Broaching Digital Twin to Predict Forces, Local Overloads, and Surface Topography Irregularities.

Broaching is a key manufacturing process that directly influences the surface integrity of critical components, impacting their functional performance in sectors such as aeronautics, automotive, and energy. Such components are subjected to severe conditions, including high thermomechanical loads, fatigue, and corrosion. For this reason, the development of predictive models is essential for determining the optimal tool design and machining conditions to ensure proper in-service performance.

Experimental evaluation and surface integrity analysis of cryogenic coolants approaches in the cylindrical plunge grinding.

Replacement of pollutant fluids with eco-friendly strategies in machining operations significantly contributes to protecting the environment, diminishing global warming, and ensuring a healthier workplace for employees. This study compares cryogenic coolants with conventional coolants in cylindrical plunge grinding using a Cubic Boron Nitride (CBN) wheel. Samples of 27MnCr5 steel used in the manufacture of automotive transmission components were ground using (i) Liquid Nitrogen (LN), (ii) a combination of LN + Minimum Quantity Lubrication (MQL), and (iii) a conventional coolant.

Load bearing performance of mechanical joints inspired by elbow of quadrupedal mammals.

One of the biggest issues of the mechanical cylindrical joints is related to premature wear appearing. Application of bioinspiration principles in an engineering context taking advantage of smart solutions offered by nature in terms of kinematic joints could be a way of solving those problems. This work is focussed on joints of one degrees of freedom in rotation (revolute or ginglymus joints in biological terms), as this is one of the most common type of mechanical joints.

In-SEM micro-machining reveals the origins of the size effect in the cutting energy.

High-precision metal cutting is increasingly relevant in advanced applications. Such precision normally requires a cutting feed in the micron or even sub-micron dimension scale, which raises questions about applicability of concepts developed in industrial scale machining. To address this challenge, we have developed a device to perform linear cutting with force measurement in the vacuum chamber of an electron microscope, which has been utilised to study the cutting process down to 200 nm of the feed and the tool tip radius.