This paper presents a web-based Island–Pocket Feature Recognition System (IPFRS) that recognises islands and blind pockets from STEP AP242 files and automatically generates CNC milling G-code. The system applies geometric data extraction to parse STEP entities and reconstruct feature boundaries using key geometric definitions such as CARTESIAN_POINT, LINE, CIRCLE, and PLANE. Feature classification is performed by comparing Z-level relationships between reference planes and extracted boundary points to distinguish raised islands (boss) from recessed blind pockets. Based on the recognised features, IPFRS generates toolpaths and converts geometric primitives into standard CNC commands, producing linear and circular motions (e.g., G01, G02/G03) while incorporating user-defined machining parameters such as tool diameter and overlap. The software is implemented using a web architecture (PHP, HTML, and JavaScript) with database support, enabling file upload, processing, code visualisation, and direct G-code download. Validation through CNC simulation using different endmill diameters (5 mm and 10 mm) confirms correct machining sequence, valid syntax, and collision-free toolpaths. The proposed system reduces manual feature identification and programming effort, providing an accessible workflow for consistent G-code generation directly from STEP AP242 models.

The identification of blind pocket and island features in modern computer-aided design (CAD) and in the manufacturing of 3D CAD models is crucial. It ensures the accuracy and efficiency in the computer numerical control (CNC) machining process. These features often pose challenges for automated detection. This study proposes an automated method for detecting blind pockets and islands in Standard for the Exchange of Product Model Data (STEP) AP242 files using a depth-based approach. The methodology involves analysing geometric information from the STEP file, arranging regions by depth (Z-values) and recognising between blind pocket and island features. The approach uses a series of geometric algorithms to detect edges, vertices and surfaces, followed by the identification of areas with different depths. Three case studies were employed to demonstrate the method’s ability and effectiveness in accurately detecting features. Results show that a feature recognition success rate of 100% was achieved for the case studies, implying that the developed method for blind pocket and island detection is effective and reliable.

Many studies have explored using natural fibers from biomass as reinforcement in thermoplastics. However, a key challenge in developing these composites is achieving effective interfacial adherence between the hydrophilic natural fibers and hydrophobic polymer matrix. Additionally, excessive or insufficient amounts of fiber and compatibilizer can lead to composite failure due to poor dispersion, inadequate interfacial bonding, or fiber agglomeration. In this work, banana fibers at 10, 20, and 30 wt

Integrating Computer-Aided Design (CAD) and Computer-Aided Manufacturing (CAM) remains critical for automating tool path generation in CNC machining. However, interoperability issues and reliance on proprietary CAM systems hinder efficiency, particularly for small-scale manufacturers. This study presents an Integrated Interface System (IIS) that directly converts STEP file geometric data into G-code, bypassing intermediary CAM software. Developed using PHP, IIS extracts and processes geometric entities such as EDGE_LOOP, ORIENTED_EDGE, and CARTESIAN_POINT to generate precise machining tool paths. Validation was performed by comparing IISgenerated G-code with SolidCAM output using CNC Simulator software, demonstrating equivalent tool path accuracy with less than 0.002% deviation. A case study on a 3-axis CNC milling machine confirmed IIS's capability to generate both linear and circular tool paths with a 10 mm depth of cut, ensuring high-precision machining. The proposed system streamlines tool path generation, offering SMEs a cost-effective and scalable solution.

Clamping systems play a crucial role in manufacturing by ensuring precision, stability, and repeatability during machining and assembly operations. However, traditional systems often lack adaptability, portability, and ease of use, particularly for diverse workpiece geometries and dynamic applications. Addressing these limitations, this study aims to develop a Universal Magnetic Portable Jig, designed to provide a versatile and user-friendly clamping solution tailored for educational, DIY, and small-scale industrial contexts. The research utilized advanced manufacturing techniques, including 3D printing, CNC machining, and MIG welding, to create a modular jig with a magnetic base and interchangeable attachments. Comprehensive testing and DFMA analysis were conducted to validate its performance, revealing significant findings. The Vise for Cylindrical Shapes achieved a DFA Index of 112.97, showcasing high efficiency and simplicity, while other attachments, like the Dial Test Indicator Holder, highlighted areas for optimization. Identified limitations, such as reliance on ferromagnetic surfaces and size constraints, provide pathways for further enhancement. This study demonstrates that the Universal Magnetic Portable Jig effectively bridges gaps in traditional clamping systems by offering enhanced adaptability and operational flexibility. The principal results confirm its ability to improve productivity and usability across various applications. Future research will explore scalability for larger workpieces and non-magnetic materials, automation features, and further optimization. The findings establish a strong foundation for innovative clamping solutions in modern manufacturing environments.

