scholarly journals Droplet Spray Behavior of an Atomization-Based Cutting Fluid (ACF) System for Machining of Titanium Alloys

2012 ◽  
Author(s):  
Chandra Nath ◽  
Shiv G. Kapoor ◽  
Anil K. Srivastava ◽  
Jon Iverson
Keyword(s):  
Tool Life ◽  
Droplet Velocity ◽  
Cutting Fluid ◽  
Spray Parameters ◽  
Gas Velocity ◽  
Spray Distance ◽  
Droplet Entrainment ◽  
Spray System ◽  
Flow Development ◽  
Droplet Spray

The aim of this research is to study droplet spray characteristics of an atomization-based cutting fluid (ACF) spray system including droplet entrainment angle and flow development regions with respect to three ACF spray parameters, viz., droplet and gas velocities, and spray distance. ACF spray experiments are performed by varying droplet and gas velocities. The flow development behavior is studied by modeling the droplets entrainment mechanism, and the density and distribution of the droplets across the jet flare. Machining experiments are also performed in order to understand the effect of the droplet spray behavior on the machining performances, viz., tool life/wear, and surface roughness during turning of a titanium alloy, Ti-6Al-4V. Experiments and the modeling of flow development behavior reveal that a higher droplet velocity and a smaller gas velocity result in smaller droplet entrainment angle leading to a gradual and early development of the co-flow with a smaller density and a better distribution of the droplet across the jet flare. Machining experiments also show that a higher droplet velocity, a lower gas velocity and a longer spray distance significantly improve the machining performances such as tool life and wear, and surface finish.

Study of Droplet Spray Behavior of an Atomization-Based Cutting Fluid Spray System for Machining Titanium Alloys

2014 ◽  
Vol 136 (2) ◽  
Author(s):  
Chandra Nath ◽  
Shiv G. Kapoor ◽  
Anil K. Srivastava ◽  
Jon Iverson
Keyword(s):  
Titanium Alloys ◽  
Tool Life ◽  
Droplet Velocity ◽  
Cutting Fluid ◽  
Gas Velocity ◽  
Spray Distance ◽  
Droplet Entrainment ◽  
Spray System ◽  
Flow Development ◽  
Droplet Spray

The atomization-based cutting fluid (ACF) spray system has been found to be effective for improving the tool life and overall productivity during the machining of titanium alloys like Ti–6Al–4 V. The aim of this research is to study droplet spray characteristics of an ACF spray system including droplet entrainment zone (e.g., angle and distance) and droplet-gas co-flow development regions with respect to three ACF spray parameters, viz., droplet and gas velocities, and spray distance. ACF spray experiments are performed by varying droplet and gas velocities. Machining experiments are performed in order to understand the effect of the droplet spray behavior on the machining performance, viz., tool life/wear, and surface roughness during turning of a titanium alloy, Ti–6Al–4 V. The flow development behavior with respect to the spray distance is studied by modeling the droplets entrainment mechanism. The model is validated by the ACF spray experiments. Experiments and the modeling of flow development behavior reveal that a higher droplet velocity and a smaller gas velocity result in smaller droplet entrainment angle leading to a gradual and early development of the co-flow, and a better distribution of the droplets across the jet flare. Machining experiments also show that a higher droplet velocity, a lower gas velocity and a longer spray distance significantly improve tool life and surface finish.

Characterization of Fluid Film Produced by an Atomization–Based Cutting Fluid (ACF) Spray System During Machining

2013 ◽  
Author(s):  
Alexander C. Hoyne ◽  
Chandra Nath ◽  
Shiv G. Kapoor
Keyword(s):  
Flow Characteristics ◽  
Fluid Film ◽  
Cutting Fluid ◽  
Spray Parameters ◽  
Film Model ◽  
Thin Fluid ◽  
Spray System ◽  
Thin Fluid Film ◽  
Film Development ◽  
Cooling And Lubrication

The atomization–based cutting fluid (ACF) spray system has recently been proposed as a cooling and lubrication solution for machining hard to machine materials (e.g. titanium alloys). On the tool rake face, the ACF spray system forms a thin film from cutting fluid that penetrates into the tool–chip interface to improve tool life. The objective of this work is to characterize this thin fluid film in terms of thickness and velocity for sets of ACF spray parameters. ACF spray experiments are performed by varying impingement angle in order to observe the nature of the spreading film, and to determine the film thickness at different locations after impingement of the droplets. It is observed that the film spreads radially outward producing three fluid film development zones (i.e. impingement, steady, unsteady). The steady zone is found to be between 3 and 7 mm from the focus (impingement point) of the ACF spray for the set of parameters investigated. An analytical 3D thin fluid film model for the ACF spray system has also been developed based on the equations for continuity of mass and momentum. The model requires a unique treatment of the cross–film velocity profile, droplet impingement and pressure distributions, as well as a strong gas–liquid shear interaction. The thickness profiles predicted by the analytical film model have been validated. Moreover, the model predictions of film velocity and chip flow characteristics during a titanium turning experiment reveal that the fluid film can easily penetrate into the entire tool–chip interface with the use of the ACF spray system.

