Experimental Investigations to Study the Effect of Solid Lubricant MOS2 on the Performance of Hard Turning

2010 ◽  
Author(s):  
Dilbag Singh ◽  
P. Venkateswara Rao
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
Hard Turning ◽  
Solid Lubricant ◽  
Research Work ◽  
Cryogenic Cooling ◽  
Experimental Investigations ◽  
Cutting Fluids ◽  
Machining Performance ◽  
Molybdenum Disulphide

In hard turning, lot of heat is generated due to plastic deformation of the work material, friction at the tool-chip interface and friction between tool and the workpiece. The heat produced in machining adversely affects the quality of the products produced. Cutting fluids have been the conventional choice to deal with this problem. However, due to the environmental restrictions, the use of cutting fluids is restricted. Machining with solid lubricants, cryogenic cooling by liquid nitrogen and minimum quantity lubrication are some of the alternative approaches in this direction. This research work deals with an investigation on using molybdenum disulphide as solid lubricant in order to reduce friction for improving the machining performance and for overcoming some of the limitations that arise due to the use of cutting fluids or while dry hard turning. An experimental setup has been designed and built, and experiments have been conducted to study the effect of using molybdenum disulphide as solid lubricant on surface finish and cutting forces. An improvement in surface finish was observed with molybdenum disulphide assisted hard turning. It was also observed that there was a considerable reduction of cutting forces, thereby reducing the specific energy needed and consequently improving the machining performance.

Performance Profiling of Nanoparticulate Graphite Powder as Lubricant in the Machining of AISI 1040 Steel under Variable Machining Conditions

2014 ◽  
Vol 984-985 ◽  
pp. 15-24 ◽  
Author(s):  
S. Srikiran ◽  
K. Ramji ◽  
B. Satyanarayana
Keyword(s):  
Particle Size ◽  
Surface Finish ◽  
Cutting Forces ◽  
Solid Lubricant ◽  
Graphite Powder ◽  
Nano Particles ◽  
Chemical Degradation ◽  
Work Piece ◽  
Tool Temperature ◽  
Cutting Zone

The generation of heat during machining at the cutting zone adversely affects the surface finish and tool life. The heat at the cutting zone, which plays a negative role due to poor thermal conductivity, resistance to wear, high strength at high temperatures and chemical degradation can be overcome by the use of proper lubrication. Advancements in the field of tribology have led to the use of solid lubricants replacing the conventional flood coolants. This work involves the use of nanoparticulate graphite powder as a lubricant in turning operations whose performance is judged in terms of cutting forces, tool temperature and surface finish of the work piece. The experimentation revealed the increase in cutting forces and the tool temperature when the solid lubricant used is decreased in particle size. The surface finish deteriorated with the decrease in particle size of the lubricant in the nanoregime.Keywords-Turning, Solid lubricant, Graphite, Minimum Quantity Lubrication, nano–particles,Weight percentage,Frictioncoefficient.

The effects of cryogenic cooling on chips and cutting forces in turning AISI 1040 and AISI 4320 steels

2002 ◽  
Vol 216 (5) ◽  
pp. 713-724 ◽  
Author(s):  
N R Dhar ◽  
Nanda S V Kishore ◽  
S Paul ◽  
A B Chattopadhyay
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Substantial Reduction ◽  
Cutting Temperature ◽  
Environmentally Friendly ◽  
Cryogenic Cooling ◽  
Experimental Investigations ◽  
High Production ◽  
On Chip

Application of conventional cutting fluids often cannot control the high cutting temperatures, especially in high production machining. In addition, they are a major source of pollution in machining industries. Cryogenic cooling is a potential environmentally friendly clean technology for desirable control of the cutting temperature. The present work deals with experimental investigations on the role of cryogenic cooling by liquid nitrogen jets on chip formation and cutting forces in turning AISI 1040 steel and AISI 4320 steel at industrial speed—feed combinations by two types of carbide inserts of different geometrical configurations. The experimental results indicate the possibility of a substantial reduction in cutting forces by cryogenic cooling, which enabled a reduction in cutting forces by favourable chip formation, chip—tool interaction and also retention of tool sharpness due to reduced cutting temperature. Thus cryogenic cooling, if properly employed, is not only environmentally friendly but can also improve machinability characteristics.

