Cutting tool wear in turning 316L stainless steel in the conditions of minimized lubrication

Szczotkarz, Natalia; Mrugalski, Roland; Maruda, Radosław W.; Królczyk, Grzegorz; Legutko, Stanisław; Leksycki, Kamil; Dębowski, Daniel; Pruncu, Catalin I.

doi:10.1016/j.triboint.2020.106813

Cited by 69 publications

(26 citation statements)

References 33 publications

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“…Sustainability can be realized in machining processes using cutting fluids, as mentioned by Sankaranarayanan et al [ 6 ]. Khanna et al [ 5 ] and Szczotkarz et al [ 7 ] reported that during metal cutting operations, the high level of heat generated at the tool–workpiece–chip interfaces leads to high tool wear and low surface integrity. To tackle this problem, Khanna et al [ 5 ] and Adler et al [ 8 ] stated that cutting fluids can be utilized to reduce the temperature in the cutting region and also perform functions such as lubrication and flushing of chips.…”

Section: Introductionmentioning

confidence: 99%

“…To tackle this problem, Khanna et al [ 5 ] and Adler et al [ 8 ] stated that cutting fluids can be utilized to reduce the temperature in the cutting region and also perform functions such as lubrication and flushing of chips. The most widespread type of cutting fluids used in machining operations is water-based emulsions, leading to a popular cutting process called flood-coolant (wet) machining, as expressed by Szczotkarz et al [ 7 ].…”

Section: Introductionmentioning

confidence: 99%

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Low and High Speed Orthogonal Cutting of AA6061-T6 under Dry and Flood-Coolant Modes: Tool Wear and Residual Stress Measurements and Predictions

et al. 2021

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The present research work aimed to study the effects of cutting environments and conditions on tool wear and residual stresses induced by orthogonal cutting of AA6061-T6. Cutting environments included dry- and flood-coolant modes and cutting conditions consisted of cutting speed and feed rate. A 2D finite element (FE) model was developed to predict tool wear and residual stresses and was validated by experimental measurements including machining forces, tool wear, and residual stresses. This was obtained by exploring various magnitudes of the shear friction factor and heat transfer coefficient and choosing proper coefficients using the calibration of the predicted results with the measured ones. The experimental results showed that the effect of cutting environment including dry and flood-coolant modes was negligible on machining forces. The experimental investigation also demonstrated that increasing feed rate raised machining forces, tool wear and residual stresses in both cutting environments. Low Speed Cutting (LSC) led to the highest value of tool wear and High Speed Cutting (HSC) provided the lowest values of resultant machining forces and residual stresses in both modes. Flood-coolant mode reduced tool wear and slightly decreased tensile residual stresses in comparison with dry mode. As a result, low feed rate and high-speed cutting under flood-coolant mode were proposed in order to improve tool wear and residual stress in orthogonal cutting of AA6061-T6.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Low and High Speed Orthogonal Cutting of AA6061-T6 under Dry and Flood-Coolant Modes: Tool Wear and Residual Stress Measurements and Predictions

et al. 2021

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“…Their results show that MQL reduced tool wear by 18% compared to dry cutting. Their results also show that MQL can very well reduce adhesive wear, but for example notch wear is not significantly affected by MQL compared to dry conditions [52].…”

Section: Simulating Cryogenic Cutting Fluids and Mqlmentioning

confidence: 91%

“…Their results did not reflect the reality of experiments with average cutting force error of 82%, and the wear depth from simulations was 10 −4 mm and 0.537 mm in experiments [51]. Szczotkarz et al (2021) investigate tool wear in machining of 316L stainless steel with MQL and dry cutting conditions. Their results show that MQL reduced tool wear by 18% compared to dry cutting.…”

Section: Simulating Cryogenic Cutting Fluids and Mqlmentioning

confidence: 92%

Evaluation of subcooled MQL in cBN hard turning of powder-based Cr-Mo-V tool steel using simulations and experiments

