Marek Balazinski

Polytechnique Montréal · Department of Mechanical Engineering

This paper presents the use of TOPSIS, a multi-criteria decision-making model combined with the Taguchi method to find the optimum milling parameters. TOPSIS is the Technique for Order Preference by Similarity to the Ideal Solution and shows the value of closeness to the positive ideal solution. This study shows the optimum combination of process p...

In the metal cutting process, the tool condition directly affects the quality of the machined component. To control the quality of the cutting tool and avoid equipment downtime, it is essential to monitor its condition during the machining process. The primary purpose is to send a warning before tool wear reaches a certain level, which could influe...

Carbon fiber–reinforced plastic (CFRP) is becoming more popular in the aerospace industry due to its high strength-to-weight ratio and low weight. Machining CFRP to achieve the required surface quality, on the other hand, remains a challenge. High temperature in the cutting zone area affects the tool life and surface quality of the machined part. A...

Carbon Fiber Reinforced Plastic (CFRP) is becoming more popular in the aerospace industry due to its high strength-to-weight ratio and low weight. Machining CFRP to achieve the required surface quality, on the other hand, remains a challenge. High temperature in the cutting zone area affects the tool life and surface quality of the machined part. A...

One of the effective strategies to improve dry machining processes is the implementation of micro-textured cutting tools. Micro-textures decrease the chip-tool contact length and thus reduce friction and heat which lead to better surface quality and longer tool life. However, micro-cutting of the bottom side of the chip, known as derivative cutting...

Skin panels are one of the most important components constituting the aircraft structures such as wing and fuselage sections. These thin-walled components were produced from 2024-T3 aluminum alloys and many pockets were usually created in these panels by chemical milling process for weight reduction purpose. However, this process is time consuming...

Rapid tool wear and limited tool life are major problems when machining Inconel 718, which still need further attention. Amongst the reported strategies, limited studies have been reported on optimizing initial cutting conditions by means of tool life improvement. Therefore, in this work, the tool wear progress and tool life were investigated by va...

The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those...

Metal-matrix composites (MMCs) are made of non-metallic reinforcements in metal matrixes, which have excellent hardness, corrosion, and wear resistance. They are also lightweight and may pose a higher strength-to-weight ratio as compared to commercial titanium alloys. One of the MMCs with remarkable mechanical properties are titanium metal matrix c...

Current surface modification chemistry of silicon nitride (Si3N4) in the fabrication of micro/nano systems (MEMS/NEMS) mainly relies on multistep chemical processes, essentially consisting of a surface pretreatment and a challenging silanization procedure. Although direct modification of Si3N4 surface has rarely been reported in the literature, her...

Multi-criteria decision-making methods are commonly used to rank manufacturing processes based on weighted economic and environmental criteria. The weighting process can be challenging, especially at early design stages where costs and environmental data are not precisely defined. In addition, for weights resulting in equivalent alternatives, no co...

Hybrid structures of metals and composite materials are increasingly common in aerospace industry, and the optimization and monitoring of the machining of these stacks are an area of active research. Online tool condition monitoring in particular is a valuable capability and is facilitated by real-time treatment of cutting force signals. Cutting fo...

Three distinctive regions of tool wear, known as initial wear, steady-state wear, and accelerated wear, are well understood. However, the effects of cutting parameters on the initial tool wear mechanism, morphology, and size have received less attention as compared to the other two regions. Knowing that adequate control of initial tool wear may lea...

Machining of aircraft structural components can waste up to 90% of the raw material. Therefore, evaluation of alternative manufacturing processes for those components is crucial for reducing the economic and environmental impacts of manufacturing. As the shape and material of a component must match the manufacturing process used, it is necessary to...

Titanium metal matrix composite (Ti-MMC) has excellent features and capabilities which can be considered a potential candidate to replace commercial titanium and superalloys within an extensive range of products and industrial sectors. Regardless of the superior features in Ti-MMC, however, referring to several factors including high unit cost and...

