A techno-health study of the use of cutting fluids and future alternatives

Chaharsooghi, Alborz Shokrani; Dhokia, Vimal; Newman, Stephen T.

doi:10.14809/faim.2014.0625

Cited by 10 publications

(3 citation statements)

References 34 publications

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“…24,30 The presence of harmful chemicals such as formaldehyde and aromatic chains and the existence of dead bacterial masses such as endotoxin are proven sources of health hazards. 31 The exposure to cutting fluids is linked to a group of occupational health diseases ranging from asthma and dermatitis 32,33 to various types of cancers. 34,35 Cryogenic cooling has been acknowledged as an alternative method for cooling in machining difficultto-machine materials.…”

Section: Introductionmentioning

confidence: 99%

Energy conscious cryogenic machining of Ti-6Al-4V titanium alloy

Shokrani

Dhokia

Newman

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Manufacturing and in particular machining are responsible for a significant portion of global industrial energy consumption (25%). Previous research has shown that precise selection of cutting parameters can improve the energy consumption of machining processes. Cryogenic machining has attracted significant attention for improving the machinability of difficult-to-machine materials whilst also eliminating the environmental and health issues associated with the use of cutting fluids. Despite the advantages, there is a considerable research gap in cryogenic milling operations. This article investigates the effect of cryogenic cooling using liquid nitrogen in end milling of Ti-6Al-4V. A robust and rigorous methodology was developed and a series of machining experiments were conducted using a combination of cutting parameters repeated at dry, flood and cryogenic cooling environments. The investigations indicated that cryogenic cooling considerably reduces tool wear when compared to dry and flood cooling whilst allowing for using higher cutting speeds. The cutting tool used for cryogenic machining at 200m/min cutting speed, 0.03mm/tooth feed rate and 5mm depth of cut showed minimum flank wear. Furthermore, the investigations demonstrated that using the machine's coolant pump in flood cooling resulted in higher power and energy consumption than dry and cryogenic cooling. This article clearly shows that higher material removal rates are required in order to minimise specific machining energy. Therefore, since cutting speed is limited in dry machining, cryogenic machining is the more favourable as higher cutting speeds can be used. Using cryogenic machining at 200m/min cutting speed resulted in an 88% reduction in energy consumption of the machine tool as compared to flood cooling at 30m/min whilst minimum tool wear (10µm) was detected. This clearly demonstrates the significant capabilities of cryogenic machining when compared with more conventional machining approaches.

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Section: Introductionmentioning

confidence: 99%

Energy conscious cryogenic machining of Ti-6Al-4V titanium alloy

Shokrani

Dhokia

Newman

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Within the published literature on machining, the latter is mostly focused on the adverse health impacts of conventional water-based cutting fluids. Water-based cutting fluids are designed to recirculate in the machine tool for a prolonged length of time and they are susceptible to contamination and fungi and bacterial growth [8]. Exposure to the water-based cutting fluids has been linked to many occupational health diseases such as asthma and dermatitis.…”

Section: Discussionmentioning

confidence: 99%

“…Water-based cutting fluids have been repeatedly identified as one of the major sources of environmental impacts of machining. The main evidence supporting these claims is the fact that a large quantity of cutting fluids is used in flood cooling and that water-based cutting fluids are susceptible to bacterial and fungi growth, which can lead to a number of occupational health diseases [7,8]. This has led to numerous innovations in coolant and lubricants for machining as an alternative to flood cooling.…”

Section: Introductionmentioning

confidence: 99%

Towards Sustainable and Intelligent Machining: Energy Footprint and Tool Condition Monitoring for Media-Assisted Processes

Doğan¹,

Jones²,

Hall³

et al. 2023

Journal of Machine Engineering

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Reducing energy consumption is a necessity towards achieving the goal of net-zero manufacturing. In this paper, the overall energy footprint of machining Ti-6Al-4V using various cooling/lubrication methods is investigated taking the embodied energy of cutting tools and cutting fluids into account. Previous studies concentrated on reducing the energy consumption associated with the machine tool and cutting fluids. However, the investigations in this study show the significance of the embodied energy of cutting tool. New cooling/lubrication methods such as WS2-oil suspension can reduce the energy footprint of machining through extending tool life. Cutting tools are commonly replaced early before reaching their end of useful life to prevent damage to the workpiece, effectively wasting a portion of the embodied energy in cutting tools. A deep learning method is trained and validated to identify when a tool change is required based on sensor signals from a wireless sensory toolholder. The results indicated that the network is capable of classifying over 90% of the tools correctly. This enables capitalising on the entirety of a tool's useful life before replacing the tool and thus reducing the overall energy footprint of machining processes. Nomenclature

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