Optimization algorithms play as a crucial role in solving complex real-world problems, where achieving global optimal in high-dimensional spaces remains challenging. This article presents a novel hybrid algorithm, which combining the Modified Adaptive Bats Sonar Algorithm (MABSA) with the Squirrel Search Algorithm (SSA). This synergistic approach is designed to improve conjunction speed and solution accuracy, particularly in high-dimensional in solving optimization problems using evolutionary algorithms. To evaluate the performance of this enhanced MABSA, experimental evaluations are conducted using a comprehensive suite of seven single objective benchmark test functions to assess the performance of MABSA-SSA against the original MABSA. Notably, the SSA component enhances the capability and improves their exploration diversity. The results demonstrate that MABSA-SSA consistently better solution quality compared to the original MABSA alone. The comparative analysis demonstrates that the enhancement of MABSA exhibits superior performance in avoiding local optima and maintaining solution diversity. As conclusion, the enhancement of MABSA-SSA approach represent a significant advancement in benchmark optimization fields, providing a foundation for future developments in metaheuristic optimization and potential addressing the complex optimization challenges.

Inconel 718, a nickel-based super alloy widely used in aerospace and gas turbine industries, offers exceptional temperature strength, corrosion resistance, and work hardening behaviour. However, machining this material presents challenges due to its high strength, low thermal conductivity and work-hardening characteristics. To address these difficulties, Abrasive Waterjet Turning (AWJT) emerges as a promising alternative to conventional machining methods. This paper focuses on the application of AWJT in turning Inconel 718, exploring its principles and effects. Various factors influencing machining performance, such as spindle speed, feed rate and depth of cut are thoroughly examined and optimized. The surface roughness of the machining surface had a minimum value of 2.09 inm at run 7 while run 8 had a maximum value of Ra of 2.61 inm. Based on the results, the machine quality falls under N7 on the surface roughness chart. The investigation delves into the impact of AWJT on surface roughness while also discussing methods for monitoring the AWJT process. Through this comprehensive analysis, the potential of AWJT for machining Inconel 718 is explored, offering valuable insights for enhancing performance and its broader application in the industrial sector.

In the context of a CNC machining application, this study proposes an alternate approach for creating toolpaths designed explicitly for machining rectangular bosses utilizing the STEP AP242 file format as a data source. The suggested methodology ensures data accuracy and integrity maintenance by extracting exact geometric information from digital models using Geometric Data Extraction (GDE) tools. The value of the Cartesian multi-point decimal point in the data structure and variations in the reference number of the Cartesian point every time a user accesses and converts to a STEP (AP203) file are two drawbacks of AP203 when compared to the widely utilized AP203 in prior technique studies. This method makes it possible to create G-code efficiently, which is necessary for managing computer numerical control (CNC) machines, by utilizing the power of STEP AP242 and GDE. The process entails finding and separating the rectangular island milling features in the STEP AP242 files, taking out critical geometric characteristics, and creating toolpaths that are optimal for CNC machining. Through this approach, the final G-code instructions are guaranteed to be precisely calibrated to consider every island feature's distinct quality while preserving overall machining efficiency. Several real-world case studies and valuable applications are investigated to confirm the efficacy of the suggested method. The results show significant increases in productivity, decreased waste material, and improved precision of CNC machining, all of which contribute to a more effective and economical production process.