Titanium metal matrix composites (Ti-MMCs) have been successfully incorporated into a vast number of products within various industrial sectors. Despite excellent mechanical and physical features, due to the presence of hard and abrasive ceramic particles in metal matrices of Ti-MMCs, various issues have been emerged regarding machining and machina...

Tool wear mode and life are considered as critical machinability attributes. Three distinctive regions of tool wear, mainly known as initial wear, steady-state wear, and accelerated wear are understood to a large extent. The effects of cutting parameters on the initial tool wear have received less attention as compared to other two regions. Previou...

Industry 4.0 has been advertised for a decade as the next disruptive evolution for production. It relies on automation growth and particularly on data exchange using numerous sensors in order to develop faster production with tight monitoring. The huge amount of data generated by clouds of sensors during production is often used to feed machine lea...

Despite excellent mechanical and physical features of titanium metal matrix composite (Ti-MMC), hard and abrasive ceramic particles within the matrix structure, as well as high price, may lead to severe difficulties on machining and machinability of Ti-MMCs. Review of literature denotes that only limited studies are available on machining Ti-MMCs w...

In the aerospace industry which widely uses aluminum alloys to manufacture aircraft structures, end-milling is a common process to produce the desired components. However, in order to adjust this mechanical process, several complex factors occurring during the cutting stage have to be considered, making the process development difficult. In order t...

A machine learning approach based on fractal analysis is developed for optimal tool life exploitation in intensive drilling operations for aeronautical assembly. Fractal analysis of sensor signals detected during the drilling process allows for the extraction of key features to build cognitive paradigms in view of condition monitoring for tool life...

Quantitative information about the contributions of individual cutting phenomena to linear roughness profiles may aid in optimizing processes with fewer expensive successive trial parts. Linear roughness profiles of metallic hard turned parts contain feed marks, each mark representing a snapshot in time of the state of the cut. This suggests that r...

Sensor failure may be difficult to detect depending on the nature of the defect. In this study, fractal analysis was used to analyse the raw signal of capacitive displacement sensors in order to detect abnormalities. The fractal analysis of the signals was performed for stationary and dynamic measurements of the target–sensor distance mounted in a...

The development of facile and environment friendly strategies to metallize the surface of insulating polymeric substrates is of paramount important. An acceptable film adhesion with the polymeric substrate usually requires a chemical pretreatment of the polymer surfaces. Here we report a one-step process of covalent grafting of vinylpyridine groups...

Aluminum alloys are widely used in the industry such as aerospace. This study was motivated by the replacement of the chemical milling of thin aluminum parts with mechanical milling. To remain within requirements of design specifications, this process needs to be tuned and optimized using e.g. cutting forces, vibrations and surface integrity assess...

Metal matrix composites (MMCs) are composed of non-metallic reinforcements (i.e., ceramic) in metal matrices which feature high toughness, wear and fatigue resistant and relatively light-weight. One of the metallic composites with remarkable mechanical properties is titanium metal matrix composite (Ti-MMC) that is considered as an alternative to ni...

Burr formation and surface roughness are crucial surface quality attributes that vary widely according to machining conditions used. Inappropriate selection of cutting parameters may lead to tremendous non-desirable expenses and poor product quality. This becomes more apparent in slot milling operation that has a complex burr formation mechanism, a...

Titanium-based metal matrix composite (T-MMC) is a relatively new material with increasing demand in different industries particularly in aerospace. Yet, there is a significant lack of knowledge regarding its machinability. Tool wear mechanisms of cBN inserts during turning of TiMMCs including adhesion, abrasion, chemical interactions, and their ef...

This article presents a new tool wear multiclass detection method. Based on the experimental data, tool wear classes are defined using the Douglas–Peucker algorithm. Logical analysis of data (LAD) is then used as machine learning, pattern recognition technique for double objectives of detecting the present tool wear class based on the recent sensor...

Feature selection in machine learning is of great interest since it is reckoned as creating more efficient predictive models in several engineering domains. It is even of special importance in the pulp and paper transformation industry as the knowledge of this particular process is generally very limited. In this paper, we first compared the perfor...

Feature selection in machine learning is of great interest since it is reckoned as creating more efficient predictive models in several engineering domains. It is even of special importance in the pulp and paper transformation industry as the knowledge of this particular process is generally very limited. In this paper, we first compared the perfor...

