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In the field of electronics thermal management (TM), there has already been a lot of work done to create cooling options that guarantee steady-state performance. However, electronic devices (EDs) are progressively utilized in applications that involve time-varying workloads. Therefore, the TM systems could dissipate the heat generated by EDs; however, there seemed to be a necessity for a design that would contain temperature rise within an acceptable range for limiting hot spots and managing thermal transients induced by higher-frequency operating cycles. Heat dissipation issues become more significant when miniaturization in electronics increases. More effective TM often results in enhanced reliability as well as a longer life expectancy for devices. Hence, this paper explicates the TM of EDs, the comparison of cooling methods, the comparison of convections for TM on EDs, the heat source (HS) mounted on the substrate board, and optimization techniques to optimize the size and position of HSs mounted on the substrate board. This paper also analyzes the TM technologies on different EDs from 2014 to 2023 and the comparison of the thermal conductance of EDs with two types of phase change materials (PCMs) and pin-fin heat pipes (HPs).

Wire electric discharge machining (WEDM) is a recent technique that is useful in machining Ti-6Al-4 V alloy, which is a material that is preferred in many industries due to its exceptional hardness. This paper aims to evaluate the effects of WEDM process parameters on the machining characteristics of Ti-6Al-4 V alloy. The 4-axis CNC WEDM machine that was used in this study had brass wire as the electrode and de-ionized water as the dielectric fluid. The parameters under investigation were the peak current (Ip), pulse on time (TON), pulse off time (TOFF), and servo voltage (SV) set at 3 levels each. The experimentation was based on Taguchi’s L9 orthogonal array design. The material removal rate (MRR) and surface roughness of machined ash components were Ra. A total of three Ra results were analyzed using ANOVA. It was shown that response surface methodology, pulse time ton and peak electric current had more significant effects on MRR. Effect-wise results indicated that peak current and time on P ring test allow surface finish to be within MRR levels. It is peak electric current that determines a 72.75% effect on MRR whereas extreme time has an 11.68 balanced effect on peak current. In the case of Ra, peak electric current and extreme pulse time remain dominant factors. The results suggest that higher Ra is favored by less increase in input energy as both peak current and time have been decreased.

Mono-type and dihybrid nanoparticle-enriched cutting fluids in machining processes are gaining popularity because of their outstanding benefits such as enhanced tool life and surface finish. In this work, a trihybrid nanocutting fluid was developed by mixing MWCNT Al 2 O 3 graphene nanoparticles with different weight concentrations. The prepared tri-hybrid nanofluids were tested during the machining of SS304 steel. Coated tungsten carbide and PVD TiAlN carbide tools are used for the machining. Analysis of variance (ANOVA) and response surface methodology (RSM) were used to analysed the obtained data. ANOVA revealed that the interaction of cutting speed and feed had shown a good impact on surface roughness. The combinations of minimum quantity lubrication (MQL) and tri-hybrid nanofluid characteristics increase surface quality by 16% and the cutting temperature by 76%, respectively, which offers future applications in the machining industry. The correlations are verified using a conformance test and have acceptable variances of 3.11% and 1.13% with the ANN approach regression analysis.

Titanium alloy has a high specific resistance, excellent machining performance is non-corrosive, and the capability to withstand greater temperatures while maintaining outstanding mechanical properties. This alloy is, therefore, the right choice for aerospace, maritime, biomedical, and industrial applications. But machinability of titanium alloy is challenging as a result of its poor thermal conductivity, highly chemically reactive, and low elastic modulus hence it is treated as a difficult-to-cut material. Fast tool wear is observed during the machining of titanium alloy in conventional machining methods. Therefore, unconventional processing methods are used for the treatment of titanium alloy. Electric discharge machining (EDM) is one of these unconventional machining processes which are used for cutting with high precision, having a high degree of machinability, and getting a better surface finish. It is considered the best choice for machining titanium alloy. In the EDM process, different techniques are used to understand the effects of process parameters such as polarity, peak current, electrode type, pulse on time, and gap voltage on material removal rate, tool wear rate, surface roughness, and wear ratio. This paper critically investigates different types of EDM processes, experimental setups used for machining of titanium alloy, the effect of different tool electrodes and dielectric media on machining parameters, machined surface characteristics, and metal removal rate and tool wear rate.

The friction and wear volume loss is the main cause for a failure & energy losses in heavy-duty gearboxes and it can be controlled by using a modified lubricant mixed with nano additives. This study investigates the wear and friction behaviour of gear EP oil blended with composite nano additives (Al2O3/SiO2/ZrO2) in combination with Zinc dialkyl dithiophosphate. All trials were conducted under various concentrations of composite nanoparticles, at loads of 60-100 N and sliding velocities of 0.65-1.5 m/s. The experimental study on antiwear and anti-friction properties for the oil was conducted on a pin-on-disc apparatus. The design of experiment was developed using response surface approach to investigate optimum friction coefficient and wear volume loss in lubricant. It is found that blending of nano composite add-ons blended with Zinc dialkyl dithiophosphate in gear EP lubricant significantly diminishes a wear volume loss, friction coefficient by 15.62 % and 20.6 % respectively as compared to a base lubricant. The findings of this investigation and the obtained correlations were converted in to customized visual basis based soft tool as a predictor for future aspects.

