a b s t r a c tMachining difficult-to-machine materials such as alloys used in aerospace, nuclear and medical industries are usually accompanied with low productivity, poor surface quality and short tool life. Despite the broad use of the term difficult-to-machine or hard-to-cut materials, the area of these types of materials and their properties are not clear yet. On the other hand, using cutting fluids is a common technique for improving machinability and has been acknowledged since early 20th. However, the environmental and health hazards associated with the use of conventional cutting fluids together with developing governmental regulations have resulted in increasing machining costs. The aim of this paper is to review and identify the materials known as difficult-to-machine and their properties. In addition, different cutting fluids are reviewed and major health and environmental concerns about their usage in material cutting industries are defined. Finally, advances in reducing and/or eliminating the use of conventional cutting fluids are reviewed and discussed.

By synergistically combining additive and subtractive processes within a single workstation, the relative merits of each process may be harnessed. This facilitates the manufacture of internal, overhanging and high aspect ratio features with desirable geometric accuracy and surface characteristics. The ability to work, measure and then rework material enables the reincarnation and repair of damaged, high-value components. These techniques present significant opportunities to improve material utilisation, part complexity and quality management in functional parts. The number of single platform workstations for hybrid additive and subtractive processes (WHASPs) is increasing. Many of these integrate additive directed energy deposition (DED) with subtractive CNC machining within a highly mobile multi-axis machine tool. Advanced numerical control (NC), and computer aided design (CAD), manufacture (CAM) and inspection (CAI) software capabilities help to govern the process. This research reviews and critically discusses salient published literature relating to the development of Workstations for Hybrid Additive and Subtractive Processing (WHASPs), and identifies future avenues for research and development. It reports on state-of-the-art WHASP systems, identifying key traits and research gaps. Finally, a future vision for WHASPs and other hybrid machine tools is presented based upon emerging trends and future opportunities within this research area

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Machining is one of the major activities in manufacturing industries and is responsible for a significant portion of the total consumed energy in this sector. Performing machining processes with better energy efficiency will, therefore, significantly reduce the total industrial consumption of energy. In this paper, a framework is presented to validate the introduction of energy consumption in the objectives of process planning for CNC machining. The state of the art in process planning and energy consumption in manufacturing research is utilised as a basis for the framework. A mathematical representation of the logic used is presented followed by two sets of experiments on energy consumption in machining to validate the logic. It is shown that energy consumption can be added to multi-criteria process planning systems as a valid objective and the discussion on using resource models for energy consumption estimation concludes the paper. These experiments represent a part test procedure machining proposal for the new environmental machine standard IS014955 Part 3.

BackgroundObjective assessment methods to monitor residual limb volume following lower-limb amputation are required to enhance practitioner-led prosthetic fitting. Computer aided systems, including 3D scanners, present numerous advantages and the recent Artec Eva scanner, based on laser free technology, could potentially be an effective solution for monitoring residual limb volumes.PurposeThe aim of this study was to assess the validity and reliability of the Artec Eva scanner (practical measurement) against a high precision laser 3D scanner (criterion measurement) for the determination of residual limb model shape and volume.MethodsThree observers completed three repeat assessments of ten residual limb models, using both the scanners. Validity of the Artec Eva scanner was assessed (mean percentage error <2%) and Bland-Altman statistics were adopted to assess the agreement between the two scanners. Intra and inter-rater reliability (repeatability coefficient <5%) of the Artec Eva scanner was calculated for measuring indices of residual limb model volume and shape (i.e. residual limb cross sectional areas and perimeters).ResultsResidual limb model volumes ranged from 885 to 4399 ml. Mean percentage error of the Artec Eva scanner (validity) was 1.4% of the criterion volumes. Correlation coefficients between the Artec Eva and the Romer determined variables were higher than 0.9. Volume intra-rater and inter-rater reliability coefficients were 0.5% and 0.7%, respectively. Shape percentage maximal error was 2% at the distal end of the residual limb, with intra-rater reliability coefficients presenting the lowest errors (0.2%), both for cross sectional areas and perimeters of the residual limb models.ConclusionThe Artec Eva scanner is a valid and reliable method for assessing residual limb model shapes and volumes. While the method needs to be tested on human residual limbs and the results compared with the current system used in clinical practice, it has the potential to quantify shape and volume fluctuations with greater resolution.