Danil Yurievich Pimenov

Danil Yurievich Pimenov
South Ural State University | SUSU · Automated Mechanical Engineering

MSc, Eng

About

227
Publications
132,354
Reads
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Introduction
Research interests include sustainability manufacturing, the different manufacturing processes such as macro-, micro- machining etc., tool wear, mathematical modelling using FEM, optimization of cutting conditions, use of artificial intelligence. I am open for cooperation. You may consider our Special Issues for publication: https://www.mdpi.com/journal/sensors/special_issues/AI_Machining
Additional affiliations
October 2007 - March 2020
South Ural State University
Position
  • Lecturer
October 2004 - September 2007
South Ural State University
Position
  • Assistant (Teaching, Researching)
September 2004 - present
South Ural State University
Position
  • Lecturer
Description
  • Research interests include improving operational efficiency of machining on CNC machines, taking into account the tool wear, mathematical modeling using finite element method, optimization of cutting conditions.

Publications

Publications (227)
Article
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The wear of cutting tools, cutting force determination, surface roughness variations and other machining responses are of keen interest to latest researchers. The variations of these machining responses results in change in dimensional accuracy and productivity upto great extent. In addition, an excessive increase in wear leads to catastrophic cons...
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Difficult-to-cut alloys, which include titanium, cobalt, nickel alloys, and high-strength and heat-resistant steels, can nowadays be manufactured using selective melting (SLM), and products made of such materials are widely used in aerospace, automotive, and medical applications. SLM is widely used among other methods of additive manufacturing (AM)...
Article
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Aluminum alloys are widely used in many industries, including aerospace, automotive, civil, and electrical engineering. When compared to pure aluminum, most aluminum alloys have lower electrical and thermal conductivity, corrosion resistance, and weldability, as well as a low density and specific gravity. At the same time, the properties of aluminu...
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In conventional machining, one of the main tasks is to ensure that the required dimensional accuracy and the desired surface quality of a part or product meet the customer needs. The successful accomplishment of these parameters in milling, turning, milling, drilling, grinding and other conventional machining operations directly depends on the curr...
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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...
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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...
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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...
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This review reports on the influencing parameters on the joining parts quality of tools and techniques applied for conducting process analysis and optimizing the friction stir welding process (FSW). The important FSW parameters affecting the joint quality are the rotational speed, tilt angle, traverse speed, axial force, and tool profile geometry....
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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...
Article
This research aims to assess the mechanical characteristics of high-performance copper composites made utilizing powder metallurgy. The composites were produced by adding reinforcement elements (Al 2 O 3 -Cr 3 C 2 ) at different rates (3-6–9 wt.%) into copper-graphite (Cu-5Gr) via hot pressing technique. The microstructure, hardness, three-point be...
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The minimum uncut chip thickness (MUCT) is an important phenomenon observed both in orthogonal and oblique cutting. Rounding the cutting edge influences the initiation of the cutting process and chip formation. In a previous study, the authors presented a theoretical analysis and experimental validation on the effect of edge inclination angle λ s i...
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One of the essential requirements for intelligent manufacturing is the low cost and reliable predictions of the tool life during machining. It is crucial to monitor the condition of the cutting tool to achieve cost-effective and high-quality machining. Tool conditioning monitoring (TCM) is essential to determining the remaining useful tool life to...
Article
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In the present study, the effect of alumina (Al2O3) nano-powder was investigated for the electrical discharge machining (EDM) of a Nitinol shape memory alloy (SMA). In addition to the nanopowder concentration, other parameters of pulse-on-time (Ton), pulse-off-time (Toff), and current were selected for the performance measures of the material remov...
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This review paper summarizes the application of smart manufacturing systems utilized in drilling and hole machining processes. In this perspective, prominent sensors such as vibration, cutting forces, temperature, current/power and sound used in the contemporary indirect and direct tool condition monitoring systems are handled one-by-one according...
Article
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....
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Milling is a high-performance method that allows an efficient machining of both flat and complexly shaped surfaces. During the milling process, the cutting tool (cutters), its cutting edges are constantly subjected to tool wear, which affects the accuracy and roughness of the processing. It is important to understand the current condition of the cu...
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Friction-stir techniques are the potential alternative to fusion-based systems for processing and welding metallic alloys and other materials. This review explores the advantages, applications, limitations, and future directions of seven friction-based techniques namely, Additive Friction Stir Deposition (AFSD), Friction Stir Additive Manufacturing...
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AISI 5140 steel is mostly used in gear manufacturing for variety of industries. Those gears can be manufactured via casting, powder metallurgy or forging techniques. Nevertheless, machining (via turning and milling processes) remains the most common manufacturing method to fabricate them. Milling of gears made from 5140 steel can be challenging due...
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In engineering applications, such as automobile, marine, aerospace, and railway, lightweight alloys of aluminum (Al) and magnesium (Mg) ensure design fitness for fuel economy, better efficiency, and overall cost reduction. Friction stir welding (FSW) for joining dissimilar materials has been considered better than the conventional fusion welding pr...
