Khaled Hamdy - Academia.edu (original) (raw)

Papers by Khaled Hamdy

Technologies

The paper aims to extend the current knowledge on electrical discharge machining of insulating ma... more The paper aims to extend the current knowledge on electrical discharge machining of insulating materials, such as cutting ceramics used to produce cutting inserts to machine nickel-based alloys in the aviation and aerospace industries. Aluminum-based ceramics such as Al2O3, AlN, and SiAlON are in the most demand in the industry but present a scientific and technical problem in obtaining sophisticated shapes. One of the existing solutions is electrical discharge machining using assisting techniques. Using assisting Cu-Ag and Cu mono- and multi-layer coatings of 40–120 µm and ZnO powder-mixed deionized water-based medium was proposed for the first time. The developed coatings were subjected to tempering and testing. It was noticed that Ag-adhesive reduced the performance when tempering had a slight effect. The unveiled relationship between the material removal rate, powder concentration, and pulse frequency showed that performance was significantly improved by adding assisting powder ...

Technologies

Aluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechani... more Aluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechanical and thermal load conditions during the machining of Ni-based and high-entropy alloys. There is wide field of application also in the aerospace industry. Microtexturing of cutting ceramics reduces contact loads and wear of cutting tools. However, most of the published works are related to the electrical discharge machining of alumina in hydrocarbons, which creates risks for the personnel and equipment due to the formation of chemically unstable dielectric carbides (methanide Al3C4 and acetylenide Al2(C2)3). An alternative approach for wire electrical discharge machining Al2O3 in the water-based dielectric medium using copper tape of 40 µm thickness and TiO2 powder suspension was proposed for the first time. The performance was evaluated by calculating the material removal rate for various combinations of pulse frequency and TiO2 powder concentration. The obtained kerf of 54.16 ± 0.05 ...

Metals

Aluminum-based ceramics exhibit excellent wear resistance and hot hardness that are suitable for ... more Aluminum-based ceramics exhibit excellent wear resistance and hot hardness that are suitable for various responsible applications allowing products to work under extreme mechanical and thermal loads (up to 1000 °C). The problem of high-precision forming complex-shaped parts is a known engineering challenge due to the insulating properties of aluminum-containing ceramics and the formation of chemically active carbides in a hydrocarbon medium. The alternative approach for electrical discharge machining non-conductive sintered Al2O3 in the water-based medium using nickel-chrome plasma-vapor-deposed coating of 12 mm, SnO powder suspension (particle diameter of ⌀10 µm, concentration of 150 g/L), and brass wire-tool is proposed. The productivity was evaluated by calculating the material removal rate and discharge gap for various combinations of pulse frequency and duration. The maximal material removal rate of 0.0014 mm3/s was achieved for a pulse frequency of 30 kHz and pulse duration of...

Materials

The mechanism of the material destruction under discharge pulses and material removal mechanism b... more The mechanism of the material destruction under discharge pulses and material removal mechanism based on the thermochemical nature of the electrical erosion during electrical discharge machining of conductive materials were researched. The experiments were conducted for two structural materials used in the aerospace industry, namely austenite anticorrosion X10CrNiTi18-10 (12kH18N10T) steel and 2024 (D16) duralumin, machined by a brass tool of 0.25 mm in diameter in a deionized water medium. The optimized wire electrical discharge machining factors, measured discharge gaps (recommended offset is 170–175 µm and 195–199 µm, respectively), X-ray photoelectron spectroscopy for both types of materials are reported. Elemental analysis showed the presence of metallic Zn, CuO, iron oxides, chromium oxides, and 58.07% carbides (precipitation and normal atmospheric contamination) for steel and the presence of metallic Zn, CuO, ZnO, aluminum oxide, and 40.37% carbides (contamination) for duralu...

