Materials and Manufacturing Processes (MATER MANUF PROCESS )

Publisher: Taylor & Francis

Description

Materials and Manufacturing Processes deals with issues that result in better utilization of raw materials and energy, integration of design and manufacturing activities requiring the invention of suitable new manufacturing processes and techniques, unmanned production dependent on efficient and reliable control of various processes including intelligent processing, introduction of new materials in industrial production necessitating new manufacturing process technology, and more. Information is offered in various formats, including research articles, letter reports, review articles, conference papers, applied research, book and conference reviews, patent reports, and entire issues devoted to symposia.

  • Impact factor
    1.49
    Show impact factor history
     
    Impact factor
  • 5-year impact
    1.39
  • Cited half-life
    4.00
  • Immediacy index
    0.17
  • Eigenfactor
    0.00
  • Article influence
    0.24
  • Website
    Materials and Manufacturing Processes website
  • Other titles
    Materials and manufacturing processes (Online)
  • ISSN
    1042-6914
  • OCLC
    45552471
  • Material type
    Document, Periodical, Internet resource
  • Document type
    Internet Resource, Computer File, Journal / Magazine / Newspaper

Publisher details

Taylor & Francis

  • Pre-print
    • Author can archive a pre-print version
  • Post-print
    • Author can archive a post-print version
  • Conditions
    • Some individual journals may have policies prohibiting pre-print archiving
    • On author's personal website or departmental website immediately
    • On institutional repository or subject-based repository after either 12 months embargo for STM, Behavioural Science and Public Health Journals or 18 months embargo for SSH journals
    • Publisher's version/PDF cannot be used
    • On a non-profit server
    • Published source must be acknowledged
    • Must link to publisher version
    • Set statements to accompany deposits (see policy)
    • The publisher will deposit in on behalf of authors to a designated institutional repository including PubMed Central, where a deposit agreement exists with the repository
    • STM: Science, Technology and Medicine
    • SSH: Social Science and Humanities
    • Publisher last contacted on 25/03/2014
    • 'Taylor & Francis (Psychology Press)' is an imprint of 'Taylor & Francis'
  • Classification
    ​ green