On the improvement of process performance of hard turning using vibration-assisted machining

2021 ◽  
pp. 251659842110080
Author(s):  
Pranesh Dutta ◽  
Gaurav Bartarya
Keyword(s):  
Tool Wear ◽  
Residual Stresses ◽  
Cutting Forces ◽  
Hard Turning ◽  
Fe Model ◽  
Process Performance ◽  
Machining Performance ◽  
Cutting Velocity ◽  
Low Amplitude ◽  
Conventional Machining

In hard turning, the cutting forces are large, which leads to tool wear and tensile nature of residual stresses. Vibration-assisted machining (VAM), where the tool is provided with a low amplitude vibration at significantly high frequency, might improve the process performance of hard turning in terms of cutting forces, residual stress, etc., as VAM helps in reduction of cutting forces and tool wear significantly. To improve the machining operation, a comparative study of VAM with conventional machining is undertaken to study and improve the hard turning performance. A two-dimensional (2D) finite element (FE) model is developed to understand the effect of process parameters better and to study the effect on machining performance by applying one-dimensional ultrasonic vibration to the tool. The model developed is validated with results from a previous work for continuous hard turning conditions. The effect of vibrations induced in cutting velocity direction is studied on the cutting forces and residual stresses induced on the machined workpiece. The ratio of cutting velocity to critical vibrating velocity is an important process parameter that affects the average cutting forces during hard turning using VAM. The nature of cutting force and temperature for a complete cycle of vibration is also studied. The simulation results establish that hard turning using VAM yields lower average cutting forces and more compressive residual stresses in comparison to conventional hard turning.

Machining Performance of PM Material Containing MnX Additives1

2000 ◽  
Vol 122 (4) ◽  
pp. 379-383 ◽  
Author(s):  
Stuart Barnes ◽  
Michael J. Nash ◽  
Moh. H. Lim
Keyword(s):  
Powder Metallurgy ◽  
Tool Wear ◽  
Surface Finish ◽  
Cutting Forces ◽  
Superior Performance ◽  
Machining Performance ◽  
Turning Operation ◽  
Cutting Speeds

A new free-machining additive, MnX, has been reported to improve the machining performance of ferrous powder metallurgy (PM) materials. This work investigated this claim by comparing the performance of three otherwise identical PM materials containing: no additive, conventional manganese sulphide (MnS) additions and the new MnX additive. A turning operation and cutting speeds of 100–250 m/min were used during which cutting forces, tool wear and surface finish were measured. The MnX material was found to exhibit superior performance. However, this was most noticeable at higher cutting speeds and at the lower cutting speeds, differences in performance were substantially reduced. [S0094-4289(00)02004-1]

scholarly journals Effect of Yttrium and Rhenium Ion Implantation on the Performance of Nitride Ceramic Cutting Tools

Materials ◽  
2020 ◽  
Vol 13 (20) ◽  
pp. 4687
Author(s):  
Dmitrij Morozow ◽  
Zbigniew Siemiątkowski ◽  
Edwin Gevorkyan ◽  
Mirosław Rucki ◽  
Jonas Matijošius ◽  
...  
Keyword(s):  
Ion Implantation ◽  
Cutting Forces ◽  
Cutting Tools ◽  
Metal Vapor ◽  
Vacuum Arc ◽  
Experimental Investigations ◽  
Unexpected Result ◽  
Turning Process ◽  
Machining Performance ◽  
Tool Surface

In the paper, the results of experimental investigations of ion implanted cutting tools performance are presented. The tools, made out of Si3N4 with additives typically used for turning of Ti-6Al-4V alloy, underwent implantation with ions of yttrium (Y+) and rhenium (Re+) using the metal vapor vacuum arc method. Distribution of ions on the tool surface was measured. The cutting tools were tested in turning process with measurement of cutting forces and analysis of wear. A rather unexpected result was the increased wear of the tool after Y+ implantation with 1 × 1017 ion/cm2. It was demonstrated, however, that the tool after Y+ 2 × 1017 ion/cm2 ion implantation provided the best machining performance.

scholarly journals Evaluation of subcooled MQL in cBN hard turning of powder-based Cr-Mo-V tool steel using simulations and experiments

2021 ◽  
Author(s):  
Sampsa V.A. Laakso ◽  
Dinesh Mallipeddi ◽  
Peter Krajnik
Keyword(s):  
Tool Steel ◽  
Cutting Forces ◽  
Hard Turning ◽  
Metal Cutting ◽  
Cooling Capacity ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Workpiece Surface ◽  
Residual Strains ◽  
Cooling And Lubrication

