MATERIALS AND MANUFACTURING PROCESSES

C. Karpagavalli, M. Shunmugasundaram, Maneiah D, C. Govinda Rajulu

This study proposes an Artificial Intelligence-based framework to optimize the 3D printing of high-performance ceramic composites by predicting key mechanical properties from process parameters. A Temporal Attention Recurrent Graph Neural Network (TAR-GNN) models the spatial and temporal relationships between printing parameters, including infill density, wall thickness, and la…

Zhipeng Li, Hong Yu, Yandan Zhu, Quanli Zhang

Structured wheels exhibit significant potential for surface microstructuring while reducing grinding forces and temperature. Due to theheterogeneity and high hardness of the CBN wheel, achieving efficient and precise microstructures remains a significant challenge. In this paper, a temperature-dependent material removal model combined with experiments was executed to explore th…

Sandeep Ghosh, Arpita Nath

This work explores a data-driven modeling approach for laser micromachining of biopolymers [polylactic acid (PLA)] using Fibonacci-inspired neural networks (FINN). The main goal is to predict key machining outcomes, specifically the Machining Width (MW), Heat Affected Zone (HAZ), and ablation volume from laser parameters, providing a pre-estimate of the appearance of machining …

Jitendra Kumar, Dipiti Porwal

This study presents the design, development, and experimental validation of a cost-effective, portable, and automated abrasive jet machining system with programmable nozzle motion control. The developed system incorporates a microcontroller-based control unit and a mechanical actuation mechanism to enable precise two-axis motion of the nozzle movement with minimal operator inte…

Namadi Vinod Kumar, D. Chakradhar

This study investigates discharge-informed multi-objective optimization of wire electrical discharge machining of Inconel 718 using NSGA-II. Experiments based on an L18 orthogonal array were conducted to examine the influence of pulse parameters, wire feed, and servo voltage on surface roughness, kerf width, and cutting speed. Regression-based response models developed from the…

Shun-Tong Chen, Yi-Jing Chen

This study proposes a hybrid steady-flow electroforming process integrating steady-flow immersion and gradual rising for fabricating high-aspect-ratio tapered microhole array microstructures. A high-precision tapered micropillar master mold was fabricated by planetary electrical discharge machining (p-EDM), and a steady-flow electroforming system with automatic makeup water con…

Qingsong Hu, Shujun Chen, Zhaoyang Yan

The heat-force output characteristics are the key factors for determining deposition geometric consistency. This study innovatively introduces an alternating arc technology based on polarity-switching self-adaptive shunting (PSSAS), aiming to optimize the heat-force output characteristics and deposition geometric consistency for aluminum alloys. By comparing the arc pressure of…

Jialong Chen, Hao Tong, Yong Li, Yujie Liu

Traditional mechanical grinding of hard and brittle materials suffers from low efficiency and surface damage due to brittle-fracture removal. Electrochemical discharge-assisted grinding (ECDAG) softens surfaces via high-temperature discharges, enabling plastic removal to improve efficiency and reduce damage. However, existing methods for constraining discharge location are inco…

P. Mallikarjuna, P. Sivaiah, P. Prasanna, N. Bhaskar

High tool wear and poor surface quality significantly lead to high production cost in a metal cutting operation. Additionally, excessive usage of chemically contaminated coolants during machining negatively affects the operator health. To address these issues, novel surface textured tools were fabricated in the present work and assessed the machining performance of developed to…

Nallusamy M, Suriya Prakash M, Kiran K

Metal Matrix Composites (MMCs) have been progressively replaced the conventional materials in structural engineering applications owing to their exceptional specific strength, making them promising alternatives to traditional materials especially in the automotive, aerospace and defense sectors. Among these, Al/TiC composites, which consist of an aluminum matrix reinforced with…

