https://www.iranjme.ir/ Iranian Journal of Manufacturing Engineering en daily 1 Tue, 23 Sep 2025 00:00:00 +0330 Tue, 23 Sep 2025 00:00:00 +0330 https://www.iranjme.ir/article_229715.html Grain size, as a key structural parameter, plays a significant role in determining the mechanical and physical behavior of materials. In this regard, this research dealt with the effect of surface mechanical attrition treatment on the mechanical and corrosion behavior of 7075 aluminum alloy, which was investigated by varying the shot peening duration and shot size. The results showed that this process, in addition to refining the grain size from about 15 μm to less than 3 μm, significantly increased the hardness of the samples by up to 50%. Increasing the shot peening duration and decreasing the shot size led to further improvements in hardness, with the sample treated with 3 mm shots for 10 minutes (sample 3-10) exhibiting the highest hardness (72 Vickers). Moreover, surface mechanical attrition treatment reduced the corrosion rate of the samples compared to the as-received condition, with sample 3-10 showing the lowest corrosion rate. Electrochemical impedance spectroscopy results were consistent with polarization tests, confirming the enhancement of impedance and corrosion resistance in the processed samples. The Warburg parameter was identified as an indicator for evaluating the quality of the protective layer and ion diffusion. Additionally, grain refinement and increased grain boundary area, despite increased surface roughness, contributed to improved corrosion resistance. Also, the surface mechanical attrition treatment formed a harder outer layer that became thicker with longer peening durations and smaller shot sizes. Uniform distribution of intermetallic phases and grain refinement transformed the corrosion mode from localized to uniform. These changes were evident in X-ray diffraction patterns as decreased peak intensity and increased peak broadening. https://www.iranjme.ir/article_230741.html This research investigates the effect of strain rate on the strength of friction stir welded joints. Experimental tests were conducted on overlapping polyamide sheets, as strain rate significantly influences the mechanical behavior of thermoplastics. To evaluate the impact of strain rate on the joint strength of polyamide, four displacement rates (20, 30, 40, and 50 mm/min) were examined in tensile tests. The results demonstrated that the maximum strength of 1792.5 N was achieved at the displacement rate of 20 mm/min. Furthermore, the findings revealed an inverse relationship between displacement rate and tensile strength in polyamide joints. For more precise evaluation of joint behavior, the tensile test conditions were simulated using ABAQUS finite element analysis software. The numerical results showed good agreement with experimental data, confirming the reliability of this computational model for predicting joint behavior under tensile loading conditions. The developed finite element model effectively captured the stress distribution and failure mechanisms observed in the physical tests, validating its applicability for mechanical analysis of friction stir welded thermoplastic joints. This research provides valuable insights into the strain rate sensitivity of polyamide friction stir welds, with implications for optimizing welding parameters in industrial applications where dynamic loading conditions are anticipated. The combination of experimental and numerical approaches offers a comprehensive understanding of the mechanical performance of these joints across different loading rates. https://www.iranjme.ir/article_230742.html The purpose of this study is to investigate the effect of the components of the polypropylene (PP)/nitrile butadiene rubber (NBR)/silicon carbide (SiC) nanocomposite on the mechanical behavior (modulus of elasticity and impact resistance) in the presence of polypropylene-grafted- maleic anhydride (PP-g-MA) as a compatibilizer. To achieve this, the Box-Behnken Design (BBD) was initially utilized for experiment design and sample selection; The melt blending process was used for sample preparation. Next, a statistical model was developed using the analysis of variance (ANOVA) table based on experimental data, showing a good level of accuracy compared to the actual results. The results obtained from the Response Surface Methodology (RSM) generally show a decrease in the elastic modulus and an increase in impact resistance with the increase of the NBR phase, ranging from 10% to 30% by weight; As the compatibilizer content increases from 3% to 15% by weight, both the elastic modulus and impact resistance continuously improve; Additionally, increasing the SiC nanoparticles from 1% to 5% by weight increases the elastic modulus and improves impact resistance. Optimization of the mechanical properties resulted in values of 273.75 MPa for the elastic modulus and 69.01 J/m for impact resistance. These values were achieved with the optimal composition, which contained 17.62% NBR, 15% PP-g-MA, and 4.47% SiC by weight. Considering the effect of microstructure on the mechanical properties of materials, scanning electron microscopy (SEM) images were used to study the microstructure to confirm the results. https://www.iranjme.ir/article_234530.html The present research investigates the feasibility of producing a flanged axial component from C26000 brass alloy using