Numerical study of flow and thermal characteristics in titanium alloy milling with hybrid nanofluid minimum quantity lubrication and cryogenic nitrogen cooling

Kim, Woo-Yul; Senguttuvan, Santhosh; Kim, Seong Hoon; Lee, Sang Won; Kim, Sung-Min

doi:10.1016/j.ijheatmasstransfer.2021.121005

Cited by 21 publications

(9 citation statements)

References 46 publications

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“…In the process of milling, graphene sheets with vegetable oil [ 12 ], MoS 2 with vegetable-based oil, GnP with vegetable-based oil [ 13 , 14 ], graphite nanoplatelets with distilled water [ 18 ], HBN with vegetable oil [ 19 ], LN 2 with vegetable oil [ 120 ], silicon dioxide with water [ 23 ], montmorillonite clay with water-soluble mineral oil [ 26 ], silicon dioxide with mineral oil [ 35 ], silver with EG, ZnO with EG [ 32 ], Al 2 O 3 with palm oil [ 33 ] and hBN with vegetable oil [ 34 ], all reduce the machinery wear and tear, and thus the machine damage is reduced, which, in turn, improves the machine life time, and so improves the tool life specifically.…”

Section: Impact Of Nanofluids In Various Machining Processesmentioning

confidence: 99%

“…In the milling machining operation, different nanofluids show a noticeable reduction in the magnitude of the cutting forces, which helps to obtain the maximum benefit out of the operation, in such a way that the amount of force applied is reduced, and then all of the work carried out is converted to a useful trait and the losses due to heat and other changes are minimized. A few of the possible most important combinations of the nanoparticles with the base fluids are GnP with vegetable oil [ 13 ], hBN with vegetable-based oil, MoS 2 with vegetable-based oil, carbon onions with Alumicut oil [ 17 ], graphite nanoplatelets with distilled water [ 18 ], GO with metal work coolant, nanocarbon onions with mineral oil, silicon dioxide with ECOCUT SSN 322 mineral oil [ 20 ], Fe 3 O 4 with water and oil [ 21 ], LN 2 with vegetable oil [ 120 ], HBN with vegetable oil, MoS 2 with deionized water [ 22 ], TiO 2 , with water [ 23 ], MoS 2 with ECOCUT HSG 9055 oil [ 24 ], MoS 2 with ECOCUT HSG 905S neat cutting oil [ 25 ], MMT clay with water oil [ 26 ], silicon dioxide with mineral oil [ 35 ], Al 2 O 3 with oil [ 31 , 33 ], Ag with EG [ 32 ], ZnO with EG [ 32 ], and Al 2 O 3 with palm oil [ 33 , 34 ], which all show a significant decrease in terms of the cutting force when used at a nanoparticle size.…”

Section: Impact Of Nanofluids In Various Machining Processesmentioning

confidence: 99%

“… Cutting machining operation ( a ) simple cutting operation, Effects of nanofluids ( b ) rolling, ( c ) protective film, ( d ) mending and ( e ) polishing [ 120 ]. …”

Section: Figurementioning

confidence: 99%

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Application of Nanofluids for Machining Processes: A Comprehensive Review

Amin

Ali

2022

Nanomaterials

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According to the demand of the present world, as everything needs to be economically viable and environment-friendly, the same concept applies to machining operations such as drilling, milling, turning, and grinding. As these machining operations require different lubricants, nanofluids are used as lubricants according to the latest technology. This paper compares different nanofluids used in the same machining operations and studies their effects. The variation in the nanofluid is based on the type of the nanoparticle and base fluid used. These nanofluids improve the lubrication and cooling in the machining operations. They also aid in the improvement in the surface roughness, cutting forces, cutting temperature of the workpiece, and tool life in the overall process taking place. It is worth noting that nanofluids are more effective than simple lubricating agents. Even within the nanofluid, the hybrid type is the most dominating, and helps to obtain a maximum efficiency through certain machining processes.

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Section: Impact Of Nanofluids In Various Machining Processesmentioning

confidence: 99%

Section: Impact Of Nanofluids In Various Machining Processesmentioning

confidence: 99%

See 1 more Smart Citation

Application of Nanofluids for Machining Processes: A Comprehensive Review

Amin

Ali

2022

Nanomaterials

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“…They found that the main cutting forces were reduced (on average by 22%) due to cryogenic cooling, which also produced more damaged and fragmented chips. Kim et al (2021) reported that the 0³ nMQL spray angle is found to be best suited for improved cooling and lubrication performance under both the N 2 and LN 2 spraying conditions. Karthik et al (2021) investigate the processing execution of SS316 in manageable machining cooling ways such as dry, wet and cryogenic (LN 2 ).…”

Section: Introductionmentioning

confidence: 99%

Research on liquid nitrogen cryogenic milling of 11Cr-3Co-3W martensitic heat-resistant steel