Characterization of Fluid Film Produced by an Atomization-Based Cutting Fluid Spray System During Machining

2013 ◽  
Vol 135 (5) ◽  
Author(s):  
Alexander C. Hoyne ◽  
Chandra Nath ◽  
Shiv G. Kapoor
Keyword(s):  
Stokes Equations ◽  
Flow Characteristics ◽  
Fluid Film ◽  
Cutting Fluid ◽  
Spray Parameters ◽  
Film Model ◽  
Thin Fluid ◽  
Spray System ◽  
Thin Fluid Film ◽  
Cooling And Lubrication

The atomization-based cutting fluid (ACF) spray system has recently been proposed as a cooling and lubrication solution for machining hard to machine materials (e.g., titanium alloys). On the tool rake face, the ACF spray system forms a thin film from cutting fluid that penetrates into the tool–chip interface to improve tool life. The objective of this work is to characterize this thin fluid film in terms of thickness and velocity for a set of ACF spray parameters. ACF spray experiments are performed by varying impingement angle to observe the nature of the spreading film and to determine the film thickness at different locations after impingement of the droplets. It is observed that the film spreads radially outward producing three fluid film development zones (i.e., impingement, steady, and unsteady). The steady zone is found to be between 3 and 7 mm from the focus (impingement point) of the ACF spray for the set of parameters investigated. An analytical 3D thin fluid film model for the ACF spray system has also been developed based on the Navier–Stokes equations for mass and momentum. The model requires a unique treatment of the cross-film velocity profile, droplet impingement, and pressure distributions, as well as a strong gas–liquid shear interaction. The thickness profiles predicted by the analytical film model have been validated. Moreover, the model predictions of film velocity and chip flow characteristics during a titanium turning experiment reveal that the fluid film can easily penetrate into the entire tool–chip interface with the use of the ACF spray system.

A Thermal Model to Predict Tool Temperature in Machining of Ti-6Al-4V Alloy With an Atomization-Based Cutting Fluid Spray System

2016 ◽  
Author(s):  
Asif Tanveer ◽  
Deepak Marla ◽  
Shiv G. Kapoor
Keyword(s):  
Heat Transfer ◽  
Interaction Model ◽  
Spray Cooling ◽  
Droplet Surface ◽  
Cutting Fluid ◽  
Design Parameters ◽  
Transfer Model ◽  
Tool Temperature ◽  
Spray System ◽  
Heat Transfer Phenomenon

In this study a heat transfer model of machining of Ti-6Al-4V under the application of atomization-based cutting fluid spray coolant is developed to predict the temperature of the cutting tool. Owing to high tool temperature involved in machining of Ti-6Al-4V, the model considers film boiling as the major heat transfer phenomenon. In addition, the design parameters of the spray for effective cooling during machining are derived based on droplet-surface interaction model. Machining experiments are conducted and the temperatures are recorded using the inserted thermocouple technique. The experimental data are compared with the model predictions. The temperature field obtained is comparable to the experimental results, confirming that the model predicts tool temperature during machining with ACF spray cooling satisfactorily.

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 Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771061 ◽  
Author(s):  
Duc Tran Minh ◽  
Long Tran The ◽  
Ngoc Tran Bao
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Minimum Quantity Lubrication ◽  
High Hardness ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Hard Milling ◽  
Minimum Quantity ◽  
Coated Carbide ◽  
Lubrication Conditions

In this article, an attempt has been made to explore the potential performance of Al2O3 nanoparticle–based cutting fluid in hard milling of hardened 60Si2Mn steel (50-52 HRC) under different minimum quantity lubrication conditions. The comparison of hard milling under minimum quantity lubrication conditions is done between pure cutting fluids and nanofluids (in terms of surface roughness, cutting force, tool wear, and tool life). Hard milling under minimum quantity lubrication conditions with nanofluid Al2O3 of 0.5% volume has shown superior results. The improvement in tool life almost 177%–230% (depending on the type of nanofluid) and the reduction in surface roughness and cutting forces almost 35%–60% have been observed under minimum quantity lubrication with Al2O3 nanofluids due to better tribological behavior as well as cooling and lubricating effects. The most outstanding result is that the uncoated cemented carbide insert can be effectively used in machining high-hardness steels (>50 HRC) while maintaining long tool life and good surface integrity (Ra = 0.08–0.35 µm; Rz = 0.5–2.0 µm, equivalent to finish grinding) rather than using the costlier tools like coated carbide, ceramic, and (P)CBN. Therefore, using hard nanoparticle–reinforced cutting fluid under minimum quantity lubrication conditions in practical manufacturing becomes very promising.