In the aerospace industry, deburring operations are often difficult to achieve and can be very costly. Hence, burrs generated during the machining should be studied. In this research, the drilling operations were performed and analysed for a stack composed of carbon fibre reinforced polymer (CFRP), titanium and aluminium alloys, using three cutting...

Cutting forces and acoustic emissions signals while machining Fiber Reinforced Plastics (FRP) depends strongly on the tool wear. Fractal analysis can be adapted to those signals to characterize their variations. This tool wear monitoring technique is presented herein for the carbon FRP (CFRP) orbital drilling. Fractal parameters, characterizing the...

The surface finish of Fiber Reinforced Plastic (FRP) laminate is challenging to characterize, due to the heterogeneous structure of the composite. Profile roughness parameters are highly impacted by the different layer properties, and their distributions are relatively spread out. In this paper, the surface topography of a 24-ply quasi-isotropic Ca...

The surface quality of machined carbon fibre reinforced plastics (CFRP) differs depending on cutting conditions, e.g. cutting parameters and tool wear. Fractal analyses were performed on the cutting force signals, acquired during the trimming of CFRP, to describe the signal complexities variations. Fractal parameters, such as dimension and topothes...

Titanium Metal Matrix Composite (Ti-MMC) is a relatively new class of material, which has high potential applications in the aeronautical and biomedical sectors. Similar to titanium alloys, Ti-MMC produces segmented chips, which are characterized by Adiabatic Shear Bands (ASB). Transmission Electron Microscopy (TEM) observations were performed and...

The surface texture characterization of laminate composites is complex due to its heterogeneous structure and to the different stratified surface properties. Profile roughness parameters are highly impacted by those different layer properties, and their distributions are relatively spread out. A new filtering technique is proposed to improve the su...

Exceptional mechanical characteristics make metal matrix composites (MMCs) a popular choice in various industries. However, the knowledge related to the behavior of MMCs during machining is very limited. This is mainly due to complications in mechanics of chip formation arising from existence of very hard reinforcements. This paper aims to improve...

A survival analysis methodology is employed through a novel approach to model the progressive states of tool wear under different cutting conditions during machining of titanium metal matrix composites (Ti-MMCs). A proportional hazards model (PHM) with a Weilbull baseline is developed to estimate the reliability and hazard functions of the cutting...

Utilizing the full tool life capacity of cutting tools has always been a concern, due to the considerable costs associated with suboptimal replacement of tools. Reliable reuse of worn inserts could significantly reduce machining costs. This study aims at estimating the remaining useful life of worn cutting inserts under multiple cutting parameters...

This paper presents a new tool wear monitoring and alarm system that is based on logical analysis of data (LAD). LAD is a data-driven combinatorial optimization technique for knowledge discovery and pattern recognition. The system is a nonintrusive online device that measures the cutting forces and relates them to tool wear through learned patterns...

This innovation introduces a new method for tool wear monitoring and control, with an alarm system and a machining process controller. The method is based on knowledge discovery and pattern recognition. The method is tested by using experimental results and validated by comparing to to the famous statistical technique, Proportional Hazard Model (PH...

This paper presents a new tool wear monitoring and alarm system that is based on Logical Analysis of Data (LAD). LAD is a data-driven combinatorial optimization technique for knowledge discovery and pattern recognition. The system is a non-intrusive on-line device that measures the cutting forces and relates them to tool wear through learned patter...

A new method is detailed to identify the positions of the ends of the tool marks in linear surface roughness profiles. No feed mark shape must be assumed and the process is entirely automated. The approach may find applications in automated quality control, surface texture classification, and modeling of metal cutting processes. Validation was done...

This paper presents a new mathematical model to characterize chaotic tool wear phenomenon during a machining process. The divergence of the chaotic wear curves under different initial cutting conditions that take into account the ordinary differential equations is solved based on cubic B-spline functions of rational interpolation for the first time...

