Northeast University At Qinhuangdao Campus - china high performance carbide end mills

 2024-06-24 10:26:48

Legacy Precision Molds takes us on a tour of their moldbuilding facility. They've recently implemented two automated 5-axis cells for metal and graphite machining that run lights out during nights and weekends.

CD: Conceptualization, Data curation, Formal Analysis, Investigation, Methodology, Validation, Visualization, Writing–original draft. SM: Conceptualization, Methodology, Supervision, Writing–review and editing. RC: Conceptualization, Funding acquisition, Methodology, Resources, Software, Writing–review and editing. ME: Conceptualization, Funding acquisition, Methodology, Resources, Software, Writing–review and editing.

Kalita, K., Pal, S., Haldar, S., and Chakraborty, S. (2022). A hybrid TOPSIS-PR-GWO approach for multi-objective process parameter optimization. Process Integr. Optim. Sustain 6 (4), 1011–1026. doi:10.1007/s41660-022-00256-0

The tungsten carbide inserts underwent cryogenic treatment in a specially designed cryogenic chamber (KRYO 550-16), capable of cooling samples down to deep cryogenic temperatures (-196 °C). The chamber’s temperature was gradually reduced from room temperature (RT) to the cryogenic temperature (CT, approximately -196 °C) at a rate of 2 °C/min as shown in Figure 1B. After being maintained at this temperature (-196 °C) for 24 and 36 h, the temperature was gradually raised back to room temperature (Devi and Mahalingam, 2023). Additionally, the current experiment was conducted to thoroughly examine the performance of cryo-treated cutting tools on Custom 450 stainless steel. The objective was to determine the optimal parameters at various spindle speeds (1,500 rpm, 2,300 rpm, 3,100 rpm), feed rates (0.1, 0.15, 0.2 mm/min), and a constant depth of cut (0.5 mm).

In this formula, Rij represents the i th run j th response value, Rbj is the best j th response value, and Edi is the Euclidean distance. The process involves calculating the Euclidean distance for each run and then computing the IGD as the sum of each Euclidean distance squared, divided by the number of runs (27 in this case).

Figure 3 shows that cryo-treated inserts exhibit better surface roughness than untreated inserts. Surface roughness decreases with increased spindle speed and increases with feed rate from 0.1 to 0.15 mm/min and further with 0.2 mm/min.

Chiron Group combines the best of both worlds at IMTS 2024, featuring live demonstrations of their Micro5 and Mill 2000 machines, alongside a cutting-edge virtual showroom. This innovative approach allows visitors to explore Chiron’s full product lineup without the logistical challenges of transporting large equipment.

Mitsui Seiki USA Inc. appoints Joseph Farkas as its director of sales West and Terry Ritterbush as its director of sales East.

Vickram, A. S., Srikumar, P. S., Srinivasan, S., Jeyanthi, P., Anbarasu, K., Thanigaivel, S., et al. (2021). Seminal exosomes–an important biological marker for various disorders and syndrome in human reproduction. Saudi J. Biol. Sci. 28 (6), 3607–3615. doi:10.1016/j.sjbs.2021.03.038

The choice between buying a new machine or refurbishing the current one will become clear after a thorough assessment of the machine.

Disclaimer: All claims expressed in this article are solely those of the authors and do not necessarily represent those of their affiliated organizations, or those of the publisher, the editors and the reviewers. Any product that may be evaluated in this article or claim that may be made by its manufacturer is not guaranteed or endorsed by the publisher.

Shanmugasundar, G., Pal, S., Chohan, J. S., and Kalita, K. (2023a). “Pareto optimization of laminated composite plates with non-dominated sorting whale optimization algorithm (NSWOA) ensemble,” in International conference on intelligent computing & optimization (Cham: Springer Nature Switzerland), 350–357.

Cryogenic treatment of metal leads to the transformation of the austenite phase into the martensite phase, characterized by a well-structured grain structure and a body-centred tetragonal crystal structure (Sert and Celik, 2019). The superior, tougher structure of martensite provides high wear resistance. Cryo-treatment of cutting tools has been identified as an effective method for reducing cutting force, extending tool life, and improving wear resistance (Reddy et al., 2009; Ozbek et al., 2016). (Korade et al., 2017) observed that combining various types of cryogenic treatment with increasing tempering temperatures and levels led to decreased hardness and increased wear volume. Literature reviews indicate that cryogenically treated coated carbide inserts have enhanced machining capabilities and tool wear resistance (Kumar and Singh, 2015; Singla et al., 2018; Panchagnula et al., 2023a; Panchagnula et al., 2023b). High spindle speed operations benefit from increased tool life with cryo-treated tungsten carbide inserts. Tool life and surface finishing are significant factors in the machining process. Coatings and cryogenic treatment have been shown to improve surface polishing and increase wear resistance (Gill et al., 2012; Sahoo et al., 2020). (Jadhav et al., 2020) performed turning operations on P20 tool steel using cryo-treated cutting inserts, with experiments conducted using Taguchi’s L27 orthogonal array and results analysed using MATLAB surface plots and ANNs. Mukkoti et al. (Mukkoti et al., 2018) conducted end milling on P20 steel using cryo-treated tungsten carbide cutting inserts, with a focus on optimizing parameters affecting cutting forces and power consumption, using regression analysis to relate process factors to these outcomes.

From quadruped robot dogs, to an in-booth putting green where you can test out a new golf putter, to a 3D-printed car and more, attendees enjoyed cutting-edge technology and innovations all week long. Take a look to see what (or who!) you might have missed this week!

Spurred by often unpredictable tool life and lengthy production times, TNG turned to ceramic inserts from Greenleaf. In the ring groove application, the company decided to use the Ring Max API ring groove cutter with WG-300 whisker-reinforced ceramic inserts. Designed specifically for the oil and gas industry, Greenleaf’s Ring Max line of ring groove tooling is engineered to reduce the machining time of API ring grooves, while the basic concept of WG-300 involves reinforcing a hard ceramic matrix with extremely strong, stiff, silicon-carbide crystals, or “whiskers.” The whiskers are dispersed into a matrix of fine-grained aluminum oxide, where they act much like glass filaments do in fiberglass, for example, by adding tensile strength and improving the fracture toughness of the brittle matrix.

Kalita, K., Ghadai, R. K., Cepova, L., Shivakoti, I., and Bhoi, A. K. (2020). Memetic cuckoo-search-based optimization in machining galvanized iron. Mater. (Basel) 13 (14), 3047. doi:10.3390/ma13143047

SSP’s commitment to adopting the latest machining technology benefits not only the business, but its employees as well.

Understanding all the things that contribute to a machine’s full potential accuracy will inform what to prioritize when fine-tuning the machine.

• ALO showed higher efficiency in achieving closer-to-ideal values in end milling, with an overall performance index of 1.133. The optimal parameters included a spindle speed of 2436.3 rpm, feed rate of 0.1 mm/min, and a cryogenic treatment soaking period of approximately 15.76 h.

Misapplication of these important CNC features will result in wasted time, wasted or duplicated effort and/or wasted material.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

When Puneet and Neelam Neotia moved from India to the United States several years ago, they brought with them a family background in manufacturing and CNC machining. Now the couple is working to get their startup machine shop off the ground, sourcing new customers and getting the word out about their shop in Clarksville, Indiana. The couple — proud to publicize their "Made in the USA" parts — is leveraging family connections and manufacturing capabilities back in India, but not in the way that some people assume.

The mathematical model for temperature (Eq. (13)) includes spindle speed, feed rate, and cryogenic treatment as independent variables:

Mr. Hylton says he’s noticed the Xsytin-1 grade shows significantly less damage when the groove is complete, so he plans to transition the Ring Max application to the new insert grade once he runs through his batch of WG-300.

Panchagnula, K. K., Sharma, J. P., Kalita, K., and Chakraborty, S. (2023a). CoCoSo method-based optimization of cryogenic drilling on multi-walled carbon nanotubes reinforced composites. Int. J. Interact. Des. Manuf. 17 (1), 279–297. doi:10.1007/s12008-022-00894-1

Manjunath, S., and kumar, A. (2017). Analysis the effectiveness of cryogenic treatment through roughness and temperature prediction using Bonn technique. J. Mech. Eng. 14 (2), 16–35.

The Friedman statistic Ff is then calculated under the null hypothesis that all algorithms perform similarly, and their ranks Rj should be equal. (36).

