Guy Littlefair

Free search: a comparative analysis

The article presents a novel population-based optimisation method, called Free Search (FS). Essential peculiarities of the new method are introduced. The aim of the study is to identify how robust is Free Search. Explored and compared are four different population-based optimisation methods, namely Genetic Algorithm (in real coded BLX-α modification), Particle Swarm Optimisation, Differential Evolution and Free Search. They are applied to five non-linear, heterogeneous, numerical, optimisation problems. The achieved results suggest that Free Search has stable robust behaviour on explored tests; FS can cope with heterogeneous optimisation problems; FS is applicable to unknown (black-box) real-world optimisation tasks.

Machining and tool wear mechanisms during machining titanium alloys

This paper investigates the machining mechanism of titanium alloys and analyses those understandings systematically to give a solid understanding with latest developments on machining of titanium alloys. The chip formation mechanism and wear of different cutting tools have been analyzed thoroughly based on the available literature. It is found that the deformation mechanism during machining of titanium alloys is complex and it takes place through several processes. Abrasion, attrition, diffusion–dissolution, thermal crack and plastic deformation are main tool wear mechanisms.

Machining of titanium alloy (Ti-6Al-4V) - theory to application

This article correlates laboratory-based understanding in machining of titanium alloys with the industry based outputs and finds possible solutions to improve machining efficiency of titanium alloy Ti-6Al-4V. The machining outputs are explained based on different aspects of chip formation mechanism and practical issues faced by industries during titanium machining. This study also analyzed and linked the methods that effectively improve the machinability of titanium alloys. It is found that the deformation mechanism during machining of titanium alloys is complex and causes basic challenges, such as sawtooth chips, high temperature, high stress on cutting tool, high tool wear and undercut parts. These challenges are correlated and affected by each other. Sawtooth chips cause variation in cutting forces which results in high cyclic stress on cutting tools. On the other hand, low thermal conductivity of titanium alloy causes high temperature. These cause a favorable environment for high tool wear. Thus, improvements in machining titanium alloy depend mainly on overcoming the complexities associated with the inherent properties of this alloy. Vibration analysis kit, high pressure coolant, cryogenic cooling, thermally enhanced machining, hybrid machining and, use of high conductive cutting tool and tool holders improve the machinability of titanium alloy.

Electrical discharge machining of 6061 aluminium alloy

The wire electrical discharge machining (EDM) of 6061 aluminium alloy in terms of material removal rate, kerf/slit width, surface finish and wear of electrode wire for different pulse on time and wire tension was studied. Eight experiments were carried out in a wire EDM machine by varying pulse on time and wire tension. It is found that the material removal rate increases with the increase of pulse on time though the wire tension does not affect the material removal rate. It seems that the higher wire tension facilitates steady machining process, which generates low wear in wire electrode and better surface finish. The surface roughness does not change notably with the variation of pulse on time. The appearance of the machined surfaces is very similar under all the machining conditions. The machined surface contains solidified molten material, splash of materials and blisters. The increase of the pulse on time increases the wear of wire electrode due to the increase of heat input. The wear of wire electrode generates tapered slot which has higher kerf width at top side than that at bottom side. The higher electrode wear introduces higher taper.

Weldability of duplex stainless steel

Duplex stainless steels (DSSs) have many advantages due to the unique structural combination of ferrite and austenite grains. The structural change of these materials is very complex during welding, and it deteriorates the functional properties. This research investigates different welding processes such as laser beam, resistance, tungsten inert gas, friction stir, submerged arc, and plasma arc weldings considering the research available in the literature. The welding mechanism, change of material structure, and control parameters have been analyzed for every welding process. This analysis clearly shows that DSS melts in all most all welding processes, but the thermal cycle and maximum heat input are different. This difference affects the resulting structure and functional properties of the weld significantly.

Fabrication of Nano-Particle Reinforced Metal Matrix Composites

Nanoparticle reinforced metal matrix possess much better mechanical properties over microparticle reinforced metal matrix composites as well as corresponding monolithic matrix materials. However, the fabrication methods of nanoparticle reinforced metal matrix composites are complex and expensive. This paper investigates and discusses the mechanisms of all the fabrication process, such as powder metallurgy, liquid metallurgy, compocasting and hybrid methods, available in the literature. This gives an insight on challenges associated with different processes and ways to improve the fabrication processes. It is found that modified traditional fabrication processes are mainly applied for these materials. The main problem is to achieve reasonably uniform distribution of nanoparticle reinforcement in the methods other than mechanical alloying when the volume or weight percent of reinforcement is higher (> 1%).