Abstract The Lower Cretaceous Minagish formations in Umm Gudair field is a prolific conventional oil reservoir located in onshore West Kuwait. The primary reservoir units are located in thick Oolitic Middle Minagish Member. The long-term field development plan for Umm Gudair field is focused on enhancing hydrocarbon production and extending the plateau rate for its large and matured carbonate reservoirs. Multiple horizontal wells are currently being used to improve well production from the Minagish Oolitic limestone reservoir. The success of these horizontal wells has led to the development of a reactive geosteering technique that allows for optimized placement of horizontal wellbores within the target Oolitic limestones. The geosteering technique is designed to utilize the reservoir character of the Oolitic limestones which in turn requires the implementation of a bottom hole assembly (BHA) configuration that positions the density/porosity logging while drilling (LWD) tool sensors close to the drill bit and ahead of other logging tools. This BHA configuration also provides porosity calculation to as much as close to the bit in TVD and MD mode. This technique has also been useful to steer the well above the barrier and baffle zone (high-density markers) to delay the water cut. A case study on five horizontal wells drilled in Minagish Oolite limestone reservoir, Umm Gudair field West Kuwait, where the geosteering technique of utilizing the near-bit-density-porosity BHA configuration was implemented. The study aims to highlight the impact of the geosteering technique on horizontal well drilling and hydrocarbon production, as well as explore the merits and demerits of the unique BHA configuration from an application engineering viewpoint. The positioning of the density/porosity sensors close to the drill bit reduces the reaction time in mitigating against structural play and layers’ property variations resulting in optimized horizontal wellbore placement and hydrocarbon production. This BHA is also helpful to detect early high-density markers within the reservoir which are compared to tight zones in Umm Gudair field. The interpolation of these high-density markers with respect to current oil water contact helps to keep the wellbore above the barrier and baffles lithology to delay water cut from underlying current oil water contact. The density/neutron LWD tool undergo more vibration in the optimized BHA configuration when compared to the conventional BHA configuration due to the components of vibrations being higher closer to the drill bit. This invariably accelerates wear and tear conditions in the fragile density/neutron LWD tool, increasing the likelihood of the tool failure while drilling. However, operational and engineering solutions are successfully being used to mitigate vibration problems associated with the near-bit-density-porosity BHA configuration which eliminates incurring potential additional costs due to the increase frequency of tool maintenance and repair. Utilizing the near-bit-density-porosity BHA configuration in optimizing horizontal well placement and hydrocarbon production in Oolitic limestone reservoir.

This paper presents a comprehensive study on the design and optimization of LPG safety caps, aimed at enhancing safety, reducing material consumption, and optimizing performance. The project employs SolidWorks simulation tools to conduct research and concept design phases. The primary objective is to ensure product safety while minimizing costs through Finite Element Analysis (FEA). The final product undergoes rigorous evaluation for performance and consumer safety. Three main goals guide this investigation: to scrutinize existing LPG safety cap designs, minimize material usage, and simulate the optimal design for enhanced safety. Analysis of the current design reveals vulnerabilities, including theft of LPG gas from sealed cylinders and escalating HDPE prices. Proposed designs simplify the current model and economize material consumption, successfully addressing the second objective. Through simulation, an optimal design (Design 8) emerges with superior characteristics compared to the existing model. Design 8 demonstrates a reduced total weight, higher safety factor, and lower maximum von Mises stress value. Notably, it exhibits enhanced safety and resilience, mitigating failure risks under stress conditions. The findings highlight the potential for creating stronger and safer designs while minimizing material requirements. In conclusion, Design 8 emerges as a superior alternative to the current design, boasting advantages in weight reduction, stress tolerance, safety factor, and optimization potential. This study underscores the significance of utilizing advanced computational methods to refine engineering designs for improved safety and efficiency in LPG safety caps.

Corrosion is a natural phenomenon that deteriorates and damages the surface of metallic material. Over time, the surface of the material deteriorates due to electrochemical reactions with the surrounding environment. If corrosion is not identified early on, it can become a major financial burden for industries, costing billions of dollars. Despite swift technological developments, preventing and maintaining corrosion progression with reactive maintenance remains difficult. Due to that, predictive maintenance has been developed to predict the deterioration, degradation, and fault over the remaining useful life of the material by using real-time data, historical data, simulation, modelling, and failure probability. Predictive maintenance allows inspectors to monitor the health and predict the corrosion level of the material. However, it is hard to predict the unexpected degradation of the material from the developed prediction model without considering the harsh environment and other external factors. Hence, there is a need to investigate these problems and their effect on predictive maintenance for corrosion detection and maintenance. Therefore, this paper reviews and compares the state-of-the-art predictive maintenance solutions developed to solve corrosion issues in various applications, industries, and academic research. The challenges and opportunities for the predictive maintenance application of corrosion detection and maintenance are also presented. This review will provide new and additional knowledge that can be used to develop prediction models for corrosion detection and maintenance, which will help prevent unexpected failures.

