Analysis of Thermal and Mechanical Effects on Residual Stress in Minimum Quantity Lubrication (MQL) Machining

2016 ◽  
Vol 34 (1) ◽  
pp. 41-46 ◽  
Author(s):  
X. Ji ◽  
B.-Z. Li ◽  
Steven Y. Liang
Keyword(s):  
Residual Stress ◽  
Thermal Load ◽  
Compressive Residual Stress ◽  
Mechanical Load ◽  
Orthogonal Cutting ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Minimum Quantity ◽  
Stress Prediction ◽  
Aisi 4130

AbstractA physics-based model of residual stress in minimum quantity lubrication (MQL) machining is presented. The stresses resulting from thermal and mechanical loading in the MQL machining process are coupled into an incremental thermal-elastic-plastic model for predicting the final resultant residual stress in the machined workpiece. Comparative analysis is made between the stresses produced by the thermal load and mechanical load in the machining process. Results manifest that for the surface of the machined workpiece, the stress produced by thermal load is on par with the contact stress produced by mechanical load in the magnitude. With the increase of depth into the workpiece, the stress produced by mechanical load is dominant of the total stresses. The rationale demonstrates that thermal load is prone to generate the tensile residual stress at the surface of the machined workpiece, while the mechanical load is prone to generate the compressive residual stress at the surface of the machined workpiece. Finally, the residual stress prediction model is verified by orthogonal cutting of AISI 4130 alloy steel.

Predictive Modeling of Minimum Quantity Lubrication: Cutting Force, Temperature and Residual Stress

2013 ◽  
Vol 365-366 ◽  
pp. 1181-1184 ◽  
Author(s):  
Xia Ji ◽  
Xue Ping Zhang ◽  
Bei Zhi Li ◽  
Steven Y. Liang
Keyword(s):  
Residual Stress ◽  
Cutting Force ◽  
Predictive Modeling ◽  
Analytical Approach ◽  
Orthogonal Cutting ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
Machining Force ◽  
Tc4 Alloy ◽  
Cooling Effects

This paper presents an analytical approach to predict the machining force, temperature and residual stress under minimum quantity lubrication (MQL) condition. Both the lubrication and cooling effects are considered to change the tribological and thermal properties in the modified Oxleys model, which is capable to predict the cutting force and temperature in MQL machining directly from cutting conditions. The machining-induced residual stress is predicted by modified McDowell hybrid algorithm. The predicted cutting forces and residual stresses are verified by orthogonal cutting tests for C45 steel and TC4 alloy steel.

Hook Shaped Residual Stress: The Effect of Tool Ploughing, and the Analysis of the Mechanical and Thermal Effects

2012 ◽  
Author(s):  
Xueping Zhang ◽  
Shenfeng Wu ◽  
C. Richard Liu
Keyword(s):  
Residual Stress ◽  
Formation Process ◽  
Chip Formation ◽  
Thermal Effects ◽  
Thermal Load ◽  
Compressive Residual Stress ◽  
Mechanical Load ◽  
Stress Profile ◽  
Fe Model ◽  
Residual Stress Profile

To investigate the unique hook-shaped residual stress profile generated from hard turning process, an improved orthogonal (2-D) Finite Element (FE) model is established to include the ploughing effect of cutting edge. The model is further decomposed into two FE sub-models (sub-model 1 and sub-model 2) to determine the thermal and mechanical effects on the residual stress profiles by saw-tooth chip formation process and honed-edge ploughing process respectively. The two FE sub-models are sequentially adopted to evaluate the compression effect induced by chip formation process and ploughing effect resulted from honed-edge cutting tool on residual stress profile. Their separated and integrated effects on residual stress hook-shape profile are addressed by comparing the predicted residual stresses by sub-model 1, sub-model 2, the two sub-models’ superposition, and the whole improved FE model. The results show that chip formation effect on residual stress profile happens earlier than the ploughing effect. Chip formation effect provides a foundation for the finalized residual stress profile by determining the maximum depth and magnitude of the compressive residual stress. Ploughing process generates much more thermal load to produce the tensile residual stress in hard turned surface and sequentially drives the final resultant residual stress into an obvious hook-shaped by modifying the previous compressive residual stress profile. The location with the maximum compressive residual stress is identified as the critical position to separate the mechanical load and thermal load generated from ploughing effect. The decomposition methodology on mechanical and thermal effects is proposed and thoroughly discussed in the paper.