Laakso

Mallipeddi

Krajnik

2021

Int J Adv Manuf Technol

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Metal cutting fluids for improved cooling and lubrication are an environmental risk and a health risk for workers. Minimizing water consumption in industry is also a goal for a more sustainable production. Therefore, metal cutting emulsions that contain hazardous additives and consume considerable amounts of water are being replaced with more sustainable metal cutting fluids and delivery systems, like vegetable oils that are delivered in small aerosol droplets, i.e., via minimum quantity lubrication (MQL). Since the volume of the cutting fluid in MQL is small, the cooling capacity of MQL is not optimal. In order to improve the cooling capacity of the MQL, the spray can be subcooled using liquid nitrogen. This paper investigates subcooled MQL with machining simulations and experiments. The simulations provide complementary information to the experiments, which would be otherwise difficult to obtain, e.g., thermal behavior in the tool-chip contact and residual strains on the workpiece surface. The cBN hard turning simulations and experiments are done for powder-based Cr-Mo-V tool steel, Uddeholm Vanadis 8 using MQL subcooled to −10 °C and regular MQL at room temperature. The cutting forces and tool wear are measured from the experiments that are used as the calibration factor for the simulations. After calibration, the simulations are used to evaluate the thermal effects of the subcooled MQL, and the surface residual strains on the workpiece. The simulations are in good agreement with the experiments in terms of chip morphology and cutting forces. The cutting experiments and simulations show that there is only a small difference between the subcooled MQL and regular MQL regarding the wear behavior, cutting forces, or process temperatures. The simulations predict substantial residual plastic strain on the workpiece surface after machining. The surface deformations are shown to have significant effect on the simulated cutting forces after the initial tool pass, an outcome that has major implications for inverse material modeling.

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“…The tribofilm layer formed on the workpiece and tool surfaces helps to reduce the friction and the associated heat generation at the cutting zone when compared to dry and flood machining. 8,9 Unlike the minimal quantity lubricant (MQL) method, cutting fluid particles are not mixed with compressed air in the minimal fluid application method. However, the cooling and lubrication ability achieved with a small amount of cutting fluid is lower than that is possible with flood or wet cooling.…”

Section: Introductionmentioning

confidence: 99%

Investigations on the effect of silver nanoparticles on performance of coconut oil based cutting fluid in minimal fluid application

Gnanadurai

Mesfin

2022

Advances in Mechanical Engineering

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In this work, an innovative nanocutting fluid, based on coconut oil was developed by dispersing silver nanoparticles (AgNPs) of size less than 50 nm. The tribological and physical properties of the prepared nanocutting fluid with different volumes of silver nanoparticles were studied. It was found that the addition of 4% by volume of nanoparticles enhanced the properties of the nanocutting fluid compared to the other concentrations studied, thus demonstrating its excellent tribological performance. The effect of the newly developed nanocutting fluid with 4% of silver nanoparticles on cutting performance was also investigated while machining AISI4340 steel with minimal fluid application. Results revealed that the cutting force, cutting temperature, and tool wear are reduced on an average by 22.6%, 12.6%, and 5.3% respectively. It was evident that efficient cooling and lubrication of nanocutting fluid dispersed with silver nanoparticles improved the cutting performance. The outcomes of this work can be considered as a development toward eco-friendly and sustainable machining.

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Cutting tool wear in turning 316L stainless steel in the conditions of minimized lubrication

Cited by 69 publications

References 33 publications

Low and High Speed Orthogonal Cutting of AA6061-T6 under Dry and Flood-Coolant Modes: Tool Wear and Residual Stress Measurements and Predictions

Low and High Speed Orthogonal Cutting of AA6061-T6 under Dry and Flood-Coolant Modes: Tool Wear and Residual Stress Measurements and Predictions

Evaluation of subcooled MQL in cBN hard turning of powder-based Cr-Mo-V tool steel using simulations and experiments

Investigations on the effect of silver nanoparticles on performance of coconut oil based cutting fluid in minimal fluid application

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