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In this study, a new machining approach (aqueous machining) is applied for mill machining and its performance is compared with traditional wet machining. AISI 1020 steel is employed as the test material and Taguchi statistical methodology is implemented to analyze and compare the performance of the two machining approaches. The cutting speed, feed...
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During milling operations, wear of cutting tool is inevitable; therefore, tool condition monitoring is essential. One of the difficulties in detecting the state of milling tools is that they are visually inspected, and due to this, the milling process needs to be interrupted. Intelligent monitoring systems based on accelerometers and algorithms hav...
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The development of the best properties in polyester composite from pineapple leaf fiber (PALF) as a reinforcing material is a subject of interest. The properties of PALF are reliant upon fiber length, wherein technical difficulties in production of long fibers and processing for better characteristics in polyester composites possess inherent challe...
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Nitinol-shape memory alloys (SMAs) are widely preferred for applications of automobile, biomedical, aerospace, robotics, and other industrial area. Therefore, precise machining of Nitinol SMA plays a vital role in achieving better surface roughness, higher productivity and geometrical accuracy for the manufacturing of devices. Wire electric dischar...
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The cutting parameters in drilling operations are important for high-quality holes and productivity improvement in any manufacturing industry. This study investigates the effects of spindle speed and feed rate on temperature, surface roughness, hole size, circularity, and chip formation during dry drilling of gray cast iron ASTM A48. The results sh...
Article
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Because of their high thermal conductivity, good corrosion resistance, and great mechanical qualities, copper matrix composites are appealing materials utilized in a variety of industries. This study investigates the mechanical properties of copper–graphite (Cu–Gr) matrix composites reinforced with silicon carbide (SiC) and tungsten carbide (WC) pa...
Article
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Currently, there is an intensive development of bipedal walking robots. The most known solutions are based on the use of the principles of human gait created in nature during evolution. Modernbipedal robots are also based on the locomotion manners of birds. This review presents the current state of the art of bipedal walking robots based on natural...
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High precision rotary shafts with precise geometrical tolerances are generally mounted with a micron level clearance between the gears and casing during operation in industrial applications. Dynamics cyclic loads are inevitable in most of these applications which has an adverse effect on the fatigue life of the critical parts. Ensuring close dimens...
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On-line monitoring of the machining processes provides to detect the amount and type of tool wear which is critical for the determination of remaining useful lifetime of cutting tool. According to Industry 4.0 revolution, the machining performance in terms of cutting forces, surface roughness, power consumptions, tool wear, tool life, etc. needs to...
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Excellent characteristics of Nitinol shape memory alloys (SMAs) makes them favourable for use in industrial applications. Precision machining of such advanced alloys becomes a key requirement for industrial applications. Conventional machining processes imposes many difficulties for nitinol SMAs. Electrical discharge machining (EDM) process is appr...
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The fabrication of components involves the deposition of multiple beads in multiple layers for wire-arc additive manufacturing (WAAM). WAAM performed using gas metal arc welding (GMAW) allows for the manufacturing of parts through multiple-bead multi-layer deposition, which depends on the process variables. Thus, the selection of process parameters...
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The current study focuses on minimising the bubbles in polyester-insulated ignition coils, which were produced with a defect level of ~21–25% or 210–250 coils per 1000 batch size by using the potting method. This high-level rejection makes a substantial financial impact by increasing waste material, manufacturing, and after-sales costs. Hence, to c...
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Surface roughness is considered as an important measuring parameter in the machining industry that aids in ensuring the quality of the finished product. In turning operations, the tool and workpiece contact develop friction and cause heat generation, which in turn affects the machined surface. The use of cutting fluid in the machining zone helps to...
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Anti-abrasion thin-film-coated tool is well known for its enhanced micro machining performances. However, coating increases tool edge radius, which spurs additional ploughing and rubbing. Therefore, selecting appropriate thin-film thickness and suitable abrasion-resistant coating material for micro tool is necessary to reduce friction and size effe...
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In this study, mechanical testing of glass bead (GB), glass fiber (GF), and hybrid (GB/GF) composites was carried out. Following that, drilling tests were undertaken on glass bead/fiber-reinforced hybrid Polyamide 66 (PA66) polymer composites. The purpose of this study is to determine the mechanical properties of the cutting elements and the effect...
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Engineering materials are expected to contain physical and mechanical properties to meet the requirements and to improve the functionality according to their application area. In this direction, hybrid composites stand as an excellent option to fulfill these requests thanks to their production procedure. Despite the powder metallurgy method that al...
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Small and medium enterprises (SMEs) are vital contributors and significant drivers of any manufacturing sector. The Industry 4.0 (I 4.0) revolution has made the global economy highly competitive and automated, requiring Indian SMEs to adapt more quickly. Therefore, this study aimed to identify the barriers to implementing I 4.0, simplifying the com...
