Advances in Hard–to–Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity

Wojciechowski, Szymon; Królczyk, Grzegorz; Maruda, Radosław W.

doi:10.3390/ma13030612

Cited by 14 publications

(6 citation statements)

References 14 publications

(13 reference statements)

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“…Furthermore, these issues of reliable achievement of a stress-appropriate surface integrity are also linked to a series of questions and research priorities that have evolved in recent years. Wojciechowski et al particularly include as current major problems and directions concerning hard-to-machine materials novel production and machining techniques as well as production or machining optimization methods and novel measurement or characterization techniques [7].…”

Section: Introductionmentioning

confidence: 99%

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Schroepfer

Treutler

Boerner

et al. 2021

Int J Adv Manuf Technol

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The supply and processing of materials for highly stressed components are usually cost-intensive. Efforts to achieve cost and resource efficiency lead to more complex structures and contours. Additive manufacturing steps for component repair and production offer significant economic advantages. Machining needs to be coordinated with additive manufacturing steps in a complementary way to produce functional surfaces suitable for the demands. Regarding inhomogeneity and anisotropy of the microstructure and properties as well as production-related stresses, a great deal of knowledge is still required for efficient use by small- and medium-size enterprises, especially for the interactions of subsequent machining of these difficult-to-machine materials. Therefore, investigations on these influences and interactions were carried out using a highly innovative cost-intensive NiCrMo alloy (IN725). These alloys are applied for claddings as well as for additive component manufacturing and repair welding using gas metal arc welding processes. For the welded specimens, the adequate solidification morphology, microstructure and property profile were investigated. The machinability in terms of finishing milling of the welded surfaces and comparative analyses for ultrasonic-assisted milling processes was examined focussing on surface integrity. It was shown that appropriate cutting parameters and superimposed oscillating of the milling tool in the direction of the tool rotation significantly reduce the mechanical loads for tool and workpiece surface. This contributes to ensure a high surface integrity, especially when cutting has to be carried out without cooling lubricants.

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Section: Introductionmentioning

confidence: 99%

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Schroepfer

Treutler

Boerner

et al. 2021

Int J Adv Manuf Technol

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“…Particularly in the field of advanced materials processing, additive manufacturing has emerged as a paradigm-shifting technique that makes it possible to create complex structures with extreme accuracy and precision. Layer-by-layer material deposition is utilised in this technique to build 3D objects out of a variety of materials, including metals, ceramics, and polymers [23][24][25]. Additionally, the use of sophisticated sensors and data analytics has made it possible to monitor and manage the additive manufacturing process in real-time, enhancing the final product's quality and dependability.…”

Section: Current State Of Advanced Materials Processingmentioning

confidence: 99%

Exploring the Future of Advanced Materials Processing: Innovations and Challenges Ahead: A Review

Sharma,

Ramacharyulu,

Lakhanpal

et al. 2024

E3S Web Conf.

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This research paper investigates the future of advanced materials processing, with a focus on the innovations and challenges that lie ahead. The study begins by exploring the current state of advanced materials processing and the latest trends in the field, including the use of advanced manufacturing technologies, such as additive manufacturing, to create complex geometries and novel materials. The paper then examines the challenges facing the field, including the need to develop new processing techniques that can handle a wider range of materials and produce materials with specific properties. The study also analyses the potential impact of emerging technologies, such as artificial intelligence and machine learning, on the future of materials processing. Finally, the paper concludes with a discussion of the key innovations and trends that are likely to shape the future of materials processing, including the use of sustainable materials, the development of new nanomaterials, and the integration of advanced sensors and data analytics into the manufacturing process. Overall, this research paper provides a comprehensive analysis of the future of advanced materials processing and highlights the critical role that innovation will play in shaping the field in the coming years.

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“…The investigation of the effect of tool wear on surface roughness increase is addressed by [47], while [48] demonstrates through research that low-temperature cooling can enhance machined surface quality while minimizing tool wear. The determination of tool wear in the machining of duplex stainless steel is presented in papers [49,50], with the issue of tool wear and surface topography also discussed in [51][52][53][54][55]. Additional researchers [56] conduct experimental investigations into factors affecting stainless steel turning and assess wear parameters on the cutting tool's face and back surface.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Sustainable Production Processes in C45 Steel Machining Using a Confocal Chromatic Sensor

Jurko,

Paľová,

Michalík

et al. 2024

Lubricants

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Metal machining production faces a myriad of demands encompassing ecology, automation, product control, and cost reduction. Within this framework, an exploration into employing a direct inspection of the machined area within the work zone of a given machine through a confocal chromatic sensor was undertaken. In the turning process, parameters including cutting speed (A), feed (B), depth of cut (C), workpiece length from clamping (D), and cutting edge radius (E) were designated as input variables. Roundness deviation (Rd) and tool face wear (KM) parameters were identified as output factors for assessing process performance. The experimental phase adhered to the Taguchi Orthogonal Array L27. Confirmatory tests revealed that optimizing process parameters according to the Taguchi method could enhance the turning performance of C45 steel. ANOVA results underscored the significant impact of cutting speed (A), feed (B), depth of cut (C), and workpiece length from clamping (D) on turning performance concerning Rd and KM. Furthermore, initial regression models were formulated to forecast roundness variation and tool face wear. The proposed parameters were found to not only influence the machined surface but also affect confocal sensor measurements. Consequently, we advocate for the adoption of these optimal cutting conditions in product production to bolster turning performance when machining C45 steel.

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Advances in Hard–to–Cut Materials: Manufacturing, Properties, Process Mechanics and Evaluation of Surface Integrity

Cited by 14 publications

References 14 publications

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Exploring the Future of Advanced Materials Processing: Innovations and Challenges Ahead: A Review

Optimization of Sustainable Production Processes in C45 Steel Machining Using a Confocal Chromatic Sensor

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