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.

Effect on tool life by addition of nanoparticles with the cutting fluid

2020 ◽  
Vol 33 ◽  
pp. 2940-2954
Author(s):  
C. Sabarinathan ◽  
N. Manikandan ◽  
V.P Sureshkumar ◽  
S. Siva Murugan ◽  
G. Rathis
Keyword(s):  
Tool Life ◽  
Cutting Fluid

TRIBOLOGICAL PROPERTIES OF Al2O3 + TiO2 COATINGS MANUFACTURED BY PLASMA SPRAYING

Tribologia ◽  
2019 ◽  
Vol 283 (1) ◽  
pp. 19-24 ◽  
Author(s):  
Leszek ŁATKA ◽  
Aneta NIEMIEC ◽  
Monika MICHALAK ◽  
Paweł SOKOŁOWSKI
Keyword(s):  
Plasma Spraying ◽  
Dry Friction ◽  
Plasma Torch ◽  
Spray Parameters ◽  
Good Adhesion ◽  
Spray Distance ◽  
Compact Structure ◽  
Tio2 Coatings ◽  
Made In ◽  
Ball On Disc

In the paper the results of tribological, microscopic, and mechanical research of Al2O3 + TiO2 coatings manufactured by plasma spraying are presented. The feeding material was a powder Al2O3 + 13 wt.% TiO2 (Metco 6221, OerlikonMetco) with grain size – 45 ± 15 μm. The cylinder substrates made from stainless steel (X5CrNi18-10) had a diameter equal to 25 mm and 2 mm of thickness. The variable spray parameters were plasma torch velocity in terms of substrate and spray distance. The morphology of obtained coatings was tested by scanning electron microscope (SEM), and the microstructure was investigated by light optical microscopy (LOM) and SEM. The results of mechanical properties examinations revealed the dependence of the microhardness and fracture toughness on the spray parameters. Tribological examinations were made in the ball-on-disc mode in technical dry friction conditions. Two loads were used, 5 N and 10 N. Based on the carried out tests, it could be concluded that a shorter spray distance and a reduction of the torch velocity allows one to achieve a more compact structure, which is characterized by good adhesion at the coating-substrate interface (in range from 11 to 14 MPa) and good wear resistance.

Technological Investigation of Effect of Machining Parameter on Tool Life

2020 ◽  
Vol 22 (4) ◽  
pp. 41-53
Author(s):  
Manojkumar Sheladiya ◽  
◽  
Shailee Acharya ◽  
Ghanshyam Acharya ◽  
◽  
...  
Keyword(s):  
Surface Roughness ◽  
Mild Steel ◽  
Tool Life ◽  
Flank Wear ◽  
Cutting Speed ◽  
Numerical Control ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Time ◽  
Machining Parameter

Introduction. The machinability is typical criteria to be investigated and different authors suggested different parameters describing its quantification. Different parameters i. e. speed, feed, depth of cut, tool work-piece combination, machine types and its condition, cutting fluid, machinist expertise, etc. are contributing directly to the tool life. The selection of the tool for the machining impacts greatly on the economic viability of the machining in terms of energy usage and tooling costs. The method of investigation. The current research emphasis mainly on tool life investigation when machining the mild steel specimens ISRO 50, BIS 1732:1989 at constant cutting speed i.e. 200 m / min. In the industries the mild steel material is commonly used for various products manufacturing. Considering the high demands on productivity and surface finish, machining at 200 m / min is the preferred. The computerized numerical control machine (CNC DX-150) is used for the turning. The four corner insert (TNMG 120408) is used for different machining times i.e. 10, 15, 20 and 25 minutes respectively. The flank wear of the tool is measured with calibrated optical microscope. The temperature of the tool corner during machining is continuously measured for possible impact of temperature on bonding properties of the tool insert and impact on red hardness. Results and discussion. The plot of flank wear vs. machining time will give the value of tool life. The other quality output parameter, such as surface roughness, is measured after machining, indicating surface irregularities in root means square value. Efforts have been made to identify the relationship of tool life, machining time, the quantity of metal removed, surface roughness, and tool bit temperature.

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