Effect of different cooling strategies on surface quality and power consumption in finishing end milling of stainless steel 316

In this paper, an experimental investigation into the machinability of AISI 316 alloy during finishing end milling operation under different cooling conditions and with varying process parameters is presented. Three environmental-friendly cooling strategies were utilized, namely, dry, minimal quantity lubrication (MQL) and MQL with nanoparticles (Al$_{2}$O$_{3}$),and the variable process parameters were cutting speed and feed rate. Power consumption and surface quality were utilized as the machining responses to characterize the process performance. Surface quality was examined by evaluating the final surface roughness and surface integrity of the machined surface. The results revealed a reduction in power consumption when MQL and MQL + Al$_{2}$O$_{3}$ strategies were applied compared to the dry case by averages of 4.7% and 8.6%, respectively. Besides, a considerable reduction in the surface roughness was noticed with average values of 40% and 44% for MQL and MQL + Al$_{2}$O$_{3}$ strategies, respectively, when compared to the dry condition. At the same time, the reduction in generated surface roughness obtained by using MQL + Al$_{2}$O$_{3}$condition was marginal (5.9%) compared with using MQL condition. Moreover, the results showed that the improvement obtained in the surface quality when using MQL and MQL + Al$_{2}$O$_{3}$ coolants increased at higher cutting speed and feed rate, and thus, higher productivity can be achieved without deteriorating final surface quality, compared to dry conditions. From scanning electron microscope (SEM) analysis, debris, furrows, plastic deformation irregular friction marks, and bores were found in the surface texture when machining under dry conditions. A slight smoother surface with a nano-polishing effect was found in the case of MQL + Al$_{2}$O$_{3}$ compared to the MQL and dry cooling strategies. This proves the effectiveness of lubricant with nanoparticles in reducing the friction and thermal damages on the machined surface as the friction marks were still observed when machining with MQL comparable with the case of MQL + Al$_{2}$O$_{3}$

On the Assessment of Surface Quality and Productivity Aspects in Precision Hard Turning of AISI 4340 Steel Alloy: Relative Performance of Wiper vs. Conventional Inserts

This article reports an experimental assessment of surface quality generated in the precision turning of AISI 4340 steel alloy using conventional round and wiper nose inserts for different cutting conditions. A three-factor (each at 4 levels) full factorial design of experiment was followed for feed rate, cutting speed, and depth of cut, with resulting machined surface quality characterized by resulting average roughness (Ra). The results show that, for the provided range of cutting conditions, lower surface roughness values were obtained using wiper inserts compared with conventional inserts, indicating a superior performance. When including the type of insert as a qualitative factor, ANOVA revealed that the type of insert was most important in determining surface roughness and material removal rate, with feed rate as the second most significant, followed by the interaction of feed rate and type of insert. It was found that using wiper inserts allowed simultaneous increases in feed rate, cutting speed, and depth of cut, while providing better surface quality of lower Ra, compared to the global minimum value that could be achieved using the conventional insert. These findings show that wiper inserts produce better surface quality and a material removal rate up to ten times higher than that obtained with conventional inserts. This clearly indicates the tremendous advantages of high surface quality and productivity that wiper inserts can offer when compared with the conventional round nose type in precision hard turning of AISI 4340 alloy steel

Towards an Adaptive Design of Quality, Productivity and Economic Aspects When Machining AISI 4340 Steel With Wiper Inserts

The continuous pursue of sustainable manufacturing is motivating the utilization of new advanced technology, especially for hard to cut materials. In this study, an adaptive approach for optimization of machining process of AISI 4340 using wiper inserts is proposed. This approach is based on advance yet intuitive modeling and optimization techniques. The approach is based on Artificial Neural Network (ANN), Multi-Objective Genetic Algorithm (MOGA), as well as Linear Programming Techniques for Multidimensional Analysis of Preference (LINMAP), for modeling, optimization and multi-criteria decision making respectively. This integrated approach, to best of the authors’ knowledge, has been deployed for the first time to adaptively serve different designs of manufacturing processes. Such designs have different orientations, namely cost, quality, productivity, and balanced orientation. The capability of the proposed approach to serving such diverse requirements answers one of the most accelerating demands in the manufacturing community due to the dynamics of the uprising smart production lines. Besides, the proposed approach is presented in a straightforward manner that can be extended easily to other design orientations as well as other engineering applications. Based on the proposed design, a balanced general setting of 197.4 m/min, 0.95 mm, and 0.168 mm/rev was recommended along with other settings for more sophisticated requirements. Confirmatory experiments showed a good agreement (i.e., no more than 7% deviation) with the predicted optimum responses. This shows the validity of the proposed approach as a viable tool for designers to promote holistic and sustainable process design