Now, Mr. Hylton says the problem is the base material. “Before, I couldn’t wait to get there,” he says. “Now, when I hit the stainless, the chips come off in long strings. The inserts get a little beat up on the sides from the chips because face grooving is a nasty operation.”

The Automated Shop Conference (TASC) will give shops of all sizes and production volumes key insights and practical guidance on how to implement automation.

Shanmugasundar, G., Pal, S., Chohan, J. S., and Kalita, K. (2023b). “Ensemble approach for optimizing variable rigidity joints in robotic manipulators using MOALO-MODA,” in International conference on intelligent computing & optimization (Cham: Springer Nature Switzerland), 216–224.

Derrac, J., García, S., Molina, D., and Herrera, F. (2011). A practical tutorial on the use of non parametric statistical tests as a methodology for comparing evolutionary and swarm intelligence algorithms. Swarm Evol. Comput. 1 (1), 3–18. doi:10.1016/j.swevo.2011.02.002

AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.

Manufacturers continue to feel the pressure to reduce costs, increase efficiencies and meet their sustainability strategies. As the industry evolves to keep pace with these priorities, there are opportunities within metalworking processes to use less resources with advanced lubricants and technical expertise. Agenda: An overview of metalworking lubrication Evolutions in metalworking lubrication Experience on the shop floor Key takeaways

CNC milling processes are widely used than the conventional machining in the manufacturing sector due to the accuracy. They are frequently employed to create complex shapes like pockets and slots. In industrial settings, hard materials are often milled using tungsten carbide end mill cutting tools, which are characterized by their higher hardness and wear resistance. This high hardness enables the processing of materials with high strength-to-weight ratios. During machining, cutting tools are subjected to high heat and variable loads. The cutting tools used for machining should not deform or wear excessively due to these conditions. Excessive softening of the cutting tool material, caused by high heat production during machining, leads to increased tool wear and cutting forces. This is problematic as tool failure is a common constraint, driving up component costs due to the need for tool replacement. Numerous efforts have been made in the past to enhance tool life and reduce surface roughness. However, optimizing cutting forces and cutting temperature with cryogenically treated tools in end milling of Custom450 stainless steel has not received significant attention in the literature to date.

Before switching to ceramics, TNG used carbide inserts to produce two API ring grooves on 31/8-inch-diameter valve bodies with a 1963 manual-engine lathe, a process that took between 10 and 15 minutes each to complete. The real challenge, though, was in reconditioning these valve bodies, because it often required cutting through difficult-to-machine materials such as Inconel. For instance, after opening the grooves in the cast steel base material 3/16-inch larger than the API specifications, the valve went to the welding department for Inconel cladding. From there, the process involved opening a straight face groove with a face grooving tool followed by an API ring groove tool. This was only possible by moving into the cut 0.100-inch axially, then moving in a positive and negative radial direction to the groove’s full width. After that, the machinist would move the tool in another 0.050 inch and blend from side to side to match the width of the previous radial cut. These tiny increments were repeated until the full depth of cut was reached. An experienced, efficient machinist like TNG’s lead machinist, Cimaron Hylton, could produce one groove in about 45 minutes, though many days it took closer to an hour.

ANCA CNC Machines is celebrating its 50th anniversary as a global producer of CNC tool and cutter grinders.

This presentation focuses on the vital role that linear and angular encoders play in ensuring precision in machine tools. Attendees will learn about the common challenges compromising accuracy, such as thermal expansion, mechanical misalignments and vibration. Whether you're an OEM, integrator, or machine operator, this webinar will offer valuable insights into optimizing CNC performance. Agenda: Challenges to CNC machine accuracy Understanding encoder technology How encoders address accuracy challenges

Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

All claims expressed in this article are solely those of the authors and do not necessarily represent those of their affiliated organizations, or those of the publisher, the editors and the reviewers. Any product that may be evaluated in this article, or claim that may be made by its manufacturer, is not guaranteed or endorsed by the publisher.

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The graphical representations of the association between response and cutting variables occur under specific cutting settings that were indicated in the experimental design table. Therefore, it is essential to comprehend how cutting conditions affect cutting variables in order to better clarify these interactions. Figure 6 displayed the combined effect of feed rate and cutting speed on CF fluctuations on three-dimensional graphs. The cutting force reduced as the feed rate and cutting speed increased. The cutting force reduced as the SS increased in the surface plot of CT and SS. Pareto chart (Figure 7) indicates the least significant impact of feed rate repetition on force in the X-direction. The primary effect plot shows reduced cutting force with increased spindle speed. The statistical analysis confirms the significant impact of milling parameters on CF during titanium alloy milling. The response surface plots demonstrate these effects, highlighting improved thermal conductivity due to cryogenic treatment, influencing the heat transfer from the tool’s tip and affecting cutting forces.

Lee Wimmer invited us to tour his second-generation family-owned machine shop in Perkasie, PA. This video explores the production processes behind precision-machined parts for both Wimmer Custom Cycle and LS Wimmer Machine Co., and shows how ingenuity and determination are still at the heart of American manufacturing. Today, both companies are now managed by Wimmer’s three sons.

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

While the ceramic inserts could potentially be used for more than one groove, he says that he changes them after each groove to be on the safe side. But even at one groove per insert, he says he’s impressed with the predictability and longevity of the ceramic inserts. In fact, he’s quit trying to push tool life in the face grooving operation because the ceramic inserts are comparable in price to the carbide inserts when time savings are factored in.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Jadhav, P., Kumar, S., and Bongale, A. (2020). Optimization of cutting forces by cryogenic treatment on tungsten carbide inserts during dry turning of the P 20 tool steel. Mater Today Proc. 28, 2485–2493. doi:10.1016/j.matpr.2020.04.798

The design factors that most affect the three quality attributes—manufacturing cost, tool life, and workpiece quality—are found using ANOVA. A high F-value indicates a high efficiency level for the parameter. Another important factor is the p-value, which allows statistical analysis to be completed within a 95% confidence interval. Consequently, the parameter affects the response if the computed value is less than 5%. According to Table 3. Cutting force, surface roughness, and temperature all had p values less than 0.05, indicating significant effects from each parameter on the output responses. Similarly, input parameters have a considerable impact on the output responses (square of FR, CT excluded), but no significant influence is seen on cutting force from square of FR, CT and no significant impact is seen on surface roughness from any of the interactions.

• Comparisons of CF, TT, and SR across various algorithms showed that ALO achieved the most optimal parameter settings.

Effective team collaboration is a critical component of success in today’s manufacturing world. With cloud-based technologies that make it easy for team members to brainstorm and problem solve remotely from various locations, design-to-manufacturing processes can become faster and more efficient. This webinar will demonstrate how fully integrated CAM software can be utilized with 3DExperience SolidWorks in a seamless work environment to accelerate product development. Agenda: See how HCL CAMWorks can be used as an add-in for all SolidWorks applications working with the cloud-based 3DExperience platform Learn how fully integrated CAD/CAM saves significant amounts of time during the design to manufacturing process Gain a new understanding of how software can connect users worldwide to accelerate product development Watch a demonstration of team collaboration using platform tools in the CAD/CAM software environment

According to Table 6, the IGD value for ALO is lower than for the other algorithms, indicating superior performance. The convergence graphs for Cutting Force (CF), Surface Roughness (SR), and Temperature (TT) in Figure 12 further demonstrate the effectiveness of the ALO algorithm compared to GHO, GWO, and HSA. Therefore, it is concluded that ALO outperforms GHO, GWO, and HSA.

Mirjalili, S. (2015). The ant lion optimizer. Adv. Eng. Softw. 83, 80–98. doi:10.1016/j.advengsoft.2015.01.010

Copyright © 2024 Devi, Mahalingam, Cep and Elangovan. This is an open-access article distributed under the terms of the Creative Commons Attribution License (CC BY). The use, distribution or reproduction in other forums is permitted, provided the original author(s) and the copyright owner(s) are credited and that the original publication in this journal is cited, in accordance with accepted academic practice. No use, distribution or reproduction is permitted which does not comply with these terms.

The MLRS Linear, Interaction, and Quadratic performance of CF, TT, and SR are shown in Figure 5. The CF and TT quadratic equations respond more favorably than the linear interaction. Compared to the linear interaction, Figure 5 illustrates how well the performs on the SR quadratic equation.