Publications in this journal

  • [Show abstract] [Hide abstract]
    ABSTRACT: In this study, experimental investigations were carried out in a drilling operation on medium-carbon steel material using a conventional coolant and a liquid nitrogen (LN2) coolant separately. The variables in the experiment were cutting speed (V c) and feed (f), while the drilling depth was maintained constant. The cutting temperature (T), thrust force (f t), and surface roughness (R a) were analyzed. The results of the experiment indicate that there is 6% to 51% reduction in cutting temperature when LN2 is used. At lower feed rates, the thrust force increased by 6% to 32% in LN2 cooling conditions, and at higher feed rates, the thrust force decreased of 4% to 8% in LN2 cooling conditions.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: This paper proposes a high-precision electrochemical micromachining (EMM) system. By applying nanosecond pulses, workpiece dissolution can be restricted to a very small area around the microelectrode. First, an EMM system that meets the requirements of the EMM process is built. Second, sets of comparative experiments are performed on pure nickel and superalloy plates to study the effects of main machining parameters, e.g., pulse on time, applied voltage, pulse period, and electrode diameters, on side gap. Finally, after the preliminary experiments, complex microshapes with characteristic size of several tens of micrometers are successfully fabricated on the nickel and superalloy plates, thereby demonstrating that EMM is a very promising microfabrication technology.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: TC21 is a new type of titanium alloy that is difficult to cut. In this research, a series of orthogonal turning tests are performed to investigate the cutting mechanisms of TC21. The effects of tool geometrical parameters and cutting conditions on turning force are analyzed in detail. In addition, the orthogonal turning process of TC21 alloy is simulated using a presented three-dimensional finite element model (FEM). The results proved that tool geometrical parameters and cutting conditions have a great effect on the turning force. Further, the results of simulation agreed well with those of the experiments, and the FEM can be used to reveal the high-speed machining behavior of TC21 alloy.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: A single-pulse experiment was conducted to study the mechanism of electrical discharge machining (EDM) ablation. An equivalent model of EDM ablation was established to explain the changes in the oxide layer of electrodes. Theoretical analysis was performed to understand the machining mechanism behind EDM ablation. Four stages and three models of EDM ablation were proposed to explain the machining mechanism of this process. Tests were performed to compare normal EDM, EDM spark-induced combustion, and EDM spark-induced explosion. The processing depth and surface morphology of the machined workpiece in the experimental results are coincident with those in the theoretical analysis results.
    Materials and Manufacturing Processes 12/2014; 29.
  • [Show abstract] [Hide abstract]
    ABSTRACT: This article presents the results of experimental studies of tool temperature in ultrasonically assisted turning (UAT) of aerospace aluminum using Al2O3-coated tools. Temperature has been measured using K-Type Testo 735 thermocouple. The effects of work velocity, feed rate, and vibration amplitude are also investigated. These results show that UAT does not necessarily lower the cutting temperature in all cases. The effectiveness of the technique is highly dependent on the value of vibration amplitude, work velocity, and feed rate. At low feed rates and amplitude, the tool temperature for UAT is 60% of the conventional turning and it grows with increasing feed rate and amplitude.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: Technology development has led to the need of micro and miniaturized products in the field of automobile, aerospace, electronics, medical implants, biomedicine, robotics, and so on. Micromachining is the key technology to satisfy the need of the industry in terms of functionality and miniaturization in size. In this article, state-of-the-art review on tool-based micromachining processes such as microturning, microdrilling, micromilling, electric discharge micromachining (Micro-EDM), and electrochemical micromachining (Micro-ECM) has been carried out. The review begins with an overview of micromachining, classifications, and discussions about different aspects of tool-based micromachining processes. The research works carried out for the past 10 years are analyzed in terms of materials perspective, process parameters, size effects, performance characteristics, condition monitoring, product development, micro features generation, and fabrication of micro tools. A statistical analysis has been performed with respect to the previous review articles, numbers of publications in the related area, and their research gap. Finally, the possible future research direction is presented.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: Because nickel-based alloy Inconel718 has poor thermal conductivity and serious work hardening, it is identified as a difficult-to-process material. The serious tool wear leads to short tool life. In this study, physical vapor deposition-coated carbide tools were used to machine Inconel718. The material response for different cutting speeds at the tool–chip interface and its effect on tool wear were studied. The results showed that at low cutting speed (v c = 20 m/min), cold welding and adhesion occurred at the tool–chip interface under high stress, and then the built-up edge (BUE) formed. The peeling off of BUE led to chipping. When the cutting speed (v c) was 45 m/min, diffusion and oxidation occurred at the tool–chip interface. The new generated material reduced tool hardness and bond strength of Co. The wear debris was generated in tool rake face. Flakes of wear debris fell from the tool substrate, which increased tool wear. When the cutting speed was 32 m/min, the softer oxides generated at the tool–chip interface served as a boundary lubrication layer. They can effectively weaken the adhesion between tool and chip, which made the chemical wear and adhesive wear reach equilibrium. Furthermore, the friction coefficient is reduced. Tool wear is reduced under this cutting condition.
