This article presents the results of an experimental investigation into the machinability of Ti6Al4V alloy during hard turning, including both conventional and high-speed machining, using polycrystalline diamond (PCD) inserts. A central composite design of experiment procedure was followed to examine the effects of variable process parameters; feed rate, cutting speed and depth of cut (each at five levels) and their interaction effects on surface roughness and cutting temperature as process responses. The results revealed that cutting temperature increased with increasing cutting speed and decreasing feed rate in both conventional and high-speed machining. It was found that high-speed machining showed an average increase in cutting temperature of 65% compared with conventional machining. Nevertheless, high-speed machining showed better performance in terms of lower surface roughness despite using higher feed rates compared to conventional machining. High-speed machining of Ti6Al4V showed an improvement in surface roughness of 11% compared with conventional machining, with a 207% increase in metal removal rate (MRR) which offered the opportunity to increase productivity. Finally, an inverse relationship was verified between generated cutting temperature and surface roughness. This was attributed mainly to the high cutting temperature generated, softening, and decreasing strength of the material in the vicinity of the cutting zone which in turn enabled smoother machining and reduced surface roughness.

Experimental investigations were conducted on Mg-3Zn-0.6Zr alloy under different ECAP conditions of number of passes, die angles, and processing route types, aimed at investigating the impact of the ECAP parameters on the microstructure evolution, corrosion behavior, and mechanical properties to reach optimum performance characteristics. To that end, the response surface methodology (RSM), analysis of variance, second-order regression models, genetic algorithm (GA), and a hybrid RSM-GA were utilized in the experimental study to determine the optimum ECAP processing parameters. All of the anticipated outcomes were within a very small margin of the actual experimental findings, indicating that the regression model was adequate and could be used to predict the optimization of ECAP parameters. According to the results of the experiments, route Bc is the most efficient method for refining grains. The electrochemical impedance spectroscopy results showed that the 4-passes of route Bc via the 120°-die exhibited higher corrosion resistance. Still, the potentiodynamic polarization results showed that the 4-passes of route Bc via the 90°-die demonstrated a better corrosion rate. Furthermore, the highest Vicker’s microhardness, yield strength, and tensile strength were also disclosed by four passes of route Bc, whereas the best ductility at fracture was demonstrated by two passes of route C.

In this study, a quantitative evaluation approach was used to investigate how certain ECAP processing parameters affect the microstructural evolution, Vicker’s microhardness values and tensile properties of pure Mg. The ECAP processing parameters were number of passes, ECAP die channel angle and processing route type. The response surface methodology (RSM) technique was used to design 16 runs of the experiment using Stat-Ease design expert software. Billets of pure Mg were processed up to four passes of routes Bc, A and C at 225 °C. Two ECAP dies were used with internal channel angles of 90° and 120°. Experimental findings were used to establish empirical models to assess the influence of the ECAP processing parameters on grain size and mechanical properties of ECAPed billets. The established relationships were examined and validated for their adequacy and significance using ANOVA as well as several statistical criteria. Response surface plots and contour graphs were established to offer better understanding of the intended relationships. In addition, the optimum processing parameters for grain size, hardness values and tensile properties were defined. Both experimental results and the theoretical model revealed that route Bc is the most effective route in grain refining. The experimental findings showed that four passes of route Bc through the die channel angle 90° revealed a significant reduction in the grain size by 86% compared to the as-annealed counterparts. Similar to the grain size refining, four-passes processing through the ECAP die with an internal channel angle of 90° leads to improved Vicker’s microhardness values. Additionally, four passes of route Bc using the 90° die angle recorded a significant HV increase at the edge and central areas by 112% and 78%, respectively, compared to the as-annealed counterpart. On the other hand, according to the optimization findings, two passes of route Bc using a die angle of 120° resulted in the best ultimate tensile strength for pure Mg, whereas four passes of route Bc revealed the optimum ductility at fracture.

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