Feasibility of Supercritical Carbon Dioxide Based Metalworking Fluids in Micromilling

2013 ◽  
Vol 135 (2) ◽  
Author(s):  
S. D. Supekar ◽  
B. A. Gozen ◽  
B. Bediz ◽  
O. B. Ozdoganlar ◽  
S. J. Skerlos
Keyword(s):  
Carbon Dioxide ◽  
Surface Roughness ◽  
Stainless Steel ◽  
Supercritical Carbon Dioxide ◽  
Tool Wear ◽  
304 Stainless Steel ◽  
Metalworking Fluids ◽  
Burr Formation ◽  
Specific Cutting Energy ◽  
Cutting Energy

This article investigates the feasibility of using supercritical carbon dioxide based metalworking fluids (scCO2 metalworking fluids (MWFs)) to improve micromachinability of metals. Specifically, sets of channels were fabricated using micromilling on 304 stainless steel and 101 copper under varying machining conditions with and without scCO2 MWF. Burr formation, average specific cutting energy, surface roughness, and tool wear were analyzed and compared. Compared to dry machining, use of scCO2 MWF reduced burr formation in both materials, reduced surface roughness by up to 69% in 304 stainless steel and up to 33% in 101 copper, tool wear by up to 20% in 101 copper, and specific cutting energy by up to 87% in 304 stainless steel and up to 40% in 101 copper. The results demonstrate an improvement in micromachinability of the materials under consideration and motivate future investigations of scCO2 MWF-assisted micromachining to reveal underlying mechanisms of functionality, as well as to directly compare the performance of scCO2 MWF with alternative MWFs appropriate for micromachining.

Impact of Supercritical Carbon Dioxide Metalworking Fluids on Tool Life in Turning of Sintered Steel and Milling of Compacted Graphite Iron

2009 ◽  
Author(s):  
Douglas J. MacLean ◽  
Kim F. Hayes ◽  
Thomas Barnard ◽  
Timothy Hull ◽  
Ye Eun Park ◽  
...  
Keyword(s):  
Carbon Dioxide ◽  
Supercritical Carbon Dioxide ◽  
Tool Wear ◽  
Cutting Forces ◽  
Metalworking Fluids ◽  
Compacted Graphite Iron ◽  
Sintered Steel ◽  
Compacted Graphite ◽  
Metalworking Fluid ◽  
Water Based

This paper investigates the influence of supercritical carbon dioxide (scCO2) metalworking fluids on tool wear in two automotive manufacturing processes. scCO2 is a low-cost minimum quantity lubrication (MQL) system with excellent cooling characteristics. In valve seat machining of sintered steel with cubic boron nitride (CBN) inserts, scCO2 reduced tool wear by up to 25% and cutting forces by 10% when compared with the benchmark water-based flood metalworking fluid currently used in production operations. In end milling of compacted graphite iron (CGI) with uncoated carbide inserts, scCO2 reduced tool wear by up to 50% when compared with the currently used metalworking fluid. These results are consistent with those from other applications that show scCO2-based metalworking fluids have the potential to reduce tool wear and cutting forces when compared with commonly used water-based metalworking fluids. At the same time scCO2 is environmentally benign, eliminates metalworking fluid maintenance and disposal, and removes the major health risks associated with today’s metalworking fluids.

scholarly journals Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions

2019 ◽  
Vol 10 (2) ◽  
pp. 561-573 ◽  
Author(s):  
Muhammad Ali Khan ◽  
Syed Husain Imran Jaffery ◽  
Mushtaq Khan ◽  
Muhammad Younas ◽  
Shahid Ikramullah Butt ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Effective Means ◽  
Sustainable Manufacturing ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Positive Effect

Abstract. Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33 % whereas specific cutting energy and surface roughness were improved by 10 % and 9 % respectively by adapting the optimum machining conditions.

