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Article Enhancing machining efficiency of Ti-6Al-4V through multi-axial ultrasonic vibration-assisted machining and hybrid nanofluid minimum quantity lubrication(Journal of Manufacturing Processes, 2024-06-15) Namlu, Ramazan Hakkı; Lotfi, Bahram; Kılıç, S. EnginTi-6Al-4V offers a balance of good strength with lightweight properties. Yet, Ti-6Al-4V poses machining challenges, including low thermal conductivity, chemical adhesion to cutting tools, and chip removal difficulties. To improve machining efficiency, Ultrasonic Vibration-Assisted Machining (UVAM) has emerged as a promising approach. UVAM has demonstrated reduced tool wear, cutting forces, and improved surface quality compared to Conventional Machining (CM). Additionally, Minimum Quantity Lubrication (MQL) methods offer sustainable coolant alternatives, with recent research focusing on Nanofluid-MQL (NMQL) and Hybrid Nanofluid-MQL (HNMQL) for enhanced performance. Although there exists a body of literature showcasing the promising effects of UVAM and MQL methods individually, comprehensive investigations into the synergistic effects of these methodologies remain limited. This study addresses these critical research gaps by conducting a systematic examination of combined application of multi-axial UVAM and HNMQL. Specifically, it delves into the comparison of different vibration directions within UVAM, evaluates the effectiveness of UVAM when combined with cutting fluids incorporating Al2O3 and CuO nanoparticles in NMQLs and HNMQLs, and contrasts these novel approaches with conventional machining methods. The study unfolds in three distinct stages. The first stage examines the ultrasonic cutting mechanism and its combined application with the MQL technique. In the second stage, the study investigates the physical properties of the cutting fluids, including contact angle and surface tension. The final stage encompasses slot milling operations, where an array of parameters such as cutting forces, surface roughness, surface topography, surface texture, and the occurrence of burr formations are rigorously analyzed. The results demonstrate that the combination of multi-axial UVAM with HNMQL yields substantial advantages over traditional machining methods. Notably, it leads to a remarkable reduction in cutting forces (up to 37.6 %) and surface roughness (up to 37.4 %). Additionally, this combination engenders the production of highly homogeneous and uniform surface textures, characterized by minimal surface defects and a significantly diminished occurrence of burr formations. These findings underscore the potential of multi-axial UVAM combined with HNMQL as a promising approach in enhancing the machining of Ti-6Al-4V, thus offering a pathway to enhance the efficiency and precision of aerospace component manufacturing processes.Article An experimental study on ultrasonic-assisted drilling of Inconel 718 under different cooling/lubrication conditions(The International Journal of Advanced Manufacturing Technology, 2024-01) Erturun, Ömer Faruk; Tekaüt, Hasan; Çiçek, Adem; Uçak, Necati; Namlu, Ramazan Hakkı; Lotfi, Bahram; Kılıç, S. EnginUltrasonic-assisted drilling (UAD) is one of the efficient and innovative methods to improve the drillability of difficult-to-cut materials. In the present study, the UAD of Inconel 718 was investigated under different cooling and/or lubrication conditions. The drilling tests were carried out at a constant cutting speed (15 m/min) and a feed (0.045 mm/rev) using uncoated and TiAlN-coated solid carbide drills under dry, conventional cutting fluid (CCF), and minimum quantity lubrication (MQL) conditions. The applicability of UAD to drilling Inconel 718 was evaluated in terms of thrust force, surface roughness, roundness error, burr formation, subsurface microstructure and microhardness, tool wear, and chip morphology. The test results showed that when compared to conventional drilling (CD), UAD reduced the thrust force and improved the hole quality, tool life, and surface integrity under all conditions. Good surface finish, lower roundness error and minimum burr heights were achieved under CCF conditions. MQL drilling provided lower thrust forces, better tool performance and good subsurface quality characteristics. In addition, the simultaneous application of CCF-UAD and MQD-UAD showed significantly better performance, especially when using the coated tool.Article Machining performance and sustainability analysis of Al2O3-CuO hybrid nanofluid MQL application for milling of Ti-6Al-4V(Machining Science and Technology, 2024-01-15) Lotfi, Bahram; Namlu, Ramazan Hakkı; Kılıç, S. EnginMachining of Ti-6Al-4V presents challenges due to its low thermal conductivity, and conventional cutting fluids (CCF) are inadequate in providing a productive and sustainable solution. This study aims to achieve more sustainable and productive machining of Ti-6Al-4V by utilizing Al2O3 and CuO-added Nanofluid Minimum Quantity Lubrication (NMQL) individually and in hybrid form with different concentrations. A comparison is made with pure-MQL, CCF and dry conditions. The study consists of three stages. In the first stage, the physical properties of the coolants, like contact angle and surface tension, are investigated. The second stage involves slot milling operations, and various outputs including cutting forces, surface roughness, surface topography, surface finish, and subsurface microhardness are analyzed. In the last stage, a sustainability analysis is conducted based on the Pugh Matrix Approach. The results indicate that Al2O3-NMQL exhibits lower contact angles and surface tensions compared to other conditions. Furthermore, HNMQL applications result in lower cutting forces (up to 46.5%), surface roughness (up to 61.2%), and microhardness (up to 6.6%), while yielding better surface finish and topography compared to CCF. The sustainability analysis demonstrates that HNMQL application is the most suitable option for achieving sustainable machining of Ti-6Al-4V.Article Combined use of ultrasonic-assisted drilling and minimum quantity lubrication for drilling of NiTi shape memory alloy(Machining Science and Technology, 2023-06-24) Namlu, Ramazan Hakkı; Lotfi, Bahram; Kılıç, S. Engin; Yılmaz, Okan Deniz; Akar, SametThe drilling of shape-memory alloys based on nickel-titanium (Nitinol) is challenging due to their unique properties, such as high strength, high hardness and strong work hardening, which results in excessive tool wear and damage to the material. In this study, an attempt has been made to characterize the drillability of Nitinol by investigating the process/cooling interaction. Four different combinations of process/cooling have been studied as conventional drilling with flood cooling (CD-Wet) and with minimum quantity lubrication (CD-MQL), ultrasonic-assisted drilling with flood cooling (UAD-Wet) and with MQL (UAD-MQL). The drill bit wear, drilling forces, chip morphology and drilled hole quality are used as the performance measures. The results show that UAD conditions result in lower feed forces than CD conditions, with a 31.2% reduction in wet and a 15.3% reduction in MQL on average. The lowest feed forces are observed in UAD-Wet conditions due to better coolant penetration in the cutting zone. The UAD-Wet yielded the lowest tool wear, while CD-MQL exhibited the most severe. UAD demonstrated a ∼50% lower tool wear in the wet condition than CD and a 38.7% in the MQL condition. UAD is shown to outperform the CD process in terms of drilled-hole accuracy.Article Theoretical Modelling of Magnetron Sputtering of Boron Nitride Coating(MRS Communications, 2023-02) Rake, Nakka; Kaftanoğlu, Bilgin; Hacaloğlu, Tuğçe; Aydoğan, AsudeThe fundamentals of the magnetron sputtering (MS) technique are simple. However, the complex interplay of various physical and chemical sub-processes lies in its simplicity. The direct simulation Monte Carlo (DSMC) method is used to model the MS of the Boron Nitride (BN) coating. The Lorentz force, which is created by an electric field, magnetic field and particle collision, is utilized to model the BN coating. Three distinct bias voltages are used to generate three different BN coating models under the same conditions. The modelling of BN coatings reveals that the deposition rate decreases as the substrate voltage increases.