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Titanium alloys have gained prominence in aerospace and automotive industries due to higher strength to weight ratio and lesser weight. Titanium alloys employed in diverse applications cannot be produced as near net shape components and require holes and other machining processes for structural assembly. Drilling the most conventional machining pro...
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... joints on aircraft structures. The roughness plot as shown in Fig. 6 represents the nonlinear surface characteristics in variation with cutting speeds, but the feed rate has produced consistent progression in surface roughness. Burr thickness was measured for all the 16 set of holes which produces different forms of burrs. The plot as shown in Fig. 7 represents that there is a linear increment in burr thickness with regard to increase in cutting speed especially at the speed range of 30-50 m/min. It seems cutting speed has substantial effect on burr thickness compared to feed rate. This could be because of thermal expansion of workpiece material due to high temperature during high ...
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This paper presents the use of TOPSIS, a multi-criteria decision-making model combined with the Taguchi method to find the optimum milling parameters. TOPSIS is the Technique for Order Preference by Similarity to the Ideal Solution and shows the value of closeness to the positive ideal solution. This study shows the optimum combination of process p...
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... Other optimization methods such as TOPSIS, Analytic Hierarchy Process (AHP), and Multi-attribute optimization have also been used to optimize machining parameters such as turning, drilling and milling on various types of composite and metal materials [21][22][23][24][25][26]. It has been observed by researchers that there is a lack of reported studies on the utilization of CNC Milling for the production of prosthetic components. ...
The purpose of this research is to determine the best milling process parameters for minimizing machining time of the ankle-foot as a component of transtibial prostheses. The ankle foot prosthesis is of the energy storing type with Al 6061 material. The experimental design employed the Box Behnken technique, with four factors and three levels for each factor, and machining time as a response. The machining parameters assessed in this study are spindle speed, feed rate, step-over, and toolpath technique. The physical trials were carried out using a three-axis CNC milling machine with a flat endmill cutting tool (diameter 5.5 mm, 2 flute with HSS material). The experiment outcomes were assessed using variance analysis, graphs, and numerical approaches. The response surface method (RSM) calculates the mathematical model of the ideal cutting combination parameters based on machining time. Based on the findings, the ideal cutting parameters in the ankle-foot prosthesis production process on a CNC milling machine were spindle speed of 6500 rpm, feed rate of 800 m/min, step over of 0.2 mm, and flowline toolpath strategy. To establish the machining time value of the ankle-foot prosthesis, the ideal circumstances were identified. The findings of this study revealed that CNC milling gave the quickest time for machining transtibial prosthesis components, which can be used to guide the development of machining methods for ankle-foot prostheses constructed of Al 6061 material. The optimal machining time is 424.4601 min.
... A study on optimizing machining parameters in fiber-reinforced particulate composites is a significant step forward, providing valuable insights for future particle-reinforced polymer composite researches [16]. Technique for Order Preference by Similarity to an Ideal Solution (TOPSIS), and Analytic Hierarchy Process (AHP) methods have been used to optimize process parameters for metal and nonmetal fibre composite materials [17][18][19][20]. A study investigates the optimization of reinforcement in greener composite materials for structural applications [21- Page 3 of 24 AUTHOR SUBMITTED MANUSCRIPT -ERX-103131.R2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 A c c e p t e d M a n u s c r i p t 23] . ...
The boron carbide (B4C) reinforced AA5052-H32 aluminium composite has been initially fabricated by stir casting method. Friction stir welding (FSW) is used to join two similar AA5052-H32/B4C plates using a titanium nitride (TiN)-coated square tool. The tool wear loss, microhardness, and tensile strength of FSW joints have been investigated by the Taguchi technique. Welding parameters consist of TiN coating thickness, tool rotational speed, welding speed, and axial thrust. Taguchi analysis is used to determine the influences, contributions, and best values of welding parameters to meet optimal welding attributes. The maximum tensile strength (140.134 MPa) has been obtained by increasing the TiN coating thickness, tool's rotational speed, axial thrust, and welding speed. At the highest tool speed and axial trust, the maximum microhardness (158.3 HV) has been attained. The minimum tool wear loss (9.023 %) has been obtained by welding at a moderate speed with maximum rotational speed, axial thrust, and TiN coating thickness. Fractography and SEM analysis have been used to analyze the microstructural behaviour of welded aluminium composite materials and worn-out tool surfaces. The Additive Ratio Assessment (ARAS) multi-criteria optimization technique has been applied to predict the best welding parameters to attain the optimal welding characteristics. The 40 µm TiN coating thickness, 1200 rpm tool rotation, 20 mm/min welding speed, and 6000N axial force are predicted to achieve 108.6 MPa tensile strength, 110 HV microhardness, and 9.37% tool wear loss.