Looking to automate your shop floor? The Automated Shop Conference (TASC) will connect shops with experts who can advise them through this transition.

The IGD metric is utilized to compare the effectiveness of Grasshopper Optimization (GHO), Grey Wolf Optimization (GWO), Harmony Search Algorithm (HSA), and Ant Lion Optimization (ALO) Algorithms. This measure indicates the computational complexity of the algorithms, as detailed in Khalilpourazari et al. (Khalilpourazari et al., 2020). The IGD is calculated using the Euclidean distance formula:

Yang, X. S. (2009). “Harmony search as a metaheuristic algorithm,” in Music-inspired harmony search algorithm: theory and applications (Berlin, Germany: Springer), 1–14. doi:10.1007/978-3-642-00185-7_1

cnSEE from All World Machinery Supply combines easy installation and monitoring across multiple machines.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

Although WG-300 is designed for excellent shock and wear resistance at high surface speeds for nickel- and cobalt-based superalloys, the grade is a good match for TNG’s application, which runs the materials at a relatively modest horsepower rating (20 hp) on its Hwacheon Vesta 1050B CNC mill.

Effect of process parameters on temperature is shown in Figure 11. Cutting temperature not decreases much. The Pareto diagram (Figure 12) suggests a uniform impact of feed rate and spindle speed on temperature. Residual analysis confirms a consistent pattern across milling operations without specific residue patterns, indicating the reliability of the experimental setup. The results validate the model’s suitability for analyzing cryo-treated cutting tool residues across various milling performance variables. The residual plots demonstrate the significant impact of input parameters on TT during machining.

Ant line Optimization (ALO) (Mirjalili, 2015), is another popular metaheuristic which models the hunting behavior of ant lions using traps. The algorithm represents an ant’s walk as stochastic. The ALO algorithm is shown in Algorithm 4.

Did you know that the show was postponed for WWII? Or that McCormick Place was expanded in the ’70s just to accommodate IMTS? A fascinating look at the show’s history from 1927 to today.

The ceramic inserts really show their colors during the reconditioning applications, Mr. Hylton says. After the Inconel cladding is applied, he mills down the weld that’s bulging above the flange and follows up with the Ring Max tool, cutting the ring groove in just 28 seconds. Because ring groove machining is a continuous cut, through-spindle coolant is used. The coolant is used not to cool the insert, but to cause the chips to become more brittle and break into smaller pieces, sometimes becoming almost powder-like.

According to Mr. Hylton, taking such small depths of cut was necessary to reduce vibration and chatter, yet it didn’t fully eliminate it. Several times during the grooving process, machinists had to check the pitch diameter to ensure accuracy. They also had to hand-polish the angled groove walls.

2. Sorting the values for each problem starting with 1 (best outcome) to a, with the ranks denoted as rij.

Grey Wolf Optimization (GWO) excels in unfamiliar, challenging search areas and demonstrates strong convergence and local optima avoidance (Mirjalili et al., 2014). It simulates the Grey wolf pack’s predation process, which involves encircling, hunting, and attacking. GWO reflects the strict social hierarchy of grey wolves with alphas leading the pack, followed by betas, deltas, and omegas. In GWO, agents a,b, and d determine the best hunting strategy, while other wolves adjust their positions around the prey. The GWO algorithm is shown in Algorithm 2.

Korkmaz, M. E., Gupta, M. K., Kuntoğlu, M., Patange, A. D., Ross, N. S., Yılmaz, H., et al. (2023a). Prediction and classification of tool wear and its state in sustainable machining of Bohler steel with different machine learning models. Measurement 223, 113825. doi:10.1016/j.measurement.2023.113825

Across a range of technical presentations aimed at small and mid-sized job shops, the first-ever Automated Shop Conference (TASC) offered insights into several automated technologies, implementation strategies, shopfloor training tips, and even the untapped power of automated coolant delivery.

Shanmugasundar, G., Karthikeyan, B., Ponvell, P. S., and Vignesh, V. (2019a). Optimization of process parameters in TIG welded joints of AISI 304L-austenitic stainless steel using Taguchi’s experimental design method. Mater Today Proc. 16, 1188–1195. doi:10.1016/j.matpr.2019.05.213

The current research examines the effectiveness of cryogenically treated (CT) tungsten carbide cutting inserts on Custom450 stainless steel using multi-objective soft computing approaches. The Taguchi-based L27 orthogonal array was employed in the experiments. During milling operations, cutting force, surface roughness, and cutting temperature were measured at different spindle speeds (rpm), feed rates (mm/min), and constant depths of cut (mm). The surface roughness and chip morphology of the Custom 450 stainless steel machined by cryo-treated (CT) and untreated (UT) cutting tool inserts were compared across various responses to cutting temperature and force. This paper also carried out multi-objective optimization, employing algorithm techniques such as Grasshopper Optimization Algorithm (GHO), Grey Wolf Optimization(GWO), Harmony Search Algorithm(HAS), and Ant line Optimization (ALO). The Multi-objective Taguchi approach and TOPSIS were first used to optimize the machining process parameters (spindle speed, feed rate, and cryogenic treatment) with different performance characteristics. Second, to relate the machining process parameters with the performance characteristics (cutting force, cutting temperature, and surface roughness), a mathematical model was developed using response surface analysis. The created mathematical response model was validated using ANOVA. The results showed that in IGD values of GHO, GWO, HSA and ALO module had 2.5765, 2.4706, 2.3647 and 2.5882 respectively, ALO has the best performance indicator. A Friedman’s test was also conducted, revealing higher resolution with the ALO method than with the HSA, GWO, and GHO methods. The results of the scanning test show that the ALO approach is workable.

Thoughtful considerations will set you on a shortened path to the most optimized solution once cutter meets metal.

where Xi represents the i th solution’s position, Oi the interaction between the solution and other swarms, Bi the gravitational pull, and Ri the wind advection. The GHO algorithm is shown in Algorithm 1.

The Friedman test, a non-parametric alternative to the parametric two-way analysis of variance, is used to identify significant differences in the behavior of the algorithms. This test assumes the null hypothesis of equality of medians between the populations.

The Inconel cladding that bulges above the valve flange is later milled down and then cut with the Ring Max tool during reconditioning applications. The ring groove is cut in just 28 seconds.

Weldon Solutions is demonstrating three grinders at IMTS 2024. Though they differ in size and use case, all feature the company’s hallmark customizations.

The effectiveness of the system is evaluated using Design of Experiments (DOE), which considers several factors (Shanmugasundar et al., 2019a). DOE is an essential data collection and analysis methodology used across various experimental scenarios. It involves a planned experiment analyzing three aspects: factors, levels of these factors, and responses. The primary goal of DOE is to compare multiple solutions and identify the necessary factors to yield the best output response. It facilitates the examination of the impact of various input factors on a desired response. DOE is capable of identifying significant interactions that might be overlooked when examining a component at a time or dealing with multiple inputs simultaneously.

Though most frequently used for diameter measurements, an air plug and platen can be readily configured to measure perpendicularity.

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• TOPSIS, a multi-criteria decision analysis method, was used to evaluate the effectiveness of GHO, GWO, HSA, and ALO, with ALO demonstrating superior performance.

FIGURE 8. Surface plot for influence of parameters on surface roughness. (A) Surface plot of SR vs CT, FR. (B) Surface plot of SR vs CT, SS. (C) Surface plot of SR vs FR, SS.

The foundation of the experiment design is the Taguchi-based orthogonal array, which includes three parameters and corresponding levels. This array can be used to develop optimal parameters, minimize treatments, reduce material costs, and determine the contributing factor of each process parameter in machining. The L27 orthogonal array consists of 13 columns, which can be assigned to test factors and their interactions. For a 3-factor 3-level configuration, the total number of tests required is given by 33=27. Therefore, a total of 27 experiments are to be conducted in the L27 OA. Table 1 shows the experimental design.

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

Equations (11)–(13) depict mathematical models for cutting force, surface roughness, and temperature respectively. The developed mathematical models were verified using ANOVA shown in Table 3.

Walter USA has acquired PDQ Workholding, intending to strengthen its offering of workholding products and develop future cutting tool sales.

3. Calculating the ultimate rank Rj for each algorithm by averaging the ranks obtained across all problems.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Ceratizit USA announces it has appointed Carlos Garza as its business development leader for the oil and gas industry sector.

