In this study, a multiple sensor data fusion system is anticipated as essential for monitoring of cutting operations, by identifying suitable sensor locations to obtain feedback signals periodically. The sensor signal derives the failure during machining owing to complex cutting tool geometry even in machining of composites. Nano metal matrix composites (NMMC) being extremely upright in mechanical characteristics, consequently machining of these hybrid nano metal matrix composites reinforced with difficult-to-cut nano particles leads to reduced tool life thereby causing rapid flank wear. Therefore, it is a challenge to identify the wear features caused during machining of tailor made NMMC's, reducing wastage and preventing machine malfunction. This paper presents a comprehensive review on the machining strategies in extreme output conditions which rely on input parameters of speed, feed and depth of cut influencing tool life during CNC machining. This can be achieved only with multiple sensor data fusion technique during CNC machining.

Aluminum-based nanocomposites reinforced with carbon nanotubes have increased scientific attention in today’s life. The dispersion quality was the critical aspect, which decides the homogeneous distribution of CNTs within the Al matrix as starting precursors. In this study, a new attempt has been made to obtain a uniformly dispersed Al-0.75% CNT precursor via combining ultra-sonication, cubic tumbler rod milling, and spray drying. This process was integrated with organic deflocculant (formulator) in specific proportion to transform as a semi-wet-based route. The effect of milling media on the morphology and interface structure of the as-produced composite precursor after all the processing steps was investigated through scanning electron microscope (SEM), high-resolution transmission electron microscope (HRTEM), X-ray diffraction (XRD) analysis, Raman spectroscopy, and Fourier transform infrared spectroscopy. The results reveal that the approach is effective in CNT dispersion in Al precursor, which shields the nanotube structure from damage for longer periods of milling time due to the organic formulator mixture, and also, the CNT retention in the Al precursor with minimum clustering is identified compared to the ball milling process. Carbon traces were confirmed in the as-produced composite precursor by this approach.

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In this work, cubic tumbler rod milling was used to disperse X wt% multiwalled carbon nanotubes (X = 0.5, 0.75, 1.0) in an aluminum matrix. Dispersed precursor of aluminum–multiwalled carbon nanotube composite was subsequently consolidated by cold compaction followed by sinter-forged process. Microstructural and mechanical behaviors of as-produced aluminum–multiwalled carbon nanotube composites with different concentration were investigated. Findings revealed that the as-produced Al–0.75 wt% carbon nanotube sinter-forged composite exhibits homogenous distribution and embedded nanotubes confirmed by the scanning electron microscope and the properties were observed to be increased significantly up to addition of 0.75 wt% of carbon nanotubes concentration than the pure aluminum as well as extruded composite and decrease to 1.0 wt% carbon nanotube due to the agglomeration of multiwalled carbon nanotube. However, enhancement of hardness, tensile strength, and Young’s modulus of the nanocomposites, compared with pure aluminum are 48.5, 83.8, and 30%, respectively. The tensile fractography of sinter-forged composite shows carbon nanotubes act like a bridge and barring the crack growth of aluminum matrix, remaining are pullout. Hence, it can be concluded that aluminum carbide phase starting from 0.75 wt% carbon nanotube and a strong interfacial bonding in as-produced aluminum–carbon nanotube composite has been observed which gives effective load transfer between aluminum matrix and carbon nanotubes.

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