the radial-backward cold extrusion process under both experimental and numerical conditions. To this end, a dedicated die set was designed and manufactured to fabricate the samples, and the final product was produced using a hydraulic press. The process was simulated using DEFORM software, analyzing the effects of die geometry and friction coefficient on the final product characteristics, including hardness distribution, die filling, material flow, and punch force. The highest hardness value (71 Vickers) was observed in the flange region of the workpiece, attributed to work hardening and grain refinement. The friction coefficient, determined through a modified cylinder compression test under grease-lubricated conditions, was calculated to be 0.08. Microstructural analysis revealed that the grain size decreased from an initial value of approximately 400 µm to a range of 220–261 µm across different regions of the component, resulting from high plastic strain and increased dislocation density during the cold forming process. The experimental and numerical force-displacement curves obtained from the radial-backward extrusion process exhibited good agreement, with a maximum discrepancy of 10% in the most critical condition. The results demonstrate that the radial-backward cold extrusion process offers high potential for producing flanged brass components at room temperature, and numerical simulation can effectively predict the material's actual behavior. https://www.iranjme.ir/article_234527.html This paper presents an uncertain optimal design methodology for minimizing the total mass of a re-entry space capsule, taking into account geometric manufacturing and assembly tolerance uncertainties. Uncertain optimal design refers to the process of optimizing a design while considering the effects of uncertainties, ensuring that the final solution is both robust and stable. The proposed approach integrates multi-objective optimization with variance-based robustness analysis. Initially, the optimal design point is determined under deterministic conditions using a genetic algorithm. Subsequently, the design's robustness against potential parameter variations is assessed through an iterative process. If the initial design does not satisfy the robustness criteria, the algorithm iteratively updates the design constraints to identify a new optimal point until a robust solution is achieved. The multi-objective optimization framework is implemented using the All-At-Once (AAO) approach, and Latin Hypercube Sampling (LHS) is employed to explore the geometric uncertainty space and construct response surfaces for objective functions and constraints. Variance analysis quantifies the influence of geometric uncertainties on the optimal responses. Results show that the robust optimized capsule is 10.7% lighter than the baseline design, while exhibiting improved static stability margins. This mass reduction is accomplished through intelligent aerodynamic reshaping and the elimination of the need for balancing mass. Robustness evaluation confirms that all critical design functions maintain a minimum 2σ safety margin against geometric uncertainties, validating the reliability of the proposed design. The methodology effectively balances mass minimization with stability requirements, demonstrating particular relevance for aerospace applications where both performance and safety are paramount. https://www.iranjme.ir/article_234531.html Fiber Metal Laminates (FMLs), which combine the superior properties of metallic and polymeric composite materials, have emerged as innovative materials widely utilized in aerospace and automotive industries. Despite their advantages, the drilling process of these structures, particularly in curved components, is associated with challenges such as delamination, deteriorated surface quality, and increased machining forces. The present study aims to investigate the influence of three critical drilling parameters-spindle speed, feed rate, and drill diameter-on fiber delamination, hole quality, and drilling force in curved aluminum/polypropylene sheets reinforced with glass fibers. For sample fabrication, layers of 3105 aluminum and glass fiber-reinforced polypropylene were shaped using a hot press technique and an Ohio-shaped mold. Experiments were conducted based on a full factorial design, with spindle speeds of 1000, 2000, and 2500 rpm, feed rates of 8, 16, and 25 mm/min, and drill diameters of 3, 5, and 7 mm. Results indicated that the maximum fiber delamination (0.243 mm) occurred under conditions using a 3 mm drill bit, 1000 rpm spindle speed, and 8 mm/min feed rate, whereas the minimum delamination (0.090 mm) was observed with a 7 mm drill bit under the same conditions. Surface quality analysis revealed that lower spindle speeds and feed rates produced more regular holes with sharper edges. Furthermore, an increase in spindle speed resulted in a reduction of drilling force, while an elevated feed rate exhibited an opposing effect. The drill diameter demonstrated a dual impact on force, initially increasing it and subsequently decreasing it due to reduced unit pressure. Collectively, the findings underscore the significance of optimizing drilling parameters to enhance quality and minimize damage in curved FMLs. https://www.iranjme.ir/article_227492.html In recent years, due to the increasing demand from various industries such as military, aerospace, and automotive