When revising part designs, investigate the 3D CAD, the 2D drawing and the part’s functional requirements to determine which details should be tightened up.

Shanmugasundar, G., Sivaramakrishnan, R., Meganathan, S., and Balasubramani, S. (2019b). Structural optimization of an five degrees of freedom (T-3R-T) robot manipultor using finite element analysis. Mater Today Proc. 16, 1325–1332. doi:10.1016/j.matpr.2019.05.231

Women in Manufacturing is excited to announce that the 2024 SUMMIT will be a hybrid event — both an in-person and virtual experience. Both program offerings will enable you to grow through education and connections that are insightful, meaningful and actionable. Join Women in Manufacturing Oct. 6-9, 2024, in Boston or digitally for an event filled with plant tours at leading manufacturing facilities, professional development sessions, roundtable discussions on important topics, and inspiring keynotes. All while engaging and interacting with peers through social and networking events! __PRESENT __PRESENT

Meraihi, Y., Gabis, A. B., Mirjalili, S., and Ramdane-Cherif, A. (2021). Grasshopper optimization algorithm: theory, variants, and applications. IEEE Access 9, 50001–50024. doi:10.1109/ACCESS.2021.3067597

For future research, exploring various levels of process factors is planned. Implementing and comparing other well-known metaheuristic approaches like Particle Swarm Optimization (PSO), Artificial Neural Networks (ANN), Genetic Algorithms (GA), Differential Evolution (DE), Jaya, Cuckoo, and Stochastic Fractal Search with ALO will be considered. This comparative study aims to identify the most effective metaheuristic approach for optimizing end milling processes, thereby achieving precise parameter settings.

Though most frequently used for diameter measurements, an air plug and platen can be readily configured to measure perpendicularity.

Consistency is key for beryllium manufacturing, so the data visibility granted by Harmoni has swiftly become a vital, profitable tool in the shop’s arsenal.

Incremental mode can be more advantageous when programming sculptured surfaces or for certain hole-machining canned cycle applications.

Reddy, T. V. S., Sornakumar, T., Reddy, M. V., Venkatram, R., and Senthilkumar, A. (2009). Turning studies of deep cryogenic treated P-40 tungsten carbide cutting tool inserts – TECHNICAL COMMUNICATION. Mach. Sci. Technol. 13 (2), 269–281. doi:10.1080/10910340902979754

Kuntoğlu, M., Aslan, A., Sağlam, H., Pimenov, D. Y., Giasin, K., and Mikolajczyk, T. (2020). Optimization and analysis of surface roughness, flank wear and 5 different sensorial data via tool condition monitoring system in turning of AISI 5140. Sensors (Basel) 20 (16), 4377. doi:10.3390/s20164377

Custom 450 is a martensitic stainless-steel grade that has good resistance to corrosion up to about 650 °C and may be heat-treated to significantly enhance its mechanical properties. There are few articles regarding Custom 450 stainless steel in the literature, despite the fact that there are various studies on the machinability of stainless steels. Furthermore, publications do not contain information on end milling on Custom 450 stainless steel. The extensive use of Custom 450 stainless steel makes this experiment essential. Despite the established use of cryo-treated cutting tools in drilling, turning, and milling operations, the full potential of milling processes on Custom450 stainless steel has not been completely explored. While cryo-treated cutting tools are well-recognized in various machining operations, the specific application of end milling on Custom 450 stainless steel remains under-investigated. Furthermore, in-depth studies focusing on the end milling of Custom 450 stainless steel are still lacking. Consequently, the objective of this study is to investigate how process parameters influence the performance of a cryo-treated cutting tool during the milling of Custom 450 stainless steel. This investigation employs soft computing techniques, including the GHO, GWO, HSA, and ALO algorithms. Additionally, the study evaluates the effectiveness of these algorithms using TOPSIS multi-criteria decision analysis methods.

• Scanning Electron Microscope (SEM) examination of surfaces milled with UT inserts at high speeds and feed rates revealed significant grooves and ridges.

Part of Major Tool’s 52,000 square-foot building expansion includes the installation of this new Waldrich Coburg Taurus 30 vertical machining center.

Stainless steels are widely used in springs, nuts, bolts, screws, and other fasteners, as well as in the health, maritime, defence, and nuclear power plants industries. This is because of their exceptional strength and robust resistance to oxidation and corrosion. Their superior mechanical characteristics, low heat conduction coefficient, and remarkable resistance to corrosion are the reasons behind this. Nevertheless, stainless steel alloys are usually used because of their many beneficial properties, such as their high flexibility, high tensile strength, high fracture toughness, and high work hardening rate. Aviation fittings, aerospace parts such as bushings, shafts, valves, and certain screws, fuel tanks, exhaust components, high-temperature engine parts, structural elements and cabin components, landing gears, and other items are among the many applications for custom 450 stainless steel. In the past work, using a cryo-treated cutting tool, custom 450 stainless steel is cut in different ways depending on temperature, and cutting force. Additionally, it aims to examine the workpiece’s surface morphology, chip anatomy, surface abrasion, and tool morphology. Now the work is extended, the objective of this study is to investigate how process parameters influence the performance of a cryo-treated cutting tool during the milling of Custom 450 stainless steel. This investigation employs soft computing techniques, including the GHO, GWO, HSA, and ALO algorithms. Additionally, the study evaluates the effectiveness of these algorithms using TOPSIS multi-criteria decision analysis methods.

Katoch, S., Sehgal, R., Singh, V., Gupta, M. K., Mia, M., and Pruncu, C. I. (2019). Improvement of tribological behavior of H-13 steel by optimizing the cryogenic-treatment process using evolutionary algorithms. Tribol. Int. 140, 105895. doi:10.1016/j.triboint.2019.105895

Structured light scanning is used to create a digital twin of a manufactured part, but we must understand the measurement reproducibility to best use the data.

Sahoo, M., Gangopadhyay, V. K., and Gangopadhyay, S. (2020). An insight into microstructure and machining performance of deep cryogenically treated cemented carbide inserts. J. Manuf. Process. 58, 819–831. doi:10.1016/j.jmapro.2020.09.001

• ALO outperformed GHO, GWO, and HSA, as evidenced by the lowest IGD value. The Friedman Test further highlighted significant differences in the performance of these algorithms.

Shanmugasundar, G., Sapkota, G., Čep, R., and Kalita, K. (2022b). Application of MEREC in multi-criteria selection of optimal spray-painting robot. Processes 10 (6), 1172. doi:10.3390/pr10061172

Horn USA’s new booth concept is designed to enable attendees to (literally) get a better feel for its various tooling offerings.

In mathematics, the Multiple Linear Regression Model (MLRM) can be used to compute the response value (the output) in relation to multiple parameters (the inputs). Using experimental data and MATLAB’s “regress” function, this study establishes three variations of the MLRM equations: interaction Equations 8, (9), and (10) respectively.

• Utilizing cryo-treated (CT) inserts resulted in a 13% reduction in surface roughness compared to untreated (UT) inserts, particularly at high cutting parameters.

With the carbide inserts, Mr. Hylton says he had to peck at 0.005-inch depth increments to keep any edge at all. In addition, the retract amount that was programmed into the peck cycle had to be larger than usual due to tremendous amounts of tool pressure. In this case, the actual surface of the cutting tool/workpiece interface was 0.010-inch farther out than the actual machine position. The need to have a 0.012-inch buffer between pecks increased the actual feed travel to 1.498 inches. This meant the machine had to feed a total of six times the actual depth of the groove. The slow nature of this process was exacerbated by the need to peck.

Table 4 presents the optimal process parameters and response values obtained from 22 runs with a population size of 100 and 100 iterations for all algorithms. Table 5 shows the statistical significance of these algorithms.

Niu, P., Niu, S., liu, N., and Chang, L. (2019). The defect of the grey wolf optimization algorithm and its verification method. Knowl. Based Syst. 171, 37–43. doi:10.1016/j.knosys.2019.01.018

Each valve body features two ring grooves. These features alone would’ve taken two hours to produce on the manual engine lathe during reconditioning applications.

Another problem was the machine’s low speed. It simply didn’t have the torque necessary to efficiently machine all layers of the material, and it would rumble and beat everything up, Mr. Hylton says. He often used three carbide insert tips during the process, requiring him to stop, pull the insert, change it and hit cycle start again. The entire grooving process took between 47 minutes to an hour to complete. To make matters worse, Mr. Hylton says that sometimes the insert would break randomly; there was no consistency at all.