Materials

Machining is an indispensable manufacturing process for a wide range of engineering materials, su... more Machining is an indispensable manufacturing process for a wide range of engineering materials, such as metals, ceramics, and composite materials, in which the tool wear is a serious problem, which affects not only the costs and productivity but also the quality of the machined components. Thus, the modification of the cutting tool surface by application of textures on their surfaces is proposed as a very promising method for improving tool life. Surface texturing is a relatively new surface engineering technology, where microscale or nanoscale surface textures are generated on the cutting tool through a variety of techniques in order to improve tribological properties of cutting tool surfaces by reducing the coefficient of friction and increasing wear resistance. In this paper, the studies carried out to date on the texturing of ceramic and superhard cutting tools have been reviewed. Furthermore, the most common methods for creating textures on the surfaces of different materials ha...

Metals, 2021

The material removal mechanism, submicrostructure of surface and subsurface layers, nanotransform... more The material removal mechanism, submicrostructure of surface and subsurface layers, nanotransformations occurred in surface and subsurface layers during electrical discharge machining two structural materials such as anti-corrosion X10CrNiTi18-10 (12kH18N10T) steel of austenite class and 2024 (D16) duralumin in a deionized water medium were researched. The machining was conducted using a brass tool of 0.25 mm in diameter. The measured discharge gap is 45–60 µm for X10CrNiTi18-10 (12kH18N10T) steel and 105–120 µm for 2024 (D16) duralumin. Surface roughness parameters are arithmetic mean deviation (Ra) of 4.61 µm, 10-point height (Rz) of 28.73 µm, maximum peak-to-valley height (Rtm) of 29.50 µm, mean spacing between peaks (Sm) of 18.0 µm for steel; Ra of 5.41 µm, Rz of 35.29 µm, Rtm of 43.17 µm, Sm of 30.0 µm for duralumin. The recast layer with adsorbed components of the wire tool electrode and carbides was observed up to the depth of 4–6 µm for steel and 2.5–4 µm for duralumin. The ...

The experimental results indicate the possibility of obtaining on the surface of the aluminium al... more The experimental results indicate the possibility of obtaining on the surface of the aluminium alloy layers, modified by alloying with electron-beam technology, significantly increases its wear resistance. Such layers obtained thanks to the initiation of exothermic chemical reactions between substrate and deposited on it a thin film of titanium. In the reaction products was revealed the formation of intermetallic phases.

Nanoengineering: Fabrication, Properties, Optics, Thin Films, and Devices XVIII, 2021

This paper discusses a new complex approach and an example of its practical application to solve ... more This paper discusses a new complex approach and an example of its practical application to solve the problem of improving the precision ceramics products and parts operational performance (ensuring high operational stability). The proposed approach consists of forming micro-texture in a ceramic product surface layer through vacuum-plasma deposition of conductive nanocomposite coatings based on a multicomponent thermally stable nitrides Ti-Al-Cr system as an auxiliary electrode in electrical discharge machining such as forming a specific microtexture in the surface layer, e.g., a combination of cavities, grooves, etc. This approach considerably improves the ceramic product surface layer characteristics, reduces contact surfaces' "ceramic product – counter face" adhesion and friction intensity, and ensures increased wear resistance and ceramic product operability.

Materials & Design, 2021

Abstract Ceramics are widespread materials for engineering applications due to their properties, ... more Abstract Ceramics are widespread materials for engineering applications due to their properties, such as low wear resistance and coefficient of thermal expansion. The high hardness and brittleness of ceramics reveal their difficulties in traditional machining. Electrical discharge machining is induced to be a method for machining non-conductive ceramics in the present review. The ability to be subjected to electrical discharge machining depends on their electrical properties. Some techniques allow subjecting to electrical discharge machining insulating materials where impulses are addressed to assisting films or particles. However, the most promising cutting ceramics' machining results stayed under expectations, with a maximum depth of 1651 um. The study is devoted to the systematization of the obtained during the last decades' results, analyses of the chemical content of the formed erosion products using assisting electrodes made of Copper subgroup, elements of the second-third period, d-elements in hydrocarbon and water medium based on the theory of structure and transformation of substances for Al2O3, AlN, SiAlON, Si3N4, ZrO2, development of the alternative perspectives and unique cross-disciplinary approach that is critical for transitioning to the sixth technological paradigm associated with the Kondratieff waves.