This paper presents the design and optimisation of a cost-effective benchtop three-axis CNC milling machine aimed at improving performance and precision. Beginning with a conservative design, topology optimisation using Altair SolidThinking Inspire software was employed. Static and modal analyses revealed significant improvements in the optimised structure's integrity and dynamic performance, confirmed through Finite Element Analysis (FEA) and impact hammer tests. The machine features affordable components and standard PC interfaces, ensuring high performance while maintaining low costs. Accuracy tests, including circularity and straightness assessments, identified optimal spindle speeds and feed rates for precision machining. The optimised design showed reduced static displacement and enhanced vibration resistance, ensuring reliable operations. This CNC milling machine, suitable for educational and small-scale manufacturing environments, offers a compact, affordable and user-friendly tool for teaching CNC operations and programming. The study highlights the importance of structural optimisation in CNC machine design, demonstrating notable performance gains through advanced engineering.

Abstract The Upper Burgan Reservoir located in west Kuwait is a diverse and intricate clastic reservoir, presenting challenges in well placement due to structural and sedimentological factors, as well as uncertainty regarding the Oil Water Contact (OWC) of the reservoir. To address these uncertainties a real-time resistivity inversion coupled with the near-bit-gamma ray and litho-density image interpretation were used to map remote conductive boundaries and to provide invaluable information on the reservoir structural architecture. A geo-navigation model was created using offset well gamma ray, resistivity, and bulk density measurements. The offset wells bulk density and resistivity measurements were further used as inputs in generating synthetic high-density images and forward resistivity inversion solutions along the planned well path trajectory. The resistivity inversion solutions provided a visualization of the logging while drilling (LWD) tool’s simulated azimuthal resistivity curves at varied depths of investigation within the specific Upper Burgan target reservoir environment and was a key factor in determining the tool’s look-ahead capability. The implemented BHA comprised of a rotary steerable system, near-bit-gamma, azimuthal and extra-deep resistivity, and the density-porosity-image technologies. The resistivity inversion results acquired from the extra-deep azimuthal resistivity measurements in real-time provided the look-ahead capability used in detecting the target UB1 reservoir ahead of the drill-bit allowing for timely adjustments to the wellbore trajectory resulting in accurate positioning of the wellbore within the productive zone of the target Upper Burgan UB1 reservoir. The extra-deep azimuthal resistivity real-time measurements also provided a means of visualizing the Upper Burgan UB1 reservoir architecture on a seismic scale and were key in making the geosteering decision to divert from the original well plan maximum wellbore inclination adjusting in steps up to 94.0 degrees to align the wellbore parallel to the formation dip thereby optimizing well bore placement. A combination of the Litho-density image and the deep and shallower azimuthal resistivity measurements provided important reservoir scale structural information. These were used to successfully navigate the wellbore within the productive zone of Upper Burgan UB1 target reservoir for +/-1300-ft MD footage of the drain section achieving 100-% reservoir contact. A petrophysical evaluation of the drilled interval in the Upper Burgan UB1 target reservoir identified excellent reservoir properties. The integration of the extra-deep azimuthal resistivity and litho-density image technologies in providing detailed seismic and reservoir scale structural and geological information proved invaluable in making geosteering decisions to achieve a more accurate positioning and subsequent navigation of wellbores within a complex siliciclastic environment. This strategy has resulted in an enhanced recovery of bypassed oil located in thief zones.

Ultrasonic Assisted Milling (UAM) offers an effective means to both increase productivity and decrease tool wear. In this review, UAM for milling Inconel 718 will be discussed along with its principles and effects. Factors affecting machining performance such as spindle speed, ultrasonic amplitude, tool geometry, and fluid usage, such as ultrasonic amplitude modulated parameters, are examined and optimized accordingly. This review investigates the effects of ultrasonic vibration on cutting force, tool wear, and surface roughness, as well as methods for monitoring and controlling the (UAM) process. Ultimately, this investigation explores its potential application to machining Inconel 718 with (UAM), providing insights for improved performance as well as wider industrial applications.

