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This study aims to experimentally investigate the influence of considered process parameters, i.e. pulse on time, pulse off time, peak current and gap voltage, on tool wear rate (TWR) in electrical discharge machining (EDM) of iron (Fe)-based shape memory alloy (SMA) through designed experiments. The parametric optimization for TWR has also been attempted using the desirability approach and genetic algorithm (GA).

The response surface methodology (RSM) in the form of Box–Behnken design has been used to scheme out the experiments. The influence of considered process inputs has also been observed through variance analysis. The reliability and fitness of the developed mathematical model have been established with test results. Microstructure analysis of machined samples has also been evaluated and analyzed using a scanning electron microscope (SEM). SEM images revealed the surface characteristics such as micro-cracks, craters and voids on the tool electrode surface. SEM images provide information about the surface integrity and type of wear on the surface of the tool electrode.

The input parameters, namely, pulse on time and pulse off time, are major influential factors impacting the TWR. High TWR has been reported at large pulse on time and small pulse off time conditions whereas higher TWR is reported at high peak current input settings. The maximum and minimum TWR values obtained are 0.073 g/min and 0.017 g/min, respectively. The optimization with desirability approach and GA reveals the best parametric values for TWR i.e. 0.01581 g/min and 0.00875 g/min at parametric combination as pulse on time = 60.83 µs, pulse off time = 112.16 µs, peak current = 18.64 A and gap voltage = 59.55 V, and pulse on time = 60 µs, pulse off time = 120 µs, peak current = 12 A and gap voltage = 40 V, correspondingly.

Proposed work has no limitations.

SMAs have been well known for their superior and excellent properties, which make them an eligible candidate of paramount importance in real-life industrial applications such as orthopedic implants, actuators, micro tools, stents, coupling, sealing elements, aerospace components, defense instruments, manufacturing elements and bio-medical appliances. However, its effective and productive processing is still a challenge. Tool wear study while processing of SMAs in EDM process is an area which has been less investigated and of major concern for exploring the various properties of the tool and wear in it. Also, the developed mathematical model for TWR through the RSM approach will be helpful in industrial revelation.

This study aims to analyse the changes in mechanical and wear performance of aluminium alloy when yttrium oxide particles are incorporated. The microstructures are studied to analyse the change in the grain structures. Worn surfaces are observed via scanning electron microscope to study the wear mechanism in detail.

Stir casting is used to incorporate varying composition of yttrium particles, having an average particle size of 25 micrometer, in aluminium alloy 6063 matrix. Wear testing is carried out by DUCOM manufactured high temperature rotatory tribometer, and an indentation test is used for analysing the microhardness of the fabricated samples.

Microhardness of the material is increased with the increasing content of particulate addition. With the increasing content of reinforcement, more refined grains are produced. The load is transferred from the matrix to more rigid yttrium oxide particles. These factors contributed to escalated microhardness of the reinforced samples. Particulate addition enhanced the wear performance of the material; this might be attributed to increased microhardness and formation of an oxide layer.

Aluminium composites are finding wide applications in various industries, and there is always a requirement of material with enhanced tribological properties. Yttrium oxide particles exhibit improved mechanical properties, and their interaction with the aluminium matrix has not been studied much in the past. So, in this work, yttrium oxide incorporated aluminium matrix is studied.

The purpose of this paper is to investigate experimentally the effect of several input process factors, namely, feed rate, spindle speed, ultrasonic power and coolant pressure, on hole quality measures (penetration rate [PR] and chipping diameter [CD]) in rotary mode ultrasonic drilling of macor bioceramic material.

The main experiments were planned using the response surface methodology (RSM). Scanning electron microscopy was also used to examine and study the microstructure of machined samples. This study revealed the existence of dominant brittle fracture and little plastic flow that resulted in a material loss from the base work surface. Experiment findings have shown the dependability and adequacy of the proposed mathematical model.

The percentage of brittle mode deformation rises as the penetration depth of abrasives increases (at increasing levels of feed rate). This was due to the fact that at greater depths of indentation, material loss begins in the form of bigger chunks and develops inter-granular fractures. These stated causes have provided an additional advantage to increasing the CD over the machined rod of bioceramic. The desirability method was also used to optimize multi-response measured responses (PR and CD). The mathematical model created using the RSM method will be very useful in industrial revelation. Furthermore, the investigated answers’ particle swarm optimization (PSO) and teacher-learner-based optimization (TLBO) make the parametric analysis more relevant and productive for real-life industrial practices.