for materials with high strength-to-weight ratios, the use of metal matrix composites, particularly aluminum matrix composites, has significantly increased. Machining to achieve high dimensional accuracy is an integral part of the production process for products made with aluminum matrix composites. Due to the presence of reinforcing materials such as silicon carbide, machining these materials always faces many challenges. Therefore, studying the effective parameters on machining aluminum matrix composites is essential. In this study, using a systematic approach including statistical modeling and experimental testing by response surface methodology and extracting regression equations, the effect of spindle speed, feed rate, depth of cut, and percentage of reinforcing particles on surface roughness and material removal rate during milling of AL7075/SiC/Gr hybrid aluminum composite has been thoroughly investigated. Based on the studies conducted, it can be acknowledged that the results show that by increasing the feed rate, the material removal rate and surface quality improve. Also, increasing the cutting speed leads to a decrease in surface roughness due to the presence of graphite particles and an increase in the material removal rate. Also, the best combination of values was found to simultaneously minimize surface roughness and maximize material removal rate. The best combination of parameters is: spindle speed of 1000 rpm, feed rate of 0.0539 mm/rev, depth of cut of 1.267 mm, and 10% reinforcing particles of silicon carbide and graphite. https://www.iranjme.ir/article_227493.html In this study, the volumetric additive manufacturing (VAM) process is examined with a focus on the development of a fabrication device and programming for part production using this method. As an innovative technology, VAM addresses several limitations of other additive manufacturing techniques, such as long production times and the anisotropic properties of fabricated components. This study investigates the role of equipment and the impact of applying filters in various configurations on the final quality of components during the Radon-based image processing and fabrication process. The results indicate that the application of filters significantly improves the quality and dimensional accuracy of the produced components. Additionally, a comprehensive MATLAB-based programming solution has been developed to convert three-dimensional models designed using CAD software into playable videos suitable for VAM-based fabrication. The finalized code integrates a user-friendly graphical interface to enhance accessibility and ease of use. Overall, this approach provides a novel pathway for the rapid and precise fabrication of complex components, enabling efficient production within shorter timeframes. https://www.iranjme.ir/article_227577.html Traditional drilling of hard and brittle materials, including grey cast iron, causes excessive tool wear and reduced drill life due to the presence of abrasive carbide and silicon particles in its structure, resulting in reduced hole accuracy and quality. This research aims to improve surface quality and increase drill life in drilling grey cast iron. Using advanced and modern methods in traditional machining processes can improve machining conditions. In this article, the effect of using ultrasonic vibrations on grey cast iron drilling has been studied. First, the design and analysis of the vibrating tool were carried out using Abaqus software, and after manufacturing the ultrasonic vibrating set, it was installed on the computer numerical control milling machine. Experimental results show that the use of ultrasonic waves has reduced tool wear by 30% and improved its life, while also increasing the quality of the hole surface by 20% and improving the roundness of the hole in gray cast iron drilling operations. https://www.iranjme.ir/article_234528.html This study aims to identify the key production bottlenecks in manufacturing a high-quality tundish nozzle comparable to an imported foreign part. By overcoming these bottlenecks, we strive to develop the technical expertise necessary to produce these nozzles domestically, eliminating the need for imports in the Iranian casting industry. The tundish nozzle was examined in three parts: the metal holder, the refractory nozzle seat, and the nozzle insert. The metal holder is formed from a simple, precisely shaped low-carbon steel sheet. Analysis using ICP, SEM-EDS, and XRD revealed that this holder is composed of over 99.5% iron, with a carbon content of 0.055% and no significant alloying elements. The primary phase is alpha iron (ferrite), with a small amount (less than 1%) of iron carbide (cementite). Analysis of the refractory material and nozzle insert using XRD, XRF, and SEM-EDS indicated that these components contain alumina, mullite, silica, and spinel phases (in the refractory) and partially stabilized zirconia using 2-3% calcium oxide and magnesium oxide (in the insert). It is believed that the refractory material consists of alumina, clay compounds (including kaolin and ball clay), zircon (zirconium silicate), and carbon, while the insert utilizes partially stabilized zirconia. The research indicates that the key bottleneck in producing the metal holder is the shaping process, which uses a dedicated mold. Manufacturing the mold becomes cost-effective when making large quantities. For the