Ultrasonic-assisted chemical milling: surface roughness characterization and material removal enhancement of Al 6061 Shamim Mohammadi, Amir Rasti Ultrasonics Sonochemistry, 2026 Chemical milling (CHM) is widely used for thinning and pocketing components, especially in aerospace applications, but its low material removal rate (MRR) requires high etchant consumption and often leads to poor surface integrity. This study introduces a novel method, direct ultrasonic-assisted chemical milling (UACM), as an efficient and sustainable alternative to CHM. A full-factorial design examined three ultrasonic powers (50, 150, 250 W) across acidic and alkaline etchants at three concentration levels. MRR and roughness parameters (Ra, Rz, Sa) were experimentally quantified and modeled using ANOVA-based regression, while multi-region SEM/EDS elucidated oxide disruption, pit formation, and surface evolution on Al 6061. In 10 % HCl at 250 W, UACM increased MRR by 591 % through cavitation-enhanced agitation and rapid renewal of reactive species, enabling≈85.5 % reduction in acid use. Moreover, at matched MRR, UACM yielded 15-30 % lower Sa than CHM, producing uniform microporosity beneficial for bonding and coating applications. The best acidic condition was 15 % HCl at 250 W, where MRR increased from 0.70 to 1.30 mm/m/s and produced a clean, crack-free, homogeneous surface with optimal integrity. The optimal alkaline condition was 50 % NaOH at 250 W, where MRR increased from 0.08 to 0.23 mm/m/s (≈65.2 % time reduction), and the disruption of hydrogen-bubble shielding generated a uniform and stable morphology. Key experimental challenges included maintaining thermal stability under high acoustic power, controlling bubble adhesion in alkaline media, and achieving a reproducible initial surface. Overall, UACM substantially enhances removal efficiency, improves surface integrity, and reduces chemical consumption, offering a practical pathway toward high-precision and greener manufacturing.
Analysis of geometric dimensioning and tolerancing in sustainable hard drilling using vegetable oil-based MQL Amir Rasti, Ahmad Reza Omiddodman, Mehdi Ustad Journal of Engineering Research Kuwait, 2026 This study investigates the influence of cutting parameters on the hole precision in hard drilling of AISI 4340, with a particular emphasis on vegetable-based minimum quantity lubrication (MQL) as a green machining approach. The effect of key parameters including cutting speed, feed rate, and workpiece hardness was analyzed on the cutting force and hole precision using soybean oil as the cutting fluid. The results showed a stable trend in the time history of cutting forces during the cutting process, with no significant wear or other disruptions, indicating that vegetable oil can provide effective lubrication during hard drilling. The axial cutting force was lower than 8000 N in the studied range of cutting parameters. The findings also revealed that feed rate is the most important factor influencing output characteristics, which deteriorated hole diameter, circularity, and cylindricity tolerances of up to 200%. This is especially evident with softer materials (30 HRC). Furthermore, workpiece hardness had a minor effect on circularity, but a significant impact on straightness and overall cylindricity up to 56%. Soybean oil-assisted MQL resulted in tolerances magnitude of less than 60 μm, demonstrating its effectiveness in hard drilling AISI 4340.
Assessment on surface integrity in electrochemical grinding of AISI 304 Mohammad Yazdani, Amir Rasti Heliyon, 2025 Electrochemical grinding (ECG) offers advantages such as burr-free and stress-free material removal. Despite its proven potential, limited research has addressed the comprehensive effects of key process parameters on the surface integrity of AISI 304 stainless steel, particularly for applications requiring high-quality finishes, such as medical components. This study bridges this gap by systematically investigating the influence of ECG key parameters including voltage, rotational speed, and electrolyte concentration on main surface integrity parameters including current density, surface roughness, microhardness, and surface texture. Total of 20 experiments were carried out following a Response Surface Methodology (RSM) design, incorporating five levels of variation for the parameters of electrolyte concentration, voltage, and grinding wheel speed. Results revealed that voltage and electrolyte concentration were the dominant factors affecting current density, increasing it by 368 % and 241 %, respectively, while higher rotational speeds decreased it by 44.5 % due to reduced contact time and electrolyte removal. Surface roughness decreased by up to 65 % in the perpendicular direction as concentration and voltage increased, but higher voltages led to over-etching, increased the surface roughness. Electrolyte concentration and voltage also reduced surface microhardness by 10-14 % through intensified corrosion, while higher wheel speeds increased microhardness due to enhanced mechanical removal. The maximum variation for in-depth microhardness extended up to a depth of 40 μm below the surface. Surface texture analysis also revealed more uniform pitting across the surface at higher concentrations, indicating more consistent material dissolution. However, at higher voltages, deep pitting emerged, raising surface roughness.
