Influence of heat treatment on the machinability and corrosion behavior of AZ91 Mg alloy

In the present study,AZ91 Mg alloy was heat treated at 410℃ for 6,12 and 24 h to investigate the influence of heat treatment on machinability and corrosion behavior.The effect of soaking time on the amount and distribution of Mg 17 Al 12(β-phase)was analyzed under the optical microscope.Microhardness measurements demonstrated the increased hardness with increased heat treatment soaking time,which can be attributed to the solid solution strengthening.The influence of super saturatedα-grains on reducing the cutting force(F z)with respect to increased cutting speed was observed as prominent.The corrosion behavior of the heat treated specimens was studied by conducting electrochemical tests.Surprisingly,corrosion rate of heat treated samples was observed as increased compared with the base material.From the results,it is evident that the machinability of AZ91 Mg alloy can be improved by producing super saturatedα-grains through heat treatment but at the cost of losing corrosion resistance.

Influence of Al content on machinability of AZ series Mg alloys

Influence of A1 content on the machinability of AZ series cast Mg alloys was investigated. In order to evaluate the machinability of the alloys, measurements of the cutting forces during turning operations and surface roughness were carried out as well as considering the microstructure and tensile properties. The results show that maximum tensile properties are observed with 2% （mass fraction） A1 addition to Mg. As the A1 content of the alloy increases above 2%, the cutting forces tend to reduce along with the ductility owing to the grain boundary precipitation of intermetallic phase （fl-Mgl7All2）. Cutting forces are able to increase as the cutting speed increases for all the alloys studied, and it＇s attributed to flank built up at the tip of the cutting tool during machining.

Effect of inoculating addition on machinability of gray cast iron

Gray cast irons were inoculated with FeSi75＋RE and FeSi75＋Sr inoculants. The changes of apex angle of the drills before and after being used were used to evaluate machinability of gray cast irons. Effect of FeSi75＋RE and FeSi75＋Sr inoculants on mechanical properties, machinability and sensibility of gray cast iron used in cylinder block were investigated. Experimental results showed that gray cast iron treated with 60%FeSi75＋40% RE inoculants exhibited tensile strength consistently at about 295 MPa along with good hardness and improved metallurgical quality. While gray cast iron inoculated with 20%FeSi75＋80% Sr inoculants exhibited the best machinability, the lowest cross-section sensibility and the least microhardness difference. The tool flank wear of the drill increased correspondingly with the increase of the microhardness difference of the matrix, indicating the great effect of homogeneity of the matrix on the machinability of gray cast iron.

Experiment on Machinability of Ti2AlNb Intermetallic Alloy

Ti2AlNb intermetallic alloy is a newly developed high-temperature resistant structural material due to its excellent material and mechanical properties,which also make it to be one of the most difficult-to-cut materials.In order to study the machinability of Ti2AlNb alloy,a series of turning experiments of Ti2AlNb alloy with varying cutting speed and feed rate using coated carbide tools are carried out.The results associated with cutting forces,cutting temperature and tool wear are presented and discussed.Moreover,the cutting performance of Ti2AlNb alloy is evaluated in comparison with that of most commonly used Ti6Al4 Vand Inconel 718 alloys in terms of the cutting forces and cutting temperature.The comparison results show that there is a correlation between the machinability and the mechanical properties of work material properties.Additionally,considering material removal rate and tool life,the optimized machining parameters for cutting Ti2AlNb alloys using coated carbide tools are recommended.

Precipitation and control of BN inclusions in 42CrMo steel and their efect on machinability

The precipitation and control of boron nitrogen （BN） inclusions in 42CrMo steel were investigated and their effect on machinability was analyzed. First, the precipitation regularity of BN in 42CrMo steel was studied by theoretical calculation. Then, the machinability of the steel was investigated through contrast cutting experiments, and the composition and cooling rate of the steel were controlled to analyze the variation laws of the size, distribution, and area ratio of BN inclusions. Finally, the results were combined with the machinability of the steel to analyze the relationship among them. It is found that the machinability of the steel is mainly influenced by the diameter and quantity of BN inclusions. Fine and dispersedly distributed BN inclusions are more beneficial for the improvement in machinability of 42CrMo steel than coarse and sparse BN inclusions.