A Review of Minimum Quantity Lubrication (MQL) based on Bibliometry

2020 ◽  
Vol 13 ◽  
Author(s):  
Gaurav Gaurav ◽  
Abhay Sharma ◽  
G S Dangayach ◽  
M L Meena
Keyword(s):  
Descriptive Analysis ◽  
Minimum Quantity Lubrication ◽  
Citation Network ◽  
Machining Process ◽  
Cutting Fluid ◽  
Future Research ◽  
Research Directions ◽  
Minimum Quantity ◽  
Research Areas ◽  
Future Research Directions

Background: Minimum quantity lubrication (MQL) is one of the most promising machining techniques that can yield a reduction in consumption of cutting fluid more than 90 % while ensuring the surface quality and tool life. The significance of the MQL in machining makes it imperative to consolidate and analyse the current direction and status of research in MQL. Objective: This study aims to assess global research publication trends and hot topics in the field of MQL among machining process. The bibliometric and descriptive analysis are the tools that the investigation aims to use for the data analysis of related literature collected from Scopus databases. Methods: Various performance parameters are extracted, such as document types and languages of publication, annual scientific production, total documents, total citations, and citations per article. The top 20 of the most relevant and productive sources, authors, affiliations, countries, word cloud, and word dynamics are assessed. The graphical visualisation of the bibliometric data is presented in terms of bibliographic coupling, citation, and co-citation network. Results: The investigation reveals that the International Journal of Machine Tools and Manufacture (2611 citations, 31 hindex) is the most productive journal that publishes on MQL. The most productive institution is the University of Michigan (32 publications), the most cited country is Germany (1879 citations), and the most productive country in MQL is China (124 publications). The study shows that ‘Cryogenic Machining’, ‘Sustainable Machining’, ‘Sustainability’, ‘Nanofluid’ and ‘Titanium alloy’ are the most recent keywords and indications of the hot topics and future research directions in the MQL field. Conclusion: The analysis finds that MQL is progressing in publications and the emerging with issues that are strongly associated with the research. This study is expected to help the researchers to find the most current research areas through the author’s keywords and future research directions in MQL and thereby expand their research interests.

Effect of Minimum Quantity Lubrication to Prediction of Cutting Temperature Distribution in Turning Material AISI-1045

2020 ◽  
Vol 902 ◽  
pp. 97-102
Author(s):  
Tran Trong Quyet ◽  
Pham Tuan Nghia ◽  
Nguyen Thanh Toan ◽  
Tran Duc Trong ◽  
Luong Hong Sam ◽  
...  
Keyword(s):  
Temperature Distribution ◽  
Shear Zone ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
The Difference ◽  
Secondary Shear Zone ◽  
Cutting Model

This paper presents a prediction of cutting temperature in turning process, using a continuous cutting model of Johnson-Cook (J-C). An method to predict the temperature distribution in orthogonal cutting is based on the constituent model of various material and the mechanics of their cutting process. In this method, the average temperature at the primary shear zone (PSZ) and the secondary shear zone (SSZ) were determined for various materials, based on a constitutive model and a chip-formation model using measurements of cutting force and chip thicknes. The J-C model constants were taken from Hopkinson pressure bar tests. Cutting conditions, cutting forces and chip thickness were used to predict shear stress. Experimental cutting heat results with the same cutting parameters using the minimum lubrication method (MQL) were recorded through the Testo-871 thermal camera. The thermal distribution results between the two methods has a difference in value, as well as distribution. From the difference, we have analyzed some of the causes, finding the effect of the minimum quantity lubrication parameters on the difference.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

