Investigation on Influence of External Energy on Surface Roughness in Turning of Aluminium Metal Matrix Composite

Sudheer, N. V. V. S.; Rao, K.V.J.

doi:10.22485/jaei/2013/v83/i3-4/119927

Cited by 2 publications

(3 citation statements)

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“…They used flood, MQL, and hybrid CryoMQL (HCM) coolants and calculated the energy consumption while machining titanium alloys, and the results show that the HCM method has the lowest sustainability impact and highest productivity [13]. Sudheer et al (2014) investigated compressed refrigerated air, dry and Propylene Glycol MQL cooling mediums in a cutting of metal matrix composite (MMC) materials. Their results show that compressed refrigerated air improves the surface roughness slightly compared with dry cutting conditions and propylene glycol has significant effect by reducing the surface roughness by 50% compared with other mediums in the study [14].…”

Section: Introductionmentioning

confidence: 99%

“…Sudheer et al (2014) investigated compressed refrigerated air, dry and Propylene Glycol MQL cooling mediums in a cutting of metal matrix composite (MMC) materials. Their results show that compressed refrigerated air improves the surface roughness slightly compared with dry cutting conditions and propylene glycol has significant effect by reducing the surface roughness by 50% compared with other mediums in the study [14]. It has also been shown that using MQL decreases the tool-chip contact length [15] and leads to reduced tool wear, cutting forces, and surface roughness, but the poor cooling effect is the major disadvantage of MQL [16].…”

Section: Introductionmentioning

confidence: 99%

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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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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

View full text Add to dashboard Cite

show abstract

“…Their results show that compressed refrigerated air improves the surface roughness slightly compared with dry cutting conditions and Propylene Glycol has significant effect by reducing the surface roughness by 50% compared with other mediums in the study. [13] It has also been shown that using MQL decreases the tool-chip contact length [14] and leads to reduced tool wear, cutting forces and surface roughness, but the poor cooling effect is the major disadvantage of MQL [15]. On the other hand, in some cases the lower cooling effect can be beneficial with regard to tool wear, for example in drilling, where the center of the tool has a higher wear rate with emulsion than with MQL [16].…”

Section: Introductionmentioning

confidence: 99%

Evaluation of Subcooled MQL in cBN Hard Turning of powder-based Cr-Mo-V Tool Steel Using Simulations and Experiments

Laakso

Mallipeddi

Krajnik

2021

Preprint

View full text Add to dashboard Cite

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 tools 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 modelling.

show abstract

Investigation on Influence of External Energy on Surface Roughness in Turning of Aluminium Metal Matrix Composite

Cited by 2 publications

References 0 publications

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

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

Evaluation of Subcooled MQL in cBN Hard Turning of powder-based Cr-Mo-V Tool Steel Using Simulations and Experiments

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