Advances in Sustainable Machining and Manufacturing Processes

Cover
Half Title
Series Page
Title Page
Copyright Page
Dedication
Table of Contents
Preface
Acknowledgment
Editors
Contributors
Introduction
Part I: Sustainable Machining
Chapter 1: Challenges in Machining of Advanced Materials
1.1 Introduction
1.2 Machining Process and Materials
1.2.1 Cutting Tool
1.2.2 Material Selection
1.2.3 Types of Machining Techniques
1.3 Tool Wear/Life Span and Commercial Metal Cutting
1.4 Machinability
1.5 Machining Process Selection
1.5.1 Challenges Related to Machining
1.5.2 Practical Aspects and Developments
1.6 Conclusion
References
Chapter 2: Machining by Advanced Ceramics Tools: Challenges and Opportunities
2.1 Introduction
2.2 Cutting Tool Based on Ceramic Materials
2.2.1 Ceramic Tools Based on Aluminum Oxide
2.2.2 Ceramics Tools Based on Silicon Nitride
2.2.3 Ceramic Tools Based on Composite Materials
2.2.4 Enhance the Cutting Properties with Coatings
2.2.5 Textured-Surface Ceramic Cutting Tools
2.3 Effects of Methods of Manufacturing on the Properties of Ceramic Cutting Tools
2.3.1 Contact Manufacturing
2.3.1.1 Hot Pressing
2.3.1.2 Spark Plasma Sintering
2.3.2 Noncontact Manufacturing Methods
2.3.2.1 Microwave Sintering
2.3.2.2 Self-Propagation High-Temperature Synthesis
2.4 Effect of Different Processing Conditions on Ceramic Cutting Tools
2.5 Conclusion
2.6 Future Scope
References
Chapter 3: Characterization and Evaluation of Eco-Friendly Cutting Fluids
3.1 Introduction
3.2 Characterization of Novel Cutting Fluids
3.3 Basic Characterization Studies
3.3.1 Density
3.3.2 Viscosity and Rheological Studies
3.3.3 Specific Heat
3.3.4 Thermal Conductivity
3.3.5 Stability and Biodegradability Test
3.3.6 pH Test
3.3.7 Foam Test
3.3.8 Refractive Index
3.3.9 Thermogravimetric Analysis
3.3.10 Fourier-Transform Infrared Spectroscopy Analysis
3.4 Advanced Characterization Studies
3.4.1 Tribological Performance Studies of Developed Cutting Fluid
3.4.1.1 Anti-Wear Test
3.4.1.2 Coefficient of Friction
3.4.1.3 Wear Surface Characteristics
3.4.2 Wettability Study
3.4.3 Corrosion Study
3.4.4 Acute Skin Irritation Test
3.5 Summary
References
Chapter 4: Advances in Textured Cutting Tools for Machining
4.1 Introduction
4.2 Texturing Processes
4.2.1 Micro-Plasma Transferred Arc
4.2.2 Micro Grinding
4.2.3 Micro-Electrical-Discharge Machining
4.2.4 Focused Ion Beam Machining
4.2.5 Ultrasonic Machining
4.2.6 Micro Indentation