Superior machinability of steel enhanced with BN and MnS particles

The strategy that replacing part of MnS with BN was proposed in order to decrease the sulfur content in sulfur based free-cutting steel. The effects of BN and MnS inclusions on the microstructure and machinability of the steel were systematically investigated. The results show that most of the BN and MnS inclusions exist individually in the steel and only a small amount of them are in a composite state form- ing either isolated particles or clusters of particles. In the case of multi-phased steel, the theoretical calculation predicts that the volume of large BN particles should be 0.7 times of the volume of large MnS particles. The machinability of this type of BN and MnS alloy steel over a wide range of cutting speeds ranging from a low speed appropriate for drilling to a high speed appropriate for turning is confirmed as being equal to or superior to that of an MnS reference steel, even though the sulfur content in the composite steel is only half that of the MnS steel. The aptitude for cutting effect of 240 ppm nitrogen and 115 ppm boron in the composite steel is demonstrated to be equivalent or even better than 1000 ppm sulfur in MnS free-cutting steel.

Milling Machinability of TiC Particle and TiB Whisker Hybrid Reinforced Titanium Matrix Composites

The milling machinabilities of titanium matrix composites were comprehensively evaluated to provide a theoretical basis for cutting parameter determination. Polycrystalline diamond （PCD） tools with different grain sizes and geometries, and carbide tools with and without coatings were used in the experiments. Milling forces, milling temperatures, tool lifetimes, tool wear, and machined surface integrities were investigated. The PCD tool required a primary cutting force 15 % smaller than that of the carbide tool, while the uncoated carbide tool required a primary cutting force 10% higher than that of the TiA1N-eoated tool. A cutting force of 300 N per millimeter of the cutting edge （300 N/mm） was measured. This caused excessive tool chipping. The cutting temperature of the PCD tool was 20%-30% lower than that of the carbide tool, while that of the TiA1N-coated tool was 12% lower than that of the uncoated carbide tool. The cutting temperatures produced when using water-based cooling and minimal quantity lubrication （MQL） were reduced by 100 ~C and 200 ~C, compared with those recorded with dry cutting, respectively. In general, the PCD tool lifetimes were 2--3 times longer than the carbide tool lifetimes. The roughness Ra of the machined surface was less than 0.6μm, and the depth of the machined surface hardened layer was in the range of 0.15-0.25 mm for all of the PCD tools before a flank wear land of 0.2 mm was reached. The PCD tool with a 0.8 mm tool nose radius, 0% rake angle, 10% flank angle, and grain size of （30＋2） μm exhibited the best cutting performance. For this specific tool, a lifetime of 16 rain can be expected.

Scratching and Turning Experiments on Machinability of Optical Glass SF6 in Diamond Cutting Process

To improve the machinability of optical glass and achieve optical parts with satisfied surface quality and dimensional accuracy, scratching experiments with increasing cutting depth were conducted on glass SF6 to evaluate the influence of cutting fluid properties on the machinability of glass. The sodium carbonate solution of 10.5% concentration was chosen as cutting fluid. Then the critical depths in scratching experiments with and without cutting fluid were examined. Based on this, turning experiments were carried out, and the surface quality of SF6 was assessed. Compared with the process of dry cutting, the main indexes of surface roughness decrease by over 70% totally. Experimental results indicated that the machinability of glass SF6 can be improved by using the sodium carbonate solution as cutting fluid.

Machinability of Hastelloy C-276 Using Hot-pressed Sintered Ti(C_7N_3)-based Cermet Cutting Tools

C-276 nickel-based alloy is a difficult-to-cut material. In high-speed machining of Hastelloy C-276, notching is a prominent failure mode due to high mechanical properties of work piece, which results in the short tool life and low productivity. In this paper, a newly developed Ti（C7N3）-based cermet insert manufactured by a hot-pressing method is used to machine the C-276 nickel-based alloy, and its cutting performances are studied. Based on orthogonal experiment method, the influence of cutting parameters on tool life, material removal rates and surface roughness are investigated. Experimental research results indicate that the optimal cutting condition is a cutting speed of 50 m/min, depth of cut of 0.4 mm and feed rate of 0.15 mm/r if the tool life and material removal rates are considered comprehensively. In this case, the tool life is 32 min and material removal rates are 3000 mm^3/min, which is appropriate to the rough machining. If the tool life and surface roughness are considered, the better cutting condition is a cutting speed of 75 m/min, depth of cut of 0.6 mm and feed rate of 0.1 mm/r. In this case, the surface roughness is 0.59μm. Notch wear, flank wear, chipping at the tool nose, built-up edge（BUE） and micro-cracks are found when Ti（C7N3）-based cermet insert turned Hastelloy C-276. Oxidation, adhesive, abrasive and diffusion are the wear mechanisms, which can be investigated by the observations of scanning electron microscope and energy-dispersive spectroscopy. This research will help to guide studies on the evaluation of machining parameters to further advance the productivity of nickel based alloy Hastelloy C-276 machining.

