Machining β-titanium alloy under carbon dioxide snow and micro-lubrication: a study on tool deflection, energy consumption, and tool damage

Iqbal, Asif; Biermann, Dirk; Hashemi, Arash; Al‐Ghamdi, Khalid A.; Metzger, Maximilian

doi:10.1007/s00170-018-2267-4

Cited by 24 publications

(8 citation statements)

References 30 publications

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“…Metals 2021, 11, x FOR PEER REVIEW 10 of 23 the work hardness of workpiece material. It is a well-known fact that higher cutting forces are generated while machining harder materials [37]. Similar to the LN2 flow rate, the optimal flow rate for MQL was also found.…”

Section: Selection Of Optimal Levels Of Input Parameterssupporting

confidence: 62%

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Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy

Khan¹,

Anwar

Jamil

et al. 2021

Metals

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The quest for advanced cooling/lubrication approaches for energy-efficient, eco-benign, and cost-effective sustainable machining processes is garnering attention in academia and industry. Electrical and embodied energy consumption plays an important role in reducing CO2 emissions. In the present study, new empirical models are proposed to assess sustainable indicators. The embodied energy, environmental burden, and cost of coolant/lubricant have been added in the proposed models. Initially, optimal levels of minimum quantity lubrication (MQL) oil flow rate, liquid LN2 flow rate, air pressure, and nanoparticle concentration were found. Based on optimal technological parameters, experiments were performed under the same cutting conditions (machining parameters) for MQL and cryogenic LN2-assisted external turning of Ti6-Al-4V titanium alloy. The electric power and energy consumption, production time/cost, and CO2 emissions were assessed for a unit cutting-tool life. Later, specific responses were measured and compared between both cooling and lubrication approaches. Results showed that hybrid Al-GnP nanofluid consumed 80.6% less specific cumulative energy and emitted 88.7% less total CO2 emissions. However, cryogenic LN2 extended tool life by nearly 70% and incurred 4.12% less specific costs with 11.1% better surface quality. In summary, after Energy–Economy–Ecology–Engineering technology (4E)-based analysis, cryogenic LN2 is sustainable economically but not environmentally and there is a need to improve the sustainable production of LN2 at an industrial scale to achieve environmental sustainability. The present study provides useful information to establish clean machining processes.

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Section: Selection Of Optimal Levels Of Input Parameterssupporting

confidence: 62%

“…This phenomenon can be explained by the fact that as the LN 2 flow increases, it increases the work hardness of workpiece material. It is a well-known fact that higher cutting forces are generated while machining harder materials [37].…”

Section: Selection Of Optimal Levels Of Input Parametersmentioning

confidence: 99%

Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy

Khan¹,

Anwar

Jamil

et al. 2021

Metals

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“…Better heat dissipation mechanism helps keeping a check on tool wear progress, which, in turn, helps maintaining cutting edge's geometry and suppressing the machining forces. In other works, hybrid cryogenic cooling/lubrication was reported to yield the lowest machining forces compared to both emulsion and cryogenic conditions in machining of titanium alloys [11,13]. The effect of milling orientation was neither very significant nor clear.…”

Section: Specific Cutting Energy and Machining Forcesmentioning

confidence: 83%

“…It was found that milling of Ti-6Al-4V with liquid CO 2 could greatly reduce chipping and lateral crack propagation; therefore, it can be used to significantly prolong tool life in comparison with emulsion-based cooling [12]. The effects of using CO 2 snow as a coolant and its merger with MQL were investigated in continuous machining of a high-strength β-titanium alloy [13]. It was found that the usage of CO 2 snow and the location of its application was highly influential with respect to the sustainability measures.…”