... 25,26 In recent years, multiattribute decision-making techniques have found their application in many research studies on composites machining and other hard materials toward the determination of optimal parameters in regard to achieving the desired performance. [27][28][29][30][31] Several investigations have been performed earlier in drilling CFRP/Ti-6Al-4V hybrid stacks and also with different optimization techniques whereas this research study reports the optimization of drilling parameters on hybrid stacks by applying VIKOR decision-making methodology and such research work haven't been attempted earlier. This research article attempts the application of a hybrid decision-making methodology (combined analytic hierarchy procedure (AHP)-VIKOR) in the determination of optimal parameters in drilling CFRP/Ti-6Al-4V hybrid stacks. ...
Drilling carbon reinforced polymer composites (carbon fiber-reinforced polymers, CFRP) and the hole quality produced are highly critical and significantly influence the performance and reliability of structures used in aircraft components. When CFRP composites are stacked together with titanium alloy, the damage caused by the machining operation is incalculable due to the burr and chip evacuation of metallic phases. In this article, efforts were made toward the identification of optimal machining conditions in drilling CFRP/titanium hybrid stacks. Experimental investigations on dry drilling of CFRP/titanium stacks were conducted with the aid of tungsten carbide drills. This research article discusses an improved compromise ranking method named VIKOR (VIseKriterijumska Optimizacija I Kompromisno Resenje) to determine the optimal machining parameters in drilling of CFRP/titanium stacks to produce high-quality holes. Attributes measured from experimental trials are: delamination factor of CFRP, burr height of titanium alloy, thrust force, torque, surface roughness, roundness and hole diameter of CFRP and titanium alloy. Experimental trial 13 with a combination of speed of 30 m/min, feed of 0.025 mm/rev was chosen as an ideal machining parameter in drilling CFRP/Ti-6Al-4V stacks without any trade-off. Confirmation tests convey that the results agree well with optimal parameters and the decision making in drilling such multimaterial stacks is highly consistent and judicious. In regard to the optimal parameters determined, investigations on tool life were performed and a tool life of 20 min for 0.10 mm flank wear land was observed.
... Multicritaria decision-making (MCDM) methods are extensively employed owing to their simplicity among the diverse optimization techniques [1]. These methods have been employed by numerous researchers in various machining processes, such as optimizing milling conditions [2,3], drilling Ti-6Al-4V using the TOPSIS method [4], hard turning medium carbon steel [5], and grinding 9CrSi steel using CBN wheels [6]. Thirumalai et al (2021) [7] used the TOPSIS technique to optimize the cutting parameters for Inconel 718 while turning operations. ...
... Step 3: Find the corresponding principal component scores of the quality characteristics that can be obtained using equation (4). ...
In recent years, multiple-attribute decision-making (MADM) methods have gathered significant interest from researchers across various scientific fields. In the case of mechanical part machining when faced with conflicting objectives, these methods have become essential in the selection of necessary cutting parameters.. The integration of these techniques with multi-objective optimization procedures has proven effective in leading to an efficient solution to a multi-attribute decision-making problem. The present study falls within this context. Its primary objective being the determination of the optimal cutting parameters that reduces tool vibration, minimizes surface roughness along withmaximizing material removal rate during the turning of Inconel 718 using a coated carbide cutting tool grade (GC1105). These various objectives have been achieved through combining the principal component analysis (PCA) method to the measurement of alternatives and ranking according to the compromise solution (MARCOS), and MARCOS method coupled with the Taguchi SN ratio. The results obtained demonstrated that both methods generated the same combination of optimal cutting parameters that achieve the aforementioned objectives and represented by a nose radius r = 0.8 mm, a cutting speed Vc = 70 mm/min, a feed rate f = 0.08 mm/rev, and a depth of cut ap = 0.3 mm.
