Performance of ceramic cutting tool with groove and cross-chevron surface textures filled with semi-solid lubricants

Hari, B.N. Vedha; Narayanan, N. Sathiya; Sriraman, N.; Nanduru, V.S.P. Suraj

doi:10.1016/j.matpr.2022.03.650

Cited by 8 publications

(5 citation statements)

References 18 publications

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“…To address the heat generated during milling, coolants are employed. However, the inherent intermittent nature of milling introduces another challenge for liquid lubricants: using coolants subjects the tools, especially ceramic tools to thermal shocks, making them highly susceptible to chipping and catastrophic failure [56].…”

Section: Millingmentioning

confidence: 99%

Solid Lubricants Used in Extreme Conditions Experienced in Machining: A Comprehensive Review of Recent Developments and Applications

Hedayati,

Mofidi,

Al-Fadhli

et al. 2024

Lubricants

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Contacting bodies in extreme environments are prone to severe wear and failure due to friction and seizure, which are associated with significant thermal and mechanical loads. This phenomenon greatly impacts the economy since most essential components encounter these challenges during machining, an unavoidable step in most manufacturing processes. In machining, stress can reach 4 GPa, and temperatures can exceed 1000 °C at the cutting zone. Severe seizure and friction are the primary causes of tool and workpiece failures. Liquid lubricants are popular in machining for combatting heat and friction; however, concerns about their environmental impact are growing, as two-thirds of the 40 million tons used annually are discarded and they produce other environmental and safety issues. Despite their overall efficacy, these lubricants also have limitations, including ineffectiveness in reducing seizure at the tool/chip interface and susceptibility to degradation at high temperatures. There is therefore a push towards solid lubricants, which promise a reduced environmental footprint, better friction management, and improved machining outcomes but also face challenges under extreme machining conditions. This review aims to provide a thorough insight into solid lubricant use in machining, discussing their mechanisms, effectiveness, constraints, and potential to boost productivity and environmental sustainability.

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Section: Millingmentioning

confidence: 99%

Solid Lubricants Used in Extreme Conditions Experienced in Machining: A Comprehensive Review of Recent Developments and Applications

Hedayati,

Mofidi,

Al-Fadhli

et al. 2024

Lubricants

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“…Additionally, the significant impact of cutting fluids on the environment, on the health of the operator and their high contribution to the manufacturing cost, which can be as high as 16%, have resulted in alternative temperature control methods being favored for sustainable manufacturing. [22][23][24][25] Other methods such as the use of self-lubricated textured tool, 25 minimum quantity lubrication (MQL), and other green cutting technologies such as mist cooling, compressed air cooling, liquid nitrogen cooling, and dry cutting have been described in literature. 26 A temperature control model described by Benabid et al 27 uses a short period of reduction in cutting speed for cooling the mill.…”

Section: Workpiece Temperature Distribution Control and Thermal Error...mentioning

confidence: 99%

“…24 Therefore, alternative machining methods such as dry cutting are now being explored for more sustainable manufacturing. 24,25,44 This, however, means that the workpiece temperature change can be higher during dry cutting when compared with processes where cutting fluid is applied. Compensating for the effect of this change in temperature by using the surface temperature can lead to a reduction in accuracy of the machined part and this is because a spot temperature may not be truly representative of the workpiece volume.…”

Section: Dry Cutting Trialsmentioning

confidence: 99%

“…44 However, cutting fluids have a negative impact on the operator’s health, the environment, and on the cost of machining. 24 Therefore, alternative machining methods such as dry cutting are now being explored for more sustainable manufacturing. 24,25,44 This, however, means that the workpiece temperature change can be higher during dry cutting when compared with processes where cutting fluid is applied.…”

Section: In-process Ultrasonic Thermometrymentioning

confidence: 99%

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Core temperature measurement using ultrasound for high precision manufacturing processes

Olabode

Fletcher

Longstaff

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part B:

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During machining processes, the temperature of the workpiece may vary due to different factors. One of such factors is the heat generated due to tool/workpiece friction. Temperature may also vary due to environmental conditions. These temperature variations can affect the dimensional accuracy of the manufactured workpiece. It is known that the expansion of a part is related to a change in its average temperature, which is influenced more by the internal, core temperature than the surface temperature. The surface temperature of the part being manufactured can vary significantly from the core temperature, especially during dry cutting processes. Therefore, to effectively control or compensate for the effects of temperature variation as it relates to material expansion, there is a need to measure the core temperature of the workpiece accurately. In this article, a novel ultrasonic phase-shift method for temperature measurement is used to measure the core temperature of a workpiece on a computer numerical control machine (CNC). The results show that the phase-shift ultrasonic thermometry method measures steel workpiece temperature during subtractive manufacturing processes with deviations of less than ±1°C when compared to the reference PT100 readings. This novel temperature measurement method can be used in different manufacturing processes as part of a temperature control or thermal error compensation system.

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“…Rake face texturing of the cutting tool is most promising technique to reduce friction and cutting temperature in machining zone without use of cutting fluids for sustainability in machining [3]. Few researchers have been studied the different types textures and its influence on cutting tool performance [4][5][6].According to Yayun Liu et al [7], the geometric parameters (groove width, pitch and distance from cutting edge) of the micro-groove textures have a substantial influence on the cutting tool performance. Xu Wanget al [8] and Yong sheng su et al [9] fabricated micro-grooves by laser ablation process to improve the tool performance.…”

Section: Introductionmentioning

confidence: 99%

High Speed Steel Tool Performance through Hybrid Texturing Followed by Shock Peening towards Sustainable Machining

Prasad,

Ismail,

Satish

2024

J. Mach. Manuf. Reliab.

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Surface texturing is a promising sustainable technique to get better the machining performance of cutting tools. Laser surface texturing and micro-EDM are the most commonly used fabrication techniques and the textured tools exhibit better tool performance as compared to conventional tool. However, these processes involve re-solidification of material surface which makes the surface softening and reduction in the surface hardness. In the present work, cutting performance of the High-Speed Steel (HSS) tool is studied by fabricating hybrid (microgrooves with dimples) textures on its rake face using both laser ablation and micro-EDM methods followed by laser shock peening without ablative coating (LSPWAC) process. Hybrid textured with shock peened HSS tools are used in orthogonal dry turning of 316 L stainless steel. It has been observed that hybrid textures with shock peened HSS tool exhibits higher tool life of up to 255% and 85% than the conventional and the hybrid textured (HT) tools respectively. The results shown that surface texturing followed by shock peening is an innovative method to improve the sustainability in machining process than only surface texturing method. Moreover, analysis of chip is studied by finite element analysis.

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Performance of ceramic cutting tool with groove and cross-chevron surface textures filled with semi-solid lubricants

Cited by 8 publications

References 18 publications

Solid Lubricants Used in Extreme Conditions Experienced in Machining: A Comprehensive Review of Recent Developments and Applications

Solid Lubricants Used in Extreme Conditions Experienced in Machining: A Comprehensive Review of Recent Developments and Applications

Core temperature measurement using ultrasound for high precision manufacturing processes

High Speed Steel Tool Performance through Hybrid Texturing Followed by Shock Peening towards Sustainable Machining

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