Technologies, 2020

This work is devoted to researching the tool electrode behavior and wear under discharge pulses a... more This work is devoted to researching the tool electrode behavior and wear under discharge pulses at electrical discharge machining. The experiments were conducted on the workpieces of 12Kh18N10T (AISI 321) chrome-nickel anti-corrosion steel and D16 (AA 2024) duralumin by a 0.25-mm-diameter CuZn35 brass tool in a deionized water medium. The developed diagnostic and monitoring mean based on acoustic emission registered the oscillations accompanying machining at 4–8 kHz. The obtained workpiece and non-profiled tool surfaces were investigated by optical and scanning electron microscopy. Calculated volumetric and mass removal rates showed the difference in the character of wear at roughing and finishing. It was shown that interaction between material components in anti-corrosion steel machining had an explosive character between Zn of brass and Ni of steel at a micron level and formed multiple craters of 30–100 µm. The secondary structure and topology of worn tool surfaces were caused by ...

Technologies, 2020

One of the promising processing methods for non-conductive structural and functional ceramics bas... more One of the promising processing methods for non-conductive structural and functional ceramics based on ZrO2, Al2O3, and Si3N4 systems is electrical discharge machining with the assistance of an auxiliary electrode that can be presented in the form of conductive films with a thickness up to 4–10 µm or nanoparticles - granules, tubes, platelets, multidimensional particles added in the working zone as a free poured powder the proper concentration of which can be provided by ultrasound emission or by dielectric flows or as conductive additives in the structure of nanocomposites. However, the described experimental approaches did not reach the production market and industry. It is related mostly to the chaotic development of the knowledge and non-systematized data in the field when researchers often cannot ground their choice of the material for auxiliary electrodes, assisting powders, or nano additives or they cannot explain the nature of processes that were observed in the working tank...

Mechanics & Industry, 2018

Laser ablation is considered as an alternative to other methods that allow precise processing of ... more Laser ablation is considered as an alternative to other methods that allow precise processing of various tool materials and work with both the base material and thin films of wear-resistant coatings. This article presents an investigation of the possibility of setting the microgeometry of the surface of cutting tool made of high-speed steel M2 and hard alloy WCCo3 using ablation with nanosecond infrared marking Nd:YVO4 laser. Dependencies of the width and depth of the resulting tracks on the specified laser power are obtained. It was revealed that their depth depends on a set of several specified factors: power, scanning speed, pulse frequency rate, and a number of passes. The modes with a radiation power of up to 70% are of interest for the treatment of the tool surface using a laser because they have a more predictable profile and more efficient energy distribution. The most uniform and smooth surface were obtained after laser treatment with the following parameters: power 60%, fr...

This paper introduces a new technique of design tool by inserted one or two tips to the tool for ... more This paper introduces a new technique of design tool by inserted one or two tips to the tool for enhancing its ability for machining high accuracy. The values of electric current, metal removal rates, surface roughness and conicity are investigated. Based on the experiments, it is concluded that the new technique is very effective for angles more than 10o for high accuracy in conicity. Tool with two inserted tips, the machined hole becomes more smoother around 0.02 Ra and the range of current value does not exceed 60 A so providing low cost is given following that low price products.