Hwang, C. L., and Yoon, K. (1981). Multiple attribute decision making: methods and applications. New York: Springer-Verlag. doi:10.1007/978-3-642-48318-9

Palanivelu, J., Thanigaivel, S., Vickram, S., Dey, N., Mihaylova, D., and Desseva, I. (2022). Probiotics in functional foods: survival assessment and approaches for improved viability. Appl. Sci. 12 (1), 455. doi:10.3390/app12010455

The efficiency of ALO is compared with GHO, GWO, and HSA. ALO shows superior performance in end milling applications, achieving optimal parameter settings at a lower iteration, as illustrated in the convergence plot (Figure 13). The TOPSIS approach integrated the output responses from 22 runs into a single objective, confirming the normal distribution of output data from all algorithms. The p-value of > 0.05 further substantiates the reliability and consistency of the ALO results.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

Figure 4 demonstrates that cryo-treated cutting tools outperform untreated inserts in terms of cutting temperature.

AccuRounds has created synergy between culture and technology, driving a commitment to customer satisfaction and continuous improvement.

Shanmugasundar, G., Fegade, V., Mahdal, M., and Kalita, K. (2022a). Optimization of variable stiffness joint in robot manipulator using a novel NSWOA-Marcos approach. Processes 10 (6), 1074. doi:10.3390/pr10061074

Binali, R., Demirpolat, H., Kuntoğlu, M., and Salur, E. (2023). Different aspects of machinability in turning of AISI 304 stainless steel: a sustainable approach with MQL technology. Metals 13 (6), 1088. doi:10.3390/met13061088

Gill, S. S., Singh, J., Singh, R., and Singh, H. (2012). Effect of cryogenic treatment on AISI M2 high speed steel: metallurgical and Mechanical Characterization. J. Mater Eng. Perform. 21 (7), 1320–1326. doi:10.1007/s11665-011-0032-z

The surface plot of SR vs FR, SS in Figure 8 illustrates the effect of process parameters on surface roughness. Initially, the surface roughness was higher, but as the cutting speed increased, it decreased and then increased again. Surface roughness rises in dependence on the FR. According to the Pareto chart in Figure 9, spindle speed and feed rate significantly influence surface roughness. The production of built-up edges (BUE) at specific spindle speeds reduces Ra. The SEM image in Figure 10 shows imperfections and micro-voids on machined surfaces caused by carbide particles and BUE. Cryo-treated inserts perform better, reducing heat generation and improving surface finishing. (39).

Panchagnula, K. K., Jayaprakash, P., Čep, R., Vamsi, N., Kalita, K., and Chakraborty, S. (2023b). Regression model-based parametric analysis of drilling of multi-walled carbon nanotubes-added glass fiber composite laminates. Mater Res. Express. doi:10.1088/2053-1591/ad1129

Each tool setting technique has merit, and it depends on where you are as a shop and the type of work you do, as cost and efficiency all come into play.

When attempting to determine the best pairings between two sets of data, it can be helpful. By drawing an analogy with a topographic map, the color and patterns in Surface Charts show the places that fall within the same range of values. Three variables are often used to generate a 3D Surface Plot: X, Y, and Z. Surface plot for CF.

The test statistic value is calculated using the method described in (Derrac et al., 2011; Zhang et al., 2023). The Friedman statistic (Ff) is computed as:

Surface measurement is becoming increasingly important to ensure proper performance of a manufactured product. Advanced surface measurement tools are not only beneficial in the manufacturing industry but also have unconventional applications.

FABTECH 2024 will be held October 15-17, 2024, in Orlando, Florida, at the Orange County Convention Center. FABTECH provides a convenient ‘one-stop shop’ venue where you can meet with world-class suppliers, discover innovative solutions, and find the tools to improve productivity and increase profits. There is no better opportunity to network, share knowledge and explore the latest technology, all here in one place. Future U.S. Show Dates and Locations 2025 – September 8-11 at McCormick Place in Chicago, IL 2026 – October 21-23 at Las Vegas Convention Center in Las Vegas, NV 2027 – September 13-16 at McCormick Place in Chicago, IL

The study aimed to optimize milling parameters such as spindle speed and feed rate to minimize cutting force (CF) and surface roughness (SR) using Grasshopper Optimization (GHO), Grey Wolf Optimization (GWO), Harmony Search Algorithm (HSA), and Ant Lion Optimization (ALO) algorithms. Key findings, based on the Multi-Criteria Decision Making (MCDM) method, are summarized below:

TNG also uses ceramic inserts on its bread and butter work of cutting valve seats in 410 stainless with a Stellite overlay. According to Mr. Hylton, this application is tricky because the groove goes through the Stellite, then through the heat-affected zone and down to the base material—an application that requires cutting material ranging from 40 to 67 HRC.

Raj Deena, S., Kumar, G., Vickram, A. S., Rani Singhania, R., Dong, C. D., Rohini, K., et al. (2022). Efficiency of various biofilm carriers and microbial interactions with substrate in moving bed-biofilm reactor for environmental wastewater treatment. Bioresour. Technol. 359, 127421. doi:10.1016/j.biortech.2022.127421

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

The experiment involved end milling Custom 450 stainless steel in a dry, room-temperature environment using cutting inserts that were either untreated (UT), cryo-treated with 24 h of soaking (CT 24 h), or cryo-treated with 36 h of soaking (CT 36 h). This was conducted on a CNC vertical machining centre as shown in Figure 1A. The dimensions of 160 mm × 75 mm × 20 mm (4 numbers) were prepared. The chemical composition and mechanical properties of Custom 450 stainless steel were determined (31). The tool holder used was a standard indexable type (Diameter: 16 mm, Length: 150 mm), and the cutting tool insert was a TiAlN-coated tungsten carbide insert (APMT1135PDR YBG205). The primary cutting parameters employed in this study were spindle speed, feed rate, and depth of cut. (31).

Heidenhain and Acu-Rite Solutions are offering several hands-on experiences at their booth this year, as well as internal components that reduce energy use.

• The quadratic Multiple Linear Regression Model (MLRM) equation proved to be the most accurate for end milling, surpassing interaction and linear models.

This was especially true for TNG Energy Services Inc., a geothermal company that provides both equipment and services from its Bakersfield, California, headquarters. The company’s mostly JIT workload along with meeting strict quality control requirements led its employees to work large amounts of overtime. This was due, in large part, to the challenges of machining grooves in valve components for oilfield applications using conventional carbide inserts. By switching to ceramic inserts from Greenleaf Corp. (Saegertown, Pennsylvania), TNG was able to dramatically reduce cycle time for two valve applications, meeting deadlines without the additional overtime costs.

Kalita, K., Ghadai, R. K., and Chakraborty, S. (2023b). A comparative study on multi-objective pareto optimization of WEDM process using nature-inspired metaheuristic algorithms. Int. J. Interact. Des. Manuf. 17 (2), 499–516. doi:10.1007/s12008-022-01007-8

When it comes to utilizing the spindle’s power, there is a lot of headroom at the upper limits, provided it’s in short bursts. Be mindful of your time at these loads so you don’t stall out.

Khalilpourazari, S., Naderi, B., and Khalilpourazary, S. (2020). Multi-objective stochastic fractal search: a powerful algorithm for solving complex multi-objective optimization problems. Soft Comput. 24 (4), 3037–3066. doi:10.1007/s00500-019-04080-6

The remaining authors declare that the research was conducted in the absence of any commercial or financial relationships that could be construed as a potential conflict of interest.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

Kumar, S., and Singh, M. (2015). Cryogenic treatment as performance enhancing process for cutting tools-A review. Int. Res. J. Eng. Technol. (IRJET). 02 (9), 1902–1905.

Here, Fij represents the calculated values of the i th experiment for the j th response, c are the coefficients of variables, and X are the variables.

Zhang, P., Gao, Y., Liu, Z., Zhang, S., Wang, S., and Lin, Z. (2023). Effect of cutting parameters on the corrosion resistance of 7A04 aluminum alloy in high-speed cutting. Vacuum 212, 111968. doi:10.1016/j.vacuum.2023.111968

TNG Energy Services Inc. was experiencing inconsistent carbide insert life in valve grooving applications. Greenleaf's Ring Max and face grooving tooling helped to reduce production time and increase reliability.