Experimental Study of Machinability in Millgrinding of SiCp/Al Composites

An attempt was made to investigate the machinability of Si Cp/Al composites based on the experimental study using mill-grinding processing method. The experiments were carried out on a high-speed CNC machining center using integrated abrasive cutting tool. The effects of combined machining parameters, e g, cutting speed（vs）, feed rate（vf）, and depth of cut（ap）, with the same change of material removal rate（MRR） on the mill-grinding force and surface roughness（Ra） were investigated. The formation mechanism of typical machined surface defects was analyzed by SEM. The experimental results reveal that with the same change of material removal rate, lower mill-grinding force values can be gained by increasing depth of cut and feed rate simultaneously at higher cutting speed. With the same change of MRR value, lower surface roughness values can be gained by increasing the feed rate at higher cutting speed, rather than just increasing the depth of cut, or increasing the feed rate and depth of cut simultaneously. The machined surface of Si Cp/Al composites reveals typical defects which can influence surface integrity.

Sintering and Machinability of Monazite-Type CePO_4 Ceramics

The sintering and machinability of monazite-type CePO_4 ceramics were investigated. Relative density ≥98% and apparent porosity <2% were achieved when the monazite-type CePO_4 were sintered at 1500 ℃/1 h in air,and the maximal bending strength value (184 MPa) was achieved at this temperature. CePO_4 ceramics has a multilayer structure and an exciting 'ductility',so it can be drilled and cut with WC cutter with a small machining damage.

Influence of inoculation on cast iron machinability:Case studies

Machinability can sometimes be difficult to predict and be impacted by different characteristics of the castings.Inoculation,a key step in foundry process,is well-known to be a powerful tool to adjust the characteristics of castings in both grey and ductile irons.Some metallurgical cases were investigated to understand different machinability behaviors in correlation to their metallographic characteristics.Thus,two examples taken from grey iron processes are analyzed to illustrate how inoculation is required to adjust characteristics of iron castings,especially the modification of graphite characteristics and the prevention of micro-shrinkage,both parameters are well-known to have an impact on iron machinability.The study also illustrates the importance of the ratio Mn/S to guarantee the presence of manganese sulfides in the matrix,beneficial for iron machinability.

Influence of aluminum content on machinability of AS series cast magnesium alloys

The influence of Al content on machinability of AS series cast Mg alloys was studied. The assessment of machinability of Mg alloys was performed by measuring the cutting forces and surface roughness. The microstructure and the tensile properties were also studied. The results reveal that cutting forces are increased with the increase of the Al content. Surface roughness and mechanical properties are the highest for AS91 Mg alloy. It is assumed that the main mechanism, which has an influence on the mechanical properties, is the presence of intermetallic phases(Mg2Si and Mg17Al12). Cutting forces increase with the increase of the cutting speed in machining of all Mg alloys. These measured data are in accordance with the mechanical properties of the machined alloys.

Comparative Assessment on Machinability of Nano-Structured Bainitic Steel and Titanium64

Titanium64 has characteristics well sought after for applications in demanding environments. In general, due to titanium64’s high performance, it is a material which requires careful and well considered machining approaches in order to optimize the process. Nano-structured bainitic steel whilst having different application bases does none the less have similar machining and machinability short comes as that of titanium64. These similar characteristics have been compared and contrasted in this research study using parameters including cutting force, surface texture and metallography. The results tend to indicate that titanium64 has a poorer machinability characteristics compared to nano-structured bainitic steel. However, in terms of achieving greater surface texture characteristics, the nano-structured bainitic steel exhibited an enhanced capacity.

Machinability of Polymeric Composites and Future Reinforcements—A Review

This paper reviews the machinability and mechanical properties of natural fiber-reinforced composites. Coupling agents, operating parameters, as well as chemical treatment effects on natural fiber-reinforced composites’ machinability are also reviewed. Moreover, the impacts of fibers’ physical properties on the machinability of the composite are mentioned. Fiber volume fraction (Vf), fiber orientation as well as chemical treatment effects on mechanical properties are also defined. Conclusively, the effect of fibers’ physical properties as well as mechanical properties is described. It was discovered that chemical treatment of natural fibers improved their compatibility with the matrix by removing their surface tissues, increasing the roughness average (Ra), and reducing moisture absorption. Also, the Orientation of the fiber plays an important role in controlling the mechanical properties of the composite. Moreover, some physical properties of the fibers, including quality of fiber distributed in the matrix;fiber size, length, and diameter;moisture absorption;porosity and the way fibers break during compounding with the matrix, were found to affect the mechanical properties of the composites formed.