refractory material, the bottleneck lies in achieving a suitable formulation of raw materials to obtain the desired phase composition for optimal performance . https://www.iranjme.ir/article_234529.html Aluminum matrix composites (AMCs) are widely used in aerospace, automotive, and advanced engineering applications due to their high specific strength, wear resistance, and thermal stability. However, the presence of hard reinforcing particles makes their machining challenging, often leading to the formation of discontinuous, serrated, or unstable chips, which negatively affect surface quality and tool life. Therefore, improving chip morphology is crucial for enhancing the machinability of these materials. In this study, the effects of machining parameters (cutting speed, feed rate, depth of cut, and lubrication conditions) and the role of tin (Sn) addition on chip morphology during the turning of Al–Mg₂Si composites were investigated. Two types of composites (with and without Sn) were fabricated via in-situ casting and machined under various conditions using a Taguchi L16 orthogonal array. The results showed that cutting speed had the most significant effect on chip type and length, while feed rate and depth of cut exhibited critical influences at specific levels. SEM–EDS analysis revealed diffusion wear with the transfer of tool elements (W, Co, and C) onto the chip surface, which was mitigated under optimized machining conditions. Furthermore, the addition of 1 wt.% Sn reduced average chip length and promoted more uniform and stable chip formation. Overall, alloy modification combined with optimized machining parameters effectively improved the chip formation process, reduced tool wear, and enhanced the machinability of Al–Mg₂Si composites. https://www.iranjme.ir/article_234646.html Perforated tubes are hollow cylinders characterized by a pattern of uniform holes created in their tubular structure. The properties of perforated tubes enable their use in a wide range of applications, including filtration systems, architectural elements, chemical and process engineering, aerospace and automotive, agricultural applications, and more. In this study, the laser bending process of Perorated tubes is investigated through numerical simulation. The commercial finite element software Abaqus is used for the numerical simulations. To this end, the effects of the most important input parameters of the process, including laser output power, laser scanning speed and the number of holes located along the irradiation path, on the vertical and lateral displacements of the free edge of the laser-bent tube are investigated. The vertical displacement of the tube's free edge represents the main bending of the tube, while the lateral displacement of the free edge is an undesirable phenomenon and effect that leads to a reduction in the dimensional accuracy of the laser-bent tubes. The results show that by increasing the laser power, the vertical and lateral displacements of the free edge of the laser-bent tube increase. On the other hand, increasing the laser scan speed leads to a decrease in the vertical and lateral displacements of the free edge. Moreover, with an increase in the number of holes located along the irradiation path, the vertical displacement of the free edge of the tube decreases, while the lateral displacement increases. https://www.iranjme.ir/article_234664.html Refill Friction Stir Spot Welding (RFSSW) is a subset of friction stir welding. The term "refill" is added to this method due to its ability to eliminate the keyhole defect left behind by conventional friction stir spot welding. The core idea of the present research is to investigate how the application of horizontal ultrasonic vibrations to the refill friction stir spot welding process enhances the mechanical and microstructural properties of 6061-T6 aluminum alloy. To achieve this, a test setup consisting of an RFSSW welding unit and ultrasonic equipment was prepared. The specimens were made from 1-mm-thick 6061-T6 aluminum alloy sheets. The input variables, including ultrasonic waves, rotational speed, and plunge depth, were applied to the 6061-T6 aluminum alloy. The resulting welded samples were evaluated and compared in terms of tensile strength, hardness, and microstructure. The results indicated that increasing ultrasonic power during refill friction stir spot welding led to grain refinement in the weld nugget zone. This refinement contributed to a 23% increase in strength at tool rotational speeds ranging from 1200 to 1400 rpm. However, at a higher rotational speed of 1800 rpm, the strength decreased by 25% due to grain coarsening. https://www.iranjme.ir/article_234665.html This study investigates the application of chiral liquid crystals (CLC) in microfluidic systems for the precise detection of sodium chloride concentrations. Initially, an optical system based on 5CB liquid crystal was designed, comprising a light source, polarizer, optical microscope, and equipment for recording color changes. Sodium chloride solutions of varying concentrations were manually injected via micropipette into the liquid crystal, and color changes were recorded. Although effective in detecting color changes, this method was limited by manual injection and the need for additional optical components, reducing its portability and practical applicability. To address these challenges, a CLC, formed by combining 5CB with BDH1305 