International Journal of Control Automation and Systems

Electrochemical machining (ECM) is one of non-traditional machining process. It offers the abilit... more Electrochemical machining (ECM) is one of non-traditional machining process. It offers the ability to machine extremely hard materials or materials that are difficult to be machined using conventional methods. Moreover, it is considered one of the most effective ways to machine the complex shapes of internal and external geometries . This paper introduces a new electrode tool drilling with insert tip instead of traditional die electrode tool shape used in machining of internal cylindrical shapes. It reviews the development of high efficiency and low cost electrode for electrochemical cylindrical machining. The effect of insert tool profile on current values, metal removal rate (MRR), conicity, and surface roughness is investigated. Based on the experiments, it is concluded that by using the proposed insert tip tool profile, the hole machining becomes more accurate with smoother surface roughness with a remarkable reduction in the value of the consumed current.

Manufacturing Review, 2019

For mechanical machining the quality of cutting-tool materials is one of the most significant iss... more For mechanical machining the quality of cutting-tool materials is one of the most significant issues that need to be addressed. Enhancement of cutting tool performance may be achieved through the use of modern composition ceramic cutting tools This may be enabled through surface treatment, and also hot pressing and spark plasma sintering – the two main processes used for manufacturing such tools. In this article the advantages and disadvantages of the technologies and processes involved are analyzed and compared to identify the most appropriate methods for creating ceramic cutting-tools. In parallel the latest improvements in ceramic cutting-tool materials are reviewed. The paper shows that the choice of ceramic cutting tools is a quite complex process with a number of important factors to be taken into account.

Journal of Manufacturing and Materials Processing, 2020

The work is devoted to the research of the changes that occur in the subsurface layer of the work... more The work is devoted to the research of the changes that occur in the subsurface layer of the workpiece during electrical discharge machining of conductive nanocomposite based on alumina with the use of a brass tool. The nanocomposite of Al2O3 + 30% of TiC was electroerosively machined in a water and hydrocarbon oil. The process of electrical discharge machining is accompanied by oscillations that were registered by diagnostic means. The obtained surface of the samples was researched by the means of scanning electron microscopy and X-ray photoelectron spectroscopy. The observed surface and subsurface changes provide grounding for the conclusions on the nature of processes and reactions that occur between two electrodes and nanomodification of the obtained surfaces that can be an advantage for a series of applications.

Technologies

The paper aims to extend the current knowledge on electrical discharge machining of insulating ma... more The paper aims to extend the current knowledge on electrical discharge machining of insulating materials, such as cutting ceramics used to produce cutting inserts to machine nickel-based alloys in the aviation and aerospace industries. Aluminum-based ceramics such as Al2O3, AlN, and SiAlON are in the most demand in the industry but present a scientific and technical problem in obtaining sophisticated shapes. One of the existing solutions is electrical discharge machining using assisting techniques. Using assisting Cu-Ag and Cu mono- and multi-layer coatings of 40–120 µm and ZnO powder-mixed deionized water-based medium was proposed for the first time. The developed coatings were subjected to tempering and testing. It was noticed that Ag-adhesive reduced the performance when tempering had a slight effect. The unveiled relationship between the material removal rate, powder concentration, and pulse frequency showed that performance was significantly improved by adding assisting powder ...

Technologies

Aluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechani... more Aluminum-based ceramics are used in industry to produce cutting tools that resist extreme mechanical and thermal load conditions during the machining of Ni-based and high-entropy alloys. There is wide field of application also in the aerospace industry. Microtexturing of cutting ceramics reduces contact loads and wear of cutting tools. However, most of the published works are related to the electrical discharge machining of alumina in hydrocarbons, which creates risks for the personnel and equipment due to the formation of chemically unstable dielectric carbides (methanide Al3C4 and acetylenide Al2(C2)3). An alternative approach for wire electrical discharge machining Al2O3 in the water-based dielectric medium using copper tape of 40 µm thickness and TiO2 powder suspension was proposed for the first time. The performance was evaluated by calculating the material removal rate for various combinations of pulse frequency and TiO2 powder concentration. The obtained kerf of 54.16 ± 0.05 ...