AbstractMetal cutting fluids for improved cooling and lubrication are an environmental risk and a health risk for workers. Minimizing water consumption in industry is also a goal for a more sustainable production. Therefore, metal cutting emulsions that contain hazardous additives and consume considerable amounts of water are being replaced with more sustainable metal cutting fluids and delivery systems, like vegetable oils that are delivered in small aerosol droplets, i.e., via minimum quantity lubrication (MQL). Since the volume of the cutting fluid in MQL is small, the cooling capacity of MQL is not optimal. In order to improve the cooling capacity of the MQL, the spray can be subcooled using liquid nitrogen. This paper investigates subcooled MQL with machining simulations and experiments. The simulations provide complementary information to the experiments, which would be otherwise difficult to obtain, e.g., thermal behavior in the tool-chip contact and residual strains on the workpiece surface. The cBN hard turning simulations and experiments are done for powder-based Cr-Mo-V tool steel, Uddeholm Vanadis 8 using MQL subcooled to −10 °C and regular MQL at room temperature. The cutting forces and tool wear are measured from the experiments that are used as the calibration factor for the simulations. After calibration, the simulations are used to evaluate the thermal effects of the subcooled MQL, and the surface residual strains on the workpiece. The simulations are in good agreement with the experiments in terms of chip morphology and cutting forces. The cutting experiments and simulations show that there is only a small difference between the subcooled MQL and regular MQL regarding the wear behavior, cutting forces, or process temperatures. The simulations predict substantial residual plastic strain on the workpiece surface after machining. The surface deformations are shown to have significant effect on the simulated cutting forces after the initial tool pass, an outcome that has major implications for inverse material modeling.

scholarly journals Evaluation of Subcooled MQL in cBN Hard Turning of powder-based Cr-Mo-V Tool Steel Using Simulations and Experiments

2021 ◽  
Author(s):  
Sampsa Vili Antero Laakso ◽  
Dinesh Mallipeddi ◽  
Peter Krajnik
Keyword(s):  
Cutting Forces ◽  
Hard Turning ◽  
Metal Cutting ◽  
Wear Behavior ◽  
Cooling Capacity ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Workpiece Surface ◽  
Residual Strains ◽  
Cooling And Lubrication

Abstract Metal cutting fluids for improved cooling and lubrication are an environmental risk and a health risk for workers. Minimizing water consumption in industry is also a goal for a more sustainable production. Therefore, metal cutting emulsions that contain hazardous additives and consume considerable amounts of water are being replaced with more sustainable metal cutting fluids and delivery systems, like vegetable oils that are delivered in small aerosol droplets, i.e. via minimum quantity lubrication (MQL). Since the volume of the cutting fluid in MQL is small, the cooling capacity of MQL is not optimal. In order to improve the cooling capacity of the MQL, the spray can be subcooled using liquid nitrogen. This paper investigates subcooled MQL with machining simulations and experiments. The simulations provide complementary information to the experiments, which would be otherwise difficult to obtain, e.g. thermal behavior in the tool-chip contact and residual strains on the workpiece surface. The cBN hard turning simulations and experiments are done for powder-based Cr-Mo-V tools steel, Uddeholm Vanadis 8 using MQL subcooled to -10 °C and regular MQL at room temperature. The cutting forces and tool wear are measured from the experiments, that are used as the calibration factor for the simulations. After calibration, the simulations are used to evaluate the thermal effects of the subcooled MQL, and the surface residual strains on the workpiece. The simulations are in good agreement with the experiments in terms of chip morphology and cutting forces. The cutting experiments and simulations show that there is only a small difference between the subcooled MQL and regular MQL regarding the wear behavior, cutting forces or process temperatures. The simulations predict substantial residual plastic strain on the workpiece surface after machining. The surface deformations are shown to have significant effect on the simulated cutting forces after the initial tool pass, an outcome that has major implications for inverse material modelling.

A novel indirect cryogenic cooling system for improving surface finish and reducing cutting forces when turning ASTM F-1537 cobalt-chromium alloys

2020 ◽  
Vol 111 (7-8) ◽  
pp. 1971-1989
Author(s):  
Iñigo Rodriguez Bogajo ◽  
Pairat Tangpronprasert ◽  
Chanyapan Virulsri ◽  
Saran Keeratihattayakorn ◽  
Pedro José Arrazola
Keyword(s):  
Surface Finish ◽  
Cutting Forces ◽  
Cooling System ◽  
Cryogenic Cooling ◽  
Cobalt Chromium ◽  
Chromium Alloys
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