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Power-based estimation of cutting forces during turning of aluminum biomass ash particulate composite

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Abstract

Aluminum-biomass ash particulate composite is a reinforced composite material of aluminum and biomass ash particles. The composite offers significant mechanical property advantage and low-cost advantage because of the use of waste as the reinforcement material, and as a result, it is gaining increased industrial attention because of the many advantages they offer over conventional aluminum matrix composites. These materials are mostly accessed based on their mechanical, microstructural, and chemical properties with very limited interest in their machinability relative to the base material. In this work, the specific cutting force coefficients and cutting forces of the composite were estimated during CNC turning operations and the effects of reinforcement on the machinability responses were studied. Power-based force estimation approach was adopted for this purpose for the first time. This approach is less expensive compared to the dynamometric approach since it relies on adapting existing equipment developed for other purposes. This was done by measuring the electric power of the direct-drive motors of the CNC machine during the turning processes, and the power measurements were analyzed to obtain the force coefficients. The cutting force components were observed to decrease as the percentage rice husk ash (RHA) reinforcement increased. This agrees with known results for the composite based on the dynamometric approach. The composite therefore promises to be more cost-effective than the base material in machinability terms.

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Acknowledgements

The authors would like to appreciate Deutscher Akademischer Austauschdienst (German Academic Exchange Service) and the African Centre for Energy and Sustainable Power Development (ACE-SPED), UNN, for their support.

Funding

Emmanuella Emefe has received a master’s research sponsorship award from Deutscher Akademischer Austauschdienst (German Academic Exchange Service).

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Nigeria, Nsukka, Nigeria

    Emmanuella Emefe, Chigbogu Ozoegwu, Sylvester Edelugo, Chukwuemeka Ajibo & Noble Nweze

  2. ACE-SPED, African Centre of Excellence, University of Nigeria, Nsukka, Nigeria

    Chigbogu Ozoegwu & Sylvester Edelugo

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  1. Emmanuella Emefe
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  2. Chigbogu Ozoegwu
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The first draft of the manuscript was written by Emmanuella Emefe and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Emmanuella Emefe.

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Competing interests

Emmanuella Emefe has received a master’s research sponsorship award from Deutscher Akademischer Austauschdienst (German Academic Exchange Service). Chigbogu Ozoegwu and Sylvester Edelugo have no relevant financial interest.

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Emefe, E., Ozoegwu, C., Edelugo, S. et al. Power-based estimation of cutting forces during turning of aluminum biomass ash particulate composite. Int J Adv Manuf Technol 131, 5759–5768 (2024). https://doi.org/10.1007/s00170-024-13357-6

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