Laser-Assisted Machining of a Fiber Reinforced Metal Matrix Composite

2009 ◽  
Author(s):  
Chinmaya R. Dandekar ◽  
Yung C. Shin
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Metal Matrix ◽  
Material Removal ◽  
Volume Fraction ◽  
Cutting Speed ◽  
Surface Damage ◽  
Specific Cutting Energy ◽  
Cutting Energy ◽  
Multi Phase

Metal matrix composites due to their excellent properties of high specific strength, fracture resistance and corrosion resistance are highly sought after over their non-ferrous alloys, but these materials also present difficulty in machining. Excessive tool wear and high tooling costs of diamond tools makes the cost associated with machining of these composites very high. This paper is concerned with machining of high volume fraction long-fiber MMC’s, which has seldom been studied. The composite material considered for this study is an Al-2%Cu aluminum matrix composite reinforced with 62% by volume fraction alumina fibers (Al-2%Cu/Al2O3). Laser-machining is utilized to improve the tool life and the material removal rate while minimizing the sub-surface damage. The effectiveness of the laser-assisted machining process is studied by measuring the cutting forces, specific cutting energy, surface roughness, sub-surface damage and tool wear under various material removal temperatures. A multi-phase finite element model is developed in ABAQUS/Standard to identify and assist in selection of cutting parameters such as; tool rake angle, cutting speed and material removal temperature. The multi-phase model is also successful in predicting the damage depth on machining. The optimum material removal temperature is established as 300°C at a cutting speed of 30 m/min. LAM provides a 65% reduction in the surface roughness, specific cutting energy, the tool wear rate and minimum sub-surface damage over conventional machining using the same cutting conditions.

scholarly journals Performance Assessment of Minimum Quantity Castor-Palm Oil Mixtures in Hard-Milling Operation

Materials ◽  
2021 ◽  
Vol 14 (1) ◽  
pp. 198
Author(s):  
Binayak Sen ◽  
Munish Kumar Gupta ◽  
Mozammel Mia ◽  
Danil Yurievich Pimenov ◽  
Tadeusz Mikołajczyk
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Palm Oil ◽  
Castor Oil ◽  
Volume Fraction ◽  
Volume Ratio ◽  
Specific Cutting Energy ◽  
Minimum Quantity ◽  
Cutting Energy ◽  
Cooling Effects

The necessity to progress towards sustainability has inspired modern researchers to examine the lubrication and cooling effects of vegetable oils on conventional metal cutting operations. Consequently, as an eco-friendly vegetable product, castor oil can be the right choice as Minimum quantity lubrication (MQL) base fluid. Nonetheless, the high viscosity of castor oil limits its flowability and restricts its industrial application. Conversely, palm oil possesses superior lubricity, as well as flowability characteristics. Hence, an attempt has been made to improve the lubrication behavior of castor oil. Here, six castor-palm mixtures (varying from 1:0.5–1:3) were utilized as MQL-fluid, and the values of machining responses viz. average surface roughness, specific cutting energy, and tool wear were evaluated. Furthermore, an integrated Shannon’s Entropy-based Technique for order preference by similarity to ideal solution (TOPSIS) framework was employed for selecting the most suitable volume ratio of castor-palm oil mixture. The rank provided by the TOPSIS method confirmed that 1:2 was the best volume ratio for castor-palm oil mixture. Afterward, a comparative analysis demonstrated that the best castor-palm volume fraction resulted in 8.262 and 16.146% lowering of surface roughness, 5.459 and 7.971% decrement of specific cutting energy, 2.445 and 3.155% drop in tool wear compared to that of castor and palm oil medium, respectively.

Effect of SiC-Cu Electrode on Material Removal Rate, Tool Wear and Surface Roughness in EDM Process

2020 ◽  
Vol 38 (9A) ◽  
pp. 1406-1413
Author(s):  
Yousif Q. Laibia ◽  
Saad K. Shather
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Material Removal Rate ◽  
Material Removal ◽  
Electrical Discharge Machining ◽  
Removal Rate ◽  
304 Stainless Steel ◽  
Tool Electrode ◽  
Pulse Time ◽  
Edm Process

Electrical discharge machining (EDM) is one of the most common non-traditional processes for the manufacture of high precision parts and complex shapes. The EDM process depends on the heat energy between the work material and the tool electrode. This study focused on the material removal rate (MRR), the surface roughness, and tool wear in a 304 stainless steel EDM. The composite electrode consisted of copper (Cu) and silicon carbide (SiC). The current effects imposed on the working material, as well as the pulses that change over time during the experiment. When the current used is (8, 5, 3, 2, 1.5) A, the pulse time used is (12, 25) μs and the size of the space used is (1) mm. Optimum surface roughness under a current of 1.5 A and the pulse time of 25 μs with a maximum MRR of 8 A and the pulse duration of 25 μs.

