Experimental study on high-speed saw cutting of hybrid composite stacks using nanoparticle-enhanced minimum quantity lubrication

James, Sagil; Nejadian, Shayan

doi:10.1007/s00170-020-06008-z

Cited by 4 publications

(6 citation statements)

References 23 publications

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“…The MQL base oil of choice, ultra-pro-food-grade mineral oil, was mixed with different concentrations of aluminum oxide (Al 2 O 3 ) nanoparticles. The oil mixture was enhanced using the following five nanoparticle concentrations: The selection and the range of nanoparticle concentration in the nanofluid were decided based on previous studies conducted by our research group on high-speed machining assisted by nanofluid MQL [8,29]. The properties of the aluminum oxide nanoparticles (Al 2 O 3 , gamma) used in this study are described in Table 4.…”

Section: Mql Dispersion Preparationmentioning

confidence: 99%

“…Flooding the workpiece and tooling with cooling fluid (mostly coolant mixed with water) is a standard cooling method in conventional machining [7]. The use of flood coolant in conventional machining harms the environment and impacts the health of operators, technicians, and other personnel [8]. Transportation, maintenance, appropriate disposal, storage, and real estate costs are some major factors in conventional cooling that significantly negatively impact manufacturing businesses [9].…”

Section: Introductionmentioning

confidence: 99%

“…High-speed machining (HSM) has received increasing attention in recent years, as it offers several benefits, including a high material removal rate, superior surface quality, and reduced operational costs [24]. HSM benefits MQL-based machining to achieve high energy efficiency and environmental benefits [8]. However, to the best of our knowledge, no comprehensive studies have been conducted in an effort to understand the effects of nanoparticle-enhanced MQL on the HSM of Al2219 alloys.…”

Section: Introductionmentioning

confidence: 99%

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Study on High-Speed Machining of 2219 Aluminum Utilizing Nanoparticle-Enhanced Minimum Quantity Lubrication (MQL) Technique

James

Mazaheri

2023

Surfaces

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High-speed machining processes are significantly affected by the accumulation of heat generated by friction in the cutting zone, leading to reduced tool life and poor quality of the machined product. The use of cutting fluids helps to draw the heat out of the area, owing to their cooling and lubricating properties. However, conventional cutting fluid usage leads to considerable damage to human health and the environment, in addition to increasing overall manufacturing costs. In recent years, minimum quantity lubrication (MQL) has been used as an alternative lubricating strategy, as it significantly reduces cutting fluid consumption and eliminates coolant treatment/disposal needs, thereby reducing operational costs. In this study, we investigated microstructural surface finishing and heat generation during the high-speed cutting process of 2219 aluminum alloy using an MQL nanofluid. 2219 aluminum alloy offers an enhanced strength-to-weight ratio and high fracture toughness and is commonly used in a wide range of aerospace and other high-temperature applications. However, there is no relevant literature on MQL-based high-speed machining of these materials. In this study, we examined flood coolant and five different MQL nanofluids made by synthesizing 0.2% to 2% concentrations of Al2O3 nanoparticles into ultra-food-grade mineral oil. The study results reveal the chemistry between the MQL of choice and the corresponding surface finishing, showing that the MQL nanofluid with a 0.5% concentration of nanoparticles achieved the most optimal machining result. Furthermore, increasing the nanoparticle concentration does result in any further improvement in the machining result. We also found that adding a 0.5% concentration of nanoparticles to the coolant helped to reduce the temperature at the workpiece–tool interface, obtaining a good surface finish.

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Section: Mql Dispersion Preparationmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Study on High-Speed Machining of 2219 Aluminum Utilizing Nanoparticle-Enhanced Minimum Quantity Lubrication (MQL) Technique

James

Mazaheri

2023

Surfaces

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“…In addition, nanoparticles help improve the lubrication characteristics of grinding wheel/workpiece and grain/chip interface because of their excellent anti-wear and antifriction properties [204][205][206]. Gao et al [207][208][209] studied the grinding of CFRP with CNTs nanofluid. Compared with dry grinding, the results show that CNT nano-lubricant reduced maximum F n and F t by 20.07% and 26.81%, respectively.…”

Section: Minimum Quantity Lubricationmentioning

confidence: 99%

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

et al. 2022

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Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

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“…Using ood coolant in conventional machining is harmful to environment and impact the health of operators, technicians, and other personnel. [7]. Transportation, maintenance, appropriate disposal, storage and real estate costs are some major factors in conventional forms of cooling which create signi cant negative impact on manufacturing businesses.…”

Section: Introductionmentioning

confidence: 99%

Study on High-Speed Machining of 2219 Aluminum Utilizing Nanoparticle-Enhanced Minimum Quantity Lubrication (MQL) Technique

James

Mazaheri²

2022

Preprint

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The lubricant choice is a critical factor in the high-speed machining process, and it can impact the machining surface quality and also the ultimate material properties. This paper investigates the microstructural surface finishing and heat generated during the high-speed cutting process (machining speed 3800 RPM) of 2219 aluminum alloy. The study examines flood coolant and five different nanofluids made by synthesizing 0.2–2% concentration of Al2O3 nanoparticles into ultra-food-grade mineral oil utilizing nanoparticle-enhanced minimum quantity lubrication (MQL) technique. In the MQL method, unlike the current known cooling fluid systems, the nanofluid provides a thin lubricant film that leads the heat created by friction to be transmitted to the chips and exits the interface. Also, the small amount of lubricant used for MQL makes this technique more environmentally friendly. The study revealed the chemistry between the MQL of choice and the corresponding surface finishing. As a result, the nanofluid with a 0.5% concentration of nanoparticles has the most optimal machining result. Furthermore, increasing nanoparticle concentration does not indicate any further improvement in the result. The results of this study could be instrumental to developing environmental-friendly machining solutions for aluminum alloys at commercial scales.

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Experimental study on high-speed saw cutting of hybrid composite stacks using nanoparticle-enhanced minimum quantity lubrication

Cited by 4 publications

References 23 publications

Study on High-Speed Machining of 2219 Aluminum Utilizing Nanoparticle-Enhanced Minimum Quantity Lubrication (MQL) Technique

Study on High-Speed Machining of 2219 Aluminum Utilizing Nanoparticle-Enhanced Minimum Quantity Lubrication (MQL) Technique

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

Study on High-Speed Machining of 2219 Aluminum Utilizing Nanoparticle-Enhanced Minimum Quantity Lubrication (MQL) Technique

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