Character and Behavior of Mist Generated by Application of Cutting Fluid to a Rotating Cylindrical Workpiece, Part 1: Model Development

2004 ◽  
Vol 126 (3) ◽  
pp. 417-425 ◽  
Author(s):  
Y. Yue ◽  
J. Sun ◽  
K. L. Gunter ◽  
D. J. Michalek ◽  
J. W. Sutherland
Keyword(s):  
Control Volume ◽  
Film Theory ◽  
Model Development ◽  
Cutting Speed ◽  
Droplet Size Distribution ◽  
Rotating Disk ◽  
Operating Conditions ◽  
Cutting Fluid ◽  
Model Predictions ◽  
Cylindrical Workpiece

Increasing attention is being devoted to the airborne emissions resulting from a variety of manufacturing processes because of health, safety, and environmental concerns. In this two-part paper, a model is presented for the amount of cutting fluid mist produced by the interaction of the fluid with the rotating cylindrical workpiece during a turning operation. This model is based on relationships that describe cutting fluid atomization, droplet settling, and droplet evaporation. Experiments are performed to validate the model. In Part 1 of the paper, the emphasis is on model development. In the model, thin film theory is used to determine the maximum fluid load that can be supported by a rotating cylindrical workpiece; rotating disk atomization theory is applied to the turning process to predict the mean size of the droplets generated by atomization; and expressions for both the evaporation and settling behavior are established. Droplet size distribution and mass concentration predictions are used to characterize the fluid mist. Model predictions indicate that the droplet mean diameter is affected by both fluid properties and operating conditions, with cutting speed having the most significant affect. Model predictions and experimental results show that the number distribution of droplets within the control volume is dominated by small droplets because of the settling and evaporation phenomena. In Part 2 of the paper, the cutting fluid mist behavior model is validated using the results obtained from a series of experiments.

Character and Behavior of Mist Generated by Application of Cutting Fluid to a Rotating Cylindrical Workpiece, Part 2: Experimental Validation

2004 ◽  
Vol 126 (3) ◽  
pp. 426-434 ◽  
Author(s):  
J. Sun ◽  
C. Ju ◽  
Y. Yue ◽  
K. L. Gunter ◽  
D. J. Michalek ◽  
...  
Keyword(s):  
Dynamic Behavior ◽  
Mass Concentration ◽  
Experimental Validation ◽  
Droplet Size Distribution ◽  
Cutting Fluid ◽  
Formation Mechanisms ◽  
Model Predictions ◽  
Cylindrical Workpiece ◽  
Simulation Results ◽  
And Behavior

In Part 1 of this paper a model was developed to describe the formation mechanisms and dynamic behavior of cutting fluid mist. This part of the paper focuses on an experimental investigation of the mist generated by the interaction of the fluid with the rotating cylindrical workpiece during a turning operation and the simulation of the dynamic behavior of the mist droplets, resulting in the prediction of the droplet size distribution and the mass concentration within the machining environment. These simulation results are compared to experimental measurements in order to validate the theoretical model presented in Part 1 of the paper. It is observed that the model predictions accurately characterize the observed experimental behavior.

Cutting Tool Temperatures in Contour Turning: Transient Analysis and Experimental Verification

1997 ◽  
Vol 119 (4A) ◽  
pp. 494-501 ◽  
Author(s):  
D. A. Stephenson ◽  
T.-C. Jen ◽  
A. S. Lavine
Keyword(s):  
Transient Analysis ◽  
Cutting Tool ◽  
Process Development ◽  
Thermal Contact ◽  
Model Development ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Transient Conditions ◽  
Trouble Shooting ◽  
Model Predictions

This paper describes a model for predicting cutting tool temperatures under transient conditions. It is applicable to processes such as contour turning, in which the cutting speed, feed rate, and depth of cut may vary continuously with time. The model is intended for use in process development and trouble shooting. Therefore, emphasis is given in the model development to enable rapid computation and to avoid the need to specify parameters such as thermal contact resistances and convection coefficients which are not known in practice. Experiments were conducted to validate the predictive model. The model predictions with two different boundary conditions bound the experimental results. An example is presented which shows the utility of the model for process planning.

Pressure-Gain Combustion: Part II—Experimental and Model Results

1996 ◽  
Vol 118 (3) ◽  
pp. 469-473 ◽  
Author(s):  
G. A. Richards ◽  
R. S. Gemmen
Keyword(s):  
Control Volume ◽  
Operating Conditions ◽  
Volume Analysis ◽  
Pulse Combustor ◽  
Model Predictions ◽  
Pressure Gain Combustion ◽  
Mean Pressure ◽  
Pulse Combustion ◽  
Complex Fluid ◽  
Geometric Changes

An experimental investigation of aerovalve pulse combustion is presented. The experimental measurements compare favorably with model predictions from a control volume analysis of the pulse combustor. Particular emphasis is placed on the mean pressure differences through the combustor as an indicator of the so-called pressure gain performance. Both the operating conditions and combustor geometry are investigated. It is shown that complex fluid/combustion interactions within the combustor make it difficult to isolate the effect of geometric changes. A scaling rule developed from the control-volume analysis is used to produce a combustor geometry capable of producing pressure gain.