Evaluation of Cooling Potential and Tool Life in Turning Using Metalworking Fluids Delivered in Supercritical Carbon Dioxide

2009 ◽  
Author(s):  
Andres F. Clarens ◽  
Ye-Eun Park ◽  
Jacob Temme ◽  
Kim Hayes ◽  
Fu Zhao ◽  
...  
Keyword(s):  
Carbon Dioxide ◽  
Tool Wear ◽  
Tool Life ◽  
Heat Removal ◽  
Minimum Quantity Lubrication ◽  
Metalworking Fluids ◽  
Compacted Graphite ◽  
Lower Viscosity ◽  
Cutting Zone ◽  
Machining Operations

Carbon Dioxide is an industrial byproduct that has been proposed as an alternative metalworking fluid (MWF) carrier with lower environmental impacts and better cooling potential than existing MWFs. This paper investigates the heat removal and tool life effects of rapidly expanding supercritical CO2 (scCO2)-based MWFs relative to MWFs delivered as a flood of semi-synthetic emulsion or as minimum quantity lubrication (MQL) sprays. When cutting both compacted graphite iron (CGI) and titanium, tool wear was most effectively controlled using the scCO2-based MWF compared with the other MWFs. Analysis in this paper suggests that the performance benefit imparted by rapidly expanding scCO2 appears to be related to both the cooling potential and penetration of the sprays into the cutting zone. High-pressure gas sprays have lower viscosity and higher velocity than conventional MWFs. An experiment in which the spray direction was varied clearly demonstrated the importance of spray penetration in tool wear suppression. The type of gas spray is also a significant factor in tool wear suppression. For instance, a spray of N2 delivered under similar conditions to CO2 effectively reduced tool wear relative to water based fluids, but not as much as CO2. This result is particularly relevant for MQL sprays which are shown to not cool nearly as effectively as scCO2 MWFs. These results inform development of scCO2-based MWFs in other machining operations, and provide insight into the optimization of scCO2 MWF delivery.

scholarly journals New bio-based nanolubricants for turning of Inconel 718 towards improvement of tool wear resistance and specific cutting energy

2019 ◽  
Vol 670 ◽  
pp. 012007
Author(s):  
Mohd Asyraf Mahboob Ali ◽  
Azwan Iskandar Azmi ◽  
Mohd Zahiruddin Mohd Zain ◽  
Muhamad Nasir Murad ◽  
Ahmad Nabil Mohd Khalil ◽  
...  
Keyword(s):  
Wear Resistance ◽  
Tool Wear ◽  
Inconel 718 ◽  
Specific Cutting Energy ◽  
Cutting Energy

The Cutting Speed Influences on Tool Wear of ZTA Ceramic Cutting Tools and Surface Roughness of Work Material Stainless Steel 316L during High Speed Machining

2016 ◽  
Vol 840 ◽  
pp. 315-320 ◽  
Author(s):  
Afifah Mohd Ali ◽  
Norazharuddin Shah Abdullah ◽  
Manimaran Ratnam ◽  
Zainal Arifin Ahmad
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
High Speed ◽  
Dense Body ◽  
Cutting Speed ◽  
Optical Microscope ◽  
Stainless Steel 316L ◽  
Crater Wear ◽  
Matlab Programming

The purpose of this research is to find the effects of cutting speed on the performance of the ZTA ceramic cutting tool. Three types of ZTA tools used in this study which are ZTA-MgO(micro), ZTA-MgO(nano) and ZTA-MgO-CeO2. Each of them were fabricated by wet mixing the materials, then dried at 100°C before crushed into powder. The powder was pressed into rhombic shape and sintered at 1600°C at 4 hours soaking time to yield dense body. To study the effect of the cutting speed on fabricated tool, machining was performed on the stainless steel 316L at 1500 to 2000 rpm cutting speed. Surface roughness of workpiece was measured and the tool wears were analysed by using optical microscope and Matlab programming where two types of wear measured i.e. nose wear and crater wear. Result shows that by increasing the cutting speed, the nose wear and crater wear increased due to high abrasion. However, surface roughness decreased due to temperature rise causing easier chip formation leaving a good quality surface although the tool wear is increased.

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