Metals

Aluminum-based ceramics exhibit excellent wear resistance and hot hardness that are suitable for ... more Aluminum-based ceramics exhibit excellent wear resistance and hot hardness that are suitable for various responsible applications allowing products to work under extreme mechanical and thermal loads (up to 1000 °C). The problem of high-precision forming complex-shaped parts is a known engineering challenge due to the insulating properties of aluminum-containing ceramics and the formation of chemically active carbides in a hydrocarbon medium. The alternative approach for electrical discharge machining non-conductive sintered Al2O3 in the water-based medium using nickel-chrome plasma-vapor-deposed coating of 12 mm, SnO powder suspension (particle diameter of ⌀10 µm, concentration of 150 g/L), and brass wire-tool is proposed. The productivity was evaluated by calculating the material removal rate and discharge gap for various combinations of pulse frequency and duration. The maximal material removal rate of 0.0014 mm3/s was achieved for a pulse frequency of 30 kHz and pulse duration of...

Materials

The mechanism of the material destruction under discharge pulses and material removal mechanism b... more The mechanism of the material destruction under discharge pulses and material removal mechanism based on the thermochemical nature of the electrical erosion during electrical discharge machining of conductive materials were researched. The experiments were conducted for two structural materials used in the aerospace industry, namely austenite anticorrosion X10CrNiTi18-10 (12kH18N10T) steel and 2024 (D16) duralumin, machined by a brass tool of 0.25 mm in diameter in a deionized water medium. The optimized wire electrical discharge machining factors, measured discharge gaps (recommended offset is 170–175 µm and 195–199 µm, respectively), X-ray photoelectron spectroscopy for both types of materials are reported. Elemental analysis showed the presence of metallic Zn, CuO, iron oxides, chromium oxides, and 58.07% carbides (precipitation and normal atmospheric contamination) for steel and the presence of metallic Zn, CuO, ZnO, aluminum oxide, and 40.37% carbides (contamination) for duralu...

Materials

Machining is an indispensable manufacturing process for a wide range of engineering materials, su... more Machining is an indispensable manufacturing process for a wide range of engineering materials, such as metals, ceramics, and composite materials, in which the tool wear is a serious problem, which affects not only the costs and productivity but also the quality of the machined components. Thus, the modification of the cutting tool surface by application of textures on their surfaces is proposed as a very promising method for improving tool life. Surface texturing is a relatively new surface engineering technology, where microscale or nanoscale surface textures are generated on the cutting tool through a variety of techniques in order to improve tribological properties of cutting tool surfaces by reducing the coefficient of friction and increasing wear resistance. In this paper, the studies carried out to date on the texturing of ceramic and superhard cutting tools have been reviewed. Furthermore, the most common methods for creating textures on the surfaces of different materials ha...

Metals, 2021

The material removal mechanism, submicrostructure of surface and subsurface layers, nanotransform... more The material removal mechanism, submicrostructure of surface and subsurface layers, nanotransformations occurred in surface and subsurface layers during electrical discharge machining two structural materials such as anti-corrosion X10CrNiTi18-10 (12kH18N10T) steel of austenite class and 2024 (D16) duralumin in a deionized water medium were researched. The machining was conducted using a brass tool of 0.25 mm in diameter. The measured discharge gap is 45–60 µm for X10CrNiTi18-10 (12kH18N10T) steel and 105–120 µm for 2024 (D16) duralumin. Surface roughness parameters are arithmetic mean deviation (Ra) of 4.61 µm, 10-point height (Rz) of 28.73 µm, maximum peak-to-valley height (Rtm) of 29.50 µm, mean spacing between peaks (Sm) of 18.0 µm for steel; Ra of 5.41 µm, Rz of 35.29 µm, Rtm of 43.17 µm, Sm of 30.0 µm for duralumin. The recast layer with adsorbed components of the wire tool electrode and carbides was observed up to the depth of 4–6 µm for steel and 2.5–4 µm for duralumin. The ...

