Machining Forces Due to Turning of Bimetallic Objects Made of Aluminum, Titanium, Cast Iron, and Mild/Stainless Steel

Abstract

This article elucidates the characteristics of machining forces (an important phenomenon by which machining is studied) using three sets of bimetallic specimens made of aluminum–titanium, aluminum–cast iron, and stainless steel–mild steel. The cutting, feed, and thrust forces were recorded for different cutting conditions (i.e., different cutting speeds, feeds, and cutting directions). Possibility distributions were used to quantify the uncertainty associated with machining forces, which were helpful in identifying the optimal machining direction. In synopsis, it was found that while machining the steel-based bimetallic specimens, keeping a low feed and high cutting speed is the better option, and the machining operation can be performed in both the hard-to-soft and soft-to-hard material directions, but machining in the soft-to-hard material direction is the better option. On the other hand, very soft materials should not be used in fabricating a bimetallic part because it creates machining problems. Cutting power was estimated using the cutting and feed force signals. Manufacturers who support sustainable product development (including design, manufacturing, and assembly) can benefit from the outcomes of this study because parts/products made of dissimilar materials (or multi-material objects) are better than their mono-material counterparts in terms of sustainability (cost, weight, and CO2 footprint).

What is knowledge in Industry 4.0?

“…The first category can be described using the scenario depicted in Figure 3. been reported in 79 . Figure 3B depicts a concept map that comprises a piece of informal-induction-based knowledge that underlies the provenance depicted in Figure 3A.…”

Time Latency-Centric Signal Processing: A Perspective of Smart Manufacturing

“…The machining conditions are summarized in Table 4. The reasons for choosing a multi-material workpiece over a mono-material workpiece are as follows: (1) the usage of multi-material objects is increasing because these perform better in terms of material efficiency compared to their mono-material counterparts [44,46], and (2) Machining a multi-material object underlies more complex machining situations compared to machining a mono-material object.…”

“…to their mono-material counterparts [44,46], and (2) Machining a multi-material object underlies more complex machining situations compared to machining a mono-material object. However, the multi-material workpiece is machined from the hard-to-soft material direction (i.e., SUS304 to S15CK), as shown in Figure 13.…”

Experimental Evaluation of Surface Alterations Induced in Machining of Ti-6Al-4V Alloy

“…The microstructure change is a significant indication of surface integrity and some of the mechanical properties of workpiece including wear resistance are dependent on it [24]. During the process, due to the cutting forces and high friction between tool and material, mechanical plastic deformation occurs on the surface, which increases the hardness and tensile strength and consequently reduces the material ductility [25].…”