The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel

Salur, Emin; Kuntoğlu, Mustafa; Aslan, Abdullah; Pimenov, Danil Yurievich

doi:10.3390/met11111674

Cited by 72 publications

(30 citation statements)

References 51 publications

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“…The samples were machined under dry and MQL conditions because today's manufacturing industry is very much focused on environmental protection [47] and a reduction in the consumption of machining fluids [48]. Furthermore, MQL has been successfully applied to improve the machinability of difficult-to-cut materials [49,50]. In the MQL method, we used ECOCUT MIKRO 20 E oil, which was produced by mixing with air.…”

Section: Workpiece Details and Preparationmentioning

confidence: 99%

Corrosion Resistance and Surface Bioactivity of Ti6Al4V Alloy after Finish Turning under Ecological Cutting Conditions

et al. 2021

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The influence of cooling conditions and surface topography after finish turning of Ti6Al4V titanium alloy on corrosion resistance and surface bioactivity was analyzed. The samples were machined under dry and minimum quantity lubrication (MQL) conditions to obtain different surface roughness. The surface topographies of the processed samples were assessed and measured using an optical profilometer. The produced samples were subjected to electrochemical impedance spectroscopy (EIS) and corrosion potential tests (Ecorr) in the presence of simulated body fluid (SBF). The surface bioactivity of the samples was assessed on the basis of images from scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analysis. The inspection of the surfaces of samples after turning under dry and MQL conditions revealed unevenly distributed precipitation of hydroxyapatite compounds (Ca/P) with a molar ratio in the range of 1.73–1.97. Regardless of the cutting conditions and surface roughness, the highest values of Ecorr ~0 mV were recorded on day 7 of immersion in the SBF solution. The impedance characteristics showed that, compared to the MQL conditions, surfaces machined under dry conditions were characterized by greater resistance and the presence of a passive layer on the processed surface. The main novelty of the paper is the study of the effect of ecological machining conditions, namely, dry and MQL cutting on the corrosion resistance and surface bioactivity of Ti6Al4V titanium alloy after finish turning. The obtained research results have practical significance. They can be used by engineers during the development of technological processes for medical devices made of Ti6Al4V alloy to obtain favorable functional properties of these devices.

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Section: Workpiece Details and Preparationmentioning

confidence: 99%

Corrosion Resistance and Surface Bioactivity of Ti6Al4V Alloy after Finish Turning under Ecological Cutting Conditions

et al. 2021

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“…Satur et al [92] used a 240 × 180 pixel infrared camera by Testo company, to investigate the effects of MQL and dry environments during the end milling of AISI 1040 steel on cutting temperature, tool wear and power consumption. The thermal camera was positioned approximately 50 cm from the cutting zone and considered only the peak temperature values pixel by pixel from the interface.…”

Section: Infrared Camerasmentioning

confidence: 99%

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

Leonidas

Ayvar-Soberanis

Laalej

et al. 2022

Sensors

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During the machining process, substantial thermal loads are generated due to tribological factors and plastic deformation. The increase in temperature during the cutting process can lead to accelerated tool wear, reducing the tool’s lifespan; the degradation of machining accuracy in the form of dimensional inaccuracies; and thermally induced defects affecting the metallurgical properties of the machined component. These effects can lead to a significant increase in operational costs and waste which deviate from the sustainability goals of Industry 4.0. Temperature is an important machining response; however, it is one of the most difficult factors to monitor, especially in high-speed machining applications such as drilling and milling, because of the high rotational speeds of the cutting tool and the aggressive machining environments. In this article, thermocouple and infrared radiation temperature measurement methods used by researchers to monitor temperature during turning, drilling and milling operations are reviewed. The major merits and limitations of each temperature measurement methodology are discussed and evaluated. Thermocouples offer a relatively inexpensive solution; however, they are prone to calibration drifts and their response times are insufficient to capture rapid temperature changes in high-speed operations. Fibre optic infrared thermometers have very fast response times; however, they can be relatively expensive and require a more robust implementation. It was found that no one temperature measurement methodology is ideal for all machining operations. The most suitable temperature measurement method can be selected by individual researchers based upon their experimental requirements using critical criteria, which include the expected temperature range, the sensor sensitivity to noise, responsiveness and cost.

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“…Experimental results show that feed rate, tool speed and cutting depth are of different importance in generating surface roughness and surface hardness [ 22 ]. Salur et al studied the influence of MQL and dry conditions on the end milling process, and found that the cutting environment had the greatest influence on power consumption, while cutting speed had an important influence on tool wear [ 23 ].…”

Section: Introductionmentioning

confidence: 99%

Contribution Ratio Assessment of Process Parameters on Robotic Milling Performance

Dai

Yue

et al. 2022

Materials

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Robotic milling has broad application prospects in many processing fields. However, the milling performance of a robot in a certain posture, such as in face milling or grooving tasks, is extremely sensitive to process parameters due to the influence of the serial structure of the robot system. Improper process parameters are prone to produce machining defects such as low surface quality. These deficiencies substantially decrease the further application development of robotic milling. Therefore, this paper selected a certain posture and carried out the robotic flat-end milling experiments on a 7075-T651 high-strength aeronautical aluminum alloy under dry conditions. Milling load, surface quality and vibration were selected to assess the influence of process parameters like milling depth, spindle speed and feed rate on the milling performance. Most notably, the contribution ratio based on the analysis of variance (ANOVA) was introduced to statistically investigate the relation between parameters and milling performance. The obtained results show that milling depth is highly significant in milling load, which had a contribution ratio of 69.25%. Milling depth is also highly significant in vibration, which had a contribution ratio of 51.41% in the X direction, 41.42% in the Y direction and 75.97% in the Z direction. Moreover, the spindle speed is highly significant in surface roughness, which had a contribution ratio of 48.02%. This present study aims to quantitatively evaluate the influence of key process parameters on robotic milling performance, which helps to select reasonable milling parameters and improve the milling performance of the robot system. It is beneficial to give full play to the advantages of robots and present more possibilities of robot applications in machining and manufacturing.

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The Effects of MQL and Dry Environments on Tool Wear, Cutting Temperature, and Power Consumption during End Milling of AISI 1040 Steel

Cited by 72 publications

References 51 publications

Corrosion Resistance and Surface Bioactivity of Ti6Al4V Alloy after Finish Turning under Ecological Cutting Conditions

Corrosion Resistance and Surface Bioactivity of Ti6Al4V Alloy after Finish Turning under Ecological Cutting Conditions

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

Contribution Ratio Assessment of Process Parameters on Robotic Milling Performance

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