    Materials and Manufacturing Processes 12/2014; 29.
  • [Show abstract] [Hide abstract]
    ABSTRACT: Titanium alloy Ti6Al4V is a material that has been used extensively in industries, such as the medical field for prostheses and surgical instruments, because of its biocompatibility. However, it is considered a difficult-to-machine material owing to its inherent mechanical and thermal properties (which cause severe tool wear and shorten tool life), diminished surface quality, and it conducts low productivity. The aim of this work is to evaluate the efficiency of minimum quantity lubrication (MQL) in micromilling in terms of dry machining and jet application. The effect of cutting fluid flow was analyzed through Computational Fluid Dynamics (CFD) analysis and jet application, in the context of the microscale, was found to cause a disordered flow that did not reach the desired target, in this case the two flutes of the tool. These results were accordant with those obtained in the micromilling experiments. In addition, recent machining concerns are related to sustainability and aim to reduce or even eliminate the use of cutting fluids altogether; in this sense, applying MQL in micromilling would represent a substantial reduction in cutting fluid consumption.
    Materials and Manufacturing Processes 12/2014; 29.
  • [Show abstract] [Hide abstract]
    ABSTRACT: Glass is difficult to machine due to its susceptibility to brittle fracture during machining. Tool tilt angle can exert a remarkable effect on the surface finish of glass in micro-ball-end milling. On the basis of a theoretical analysis and simulation by three-dimensional discrete element method, an optimal mathematical model is constructed for tool inclination, which is governed by edge radius of ball-nose of end-mill and cutting thickness. Corresponding experiments are conducted for model verification. The results show that different cutting thicknesses, cutter shapes, and spindle speeds have a considerable influence on machining mechanics of glass.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: The addition of hard abrasives to the jet in waterjet machining can improve machining rate, however, embedding of particles in machined surfaces is a limitation, which results in reduced fatigue life, and limits the application of well adhered subsequent coatings to the surface. In this study, softer soluble abrasives were investigated as a potential solution. Soluble abrasives yielded a higher material removal rate compared to plain waterjet, although were not as effective as traditional hard abrasives. Soluble abrasives reduced grit embedment on all four workpiece materials. A post-machining surface cleaning operation demonstrated that any remaining soluble abrasive could be removed.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: SiCp/Al composites are one kind of difficult-to-machine material. The material removal mechanism of this material is complex due to the existence of SiC reinforcement. The chip formation reflects its material removal process to a certain extent. In this article, a study of chip formation is described, and a basic physical cutting model is presented to help reveal chip formation mechanism in mill-grinding of SiCp/Al composites. The scanning electron microscope photos are used to analyze the characteristic of chip morphology. Observed results based on the materials used in the experiment indicated that there were mainly four typical chip shapes, among them schistose chips being dominant. The chip formation mechanism depended much on plastic deformation of aluminum matrix, contact position between SiC particle and diamond grit, and the removal mode of SiC particle. Under the same machining conditions, the chips generated are irregular and uneven, and include several kinds of shapes. The effect of size of SiC particles on the morphology of chips formed was also analyzed based on correlational studies and the physical cutting model for SiCp/Al composites.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: This paper focuses on optimizing process parameters in abrasive water-jet machining with the objective of minimizing surface roughness in brass-360. The following process parameters were considered: abrasive flow rate, pump pressure, stand-off distance, and feed rate. The experiments were conducted using a Taguchi L27 orthogonal array. Response surface methodology was used to decide the optimal process parameters that minimized the surface roughness. Analysis of variance reflects the relative significance of process parameters and is used to find contribution of factors. Furthermore, a mathematical model was developed to correlate the machining performance. It was found that the pump pressure was the most significant parameter affecting the surface roughness. The optimal combination of process parameters are an abrasive flow rate = 75.37 g/min, pump pressure = 399 MPa, stand-off distance = 1 mm, and feed rate = 557 m/min. Finally, using a desirability function method, the optimal parameters for minimizing surface roughness were determined. The machined surfaces were examined with field emission scanning electron microscope and an atomic force microscope to observe the quality of surface obtained with the optimal settings obtained through response surface method.