This section provides an analysis and comparison of results from several optimization approaches, including Grasshopper Optimization (GHO), Grey Wolf Optimization (GWO), Harmony Search Algorithm (HSA), and Ant Lion Optimization (ALO). The metaheuristic efficiency is assessed with an inertia weight of 100, archive size of 100, and population size of 100.

Amrr, S. M., Sarkar, R., Banerjee, A., and Nabi, M. (2019). “Parameter optimization of spacecraft attitude controller using ant lion optimizer,” in Proceedings of the Parameter optimization of spacecraft attitude controller using ant lion optimizer, Aligarh, India, November 2019. doi:10.1109/UPCON47278.2019.8980008

Shunmugesh, K., and Panneerselvam, K. (2017). Optimization of machining process parameters in drilling of CFRP using multi-objective Taguchi technique, TOPSIS and RSA techniques. Polym. Polym. Compos 25 (3), 185–192. doi:10.1177/096739111702500301

Sert, A., and Celik, O. N. (2019). Characterization of the mechanism of cryogenic treatment on the microstructural changes in tungsten carbide cutting tools. Mater Char 150 (1-7), 1–7. doi:10.1016/j.matchar.2019.02.006

JD Machine, 2024’s Top Shops Honoree in Human Resources, embodies its “Education for Life” core value with a robust apprenticeship program and significant continuous improvement efforts.

Using Greenleaf’s Ring Max API ring groove cutter with WG-300 whisker-reinforced ceramic inserts helped TNG reduce the time it took to cut one ring groove from about 45 minutes to just 28 seconds.

Tool-holder-spindle-machine combinations each have a unique dynamic response in the same way that each person has a unique fingerprint, which can be revealed using modal testing.

The Diatool Top Speed Disc features a solid reamer body with multiple connections to produce tolerance stack up.

The latest episode “Made in the USA” podcast explores a company that uses collaborative robots, one of the key tools helping US machine shops and other manufacturers compete with lower cost countries by automating production.

Korade, D. N., Ramana, K. V., Jagtap, K. R., and Dhokey, N. B. (2017). Effect of deep cryogenic treatment on tribological behaviour of D2 tool steel-an experimental investigation. Mater Today Proc. 4 (8), 7665–7673. doi:10.1016/j.matpr.2017.07.100

FIGURE 6. Surface plot for influence of parameters on cutting force. (A) Surface plot of CF vs CT, SS. (B) Surface plot of CF vs CT, FR. (C) Surface plot of CF vs FR, SS.

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

TNG’s most common work is cutting valve seats in 410 stainless with a Stellite overlay. A face grooving tool with Greenleaf’s new Xsytin-1 ceramic inserts and a support blade help cut through all layers in this application.

Evolutionary algorithms have been utilized to optimize the various machining processes (Kalita et al., 2020; Kalita et al., 2022; Kalita et al., 2023a; Kalita et al., 2023b). Adhesive wear on the studied surface was characterized by deformation lips, surface cracks, and fractured ridges, with Particle Swarm Optimization showing promising results for increased efficiency (Katoch et al., 2019). (Manjunath and kumar, 2017) demonstrated that face milling with cryo-treated tools can reduce surface roughness. The work in this paper was theoretically validated by creating a prototype using the BONN technique and real-time experimental data. The optimization was conducted using a MATLAB Genetic algorithm solver. The analysis of the direct and indirect effects of process parameters on temperature rise assisted in selecting parameters to minimize temperature increase, indicating the stability of the end milling process. The study’s predictive models for temperature rise are expected to align within a 95% confidence interval of the experimental results (Kaushik et al., 2018). Drilling on polymer composite material varied three process constraints at four discrete levels: spindle speed, feed rate, and weight percentage of graphite. The Taguchi-Grey Theory-Based Harmony Search Algorithm (GR-HSA) was used for multi-objective optimization and predictive modelling. The results showed that the machining interface temperature increased with GR-HSA spindle speed (2,500 rpm), softening the polymeric material in the machining zone (Kumar et al., 2021). In multi-pass face milling processes, parameters were optimized using HSA and compared against HA and GA algorithms (Zarei et al., 2009). The application of ant lion optimization in spacecraft attitude controllers demonstrated the ability of the suggested control action to prevent unnecessary long manoeuvring paths, enhancing resistance to unwinding (Amrr et al., 2019). The forms of two ship propellers were optimized using ALO, presenting superior optimal designs in 3-bar truss design, cantilever beam design, and gear train design. The ideal forms for ship propellers illustrate the potential application of the proposed approach to solve real-world problems with unpredictable search areas (Gao and Zhao, 2019). An enhanced grey wolf optimization technique was compared against algorithms like ALO, PSO, BA, regular GWO, and others, showing superior performance in high-dimensional situations (Khalilpourazari and Khalilpourazary, 2018). (Khalilpourazari and Khalilpourazary, 2018) suggested the GWO for optimizing multi-pass milling process parameters, using the Taguchi technique to find optimal values for the algorithm’s essential parameters (Shunmugesh and Panneerselvam, 2017). The results showed that the GWO outperforms other solutions by reducing total production time and offering the most workable solution for different cutting strategies (Niu et al., 2019).

Harmony Search Algorithm (HSA) (Yang, 2009) operates with minimal mathematical constraints and does not require a predefined dataset for parameter selection. It draws an analogy to artists seeking harmonious music, with engineers seeking global solutions determined by an objective function. The process involves adjusting pitch and considering evolutionary algorithm modifications to achieve optimal conditions. The main principles of Harmony Search Process are: choose initial information from search memory (memory-related concerns), select the closest value from the harmony search memory (pitch modifications) and randomly select values from the range of potential values. The HSA algorithm is shown in Algorithm 3.

In the latest episode of our View From My Shop series, MMS Editor-in-Chief Brent Donaldson visited the JN Shapiro Watches headquarters and production facility where Founder Joshua Shapiro—a history teacher turned watchmaker—realized his dream of "making a watch from scratch and everything in it."

Standards for surface finishes and profiles are not static; they change as technology changes or new processes come along that need to be considered.

Mirjalili, S., Mirjalili, S. M., and Lewis, A. (2014). Grey wolf optimizer. Adv. Eng. Softw. 69, 46–61. doi:10.1016/j.advengsoft.2013.12.007

Zarei, O., Fesanghary, M., Farshi, B., Saffar, R. J., and Razfar, M. R. (2009). Optimization of multi-pass face-milling via harmony search algorithm. J. Mater Process Technol. 209 (5), 2386–2392. doi:10.1016/j.jmatprotec.2008.05.029

In this episode of Made in the USA, several executives and senior staff at Hardinge give their first-person account of how they formulated the plan to shift the manufacturing of its milling and turning product lines from its Taiwan plant to its plant in Elmira, New York, the major challenges they encountered and the rewards that made it worth the effort.

Zoller’s open house in Ann Arbor, Michigan, provided attendees with a glimpse of the connectivity and efficiency the company’s products offer to users.

The original contributions presented in the study are included in the article/Supplementary material, further inquiries can be directed to the corresponding author.

Fryer Machine Systems Inc. presents its TC Series of CNC machining centers for high-performance cutting, accuracy, reliability and ease of use.

Figure 14 reveals the impact of high heat loads and cutting zone temperature on chip morphology, with thermal softening facilitating machining at high temperatures. Increasing the feed rate results in more serrated chip teeth, especially with cryo-treated cutting tool inserts at high spindle speeds and feed rates. (36,41).

Shanmugasundar, G., Dharanidharan, M., Vishwa, D., and Sanjeev Kumar, A. P. (2021b). Design, analysis and topology optimization of connecting rod. Mater Today Proc. 46, 3430–3438. doi:10.1016/j.matpr.2020.11.778

Shanmugasundar, G., Vanitha, M., Čep, R., Kumar, V., Kalita, K., and Ramachandran, M. (2021a). A comparative study of linear, random forest and adaboost regressions for modeling non-traditional machining. Processes 9 (11), 2015. doi:10.3390/pr9112015

Metaheuristics are a popular set of algorithms that have been used in diverse optimization applications (Shanmugasundar et al., 2019b; Shanmugasundar et al., 2021b; Shanmugasundar et al., 2022a; Shanmugasundar et al., 2023a; Shanmugasundar et al., 2023b). In this study, Grasshopper Optimization Algorithm (Meraihi et al., 2021), Grey Wolf Optimization (Mirjalili et al., 2014), Harmony Search Algorithm (Yang, 2009) and Ant Lion Optimization (Mirjalili, 2015) have been used.

