Mechanical behavior and modeling of grinding force: A comparative analysis

Li, Liuyang; Zhang, Yanbin; Cui, Xin; Said, Zafar; Sharma, Shubham; Liu, Mingzheng; Gao, Teng; Zhou, Zongming; Wang, Xiaoming; Li, Changhe

doi:10.1016/j.jmapro.2023.07.074

Cited by 40 publications

(3 citation statements)

References 120 publications

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“…Similarly, to prior visual representations, the regions delineated by blue outlines signify the advantageous amalgamation of cutting fluid and cutting speed parameters, hence facilitating the attainment of reduced surface roughness (Li et al, 2023;An et al, 2024). Contour line distortions can serve as indicators of interaction effects between cutting fluid and cutting speed, thereby necessitating their consideration in the optimisation process.…”

Section: Contour Plotmentioning

confidence: 97%

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Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Patil,

Sathish,

Rao

et al. 2024

Front. Mater.

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Introduction: Among alloys of medium-carbon and high-strength steel, EN 24 steel is characterised by its nickel-chromium-molybdenum composition. EN 24 steel is highly suitable for application in heavy-duty projects due to its notable resilience to damage, especially when exposed to low temperatures. With the objective of minimising surface irregularities, this research endeavours to enhance the milling process of EN 24 steel by employing coated tungsten carbide (WC) tool inserts.Methods: Feed rate, cutting speed, depth of cut, and cutting fluid are all crucial process factors in the experimental investigation. Four distinct levels are applied to each factor. The research utilises the Design of Experiments (DOE)-based Central Composite Design of Response Surface Methodology. To predict output parameters, mathematical models are developed utilising analysis of variance (ANOVA) for optimisation purposes.Results and discussions: Through the utilisation of multi-objective optimisation, the optimal combination for tungsten carbide inserts was determined, which provided surface irregularities of 0.301 µm. Cutting speed (CS) of 149.507 m/min, feed rate (FR) of 340.27 mm/min, depth of cut (DOC) of 0.599 mm, and cutting fluid (CF) of 12.50 L/min are the optimal parameters. The surface morphologies of the machined workpiece at particular parameter values can be discerned through scanning electron microscope (SEM) analysis, yielding significant insights. The optimal parameters that have been identified provide practical recommendations for improving the milling method of EN 24 steel when tungsten carbide inserts are utilised. Understanding the milling process in its entirety is facilitated by SEM analysis of surface morphologies and microstructures under particular cutting conditions. The morphology and surface irregularities of the machined workpiece are evaluated using profilometry, which provides additional insight into surface integrity. The discourse investigates the potential applications and implications of the results, as well as suggests directions for further study concerning the enhancement of milling processes for similar steel alloys.

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Section: Contour Plotmentioning

confidence: 97%

“…The presence of contour distortion or elongation, if detected, would suggest the existence of interaction effects among the variables of depth of cut and cutting speed (Li et al, 2023). These interaction effects should be taken into account during the process optimisation phase.…”

Section: Contour Plotmentioning

confidence: 99%

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Patil,

Sathish,

Rao

et al. 2024

Front. Mater.

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“…The high-speed air pump propels this mixture into the -tool-workpiece interface via a nozzle for cooling and lubrication [24]. This technology overcomes the hindrance posed by the "air barrier" resulting from high-speed tool rotation, ensuring efficient utilization of the cutting fluid and thorough lubrication of the -tool-workpiece interface [25]. The cutting fluid consumed by MQL is less than 10% of the flood cutting supply [26], which can achieve the same or an even better lubrication effect than traditional flood cutting.…”

Section: Introductionmentioning

confidence: 99%

Nanofluids Minimal Quantity Lubrication Machining: From Mechanisms to Application

Chu,

Li,

Zhou

et al. 2023

Lubricants

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Minimizing the negative effects of the manufacturing process on the environment, employees, and costs while maintaining machining accuracy has long been a pursuit of the manufacturing industry. Currently, the nanofluid minimum quantity lubrication (NMQL) used in cutting and grinding has been studied as a useful technique for enhancing machinability and empowering sustainability. Previous reviews have concluded the beneficial effects of NMQL on the machining process and the factors affecting them, including nanofluid volume fraction and nanoparticle species. Nevertheless, the summary of the machining mechanism and performance evaluation of NMQL in processing different materials is deficient, which limits preparation of process specifications and popularity in factories. To fill this gap, this paper concentrates on the comprehensive assessment of processability based on tribological, thermal, and machined surface quality aspects for nanofluids. The present work attempts to reveal the mechanism of nanofluids in processing different materials from the viewpoint of nanofluids’ physicochemical properties and atomization performance. Firstly, the present study contrasts the distinctions in structure and functional mechanisms between different types of base fluids and nanoparticle molecules, providing a comprehensive and quantitative comparative assessment for the preparation of nanofluids. Secondly, this paper reviews the factors and theoretical models that affect the stability and various thermophysical properties of nanofluids, revealing that nanoparticles endow nanofluids with unique lubrication and heat transfer mechanisms. Finally, the mapping relationship between the parameters of nanofluids and material cutting performance has been analyzed, providing theoretical guidance and technical support for the industrial application and scientific research of nanofluids.

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The Influence of Cutting Forces on Cracks Formation During the Grinding of Products from Materials Prone to Defect Formation

Kunitsyn,

Usov,

Zaychyk

2024

Lecture Notes in Mechanical Engineering

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Mechanical behavior and modeling of grinding force: A comparative analysis

Cited by 40 publications

References 120 publications

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Optimization of surface roughness in milling of EN 24 steel with WC-Coated inserts using response surface methodology: analysis using surface integrity microstructural characterizations

Nanofluids Minimal Quantity Lubrication Machining: From Mechanisms to Application

The Influence of Cutting Forces on Cracks Formation During the Grinding of Products from Materials Prone to Defect Formation

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