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: Silicon nitride ceramics are extremely difficult and time-consuming to machine with conventional methods, such as turning and grinding. Laser-assisted machining has been a field of extensive research during the past decade, as it is a promising solution to enhance the machinability of many difficult-to-cut materials, including silicon nitride ceramics. To enhance the processing precision of silicon nitride ceramic grinding, this paper presents an experimental investigation of a two-stage laser-induced wet grinding (LIWG) process, including laser-induced thermal cracking and wet grinding. Specifically, the differences in the grinding force, grinding force ratio and surface roughness obtained for LIWG and conventional grinding (CG) conditions are compared and discussed. The normal and tangential grinding forces for LIWG condition were lower than for the CG condition with a maximum reduction of 70.4% (83.3%) for the maximum average normal (tangential) grinding forces. The values of the force ratio for the CG condition and LIWG condition were in the range of 3.7–5.5 and 6.5–11.5. Little improvement was achieved, and the surface roughness values are considerable for both conditions.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: The increasing cost of energy, growing global competition, and increasing customer demand for cheaper and more efficient products has placed tremendous pressure on the manufacturing sector to dramatically improve machining efficiency. While improving the efficiency of machining processes increases the competitiveness and profitability of the manufacturing facility, it also results in a cleaner environment and more sustainable processes in terms of better utilization of resources, reduction of waste, efficient use of energy, and lesser CO2 emission. In manufacturing the concept of sustainability is well defined and implemented on the system level, but this is not the case on the micro-level when it comes to machining processes. With this in mind, this paper analyzes the concept of hybrid machining as a possible means of enhancing machining process sustainability by reducing power consumption, lead, and setup times. Two case studies are presented: turn-grind and mill-grind to illustrate the concept. The collected machining data have been used to correlate the energy consumption, CO2 emission, and cycle time for the two approaches used. The results from the presented case studies are promising as they show the benefits of the hybrid approach on energy consumption, CO2 emission, and cycle time.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: Edge trimming of carbon fiber-reinforced composites was conducted using diamond abrasive cutters, and the effect of feed rate, spindle speed, and depth of cut on machining quality was investigated. Cutting forces, specific cutting energy, surface roughness, and workpiece temperature were measured and analyzed. It was found that depth of cut is the most important parameter to influence machinability. Trimming with low equivalent chip thickness values was found to be the most suitable in terms of the level of machining responses and machining damage. The cutting temperatures were found to exceed the glass transition temperature of the epoxy matrix when machining with large depth of cut.
    Materials and Manufacturing Processes 12/2014; 29.
  • Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: This article describes a methodology based on force distributions for predicting cutting forces in side milling 7075-T651 aluminum. The methodology includes a practical mechanism for gathering experimental data. Milling forces on each disc are measured by experimentally dividing the cutter into discs for determining the milling coefficients. Force distributions are characterized as functions of cutting and edge forces, including cutter geometry and cutting parameter effects. In contrast to previous researches, the coefficients are determined considering relations between load and shear. Owing to its high performance, this methodology can be effectively used to improve machining accuracy in side milling.
    Materials and Manufacturing Processes 12/2014; 29.
  • [Show abstract] [Hide abstract]
    ABSTRACT: Surface texture can be generated by through-mask electrochemical micromachining. However, the machining localization deteriorates by the lateral undercutting under the mask. In this article, the auxiliary anode was consisted in the mask to reduce the lateral undercutting to improve localization of the surface texture. Numerical simulation of the current density distribution in the interelectrode gap was used to theoretically verify the proposed method, and the effect of the auxiliary anode on the localization was investigated experimentally. The experimental results indicated that the machining localization could be significantly improved by the auxiliary anode, and the etch factor was decreased with the increasing machining voltage.
    Materials and Manufacturing Processes 12/2014; 29.
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    ABSTRACT: Metal matrix composites are found to have many applications in the materials and structural engineering field. In this work, an investigation is carried out to find the influence of process parameters such as pulse current (I), pulse on time (T on), pulse duty factor (τ), and voltage (V) on the machining of Al(6351)—5 wt% silicon carbide (SiC)—5 wt% boron carbide (B4C) hybrid composite through electrical discharge machining. The individual parameters were analyzed with an objective to minimize electrode wear ratio (EWR), surface roughness (SR), and power consumption (PC). The experimental result shows that the output responses were greatly influenced by pulse current, with a contribution of 33.08% to EWR, 76.65% to SR, and 48.08% to PC. The surface characteristics were also examined through scanning electron microscope and the presence of craters and recast layers was observed.
    Materials and Manufacturing Processes 12/2014; 29.