Model-based sensitivity analysis of machining-induced residual stress under minimum quantity lubrication

2015 ◽  
Vol 231 (9) ◽  
pp. 1528-1541 ◽  
Author(s):  
Xia Ji ◽  
Steven Y Liang
Keyword(s):  
Residual Stress ◽  
Sensitivity Analysis ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Mixture Ratio ◽  
Minimum Quantity

This article presents a sensitivity analysis of residual stress based on the verified residual stress prediction model. The machining-induced residual stress is developed as a function of cutting parameters, tool geometry, material properties, and lubrication conditions. Based on the residual stress predictive model, the main effects of the cutting force, cutting temperature, and residual stress are quantitatively analyzed through the cosine amplitude method. The parametric study is carried out to investigate the effects of minimum quantity lubrication parameters, cutting parameters, and tool geometry on the cutting performances. Results manifest that the cutting force and residual stress are more sensitive to the heat transfer coefficient and the depth of cut, while the cutting temperature is more sensitive to the cutting speed. Large maximum compressive residual stress is obtained under a lower flow rate of minimum quantity lubrication, small depth of cut, and the proper air–oil mixture ratio. This research can support the controlling and optimization of residual stress in industrial engineering by strategically adjusting the application parameters of minimum quantity lubrication.

Experimental Results on Lamellar-Type Solid Lubricants in Enhancing Minimum Quantity Lubrication Machining

2016 ◽  
Vol 138 (10) ◽  
Author(s):  
Trung Kien Nguyen ◽  
Kyung-Hee Park ◽  
Patrick Y. Kwon
Keyword(s):  
Vegetable Oil ◽  
Solid Lubricant ◽  
Minimum Quantity Lubrication ◽  
Solid Lubricants ◽  
Machining Process ◽  
Minimum Quantity ◽  
Aspect Ratios ◽  
Significant Difference ◽  
1045 Steel ◽  
Lamellar Type

This paper studies the effect of various lamellar-type solid lubricants (graphite and hBN) that can be mixed into a lubricant to potentially improve the machinability of minimum quantity lubrication (MQL) machining. To examine this, the solid lubricants are classified into particles and platelets based on their aspect ratios as well as their respective sizes. In particular, the particles are classified into microparticles and nanoparticles based on their dimensions (average radius), while the platelets were classified, based on their average thickness, into two types: the “microplatelets” if the thickness is typically up to few tens of microns and the “nanoplatelets” if the thickness is well below a tenth of a micron (even down to few nanometers). Our previous work has shown that the mixture of an extremely small amount (about 0.1 wt. %) of the graphitic nanoplatelets and vegetable oil immensely enhanced the machinability of MQL machining. In this paper, many lubricants, each mixed with a particular variety of nano- or micro-platelets or one type of nanoparticles, were studied to reveal the effect of each solid lubricant on MQL machining. Prior to the MQL machining experiment, the tribological test was conducted to show that the nanoplatelets are overall more effective than the microplatelets and nanoparticles in minimizing wear despite of no significant difference in friction compared to pure vegetable oil. Consequently, the MQL ball-milling experiment was conducted with AISI 1045 steel yielding a similar trend. Surprisingly, the oil mixtures with the microplatelets increased flank wear, even compared to the pure oil lubricant when the tools with the smooth surface were used. Thus, the nanoscale thickness of these platelets is a critical requirement for the solid lubricants in enhancing the MQL machining process. However, maintaining the nanoscale thickness is not critical with the tools with the rough surfaces in enhancing the MQL process. Therefore, it is concluded that finding an optimum solid lubricant depends on not only the characteristics (material as well as morphology) of solid lubricants but also the characteristic of tool surface.

Sign in / Sign up

Export Citation Format

Share Document