Ecological, economical and technological perspectives based sustainability assessment in hybrid-cooling assisted machining of Ti-6Al-4 V alloy

Gupta, Munish Kumar; Song, Qinghua; Liu, Zhanqiang; Sarıkaya, Murat; Jamil, Muhammad; Mia, Mozammel; Kushvaha, Vinod; Singla, Anil Kumar; Li, Zhixiong

doi:10.1016/j.susmat.2020.e00218

Cited by 51 publications

(30 citation statements)

References 40 publications

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“…The obvious reason associated with the unfavorable outcome yielded by the continuous mode is the simultaneous cooling and, thus, hardening, of the work material in addition to the twist drill. The supply of the coolant during the cutting process raises the strength of the material making it consume more energy for its plastic deformation and conversion into a chip [ 23 ]. The favorable outcome associated with the between-the-holes cooling when applied to the drilling of the composite material is the retention of the cutting edges’ sharpness, which does not let the SCE magnitude rise significantly.…”

Section: Resultsmentioning

confidence: 99%

Between-the-Holes Cryogenic Cooling of the Tool in Hole-Making of Ti-6Al-4V and CFRP

et al. 2021

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Lightweight materials are finding plentiful applications in various engineering sectors due to their high strength-to-weight ratios. Hole-making is an inevitable requirement for their structural applications, which is often marred by thermal damages of the drill causing unacceptable shortening of tool life. Efficient cooling of the tool is a prime requirement for enhancing the process viability. The current work presents a novel technique of cooling only the twist drill between drilling of holes with no effect of the applied cryogenic coolant transferred to the work material. The technique is applied in the drilling of two commonly used high-strength lightweight materials: carbon fibers reinforced polymer (CFRP) and an alloy of titanium (Ti-6Al-4V). The efficacy of the cooling approach is compared with those of conventionally applied continuous cryogenic cooling and no-cooling. The effectiveness is quantified in terms of tool wear, thrust force, hole quality, specific cutting energy, productivity, and consumption of the cryogenic fluid. The experimental work leads to a finding that between-the-holes cryogenic cooling possesses a rich potential in curbing tool wear, reducing thrust force and specific energy consumption, and improving hole quality in drilling of CFRP. Regarding the titanium alloy, it yields a much better surface finish and lesser consumption of specific cutting energy.

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Section: Resultsmentioning

confidence: 99%

Between-the-Holes Cryogenic Cooling of the Tool in Hole-Making of Ti-6Al-4V and CFRP

et al. 2021

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“…Energy consumption is directly related to power consumption, which can be calculated based on the elapsed time. Moreover, almost half of the total costs come from energy consumption [44]. Among other manufacturing methods, machining accounts for a huge amount of the energy consumption due to the long processing periods [45]; therefore, lowering the power consumption is necessary for many reasons and will help avoid machinability issues, resulting in longer tool life and better workpiece-related properties (i.e., surface integrity).…”

Section: Evaluation Of Power Consumption Under Mql and Dry Cutting Conditionsmentioning

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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“…Sustainability in manufacturing is the creation of products through processes that have minimum environmental impact, are economically viable, and pose no threats to workers [1]. From the viewpoint of machining processes, sustainability largely depends upon machining parameters, workpiece materials, and lubrication techniques [2]. The selection of machining parameters plays a significant role in the efficient utilization of cutting tools and machine tools during a machining operation.…”

Section: Introductionmentioning

confidence: 99%

Sustainability-Based Analysis of Conventional to High-Speed Machining of Al 6061-T6 Alloy

et al. 2021

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High-speed machining is considered to be a promising machining technique due to its advantages, such as high productivity and better product quality. With a paradigm shift towards sustainable machining practices, the energy consumption analysis of high-speed machining is also gaining ever-increasing importance. The current article addresses this issue and presents a detailed analysis of specific cutting energy (SCE) consumption and product surface finish (Ra) during conventional to high-speed machining of Al 6061-T6. A Taguchi-based L16 orthogonal array experimental design was developed for the conventional to high-speed machining range of an Al 6061-T6 alloy. The analysis of the results revealed that SCE consumption and Ra improve when the cutting speed is increased from conventional to high-speed machining. In particular, SCE was observed to reduce linearly in conventional and transitional speed machining, whereas it followed a parabolic trend in high-speed machining. This parabolic trend indicates the existence of an optimal cutting speed that may lead to minimum SCE consumption. Chip morphology was performed to further investigate the parabolic trend of SCE in high-speed machining. Chip morphology revealed that the serration of chips initiates when the cutting speed is increased beyond 1750 m/min at a feed rate of 0.4 mm/rev.

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Ecological, economical and technological perspectives based sustainability assessment in hybrid-cooling assisted machining of Ti-6Al-4 V alloy

Abstract: economical and technological perspectives based sustainability Ecological, economical and technological perspectives based sustainability assessment in hybrid-cooling assisted machining of Ti-6Al-4 V alloy assessment in hybrid-cooling assisted machining of Ti-6Al-4 V alloy

Cited by 51 publications

References 40 publications

Between-the-Holes Cryogenic Cooling of the Tool in Hole-Making of Ti-6Al-4V and CFRP

Between-the-Holes Cryogenic Cooling of the Tool in Hole-Making of Ti-6Al-4V and CFRP

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

Sustainability-Based Analysis of Conventional to High-Speed Machining of Al 6061-T6 Alloy

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