Alisson Machado

• PhD
• Professor (Full) at Pontifical Catholic University of Paraná

Glass fiber reinforced plastic (GFRP) composites, initially developed for home insulation, are now essential in aerospace, automotive, marine, and construction industries due to their lightweight, corrosion resistance, and high mechanical strength. However, their anisotropic and heterogeneous nature, coupled with the abrasive behavior of glass fibe...

High-speed steel (HSS) is commonly used in producing micro-cutting tools due to its excellent abrasive wear resistance, especially under high rotational speeds and low thermal activation conditions. Numerous studies have focused on enhancing the microstructural properties of HSS further to improve the wear resistance of these micro tools. However,...

The development of high-strength cast iron alloys has become critical for advancing manufacturing processes, particularly in the automotive and heavy machinery sectors. Vermicular cast iron offers significant advantages in terms of mechanical properties and thermal conductivity, making it a valuable alternative to traditional gray cast iron. Howeve...

Tool wear in machining is inevitable, and determining the precise moment to change the tool is challenging, as the tool transitions from the steady wear phase to the rapid wear phase, where wear accelerates significantly. If the tool is not replaced correctly, it can result in poor machining performance. On the other hand, changing the tool too ear...

In contemporary manufacturing industries, composite materials such as carbon fiber reinforced plastics (CFRPs) have become indispensable, finding extensive applications in aerospace, automotive, shipbuilding, high-tech sports equipment, and more. The exceptional chemical, physical, and mechanical properties of CFRPs, including high corrosion resist...

The extensive range of steel types and classifications results in a diverse set of properties such as plasticity, heat resistance, strength, and corrosion resistance. This diversity enables the creation of alloys with varying machinability, from easy to hard-to-cut. This review focuses on the intricate interplay between mechanical characteristics o...

A comprehensive evaluation of graphene lubricants on the integrity of surface ground aerospace materials

Superalloys find widespread application in demanding environments owing to their robust strength and highresistance to heat and corrosion. Nonetheless, these very attributes render them difficult-to-cut materials.Enhancing machinability necessitates effective lubrication and cooling techniques, the efficacy of which variesdepending on the specific...

Machining is a process that involves intense heat generation at localized points within the tool-chip interface. This leads to elevated temperatures, which can be detrimental to cutting tools. This issue becomes even more crucial when dealing with superalloys like Inconel 718, as they exhibit high shear strength and good creep resistance. Consequen...

The advancement in cast iron alloy properties has led to more efficient materials, especially in the automotive industry. However, this progress has also increased the demand for more durable tools with greater resistance to cutting operations. Conducting an in-depth investigation into the impact of these materials on tool lifespan is crucial, as i...

Machining is a widely used manufacturing process that involves removing material from a workpiece. During this process, more than 95 % of the mechanical energy from the machine tool's electrical motor is converted into heat. This can cause the cutting tool's temperature to soar to extremely high levels, reaching up to 1200 °C or even higher, especi...

Machining Inconel 718, a high-strength superalloy with applications in critical industries, presents unique challenges. Conventional cutting fluid application has long been employed for machining Inconel 718 with cemented carbide tools. While it effectively provides cooling and lubrication, it raises significant sustainability concerns. It contribu...

Out of all the mechanical energy generated during material cutting, the majority is converted into heat, raising the temperature at the chip-tool interface, particularly in difficult-to-machine materials like Inconel 718, thereby diminishing tool lifespan. Consequently, various lubri-cooling methods mitigate issues related to high temperatures, suc...

Additive manufacturing by the Fused Filament Fabrication (FFF) process is a manufacturing process that has great potential for facilitating the production of complex and customized parts quickly, with low production costs and little material waste. However, the mechanical resistance of the parts produced by this manufacturing method vary greatly ac...

The interaction of 180 fs, 775 nm laser pulses with micro grinding wheels grinding the internal radii of diesel engine cam rings has been investigated. Optimizing various scanning strategies changes the microstructure of the micro wheel surface to such an extent that production results can be significantly improved. By varying the combinations of e...

