In this present investigation, machinability studies on novel aluminum composite with hybrid reinforcements of copper-coated 4% carbon fibers (CFs) and 3% nanoclay in AA6026 matrix fabricated by compocasting method is performed. Step drill bit and multifaceted drill bit are used by adopting central composite design (CCD) in response surface methodology (RSM). The outcomes show that, with a rise in rotational speed surface irregularities, resultant force and material removal rate (MRR) intensifies, and with the additional rise in rotational speed, all the outputs decrease considerably. High MRR, resultant cutting force, and surface roughness are obtained with multifaceted carbide drills, compared with a step drill. Desirability function is used to maximize the MRR and minimize the resultant cutting forces considering the constant surface roughness of 3 μm. The optimal values are rotational speed of 1285 rpm, feed rate of 60 mm/min with the step drill bit, producing an MRR of 0.0439 kg/sec and a resultant cutting force of 185.818 N. The second-order empirical models are developed for outputs, which are fed into the non-traditional metaheuristic Evaporation Rate-based Water Cycle Algorithm (ER-WCA) therefore the lower objective value is achieved with step drill of 51.7421. It is found that using a step drill the machinability performance of this hybrid nanocomposite is well improved than the machining with other drill bits. This composite fulfills the norms of 2000/53/CE-ELV European environmental directives.

Carbon fiber and its composites are increasingly used in many fields including defence, military, and allied industries. Also, surface quality is given due importance, as mating parts are used in machineries for their functioning. In this work, the turning process is considered for Carbon Fiber Reinforced Polymer (CFRP) composites by varying three important cutting variables: cutting speed, feed, and depth of cut. Correspondingly, the surface roughness is measured after the completion of turning operation. As well, a prediction model is created using different fuzzy logic membership function and Levenberg–Marquardt algorithm (LMA) in artificial intelligence. Later, the surface roughness values from the developed models are compared against the experimental values for its correlation and effectiveness in using different membership functions of fuzzy logic and ANN. Thus, the experimental results are analyzed using the effect graphs and it is presented in detail.

The optical fibers tend to have poor machinability because of its hardness and brittleness. In the previous study, we applied the electrochemical discharge machining to fabricate the tip of the optical fiber. We could machine the optical fiber using the electrochemical discharge machining however the machined optical fiber tip had rough surface. In this study, we use electrochemical discharge machining with rotation tool which of the rough-grinding and finishing-grinding process to obtain a smooth surface of the side firing fiber. As a result, we are able to machine the optical fiber tip with smooth surface effectively from the proposed fiber machining process and the emission from the side-firing fiber clearly demonstrated the directional emission as the emission beam was reflected at 80 ° relative to the fiber axis.

The multi-direction firing of the optical fiber has been required to induce wider damage zone during the laser-assisted surgery. The optical fibers tend to have poor machinability because of its hardness and brittleness. In this study, we employed the ECDM to fabricate the tip of the optical fiber in cone-shape. The con-shaped tip made the multidirectional emission of the light at the distal end of the fiber. The result showed that the lower electrolyte concentration enhanced the surface quality. The optimal concentration of electrolyte was 15% to make high quality surface of optical fiber tip in this experimental condition. When the voltage was more lower, surface quality had been become better. The suitable voltage was 30V for the effective process time.