Due to the continuous advancement in sensors and information technologies, machining processes are easily monitored and important information are gathered from the sensors’ readings. Valuable information can thus be extracted and exploited in order to gain more understanding of the process’ physics. Although the mathematical representation of these...

While traditional maintenance cost optimization is based on finding the reliability, and thus the probability of failure over time, in this paper, we show how to exploit condition monitoring data in machining operation in order to extract intelligent knowledge, and use this knowledge to determine the tool replacement time. This work is motivated by...

Little practical results are known about the cutting tool optimal replacement time, specifically for machining of composite materials. Due to the fact that tool failure represents about 20% of machine down-time, and due to the high cost of machining, in particular when the work piece’s material is very expensive, optimization of tool replacement ti...

Clean machining is gaining ground as one of the crucial issues in future manufacturing. Many machining industries are looking for alternative solutions to wet machining because of the costs of the latter, including environmental costs, as well as its impact on occupational health and safety. Dry machining is being proposed, but in most conditions,...

Force is considered to be one of the indicators that best describe the machining process. Measured force can be used to evaluate the quality and geometric profile of the machined part. In this paper, a combinatorial optimization approach is used to characterize the effect of force on the quality of a machined part made of Carbon Fiber Reinforced Po...

The initial tool wear during machining of titanium metal matrix composite (TiMMCs) is the result of several wear mechanisms: tool layer damage, friction - tribological wear, adhesion, diffusion and brace wear. This phenomenon occurs at the first instant and extends to only ten seconds at most. In this case the adhesive wear is the most important me...

Closed door machining is a strategy for producing a part within tolerance using on-machine measurement and automatic process adjustment as opposed to manual gauging interventions. This paper presents an integrated methodology for compensating errors detected using on-machine probing. In a multi-cut process, intermittent probing which is achieved th...

Carbon fiber reinforced polymer (CFRP) is an important composite material. It has many applications in aerospace and automotive fields. The little information available about the machining process of this material, specifically when routing process is considered, makes the process control quite difficult. In this paper, we propose a new process con...

Metal matrix composites (MMCs), as a new generation of materials; have proven to be viable materials in various industrial fields such as biomedical and aerospace. In order to achieve a valuable modification in various properties of materials, metallic matrices are reinforced with additional phases based on the chemical and/or physical properties r...

In machining of composite materials, little research has been conducted in the area of optimal replacement time of the cutting tool in terms of cost and availability. Due to the fact that tool failure represents about 20% of machine down-time, and due to the high cost of machining, optimization of tool replacement time is thus fundamental. Finding...

This chapter reviews milling burr formation and the factors governing their formation, and presents limitation/avoidance strategies applied for burr size minimization. Furthermore, two case studies are also presented in this work on (i) burr formation during slot milling of aluminum alloys: the application of statistical techniques (ANOVA, Pareto a...

Closed door machining is a strategy for producing a part within tolerance using on-machine measurement and automatic process adjustment as opposed to manual gauging interventions. The paper presents an integrated methodology for compensating errors detected using on-machine probing.In a multi-cut process, intermittent probing which is achieved thro...

The Outstanding characteristics of titanium metal matrix composites (Ti-MMCs) have brought them up as promising materials in different industries, such as aerospace and biomedical. They exhibit high mechanical and physical properties, in addition to their low weight, high stiffness and high wear resistance. The presence of the ceramic reinforcement...

Prediction of cutting forces is very important for the design of cutting tools and for process planning. This paper presents a fuzzy modelling method of cutting forces based on subtractive clustering. The subtractive clustering combined with the least-square algorithm identifies the fuzzy prediction model directly from the information obtained from...

Reliable tool life estimation of cutting tool in micromilling is essential for planning machining operations for maximum productivity and quality. This chapter presents type-2 fuzzy tool life estimation system. In this system, type-2 fuzzy analysis is used as not only a powerful tool to model acoustic emission signal features, but also a great esti...

Reliable prediction of cutting forces is essential for micromilling. In this paper, a fuzzy cutting force modelling method based on subtractive clustering method filters the noise and estimates the instantaneous cutting forces using observations acquired by sensors during cutting experiments. In the experimental case study, four data sets of microm...