the L27 orthogonal array are done by selecting the controllable parameters viz speed, the rate of feed along with laser power. From the parametric study, increase in speed and laser power along with decrement in the rate of feed resulted in lower cutting force. But surface finish and tool wear reduced with a decline in speed and scale of feed and increased with increment in laser power. The investigations result in shows that with the application of moderate laser power decline the cutting force by 28%; both surface roughness along with flank wear by 60% that of CM. Results of variance test show that the speed along with the rate of feed bags the critical effect on the force, roughness, and tool wear followed by laser power. Desirability function analysis (DFA) is employed as response optimizer to determine optimum levels which minimize force, roughness as well as flank wear. At the determined optimum conditions compared to CM, 66% increment in the tool life is obtained in LAT. The presence of abrasion and flaking while the absence of chipping is observed in LAT compared to CM using an optical image. Under chip appearance, the benefit is determined due to the maximum un-deformed chip thickness of about 130 μm in LAT compared to CM.

Kannan, Venkatesan, Kannan, Vetri Velmurugan

‘Super-precision’ cylindrical roller bearings launched by SKF

16OFHP02_082/1/2016

SKF recently launched two new “super-precision” cylindrical roller bearings series, targeted at the machine tool industry. The company says both of the new series deliver much improved bearing performance compared with existing SKF offerings. “The new cylindrical roller bearings are optimized solutions for OEMs that require greater load carrying capacity and higher speeds. While the SKF super-precision single row cylindrical roller bearings have a higher speed capability, the SKF super-precision double row cylindrical bearing are more suitable for heavier loads,” said Mauro Merlo, Super Precision Bearings Product Manager, SKF.

Broge, Jean L.

Very-High-Load-Capacity Air Bearing Spindle for Large Diamond Turning Machines

TBMG-19900

6/1/2014

Large-load-capacity oil hydrostatic bearings generate prohibitive amounts of heat in large sizes when run at speeds useful for diamond turning of optical components. The viscosity of air is more than three orders of magnitude less than the thinnest oil; therefore, the frictional heating of large-diameter air bearings is very small and very manageable. A formidable manufacturing problem with large air bearings is that the extremely low viscosity of air requires that the thickness of the bearing film is also very small. This very small bearing clearance of 5–8 micrometers means that the required accuracy of geometry and dimensions of air bearing components is extremely difficult to achieve.

Optimization of Cutting Parameters in Turning Process

2014-01-9097

1/15/2014

Predicting the main cutting force during turning is of great importance as it helps in setting the appropriate cutting parameters before machining starts. Again, optimization of cutting parameters is one of the most important elements in any process planning of metal parts as economy of machining operation plays a key role in gaining competitive advantage. This paper presents an experimental study of main cutting force in turning of AISI 1040 steel and developing a model of the main cutting force during turning using Response surface Methodology (RSM) as well as optimization of machining parameters using Genetic Algorithm (GA). The second order empirical model of the main cutting force in terms of machining parameters have been developed based on experimental results. The experimentation has been carried out considering three machining parameters: cutting speed, feed rate and depth of cut as independent variables and the main cutting force as the response variable. The formulated model has been validated against new set of experimental values using Mean Absolute Percent Error (MAPE) method. The Genetic Algorithm approach is also used to optimize the cutting parameters to keep the main cutting force to a minimum.

Bhuiyan, Tanveer Hossain, Ahmed, Imtiaz

Effect of Inoculation on Turning Machinability of Gray Cast Iron

2012-01-1823

9/17/2012

Turning is the widely machining process used for brake rotor manufacturing while turning cost is a one factors that many has a huge impact on manufacturing cost for second tier manufacturer so increase tool life is always needed developed in second tier manufacturer. This paper would like to investigate effect of microstructure and graphite morphology of gray cast iron which is the most widely materials use in brake rotor on machinability. The tested material was class FC250. The raw test was made of steel scrap, returned material at the ratio of 60 : 40. Controlled inoculation technique was inoculated in ladle compare with inoculated both in ladle and were in melting stream while pouring in horizontal greensand mould. The microstructure measured by optical microscopy and cutting force investigated by dynamometer. The experimental were observed to achieve the result of minimize cost among raw material, turning process cost, insert cost, and meet the product criteria of friction brake performance.

Tongtae, Chanin, Dawan, Pimporn, Kumvong, Sukum

Pre-Finishing of SiC for Optical Applications

TBMG-98795/1/2011

A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the second step, a low-MRR process is used to machine the part to near optical quality using a novel ductile regime machining (DRM) process.