Additive Manufacturing (AM), known as 3D printing, finds application in many fields since it is able to produce complex geometries with the least wastage of materials. Of all the AM processes, Fused Filament Fabrication (FFF) is the most popular because of its low cost and versatility in available materials. The mechanical properties of 3D-printed components including tensile strength, flexural strength, impact resistance, and surface finish, are highly dependent on various process parameters. It is, therefore, imperative to study and optimize these parameters for the improvement of structural integrity and functional performance of printed parts. This review analyses key process parameters affecting the mechanical properties of 3D printing. The review discusses critical factors such as layer thickness, printing speed, nozzle and bed temperature, build orientation, raster angle, infill density, and infill pattern in detail. The study presents the point of view of the influence of these parameters on mechanical performance, where examples of some recent work discussed show that certain adjustments can result in improvements in tensile strength, dimensional accuracy, and surface quality. The role of post-processing techniques like heat treatment, annealing, and chemical smoothing in enhancing the mechanical properties is also briefly discussed. Moreover, some interdynamics between the parameters are discussed to give an insight into the overall print quality concerning their interaction. The findings of this review serve as a guide for researchers, engineers, and manufacturers to optimize 3D printing parameters, enabling the production of mechanically robust and reliable components suitable for industrial applications.

Ti6Al4V alloy is widely used in aerospace and biomedical applications due to its excellent mechanical and thermal properties, but its poor machinability makes it a difficult-to-cut material. Electrical Discharge Machining (EDM) offers an effective non-conventional machining approach for such materials, where tool electrode selection and process parameters critically influence performance. This study presents a comprehensive experimental investigation into the effect of three tool electrodes—graphite, copper, and brass—on the EDM performance of Ti6Al4V alloy. Key input parameters, including pulse-on time (T on ), pulse-off time (T off ), and current, were selected based on equipment limits and prior studies. Taguchi’s L9 orthogonal array was used for experimental design, and analysis of variance (ANOVA) was employed to determine the statistical significance of each factor. Output responses—material removal rate (MRR), tool wear rate (TWR), surface roughness (SR), and dimensional deviation (DD)—were measured and optimized using the Teaching–Learning-Based Optimization (TLBO) algorithm. Among the electrodes, graphite achieved the highest MRR (31.03 mm³/min), lowest TWR (0.4648 mm³/min), and minimal DD (101.76 μm), while brass produced the smoothest surface (SR = 3.19 μm). A collection of non-dominated responses was also found using Pareto optimal points. A minor adequate deviance was observed between the TLBO algorithm’s predicted and actual findings. Scanning electron microscopy (SEM) analysis was conducted to evaluate surface morphology. The qualitative SEM results confirmed fewer defects and better surface integrity for graphite electrodes. The findings validate TLBO as an effective tool for EDM process optimization and provide practical guidance for electrode selection in machining Ti6Al4V.

In this study, the machinability of the stir-cast Al7075-based hybrid nanocomposites is evaluated during turning under dry and compressed air-cooling conditions. Based on experimental findings, mathematical models were created that can forecast the machining performances, namely cutting force, surface roughness, and flank wear. Using the ANOVA technique, the impact of different Al7075-based hybrid nanocomposites and cutting parameters, specifically, cutting speed, feed, and depth of cut, on various responses was examined. According to experimental findings, higher cutting forces and lower surface roughness were obtained while turning harder Al7075-based nanocomposites. Under compressed air machining conditions, the surface roughness, cutting force, and flank wear were observed to decrease by 4.74%, 8.84% and 43.59% respectively. The flank wear analysed for different cutting conditions showed a substantial reduction in the flank wear while turning under compressed air-cooling conditions. Moreover, lower flank wear could also be attributed to the displacement of the abrasive particles from the cutting edge. The chip morphology is studied for the various cutting conditions as well as different machining environments. SEM analysis was carried out to compare the surface texture of the chips produced under dry and compressed air conditions.

Acrylonitrile Butadiene-Styrene (ABS) composites are being used for various engineering applications due to their higher toughness, strength, and lightweight. The properties of ABS reinforced with pistachio shell powder (PSP) have been investigated. PSP was incorporated into the ABS matrix at varying weight fractions (0%, 1%, 3%, and 5%), and composite filaments were fabricated via single screw extrusion. The experiments are conducted as per the Taguchi L16 method to analyse parameters: layer thickness (LT), infill density (ID), nozzle temperature (NT), PSP content, and infill pattern (IP) on mechanical properties. Standardized testing, in accordance with American Society for Testing and Materials (ASTM) D638, D790, D695, and D256, was conducted to evaluate tensile, flexural, compressive, and impact behaviour. The results revealed that a 3% PSP composition, coupled with an LT 0.4 mm, and ID 65–80%, yielded optimal tensile and flexural performance. The maximum tensile strength is found to be 33 MPa and modulus of 457 MPa, while the highest compressive strength reached 71 MPa at 5% PSP. Analysis of variance (ANOVA) identified PSP composition and infill density as the most significant contributors to mechanical enhancement. The findings confirm the viability of PSP as a sustainable, cost-effective reinforcement for ABS in FDM-based applications, with promising implications for eco-friendly composite manufacturing.

The current research focuses mainly on the manufacturing industries in terms of energy savings and cleaner production in order to impart sustainability. The use of conventional cutting fluid is not beneficial for high cutting speeds and feeds, as it can lead to increased tool wear and reduced machining efficiency. In addition, such cutting fluid contaminates the atmosphere in high-production machining, leading to environmental concerns and potential health risks for workers exposed to these harmful substances, such as respiratory issues and skin irritations from prolonged exposure to the chemicals present in the fluid. Cryogenic cooling is useful in lowering the high-flow cutting temperatures, which increases the quality of the workpiece and tool life. This review comprehensively analyses the relevant literature on cryogenic cooling in various machining processes. It provides a review and summary of cryogenic cooling, analyzes and evaluates benefits and developmental challenges in each area, and outlines the future developmental directions of cryogenic cooling. These cooling techniques are found to enhance the sustainability of machining processes and production as a whole, particularly by reducing energy consumption and minimizing waste generated during manufacturing. This study aims to develop new strategies for the research and development of cryogenic cooling technology in machining industries.