Macor bioceramic has been widely recognized as one of the most highly demanded innovative dental ceramics, receiving expanded industry approval because of its outstanding and superior characteristics. However, effective and efficient processing remains a problem. Among the available contemporary machining methods introduced for processing typical and advanced materials, rotary mode ultrasonic machining has been identified as one of the best suitable candidates for precise processing of macor bioceramics, as this process produces thermal damage-free profiles, as well as high accuracy and an increased material removal rate. The optimized combined setting obtained using PSO is feed rate = 0.16 mm/s, spindle speed = 4,500 rpm, ultrasonic power = 60% and coolant pressure = 280 kPa with the value of fitness function is 0.0508. The optimized combined setting obtained using TLBO is feed rate = 0.06 mm/s, spindle speed = 2,500 rpm, ultrasonic power = 60% and coolant pressure = 280 kPa with the value of fitness function is 0.1703.

Stainless steel is widely used in different manufacturing sectors. The purpose of this study is to optimize the process parameters of machining while processing SS316L alloy. The optimization of machining characteristics in the case of SS316L alloy greatly improves the quality and productivity economically.

The machining variables in current research are depth of cut, spindle speed and feed rate. The optimization of response characteristics was carried out using the intelligent approach of grey, regression and teaching learning-based optimization (TLBO) and Taguchi-Grey approach. Planning of experiments was made using Taguchi’s based L27 orthogonal array. With the implementation of grey, the response characteristics were normalized and converted into a single response. The regression analysis was used for empirical modeling of the single response induced from the grey application. TLBO is further used to investigate the combinations of machining variables and compared with grey theory.

The grey-TLBO based multi-criteria decision-making approach suggests that the optimized setting for material removal rate, mean roughness depth (Rz) and cutting force (Fz) is spindle speed (N): 720 rpm; feed rate (F): 0.3 mm/rev; depth of cut (DoC): 1.7 mm. The grey theory suggests an optimized setting as N: 720 rpm; F: 0.2 mm/rev and DoC: 1.7 mm.

The parametric optimization during the turning of SS316L using grey-TLBO based intelligent approach is not performed till now. Thus, this intelligent approach will give a path to the researchers working in this direction. However, the grey theory performs better as compared to the grey-TLBO approach.

This paper aims to investigate the flexural properties i.e. the flexural strength and the flexural modulus under the influence of selected input variables, namely; fiber type, fiber loading and fiber size in fabricated natural fiber polymeric composites through using Taguchi’s design of experiment methodology.

The Taguchi’s design of experiment approach has been used to scheme a suitable combination to fabricate the polymeric composites. Pure polypropylene (PP) has been chosen as a matrix material, whereas two types of fibers, namely; wood powder (WP) i.e. sawdust and rice husk powder (RHP), have been used as a reinforcement in the matrix. Microstructure analysis of fabricated and tested samples has also been evaluated and analyzed using a scanning electron microscope. This analysis has divulged that at moderate fiber size and higher fiber loading, no gap or cavities presented between the fillers and matrix particles, which illustrates the good interfacial bonding between the materials.

The flexural strength of the wood powder pure polypropylene (WPPP) composite decreases if the fiber content gets increased beyond 20 Wt.%. In addition, the flexural strength of hybrid composite (WPRHPPP) has been revealed to get improved more in comparison to composites with single fiber as reinforcement. Furthermore, the flexural modulus of WPPP composite has also increased with the increase in fiber loading. It has been concluded that reinforcement size plays an imperative role in influencing the flexural modulus. The optimum parametric setting for the flexural strength and the flexural modulus has been devised as; fiber type – WPRHP, fiber loading – 10 Wt.% and fiber size – 600 µm; and fiber type – WP, fiber loading – 30 Wt.% and fiber size – 1,180 µm, respectively. The microstructure images clearly revealed that during conducted flexural tests, some particles get disturbed from their bonded position that mainly represents the plastic deformation.

The fabricated polymer materials proposed in the research work are green and environmentally friendly.

The natural fiber-based composites are possessing wide-spread requirements in today’s competitive structure of manufacturing and industrial applications. The fabrication of the natural fiber-based composites has also been planned through the designed experiments (namely; Taguchi Methodology- L₉ orthogonal array matrix), which, further, makes the analysis more fruitful and qualitative too. The fabricated polymer materials proposed in the research work are green and environmentally friendly. Shisham WP has been rarely used in the past researches; therefore, this factor has been included for the present work. The injection molding process is used to fabricate the three different polymer composite by varying the fiber weight percentage and fiber size.

This article targeted to experimentally examine the impact of several considered process parameters namely, applied voltage (AV), tool feed rate, electrolyte concentration and pulse frequency (PF), on the material removal rate (MRR) and radial overcut (ROC) while performing shaped tube drilling of aviation grade Inconel 625 super alloy through electrochemical machining principle. Further, an attempt has also been made to develop mathematical models for the process responses along with advanced optimization with evolutionary methods.