dopant, replaced 5CB to enhance sensitivity to concentration changes and eliminate the need for external polarizers. Microfluidic chips were fabricated using a custom desktop CNC milling machine, which engraved microchannels with micron-scale precision (200 µm width, 300 µm depth) on PMMA sheets. This advanced CNC system ensured uniform analyte flow to the CLC reservoir. Images were processed using ImageJ software, with RGB values extracted to analyze color changes. Results demonstrated that the microfluidic-CLC system, enabled by the CNC’s precision manufacturing, achieved uniform and accurate color changes, effectively simulating sodium chloride concentrations. This innovative system, combining CNC technology and CLC sensing, offers an efficient tool for concentration measurements in medical, food industry, and environmental applications, with significant potential for future development. https://www.iranjme.ir/article_236224.html Ensuring effective energy absorption is especially critical for crewed missions and biological payloads. This study aims to design and evaluate a three-dimensional (3D) metamaterial structure, derived from a two-dimensional (2D) re-entrant unit cell, as an efficient energy absorber during the landing phase of space missions. The primary objective is to develop a lightweight structure with enhanced energy absorption capacity, suitable for integration into space systems. A novel 3D cylindrical metamaterial was developed by rotating 2D re-entrant unit cells around a central vertical axis. Two materials were used for sample fabrication: thermoplastic polyurethane (TPU) for the 2D structures and polylactic acid (PLA) for the 3D structures. All samples were produced using fused filament fabrication (FFF) 3D printing technology. Quasi-static compression tests were performed on the 3D samples to assess their mechanical behavior and energy absorption performance. Force-displacement data were recorded and analyzed to determine the energy absorption metrics. The 3D metamaterial structure demonstrated superior energy absorption capabilities. It was able to absorb a total of 148.39 J of energy and exhibited a specific energy absorption (SEA) of 2.232 kJ/kg. These values significantly surpass those reported in previous studies for comparable structures, indicating the effectiveness of the new design. The proposed 3D metamaterial structure, fabricated via FFF 3D printing and based on a rotated re-entrant unit cell design, exhibits excellent energy absorption performance. Its high SEA and lightweight configuration make it a strong candidate for use in the impact mitigation systems of space payloads, offering promising potential for future space applications. https://www.iranjme.ir/article_236225.html Austenitic stainless steels are widely used in industrial and biomedical applications owing to their excellent corrosion resistance and biocompatibility. Improving their mechanical performance through deformation-based processes such as cold working is essential for enhancing durability and functional reliability. In this study, the effect of different thickness reductions during cold rolling on the microstructure and hardness of 316 and 316LVM austenitic stainless steels was investigated. Cold rolling was performed at room temperature with thickness reductions of 20%, 40%, and 60%. Microstructural examinations revealed that increasing deformation led to grain refinement and elongation along the rolling direction, accompanied by partial formation of strain-induced martensite. This transformation was more pronounced in 316 steel, while in 316LVM, the austenitic structure remained more stable due to its lower carbon content and higher purity. The Brinell hardness of 316 steel increased from 114 HB to 342 HB at 60% reduction, whereas that of 316LVM increased from 112 HB to 333 HB. Although X-ray diffraction analysis indicated a small amount of strain-induced martensite in 316 steel, the martensite phase was not visually distinguishable in OM/SEM images due to its very low volume fraction. Overall, the findings indicate that controlling the degree of cold work provides an effective approach to tailoring the mechanical properties of austenitic stainless steels for industrial and biomedical applications. https://www.iranjme.ir/article_236226.html Recent advancements in additive manufacturing (AM), artificial intelligence (AI), and machine learning (ML) have significantly influenced engineering practices, particularly in the design and fabrication of complex components. As the demand grows for predictive capabilities in assessing the mechanical properties of parts designed and produced via layer-by-layer 3D printing, machine learning algorithms offer promising solutions. This study examines the application of classification models to predict the tensile strength and Young’s modulus of components manufactured via fused deposition modeling (FDM) under various process parameters. Tensile test data were systematically analyzed to train decision tree, support vector machine (SVM), and k-nearest neighbor (KNN) models. Among these, the decision tree algorithm exhibited the highest predictive accuracy (90.9%), with an AUC of 0.92 and an F1 score of 0.88. These findings underscore the value of data-driven methodologies in enhancing engineering design processes and establishing reliable experimental databases, contributing to the evolution of intelligent digital manufacturing