Performance Characterization of Surface Quality and Tool Wear of Wet/Dry Drilling on Steels by Using Coated Drill Bits

The creation of holes by the drilling operation is a normal process which we were followed from the earlier days. Especially the drill bits’ usage is an Important consideration among the different drilling operations. Here we considered the coated form of drill bits for the purpose of improving the surface quality and to overcome the tool wear by the particulate deposition over the surface of the specimen. The drilling features are to find out over the specimen EN 8 Alloy steel and mild steel which are experimentally verified. In the view of differentiating the eminence of surface roughness and tool wear an appearance of Alloy steel and mild steel specimens, the wet and dry conditioned drilling operations are performed by the manifestation of coolants. The importance of Pertura and Latuma tool coated drill bits developed by the Physical Vapour Deposition (PVD) method are used for this operation. Based on the drilling conditions whether usage or non-usage of coolants is majorly influenced on surface roughness, and the tool coatings are politely influenced on the surface roughness of each specimen have been found out. Likewise, the tool coatings and the rotational speed influenced more on machining time has been recognized. Tool wear patterns are categorized and compared with the simulation data of drilling in Deform 3D. Effective stress is identified and related to the value of surface coarseness in both conditions of drilling on different steel specimens

Parameter Impacts of Martensitic Structure on Tensile Strength and Hardness of TIG Welded SS410 with characterized SEM Consequences

Consuming various TIG welding settings, the impact of mechanical properties on the butt joint of 410-Martensitic Stainless Steel Plate is explored. Mechanical properties such as tensile strength and hardness are evaluated on the welded butt junction plates using three levels of 200 A, 220 A and 240 A welding currents and the electrode diameters of 1.5, 2 and 2.5 mm and four factor parameters of inputs. Welding current, wire feed rate, electrode diameter, and gas flow rate are set as input parameters. The optimal input responses of welding current, electrode diameter, wire feed rate, and gas flow rate are employed over the 27 sample specimens based on array L27 Design of Experiment tool. The input parameters 240 A of welding current have improved significantly over the structural changes on martensitic form which is evidenced by their multiple SEM Micrographs, as it can be seen in the Hardness up to maximum of 512 BHN and the Tensile strength of 1090 N/mm2 outcomes

Performance Analysis of Multi-Point Incremental Forming Tool using Martensitic AISI 420 Sheet Metals

Incremental Sheet metal Forming (ISF) Process is a suitable process which helps to produce various parts used in automotive sector by rapid prototyping. This method of producing a prototype helps industry in reducing the production cost. In ISF process, a final product is evolved through local deformation of the sheet metal made by the tool. Usually better formability is obtained when the tool makes a better contact with the sheet metal throughout the process. Improved formability elevates dimensional accuracy of the product, thus increases the market value of the product. A new tool with multiple ball ends capable of making multiple mating points over sheet metal was used in this research to enhance the efficiency of formability and surface finish. Ability of the new Multi-Point Incremental Forming Tool (MPIF) was investigated and compared to the existing Single Point Forming Tool (SPIF) based on the formability and surface finish. Forming Limit Diagram (FLD), Strain Distribution (SD) and Scanning Electron Microscope (SEM) were used to examine the formability of the sheet metal. The SEM & 3D-Surface roughness profilometer were used to observe the sheet metals surface finish. In addition to these experimental techniques a simulation results were also used to predict the stress and strain rate during forming process. The experimentation and simulation outcome shows that the MPIF provides superior formability and surface finish

Parameter Impacts of Martensitic Structure on Tensile Strength and Hardness of TIG Welded SS410 with characterized SEM Consequences

Consuming various TIG welding settings, the impact of mechanical properties on the butt joint of 410-Martensitic Stainless Steel Plate is explored. Mechanical properties such as tensile strength and hardness are evaluated on the welded butt junction plates using three levels of 200 A, 220 A and 240 A welding currents and the electrode diameters of 1.5, 2 and 2.5 mm and four factor parameters of inputs. Welding current, wire feed rate, electrode diameter, and gas flow rate are set as input parameters. The optimal input responses of welding current, electrode diameter, wire feed rate, and gas flow rate are employed over the 27 sample specimens based on array L27 Design of Experiment tool. The input parameters 240 A of welding current have improved significantly over the structural changes on martensitic form which is evidenced by their multiple SEM Micrographs, as it can be seen in the Hardness up to maximum of 512 BHN and the Tensile strength of 1090 N/mm2 outcomes

