Formulation of sub-zero metalworking fluids for cutting processes: Influence of additives

Basten, Stephan; Kirsch, Benjamin; Hasse, Hans; Aurich, Jan C.

doi:10.1016/j.cirpj.2020.09.006

Cited by 10 publications

(5 citation statements)

References 31 publications

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“…The higher the Hertzian contact stress and the higher the viscosity of the lubricating medium, the higher the lubrication gap height that is being formed in the tribological contact 30 . The viscosity of the sub‐zero MWF is about six times higher at a supply temperature of −35°C compared to −10°C 24 . This has a beneficial influence on the lubrication effect of the sub‐zero MWF and the resulting coefficient of friction.…”

Section: Discussionmentioning

confidence: 99%

“…28,29 The higher the Hertzian contact stress and the higher the viscosity of the lubricating medium, the higher the lubrication gap height that is being formed in the tribological contact. 30 The viscosity of the sub-zero MWF is about six times higher at a supply temperature of À35 C compared to À10 C. 24 This has a beneficial influence on the lubrication effect of the sub-zero MWF and the resulting coefficient of friction. This explains the trend of a slightly reduced apparent coefficient of friction, although the temperature-induced increase in material resistance against plastic deformation is also present.…”

Section: Discussionmentioning

confidence: 99%

“…The sub‐zero metalworking fluid (MWF) used in this work is an aqueous ethane‐1.2‐diol (mono‐ethylene‐glycol) mixture with a mass ratio ζ of ethane‐1.2‐diol to water of ζ MEG,water = 1.72 g/g (63 wt%). Due to the corrosive properties of sub‐zero MWFs based on polyhydric alcohols, 24 the corrosion inhibitor disodium metasilicate (Na 2 SiO 3 , CAS 6834‐92‐0) was further added (3.7 g per 1 kg sub‐zero MWF). The alkyl phosphate acid tri‐isobutyl phosphate (TiBP, C 12 H 27 O 4 P, CAS 126‐71‐6) was used as an anti‐wear (AW) and extreme‐pressure (EP) additive (14 g TiBP per 1 kg sub‐zero MWF).…”

Section: Methodsmentioning

confidence: 99%

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Surface integrity modification ofCoCrMoalloy by deep rolling in combination with sub‐zero cooling as potential implant application

et al. 2022

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Alloys made of CoCrMo are well established as implants materials since decades in orthopedic surgery. The good mechanical properties, biocompatibility and especially the corrosion resistance are important rationales for the use of these alloys. Nevertheless, retrieved implants from revision surgery showed the occurrence of abrasion and corrosion. The wear mechanisms and the occurring corrosion processes might be reduced with a functionalization of the surface. The hexagonal phase of the cobalt chromium matrix plays an important role in the surface functionalization. It can be specifically transformed and set during the manufacturing process. One possibility for the induction of the transformation is the use of a deep rolling process in combination with a novel "sub-zero" cooling strategy during machining. The influence of force and temperature during the deep rolling process on the formation of the hexagonal Co-phase is examined in this study. The results from the targeted setting of the hexagonal Co-phase in the subsurface are shown. For this purpose, EBSD studies have been carried out to detect and quantify the proportion of Co-hex phase in the subsurface of the modified alloys. To analyze the mechanical properties, we measured the residual stress and hardness in the near surface layer under conditions close to the application. Furthermore, we performed biological tests to show a potential influence of the modification on the biocompatibility when using the sub-zero cooling approach. We observed no negative effect on the osteoblastic cell line which attached similarly to all tested surfaces. The investigations provide first insights into the potential use of "sub-zero" cooling in modifying orthopedic implant materials, but also the respective limits with regard to the surface functionalization. Deep rolling in combination with an innovative cooling strategy has a great potential to improve the mechanical properties of CoCr28Mo6 wrought alloy, by subsurface hardening and phase transformation.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Section: Methodsmentioning

confidence: 99%

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Surface integrity modification ofCoCrMoalloy by deep rolling in combination with sub‐zero cooling as potential implant application

et al. 2022

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“…The mixing ratio of water and MEG influences the thermal conductivity , the specific heat capacity c p and the kinematic viscosity . Considering the heat transfer between the sub-zero MWF and the cutting zone, a low kinematic viscosity and a high heat capacity, as well as a high thermal conductivity are favorable [12,23]. At 20 °C, Water ( = 0.55 W/ mK; c p = 4.2 J/gK) inhibits a much higher thermal conductivity and specific heat capacity than MEG ( = 0.29 W/ mK, c p = 2.3 J/gK) [12].…”

Section: Characterization Of the Sub-zero Mwfmentioning

confidence: 99%

Optimization of the cooling strategy during cryogenic milling of Ti-6Al-4 V when applying a sub-zero metalworking fluid

Gutzeit¹,

Berndt²,

Schulz

et al. 2022

Prod. Eng. Res. Devel.