Lü

Deng

Tang

et al. 2023

ILT

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Purpose When processing 11Cr-3Co-3W martensitic heat-resistant steel, the traditional pouring cooling method often appears large cutting force, high cutting temperature, serious tool wear and poor surface quality. This paper aims to use new cooling methods for processing this problem. Design/methodology/approach Different performance indicators such as cutting force, tool wear and surface quality were measured and analysed under different continuous milling times. The relationship between liquid nitrogen flow and cutting force and surface roughness was analysed and measured. Findings The results show that with the increase of liquid nitrogen flow, the cutting force decreases, especially the Fx component, which decreases by 10%. When the liquid nitrogen flow reaches 8 L/min, the effect of increasing the liquid nitrogen flow on reducing the cutting force becomes smaller. The cutting force reduced by up to 15%, and the tool life increased up to 20% using liquid nitrogen cryogenic cooling than in cutting liquids cooling. When minimal quantities of lubricant (MQL) was added, the cutting force was reduced by 23%, and the tool life increased by 25%. When the cutting speed increases from 100 m/min to 250 m/min, the cutting force with cutting liquid cooling does not change significantly while the cutting force with liquid nitrogen cooling decreases with the cutting speed increasing. It shows that liquid nitrogen cooling is more suitable for high-speed machining. After the cutting length reaches 66 m, the surface roughness of the workpiece using liquid nitrogen cooling method larger than that of the cutting liquid cooling method. When MQL is added into liquid nitrogen, the lubrication performance is improved, and the surface roughness of the workpiece is reduced about 8%. Originality/value Many studies had focused on the improvement of tool life and surface quality by different cooling methods, or on the injection process and chip mechanism. However, there are few relevant studies on the variation of cooling and lubrication properties with the change of cutting length in liquid nitrogen cryogenic processing. In this research, different performance indicators such as cutting force, tool wear and surface quality were measured and analysed under different continuous milling times. The relationship between liquid nitrogen flow and cutting force and surface roughness was analysed and measured. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-03-2023-0053/

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“…Using the Design of Experiments (DOE) method, the effect of air intake pressures, inner oriented channels, cutting velocities, and feed rates on the overall spray efficiency of the MQL process was investigated [28]. The relationship between oil droplet impingement and specific parameters such as oil flow rate and distance between oil scatter and droplet impingement was investigated.The droplet trajectories and temperatures in MQL milling were investigated using the Discrete Phase Model (DPM) [29]. A numerical and experimental study reveals that when the nozzle inclination angle is set to zero degrees, the sensible cooling condition results in more droplets flowing across the cutting zone [30].…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigation of the droplet size for MQL aerosol under different operating parameters with Flow visualization

Jadhav,

Deivanathan

2023

Eng. Res. Express

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Minimum quantity lubrication (MQL) is a sustainable machining process in which oil and air are mixed to form a spray that can be directed to the cutting zone. MQL spray factors like droplet size and velocity and their effect on machining remain unclear, especially when employing diverse oils and operating settings. Mist formation factors determine how well spray droplets lubricate the targeted area during machining. Numerical and Experimental studies were conducted with different values for MQL parameters like cutting oil type, air pressure and oil flow rate, to establish the best possible combination to give the ideal droplet size and surface roughness. The study utilized three types of oils and varied air pressures to evaluate the cooling effectiveness of MQL spray during end milling operations. Experimental droplet size and velocity measurements were obtained using ‘Phase Doppler Anemometry (PDA)’ and ‘Particle Image Velocimetry (PIV)’ techniques. A numerical model within ANSYS Fluent software, employing computational fluid dynamics (CFD), predicted spray flow properties and was validated using PIV data. Raising the air pressure decreased the droplet size, while increasing velocity to achieve greater overall speed and enhanced lubrication in the cutting region. Changing the coolant flow rate or the compressed air pressure affected the Sauter mean diameter (SMD) of oil particles. The research showed that increasing air pressure from 1 bar to 3 bar reduced surface roughness by 55.40 percent and SMD by 24.58 percent for 120V oil. Among the three cutting oils tested, the 120V oil achieved the lowest surface roughness at 0.227μm under specific conditions: a flow rate of 150 ml hr−1, pressure of 3 bars, and SMD of 35.5 μm. These findings provide valuable insights into improving MQL efficiency for machining operations.

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Numerical study of flow and thermal characteristics in titanium alloy milling with hybrid nanofluid minimum quantity lubrication and cryogenic nitrogen cooling

Cited by 21 publications

References 46 publications

Application of Nanofluids for Machining Processes: A Comprehensive Review

Application of Nanofluids for Machining Processes: A Comprehensive Review

Research on liquid nitrogen cryogenic milling of 11Cr-3Co-3W martensitic heat-resistant steel

Numerical and experimental investigation of the droplet size for MQL aerosol under different operating parameters with Flow visualization

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