Deep ball burnishing of Al 2024-T4: insights into surface roughness, microhardness, topography, and chemical alteration Amir Rasti, Javad Kazemi, Shamim Mohammadi, Ali Zeinolabedin-Beygi Materials and Manufacturing Processes, 2025 This study investigates the influence of sliding deep ball burnishing (DBB) on the surface integrity of Al 2024-T4. A distinctive feature of this work is the applying of a sliding-type DBB tool in combination with a multi-pass constant-depth strategy. DBB improved the roughness (Ra) up to 75%, reducing it from an initial 3.25 μm to a minimum of 0.21 μm when db = 10 mm, htot = 0.05 mm, f = 800 mm/min. In contrast, higher feed rates and higher total depths also increased the Ra by 51% and 154%, respectively. Microhardness increased from 127 Hv to a maximum of 197 Hv, representing an average improvement of 27.2%. The maximum increase of 20.2% attributed to cumulative work hardening across multiple passes. EDS analysis revealed elevated levels of copper, magnesium, and oxygen in heavily deformed regions, suggesting thermal effects, lubricant breakdown, and tribo-chemical film formation. FE modeling showed that larger ball diameters induce broader but less concentrated strain fields.
Investigation of surface integrity in high speed machining of Ti6Al4V alloy Proceedings of the International Conference on Industrial Engineering and Operations Management, 2016
Numerical and experimental investigation of cutting force in rotary broaching process of Ti6Al4V using Johnson–Cook constitutive model A Rasti, A Zeinolabedin-Beygi, A Zarhoon, HD Azodi Journal of Engineering Research , 2026 2026
Numerical and experimental insights into fatigue failure of interference fits in AISI 4340 hardened steel and carbide interfaces SS Farshi, A Rasti International Journal on Interactive Design and Manufacturing (IJIDeM), 1-15 , 2026 2026
Surface integrity in rotary broaching of Ti6Al4V: analyzing the effects of cutting parameters A Rasti, M Tarshizi The International Journal of Advanced Manufacturing Technology 143 (5), 2953 … , 2026 2026
Ultrasonic-assisted chemical milling: surface roughness characterization and material removal enhancement of Al 6061 S Mohammadi, A Rasti Ultrasonics Sonochemistry, 107753 , 2026 2026
Deep ball burnishing of Al 2024-T4: insights into surface roughness, microhardness, topography, and chemical alteration A Rasti, J Kazemi, S Mohammadi, A Zeinolabedin-Beygi Materials and Manufacturing Processes 40 (16), 2203-2217 , 2025 2025
Feasibility Study of Manufacturing a Laparoscopic Stapler Joint Using Metal Injection Molding Process M Aminian, R Hashemi, A Rasti, A Zeinolabedin-Beygi Journal of Engineering and Applied Research 2 (2), 109-120 , 2025 2025
Sustainable Micro-Milling of Ti6Al4V: Role of MoS2 and CuO Nanofluids in Minimum Quantity Lubrication H Hassanpour, A Rasti, SS Farshi, H Sabzi Precision Engineering , 2025 2025 Citations: 1
Effect of Shot-Peening Duration on Surface Integrity of Selective Laser Melted Steel Components. MA Rahimi Jafari, R Hashemi, A Rasti, A Zeinolabedin-Beygi Modares Mechanical Engineering 25 (9) , 2025 2025
Surface Roughness and Microhardness Prediction: A Machine Learning Approach for Electrochemical Grinding. A Rasti, AH Rabiee, A Zeinolabedin-Beygi, M Yazdani Modares Mechanical Engineering 25 (9) , 2025 2025 Citations: 1
