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    Analytical Modeling Methods in Machining: A State of the Art on Application, Recent Challenges, and Future Trends
    (Springer Heidelberg, 2024) Korkmaz, Mehmet Erdi; Gupta, Munish Kumar; Sarikaya, Murat; Gunay, Mustafa; Boy, Mehmet; Yasar, Nafiz; Demirsoz, Recep
    Information technology applications are crucial to the proper utilization of manufacturing equipment in the new industrial age, i.e., Industry 4.0. There are certain fundamental conditions that users must meet to adapt the manufacturing processes to Industry 4.0. For this, as in the past, there is a major need for modeling and simulation tools in this industrial age. In the creation of industry-driven predictive models for machining processes, substantial progress has recently been made. This paper includes a comprehensive review of predictive performance models for machining (particularly analytical models), as well as a list of existing models' strengths and drawbacks. It contains a review of available modeling tools, as well as their usability and/or limits in the monitoring of industrial machining operations. The goal of process models is to forecast principal variables such as stress, strain, force, and temperature. These factors, however, should be connected to performance outcomes, i.e., product quality and manufacturing efficiency, to be valuable to the industry (dimensional accuracy, surface quality, surface integrity, tool life, energy consumption, etc.). Industry adoption of cutting models depends on a model's ability to make this connection and predict the performance of process outputs. Therefore, this review article organizes and summarizes a variety of critical research themes connected to well-established analytical models for machining processes.
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    Comparison of Tool Wear, Surface Morphology, Specific Cutting Energy and Cutting Temperature in Machining of Titanium Alloys Under Hybrid and Green Cooling Strategies
    (Korean Soc Precision Eng, 2023) Gupta, Munish Kumar; Nieslony, P.; Korkmaz, Mehmet Erdi; Kuntoglu, Mustafa; Krolczyk, G. M.; Guenay, Mustafa; Sarikaya, Murat
    Cutting energy must be reduced in order to make machining processes more eco-friendly. More energy was expended for the same amount of material removed, hence a higher specific cutting energy (SCE) implies inefficient material removal. Usually, the type of coolants or lubricants affects the SCE, or the amount of energy needed to cut a given volume of material. Therefore, the present work deals with a study of SCE in the turning of Ti-3Al-2.5V alloy under green cooling strategies. In spite of this, the research effort is also focused on the mechanism of tool wear, surface roughness, and cutting temperature under hybrid cooling, i.e., minimum quantity lubrication (MQL) and cryogenic. The tool wear rate, were explored with tool mapping analysis, and the results were compared with dry, MQL, and liquid nitrogen (LN2) conditions. The tool wear rate analysis claims that the dry condition causes more built up edge (BUE) formation. In addition, the hybrid cooling conditions are helpful in reducing the SCE while machining titanium alloys.
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    Cutting forces and temperature measurements in cryogenic assisted turning of AA2024-T351 alloy: An experimentally validated simulation approach
    (Elsevier Sci Ltd, 2022) Gupta, Munish Kumar; Korkmaz, Mehmet Erdi; Sarikaya, Murat; Krolczyk, Grzegorz M.; Gunay, Mustafa; Wojciechowski, Szymon
    Aluminium alloys are widely used in modern engineering applications such as automobile, aerospace etc because of its characteristics. The machining of aluminium alloys are also considered as difficult because of its sticky and soft nature, low thermal conductivity, strain hardening effect etc. The cooling conditions employed at cutting zone improved the machining performance but the resources, material consumption, skilled labor etc. are also required for performing the machining experiments. Therefore, the simulation of process parameters with the help of Finite Element Modelling (FEM) during machining is highly researched topic these days. In this work, a new practice from measurement science i.e., FEM simulation was performed with AdvantEdge software and the prediction models were developed for evaluating the cutting forces and cutting temperature while machining AA2024-T351 alloy under dry, liquid nitrogen (LN2) and carbon dioxide (CO2) conditions. Initially, the 3D turning model was developed and the results were compared with experimental findings. The results obtained from simulation model are very close with experimental results with minimum standard value of 0.67 (5.7%) for cutting forces and 4.58 (6.16%) for cutting temperature. Thus, it is worthy to mention that the 3D FE model is efficient and effective to predict and measurement results with minimum error.
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    In-process detection of cutting forces and cutting temperature signals in cryogenic assisted turning of titanium alloys: An analytical approach and experimental study
    (Academic Press Ltd- Elsevier Science Ltd, 2022) Gupta, Munish Kumar; Korkmaz, Mehmet Erdi; Sarikaya, Murat; Krolczyk, Grzegorz M.; Guenay, Mustafa
    In-process detection of cutting forces, temperature, roughness, wear etc. during machining of titanium alloys are very important. The Finite element (FE) analysis plays an important role in monitoring and detection of machining responses. It offers a high accuracy in modeling of dry cutting processes and its performance in modeling of cryogenic machining process is a matter of interest. In this context, current investigation focuses on the dry turning and LN2/CO2 cooling assisted turning process of commonly used Ti6Al4V alloy. It is very useful material in the biomedical sector, and the simulation of cutting forces and cutting temperature via finite element method (FEM) has been performed. In addition, the simulation results are validated with experimental work. The results show that the deviations between FE modeling and experimental results for the cutting temperature are the average of 5.54%, 5.18% and 8.42% for the dry, LN2 and CO2 cooling conditions, respectively. On the other hand, the deviations from FE modeling and cutting force test results were 3.74%, 3.358%, and 3.03% under dry, LN2 and CO2 cooling conditions, respectively.
