This research investigates the impact of nanofluid coolants on surface quality and tool wear during the turning of Ti6Al4V alloy. Machining Ti6Al4V, while desirable for its strength and corrosion resistance, is challenging due to its low thermal conductivity, high reactivity with tools, and propensity for work hardening, leading to accelerated tool wear, poor surface finishes, and reduced efficiency. This study explores the potential of nanofluids to mitigate these issues. Experimental results indicate that a hybrid nanofluid containing Al2O3 + CuO + MWCNTs nanoparticles exhibits superior performance compared to conventional coolants, yielding the best cylindrical and shoulder surface quality while minimizing flank and crater wear on the cutting tool. To determine the optimal turning parameters, the Technique for Order of Preference by Similarity to Ideal Solution method was employed. The analysis identified the following optimal parameters: a cutting speed of 60 m/min, a depth of cut of 0.8 mm, and a feed rate of 0.28 mm/rev. These findings highlight the potential of nanofluids to improve machining efficiency and surface integrity in the turning of Ti6Al4V alloy.

The advent of designing flexural systems was to provide accurate micro and nano displacement between the assembly members of the mechanism. Applications that used these mechanisms included linear compressors, optomechanical devices, Stirling engines, cryocoolers, microcheck valves, Flexure-based Electromagnetic Linear actuators, and so on. This paper focuses on the machine-tool fabrication of a novel flexural mechanism encased within the spindle head of the microdrilling head. The mechanism cushioned the micro drill and protected it from permanent damage when encountering undeclared resistance in the material matrix. Furthermore, this paper focuses solely on building a 3-axis drilling machine tool in a Product Lifecycle Management environment. The study follows a systematized approach for validating the machine tool design, starting with the hierarchical assembly of components using various kinematic chains. The next phase involves assigning the necessary motions to these components. The final stage utilizes a virtual controller and post-processor to simulate and control machine tool movements. Validation is then performed on the simulated workpiece to ensure design accuracy and functionality. The key findings of the studies indicate that the designed mechanism can move in and out and can also puncture micro-holes in metal. This is the mechanism’s capability, which is the novelty.

In the field of industrial thermal equipment, numerous theoretical concepts and frameworks exist within the literature. However, the practical implementation of these frameworks remains limited, particularly in validating their efficiency on a large scale. This paper aims to bridge the gap between theory and practice by implementing a framework to demonstrate its real-world applicability. It addresses problems in adaptation of Digital Twin in industrial domain. Specifically, it seeks to assess the effectiveness of key technical parameters and investigate the utility of Digital Twin technology for enhancing thermal equipment operations. The research methodology considers development of code to collect sensor data, route it on various cloud modules to exercise Digital Twin securely by experimentation using a small-scale model for validation purposes. It’s important to note that the study presented in this paper is confined to focus on typical sensors commonly used in industrial settings. Through the experimentation process, it is revealed that the implemented framework proves to be suitable and effective for industrial thermal equipment. Real-time processing of key sensor data enables visualization for identifying component status. The study concludes that large-scale applications utilizing IoT and Digital Twin frameworks are not only feasible but also can address industrial concerns beyond the capabilities of traditional PLC/DCS systems. Industrial plants will have impact on seamless adoption of IoT and Digital Twin frameworks that encourages integration with other emerging technologies such as artificial intelligence (AI) and machine learning (ML), leading to further advancements in thermal equipment management. By optimizing thermal equipment operations through real-time monitoring and predictive maintenance, and positive environmental impact by significantly improved energy efficiency, resulting in reduced consumption and greenhouse gas emissions.

The rapid evolution of innovative manufacturing techniques is gradually phasing out traditional methods. This research delves into one such cutting-edge approach based on fluid shaping, leveraging Saffman-Taylor instability and the viscous fingering phenomenon by utilizing a setup known as the Lifting Plate Hele-Shaw Cell (LPHC). Through exploring the potential of this fluid dynamic behaviour, the study aims to understand the formation of net-shaped microstructures, particularly for applications in microchannel systems and microfluidics. The study underlines the significance of surface roughness on fractal growth. An analysis utilizing dimensionless numbers derived from geometric cell parameters such as fluid film thickness, surface roughness, and fluid film diameter correlated with fluid capillary number is employed to develop a deeper understanding. Six surfaces with differing roughness values ranging from 40 μm to 2.5 μm are tested alongside various separation velocities ranging from 2 mm/min to 6 mm/min in the LPHC. The research illustrates that when the surface roughness is very high, the fractal growth is driven by the geometric parameters, resulting in the fractals with shorter and wider fractals, while the fractals formed on the surfaces with very low roughness value are driven mainly due to the capillary action resulting into longer, thin and peaky fractals.