The experimental results indicate the possibility of obtaining on the surface of the aluminium al... more The experimental results indicate the possibility of obtaining on the surface of the aluminium alloy layers, modified by alloying with electron-beam technology, significantly increases its wear resistance. Such layers obtained thanks to the initiation of exothermic chemical reactions between substrate and deposited on it a thin film of titanium. In the reaction products was revealed the formation of intermetallic phases.

Nanoengineering: Fabrication, Properties, Optics, Thin Films, and Devices XVIII, 2021

This paper discusses a new complex approach and an example of its practical application to solve ... more This paper discusses a new complex approach and an example of its practical application to solve the problem of improving the precision ceramics products and parts operational performance (ensuring high operational stability). The proposed approach consists of forming micro-texture in a ceramic product surface layer through vacuum-plasma deposition of conductive nanocomposite coatings based on a multicomponent thermally stable nitrides Ti-Al-Cr system as an auxiliary electrode in electrical discharge machining such as forming a specific microtexture in the surface layer, e.g., a combination of cavities, grooves, etc. This approach considerably improves the ceramic product surface layer characteristics, reduces contact surfaces' "ceramic product – counter face" adhesion and friction intensity, and ensures increased wear resistance and ceramic product operability.

Materials & Design, 2021

Abstract Ceramics are widespread materials for engineering applications due to their properties, ... more Abstract Ceramics are widespread materials for engineering applications due to their properties, such as low wear resistance and coefficient of thermal expansion. The high hardness and brittleness of ceramics reveal their difficulties in traditional machining. Electrical discharge machining is induced to be a method for machining non-conductive ceramics in the present review. The ability to be subjected to electrical discharge machining depends on their electrical properties. Some techniques allow subjecting to electrical discharge machining insulating materials where impulses are addressed to assisting films or particles. However, the most promising cutting ceramics' machining results stayed under expectations, with a maximum depth of 1651 um. The study is devoted to the systematization of the obtained during the last decades' results, analyses of the chemical content of the formed erosion products using assisting electrodes made of Copper subgroup, elements of the second-third period, d-elements in hydrocarbon and water medium based on the theory of structure and transformation of substances for Al2O3, AlN, SiAlON, Si3N4, ZrO2, development of the alternative perspectives and unique cross-disciplinary approach that is critical for transitioning to the sixth technological paradigm associated with the Kondratieff waves.

Technologies, 2020

This work is devoted to researching the tool electrode behavior and wear under discharge pulses a... more This work is devoted to researching the tool electrode behavior and wear under discharge pulses at electrical discharge machining. The experiments were conducted on the workpieces of 12Kh18N10T (AISI 321) chrome-nickel anti-corrosion steel and D16 (AA 2024) duralumin by a 0.25-mm-diameter CuZn35 brass tool in a deionized water medium. The developed diagnostic and monitoring mean based on acoustic emission registered the oscillations accompanying machining at 4–8 kHz. The obtained workpiece and non-profiled tool surfaces were investigated by optical and scanning electron microscopy. Calculated volumetric and mass removal rates showed the difference in the character of wear at roughing and finishing. It was shown that interaction between material components in anti-corrosion steel machining had an explosive character between Zn of brass and Ni of steel at a micron level and formed multiple craters of 30–100 µm. The secondary structure and topology of worn tool surfaces were caused by ...

Technologies, 2020

One of the promising processing methods for non-conductive structural and functional ceramics bas... more One of the promising processing methods for non-conductive structural and functional ceramics based on ZrO2, Al2O3, and Si3N4 systems is electrical discharge machining with the assistance of an auxiliary electrode that can be presented in the form of conductive films with a thickness up to 4–10 µm or nanoparticles - granules, tubes, platelets, multidimensional particles added in the working zone as a free poured powder the proper concentration of which can be provided by ultrasound emission or by dielectric flows or as conductive additives in the structure of nanocomposites. However, the described experimental approaches did not reach the production market and industry. It is related mostly to the chaotic development of the knowledge and non-systematized data in the field when researchers often cannot ground their choice of the material for auxiliary electrodes, assisting powders, or nano additives or they cannot explain the nature of processes that were observed in the working tank...