Inconel 718 is a superalloy known for its excellent mechanical, corrosion, and creep resistance, even at high temperatures up to 700 °C. It is a valuable material that accounts for almost 50% of all superalloys used worldwide. However, its outstanding properties also make it a difficult-to-cut material that generates high heat at the chip tool inte...

Aluminum alloys are applied in large volumes to various mechanical components. However, during the boring process of such alloys, it becomes necessary that H7 tolerances be obtained. Additionally, when machining aluminum alloys, adhesion problems are often noted due to ductility. Furthermore, owing to the high cutting speeds used in this process, t...

The advancement of cast iron alloy properties has enabled increased efficiency in automotive vehicles. Nevertheless, this progress is accompanied by a growing demand for more durable tools with higher resistance to successfully execute cutting operations. This work conducts an investigation of the machinability of different high-strength cast iron...

This work implements artificial neural networks (ANNs) to monitor tool wear during turning of AISI D6 steel. The goal is to detect wear, prevent tool breakage, and enhance productivity. Experimental tests involve using polycrystalline cubic boron nitride tools to turn AISI D6 steel, measuring wear and surface roughness. ANNs are trained with machin...

The use of mineral-based cutting fluids in machining has the drawback of affecting the environment and industries are under pressure to reduce its use in favor of cleaner productions. In this regard, vegetal-based cutting fluids can be a superior alternative, provided they improve the technical outcomes. In the milling process, dry cutting is commo...

Due to the low cost and high vibration damping capacity, gray cast irons are commonly used in machine tool bases, in addition to applications with noise restrictions, such as engine blocks, housings, and brakes. The matrix’s graphite, sulfides, and ferrite/pearlite ratio are some of the most important parameters governing the machinability of the g...

High heat generation with the consequent increase in temperature is still a limiting factor for productivity and quality in machining processes, mainly because it strongly affects the tool's life and the quality of the workpiece. Cutting fluids in abundance (CFA), often named flood cooling, is the standard machining cooling technique used industria...

In the aeronautical industry, many components are subjected to abrasive machining processes to ensure surface integrity. However, many of these components are manufactured from titanium alloys, such as the Ti-6Al-4V alloy, which is considered a difficult material to machine due to its low thermal conductivity, high mechanical strength, and chemical...

Due to the increase in environmental degradation, industries are forced to work with less harmful manufacturing means. In machining, it is known that one of the best ways to preserve cutting tool life is by using cutting fluids. However, even if this component proves to be effective, its use is still questionable because it strongly contributes to...

O presente certificado de adição tem como finalidade lubrificar e facilitar a remoção de cavaco das ferramentas refrigeradas internamente durante a usinagem. O diferencial é utilizar um sistema de lubrificação em ferramentas com canais internos de refrigeração. A ideia principal é utilizar dois canais, um de lubrificação, outro de refrigeração. Ess...

A presente invenção propõe um dispositivo de bancada, em tamanho reduzido, para testes de fluidos para que possa estressa-lo sob diversas condições e com isso avaliar diferentes propriedades ao longo do tempo. Este fluido pode ser de qualquer natureza e o tipo de propriedade a ser avaliada irá depender do que se deseja. O presente dispositivo conté...

A presente invenção propõe um dispositivo de bancada, em tamanho reduzido, para testes de fluidos para que possa estressa-lo sob diversas condições e com isso avaliar diferentes propriedades ao longo do tempo. Este fluido pode ser de qualquer natureza e o tipo de propriedade a ser avaliada irá depender do que se deseja. O presente dispositivo conté...

For ecological and health issues of those involved in the manufacturing, usage, handling, and disposal of cutting fluids, research has been developed for scientific and technological advances in biodegradable cutting fluids, application methods, and solid nanolubricants. Using a minimum quantity of lubricant (MQL) in machining processes proved to b...

The development of new chemical compositions of cast iron contributes to increasing the competitiveness of foundry and manufacturing companies that always seek to optimize the properties of these materials. Previous works detected machinability variation along the cross-section of nodular cast irons (DI) bars produced by continuous casting due to t...

The use of cutting fluids during machining processes remains one of the main challenges toward greener manufacturing, mainly when applied by flooding. The use of vegetable-based cutting fluids stands out as one of the alternatives toward more sustainability by making the process ecofriendlier without much impact on the economic aspects of the chain...

