Towards sustainability assessment, energy consumption, and carbon emissions in cryogenic drilling of Alloy 20: a new approach towards sustainable future and challenges

Sivalingam, Vinothkumar; Liu, Haochen; Selvam, Baskaran; Kai, Guo; Kumar, Poongavanam Ganesh; Gupta, Munish Kumar; Korkmaz, Mehmet Erdi; Sun, Jie

doi:10.1007/s00170-024-13144-3

Cited by 3 publications

(1 citation statement)

References 35 publications

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“…However, the surface quality deteriorates due to tool damage such as microfractures and chipping that occur on the cutting tool in the cryogenic environment [28,29]. On the other hand, it is emphasized that MQL + Cryo contributes to sustainable machining for outputs such as cutting force and surface quality in drilling applications [30]. As can be understood from the research in the literature, the effects of MQL, nano-MQL, cryogenic, or hybrid applications formed by combining them on the machinability indicators vary [31].…”

Section: Introductionmentioning

confidence: 99%

Understanding the Relationship between Surface Quality and Chip Morphology under Sustainable Cutting Environments

Günay,

Korkmaz

2024

Materials

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Although chip morphology changes according to the machining method and related cutting parameters, chip formation affects the quality of the machined surface. In this context, it is very important to understand the relationship between chip morphology and surface quality, especially in materials that are difficult to machine. In the presented study, the changes in chip morphology, surface morphology, and surface quality criteria (Ra and Rz) that occurred during the milling of precipitation-hardened steel in different cutting environments were analyzed. Milling experiments were carried out in dry, MQL (minimum quantity lubrication), nano-MQL (graphene), nano-MQL (hBN), Cryo, and Cryo-MQL environments using TiAlN-coated inserts and three different cutting speeds and feed rates. While the highest values in terms of Ra and Rz were measured in dry machining, the minimum values were obtained in a nano-MQL (hBN) cutting environment. Due to the lubrication and low friction provided by the MQL cutting environment, chips were formed in thinner segmented forms. This formation reduced the chip curve radius and thus provided a more stable surface morphology. On the other hand, Cryo-ambient gas could not effectively leak into the cutting zone due to the intermittent cutting process, but it increased the brittleness of the chips with the cooling effect and provided a similar surface morphology. The values of minimum Ra and Rz were obtained as 0.304 mm and 1.825 mm, respectively, at a 60 m/min cutting speed and 0.04 mm/rev feed. Consequently, the use of nano-MQL cutting medium is seriously recommended in terms of surface quality in milling operations of difficult-to-machine materials.

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Section: Introductionmentioning

confidence: 99%

Understanding the Relationship between Surface Quality and Chip Morphology under Sustainable Cutting Environments

Günay,

Korkmaz

2024

Materials

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Predictive modelling and optimization for machinability indicators in cleaner milling of PH13-8Mo using sustainable cutting environments

Yurtkuran,

Günay

2024

J Braz. Soc. Mech. Sci. Eng.

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Enhancing Machinability and Sustainability: The Effects of Hybrid MQL+CO2 Cooling on the Drilling of AA7075T6 with TiO2 and C-Reinforced Composites

Chen,

He,

Zhao

et al. 2024

Machines

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This study investigates the impact of various auxiliary cooling techniques on machinability, energy consumption, carbon emissions, and economic factors in the drilling process of AA7075T6 aluminium alloy using TiO2 and C-reinforced composites. The study employed various cooling conditions (dry, MQL, CO2, and hybrid MQL+CO2), with different cutting speeds and feed rates, to evaluate their effects on drilling characteristics. The findings indicated that the combined MQL and CO2 cooling notably enhanced the drilling process by reducing cutting forces by 32% and surface roughness by 65% compared to dry cutting. This synergy between lubrication and cooling significantly improves machinability, resulting in higher-quality machining outputs with smoother surfaces and more precise circularity. Energy analysis revealed that the MQL+CO2 method reduces energy consumption to 64% observed under dry conditions, underscoring its efficiency through better heat dissipation and reduced friction. Furthermore, this method demonstrates a significant reduction in carbon emissions, contributing to environmental sustainability. Economically, although initial costs associated with the implementation of cooling systems are higher, they are offset by reduced tool wear and energy costs, making it a viable solution for sustainable manufacturing practices.

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Towards sustainability assessment, energy consumption, and carbon emissions in cryogenic drilling of Alloy 20: a new approach towards sustainable future and challenges

Cited by 3 publications

References 35 publications

Understanding the Relationship between Surface Quality and Chip Morphology under Sustainable Cutting Environments

Understanding the Relationship between Surface Quality and Chip Morphology under Sustainable Cutting Environments

Predictive modelling and optimization for machinability indicators in cleaner milling of PH13-8Mo using sustainable cutting environments

Enhancing Machinability and Sustainability: The Effects of Hybrid MQL+CO2 Cooling on the Drilling of AA7075T6 with TiO2 and C-Reinforced Composites

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