systems. https://www.iranjme.ir/article_236227.html This paper presents a multidisciplinary design optimization of the rear leaf spring for a Dayun truck, aiming to simultaneously enhance mechanical performance, reliability, and ride comfort. The research methodology integrates analytical calculations, advanced numerical simulations, and systematic experimental tests. A detailed parametric model, incorporating all geometric details and the material properties of 55Cr3 alloy steel, was developed in SolidWorks software. This model was subsequently imported into ANSYS software for comprehensive finite element analysis (FEA), including nonlinear contact simulation between layers, stress distribution assessment under combined loading, and fatigue life prediction. Experimental validation involved fatigue tests conducted in accordance with ASTM standards and spring rate evaluation using a RANJBAR QCS98 testing machine. Statistical analysis of the results in Minitab software demonstrated that the implemented thickness modifications, while maintaining the spring rate within the desired specification (standard deviation < 2%), yielded a significant 18.5% improvement in fatigue life and 12.3% reduction in maximum stress. These performance enhancements achieved with only a marginal production cost increase of less than 4%, confirming the economic viability and practical feasibility of the optimized design. https://www.iranjme.ir/article_236228.html This paper presents an advanced approach to optimize the topology of structures by combining the Bidirectional Evolutionary Structural Optimization (BESO) method with the Mesh-Free Galerkin (EFG) method. The main goal of this hybrid approach is to significantly reduce the computational time while maintaining high accuracy in the optimization process. Traditional mesh-based methods, especially in problems involving complex geometries, often require precise mesh generation and repeated mesh reconstruction during the optimization process, which can significantly increase the computational cost and complexity. By incorporating a mesh-free method such as EFG, the proposed approach eliminates the need for mesh generation and, when combined with the evolutionary efficiency of the BESO algorithm, results in a faster and simpler optimization process. Numerical results presented in this study show that this combined method is up to 2.5 times faster than conventional approaches based on the finite element method (FEM), while still ensuring reliable mechanical performance and structural integrity. Furthermore, due to the flexibility of the EFG method in handling complex geometries and variable boundary conditions, the proposed technique is particularly effective for real-world engineering applications. This method is particularly suitable for industries such as aerospace, automotive, and mechanical engineering where the demand for lightweight, strong, and complex structural designs is high. Overall, the integration of BESO and EFG provides a robust and efficient solution to the limitations of traditional topology optimization techniques. https://www.iranjme.ir/article_241065.html Research in the field of lubrication technology is always of interest to researchers. One of the new cases in recent researches is the study of the performance of ionic liquids as lubricants. Also, to reduce the amount of lubricant consumption in various processes, a system called minimum lubrication system is used. In this research, the performance of sunflower oil and also the combination of ionic liquid [BMIM] [PF6] with sunflower oil as a lubricant in the turning process of AISI 4140 steel with minimum lubrication has been investigated. In addition to the effect of changing the distance between the nozzle and the workpiece and the pressure of the MQL system was also investigated in the turning process. According to the obtained results, as the distance between the nozzle and the workpiece decreases, the effect of lubrication with ionic liquid increases compared to lubrication with sunflower oil. Also, the use of ionic liquid [BMIM] [PF6] as an additive to sunflower oil was able to reduce the circular and cylindrical tolerances of the work piece by 12 and 22%, respectively, compared to lubrication with sunflower oil. https://www.iranjme.ir/article_242856.html Turn-milling is a new process that uses, turning and milling operations together, so that the tool and the work piece rotate simultaneously, for this reason, it has a wide ability in machining curved and complex surfaces. The main subject of the present study is the experimental and numerical investigation of the effect of changes in independent machining parameters, including work piece rotational speed, tool rotational speed, and tool feed rate, on dependent cutting parameters such as cutting force and specific energy. The result is that, according to experimental tests as well as numerical studies, increasing the tool feed rate increases the cutting force components and reduces the specific cutting energy. According to experimental tests, a threefold increase in the tool feed rate increases the resulting machining force by about 2.3 times and reduces the specific cutting energy by about 27%. A numerical study in the ABAQUS shows a 2.7-fold increase in the resulting machining force and a 4% reduction in the specific cutting energy following an approximately three-fold increase in the tool feed rate.