Titanium Alloy Grade 5 (Ti6Al4V) is a strong, lightweight, corrosion-resistant, and highly recommended material for various Aerospace components. The machining efficiency during milling is poor due to a lack of proper cooling and lubrication. Also, Ti6Al4V's sensitive metallurgy will affect the Material Removal Rate and Tool wear. The selection of shearing process parameters and proper cooling method is a crucial success in machining Ti6Al4V. The article explains the experimental investigation of open pocket milling under various cooling methods and shearing parameters through the Taguchi Design of Experiments. The L9 orthogonal array combines cutting speed, feed, Depth of Cut, and Cooling methods in a systematic way. The investigation was conducted through Cavity milling Computer-Aided Machining strategy with PVD-TiN coated insert. The experimental results wear measured in terms of Average Surface Roughness, Flank, and Crater Wear. Investigation proves that Nano Hybrid Flood Coolant + Cryogenic Air releases adequate lubrication and cooling. Consecutively reduction in the cutting tool wear is measured by scanning electron microscopy. The effective combination of process parameters viz. cutting speed=60 m/min, feed rate=0.19 mm/rev, axial depth of cut=0.35 mm under Nano Hybrid Flood Coolant + Cryogenic Air is delving by Grey Relational Approach.

Additive manufacturing (AM) is showing promising results in manufacturing technology and could be the next generation of industrial revolution. This paper presents an application based on AM in the field of precision scanning system. Rigid link scanning mechanisms limit accuracy of positioning due to several factors such as friction, backlash in joints. Notably, flexural mechanisms offer great advantage in micro- and nano-position accuracy. Flexural mechanism, unlike sliding or rolling motions of rigid links, generate motion from the intrinsic flexibility of the material. Here, we present a cost effective and less-waste generating fabrication approach of flexural mechanism via AM. Different limbs of the stage are first modularly fabricated by a desktop fused filament fabrication (FFF) printer and later assembled. System identification (static i.e. force deflection curve and dynamic i.e. frequency response curve) are carried out using standard test methods. An experimental model is estimated for development of a closed loop control algorithm. Various close loop control experiments (set point control and trajectory tracking control) are conducted and accuracy of less than 5 μm is achieved at the scanning speed of 5 mm s−1. Such fast and customized XY flexural mechanisms have numerous applications ranging in micromachining, biomedical imaging, and organ manufacturing.

This paper presents the deployment of Runge-Kutta method to overcome the main challenge in analysis of failure of aircraft wing structure subjected to wind pressure and point loading. Failure phenomenon of any structure is time dependents and is typically referred as dynamic in engineering mechanics and is fairly a complex to investigate. In this context, the dynamic analysis concept has successfully implemented by using computer program in SCILAB software. The numerical technique is adopted as Runge-Kutta fourth order (RK4) method for performing dynamic behaviour of wind structure. The demonstration of failure mode of wing structure is based on function of time. The numerical approach is deemed to provide a detailed description of these phenomena affecting the overall dynamic of failure envelope of wing structure. The parametric study is presented; likewise the effect on failure of wing structure by changing different wind pressure, length and moment, respectively. The wing structure is analytically validated against available literature. Finally, others important failure results obtained from this analysis has discussed in detail.

Machining of Ti6Al4V is most challenging when looking towards the cutting tool performance in the context of surface quality, spindle load, and tool health. It is a popular material for the Aircraft, Automobile, and Bio-implant industries have of its pervasiveness in high strength, good corrosive resistance, and adaptive formability. The cutting tools’ wear, like Crater and Flank, is inherent during the milling of Ti6Al4V due to poor thermal conductivity and thermo-chemical affinity with cutting tool material. This experimental analysis carried out by using Solid and Hollow End Mills of Carbide-PVD TiAlN and HSS-TiN coated under a hybrid nano flood coolant environment. The 2.5D profile is milled at a 2 mm constant axial depth of cut following the Cavity tool path by tracing the periphery of the cavity shape with corner smoothing; by mines of Computer Aided Machining strategy. Cutting tool performance is observed in terms of Cutting tool wear, Spindle load, and Surface Quality of the machined portion. The novel hollow cutting tools reveal adequate performance in Ti6Al4V shearing, securing better tool life and giving rise to smooth surface texture. Also, diminished spindle loads were observed owing to the high volume of Hybrid Nano Flood Coolant at the cutting zone through the hollow portion and supporting with external nozzle flow with immense pressure. The balanced Lubri-Cooling and increased cutting tool surface area improve the thermal health of the cutting tool during milling. Carbide Hollow cutting tools elaborate the successive performance in the decided context than Solid cutting tools.

