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Article Citation - WoS: 3Citation - Scopus: 4Investigation of the Combined Effects of Ultrasonic Vibration-Assisted Machining and Minimum Quantity Lubrication on Al7075-T6(John Wiley and Sons Ltd, 2024) Namlu, R.H.; Cetin, B.; Lotfi, B.; Kiliç, S.E.The aluminum alloy Al7075-T6 finds extensive application in the aviation and automotive industries, where machining plays a pivotal role. Emerging techniques such as Ultrasonic Vibration-Assisted Machining (UVAM) and Minimum Quantity Lubrication (MQL) hold promise for enhancing machining efficiency. In this study, the combined use of UVAM and MQL for slot milling of Al7075-T6 was investigated. The results demonstrate that UVAM reduced cutting forces by an average of 10.87% in MQL and 8.31% in Conventional Cutting Fluid (CCF) conditions when compared to Conventional Machining (CM). In addition, UVAM yielded significantly improved surface finishes, characterized by an average reduction in surface roughness of 41.86% in MQL and 32.11% in CCF conditions relative to CM. Furthermore, surfaces subjected to UVAM exhibited fewer instances of burn marks and tool-induced markings, reduced chip splashing, and more uniform surface integrity compared to those manufactured with CM. Lastly, chips generated through UVAM exhibited distinct characteristics, notably shorter length, curvier shape, and a distinctive half-turn morphology when compared with the irregular chips produced through CM. In conclusion, our findings underscore the potential of UVAM in synergy with MQL to augment the machining of Al7075-T6 alloy, thereby yielding superior-quality machined components with enhanced operational efficiency. © 2025 Elsevier B.V., All rights reserved.Conference Object Effect of Tool Cavity Conditions on Damping, Chatter Mitigation, and Surface Quality in Internally Cooled Milling Tools(Elsevier B.V., 2025) Namlu, R.H.; Dogan, H.; Ozsoy, M.Chatter is a critical factor limiting productivity and efficiency in machining processes. Cutting tools significantly impact chatter stability, as they often serve as the most flexible component. The influence of cutting tools on chatter varies depending on their design and cooling mechanisms. Internally cooled cutting tools, commonly used in industrial applications, have the potential to exhibit distinct damping characteristics due to the presence of internal cavities, differentiating them from conventional solid tools. This study explores the effects of internally cooled milling cutting comparing an empty cavity cutting tool with a tool filled with viscous fluid. The primary objective is to evaluate how these conditions influence the damping of the machining system and their subsequent impact on surface quality, a key outcome sensitive to chatter. Surface topography and roughness measurements were taken after the experiments to assess changes in surface quality. The findings offer valuable insights into the role of internal cooling and fluid properties in not only chatter but also vibration suppressions in milling operations, highlighting their potential to enhance machining performance. © 2025 The Author(s).Book Part Citation - Scopus: 7Vibration-Assisted Machining of Aerospace Materials(Springer Nature, 2022) Namlu, R.H.; Sadigh, B.L.Recent technologic advancements, especially in cutting-edge sectors like aerospace industries, call for new materials with superior properties. Like advanced engineering alloys, composites, and superalloys, these new materials provide the required specifications; however, to make use of these materials, they are needed to be formed into a final product. Machining is one of the most used manufacturing processes. Since in this process, the chip removal action occurs with direct contact between the cutting tool and workpiece, therefore, cutting materials with superior mechanical properties become a backbreaking process to be carried out. Along with the desired properties of the new advanced engineering materials in the aerospace industry, superior mechanical properties such as high wear resistance and low thermal conductivity of these materials lead to low machinability and difficulties in producing the desired end products by machining. As traditional machining methods are not efficient enough in machining such materials, new machining techniques have been invented to deal with these problems. Nontraditional machining processes are developed to deal with such obstacles that use chemical, electrochemical, thermal, and mechanical energy sources to facilitate the material removal process, reduce cost, and enhance product quality. However, in some cases, these methods’ low production efficiency forced engineers to combine the advantages of multiple machining methods in one hybrid process and improve the process efficiency by expediting the manufacturing process. One of these hybrid manufacturing methods is vibration-assisted machining. The vibration-assisted machining method aims to improve the material removal process by giving high frequency and low amplitude mechanical energy in vibrations to the workpiece or cutting tool. Vibration-assisted machining methods first emerged in the late 1960s and gained popularity in the early 2000s, and nowadays, research stages have gained momentum and are used even in mass production. Vibration-assisted machining has many benefits over traditional machining processes, like reducing costs, cutting forces, required power, secondary operations, cutting tool wear, and increasing the machined surface quality, tool life, and finally, the process performance. In this chapter, a detailed literature survey on the effects of vibration implementation on the performance of various machining processes, including turning, milling, drilling, and cutting advanced aerospace materials, is systematically summarized and discussed. At the end of this chapter, a case study is provided to understand the topic deeply. The detailed review shows that vibration-assisted machining enhances the cutting process in terms of cutting forces, tool wear, and surface roughness compared to traditional methods. Also, case study outcomes support those findings. Likewise, future studies show that vibration-assisted machining process still needs to be investigated deeply and it is a promising research area. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2022.