Mechanics & Industry, 2018

Laser ablation is considered as an alternative to other methods that allow precise processing of ... more Laser ablation is considered as an alternative to other methods that allow precise processing of various tool materials and work with both the base material and thin films of wear-resistant coatings. This article presents an investigation of the possibility of setting the microgeometry of the surface of cutting tool made of high-speed steel M2 and hard alloy WCCo3 using ablation with nanosecond infrared marking Nd:YVO4 laser. Dependencies of the width and depth of the resulting tracks on the specified laser power are obtained. It was revealed that their depth depends on a set of several specified factors: power, scanning speed, pulse frequency rate, and a number of passes. The modes with a radiation power of up to 70% are of interest for the treatment of the tool surface using a laser because they have a more predictable profile and more efficient energy distribution. The most uniform and smooth surface were obtained after laser treatment with the following parameters: power 60%, fr...

This paper introduces a new technique of design tool by inserted one or two tips to the tool for ... more This paper introduces a new technique of design tool by inserted one or two tips to the tool for enhancing its ability for machining high accuracy. The values of electric current, metal removal rates, surface roughness and conicity are investigated. Based on the experiments, it is concluded that the new technique is very effective for angles more than 10o for high accuracy in conicity. Tool with two inserted tips, the machined hole becomes more smoother around 0.02 Ra and the range of current value does not exceed 60 A so providing low cost is given following that low price products.

International Journal of Control Automation and Systems

Electrochemical machining (ECM) is one of non-traditional machining process. It offers the abilit... more Electrochemical machining (ECM) is one of non-traditional machining process. It offers the ability to machine extremely hard materials or materials that are difficult to be machined using conventional methods. Moreover, it is considered one of the most effective ways to machine the complex shapes of internal and external geometries . This paper introduces a new electrode tool drilling with insert tip instead of traditional die electrode tool shape used in machining of internal cylindrical shapes. It reviews the development of high efficiency and low cost electrode for electrochemical cylindrical machining. The effect of insert tool profile on current values, metal removal rate (MRR), conicity, and surface roughness is investigated. Based on the experiments, it is concluded that by using the proposed insert tip tool profile, the hole machining becomes more accurate with smoother surface roughness with a remarkable reduction in the value of the consumed current.

Manufacturing Review, 2019

For mechanical machining the quality of cutting-tool materials is one of the most significant iss... more For mechanical machining the quality of cutting-tool materials is one of the most significant issues that need to be addressed. Enhancement of cutting tool performance may be achieved through the use of modern composition ceramic cutting tools This may be enabled through surface treatment, and also hot pressing and spark plasma sintering – the two main processes used for manufacturing such tools. In this article the advantages and disadvantages of the technologies and processes involved are analyzed and compared to identify the most appropriate methods for creating ceramic cutting-tools. In parallel the latest improvements in ceramic cutting-tool materials are reviewed. The paper shows that the choice of ceramic cutting tools is a quite complex process with a number of important factors to be taken into account.

Journal of Manufacturing and Materials Processing, 2020

The work is devoted to the research of the changes that occur in the subsurface layer of the work... more The work is devoted to the research of the changes that occur in the subsurface layer of the workpiece during electrical discharge machining of conductive nanocomposite based on alumina with the use of a brass tool. The nanocomposite of Al2O3 + 30% of TiC was electroerosively machined in a water and hydrocarbon oil. The process of electrical discharge machining is accompanied by oscillations that were registered by diagnostic means. The obtained surface of the samples was researched by the means of scanning electron microscopy and X-ray photoelectron spectroscopy. The observed surface and subsurface changes provide grounding for the conclusions on the nature of processes and reactions that occur between two electrodes and nanomodification of the obtained surfaces that can be an advantage for a series of applications.