Studies on Geometrical Features of Tool Wear and Other Important Machining Characteristics in Sustainable Turning of Aluminium Alloys

Abstract

The aerospace and automotive industries make extensive use of aluminium and its alloys. Contrarily, machining of aluminium (Al) alloys presents a number of difficulties, including, but not limited to, poor surface finishing, excessive tool wear, decreased productivity etc. Therefore, it’s very important to measure the machining characteristics during machining of aluminium alloy with sustainable cooling strategies. In this work, a new approach of measurement was adopted to measure the critical geometrical aspects of tool wear, surface roughness, power consumption and microhardness while machining AA2024-T351 alloy under dry, minimum quantity lubrication (MQL), liquid nitrogen (LN2) and carbon dioxide (CO2) cooling conditions. Initially, the various aspects of tool wear were studied with the help of Sensofar Confocal Microscope integrated with Mountains map software and then, the other results such as surface roughness, power consumption and microhardness were measured as per the ISO standards. The outcome of these measurement studies confirms that LN2 and CO2 cooling is helpful in improving the machining characteristics of AA2024-T351 alloy. When compared to dry conditions, the surface roughness values of MQL, LN2, and CO2 all have values that are lowered by 11.90%, 30.95%, and 39.28% respectively, and also power consumption values were lowered by 3.11%, 6.46% and 11.5% for MQL, CO2 and LN2 conditions, respectively.

Experimental Optimization of High-precision Turning Parameters of AL6061 Materials for Automotive Industry Based on Grey Relational Analysis

“…Afterwards, the Analytic Hierarchy Process (AHP) was employed to construct the response matrix P, as illustrated in Eq. (10). The maximum eigenvalue λmax was determined to be 3.0658, and its corresponding eigenvectors were presented in Eq.…”

“…In order to create nanostructures, which require materials with excellent mechanical strength and thermal stability, aluminum alloys are also employed quite successfully. The lightweight and advantageous mechanical and thermal properties of aluminum alloys make them highly significant in the future generation of cars, opening up new possibilities for various applications in the automotive industry [8][9][10]. There is a wide range of opportunities to utilize aluminum alloys in automotive powertrains, chassis, and body structures [11,12].…”

Turning of Al 7075-T6 aerospace alloy under different sustainable metalworking fluid strategies by coated carbide tools

“…Li et al reported that with the increase in depth of cut, energy consumption increases with coated tool while turning aluminium alloy 6063 composite [11]. For MQL, carbon dioxide, and liquid nitrogen conditions, power consumption was reduced by 3.11%, 6.46%, and 11.5%, respectively as compared to dry conditions reported by Gupta et al [12]. In comparison to the depth of cut and cutting speed, the feed rate significantly contributes less.…”

A Short Review on Minimum Quantity Lubrication Method in Machining Applications

“…The use of abundant coolants and lubricants stands out when the studies on the machining of engineering materials are examined (Demirpolat et al, 2023;Gupta et al, 2023b;Srinivas et al, 2023). In particular, the dangers of chemical and petroleum-based lubricants and coolants used in traditional cooling for the environment and human health have become more evident (Kuntoğlu et al, 2023;, and new lubrication and cooling conditions have begun to be developed to reduce these effects (Binali et al, 2023b;Etri et al, 2023).…”