4.2.7 Chemical Etching
4.2.8 Laser Surface Texturing
4.3 Advances in the Machining Performance Using Textured Cutting Tools
4.4 Summary and Conclusion
References
Chapter 5: Advances in MQL Machining
5.1 Introduction
5.1.1 Heat Generation in Machining
5.1.2 Role of MWF in Machining
5.1.3 Flood Lubrication/Cooling System
5.1.4 Dry Machining System
5.1.5 Need for Alternative System
5.1.6 MQL and Its Advantages
5.1.7 MQL: A Comparison with Other Systems
5.2 Sustainable Manufacturing and Clean Machining
5.2.1 Challenges in Sustainability and MQL
5.2.1.1 Cooling Effect
5.2.1.2 Workpiece that is Difficult to Machine
5.2.1.3 Formation of Chips
5.2.1.4 Selection of Optimized Parameters
5.2.1.5 Economic Factors
5.2.1.6 Machining and High-Speed Machining
5.2.1.7 Formation of Mist
5.2.1.8 Lack of Numerically Simulated Data
5.3 Advances in MQL
5.3.1 Advancement of MQL Concerning Industry 4.0 Standards
5.3.2 Awareness among Researchers
5.3.3 SMEET Framework
5.3.4 MQL Supply System
5.4 Conclusion
References
Chapter 6: Nanofluids Application for Cutting Fluids
6.1 Introduction
6.2 Machining and Sustainability
6.2.1 Dry Machining and Semi-Dry Machining
6.2.1.1 Dry Machining
6.2.1.2 Semi-Dry Machining
6.3 Application of MQL in Machining Processes
6.4 MQL and Machining Parameters
6.5 Improving MQL Lubrication
6.6 Nature of Heat Transfer in Nanoparticles
6.7 Nanomaterials for Nanofluids
6.7.1 Nonmetallic Nanoparticle Dispersion
6.7.2 Metallic Nanoparticle Dispersion
6.7.3 Carbon Nanotube Dispersion
6.8 Hybrid Nanofluids
6.9 Machine Tools Application
6.9.1 Grinding
6.9.2 Turning
6.9.3 Milling
6.9.4 Drilling
6.10 Nanofluids: Effect on Machining Parameters
6.10.1 Cutting Force
6.10.2 Surface Roughness
6.10.3 Machining Temperature
6.10.4 Tool Wear
6.10.5 Environmental Aspects
6.11 Difficulties of Applying Nanofluids in Machining
6.12 Conclusion
References
Chapter 7: Nanofluids for Machining in the Era of Industry 4.0
7.1 Introduction
7.2 Preparation of the Nanofluids
7.3 Types of Nanofluids
7.3.1 Graphene-Based Nanofluids
7.3.2 Carbon Nanotube–Based Nanofluids
7.3.3 Al 2 O 3 -Based Nanofluids
7.3.4 MoS 2 -Based Nanofluids
7.3.5 Pentaerythritol Rosin Ester–Based Nanofluids
7.4 Sustainability Evaluation of Nanofluids
7.5 Applications of Nanofluids in Modern Machining Operations
7.6 Conclusion and Future Trends
Acknowledgments
References
Chapter 8: Ionic Liquids as a Potential Sustainable Green Lubricant for Machining in the Era of Industry 4.0