Study of surface roughness, texture, and microhardness in hard drilling of AISI D2: The critical role of cutting oil in minimum quantity lubrication A Rasti, A Zeinolabedin-Beygi, H Hassanpour, AR Omiddodman Journal of Mechanical Science and Technology 39 (9), 5397-5403 , 2025 2025 Citations: 1
Stress corrosion behavior of AISI 4340 in high-speed hard milling using MQL A Rasti, H Hassanpour, SS Farshi, JH Khosrowshahi Journal of Materials Engineering and Performance 34 (17), 19630-19639 , 2025 2025 Citations: 2
Fault diagnosis radial bearing mounted on shaft using classification with audio spectrogram and convolutional neural network M Ustad, A Rasti, A Rezaei Iranian Journal of Manufacturing Engineering 12 (5), 1-10 , 2025 2025
Analysis of geometric dimensioning and tolerancing in sustainable hard drilling using vegetable oil-based MQL A Rasti, AR Omiddodman, M Ustad Journal of Engineering Research , 2025 2025 Citations: 2
Design and performance analysis of integrated roller bearing and roller screw mechanism for precision linear motion A Rasti, D Jafari, I Rafierad Iranian Journal of Manufacturing Engineering 12 (2), 59-69 , 2025 2025 Citations: 2
Assessment on surface integrity in electrochemical grinding of AISI 304 M Yazdani, A Rasti Heliyon 11 (1) , 2025 2025 Citations: 6
Evaluation and Prediction of Surface Roughness and Microhardness in the Deep Ball Burnishing Process Using Machine Learning Approach J Kazemi, A Rasti, A Zarhoon 2025
Effect of Shot-Peening Duration on Surface Integrity of Selective Laser Melted Steel Components MAR Jafari, R Hashemi, A Rasti, A Zeinolabedin-Beygi 2025
Surface integrity in rotary broaching of Ti6Al4V: analyzing the effects of kinematic and cutting parameters A Rasti, M Tarshizi, JH Khosrowshahi 2024 Citations: 1
Effect of ball nose flank wear on surface integrity in high-speed hard milling of AISI 4340 steel using MQL H Hassanpour, A Rasti, JH Khosrowshahi, SS Farshi Heliyon 10 (18) , 2024 2024 Citations: 17
Study of surface roughness, texture, and dimensional accuracy in thread whirling of Ti6Al4V screw AZB Amir Rasti, Mohammad Tarshizi Iranian Journal of Manufacturing Engineering 11 (4), 1-12 , 2024 2024 Citations: 4
MOST CITED SCHOLAR PUBLICATIONS
Investigation of surface roughness, microhardness and white layer thickness in hard milling of AISI 4340 using minimum quantity lubrication H Hassanpour, MH Sadeghi, A Rasti, S Shajari Journal of Cleaner Production 120 (H Hassanpour, A Rasti, M H Sadeghi , M H … , 2016 2016 Citations: 134
Experimental study of cutting force, microhardness, surface roughness, and burr size on micromilling of Ti6Al4V in minimum quantity lubrication H Hassanpour, MH Sadeghi, H Rezaei, A Rasti Materials and Manufacturing Processes 31 (13), 1654-1662 , 2016 2016 Citations: 106
An investigation into the effect of surface integrity on the fatigue failure of AISI 4340 steel in different drilling strategies A Rasti, MH Sadeghi, SS Farshi Engineering Failure Analysis 95, 66-81 , 2019 2019 Citations: 35
Application of GONNS to predict constrained optimum surface roughness in face milling of high-silicon austenitic stainless steel S Elhami, MR Razfar, M Farahnakian, A Rasti The International Journal of Advanced Manufacturing Technology 66 (5), 975-986 , 2013 2013 Citations: 29
