Machining, the art of processing materials, has progressed significantly over the past century. Advances in tool materials look at blended advantages of conventional and modern tool materials through coatings at micro-scales. Tool coatings improve the hot hardness and wear resistance of tool tip and faces. The current study utilizes the Taguchi technique to analyze the deformation response of HSS tools with three different tool coatings—titanium carbide, titanium nitride and titanium aluminum nitride. The coating thicknesses of 10, 50 and 100 $$\upmu$$ μ m were employed on the rake face and the flank faces of the single-point cutting tool. The response of the tools while machining medium carbon steel 42CrMo4 has been studied using the finite element approach—transient structural analysis module on ANSYS®. The tool deformation was taken up as the key metric.
The development of hybrid composite materials using honeycomb structure, typically a lightweight material, is commonly used in aircraft structures. However, the use of honeycomb with natural or synthetic composite remains unexplored in the literature. Therefore, this study aims to partially replace synthetic fiber, woven glass with a natural fiber of woven kenaf and honeycomb core. An experimental analysis investigated the mechanical strength of three different compositions using glass, kenaf, and honeycomb materials for structural application purposes. The properties of the sample were evaluated through the tensile, flexural, and impact strength, and the morphological damage was observed using scanning electron microscopy. The results showed that the composition of GKGKG laminate composite is the highest in tensile strength (147.64 MPa) and modulus (3.9 GPa), while the GKHKG composite was good in flexural strength (219.03 MPa) and modulus (11.47 GPa). In terms of impact properties, there was a slight difference in energy level (20–30 J) by GKGKG and GKHKG, showing the optimal hybrid configuration of composite for the newly developed material. In conclusion, the application of the new hybrid of GKHKG composite is promising in semi-structural and structural light-weight applications.
Modern Aircraft structures use titanium alloys where the processing of holes becomes essential to assemble aerospace parts. Considering the limitations of drilling, the study evaluates the helical milling for hole processing in Ti6Al4V. The experimental evaluation was conducted by considering burr size, surface roughness, machining temperature, and microhardness under coolant-free conditions. The axial feed and cutting speed were varied at three levels, and nine experiments were conducted. The results exhibit a lower machining temperature during helical milling than during drilling. In addition, the helical milling helped to lower the surface roughness and size of the exit burrs. However, helical-milled holes showed higher subsurface microhardness than conventionally drilled holes. The process variables were influential on machining temperature magnitude. The highest recorded temperature of 234.7 °C was observed at 60 m/min of cutting speed and 0.6 mm/rev feed. However, the temperature rise did not affect the microhardness. Strain hardening associated with mechanical deformation was the primary mechanism driving the increase in microhardness. Helical-milled holes exhibited an excellent surface finish at lower axial feeds, while chatter due to tool deformation at higher feeds (0.6 mm/rev) diminished the surface finish. The surface roughness increased by 98% when the cutting speed increased to 60 m/min from 20 m/min, while a moderate increment of 28% was observed when the axial feed increased to 0.6 mm/rev from 0.2 mm/rev. Furthermore, the formation of relatively smaller burrs was noted due to significantly lower thrust load and temperature produced during helical milling.
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