This book focus on the challenges faced by cutting materials with superior mechanical and
chemical characteristics, such as hardened steels, titanium alloys, super alloys, ceramics
and metal matrix composites. Aspects such as costs and appropriate machining strategy are
mentioned. The authors present the characteristics of the materials difficult to cut and
comment on appropriate cutting tools for their machining. This book also serves as a
reference tool for manufacturers working in industry.
Manufacturing of parts and products regardless of their shape, geometric features and materials
involves a series of processes and operations. Nowadays, it is broadly recognized through the
industrial sectors that many manufacturing techniques which are currently implemented in fabricating
products lead to production of industrial waste. Lean manufacturing (LM) is a business template that
has philosophies designed to eliminate waste in the manufacturing process...
The chip formation in machining operations is commonly accomplished by a combination of several
elements working together to complete the job. Among these components, cutting tool is the key
element that serves in the front line of cutting action. Cutting action becomes a challenge when it
comes to machining difficult-to-cut materials. Titanium and its alloys are among the most
difficult-to-cut materials which are widely used in diverse industrial sectors...
Titanium and its alloys are outstanding materials of choice, and their applications are rapidly
growing worldwide in high-value markets such as aerospace, marine, power generation, heat
exchangers, automotive and biomedical industries. They owe their popularity to their superior
characteristics such as high strength to density ratio, also known as high strength to weight ratio
or specific strength, as well as high corrosion resistance. Titanium alloys are used in aerospace
industry to protect the fuselage, especially in military aircraft, from corrosion and heat damages
caused by air friction in supersonic and hypersonic speeds...
Characteristics and behaviors of materials during manufacturing processes highly depend on their
mechanical properties and microstructures. However, these characteristics and behaviors can be
greatly influenced by other factors such as strain, strain rate, and temperature during the
process. The Johnson-Cook (J-C) constitutive material model has been extensively used to
describe the material behavior under such circumstances. The J-C parameters are usually
determined using the Split Hopkinson Pressure Bar (SHPB) test which is time consuming and
Application of additively manufacturing (AM) metals is growing rapidly; however, post-process
finish machining is still required to improve dimensional accuracy and surface quality.
Determining the high-strain high-temperature behavior of AM metals is critical in simulating
finish machining, designing appropriate cutting tools, and predicting surface integrity. This
paper investigated the machining characteristics of AM Ti-6Al-4V produced using powder bed
fusion. High-strain high-temperature behavior of AM Ti-6Al-4V was determined numerically and
used in simulating the process...
Determining the mechanical characteristics of additively manufactured materials has been an
active topic of research in recent years. Many studies have been performed analyzing the impact
of different 3D print parameters on the tensile properties of the printed material. However,
compared to typical metals and polymers, there is no widely adopted standard for testing
additively manufactured polymers. Consequently, the test results reported by the researchers in
this field exhibit high amounts of variability between studies...
The goal of active ankle-foot orthoses (AAFO) is to assist the user in recreating a nominal gait
motion. Previously proposed control systems for AAFOs have been reactive, with controllers based
on the current tracking error. However, the optimal AAFO controller must ensure adequate
trajectory tracking while minimizing the amount of assistance provided to the user. To this end,
a model predictive controller (MPC) can be considered to determine the optimal control sequence
for a given trajectory...
This work investigated the impact of cutting tools varying edge radii by presenting a
3-dimensional finite element
analysis (3D FEA) model during the milling of hardened steels. The proposed numerical model was
able to capture the
effect of micro geometrical changes between cutting tools of five different edge radii (25 μm,
and 45 μm
). Experimental milling tests were performed to validate the numerical model and close agreement
between the experimentally acquired cutting forces and the numerically simulated ones...
Proper design of micro-textured cutting tools is an effective strategy to improve the machining
performance by reducing the tool-chip contact length and the resultant friction and thus
improving tool life and workpiece surface integrity. In this paper, an Oxely-based analytical
model is developed to optimize micro-textured cutting tool design(s) which eliminate the
occurrence of derivative cutting. The model accommodates any workpiece material, tool geometry,
and machining parameter...
This letter outlines the modelling, design, and experimental validation of a novel
power-efficient actuator for an active ankle-foot orthosis (AAFO). The actuator is based on a
new principle of discrete non-linear stiffness. Two or more linear springs are discretely
compressed at specified displacement intervals to reduce the peak mechanical power required to
actuate the AAFO. The actuator uses a crank-rocker configuration...
Manufacturing industries are constantly pressured by market demands to produce low-cost,
high-quality products. Market demands tend to be complex and full of variations, especially in
fast-paced industrial settings. To cope with the rising market demands, traditional
manufacturing techniques are forced to develop and adapt advanced practices and methods.
However, as advances in manufacturing technology grow, so does the need to implement them in an
efficient and cost-effective manner...
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, is an issue when
using textured tools. Derivative cutting increases the cutting forces, heat, and ultimately tool
Manufacturing processes are typically divided into three categories: formative, subtractive, and
additive. While formative and subtractive manufacturing processes are considered more
traditional, additive manufacturing (AM) is a family of evolving technologies that are rapidly
growing with techniques and constraints yet to be explored. In this paper, a life cycle
assessment comparison of casting (formative), machining (subtractive), and three AM methods,
namely, binder jetting (BJ), powder bed fusion (PBF), and novel bound powder extrusion (BPE) has
For more publications, please access the lab directors' Google Scholar profiles below.