This study focuses on the evaluation of Inconel 718's machining surface quality. Inconel 718 is a superalloy based on nickel that is widely utilized in numerous important applications because of its remarkable mechanical qualities, resistance to corrosion, and stability at high temperatures. The utilization of various coolant and lubrication systems, including chilled minimum quantity lubrication (MQL), chilled air cooling, and dry cutting, is examined in this article. Cutting speed, Vc (100-140 m/min), feed rate, fz (0.1-0.2 mm/tooth), and cooling method (dry, chilled air, chilled MQL) are the three changeable parameters. The paper describes the experiment's findings on cutting force, surface roughness, and tool life. Additionally, explained is the relationship between the outcomes of tool life, surface finish, cutting force, and lubrication method. In comparison to chilled air cooling and dry cutting methods, chilled MQL with a cutting speed of 100 m/min and feed rate of 0.15 mm/tooth was found to give obvious advantages in extending tool life by 65.46 min, lowering surface roughness (0.221 mu m), and reducing cutting force (163 N) throughout the machining process.

This paper examines the effects of lubrication and cooling techniques on cutting force generated during milling Inconel 718. The study focuses on three different lubrication cooling strategies, namely dry, chilled, and chilled minimum quantity lubrication (MQL). In this study, the cutting parameters considered are a cutting speed between 100 and 140 m/min, a feed rate between 0.1 and 0.2 mm/tooth, and a constant depth of cut of 0.1 mm. 720 ml/h of Synkool 300G was used as the cutting fluid during the experiments. The results of the experimental analysis reveal that the chilled MQL strategy exhibits a noteworthy reduction in the main cutting force, even under high cutting speed conditions. This reduction in cutting force signifies improved machining efficiency and suggests the effectiveness of chilled MQL as a cooling and lubricating technique during the milling of Inconel 718. This research contributes to the optimization of cutting parameters and the selection of suitable cooling/lubricating strategies for improved machining performance and tool life in Inconel 718 milling.

Inconel 718 is widely used in components under harsh conditions. The abrasiveness of the carbide particles, poor heat conductivity and built-up edge (BUE) formation are common issues which warrant further investigation. In this work, the failure mode of a TiAlN/AlCrN-coated tungsten carbide (WC) tool during milling of Inconel 718 using different lubrication strategies, namely pulsating lubrication (PLS) and flood-coolant (FC), were compared. The effects of the pulsating water stream at 2000 pulse/min, when applying lubrication pressures at 8 bar, were discussed. Reduction of BUE at the tool tip was observed. The study revealed that this approach is better in delaying pitting, notch wear formation and flaking damage. Hence, the service life of a cutting tool can be extended when compared to the flood-coolant strategy.

This study emphasizes the catalytic function of TiF3 on hydrogen storage properties and the reaction mechanism of the MgH2-Na3AlH6-LiBH4 produced by employing the ball-milling technique, which has a molar ratio of 1:1:4. It discovered that the mixture of Na3AlH6 and LiBH4 reacted through a metathesis reaction and transformed into Li3AlH6 and NaBH4 composite upon the ball milling procedure. MgH2-Li3AlH6-NaBH4 destabilized system with TiF3 catalyst has displayed four decomposition tiers throughout the heating procedure. The initial tier of hydrogen release in the composite occurs at temperatures of 100 degrees C and 75 degrees C lower than in the catalyst-free composite. Continuous heating resulted in two through four dehydrogenation tiers, with an overall capacity of 10.1 wt% hydrogens released (at temperatures of 200 degrees C, 350 degrees C, and 400 degrees C, respectively). In contrast to the Mg-Na-Al-Li-B-H catalyst-free composite, incorporating the TiF3 catalyst demonstrates a faster hydrogen uptake and release rate. The apparent activation energy (Ea) for the dissociation of Li3AlH6, MgH2, and NaBH4 in the composite with TiF3 catalyst was remarkably abridged compared to the catalyst-free ternary system (Kissinger plot; 23, 20, and 13 kJ/mol, respectively for doped composite). TiF3's considerable catalytic performance is ascribed to the in-situ production of Al-Ti and Al-F phases during the dehydrogenation process of TiF3 and Li3AlH6. Once generated, the Al-Ti and Al-F phase serves as a genuine catalyst in the MgH2-Na3AlH6-4LiBH4- TiF3 ternary system.