... Therefore, grey based Taguchi method is the more effective method when multiple output responses are needed to be optimized simultaneously. In this method, multiple output responses are converted into a single output response using grey relation grade [10,[13][14][15]21]. The main advantage of grey based Taguchi method is to find the same significant parameter's level setting for multiple responses. ...
Tungsten inert gas can be used to weld stainless steel due to its offering sound weld, narrow fusion zone, precise control weld’s shape and over penetration, spatter free, slagless, stable arc and low electrode wear. The goal of this study was to offer the best process parameters for improving the mechanical characteristics of the weld joint. The experimental analysis approach was applied in this work, and the experiment was carried out on 304L stainless steel using L16. The selected welding parameters were welding travel speed, current of welding, gas flow rate, arc length, and root gap. Rockwell hardness, tensile strength, and bending strength tests were the examined mechanical properties on the weld joint. Based on the grey based Taguchi method, the optimal level-settings of welding travel speed, current of welding, flow rate of gas, arc length, and root gap were obtained 2.7 mm s ⁻¹ , 160 A, 14 l min ⁻¹ , 3 mm, and 1 mm, respectively. The analysis result of ANOVA showed that the current has the greatest impact and it was followed by travel speed and root gap on weld joint quality with percentage contribution of 80.77%, 10.86%, and 5.98%, respectively. According to confirmation results, the average grey relational grade of 0.863 which was found between the confidence interval of 0.800 to 1.082 for the 95% confidence level, and the maximum Rockwell hardness, tensile strength and bending strength were obtained 101.38 HRB, 1425.8 MPa and 1648.6 MPa, respectively.
... The main steps of the traditional TOPSIS are as follows: [1,2,[23][24][25] Page 2 of 18 AUTHOR SUBMITTED MANUSCRIPT -MRX-124357.R1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 A c c e p t e d M a n u s c r i p t 3 Step 1: Construct the normalized decision-matrix Z= (zik)n×p from the decision-matrix X= (xik)n×p. Commonly, the following vector normalization formula is used: ...
Technique for order preference by similarity to ideal solution (TOPSIS) is a
well-known multi attribute decision making (MADM) method and it has been widely used in
materials selection. However, the main drawback of the traditional TOPSIS is that it has a rank
reversal phenomenon. To overcome this drawback, we propose an improved TOPSIS without rank
reversal based on linear max-min normalization with absolute maximum and minimum values by
modifying normalization formula and ideal solutions. Moreover, to study the impacts of changing
attribute weights on relative closeness values of alternatives, we propose a sensitivity analysis method
to attribute weights on the relative closeness values of the alternatives. We applied the proposed
method to select best absorbent layer material for thin film solar cells (TFSCs). As a result, copper
indium gallium diselinide was selected as the best one and the next cadmium telluride from among
five materials. When the alternative is added to or removed from the set of original alternatives, the
elements of the normalized decision-matrix, PIS, NIS and the relative closeness values don’t change
at all, they are always coincided with the corresponding elements of the original ones. The relative
closeness values are absolute values irrelevant to the composition of the alternatives in the improved
TOPSIS, while the relative closeness values are relative values relevant to the composition of the
alternatives in the traditional TOPSIS. Therefore, the proposed TOPSIS overcomes the rank reversal
phenomenon, perfectly. It could be actively applied to practical problems for materials selection.
Aluminium alloy is increasingly being used in the industries because of its high strength to weight and corrosion resistance ability. However, there is a need to investigate its machinability to ensure that it will meet the quality and functional requirements for its intended applications. Hence, this study employs the computer-aided simulation and experimental approach to investigate the machinability of Al 6065 T6 using response surface methodology (RSM) during milling operation. The RSM was implemented in the Design Expert 2022 environment and the designed experiment produced 20 experimental trials whose responses specifically, maximum contact stress, reaction force, and surface roughness determined via modelling and simulation in the Complete Abaqus Environment (CAE). The validation of the numerical analysis was done by conducting physical experimentations. This established the feasible range of process parameters that can ensure effective machinability of Al 6065 T6 during milling operation. The values of the process parameters that produced the least surface roughness for both the computer-aided simulation and experimental approaches are feed rate (0.07 mm/rev), cutting speed (15 m/min), and tool slip factor (25%). Furthermore, predictive models were developed for estimating the magnitude of maximum contact stress, reaction force, and surface roughness. The statistical analysis of the predictive models indicates that they are suitable for predictive purposes. The outcome of this study adds to the understanding of the machinability of Al 6065 T6. The empirical results can assist machinists to develop products from Al 6065 T6 that will meet the required service requirements.
