Reduction of Power Consumption by Chip Breakability Control in Ti6Al4V Titanium Alloy Turning

Zębala, Wojciech; Struzikiewicz, Grzegorz; Słodki, Bogdan

doi:10.3390/ma13112642

Cited by 9 publications

(6 citation statements)

References 38 publications

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“…The longitudinal dimension of the chips was adopted as the main criterion when assessing the form of chips. For the chip length L ch a simplified classification has been adopted [26]:…”

Section: Methodsmentioning

confidence: 99%

Study on Chip Breakability Index During Longitudinal Turning of Cast and DMLS Additively Manufactured AlSi10Mg Aluminum Alloy

Struzikiewicz¹,

Słodki²,

Zębala³

et al. 2022

Adv. Sci. Technol. Res. J.

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The article presents selected issues related to the process of turning samples made of the AlSi10Mg alloy with the use of various manufacturing technologies, i.e. casting and DMLS (Direct Metal Laser Sintering). Machining processes of cylindrical surfaces of samples made with these two methods were subjected to a comparative analysis. The main idea behind the research was to develop guidelines for turning parts obtained using laser powder sintering. Study on the infl uence of cutting parameters on the value of breakability index C in . as well as the type, shape and form of chips produced during longitudinal turning is presented. The chips were also measured and the results of the microscopic analysis of the chips form are described. Results showed that the values of C in index for turning of the cast AlSi10MG alloy depend mainly on the value of feed f. According to adopted chip classifi cation for the feed value of f > 0.1 mm/rev the chips had a favorable, short form. In the case of turning the sample obtained by the DMLS method, the values of the chip breakability index C in are not signifi cantly dependent on the adopted ranges of cutting parameters. The Taguchi method was used to develop the conclusions obtained on the basis of the research results.

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“…The longitudinal dimension of the chips was adopted as the main criterion when assessing the form of chips. For the chip length L ch a simplified classification has been adopted [26]:…”

Section: Methodsmentioning

confidence: 99%

Study on Chip Breakability Index During Longitudinal Turning of Cast and DMLS Additively Manufactured AlSi10Mg Aluminum Alloy

Struzikiewicz¹,

Słodki²,

Zębala³

et al. 2022

Adv. Sci. Technol. Res. J.

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“…Machining activities account for a large portion of manufacturing energy consumption, and lowering energy usage in these operations can result in considerable cost savings. Zebala et al [86] described a technique for minimizing power consumption during turning Ti6Al4V titanium alloy, which involves managing the breakability of the turning chips. The power consumption is lowered when the chips are fragmented into little bits.…”

Section: (D) Energy Utilizationmentioning

confidence: 99%

“…This may be accomplished by utilising high-efficiency cooling pumps, heat exchangers, and cooling fluids. Further studies are necessary to create effective control mechanisms for specific materials such as Ti6Al4V titanium alloy [86,91].…”

Section: (G) Energy Conservationmentioning

confidence: 99%

Review of Lubrication and Cooling in Computer Numerical Control (CNC) Machine Tools: A Content and Visualization Analysis, Research Hotspots and Gaps

et al. 2023

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Lubrication and cooling (LC) are critical for mechanical devices’ effective and dependable functioning, because they decrease friction and wear of moving components, ensuring superior efficiency. However, the cutting fluids in machining operations are a key cause of fear, due to their high cost, environmental impact, and health risks, particularly in computer numerical control (CNC) machine tools (MTs). During the industrial revolutions, MTs superseded manual labour and increased efficiency and output. Therefore, much research was conducted on lubrication and cooling in CNC machine tools (LC in CNC MTs). Therefore, it has become necessary to review and highlight research hotspots and gaps using specific means that can benefit budding researchers. The present review aims to identify research hotspots and gaps of LC in CNC MTs utilizing content and visualization analysis, employing VOSviewer and Biblioshiny software. The analysis comprises 136 documents retrieved by Scopus between 1988 and 2022. The analysis revealed a consistent growth in publications, primarily consisting of articles, with a minor proportion of review documents and conference papers. The keywords were categorized into seven clusters, with a notable prevalence of ‘surface roughness’ and ‘CNC machine tools’. A word cloud was generated to visualize the author’s frequently used keywords, where larger font sizes represented higher frequency. The treemaps demonstrated that ‘CNC’ appeared 34 times and contributed 8%, followed by ‘machine’, ‘tool’, ‘machining’, and ‘thermal’. In the abstract-terms tree plot, ‘machine’ appeared 235 times and contributed 7%, followed by ‘CNC’, ‘machining’, ‘tool’, and ‘cutting’. The content and visualization analysis identified six research hotspots: computer control systems, machine tools, computer numerical control, machining, numerical control systems, and surface roughness (Ra). The research gaps are temperature, cooling systems, cutting forces, energy utilization, tool life, nanoparticles, electric power utilization, and energy conservation. Based on hotspots and gaps, literature evaluations extensively addressed the strong roadmap of technical improvements and problems of LC in CNC MTs. A complete visualization and content analysis also produced a conceptual framework for best practices, and the study offers insight into the issues and prospects.

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“…Chip formation reflects the underlying mechanisms of the cutting process and workpiece-tool interaction in the cutting zone [2] and is affected by machining parameters such as feed, cutting speed and depth of cut [3], as well as thermal behavior during machining and friction between tool rake face and deformed chips [4]. Chip formation is directly related to surface quality, tool wear and machining efficiency [5,6]. Thus, the control of the chip formation mechanism at both micro and macro levels is a possible means to improve machinability [7].…”

Section: Introductionmentioning

confidence: 99%

Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V

Abdelnasser,

El-Sanabary,

Nassef

et al. 2023

Micromachines

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This article presents the results of an experimental investigation into the effect of process parameters in the precision hard turning of Ti-6Al-4V on chip morphology at both macro and micro levels. It also reports on the control of chip generation to improve chip evacuation and breakability at the macro level by varying the process parameters, namely, feed rate, cutting speed and depth of cut during turning tests. A scanning electron microscope (SEM) was used to examine the chips produced for a better understanding of chip curling mechanisms at the micro level. Surface roughness of the machined specimens was measured to assess the effect of chip evacuation on obtainable surface quality. From the results, it was found that the interaction of process parameters has a significant effect on the control of chip formation. In particular, the interaction of higher cutting speeds and greater depths of cut produced chip entanglement with the workpiece for all values of feed rates. Using relatively higher feed rates with a low depth of cut showed good results for chip breaking when machining at higher cutting speeds. Different chip curling mechanisms were identified from the SEM results. Chip side-curl formation showed different segmentation patterns with an approximately uniform chip thickness along the chip width, while chip up-curl occurred due to variations in chip thickness. Finally, it was found that the tangling of the chip with the workpiece has a significant effect on the final surface quality.

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Reduction of Power Consumption by Chip Breakability Control in Ti6Al4V Titanium Alloy Turning

Cited by 9 publications

References 38 publications

Study on Chip Breakability Index During Longitudinal Turning of Cast and DMLS Additively Manufactured AlSi10Mg Aluminum Alloy

Study on Chip Breakability Index During Longitudinal Turning of Cast and DMLS Additively Manufactured AlSi10Mg Aluminum Alloy

Review of Lubrication and Cooling in Computer Numerical Control (CNC) Machine Tools: A Content and Visualization Analysis, Research Hotspots and Gaps

Influence of Technological Parameters on Chip Formation and Chip Control in Precision Hard Turning of Ti-6Al-4V

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