Experimental and Numerical Study of Texture Evolution and Anisotropic Plastic Deformation of Pure Magnesium under Various Strain Paths

The deformation behavior and texture evolution of pure magnesium were investigated during plane strain compression, simple compression, and uniaxial tension at room temperature. The distinctive stages in the measured anisotropic stress-strain responses and numerically computed strain-hardening rates were correlated with texture and deformation mechanisms. More specifically, in plane strain compression and simple compression, the onset of tensile twins and the accompanying texture-hardening effect were associated with the initial high strain-hardening rates observed in specimens loaded in directions perpendicular to the crystallographic c-axis in most of the grains. The subsequent drop in strain-hardening rates in these samples was correlated with the exhaustion of tensile twins and the activation of pyramidal <c+a> slip systems. The falling strain-hardening rates were observed in simple compression and plane strain compression with loading directions parallel to the c-axis where the second pyramidal <c+a> slip systems were the only slip families that can accommodate deformation. For uniaxial tension with the basal plane parallel to the tensile axis, the prismatic <a> and second pyramidal <c+a> slips are the main deformation mechanisms. The predicted relative slip and twin activities from the crystal plasticity simulations clearly showed the effect of texture on the type of activated deformation mechanisms

Sustainable and Smart Manufacturing: An Integrated Approach

The necessity for decreasing the negative impact of the manufacturing industry has recently increased. This is getting recognized as a global challenge due to the rapid increase in life quality standards, demand, and the decrease in available resources. Thus, manufacturing, as a core of the product provision system and a fundamental pillar of civilized existence, is significantly influenced by sustainability issues. Furthermore, current manufacturing modeling and assessment criteria require intensive revisions and upgrades to keep up with these new challenges. Nearly all current manufacturing models are based on the old paradigm, which was proven to be inadequate. Therefore, manufacturing technology, along with culture and economy, are held responsible for providing new tools and opportunities for building novel resolutions towards a sustainable manufacturing concept. One of such tools is sustainability assessment measures. Revising and updating such tools is a core responsibility of the manufacturing sector to efficiently evaluate and enhance sustainable manufacturing performance. These measures should be adequate to respond to the growing sustainability concerns in pursuit of an integrated sustainability concept. The triple bottom line (TBL) that includes environment, economic, and social dimensions has usually been used to evaluate sustainability. However, there is a lack of standard sets of sustainable manufacturing performance measures. In addition to the sustainability concept, a new concept of smart manufacturing is emerging. The smart manufacturing concept takes advantage of the recent technological leap in Artificial Intelligent (AI), Cloud Computing (CC), and the Internet of Things (IoT). Although this concept offers an important step to boost the current production capabilities to meet the growing need, it is still not clear whether the two concepts of smart manufacturing and sustainability will constructively or destructively interact. Therefore, the current study aims to integrate the sustainable smart manufacturing performance by incorporating sustainable manufacturing measures and discussing current and future challenges that are faced by the manufacturing sector. In addition, the opportunities for future research incorporating sustainable smart manufacturing are also presented

Grain refinement mechanism and its effect on mechanical properties and biodegradation behaviors of Zn alloys – A reviewStatement of significance

Along the way, investigations over the past few years have focused on developing new Zn-based alloys as future materials for medical implants due to the poor mechanical and degradation properties. Effective grain size control is a fundamental property of Zn-based alloys that has a significant impact on their mechanical properties and degradation rate through various methodical adjustments of the microstructure. In particular, these critical properties of Zn-based alloys largely depend on grains' size and distribution in the respective microstructures. The review article critically analyzes the influence of grain refinement and microstructure on the mechanical properties, biodegradability, and biocompatibility of Zn-based alloys. The article establishes the interdependence between microstructure, mechanical properties, degradation rate, and biocompatibility of both Zn and its alloys. We conclude integration of alloying and fabrication techniques can significantly control grain refinement in Zn-based alloys, and the use of innovative techniques such as dynamic recrystallization and inoculation can further improve the grain refinement process

Influence of Milling Route on the Corrosion Passivation of Al-2%SiC Nanocomposites in Chloride Solutions

In this work, the fabrication of three Al-2wt.% SiC nanocomposites processed by novel milling route was carried out. The beneficial influence of milling route on the corrosion passivation of the new fabricated composites was investigated. The cyclic polarization measurements have proved that increasing the time of ball milling highly reduced the corrosion of Al-SiC nanocomposite via reducing obtained corrosion current and so increasing the corrosion resistance. These results were affirmed by the electrochemical impedance spectroscopy experiments. The pitting corrosion of the manufactured composites was also reported, and its intensity decreased with the increase of ball milling time. The electrochemical experiments were also performed after expanding the exposure time in the chloride solution to 24 and 48. It was found that both the uniform and pitting corrosion decrease with prolonging the time. The study was complemented by examining the surface morphology and the elemental analyses for the different composites by using surface analyses techniques