Liming Liu, Yao Li, Xianli Ba, Zhaodong Zhang

To address the strong coupling between forming quality and melting wire speed inherent in wire arc additive manufacturing techniques for 5356 aluminum alloy, an indirect arc additive manufacturing process was developed. A systematic investigation was conducted for main wire feed speed to achieving stable composite indirect arcs and favorable weld bead formation under total side…

Sabana Azim, Chetan, Gaurav Bartarya

This work examines the effect of plain drills and bionic (leaf-vein) textured twist drills on the drilling performance of chosen titanium alloy (Ti-6Al-4 V). Bio-inspired textures were created on flute surfaces through laser micromachining with aim of improving chip evacuation and reducing friction between tool and workpiece. Performance was evaluated on thrust force, oversize …

Amani Mahdi, Malek Habak, Yosra Turki, Zoubeir Bouaziz

Drilling of carbon fiber reinforced polymer (CFRP) laminates often generates defects that compromise structural integrity and service life. This study investigates drilling-induced damage in bidirectional woven CFRP laminates by examining the effects of machining parameters, laminate thickness, and thermal evolution. Results show that damage is mainly concentrated at the hole e…

M. Shanmuka Srinivas, M. Ravi Sankar, N. Venkaiah

Additive manufacturing (AM) offers great design freedom and fast prototyping but often leaves stainless-steel parts with high surface roughness and defects that can affect their use in surgical applications. In this study, stainless-steel samples made by laser powder bed fusion (LPBF) were finished using a specially designed viscoelastic porous abrasive tool. The process was ca…

R. Naveen Anthuvan, V. Krishnaraj, Josko Valentincic, M. Mohana Krishnan

This work presents the fabrication and optimization of a T-shaped micro-mold insert using Micro-Electrical Discharge Machining. Aluminum 7075 was employed as the work material, while EC – grade copper electrode was used as the tool. Experiments were designed using a Taguchi L9 orthogonal array to vary current, voltage, and duty cycle. ANOVA revealed that current is the most dom…

Hao Chen, Qiyao Hu, Wenjun Fu, Lanming Zhou

This study combined experiments and simulation to investigate how pulsed magnetic field frequency (0–10 Hz) affects solidification and wear performance of SiCp/Al composites. The optimal frequency of 2.5 Hz produced the most uniform SiC distribution, refined α-Al grains, and reduced porosity. At 10 Hz, the skin effect caused particle segregation. Simulations revealed that non-u…

Deepak Agarwal, Rabesh Kumar Singh, Anuj Kumar Sharma, Usha Sharma

In the present experimentation, a micropillar is generated on a titanium sheet with tungsten carbide of 500 µm diameter by micro-EDM milling process. Discharge energy, tool rotation, and tool feed are selected as machining parameters. Taguchi’s L16 technique decides experimental sequences. Moreover, the first objective is to investigate the effect of process parameters on MRR, …

Aatish Sharma, Sharib Imam, Chandrakant K. Nirala, Sunny Zafar

Natural fiber-reinforced polymer composites are lightweight alternatives to synthetic materials, but micro-machining is difficult due to heterogeneity and fiber matrix anisotropy. This study examines micro-milling of a unidirectional hemp/bio-polybutylene succinate (bio-PBS) composite produced by microwave-assisted compression molding technique. A TiSiN-coated tungsten carbide …

Liang Zhou, Ping Zou, Xue Wang, Zhehao Yao

Derivative cutting is the primary cause of textured tool failure, yet few have considered the importance of matching cutting parameters (cutting speed v, feed rate f, and cutting width w) and texture parameters (texture location ld, texture width wd, and texture spacing ws) to suppress it. Accordingly, two sets of experiments were carried out. First, the influence of texture pa…

Ankush Katheria, Leeladhar Nagdeve, Krishnakant Dhakar, Harish Kumar

This research article is an experimentally investigated for the machinability of Magnesium Alloy (AZ80) using design of experiment (DOE) technique employed to analyze the impact of three key input parameters, pulse-on-time, voltage, and discharge current on machining performance, and the experiment was performed using an in-house designed and developed, MX–ND–EDM was used with …