Gao, Z. M., and Zhao, J. (2019). An improved grey wolf optimization algorithm with variable weights. Comp. Intell. Neurosci. 2019, 1–13. doi:10.1155/2019/2981282

The groove is produced in one shot, eliminating the finish pass as well. When TNG started using the ceramic face grooving tool, Mr. Hylton says he was nervous. He questioned his Greenleaf representative about his suggested cutting speeds. However, he says his fears were soon calmed when he saw the Stellite coming off like powder. The ceramic face grooving tool can cut the groove in 30 to 40 seconds.

New tech center is serving as a cutting-edge showroom and a technological hub for advanced machining applications.

Q-Mark has built its metrology business by providing what customers need, when they want it. This goes for its IMTS booth, too, with free drinks alongside custom technology.

Are AMRs the next big trend in job shop automation? System 3R’s IMTS booth will emphasize both its specialty EDM tooling and its automation products, including an autonomous moving robot.

Kuntoğlu, M., and Sağlam, H. (2021). Investigation of signal behaviors for sensor fusion with tool condition monitoring system in turning. Measurement 173, 108582. doi:10.1016/j.measurement.2020.108582

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

Kumar, J., Verma, R. K., and Mondal, A. K. (2021). Taguchi-grey theory based harmony search algorithm (GR-HSA) for predictive modeling and multi-objective optimization in drilling of polymer composites. Exp. Tech. 45, 531–548. doi:10.1007/s40799-020-00428-y

In mathematics, the response value (the output) can be determined in terms of many parameters (the inputs) by using the many Linear Regression Model (MLRM). This study uses experimental data and the “regress” tool in MATLAB to establish three variations of the MLRM equations: linear Equation of cutting force, surface roughness and cutting temperature (Eqs 5, 6, 7) respactively.

In this webinar, industry-leading experts will demonstrate how additive manufacturing can revolutionize your operations and answer the question: Can you afford not to? From rapid prototyping to robust fixturing and specialized custom tooling, it’ll showcase the diverse applications that can drive your business forward in a time where cost and time saving can be crucial. Discover how to reduce costs, accelerate production cycles and achieve unparalleled design freedom through the strategic integration of 3D printing technology. Phillip’s panel of seasoned professionals will share real-world examples and practical insights to help you understand the potential of additive manufacturing. Learn how to overcome production challenges, improve product quality and gain a competitive advantage. It will explore the cost-benefit analysis of 3D printing — including material and labor savings — as well as the potential for increased revenue. Join this webinar to discover why additive manufacturing is no longer a luxury, but a necessity for success. Agenda: Prototyping example: quick-change prototype Custom tooling real-world example: press brake, tube bending die CMM fixturing and workholding example: CMM fixture and soft jaw

Diagnosing when a tool is failing is important because it sets an expectation and a benchmark for improvements. Finding out why gives us a clue for how to fix it.

Part of Major Tool’s 52,000 square-foot building expansion includes the installation of this new Waldrich Coburg Taurus 30 vertical machining center.

Korkmaz, M. E., Gupta, M. K., Singh, G., Kuntoğlu, M., Patange, A., Demirsoz, R., et al. (2023b). Machine learning models for online detection of wear and friction behaviour of biomedical graded stainless steel 316L under lubricating conditions. Int. J. Adv. Manuf. Technol. 128 (5-6), 2671–2688. doi:10.1007/s00170-023-12108-3

Learn more about the variety of technology and machinery Hwacheon Machinery America, Inc. is featuring at its IMTS 2024 booth.

While manufacturing parts just in time (JIT) has many advantages for a shop’s customer, shops oftentimes face challenges with this sort of production schedule. Namely, there’s no wiggle room for meeting deadlines.

The Walter Turn toolholder features rake-face cooling to help break and control chips, and double flank-face cooling directly at the cutting edge to extend tool life.

Figure 2 illustrates the relationship between milling operation factors and cutting forces. Increased spindle speed and feed rate correlate with decreased cutting forces, indicating potential areas for parameter optimization. Feed rate significantly influences cutting forces, affecting tool life.

New U.S.-based event announced in 2021 finally debuts next year: focuses on complete additive manufacturing value chain. More at formnextchicago.com.

The L.S. Starrett Co. has been manufacturing precision measurement tools in Athol, Massachusetts, since 1880. Attention to U.S. manufacturing often focuses on reshoring manufacturing from other countries, but Starrett never left. The facility in Athol employs hundreds and produces thousands of tools that remain vital for measurement in machining and other fields.

Take a look inside James Engineering, a high-end CNC Deburring OEM that became a job shop when they decided to produce their own parts in-house.

Ozbek, N. A., Gulesin, M., and Ozbek, O. (2016). Application of deep cryogenic treatment to uncoated tungsten carbide inserts in the turning of AISI 304 stainless steel. Metall. Mater Trans. A 47 (12), 6270–6280. doi:10.1007/s11661-016-3767-1

Rob Guiao, Chris Hall and Bassanio Peters will demonstrate relatable situations to equip you with data to improve predictability, future-proof operations and maximize ROI. Agenda: Explore the importance of data in decision-making, especially for facility upgrades or new projects Learn how comprehensive solutions for manufacturing and construction projects can improve predictability and ROI See real demonstrations of machine integrations, facility layouts and automations to ensure proper throughput and integration

User-friendly inspection software for CNC machining centers is shown monitoring measurements between and after machining while performing SPC based on recorded measurement values.

Kaushik, V. S., Subramanian, M., and Sakthivel, M. (2018). Optimization of processes parameters on temperature rise in CNC end milling of al 7068 using hybrid techniques. Mater Today Proc. 5 (2), 7037–7046. doi:10.1016/j.matpr.2017.11.367

Refined machines at EROWA are handling heavier loads, while its precision workholding enhances stability and rigidity.

FIGURE 11. Surface plot for influence of parameters on cutting temperature. (A) Surface plot of TT vs CT, FR. (B) Surface plot of TT vs FR, SS. (C) Surface plot of TT vs CT, SS.

Surface roughness is impacted by feed rate, cryogenic treatment, and spindle speed. Eq. (12) mathematically represents surface roughness:

Shanmugasundar, G., Mahanta, T. K., Čep, R., and Kalita, K. (2022c). Novel fuzzy measurement alternatives and ranking according to the compromise solution-based green machining optimization. Processes 10 (12), 2645. doi:10.3390/pr10122645

FANUC’s IMTS 2024 booth includes real-time demonstrations that show the abilities of its equipment, including robots, controllers and machine tools.

Khalilpourazari, S., and Khalilpourazary, S. (2018). Optimization of production time in the multi-pass milling process via a robust grey wolf optimizer. Neural Comput. Appl. 29 (12), 1321–1336. doi:10.1007/s00521-016-2644-6

Previous research has focused on identifying the ideal level of machining parameters for CNC milling operations, often employing artificial intelligence approaches like genetic algorithms (GA), artificial neural networks, and fuzzy logic. Commonly enhanced input parameters include feed rate, depth of cut, and spindle speed (Jia et al., 2012). However, limited research has been conducted on using the length of the cryogenic treatment soaking as a process parameter to achieve optimal machining parameters. Only a few studies briefly mention the use of deep cryogenic treatment (DCT) to enhance tool life, often focusing on single objectives like tool wear and flank wear. Additionally, little work has examined the impact of cryogenic treatment on the material of cutting tools. Thus, providing a robust technological model to enhance the process’s productivity is crucial. To address this gap, experimental tests were conducted to investigate the impact of cryogenic treatment on end mill cutters on the cutting force and temperature of Custom 450 stainless steel using a CNC end milling process. These steels are particularly useful in industries such as medical, food, nuclear power, and chemicals, where precise machining into complex aeronautical fittings, aerospace components like shafts, valves, and specific screws, cabin components, and landing gears is essential (Kuntoğlu et al., 2020; Kuntoğlu and Sağlam, 2021; Korkmaz et al., 2023a; Binali et al., 2023; Korkmaz et al., 2023b). CNC end milling was carried out on a vertical milling machine. Various soaking times (between 24 and 36 h) of CT were applied to tungsten carbide end milling cutters. A scanning electron microscope (SEM) was used to investigate the chip and surface morphology of the cryo-treated and untreated tools. SEM (Vickram et al., 2021; Palanivelu et al., 2022; Raj Deena et al., 2022) imaging finds widespread utility in various fields.

