Comparative analysis of dry, flood, MQL and cryogenic CO2 techniques during the machining of 15-5-PH SS alloy

Khanna, Navneet; Shah, Priyanka; Chetan,

doi:10.1016/j.triboint.2020.106196

Cited by 120 publications

(22 citation statements)

References 49 publications

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“…For these reasons, it is di cult to conduct a scienti c and rigorous comparison between previous studies and this study. Although MQL provides lubrication for the contact area between the tool and the workpiece, effective heat dissipation is also very important for the machining area, which was con rmed by the ndings of Khanna et al Although MQL has a good lubrication ability, its cooling characteristics have certain disadvantages [30] . However, after cooling for MQL (LN 2 + MQL), the tool wear was signi cantly reduced, to 0.374 mm.…”

Section: Flank Wearmentioning

confidence: 98%

The effect of addition of MWCNTs nanoparticles to CryoMQL conditions on tool wear patterns, tool life, roughness and temperature in turning of Ti-6Al-4V.

Wang

Kong²

2022

Preprint

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In recent years, advancements in the field of nanotechnology have actively been reflected in the manufacturing industry, particularly in the production of aviation components, ships, and medical devices. However, titanium alloys have low thermal conductivity, making them difficult to cut at high temperatures. The traditional processing method is not only inefficient, but can also cause serious harm to the environment and operators. In this paper, multi-walled carbon nanotubes were used as additives to disperse into degradable vegetable oil as a green cutting fluid. This green cutting fluid was cooled to analyze the processing of a titanium alloy (LN2 + Nano-MQL (0.6%)). Cutting experiments were carried out under dry, MQL, LN2, LN2 + MQL, and LN2 + Nano-MQL (0.6%) conditions. The temperature of the machining area, tool wear process, tool wear mechanism, surface roughness, and surface morphology were studied. The results show that the cutting-zone temperature is reduced by 65.1%, the tool life is prolonged by 30%, and the surface roughness is reduced by 48.1% under LN2 + Nano-MQL (0.6%) in comparison to the dry condition. The cutting environment supported by MQL is conducive to inhibiting the formation of craters. Element detection confirmed that the tool coating was well protected under the condition of LN2 + Nano-MQL (0.6%). In addition, the tool nose wear is small under the LN2 + MQL and LN2 + Nano-MQL (0.6%) conditions.

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Section: Flank Wearmentioning

confidence: 98%

The effect of addition of MWCNTs nanoparticles to CryoMQL conditions on tool wear patterns, tool life, roughness and temperature in turning of Ti-6Al-4V.

Wang

Kong²

2022

Preprint

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“…Surface roughness was better in cryogenic and flood cooling as compared to MQL and dry cutting. In Figure 22, SEM images show the smoothness in the wear pattern of the flank face of the tool in cryogenic as compared to other techniques [89]. The growth of global production and the increase of cutting fluids application has caused intensive research concerning economic and environmental aspects of systems for cooling/lubricating the cutting zone.…”

Section: Cryogenic Coolingmentioning

confidence: 99%

Section: Sustainable Techniquesmentioning

confidence: 99%

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Progressing towards Sustainable Machining of Steels: A Detailed Review

et al. 2021

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Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

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“…On the other hand, dry cutting has an advantage in that it requires no fluid, which also removes the extra equipment needed to supply the fluid and reduces the cleaning and disposal costs. Nevertheless, some disadvantages emerge from dry machining, such as insufficient chip evacuation, rapid tool wear, sudden tool breakage, and reduced surface quality [9,10]. It is necessary to use sustainable and clean methods as alternatives to conventional flooding, thereby reducing the quantity of the fluid used and improving the machining efficiency [11].…”

Section: Introductionmentioning

confidence: 99%

The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel

Salur

Kuntoğlu

Aslan

et al. 2021

Metals

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Minimum quantity lubrication (MQL) is a sustainable method that has been efficiently applied to achieve machinability improvements with various materials in recent years, such as hardened steels, superalloys, soft metals, and composites. This study is the first to focus on the performance evaluation of MQL and dry milling environments with AISI 1040 steel. The tool wear, cutting temperature, and power consumption were considered as the quality responses while cutting speed, feed rate and machining environment are taken as input parameters. The effects of the influential factors are analyzed using analysis of variance (ANOVA) and bar charts. Additionally, Taguchi signal-to-noise (S/N) ratios are utilized in order to determine the optimum parameters for the best quality responses. The results show that the MQL system provides better performance compared to dry milling by reducing the tool wear, cutting temperature, and power consumption. According to the ANOVA results, the cutting environment affects the cutting temperature (37%) and power consumption (94%), while cutting speed has importance effects on the tool wear (74%). A lower cutting speed (100 m/min) and feed rate (0.10 mm/rev) should be selected under MQL conditions to ensure minimum tool wear and power consumption; however, a higher feed rate (0.15 mm/rev) needs to be selected along with a low cutting speed and MQL conditions to ensure better temperatures. A comparative evaluation is carried out on the tool wear, cutting temperature, and power consumption under MQL and dry environments. This investigation is expected to contribute to the current literature, highlighting the superiority of sustainable methods in the milling of industrially important materials.

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Comparative analysis of dry, flood, MQL and cryogenic CO2 techniques during the machining of 15-5-PH SS alloy

Cited by 120 publications

References 49 publications

The effect of addition of MWCNTs nanoparticles to CryoMQL conditions on tool wear patterns, tool life, roughness and temperature in turning of Ti-6Al-4V.

The effect of addition of MWCNTs nanoparticles to CryoMQL conditions on tool wear patterns, tool life, roughness and temperature in turning of Ti-6Al-4V.

Progressing towards Sustainable Machining of Steels: A Detailed Review

The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel

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