A fibre-based hybrid polymer composite occupies the chief percentage in various applications owing to its low cost and eco-friendly nature. This study focuses on mechanical characteristics of hybrid potassium permanganate (KMnO4) treated Borassus Fruit Fiber (BFF) and untreated Cigarette Butts Fiber (CBF) reinforced vinyl ester matrix composite. The hybrid composites were manufactured with various combinations (0%, 5%, and 10%) of Egg Shell Powder (ESP) by compression molding process. Fabricated composites were analyzed with various characterizations, such as FTIR, FE-SEM, and TGA. Multi-criteria decision-making (MCDM) using Criteria Importance through Inter-Criteria Correlation (CRITIC) integrated Weighted Aggregated Sum Product Assessment (WASPAS) methodology is employed to evaluate the optimal composite compositions for superior mechanical characteristics. The tensile, flexural, and impact properties of BFF (30 wt%)–CBF (30 wt%) with ESP 5 wt% were attained to be 52.26 MPa, 37.76 MPa, and 36.87 J/m, respectively. Based on the experimentation and hybrid optimization response, it is concluded that BCE9 composites provided enhanced mechanical properties as compared with other test composites.
Maraging steel material characteristics are greatly affected by build orientation and scanning strategies during manufacturing. This research aims to examine the effect of various build orientations and scan strategies on the ultimate strength and microhardness of 18 Ni-300 grade maraging steel. The maraging steel is made using a technology called direct metal laser sintering. Using the Analysis of Variance approach, the effects of processing factors like build orientation, scan techniques, and type of process on ultimate strength, microhardness, and roughness are optimized. The properties tend to be greater in the horizontal orientation when using the XY scan strategy as a result of thermal history variations,. The mechanical performances of MS1 components in terms of strength values observed were lower in the vertical position compared to all other orientations. The tests are carried out using an L27 orthogonal array and a Taguchi design of experiment. Build orientation XZ, scan method XY, and Solution-aging-aging(SAAT) has the most significant influence on the final ultimate strength, microhardness, and roughness of all the input factors. A2B2C3 is the optimal combination level of control factors. Additionally, a percentage inaccuracy was identified after conducting confirmation tests on the most prominent experimental data.
Machine tool structures produced with Epoxy Granite reinforced polymer composites (EGPCs) have gained prominence in recent years and have replaced conventional cast iron materials and other metals due to its remarkable damping characteristics. However, machine tool structures manufactured with EGPCs tends to exhibit limited strength, stiffness and stability. Such challenges in EGPCs are resolved by incorporation of steel as additional reinforcement and enhanced mechanical properties are observed in these hybrid machine‐tool structures. Hybrid epoxy granite machine tool structures with enhanced mechanical performance are prone to thermal errors resulting in machining inaccuracies and limited performance. Thermal errors induced in machine tool structures could be attributed due to effect of temperature distribution and displacements at the Tool Center Point (TCP). This review work carried out focuses predominantly on design methods adopted in resolving the challenges identified in development of machine tool structures and further analyses results of several polymer concrete‐based machine tool structures with regard to static, dynamic and thermal characteristics. Several review works conducted earlier have discussed the results of static and dynamic characteristics, whereas this review work provides additional information on thermal based errors induced and discusses the methods adopted in compensation of thermal errors. In this review paper, research studies pertaining to static and dynamic characteristics of different machine tool structures performed in last three decades have been discussed and a wholistic information is provided in relation with static, dynamic and thermal characteristics and properties toward developing a machine tool structure with a novel, newer class or alternative materials. Challenges in development of machine tool structures – static, dynamic and thermal characteristics.