Now, the company uses a face grooving tool with Greenleaf’s new Xsytin-1 ceramic inserts and a support blade. According to Greenleaf, Xsytin-1 is a phase-toughened ceramic insert grade that is showing promise for a wider range of materials than traditional ceramic insert technology, bridging the gap between conventional carbide and ceramic inserts for exotic materials, as well as more conventional metals such as mild and stainless steels. The company says its proprietary phase-toughening ceramic manufacturing process developed for this coating-free grade results in predictable, wear- and thermal-shock-resistant inserts that are twice as strong as the company’s WG-300 whisker grade. It also enables the generation of a sharper insert edge, which can lead to reduced tool pressure and better surface finishes.

Mukkoti, V. V., Sankaraiah, G., and Yohan, M. (2018). Effect of cryogenic treatment of tungsten carbide tools on cutting force and power consumption in CNC milling process. Prod. Manuf. Res. 6 (1), 149–170. doi:10.1080/21693277.2018.1436011

Jia, X. J., Deng, X. Z., and Su, J. X. (2012). Machining parameters optimization for form milling the gear using improved harmony search algorithm. Adv. Mater Res. 472-475, 1809–1812. doi:10.4028/www.scientific.net/AMR.472-475.1809

Citation: Devi C, Mahalingam SK, Cep R and Elangovan M (2024) Optimizing end milling parameters for custom 450 stainless steel using ant lion optimization and TOPSIS analysis. Front. Mech. Eng 10:1353544. doi: 10.3389/fmech.2024.1353544

Moving from cut tapping to form tapping for a notable application cut tooling costs at Siemens Energy and increased tool life a hundredfold.

Ever wonder what sets Top Shops apart from the competition? Dive into their award-winning practices and explore behind-the-scenes strategies for operational excellence.

Grasshopper Optimization Algorithm (GHO) is inspired by the nymph and adult stages of grasshopper life (Meraihi et al., 2021). The nymph stage involves short, leisurely steps, while the adult stage features long, rapid movements. These behaviors underlie GHO’s intensification and diversification phases. In the exploration phase, GHO updates the position value of each grasshopper in the swarm and evaluates fitness, symbolizing the search for food sources. During the exploitation phase, it identifies the optimal solution among all options, akin to seeking better food sources.

• Analyses indicate that spindle speed, feed rate, and cryogenic treatment are critical in milling. Increases in these parameters correspond to higher CF and Temperature (TT).

Ever wonder what sets Top Shops apart from the competition? Dive into their award-winning practices and explore behind-the-scenes strategies for operational excellence.

Automation is no longer a luxury in manufacturing today – it’s a necessity. The Automated Shop Conference (TASC) will connect job shops with experts who offer advice and considerations for this process.

FIGURE 5. MLRS Performance comparison of CF, TT&SR. (A) Surface plot of CF vs CT, SS. (B) Surface plot of CF vs CT, FR. (C) Surface plot of CF vs FR, SS.

It should be noted that TOPSIS (Hwang and Yoon, 1981), a commonly used multi-criteria decision-making (Shanmugasundar et al., 2022b; Shanmugasundar et al., 2022c) tool is used to convert the fi into RCVi.

Weldon Solutions is demonstrating three grinders at IMTS 2024. Though they differ in size and use case, all feature the company’s hallmark customizations.

The Multiple Linear Regression Model (MLRM) can be employed in mathematics to calculate the response value (the output) in terms of several parameters (the inputs) (Shanmugasundar et al., 2021a). This study establishes three variants of the MLRM equations—linear, quadratic, and interaction—using experimental data and MATLAB’s “regress” function. These three models are represented in their standard forms as Eq. 1, Eq. 2, and Eq. 3:

Here, a is the number of algorithms, r is the number of runs, and Rj represents the ultimate rank for each algorithm. The test statistic is compared against the F-distribution table value. If the computed Ff is higher than the table value, the result is considered significant.

Singla, A. K., Singh, J., and Sharma, V. S. (2018). Processing of materials at cryogenic temperature and its implications in manufacturing: a review. Mater Manuf. Process. 33 (15), 1603–1640. doi:10.1080/10426914.2018.1424908

The author(s) declare that no financial support was received for the research, authorship, and/or publication of this article.

Attend TASC, The Automated Shop Conference, in Novi, Mich on Oct. 11, 2023 for a comprehensive look into how to use automation to transform your machine shop.

Working closely with customers and making careful investments has enabled this Wisconsin machine shop to tackle difficult jobs with tight deadlines as a core part of its business.

Table 6 shows the IGD values for the selected algorithms. It is evident from the IGD values that the ALO algorithm outperforms GHO, GWO, and HSA.

Pairing a shoulder mill with a five-axis machine has cut costs and cycle times for one of TTI Machine’s parts, enabling it to support a niche racing community.

The MB45 series is designed to deliver the low cutting force benefits of positive inserts and the fracture resistance of negative inserts.

Mastercam 2025 incorporates big advancements and small — all based on customer feedback and the company’s commitment to keeping its signature product best in class.

So far, Made in the USA has looked into system-wide effects of broken supply chains, automation, skilled workforce issues and our perception of manufacturing jobs — examining each topic through a prism of individual experiences. For this final episode for Season 1, let’s look at one more system-wide question and bring it back to personal perspectives: Is there today a new dawn, a new moment for American manufacturing?

Join Mahr for an informative webinar to discover the latest advancements in precision measurement, designed to elevate your quality assurance processes and unlock peak productivity. It'll explore cutting-edge technologies — such as modern height gages and contour measuring systems — along with their applications, benefits and technical capabilities. Discover the power of height gages: Learn how intuitive and sophisticated height gages can revolutionize your measurement processes, enabling quick and accurate results in inspection and production areas. Explore the practical functions and ease of use that make height gages an ideal solution for manufacturers seeking high-performance and reliable measuring technology. Examine sample applications and industries where height gages excel, such as qualifying first parts, inspecting incoming parts and measuring series of parts in industries like aerospace, automotive and medical. Unlock efficient contour measurement: An introduction to the latest contour measuring technologies that enable fast, simple and comprehensive contour measurement in the production environment. Discover how these innovative solutions ensure reliable measurements, saving time and increasing efficiency while measuring a wide range of workpieces. Learn how to streamline your contour measuring process with speed and simplicity, achieving fast and precise measurements with incredible versatility. Register now and discover how to unlock peak productivity with new innovations in precision measurement. Agenda: Insights into the latest precision measurement technologies and their applications Understanding of how to improve quality assurance processes and increase productivity Knowledge of how to select the right measurement solutions for your specific needs Tips on how to optimize your measurement processes for maximum efficiency

Pairing automation with air-driven motors that push cutting tool speeds up to 65,000 RPM with no duty cycle can dramatically improve throughput and improve finishing.

Kalita, K., Kumar, V., and Chakraborty, S. (2023a). A novel MOALO-MODA ensemble approach for multi-objective optimization of machining parameters for metal matrix composites. Multiscale Multidiscip. Model Exp. Des. 6 (1), 179–197. doi:10.1007/s41939-022-00138-5

Keywords: end milling optimization, custom 450 stainless steel, ant lion optimization, multi-objective TOPSIS, parametric analysis

Job shops are implementing automation and digitalization into workflows to eliminate set up time and increase repeatability in production.

Devi, C., and Mahalingam, S. K. (2023). Robert cep, and Karel Kouril, effect of cryo-treated cutting tool end milling on Custom 450 stainless steel. J. Mater 16, 0. doi:10.3390/ma16130000

Given the productivity gains for just one valve feature, Mr. Hylton has no question about moving forward using ceramic inserts. TNG is even planning on producing two valves per week in the future because of these improvements.

Entrepreneur Scott Colosimo found early success in China producing parts for his Cleveland-based motorcycle company in the mid-2000s. This is the story of how IP theft issues overwhelmed the business, prompting Colosimo and his team to start over from scratch — and move production back to the United States.

Northeast University At Qinhuangdao Campus - china high performance carbide end mills

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