Due to the low cost and high vibration damping capacity, gray cast irons are commonly used in machine tool bases, in addition to applications with noise restrictions, such as engine blocks, housings, and brakes. The matrix's graphite, sulfides, and ferrite/pearlite ratio are some of the most important parameters governing the machinability of the g...

In the current scenario, industry has been faced with growing restrictions imposed by law, aimed at reducing the emission of fuel gases and pollutants into the atmosphere. The automotive industry is seeking to produce vehicles with higher performance to match these needs, so that engines become increasingly smaller, less pollutant and silent. Regul...

O dispositivo, objeto do presente modelo de utilidade, tem como objetivo reduzir o consumo de água e energia elétrica em chuveiros elétricos, ou ainda chuveiros por aquecimento solar, ou de qualquer outro tipo de chuveiro, através da redução, parcial ou total, do fluxo de água e da energia dissipada na resistência elétrica. Este dispositivo pode se...

The most important aspect of sustainability in manufacturing is the preservation of energy and natural resources. For modern production, optimized processes that minimize negative impacts on the environment are becoming increasingly important. This can be achieved by increasing energy efficiency through low, clean, and renewable energy consumption....

The growing need to increase productivity and pressures for more sustainable manufacturing processes lead to a shift to less harmful lubrication systems that are less harmful to nature and the people involved. The minimal quantity lubrication system (MQL) stands out in this respect, especially in interrupted cutting processes such as milling, due t...

A presente invenção trata de um dispositivo que permite promover a circulação de fluido interno a ferramentas rotativas em ciclo fechado. A ideia principal consiste em utilizar um sistema que permite a entrada e a retirada de fluidos de um porta-ferramentas rotativo assim como de ferramentas rotativas refrigeradas internamente. Para isso, é necessá...

A presente invenção trata de um dispositivo que permite promover a circulação de fluido interno a ferramentas rotativas em ciclo fechado. A ideia principal consiste em utilizar um sistema que permite a entrada e a retirada de fluidos de um porta-ferramentas rotativo assim como de ferramentas rotativas refrigeradas internamente. Para isso, é necessá...

In this paper, drilling tools were subjected to different post-treatment polishing processes using aluminum, silicon, and diamond-based abrasives, and the effects resulting from these processes on the roughness of the rake and margin were correlated with thrust force, maximum flank, crater wear, and tool life. The results showed that the polishing...

Additive manufacturing (AM) has revolutionized and continues to revolutionize the manufacture of parts and components with complex geometries that are difficult to manufacture by traditional processes. There are many materials, including polymers, that can be used in this process. The improvement of mechanical, electrical, thermal, tribological, an...

Electrical discharge machining (EDM) is an unconventional machining process based on removing material by successive electrical discharges. The tool electrode wear must be kept as minimal as possible to produce high-precision components. This scope proposes the development of a new technique for identifying wear on electrodes and its evolution usin...

The modelling of machining processes by means of machine-learning algorithms is still based on principles that are especially adapted to mechanical approaches, in which very few inputs are varied with little repetition of experimental conditions. These principles might not be ideal to achieve accurate machine-learning models and they are certainly...

Femtosecond laser pulses were used for texturing cutting tools in order to obtain better results in the traditional metal turning process. Some significant examples are presented in this work.

A presente invenção trata de uma Ferramenta Refrigerada Internamente - FRI em ciclo de refrigeração fechado. A ideia principal consiste em fazer circular fluido refrigerante por dentro da FRI através de Canais Internos à ferramenta especialmente projetados e fabricados para que o fluido possa circular por dentro da ferramenta removendo calor do pro...

Cutting Fluid in Abundancy – CFA is a standard cooling technique used in machining due to the good relationship between quality and productivity. However, due to sustainability problems, economic, social, and environmental, several research types have been carried out worldwide about replacing or eliminating these inputs in the cutting process. In...