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Due to an excellent ratio of high strength to low density, as well as a strong corrosion resistance, the titanium alloy Ti-6Al-4 V is widely used in industrial applications. However, Ti-6Al-4 V is also a difficult-to-cut material because of its low thermal conductivity and high chemical reactivity, especially at elevated temperatures. As a result, machining Ti-6Al-4 V is characterized by high thermal loads and a rapidly progressing thermo-chemical induced tool wear. An adequate cooling strategy is essential to reduce the thermal load and therefore tool wear. Sub-zero metalworking fluids (MWF) which are applied at liquid state but at supply temperatures below the ambient temperature, offer great potential to significantly reduce the thermal load when machining Ti-6Al-4 V. Within the presented research, systematically varied sub-zero cooling strategies are applied when milling Ti-6Al-4 V. The influences of the supply temperature, as well as the volume flow and the outlet velocity are investigated aiming at a reduction of the thermal loads that occur during milling. The milling experiments were recorded using high-speed cameras in order to characterize the impact of the cooling strategies and resolve the behavior of the MWF. Additionally, the novel sub-zero cooling approach is compared to a cryogenic CO2 cooling strategy. The results show that the optimized sub-zero cooling strategy led to a sufficient reduction of the thermal loads and does outperform the cryogenic cooling even at elevated CO2 mass flows.

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“…These sub-zero MWF can be applied at supply temperatures well below 0 °C while maintaining their liquid state. This enables high cooling effects due to the combination of low supply temperatures and a beneficial wetting behavior [36,37]. The promoted heat transfer in superposition with the lubrication effects of the sub-zero MWF promotes a lower thermo-mechanical load when machining Ti-6Al-4V [38].…”

Section: Introductionmentioning

confidence: 99%

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

Gutzeit

Bulun²,

Stelzer³

et al. 2023

Preprint

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Due to an excellent ratio of high strength and low density, Ti-6Al-4V is suitable for many industrial applications, especially in the aerospace industry. However, Ti-6Al-4V is also characterized as a hard to-cut material. This is mainly attributed to its very low thermal conductivity and high chemical reactivity, especially at elevated temperatures. Machining Ti-6Al-4V leads to high cutting temperatures and thermal loads of the tools within the cutting zone. This enhances a rapidly progressing, thermo-chemical induced tool wear reducing tool life and productivity. To enhance the cutting performance, suitable cooling strategies are a necessity to reduce the thermal load and hence to improve the machinability of Ti-6Al-4V. A novel, highly efficient cooling approach is to apply sub-zero metalworking fluids (MWF) at liquid state but at supply temperatures well below 0°C. These sub-zero MWF inhibit high cooling effects due to their low supply temperature in superposition with a beneficial wetting behavior. Within this paper, the application of a sub-zero cooling strategy is investigated and compared to a cryogenic CO2 cooling. The performance of both cooling strategies is analyzed when milling Ti-6Al-4V by systematically varying the cutting parameters and the milling strategy. The milling process is described on the basis of the occurring forces, the resulting wear and the surface quality. The results show that the sub-zero cooling outperforms the cryogenic CO2 cooling, especially at elevated cutting parameters and unfavorable cutting conditions. Less tool wear and an overall better surface quality are observed for sub-zero milling when being compared to cryogenic milling.

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Formulation of sub-zero metalworking fluids for cutting processes: Influence of additives

Cited by 10 publications

References 31 publications

Surface integrity modification ofCoCrMoalloy by deep rolling in combination with sub‐zero cooling as potential implant application

Surface integrity modification ofCoCrMoalloy by deep rolling in combination with sub‐zero cooling as potential implant application

Optimization of the cooling strategy during cryogenic milling of Ti-6Al-4 V when applying a sub-zero metalworking fluid

Sub-zero milling of Ti-6Al-4V – Impact of the cutting parameters on the resulting forces, tool wear, and surface quality

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