Reduction of Cutting Temperature Effect and Surface Deficiencies on CNC Turned AZ91 Mg Alloy with Fluidized Nano Oxide Coolants

Tool wear is a natural phenomenon in machining process and it leads to get damage to tool. According to more demand in the market, the selection of high speed, feed rate and depth of cut of machining process are latest trends in all industry. Such machining process creates high cutting temperature, which not only reduces tool life but also induces the product quality. Cutting fluids are used to maintain the tool life and to preserve the workpiece surface properties without damages. To avoid this imperfection, it is necessary to use standard coolants during machining operations. The temperature and surface finish play a vital role in a machining process. In this work, three different nano fluids, like aluminium oxide, copper oxide and titanium oxide,are introduced, and used as a coolant in CNC lathe for turning operation. The output responses of temperature and surface roughness of the workpieces are analyzed with the help of Design of Experiment (DOE) by using L9 orthogonal array of each nano coolant. The result of output responses like temperature and surface roughness are compared with three nano fluids. The copper oxide nano fluid gives a better surface finish as compared to aluminium oxides and titanium oxide

Experimental Investigation on the Mechanical Properties of Hybrid Composites Made with Banyan and Peepal Fibers

Industries demand a material with better strength and light weight for various applications. Natural composites are fulfilling the needs of industries partially. The purpose of the present research is to develop a new composite material with light weight and better strength. In this research, hybrid composites were fabricated by conventional hand layup method using natural fibers such as banyan and peepal. Totally, four composites were manufactured namely banyan (Epoxy: banyan: 70 wt%: 30 wt %), peepal (Epoxy: peepal: 70 wt%: 30 wt %), BPB (Epoxy: banyan: peepal: 70 wt%: 20 wt%: 10 wt %) and PBP (Epoxy: banyan: peepal: 70 wt%: 10 wt%: 20 wt %). Density and porosity of the composites were determined and the results showed that BPB composite exhibited a least density. Further, all the composites displayed the maximum porosity percentage of 5. Moreover, the mechanical properties like tensile, flexural and impact strengths were tested. The hybrid composite BPB showed 2.7%, 4.9% and 13.5% increase in tensile, flexural and impact strength respectively, compared to PBP composite. Furthermore, water absorption study was conducted and the results revealed that BPB composite absorbed less amount of water (9%) at the immersion time of 12 hours. Hence, it is suggested from the present investigation that the BPB hybrid composite could be a suitable candidate for the industrial applications with better mechanical properties and light weight

Parametric Optimization of Powder-Mixed EDM of AA2014/Si₃N₄/Mg/Cenosphere Hybrid Composites Using Fuzzy Logic: Analysis of Mechanical, Machining, Microstructural, and Morphological Characterizations

This research focuses on a comprehensive exploration of the experimental and mechanical aspects of the electrical discharge machining (EDM) process, specifically targeting the machining characteristics of AA2014/Si3N4/Mg/cenosphere hybrid composites. The aim is to optimize the process parameters for enhanced machining performance through a combination of testing, optimization, and modelling methodologies. The study examines the effects of key EDM variables—peak current, pulse on time, and pulse off time—on critical output responses: surface roughness (Ra), electrode wear rate (EWR), and material removal rate (MRR). Leveraging an L9 Taguchi orthogonal array experimental design, the impact of controllable factors on these responses is analysed. An integrated approach utilizing MATLAB’s logic toolbox and Mamdani’s technique is employed to model the EDM process, and a multiple-response performance index is calculated using fuzzy logic theory, enabling multiobjective optimizations. Furthermore, a mechanical behaviour evaluation of AA2014/Si3N4/Mg/cenosphere hybrid composites is performed through mechanical testing, with a comparison between experimental machining results and predicted values. Scanning electron microscopy (SEM) images reveal the presence of filler reinforcements within the base alloy, displaying an improved microstructure and uniform reinforcement dispersion. An X-ray diffraction (XRD) analysis confirms the major elemental constituents—aluminium, silicon, and magnesium—in the hybrid composites. A microstructural analysis of the hybrid metal matrix composites (MMCs) prepared for EDM showcases closely packed reinforcement structures, circular ash-coloured spots indicating silicon and nitrates, and a fine dispersion of cenosphere reinforcement particles. The study’s outcomes demonstrate a promising application potential for these hybrid composites in various fields