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    Key initiatives to improve the machining characteristics of Inconel-718 alloy: Experimental analysis and optimization
    (Elsevier, 2022) Rubaiee, Saeed; Danish, Mohd; Gupta, Munish Kumar; Ahmed, Anas; Yahya, Syed Mohd; Yildirim, Mehmet Bayram; Sarikaya, Murat
    Inconel 718 is a heat-resistant Ni-based superalloy widely used, particularly, in aircraft and aero-engineering applications. It has poor machinability due to its unique thermal and mechanical properties. For this reason, studies have been carried out from past to present to improve the machinability of Nickel-based (Ni) alloys. Further improvement can be achieved by applying hybrid multi-objective optimization strategies to ensure that cutting parameters and cooling/lubrication strategies are also adjusted effectively. That is why, in this research, the machinability of Inconel 718 is optimized under various sustainable lubricating environments i.e., dry medium, minimum quantity lubrication (MQL), nano-MQL, and cryogenic conditions at different machining parameters during end-milling process. Subsequently, the analysis of variance (ANOVA) approach was implanted to apprehend the impact of each machining parameter. Finally, to optimize machining en-vironments, two advanced optimization algorithms (non-dominated sorting genetic algo-rithm II (NSGA-II) and the Teaching-learning-based optimization (TLBO) approach) were introduced. As a result, both methods have demonstrated remarkable efficiency in ma-chine response prediction. Both methodologies demonstrate that a cutting speed of 90 m/ min, feed rate of 0.05 mm/rev, and CO2 snow are the optimal circumstances for minimizing machining responses during milling of Inconel 718. (C) 2022 The Author(s). Published by Elsevier B.V.
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    Studies on Geometrical Features of Tool Wear and Other Important Machining Characteristics in Sustainable Turning of Aluminium Alloys
    (Korean Soc Precision Eng, 2023) Gupta, Munish Kumar; Nieslony, P.; Sarikaya, Murat; Korkmaz, Mehmet Erdi; Kuntoglu, Mustafa; Krolczyk, G. M.
    The aerospace and automotive industries make extensive use of aluminium and its alloys. Contrarily, machining of aluminium (Al) alloys presents a number of difficulties, including, but not limited to, poor surface finishing, excessive tool wear, decreased productivity etc. Therefore, it's very important to measure the machining characteristics during machining of aluminium alloy with sustainable cooling strategies. In this work, a new approach of measurement was adopted to measure the critical geometrical aspects of tool wear, surface roughness, power consumption and microhardness while machining AA2024-T351 alloy under dry, minimum quantity lubrication (MQL), liquid nitrogen (LN2) and carbon dioxide (CO2) cooling conditions. Initially, the various aspects of tool wear were studied with the help of Sensofar Confocal Microscope integrated with Mountains map software and then, the other results such as surface roughness, power consumption and microhardness were measured as per the ISO standards. The outcome of these measurement studies confirms that LN2 and CO2 cooling is helpful in improving the machining characteristics of AA2024-T351 alloy. When compared to dry conditions, the surface roughness values of MQL, LN2, and CO2 all have values that are lowered by 11.90%, 30.95%, and 39.28% respectively, and also power consumption values were lowered by 3.11%, 6.46% and 11.5% for MQL, CO2 and LN2 conditions, respectively.
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    Tool wear patterns and their promoting mechanisms in hybrid cooling assisted machining of titanium Ti-3Al-2.5V/grade 9 alloy
    (Elsevier Sci Ltd, 2022) Gupta, Munish Kumar; Nieslony, P.; Sarikaya, Murat; Korkmaz, Mehmet Erdi; Kuntog, Mustafa; Krolczyk, G. M.; Jamil, Muhammad
    Hybrid lubri-cooling is a latest technology that provides synergistic cooling and lubrication effect in the machining area especially in the cutting of titanium and its alloys. In this current study, cryogenic-LN2, minimum quantity lubrication (MQL), and hybrid cryogenic LN2-MQL are applied and compared against dry medium in perspective of in-depth analysis of tool flank wear, EDS mapping, and intensity of tool wear. Experimental results showed that in comparison with dry, hybrid LN2-MQL substantially reduced the tool flank and rake wear fol-lowed by LN2, MQL, and dry conditions, respectively. Additionally, the SEM and EDS analysis depicted relatively less severe wear and chemical elements adhesion on the tool's main cutting edge, while turning titanium alloy under a hybrid LN2-MQL lubri-cooling environment. In addition, the dry condition has maximum value of tool wear progressions i.e., 1.04 mm and hybrid LN2-MQL have 0.06 mm while machining titanium alloys. When tool wear is evaluated from a tribological point of view, the reduction in flank wear value compared to dry machining is 89.4 %, 92.3 % and 94.2 % owing to MQL, LN2, MQL and hybrid LN2-MQL cutting strategies. In terms of crater wear, the improvement was 87.7 %, 90.4 % and 90.8 % thanks to MQL, LN2, MQL and hybrid LN2-MQL.