A Comparative Study of the Electrochemical Behavior of α and β Phase Ti6Al4V Alloy in Ringer’s Solution

Owing to their superior biocompatibility, titanium and its alloys are often the first choice for implant materials in biomedical applications, especially for dental and bone repairs (orthodontics and prosthodontics). Titanium has low density and shows good mechanical and chemical properties. Although Ti-6Al-4V alloy exhibits excellent corrosion resistance properties, the metal ions released during corrosion are likely to induce aseptic loosening in long-term implantations. In the present study, Ti-6Al-4V alloy was subjected to two specific heat treatments, namely, air cooling and water quenching. The potentiodynamic polarization and electrochemical impedance spectroscopy measurements revealed remarkable improvement in the corrosion resistance properties of the heat-treated specimens. The presence of the &beta; phase is a plausible reason for the improvement. Scanning electron microscopy, X-ray diffraction phase composition analysis, and microstructural characterization were performed to confirm the presence of the &beta; phase

Microstructural and Corrosion Characteristics of Al-Fe Alloys Produced by High-Frequency Induction-Sintering Process

Al-x wt.% Fe bulk alloys were fabricated from a powder mixture of pure Al and x wt.% of Fe, where x = 2 wt.%, 5 wt.% and 10 wt.%. Initially, as-mixed mixtures were processed using a mechanical-alloying (MA) technique in an attritor for 4 h. The milling was performed in an argon atmosphere at room temperature followed by the sintering of the milled powders in a high-frequency induction furnace to produce bulk samples. Scanning electron microscopy (SEM) was used to study the morphology of the produced alloys, and X-ray diffraction (XRD) to determine the phases formed after the sintering process and their crystallite size. The corrosion behavior of the fabricated samples was studied by immerging them in a 3.5% sodium chloride (NaCl) solution at room temperature using cyclic-polarization (CP) and electrochemical-impedance-spectroscopy (EIS) techniques. The SEM results showed that Fe was uniformly distributed in the Al matrix, and XRD revealed the formation of Al and intermetallic, i.e., Al6Fe and Al13Fe4, phases in the Al-Fe alloys after sintering. The hardness of the Al-Fe alloys was increased with the addition of Fe due to the formation of intermetallic compounds. Electrochemical results showed that there was a proportional relationship between the percentage of Fe additives and corrosion potential (Ecorr) where it shifted toward a nobler direction, while corrosion current density (icorr) and corrosion rate decreased with an increasing Fe%. This observation indicates that the addition of Fe into an Al matrix leads to an improvement in the corrosion resistance of the alloys

Efficient detection and adsorption of cadmium(II) ions using innovative nano-composite materials

© 2018 Elsevier B.V. In this study, a ligand was anchored with mesoporous silica, named as nano-composite materials, was applied in the detection and adsorption of cadmium (Cd(II)) ions from wastewater samples. The effects of solution pH, color optimization, limit of detection, contact time, initial concentration, ion selectivity and regeneration were systematically performed in the case of detection and adsorption operations. The solution pH was played an important factor both in the case of detection and adsorption, and the optimum pH were selected at 5.50 based on the high absorbance and adsorption ability. Upon addition of Cd(II) ions, the nano-composite materials was provided an excellent color, which was observed by the naked-eye. The detection limit was calculated to be 0.33 µg/L, which was lower than the permissible limit. Therefore, the Cd(II) ions was detected without using any sophisticated instruments. The equilibrium isotherm has been analyzed using Langmuir isotherm models, and the maximum adsorption capacity was 148.32 mg/g. The results clarified that the nano-composite material had the higher selectivity towards Cd(II) ions even in the presence of high concentration of divers metal ions. The material was reused in several cycles after elution operation with a suitable eluent of 0.25 M HCl. The nano-composite materials exhibited an excellent reusability because of its remarkable mechanical strength and highly efficient elution/regeneration operations ability. In the static treatment process, after seven cycles, Cd(II) ions was adsorbed efficiently and holding over 93% adsorption efficiency. The developed ligand functionalized nano-composite materials is quite simple and rapid with excellent repeatability for Cd(II) ions capturing and has a great potential for potential scale up for field application in real wastewater samples.The authors extend their appreciation to the International Scientific Partnership Program ISPP at King Saud University for funding this research work through ISPP# 87 . The authors also wish to thank the anonymous reviewers and editor for their helpful suggestions and enlightening comments