Comparative Study on EDM Parameter Optimization for Adsorbed Si3N4–TiN using TOPSIS and GRA Coupled with TLBO Algorithm

Electrical discharge machining is a thermo-physical-based material removal technique. 25 combinations of process variables were formulated with the aid of Taguchi technique for EDM of adsorbed Si3N4–TiN. Machining variables like pulse current, pulse-on time, pulse-off time, dielectric pressure, and spark gap voltage varied, and impact of each variables on the performance metrics (MRR, EWR, SR, ROC, θ, CIR, and CYL) was assessed. MCDM strategies like grey relational analysis and TOPSIS are utilized to find out the ideal arrangement of machining parameters to achieve most acute productivity of the multitude of reactions. Likewise, metaheuristic algorithm in particular GRA combined with teaching-learning-based optimization algorithm is utilized for getting global optimized input factors. Important factors like pulse current, pulse-on time, and spark gap voltage characteristically affect the outputs. It is recognized that the pulse-on time and the pulse current are the most significant input factors than others. The ideal machining parameters in view of GRA and TOPSIS techniques for acquiring better output factors are I, 12 amps; PON, 7 μsec; POFF, 4 μsec; DP, 12 kg/cm2; and SV, 36 volts

Physicomechanical, morphological and tribo-deformation characteristics of lightweight WC/AZ31B Mg-matrix biocomposites for hip joint applications

Exploring high strength materials with a higher concentration of reinforcements in the alloy proves to be a challenging task. This research has explored magnesium-based composites (AZ31B alloy) with tungsten carbide reinforcements, enhancing strength for medical joint replacements via league championship optimisation. The primary objective is to enhance medical joint replacement biomaterials employing magnesium-based composites, emphasising the AZ31B alloy with tungsten carbide reinforcements. The stir casting method is utilised in the manufacture of magnesium matrix composites (MMCs), including varied percentages of tungsten carbide (WC). The mechanical characteristics, such as micro-hardness, tensile strength, and yield strength, have been assessed and compared with computational simulations. The wear studies have been carried out to analyse the tribological behaviour of the composites. Additionally, this study investigates the prediction of stress and the distribution of forces inside bone and joint structures, therefore offering significant contributions to the field of biomedical research. This research contemplates the use of magnesium-based MMCs for the discovery of biomaterials suitable for medical joint replacement. The study focuses on the magnesium alloy AZ31B, with particles ranging in size from 40 to 60 microns used as the matrix material. Moreover, the outcomes have revealed that when combined with MMCs based on AZ31B-magnesium matrix, the WC particle emerges as highly effective reinforcements for the fabrication of lightweight, high-strength biomedical composites. This study uses the league championship optimisation (LCO) approach to identify critical variables impacting the synthesis of Mg MMCs from an AZ31B-based magnesium alloy. The scanning electron microscopy (SEM) images are meticulously analysed to depict the dispersion of WC particulates and the interface among the magnesium (Mg) matrix and WC reinforcement. The SEM analysis has explored the mechanisms underlying particle pull-out, the characteristics of inter-particle zones, and the influence of the AZ31B matrix on the enhancement of the mechanical characteristics of the composites. The application of finite element analysis (FEA) is being used in order to make predictions regarding the distribution of stress and the interactions of forces within the model of the hip joint. This study has compared the physico-mechanical and tribological characteristics of WC to distinct combinations of 0%, 5%, 10% and 15%, and its impact on the performance improvements. SEM analysis has confirmed the findings’ improved strength and hardness, particularly when 10%–15% of WC was incorporated. Following the incorporation of 10% of WC particles within Mg-alloy matrix, the outcomes of the study has exhibited enhanced strength and hardness, which furthermore has been evident by utilising SEM analysis. Using ANSYS, structural deformation and stress levels are predicted, along with strength characteristics such as additional hardness of 71 HRC, tensile strength of 140–150 MPa, and yield strength closer to 100–110 MPa. The simulations yield significant insights into the behaviour of the joint under various loading conditions, thus enhancing the study’s significance in biomedical environments