Investigation of roughness, topography, microhardness, white layer and surface chemical composition in high speed milling of Ti-6Al-4V using minimum quantity lubrication H Hassanpour, A Rasti, MH Sadeghi, JH Khosrowshahi Machining Science and Technology 24 (5), 719-738 , 2020 2020 Citations: 19
Effect of ball nose flank wear on surface integrity in high-speed hard milling of AISI 4340 steel using MQL H Hassanpour, A Rasti, JH Khosrowshahi, SS Farshi Heliyon 10 (18) , 2024 2024 Citations: 17
Compare and study of hole quality characteristics in helical milling and conventional drilling MH Saadatbakhsh, A Rasti, MH Sadeghi, H Hassanpour, ... Modares Mechanical Engineering 14 (16), 332-338 , 2015 2015 Citations: 16
Numerical simulation of plastic deformation in direct-drive friction welding of AISI 4140 and ASTM A106 steel tubes JH Khosrowshahi, MH Sadeghi, A Rasti Archives of Civil and Mechanical Engineering 20 (4), 116 , 2020 2020 Citations: 15
An analytical study on residual stresses in drilling of hardened steel A Rasti, MH Sadeghi, SS Farshi The International Journal of Advanced Manufacturing Technology 99 (9), 2389-2405 , 2018 2018 Citations: 13
Experimental study of tool wear and surface roughness on high speed helical milling in D2 steel N Molla Ramezani, A Rasti, MH Sadeghi, B Jabbaripour, ... Modares Mechanical Engineering 15 (20), 198-202 , 2016 2016 Citations: 13
Investigation of milling strategies effect on microhardness of a typical curved surface. H Hassanpour, S Shajari, A Rasti, M Hossein Sadeghi Modares Mechanical Engineering 15 (2) , 2015 2015 Citations: 12
Empirical study of dimensional and geometrical tolerances in helical milling of AISI 4340 steel MH SAADATBAKHSH, A RASTI, MH SADEGHI, H HASSANPOUR, ... Modares Mechanical Engineering 14 (15), 119-126 , 2015 2015 Citations: 12
Effect of cutting fluid application on surface roughness in hard milling of 4340-alloyed steel H Hassanpour, A Rasti, MH Sadeghi Modares Mechanical Engineering 14 (14), 50-60 , 2015 2015 Citations: 10
Evaluation of workpiece hardness and cutting parameters effects on cutting force and surface roughness in drilling using vegetable-based cutting fluid. AR Omiddodman, H Hassanpour, MH Sadeghi, A Rasti, ... Modares Mechanical Engineering 14 (13) , 2015 2015 Citations: 7
Assessment on surface integrity in electrochemical grinding of AISI 304 M Yazdani, A Rasti Heliyon 11 (1) , 2025 2025 Citations: 6
Investigation of interference fit and its effect on fatigue life in hardened steel S Sabbaghi Farshi, A Rasti, MH Sadeghi, J Hashemi Khosrowshahi Modares Mechanical Engineering 17 (10), 420-428 , 2017 2017 Citations: 5
Helical milling of cold-work AISI D2 steel with PVD carbide tool under dry conditions N Molla Ramezani, H Ranjbar, MH Sadeghi, A Rasti Modares Mechanical Engineering 15 (20), 203-206 , 2016 2016 Citations: 5
Study of surface roughness, texture, and dimensional accuracy in thread whirling of Ti6Al4V screw AZB Amir Rasti, Mohammad Tarshizi Iranian Journal of Manufacturing Engineering 11 (4), 1-12 , 2024 2024 Citations: 4
The effect of hole making method on cutting force and surface roughness H Imani, N Molla Ramezani, MH Sadeghi, A Rasti Modares Mechanical Engineering 15 (20), 285-290 , 2016 2016 Citations: 4
Evaluation of Surface Roughness Effect on Fatigue Life in Drilling of Hardened Steel A Rasti, MH Sadeghi, S SABBAGHI FARSHI Modares Mechanical Engineering 18 (1), 103-110 , 2018 2018 Citations: 3