In the prevailing era, an influential shape memory alloy (SMA) nitinol has emerged as a potentially viable and economically affordable material that is capable of playing a significant role in both existing and emerging technological applications spanning the domains of aircraft and aerospace, biomaterials in bioengineering, sensors in health monitoring, advanced manufacturing, and microelectromechanical systems (MEMS), to name a few. A high strain recovering capability coupled with superelasticity are two key and essential characteristics of a “smart” material that distinguish it easily from its conventional counterparts. The phase transformation behavior shown by nitinol (NiTi) was found to be governed by intrinsic variations in temperature. In order to obtain the desired application-based functionality of this high performing material, potentially viable approaches include the following: (i) an alteration of its chemical composition, (ii) the addition of ternary elements and quaternary elements, and (iii) the use different processing treatments. These approaches are being constantly studied, carefully and systematically examined and frequently reported in the published literature. In this manuscript, an effort is made to present and discuss several of the recent advances specific to the NiTi-based shape memory alloy applications and its phase transformation behaviour when subject to processing treatments. The influence of compositional variation of the NiTi-based shape memory alloys (SMAs) and even its ternary variants and quaternary variants, coupled with the role and/or influence of different processing treatments on both macroscopic properties and microscopic properties is the focus. The emphasis on increasing the suitability of shape memory alloys (SMSs) for selection and use in a spectrum of sensing-related or sensing specific applications is highlighted and briefly discussed.

The development of viscous fingering patterns using fluid shaping techniques is required to mimic several natural and biological systems. The conventional Hele-Shaw cell and Lifting Plate Hele-Shaw cell perform fluid shaping operations. These apparatuses have great scientific importance in studying the Saffman-Taylor instabilities phenomenon. The instabilities are developed at the fluid-fluid interface due to one of the fluids displacing the other in the mixture. This unstable interface creates a resemblance of fingers due to viscosity. Hence it is called viscous fingering. The viscous fingers are developed due to less viscous fluid displacing the more viscous fluid confined between two parallel plates of the Hele-Shaw cell apparatus. The fluid patterns are nothing but the instabilities that are developed at the fluid-fluid interface. The main reason for getting desired patterns are suitable anisotropies, the difference in viscosity, adequate fluid injection velocity, and lifting velocity of lifted Hele-Shaw cell. This paper briefly overviews some theoretical, practical, and simulation strategies used in the Hele-Shaw cell for fingering instabilities. Also, some critical process parameters required for pattern generation are studied and presented.

Bacterial adhesion to the surface can quickly lead to the development of biofilms, which can create a variety of economic and health issues. In the marine industry, Biofouling causes sailing resistance, resulting in higher fuel consumption and waste emissions for boats, ships, and submarines. Metals such as titanium and its alloys along with stainless steel are commonly used in orthopedic implants and the most common complications seen after the implantation are bacterial infections acquired through invasive and post-operative medical procedures. This type of infection damages the bone and surrounding tissues. Separating a biofilm from an implant surface is time-consuming because even minor biofilm residues left on the implant surface might cause the infection to reappear. Implant replacement or long-term antibiotic therapy are usually suggested in such circumstances, which is not optimal for individuals with co-morbid conditions. In the case of long-term use of antibiotics, antibiotic resistance is a serious issue. As a result, several techniques aimed at lowering the risk of bacterial infections in bio-implants are critical. Surface textures on a micro scale can help in the fight against Biofouling by increasing antibacterial properties, preventing bacterial adhesion, or killing or inactivating adherent microorganisms and creating an inapt environment for biofilm formation. As a result, the capacity to generate passive antibacterial surfaces on components has far-reaching consequences in practically every industry. In this study, micro-textures were generated on the surfaces of titanium (Grade 5), aluminum, and stainless steel. The topographical characteristics of the textured surfaces were studied, and a comparative study of wettability between textured and non-textured surfaces was conducted. S. aureus and E. coli, being the most common infection-causing bacteria in implants and were used to investigate the antibacterial properties. The results show that the textured surface lowers bacterial adhesion and growth up to 91.57% in comparison to the non-textured samples for E. coli and 51.40% for S. aureus, which can be related to the surface topography and the presence of peaks and troughs, which also contribute to the surface's Hydrophilicity.