The central composite rotatable design matrix was used to scheme out the experiments in the present study. The consistency and accuracy of the developed mathematical models were confirmed through statistical results. Additionally, a field emission scanning electron microscope analysis was conducted to assess and analyze the microstructure of the machined work samples. The study also seeks to optimize the selected process inputs for MRR and ROC through the implementation of the desirability method, particle swarm optimization (PSO) and Teaching Learning-Based Optimization (TLBO).

The ROC is significantly influenced by the input parameters, specifically the PF and AV. Less ROC values were observed when the high PF with moderate AV. The minimum and maximum values of ROC and MRR were obtained as; 135.128 µm and 380.720 µm; 1.37 mg/min and 2.3707 mg/min, correspondingly. The best optimized confirmatory results were obtained through the TLBO approach, with an MRR value of 3.1587 mg/min and a ROC of 71.9629 µm, in comparison to the PSO and desirability approaches.

The various challenges associated with the productive machining of aviation grade Inconel 625 superalloy have been explored experimentally. The conducted experimentation has been performed on the in-house fabricated micro-electrochemical setup capable of performing a variety of advanced machining operations at the miniaturized level. Further, the application of shaped tube drilling while processing aviation grade Inconel 625 superalloy has been explored with the developed micro-ECM set-up. Moreover, the performed microstructure analysis of the machined work samples has elaborated and explored the various associated surface integrity aspects which are quite crucial when it comes to real-life aerospace-related applications. The utility of designed experiments has further made the attempted experimental analysis more fruitful and qualitative too.

PolyJet technology allows printing complex multi-material composite configurations using Voxel digital designs' capability, thus allowing rapid prototyping of 3D printed structural parts. This paper aims to investigate the processing and mechanical characteristics of composite material configurations formed from soft and hard materials with different distributions and sizes via voxel digital print design.

Voxels are extruded representations of pixels and represent different material information similar to each pixel representing colors in digital images. Each geometric region of a digitally designed part represented by a voxel can be printed with a different material. Multi-material composite part configurations were formed and rapidly prototyped using a PolyJet printer Stratasys J750. A design of experiments composite part configuration of a soft material (Tango Plus) within a hard material matrix (Vero Black) was studied. Composite structures with different hard and soft material distributions, but at the same volume fractions of hard and soft materials, were rapidly prototyped via PolyJet printing through developed Voxel digital printing designs. The tensile behavior of these formed composite material configurations was studied.

Processing and mechanical behavior characteristics depend on materials in different regions and their distributions. Tensile characterization obtained the fracture energy, tensile strength, modulus and failure strength of different hard-soft composite systems. Mechanical properties and behavior of all different composite material systems are compared.

Tensile characteristics correlate to digital voxel designs that play a critical role in additive manufacturing, in addition to the formed material composition and distributions.

Results clearly indicate that multi-material composite systems with various tensile mechanical properties could be created using voxel printing by engineering the design of material distributions, and sizes. The important parameters such as inclusion size and distribution can easily be controlled within all slices via voxel digital designs in PolyJet printing. Therefore, engineers and designers can manipulate entire morphology and material at each voxel level, and different prototype morphologies can be created with the same voxel digital design. In addition, difficulties from AM process with voxel printing for such material designs is addressed, and effective digital solutions were used for successful prototypes. Some of these difficulties are extra support material or printing the part with different dimension than it designed to achieve the final part dimension fidelity. Present work addressed and resolved such issued and provided cyber based software solutions using CAD and voxel discretization. All these increase broad adaptability of PolyJet AM in industry for prototyping and end-use.

This study aims to generate different three-dimensional (3D) foam models using computer tomography (CT) scan and solid continuum techniques. The generated foam models were used to study deformation mechanism and the elastic-plastic behaviour with the existing experimental foam behaviour.

CT scan model was generated by combing 2D images of foam in MIMICS software. Afterwards, it was imported in ABAQUS/CAE software. However, solid continuum model was generated in ABAQUS/CAE software by using crushable foam properties. Then, the generated foam models were sets boundary conditions for a compression test.

CT scans capture the actual morphology of foam sample which may directly an image based finite element foam model. The sectional views of both the models were used to observe deformation mechanism on compression. The real compressive behaviour of foam was visualised in CT-Scan foam model. It was observed that CT-scan model was the more accurate modelling method than crushable foam model.

The internal structure of foam is very complex and difficult to analyse. Therefore, CT-scanning may be the accurate method for capturing the macro-level detailing of foam structure. A CT-scan foam model can be used for multiple times for mechanical analysis using a simulation software, which may reduce the manufacturing and the experimental cost and time.