8.1 Introduction
8.2 Fundamental of MWFs
8.2.1 Definition, Purpose, and Types of MWFs
8.2.2 Supply Methods of MWFs
8.3 What Are Ionic Liquids?
8.4 Potential of ILs in Machining
8.5 Effect of ILs on Machining Parameters
8.5.1 Effect of ILs on Machining Forces
8.5.2 Effect of ILs on Surface Roughness
8.5.3 Mechanism of Tool Wear Lubricated with ILs
8.5.4 Physicochemical Properties of ILs on Machining Conditions
8.5.5 Effect of ILs Concentrations on Machining
8.6 Conclusion and Outlook
References
Chapter 9: Sustainable Electrical Discharge Machining Process: A Pathway
9.1 Introduction
9.2 Description of EDM Process
9.2.1 Conventional EDM and Its Variants
9.2.2 Micro-EDM Process
9.3 Classification of Dielectric
9.3.1 Hydrocarbon-Based Dielectric
9.3.2 Water-Based Dielectric
9.3.3 Gaseous-Based Dielectric
9.4 Environmentally Friendly Dielectrics for Achieving Sustainability in EDM
9.4.1 Bio-Friendly Alternatives
9.5 Development of Dry to Near-Dry EDM for Sustainability
9.5.1 Dry EDM
9.5.2 Near-Dry EDM
9.6 Conclusion
References
Chapter 10: Sustainable Abrasive Jet Machining
10.1 Introduction
10.2 Why Is AJM Preferred?
10.3 Evaluation of AJM in Terms of Environmentally Friendly Cutting
10.4 Theory of AJM
10.5 Machining Quality and Performance in AJM
10.6 Concluding Remarks
References
Chapter 11: Artificial Neural Networks for Machining
11.1 Introduction to Artificial Neural Networks
11.2 Why Are ANNs Used?
11.3 ANNs in Machining?
11.4 ANN Applications in Machining
11.5 Concluding Remarks
References
Chapter 12: Machining and Vibration Behavior of Ti-TiB Composites Processed through Powder Metallurgy Techniques
12.1 Introduction
12.2 Materials and Methods
12.3 Results and Discussion
12.3.1 Variation of the MRR with Respect to Current and Gap Voltage
12.3.2 Variation of the TWR with Respect to Current and Gap Voltage
12.3.3 Variation of Machining Time with Respect to Current and Gap Voltage
12.3.4 Damping Analysis
12.4 Conclusion
References
Chapter 13: Numerical Analysis of Machining Forces and Shear Angle during Dry Hard Turning
13.1 Introduction
13.2 Experimental Procedures
13.2.1 2D FEM Formulation of Orthogonal Cutting
13.2.2 Boundary Conditions
13.2.3 Element Formulation
13.2.4 Material Model
13.2.5 Contact Properties
13.2.6 ALE Adaptive Meshing Technique
13.3 Results and Discussion
13.3.1 Cutting Force Model Validation
13.3.2 Variation of Shear Angle
13.4 Conclusion
References
Chapter 14: Machining Performance Evaluation of Titanium Biomaterial, Ti6Al4V in CNC cylindrical turning Using CBN Insert
14.1 Introduction
14.2 Literature Review
14.3 Materials and Methods
14.3.1 Input Machining Parameters
14.3.1.1 Cutting Speed
14.3.1.2 Depth of Cut
14.3.1.3 Feed
14.3.2 Selection of Response Variables
14.3.2.1 Machining Forces
14.3.2.2 Surface Roughness
14.3.2.3 Acoustic Emission Signal Parameters
14.3.3 Selection of Workpiece Material
14.3.4 Tool Material
14.3.5 Cutting Tool and Tool Holder
14.3.6 Experimental Procedure
14.3.7 Machine Tool and Measuring Instruments
14.3.7.1 CNC Lathe
14.3.7.2 Cutting Force Dynamometer
14.3.7.3 Surface Roughness Tester
14.3.7.4 Digital Microscope
14.4 Results and Discussion
14.4.1 Cutting Force Analysis
14.4.2 Surface Roughness Analysis
14.4.3 Tool Wear Analysis
14.4.4 AE Analysis
14.5 Conclusion
14.6 Future Scope
References
Part II: Manufacturing Processes
Chapter 15: Industrial Internet of Things in Manufacturing
15.1 Introduction
15.2 IIOT Architecture, Communication Protocols, and Data Management
15.2.1 IIOT Architectures
15.2.2 Communication Protocols
15.2.3 Data Management in the IIOT
15.3 Industrial Automation Software Design Methodologies
15.3.1 Component-Based Software Systems
15.3.2 Multi-Agent-Based Models
15.3.3 SOA
15.3.4 MDE
15.4 Future Scope
15.5 Conclusion
References
Chapter 16: Improvement in Forming Characteristics Resulted in Incremental Sheet Forming
16.1 Introduction
16.2 Forming Characteristics in ISF
16.3 Deformation Mechanism and Its Influence on Forming Characteristics
16.4 Experimental and Numerical Investigations on Forming Characteristics
16.5 Forming Characteristics as a Function of Tool Path and Forming Strategies
16.6 Improvement in Process Capabilities by Process Variations
16.6.1 Heat-Assisted Modifications
16.6.2 Process Modification
16.7 Conclusion
References
Chapter 17: Deformation Mechanism of Polymers, Metals, and Their Composites in Dieless Forming Operations
17.1 Introduction
17.2 Deformation Mechanism in Metals and Metal Alloys
17.3 ISF of Polymers and Composites: Feasibility and Deformation Mechanisms
17.3.1 ISF Studies in Polymers
17.3.2 ISF Applied to Composites
17.4 Conclusion
References
Chapter 18: Sustainable Polishing of Directed Energy Deposition–Based Cladding Using Micro-Plasma Transferred Arc
18.1 Introduction
18.1.1 Ultrasonic Surface Treatment
18.1.2 Machining
18.1.3 Surface Finishing Using Energy Beam Irradiation
18.2 Experimental Details
18.2.1 Experimental Apparatus and Materials Used
18.2.2 Process Parameters for Experimentation
18.2.3 Investigation of Performance Characteristics
18.3 Result and Discussions
18.3.1 Microstructure and Microhardness
18.3.2 Scratch and Wear Resistance
18.3.3 Surface Deviation
18.4 Conclusion
References
Index