Performance assessment of MQSL: Minimum quantity solid lubricant during turning of Inconel 718

Marques, António Cardoso; Narala, Suresh Kumar Reddy; Machado, Álisson Rocha; Gunda, Rakesh Kumar; Josyula, Saravan Kumar; Silva, RB Da; Silva, MB Da

doi:10.1177/0954405415592128

Cited by 27 publications

(13 citation statements)

References 21 publications

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“…To penetrate lubricating particles more effectively, it is always recommended that the lubricants are atomized with small droplets with high velocity, which will cover the maximum surface machining area which eventually improves surface roughness and tool wear. 36 During the experiment, it is observed that when the solid lubricants are atomized at 20 mL/h flow rate, considerable quantity of lubricant droplets is streamed towards the tool–workpiece interface eventually adhering to the tool–workpiece interface. With increasing the lubricant quantity, it is observed that the atomized lubricant droplet size is increasing.…”

Section: Resultsmentioning

confidence: 99%

Analysis of electrostatic solid lubricant spray process parameters during turning Ti-6Al-4V alloy

Gunda¹,

Narala

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Titanium alloys are considered as hard-to-cut material due to its relatively high resistance to corrosion, low thermal conductivity and high chemical reactivity. Effective penetration of sufficient amount of lubricant in the metalworking process is of utmost importance to (a) reduce frictional resistance at the high-temperature tool–workpiece interface and (b) avert the formation of built-up edge in machining process. Traditionally, the lubricant forms a thin fluid film to reduce the friction. In order to reduce or eliminate coolant usage and to apply lubri-coolant efficiently at tool–chip–workpiece interface, a novel near-dry machining technique called electrostatic charged solid lubricant spray system has been developed. In electrostatic charged solid lubricant spray technique, the aerosolized micro-droplet particles were sprayed from the nozzle tip which uses a phenomenon called contact-charge electrification principle. The quick penetration and wettability of charged atomized droplet particles are impinged with high velocity at the tool–chip interface. The focus of the present experimental research is to analyse the optimum lubrication process parameters of the experimental set-up in terms of effectively applying cutting fluid in the machining zone. The study shows that the desired atomization and machining performance of the electrostatic charged solid lubricant spray technique can be obtained by governing different spray parameters (lubricant flow rate, air pressure, spray nozzle position, nozzle distance, electrostatic voltage). The results revealed that when the charged lubricants are applied with high velocity and large number of droplets, it will have significant influence on surface roughness and cutting force. The fabricated electrostatic charged solid lubricant spray technique provides us with an efficient and economic machining solution by applying solid lubricants effectively at tool–material interface during turning of Ti-6Al-4V alloy material. The present approach and the obtained results will help in better understanding of the machinability of hard-to-cut materials in manufacturing industries.

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Section: Resultsmentioning

confidence: 99%

Analysis of electrostatic solid lubricant spray process parameters during turning Ti-6Al-4V alloy

Gunda¹,

Narala

2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…Attrition and abrasion depend more on the active lubricant area. 39 Whereas in the rougher portions of the worn area due to attrition mechanism particles of the tool were plucked off. By observing parallel ridges, abrasion as a typical wear mechanism can be characterized on the tool surface.…”

Section: Effect Of Ehvsl On Tool Wearmentioning

confidence: 99%

Electrostatic high-velocity solid lubricant machining system for performance improvement of turning Ti–6Al–4V alloy

Gunda

Narala

2017

Proceedings of the Institution of Mechanical Engineers, Part B:

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In any machining operation, a major division of energy is converted into heat which creates detrimental effects on tool wear, tool life and surface quality of machined work material. Effective cooling/lubrication in the machining zone is essential to improve friction and temperatures by efficient heat dissipation which increases tool life and surface quality. But adverse health effects caused by use of flood cooling are drawing manufacturers’ attention to develop methods for controlling occupational exposure to cutting fluids. In demanding the improvement of productivity and product quality of machining, use of solid lubricant thin film was suggested as one of the necessary alternative machining techniques to apply lubricants effectively to the high-temperature zone. There is a general concern in the machining process in terms of applying lubricants effectively to the machining zone. Therefore, this research work contributes to the development of a novel approach to apply lubricants effectively to the rake face and flank face of the cutting tool without polluting the environment. Electrostatic high-velocity solid lubricant assisted machining is a novel technique used in the machining process with a very low flow rate (1–20 mL/h) to enhance the process performance of turning difficult-to-cut materials. The performance of electrostatic high-velocity solid lubricant technique is studied in comparison to minimum quantity solid lubricant, minimum quantity lubricant and dry and wet (flood cooling) to assess the performance considering surface roughness, cutting force and tool wear as performance indices. The experimental results revealed that electrostatic high-velocity solid lubricant with MoS2 solid lubricant at low volume and constant flow rate has observed high potential to apply lubricants effectively in the machining zone when compared with the considered environmental conditions. This work is expected to form a scientific basis toward developing electrostatic high-velocity solid lubricant technique for reducing the manufacturing impact in the machining of aerospace components such as Ti–6Al–4V alloy in terms of both machinability and environmental perspectives.

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“…In addition, a smaller quantity of coolant permits us to save money that can be used for the chip recycling purpose [3]. Several researchers including Li et al [26], Devillez et al [27], Thakur et al [28], Zhang et al [29], Pusavec et al [30], Tazehkandi et al [31], Tazehkandi et al [13], Pusavec et al [32], and Marques et al [33] have performed various machining experiments on Inconel alloys by considering dry and MQL conditions.…”

Section: Introductionmentioning

confidence: 99%

Machinability Investigations of Inconel-800 Super Alloy under Sustainable Cooling Conditions

et al. 2018

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With regard to the manufacturing of innovative hard-machining super alloys (i.e., Inconel-800), a potential alternative for improving the process is using a novel cutting fluid approach. Generally, the cutting fluids allow the maintenance of a better tool topography that can generate a superior surface quality of machined material. However, the chemical components of fluids involved in that process may produce harmful effects on human health and can trigger environmental concerns. By decreasing the cutting fluids amount while using sustainable methods (i.e., dry), Near Dry Machining (NDM) will be possible in order to resolve these problems. This paper discusses the features of two innovative techniques for machining an Inconel-800 superalloy by plain turning while considering some critical parameters such as the cutting force, surface characteristics (Ra), the tool wear rate, and chip morphology. The research findings highlight the near-dry machining process robustness over the dry machining routine while its great potential to resolve the heat transfer concerns in this manufacturing method was demonstrated. The results confirm other benefits of these methods (i.e., NDM) linked to the sustainability aspects in terms of the clean process, friendly environment, and permits as well as in terms of improving the manufacturing characteristics.

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Performance assessment of MQSL: Minimum quantity solid lubricant during turning of Inconel 718

Cited by 27 publications

References 21 publications

Analysis of electrostatic solid lubricant spray process parameters during turning Ti-6Al-4V alloy

Analysis of electrostatic solid lubricant spray process parameters during turning Ti-6Al-4V alloy

Electrostatic high-velocity solid lubricant machining system for performance improvement of turning Ti–6Al–4V alloy

Machinability Investigations of Inconel-800 Super Alloy under Sustainable Cooling Conditions

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