Aerospace Engineering 2011-02-09

11AERD02092/9/2011

Composite simulation helps fill gaps There is no turning back from using carbon-fiber reinforced plastics and other composite materials for aerospace parts. Simulation providers are finding new opportunities to help reduce cost and improve efficiencies in designing and making aerospace parts made of composites. Shifting gears smoothly Ric Kleine, a 30-year veteran of Cummins Inc. and former SAE Commercial Vehicle VP, seeks continuity over change as he moves into SAE's driver's seat.

Original Equipment

10OFHD0114_03

1/14/2010

Case CE says new crawler dozer offers big performance, not weight Case Construction Equipment says its new 650L crawler dozer for residential job sites and confined commercial work areas retains the features of the Case crawler dozer line, such as hydrostatic drive, the operator compartment, and two undercarriage options. The 650L delivers 74 net hp (55 kW) through a four-cylinder, 4.5-L turbocharged Case Family IV engine with electronic fuel injection for maximum fuel efficiency and easier starts in cold weather. The Tier 3-certified engine is equipped with a high-pressure common-rail injection system and a charge air cooler that Case says reduces emissions and provides a cleaner, more efficient fuel burn.

Broge, Jean L.

Fanuc Painting Robot Boosts Production for Metal Finisher

TBMG-9576

10/1/2009

Classic Metal Finishing, based in Jackson, Mich., supplies components for the aerospace, motorcycle, racing, and medical industries. The plant was purchased in February, 2008 by Classic Metal Finishing and Classic Turning. Classic Turning performs high-end CNC machining of components and Classic Metal Finishing performs anodizing and dry film lubricant applications. Classic Metal Finishing’s anodizing line can anodize with two different types for corrosion inhibitor resistance, and can die aluminum in eight different colors. Dry film lubricant is applied to parts to help with high friction tolerance fits and moving assemblies.

Single-Mode WGM Resonators Fabricated by Diamond Turning

TBMG-27995/1/2008

A diamond turning process has made possible a significant advance in the art of whispering-gallery- mode (WGM) optical resonators. By use of this process, it is possible to fashion crystalline materials into WGM resonators that have ultrahigh resonance quality factors (high Q values), are compact (ranging in size from millimeters down to tens of microns), and support single electromagnetic modes.

Machining and turning centers take center stage

AEROMAR08_033/1/2008

Makers of CNC machining equipment are incorporating more and better functionality into their products so users cope better with processing challenges such as those posed by tough new grades of aerospace materials. The name of the game in manufacturing is new product-be it a car, a computer, or a can opener-and making it available to the customer as quickly as possible. The new-product imperative applies no less to companies that make manufacturing equipment than it does to companies that make products with trendy mass-market appeal. The average consumer would not know it, but the makers of machining centers-Mazak, Haas, MAG, Mitsui Seiki, Stama, and others-pay close attention to trends, albeit not-mass market types, in cultivating new ideas for growth, all the while improving their own internal manufacturing processes to quickly translate their new ideas into finished goods.

Ponticel, Patrick

Aerospace Engineering & Manufacturing 2008-03-01

AEROMAR083/1/2008

Making an impact in fastening Engineers at Electroimpact help the company get a leg up on the competition in automated fastening. Narrowing in on military requirements UAVs/UCAVs are increasingly important, with the accent on integration- and wider engine choice. Machining and turning centers take center stage Makers of CNC machining equipment are incorporating more and better functionality into their products so users cope better with processing challenges such as those posed by tough new grades of aerospace materials. Open (and often) communication As aircraft companies battle for market share, uniting design and manufacturing teams remains a key challenge.

Fabrication of Submillimeter Axisymmetric Optical Components

TBMG-11620

5/1/2007

It is now possible to fashion transparent crystalline materials into axisymmetric optical components having diameters ranging from hundreds down to tens of micrometers, whereas previously, the smallest attainable diameter was 500 μm. A major step in the fabrication process that makes this possible can be characterized as diamond turning or computer numerically controlled machining on an ultrahigh-precision lathe. This process affords the flexibility to make arbitrary axisymmetric shapes that have various degrees of complexity: examples include a flat disk or a torus supported by a cylinder (see figure), or multiple closely axially spaced disks or tori supported by a cylinder. Such optical components are intended mainly for use as whispering-gallery-mode optical resonators in diverse actual and potential applications, including wavelength filtering, modulation, photonic generation and detection of microwaves, and research in quantum electrodynamics and quantum optics.