Comprehensive Study on Machinability of Titanium Composite

Metal framework composites have higher mechanical properties in examination to metals over an extensive variety of working conditions. This makes them an alluring alternative in swapping metals for different building applications. The present review is a study on the influence of composite titanium on the cutting parameters, mechanical behavior, reinforcements, structure and nanostructure. This review will provide an understanding into selecting the optimum machining parameters for machining titanium composites. It’s also an attempt to give brief explanation by suitably machining the titanium composite which can be made reasonable.

A review on machinability of carbon fiber reinforced polymer(CFRP)and glass fiber reinforced polymer(GFRP)composite materials

Fiber reinforced polymer(FRP) composite materials are heterogeneous and anisotropic materials that do not exhibit plastic deformation. They have been used in a wide range of contemporary applications particularly in space and aviation,automotive,maritime and manufacturing of sports equipment. Carbon fiber reinforced polymer(CFRP) and glass fiber reinforced polymer(GFRP) composite materials,among other fiber reinforced materials,have been increasingly replacing conventional materials with their excellent strength and low specific weight properties. Their manufacturability in varying combinations with customized strength properties,also their high fatigue,toughness and high temperature wear and oxidation resistance capabilities render these materials an excellent choice in engineering applications.In the present review study,a literature survey was conducted on the machinability properties and related approaches for CFRP and GFRP composite materials. As in the machining of all anisotropic and heterogeneous materials,failure mechanisms were also reported in the machining of CFRP and GFRP materials with both conventional and modern manufacturing methods and the results of these studies were obtained by use of variance analysis(ANOVA),artificial neural networks(ANN) model,fuzzy inference system(FIS),harmony search(HS) algorithm,genetic algorithm(GA),Taguchi's optimization technique,multi-criteria optimization,analytical modeling,stress analysis,finite elements method(FEM),data analysis,and linear regression technique. Failure mechanisms and surface quality is discussed with the help of optical and scanning electron microscopy,and profilometry. ANOVA,GA,FEM,etc. are used to analyze and generate predictive models.

Machinability Investigation and Optimization of Process Parameters in Cryogenic Assisted Sustainable Turning of AISI‑L6 Tool Steel

The application of cutting fluid is significantly increased in the machining sector to improve productivity.However,the inherent characteristics of cutting fluids on ecology,environment,and society shift the interest of researchers to work on environmentally friendly cooling conditions such as cryogenic cooling.Here,the effect of cutting speed and feed rate on the machining performance of the AISI‑L6 tool steel is investigated under cryogenic cooling conditions.Then,the L9 Taguchi based grey relational analysis(GRA)is conducted to investigate the essential machining indices such as cutting energy,surface roughness,tool wear,and material removal rate(MRR).The results indicate that the cutting speed of 160 m/min and feed rate of 0.16 mm/r are the optimum parameters that significantly improves the machining performance of AISI‑L6 tool steel.

Forgeability and Machinability of Stir Cast Aluminum Alloy Metal Matrix Composites

In the present paper, the aluminum alloy i.e. LM6 based composites reinforced with different weight fraction of SiC particles was produced by stir cast technique and the effect of reinforced ratios on the forgeability and the machinability was examined. The test results show that the increment in weight fraction of reinforcement particles in the matrix metal produced better mechanical property like hardness but the forgeability of the cast MMCs decreases. The forgeability of the as cast MMCs were also varied with the change in thickness of the casting. The results show that the forgeability of cast metal matrix composites at the mid section of the casting is minimum compared to both end section of a three-step casting. The effect of machining parameters, e.g. cutting speed and depth of cut on the surface roughness and cutting forces at constant feed rate was investigated during experimentation. The results show that higher weight percentage of SiCp reinforcement produced a higher surface roughness and needs higher cutting forces during machining operation. It has also observed that the depth of cut and the cutting speed at constant feed rate affected the surface roughness and the cutting forces. This practical research analysis and test results on the forgeability and machinability of Al/SiC-MMC will provide useful guidelines to the present day manufacturing engineers.

Influence of Coolant in Machinability of Titanium Alloy (Ti-6Al-4V)

Application of titanium alloy has increased many fields since the past 50 years. The major drawback encountered during machining was difficult to cut and the formation of BUE (Built up Edge). This paper presents the tool wear study of TTI 15 ceramic insert (80% Aluminum oxide and 20 % Titanium carbide) on machining Ti-6Al-4V at moderate speed with and without the application of water soluble servo cut S coolant. Titanium alloy is highly refractory metal and machining titanium is challenging to the manufacturers. Experiments were carried out on medium duty lathe. Application of coolant tends to reduce toolwear and minimize adhesion of the work material on the cutting tool during machining and also improves the surface finish. Result provides some useful information.