Fabrication of micro-fractals in lifting plate Hele-Shaw cell for bio-mimicking and micro-level applications has been gaining popularity in recent years. Instability in the interface between the two distinctly viscous fluids due to the Saffman-Taylor instability phenomenon leads to this spontaneous fabrication. Micro-fractals have already been developed on flat surfaces in lifting plate Hele-Shaw cell at the primary level and validated by its numerical simulation. Developed micro-fractals mimic different ordered patterns found in nature. This paper presents the experimental characterization of the micro-fractals formed on conical surfaces. The fractal formation process is experimented on lifting plate Hele-Shaw cell apparatus. A Bingham plastic fluid (toothpaste) is used as a high-viscosity fluid, and air as a low-viscosity fluid. Variations are observed in the micro-fractals pattern obtained by varying process controlling parameters, viz. initial thickness of the high-viscosity fluid, velocity of lifting plate and semi-cone angle. Characterization of the formed fractals results in optimum process control parameters that can lead to desired micro-fractal formation for various micro-applications in the future.

Using an unconventional method of machining, electric discharge machining is capable of processing extremely hard materials that are inaccessible to more traditional machining methods. Electric discharge machining is a metalworking technique that uses an electric erosion effect in conjunction with an electrosparking spark. A current discharge takes place in a narrow space between the work piece and the electrode, melting and vaporizing the unwanted material and separating it from the parent metal in the process. When it comes to enhancing material removal rates and decreasing tool wear, powder-mixed electrical discharge machining is one of the most recent techniques. The machining mechanism, the cost-effectiveness of powder, the powder concentration in the working fluid, and the safety and environmental impact of this new development are just a few of the many questions that remain unanswered. As a result, it sees very little use in the manufacturing sector. EN-31 with aluminium as a tool electrode was examined in this study to determine its machining characteristics during EDM processing. The EDM procedure is used to study the MRR, TWR, and SR of the MWCNT combined with dielectric fluids. EDM process output parameters were predicted using regression models. Predictive models were built using the peak current, pulse on time, and pulse off time parameters of machining. In order to collect data, we used a full factorial design. ANOVA is used to identify the most influential input parameter that has the greatest impact on the final outcome. Using design expert software, the characteristics of EN-31 steel were improved and regression equations with and without MWCNT were compared using an electro-destructive method (EDM). Carbon nano tube combined as dielectric fluid improved surface roughness by an average of 30% while improving MRR by an average of 19% while decreasing TWR by 8.51 percent.

The design of fixtures for slot or slab machining operations and their clamping schemes is an intricate and highly static problem that entails workpiece deformation due to the clamping and machining forces. The numerous parameters, such as clamping and machining forces, von Misses stress, and workpiece deformation in the component, are of particular relevance in this context. A practical fixture layout must include the optimum values of clamping, machining forces, von misses stress and w/p deformation. More research is required to address the complex issue in the fixture design field. This paper explores to resolve a model of the workpiece-fixation system for the slot milling operation under cutting and clamping pressures through Finite Element Analysis. The workpiece-fixture system must use a finite element model to identify a relationship between the clamping forces and von Misses stress. To determine factors like workpiece deformation, von Misses stress, clamping forces, and machining forces, the usage of machining force is recommended. This work aims to minimize the magnitude of clamping, machining forces and deformation of the work piece for the slot milling process. The behavior of the workpiece's deformation and von Misses stress were discovered in this analysis. Computer-aided process planning and automation of fixture design are the driving forces behind this current study.

The Ti6Al4V is an eminent material by its high strength, dimensional stability, lower weight and corrosion resistance. Its lower thermal conductivity leads to poor machinability by exhibiting metallurgical alterations. This article discusses the details of dry, wet, cryogenic, minimum quantity lubrication and hybrid cooling methods in the milling of Ti6Al4V. Dry cooling has a worse acute effect on tool life and surface quality by thermal degradation. The widespread high-pressure cooling controls heat dissipation, but cutting tools are affected by chipping and adhesion under long-run milling. In the first instance, cryogenic cooling like liquid nitrogen and liquid carbon dioxide assisted cooling shows excellent tool life and surface integrity; however, excessive uncontrolled chilling and abnormal lubrication affect milling performance. Minimum quantity lubrication with nanoparticles and their combination with multi-wall carbon nanotubes improves the machinability by balanced cooling and lubrication under the concept of green manufacturing engineering. Indirect hybrid cryogenic cooling is a new era in superalloy's cooling methods for long-run applications. The prime drive of this review is to formulate a bridge between cooling and performance under sustainability concerns and propounds the hybrid nanofluids and indirect hybrid cryogenic cooling being the future of Ti6Al4V milling under the mapping of sustainable scale.