The surface modification via subtractive manufacturing intends to localize the desired properties on the produced surface during the machining. In the case of miniaturized components, the powder mixed-micro-electric discharge machining (PM-µ-EDM), a potential variant of EDM, can achieve superior microfeatures such as dimensional accuracy and surfac...

This study investigates the effects of applying two vegetable and one mineral-based cutting fluids with 0.05 %wt and 0.1 %wt dispersion of graphene sheets on the tribosystem generated at the interface between the cemented carbide tool and the AISI 1045 steel workpiece. The fluids are firstly characterized (viscosity, thermal conductivity and diffus...

In most grinding processes, the use of cutting fluid is required, and research has been carried out to reduce the amount of fluid used due to costs and environmental impacts. However, such a reduction of fluid can result in thermal damage to the machined component because the amount of cutting fluid may not be sufficient to lubricate and cool the s...

In this study, the short-time Fourier transform (STFT) technique was used to determine the wear mechanisms acting on uncoated and AlCrN-coated carbide tools and their variations during the machining process. To this end, tensile tests were performed on hardened AISI 4340 steel to characterize the acoustic emission (AE) signals and subsequently isol...

In the search for more energy-efficient internal combustion engines, the automotive companies keep pushing the working temperatures and pressures of the engines, leading to more extreme working conditions and so the necessity of new materials. Among the most promising materials for the new generations of engines is the compacted graphite cast iron,...

Hard turning is considered a strong candidate to partially replace grinding in finishing operations. However, as in the grinding operation, hard turning produces high temperatures that contributes to accelerate the cutting tool wear. In order to minimize this effect, cutting fluids can be applied as an alternative, even when PCBN inserts are used a...

Steels can go through a duplex treatment process, consisting of depositing a physical vapor deposition (PVD) coating on plasma-nitrided substrates. The coating layer varies from 1.5 to 5 μm, depending on the application needs. The work's objective is to analyze the performance and evaluate the mechanical characteristics of titanium nitride (TiN) an...

The cutting fluids applied to the machining processes by the MQL process aim to reduce the machining temperatures and tool wear as well as improve the surface and dimensional finishing of the parts. To increase the efficiency of these fluids, graphene lubricating platelets are added. This work investigated the performance of three different cutting...

Electrical Discharge Machining (EDM) is an unconventional machining process based on removing material by successive electrical discharges. The tool electrode wear must be kept as minimal as possible to produce high precision components. This scope proposes the development of a new technique for identifying wear on electrodes and its evolution usin...

Cryogenic machining is becoming a sustainable choice due to its extraordinary performance (such as non-toxic and environmentally friendly) superiority to other traditional coolants and lubricants to produce products with superior quality. This paper also critically reviews improvements in designing the cryogenic delivery setup used by researchers f...

Nickel-based superalloy Inconel 718 is widely used for aeronautical applications, such as blades and discs of aircraft engines, and therefore is generally submitted to a grinding process in order to meet the required surface finish and dimensional accuracy. However, the mechanical and thermal properties of Inconel 718 make it a material with low ma...

Dies and molds steels are essential materials in the manufacturing industry of engineering products. These materials are usually machined in the aged condition and therefore, can be problematic to transform them in chips. Calcium treatment can be a viable alternative to increase machinability without compromising the main properties of the steel. T...

Nickel-based superalloys are known for their high-temperature performance regarding oxidation, creep and fatigue resistance. For this reason, they are widely used as structural components in the aerospace industry. However, because of these properties, they are difficult to machine, and normally a rigorous control of the surface integrity and resid...

The identification and monitoring state variables in the machining process are one of the best methods to increase machinability. This study evaluated the use of different signal analysis parameters for a vertical machining center's electric current input during the milling process of three different high-strength compacted graphite cast irons. The...

In most of the machining processes, the application of surface texturing is one of the most remarkable and promising research fronts in relation to the use of tribological concepts for improving machinability. This paper aims to review the most recent articles on this theme (from 2016 to date) to assist researchers in the state of the art of this t...

Nickel-based superalloys present excellent thermo-mechanical properties that can be maintained at high temperatures, making them suitable for application in aerospace and nuclear industries. Such components require a combination of superior surface finish and tight dimensional tolerances, thus grinding is the first option. However, these properties...