Production of Ti-6Al-4V acetabular shell using selective laser melting: possible limitations in fabrication

Purpose The purpose of this paper is to improve the manufacturing of a prosthetic acetabular shell by analyzing the main factors leading to failure during the selective laser melting (SLM) additive manufacturing (AM) process. Design/methodology/approach Different computer-aided design and computer-aided manufacturing processes have been applied to fabricate acetabular parts. Then, various investigations into surface quality, mechanical properties and microstructure have been carried out to scrutinize the possible limitations in fabrication. Findings Geometrical measurements showed 1.59 and 0.27 per cent differences between the designed and manufactured prototypes for inside and outside diameter, respectively. However, resulting studies showed that unstable surfaces, cracks, an interruption in powder delivery and low surface quality were the main problems that occurred during this process. These results indicate that SLM is an accurate and promising method for production of intricate shapes, provided that the appropriate settings of production conditions are considered to minimize possible limitations. Originality/value The contributions of this paper are discussions covering different issues in the AM fabrication of acetabular shells to improve the mechanical properties, quality and durability of the produced parts.

On the role of different annealing heat treatments on mechanical properties and microstructure of selective laser melted and conventional wrought Ti-6Al-4V

Purpose The purpose of this study was to conduct various heat treatments (HT) such as stress relief annealing, mill annealing, recrystallization (α + β) annealing and β annealing followed by furnace cooling (FC) that were implemented to determine the effect of these on mechanical properties and the microstructure of selective laser melted and wrought samples. The mentioned annealings have been carried out to achieve the related standards in the fabrication of surgery implants. Design/methodology/approach In this paper, based on F2924-14 ASTM standard SLM and conventionally wrought parts were prepared. Then HT was performed and different characteristics such as microstructure, mechanical properties, macro-hardness and fracture surface for selective laser melted and wrought parts were analysed. Findings The results show that the high cooling rate in selective laser melting (SLM) generates finer grains. Therefore, tensile strength and hardness increase along with a reduction in ductility was noticed. Recrystallization annealing appears to give the best combination of ductility, strength and hardness for selective laser melted parts, whilst for equivalent wrought samples, increasing HT temperature results in reduction of mechanical properties. Originality/value The contributions of this paper are discussing the effect of different annealing on mechanical properties and microstructural evolution based on new ASTM standards for selective laser melted samples and comparing them with wrought parts.

Accuracy and finish during wire electric discharge machining of metal matrix composites for different reinforcement size and machining conditions

Electric discharge machining has been established as an effective alternative process to conventional material removal processes for machining reinforced metal matrix composites. Wire cut electric discharge machining holes were produced in a metal matrix composite (10 vol% of SiC in Al6061), which were then investigated to determine the machinability of the material using this process. It was observed that the input factors such as the size of reinforced particles, wire tension and pulse-on time significantly affect diameter error, circularity and surface roughness. Pulse-on time, the interaction between pulse-on time and wire tension contribute to the maximum diameter error. The wire tension is the most significant factor to circularity, which is followed by the interaction between pulse-on time. In particular, wire tension with low and high tensions results in poor circularity. It has been found that there are more surface defects encountered when particle sizes are smaller, and circularity is improved when particles are in a medium size. In addition, the surface defect is reduced as the particles increase the melting resistance of the surface. The higher pulse-on time leads to higher heat and more time to degrade the surface. Therefore, low pulse-on time and wire tension gave better surface finish.

Wire EDM Mechanism of MMCs with the Variation of Reinforced Particle Size

The size of reinforced particles notably affects the electro-discharge machining (EDM) of metal matrix composites (MMCs). This paper explores the mechanism of wire EDM of MMCs with different sizes of reinforced particles as well as the corresponding unreinforced matrix material. The mechanisms of material removal, surface generation, and taper kerf formation were investigated. This study shows that the particles’ ability to protect matrix materials from the intense heat of electric arc controls the material removal rate, surface generation, and taper of kerf. The low melting point matrix material is removed very easily, but the heat resistance reinforced particles delay the removal of material and facilitate the transfer of the workpiece material to wire electrode and vice versa. Thus, the material stays longer in touch with intense heat and affects the surface generation, wire electrode wear, and width of the kerf.