Performance Analysis of Trihexyltetradecylphosphonium Chloride Ionic Fluid under MQL Condition in Hard turning

2020 ◽  
Vol 17 (1) ◽  
pp. 7629-7647
Author(s):  
A. Pandey ◽  
R. Kumar ◽  
A. K. Sahoo ◽  
A. Paul ◽  
A. Panda
Keyword(s):  
Material Removal Rate ◽  
Feed Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Cutting Speed ◽  
Coconut Oil ◽  
Chip Morphology ◽  
Weight Fraction ◽  
Cutting Fluid ◽  
Depth Of Cut

The current research presents an overall performance-based analysis of Trihexyltetradecylphosphonium Chloride [[CH3(CH2)5]P(Cl)(CH2)13CH3] ionic fluid mixed with organic coconut oil (OCO) during turning of hardened D2 steel. The application of cutting fluid on the cutting interface was performed through Minimum Quantity Lubrication (MQL) approach keeping an eye on the detrimental consequences of conventional flood cooling. PVD coated (TiN/TiCN/TiN) cermet tool was employed in the current experimental work. Taguchi’s L9 orthogonal array and TOPSIS are executed to analysis the influences, significance and optimum parameter settings for predefined process parameters. The prime objective of the current work is to analyze the influence of OCO based Trihexyltetradecylphosphonium Chloride ionic fluid on flank wear, surface roughness, material removal rate, and chip morphology. Better quality of finish (Ra = 0.2 to 1.82 µm) was found with 1% weight fraction but it is not sufficient to control the wear growth. Abrasion, chipping, groove wear, and catastrophic tool tip breakage are recognized as foremost tool failure mechanisms. The significance of responses have been studied with the help of probability plots, main effect plots, contour plots, and surface plots and the correlation between the input and output parameters have been analyzed using regression model. Feed rate and depth of cut are equally influenced (48.98%) the surface finish while cutting speed attributed the strongest influence (90.1%). The material removal rate is strongly prejudiced by cutting speed (69.39 %) followed by feed rate (28.94%) whereas chip reduction coefficient is strongly influenced through the depth of cut (63.4%) succeeded by feed (28.8%). TOPSIS significantly optimized the responses with 67.1 % gain in closeness coefficient.

Treatment system response to transient AOX (adsorbable organic halogen) loadings

1997 ◽  
Vol 35 (2-3) ◽  
pp. 85-91
Author(s):  
D. A. Barton ◽  
J. D. Woodruff ◽  
T. M. Bousquet ◽  
A. M. Parrish
Keyword(s):  
Paper Industry ◽  
Model Development ◽  
Operating Conditions ◽  
System Response ◽  
Additional Information ◽  
Organic Halogen ◽  
Aox Removal ◽  
Variable Operating Conditions ◽  
Plant Shutdown

If promulgated as proposed, effluent guidelines for the U.S. pulp and paper industry will impose average monthly and maximum daily numerical limits of discharged AOX (adsorbable organic halogen). At this time, it is unclear whether the maximum-day variability factor used to establish the proposed effluent guidelines will provide sufficient margin for mills to achieve compliance during periods of normal but variable operating conditions within the pulping and bleaching processes. Consequently, additional information is needed to relate transient AOX loadings with final AOX discharges. This paper presents a simplistic dynamic model of AOX decay during treatment. The model consists of hydraulic characterization of an activated sludge process and a first-order decay coefficient for AOX removal. Data for model development were acquired by frequent collection of influent and effluent samples at a bleach kraft mill during a bleach plant shutdown and startup sequence.

Numerical prediction of the performance of gas-lubricated spiral groove thrust bearings

1997 ◽  
Vol 211 (2) ◽  
pp. 117-128 ◽  
Author(s):  
Y Yue ◽  
T. A. Stolarski
Keyword(s):  
Control Volume ◽  
Numerical Procedure ◽  
Operating Conditions ◽  
Hydrodynamic Bearings ◽  
Thrust Bearings ◽  
Flow Balance ◽  
Control Volumes ◽  
Volume Method ◽  
Spiral Angle ◽  
Spiral Grooves

The objective of this paper is to develop an accurate numerical procedure for the analysis of nominally flat contacts with spiral grooves lubricated by gases. The numerical procedure, which is based on the control-volume method, enables the solutions of the non-linear Reynolds equation to be obtained without limitation in geometry and operating conditions. Satisfactory flow balance was achieved on the control volumes as well as on the whole boundary and the method was proved to be very accurate. Convergence of the method was quick for any compressibility number. Three types of contact with spiral grooves were analysed. They were hydrodynamic bearings without interior chambers, hydrodynamic bearings with interior chambers and hybrid bearings. The effects of spiral angle, groove geometry (length, depth and width) and compressibility on performances were investigated for all possible designs.