The Stokes flow between two flat parallel plates caused when the plates are separated by an infinitesimal distance is termed Hele-Shaw flow. This flow is replicated with the help of a lifting plate Hele-Shaw Cell. This system allows a low viscous liquid to penetrate a high viscous liquid, leading to the Saffman–Taylor instability. This instability at the interface promotes the branching of low viscous fluid into minute fractal branches. There have been various methods to control this branching. This paper aims at providing a novel way to use machine learning to predict this fractal pattern. Since the fractal pattern is radical but unpredictable in nature, geometrical anisotropy is introduced in the experiment with the help of holes to control the formation of fractals. The fluid is initially represented with the help of a mesh grid consisting of grid points, and a machine learning model is used to train on the grid points to be able to predict the branching pattern using these grid points, given the initial experimental conditions. The paper describes the steps and processes that were required to perform the experiment, build the dataset, pre-process and post-process the images, train, test, and tune the model and dataset. Moreover, model modifications and setup deficiencies are also described in detail in this paper. The nature of the described model could provide an accurate and robust method to predict these irregular branches.

Flexural cartridge/suspension is compliant mechanism that is used in nano precision engineering application due to its excellent advantages of providing no backlash, no friction and compact in size. These inbuilt qualities which are obtained help them to suit as a single one piece coupling that serves kinematic–mechanical behavior with small and very large deflection for variety of applications. The spiral shaped flexural cartridge is used in multiple number and multiple configurations to achieve the desired output for an application. To address the net deflection as the output (net deflection of the stack in assembled condition) it is very necessary to understand the changes which are brought in the geometrical parameters of the spiral shaped flexural cartridge/suspension. The importance geometrical parameters of spiral shape cartridge is been reported in this paper. The paper reviews the key concepts, technical advancements, identifying the most sensitive parameters of the spiral shaped flexural cartridge. This paper presents a guide to select the most appropriate parameter for the application engaged in flexural system.

Hole creation is a common contour in drilling and milling. However, drilling big holes in Ti6Al4V is difficult. It is due to the thermally increased metallurgical behavior of Ti6Al4V, which mortifies drill bits and degrades hole quality. To solve this issue, the current research investigates Helical milling through Computer Aided Tool Path as a viable option for Hole production by functionally managing shearing parameters. This approach drives the process parameters helically at a certain Ramp angle to achieve improved surface quality in the Hole. The analysis of variance reveals that the Cutting Speed and Feed/tooth affect the Circularity of the Hole. Furthermore, Axial DOC and Ramp angle significantly impactHole surface texture. The cumulative impact of Cutting Speed at 60 m/min, Feed/tooth at 0.06 mm, and Axial Depth of Cut at 0.6 mm applied at a Ramp angle of 1.50 through theHelical milling tool path under Hybrid nano Flood lubrication catch the outstanding Hole Quality.

With the continuous improvement in manufacturing processes there is an amalgamation of digital technology with traditional concepts. Electric discharge machining is one such example of it. The more industries digitalize it the more is the degree of automation. In present experimental work ZNC Electrical Discharge Machine has been used to perform the experiments. Total 18 experiments have been performed on Inconel 625 alloy as per the orthogonal array prepared by Minitab software. Tool electrode, peak current, pulse on time (Ton) and pulse of time (Toff) are considered as input parameters. There were two levels of tool and rest were assigned three levels. 9 experiments were conducted via copper tool without vibration and in remaining 9 experiments vibration assisted copper tool was used. Vibration was given to tool with coin vibration motor which was powered by battery. It was observed that when Toff was increased from 25 to 35 µs the surface roughness enhances by 23.23%. Also, it was found that circularity improves by 25.85% when Ton is raised from 140 to 160 µs. Surface roughness of each drilled hole was measured using surface roughness tester and circularity was measured using Quick Image. The FESEM and EDS has performed on the machined specimen to analyze the microstructure and chemical composition.

Experimental studies on heat transfer enhancement and friction factor characteristics of water flowing in Laminar flow regime through a square duct, fitted with full-length helical inserts of varying twist ratio have been reported in the present paper. The test liquid flows in the laminar flow through a square duct and in counter current manner a hot water at very high flow rate is directed though the annulus to ensure a constant wall temperature conditions. A plain duct fitted with helical inserts provides higher friction factor and Nusselt number than that of empty duct. The heat transfer and pressure loss were observed to be higher at minimum twist ratio. The thermo hydraulic performance ratio on constant pumping power of the duct induced by helical inserts at different twist of 1.44, 2.55, 3.66, 4.66 were found to be 5.20, 4.44, 4.01, and 3.50 times higher than the plain duct.