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confidence: 99%

Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

Iqbal

Suhaimi

Zhao

et al. 2020

Metals

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Ti-6Al-4V, the most commonly used alloy of titanium, possesses excellent mechanical properties and corrosion resistance, which is the prime reason for the continual rise in its industrial demand worldwide. The extraordinary mechanical properties of the alloy are viewed as a hindrance when it comes to its shaping processes, and the process of milling is no exception to it. The generation of intense heat flux around the cutting zones is an established reason of poor machinability of the alloy and unacceptably low sustainability of its machining. The work presented in this paper attempts to enhance sustainability of milling Ti-6Al-4V by investigating the effects of milling orientation, cutter's helix angle, cutting speed, and the type of cryogenic coolant and lubricant on the sustainability measures, such as tool damage, cutting energy consumption, process cost, milling forces, and work surface roughness. It was found that micro-lubrication is more effective than the two commonly used cryogenic coolants (carbon dioxide snow and liquid nitrogen) in reducing tool wear, work surface roughness, process cost, and energy consumption. Furthermore, down-milling enormously outperformed up-milling with respect to tool wear, work surface quality, and process cost. Likewise, the high levels of cutter's helix angle and cutting speed also proved to be beneficial for milling sustainability.Metals 2020, 10, 258 2 of 25 environmentally [3]. The problem is generally negotiated either by lowering the material removal rates or by applying emulsion-based coolants, neither of which actually offers a sustainable solution.With regard to quashing the intense heat flux around the cutting areas, the application of cryogenic fluids, especially liquid nitrogen (LN 2 ), fares very well. The fluids offer a viable solution because of extremely low operational temperatures, no waste generation, and controllable flow rates. Additionally, application of micro-lubrication, also known as minimum quantity of lubrication (MQL), also proved to be very beneficial in enhancing tool life and improving surface quality in machining of titanium alloys conducted at medium cutting speeds [4,5]. MQL is a near-dry machining method in which a miniscule quantity of lubricating oil is pulverized into a stream of air, and the resulting aerosol is applied onto the cutting areas [6].Although steady progress is being made regarding quantification of the effects of cryogenic coolants with regard to the continuous machining processes, not much effort is being put up concerning interrupted machining processes, such as milling. Cryogenic milling is distinct from continuous machining processes performed under cryogenic environment in the sense that the cutting teeth of a milling tool periodically and rapidly engage and disengage with the work material, leading to cyclic heating (caused by thermal energy released by work material's plastic deformation) and cooling (caused by interaction with the incoming cryogenic fluid) of the cutting edges. Such a course is expected to induce...

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“…The approach was found to have prolonged tool life by 60% and 30% in comparison with dry cutting and single-jet cryogenic cutting, respectively. Likewise, CO 2 snow was reported to be used as a cryogenic coolant at different locations of a grooving tool with and without the merger of microlubrication in continuous machining of a high-strength β-titanium alloy [ 14 ]. The results showed that the hybridization of the cryogenic fluid and the location of its application have significant effects on the sustainability measures.…”

Section: Introductionmentioning

confidence: 99%

On Coolant Flow Rate-Cutting Speed Trade-Off for Sustainability in Cryogenic Milling of Ti–6Al–4V

et al. 2021

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Application of cryogenic fluids for efficient heat dissipation is gradually becoming part and parcel of titanium machining. Not much research is done to establish the minimum quantity of a cryogenic fluid required to sustain a machining process with respect to a given material removal rate. This article presents an experimental investigation for quantifying the sustainability of milling a commonly used titanium alloy (Ti–6Al–4V) by varying mass flow rates of two kinds of cryogenic coolants at various levels of cutting speed. The three cooling options tested are dry (no coolant), evaporative cryogenic coolant (liquid nitrogen), and throttle cryogenic coolant (compressed carbon dioxide gas). The milling sustainability is quantified in terms of the following metrics: tool damage, fluid cost, specific cutting energy, work surface roughness, and productivity. Dry milling carried out the at the highest level of cutting speed yielded the worst results regarding tool damage and surface roughness. Likewise, the evaporative coolant applied with the highest flow rate and at the lowest cutting speed was the worst performer with respect to energy consumption. From a holistic perspective, the throttle cryogenic coolant applied at the highest levels of mass flow rate and cutting speed stood out to be the most sustainable option.

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Machining β-titanium alloy under carbon dioxide snow and micro-lubrication: a study on tool deflection, energy consumption, and tool damage

Cited by 24 publications

References 30 publications

Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy

Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy

Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

On Coolant Flow Rate-Cutting Speed Trade-Off for Sustainability in Cryogenic Milling of Ti–6Al–4V

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