Tool Life Analysis when Turning Ti-6Al-4V Using Vegetable Oil-Based Cutting Fluid

2017 ◽  
Vol 882 ◽  
pp. 36-40
Author(s):  
Salah Gariani ◽  
Islam Shyha ◽  
Connor Jackson ◽  
Fawad Inam
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Vegetable Oil ◽  
Flank Wear ◽  
Cutting Speed ◽  
Fractional Factorial ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Tool Flank Wear ◽  
Fluid Concentration

This paper details experimental results when turning Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. The effects of coolant concentration and working conditions on tool flank wear and tool life were evaluated. L27 fractional factorial Taguchi array was employed. Tool wear (VBB) ranged between 28.8 and 110 µm. The study concluded that a combination of VOs based cutting fluid concentration (10%), low cutting speed (58 m/min), feed rate (0.1mm/rev) and depth of cut (0.75mm) is necessary to minimise VBB. Additionally, it is noted that tool wear was significantly affected by cutting speeds. ANOVA results showed that the cutting fluid concentration is statistically insignificant on tool flank wear. A notable increase in tool life (TL) was recorded when a lower cutting speed was used.

scholarly journals Nanofluid-based Minimum Quantity Lubrication (MQL) Face Milling of Inconel 625

2019 ◽  
Vol 16 (3) ◽  
pp. 6874-6888
Author(s):  
P. Singh ◽  
J. S. Dureja ◽  
H. Singh ◽  
M. S. Bhatti
Keyword(s):  
Negative Impact ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Face Milling ◽  
Cutting Fluid ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Base Oil ◽  
Minimum Quantity ◽  
Milling Parameters

Machining with minimum quantity lubrication (MQL) has gained widespread attention to boost machining performance of difficult to machine materials such as Ni-Cr alloys, especially to reduce the negative impact of conventional flooded machining on environment and machine operator health. The present study is aimed to evaluate MQL face milling performance of Inconel 625 using nano cutting fluid based on vegetable oil mixed with multi-walled carbon nanotubes (MWCNT). Experiments were designed with 2-level factorial design methodology. ANOVA test and desirability optimisation method were employed to arrive at optimised milling parameters to achieve minimum tool wear and machined surface quality. Experiments were performed under nanoparticles based minimum quantity lubrication (NMQL) conditions using different weight concentrations of MWCNT in base oil: 0.50, 0.75, 1, 1.25 and 1.5 wt. %; and pure MQL environment (without nanoparticles). The optimal MQL milling parameters found are cutting speed: 47 m/min, table feed rate: 0.05 mm/tooth and depth of cut: 0.20 mm. The results revealed improvement in the surface finish (Ra) by 17.33% and reduction in tool flank wear (VB) by 11.48 % under NMQL face milling of Inconel 625 with 1% weight concentration of MWCNT in base oil compared to pure MQL machining conditions.

scholarly journals Model for Predicting the Machinability of Continuously Cast and Subsequently Rolled Steel Using the Artificial Neural Network

2021 ◽  
Vol 15 (3) ◽  
pp. 381-386
Author(s):  
Miha Kovačič ◽  
Shpetim Salihu ◽  
Uroš Župerl
Keyword(s):  
Neural Network ◽  
Artificial Neural Network ◽  
Production Process ◽  
Chemical Elements ◽  
Cast Steel ◽  
Model Development ◽  
Cutting Speed ◽  
Steel Production ◽  
Continuously Cast ◽  
Artificial Neural

The paper presents a model for predicting the machinability of steels using the method of artificial neural networks. The model includes all indicators from the entire steel production process that best predict the machinability of continuously cast steel. Data for model development were obtained from two years of serial production of 26 steel grades from 255 batches and include seven parameters from secondary metallurgy, four parameters from the casting process, and the content of ten chemical elements. The machinability was determined based on ISO 3685, which defines the machinability of a batch as the cutting speed with a cutting tool life of 15 minutes. An artificial neural network is used to predict this cutting speed. Based on the modelling results, the steel production process was optimised. Over a 5-month period, an additional 39 batches of 20MnV6 steel were produced to verify the developed model.

Development of Cutting Tools With Micro-Textured Surface for High Speed Machining of Ti-6Al-4V

2021 ◽  
Author(s):  
Mitsuru Hasegawa ◽  
Tatsuya Sugihara
Keyword(s):  
Tool Life ◽  
High Speed ◽  
Metal Cutting ◽  
Failure Process ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Textured Surface ◽  
Textured Surfaces

Abstract In cutting of Ti-6Al-4V alloy, the cutting speed is limited since a high cutting temperature leads to severe tool wear and short tool life, resulting in poor production efficiency. On the other hand, some recent literature has reported that various beneficial effects can be provided by forming micro-textures on the tool surface in the metal cutting process. In this study, in order to achieve high-performance machining of Ti-6Al-4V, we first investigated the mechanism of the tool failure process for a cemented carbide cutting tool in high-speed turning of Ti-6Al-4V. Based on the results, cutting tools with micro textured surfaces were developed under the consideration of a cutting fluid action. A series of experiments showed that the textured rake face successfully decreases the cutting temperature, resulting in a significant suppression of both crater wear and flank wear. In addition, the temperature zone where the texture tool is effective in terms of the tool life in the Ti-6Al-4V cutting was discussed.

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