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In the rail industry, there are four types of steel grades used for monoblock wheels, namely ER6, ER7, ER8 and ER9. ER7 steel is manufactured in accordance with the EN13262 standard and is utilized in European railway lines. These train wheels are formed by pressing and rolling after which they are machined using turning process to achieve their fi...
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In this work, the drilling performance of carbon fibre reinforced plastic (CFRP) composites is analysed in terms of thrust force (Fn), torque (Mz), specific cutting energy (SEC), delamination factor (Fd), and hole quality under dry and cryogenic cooling conditions. An in-house developed multi-jet liquid nitrogen (LN2) delivery setup is used for exp...
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Shape memory alloy (SMA), particularly those having a nickel–titanium combination, can memorize and regain original shape after heating. The superior properties of these alloys, such as better corrosion resistance, inherent shape memory effect, better wear resistance, and adequate superelasticity, as well as biocompatibility, make them a preferable...
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Microturning is a micromechanical machining process used to produce microcylindrical or axially symmetrical parts. Micro-cylindrical parts are mainly used in microfluidic systems, intravenous micromotors, microsurgical applications, optical lens applications, and microinjection systems. The workpiece diameter is very small in microturning and there...
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MMCs (metal matrix composites) are widely used in many industrial applications thanks to their high specific strength. Nevertheless, this also poses a great challenge to their machinability due to rapid tool wear and poor surface finish caused by the added reinforcement particles. Improving the machinability of MMCs is of great importance as it wil...
Article
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Shape memory alloys (SMA) hold a very promising place in the field of manufacturing, especially in biomedical and aerospace applications. Owing to the unique and favorable properties such as pseudo elasticity, shape memory effect and Superelasticity, Nitinol is the most popular amongst other SMAs. However, a major challenge lies in the final surfac...
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Prognostics and health management (PHM) is a framework to identify damage prior to its occurrence which leads to the reduction of both maintenance costs and safety hazards. Based on the data collected in condition monitoring, the degradation of the part is predicted. Studies show that most failures are caused by faults in rolling element bearing, w...
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The plasma electrolytic method is one of the techniques which can be used to form an oxide layer on the substrate material surface. This technique employs ion exchange by developing an electrolytic arc between the cathode and the anode. The strong bond at high temperatures promotes the formation of an oxide layer on the metal surface. The electroly...
Article
Being easily fabricated, welded, biocompatible, having a high strength-to-weight ratio, withstanding comparatively high temperatures up to 800 °C and low modulus of elasticity make grade titanium and its alloys an important choice for automotive , biomedical and aerospace industries. In contempt of the different pleasant assets of Ti-6Al-4V alloy,...
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The current study aims to determine the influence of machining and production parameters during the milling of Cu/B-CrC composites. The relationship between energy consumption and cutting speed, feed rate and reinforcement ratio were investigated. For this purpose, 2d and 3d graphs for comparison of the effects of input parameters were demonstrated...
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A better understanding of material deformation behaviours with changes in size is crucial to the design and operation of metal microforming processes. In order to facilitate the investigation of size effects, material deformation behaviours needed to be determined directly from material characterizations. This study was aimed at the design and manu...
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This research work highlights the benefits of abrasive flow polishing (AFP) applied to tungsten carbide dies compared with conventional hand polishing (HP). An indigenous experimental setup for AFP was developed. The effect of prominent process parameters viz. extrusion pressure , number of cycles, and abrasive particle concentration on the final s...
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Properties of metal matrix composites (MMCs) are affected by various process variables such as particle size of powders, the proportion of reinforcement material, mixing methods, sintering temperature, and duration. The significant drawback of stir casting is reinforcement segregation, which is too difficult to avoid. Hence, the powder metallurgy r...
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In the present research, the AZ31 alloy is machined by wire-cut electric discharge machining (WEDM). The experiments were designed according to the Box-Behnken design (BBD) of response surface methodology (RSM). The input process variables, namely servo feed (SF), pulse on-time (Ton), servo voltage (SV), and pulse off-time (Toff), were planned by B...
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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...
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This research article interprets the findings of experimental investigation on synthesis and characterization of a Ti alloy powder by using a high-energetic ball milling (HEBM) process. The work focuses on the synthesis of alloy powder with 70:10:20 (atomic %) of Ti, Mg, and Sr powders by process of mechanical alloying thereby decreasing the grain...
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Selective laser melting (SLM) has been considered as the well-researched technology used to produce near net shape metallic components with superior mechanical and physiochemical characteristics. Recently SLM has recently been used for the production of components made by high-performance alloys such as Titanium and Nickel. However, the microstruct...
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Ceramics-based composites are a special class of materials carrying combined properties that belongs to alloys and metals according to market demands. This makes composites completely different and paves the way for new applications that requires the utmost properties. Machining of such composites is of great importance to finalize the fabrication...
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This study aims to investigate the influence of fibre orientation and varied incident energy levels on the impact-induced damage of S2/FM94, a kind of aerospace glass fibre epoxy/composite regularly used in aircraft components and often subjected to low-velocity impact loadings. Effects of varying parameters on the impact resistance behaviour and d...