Study of Cutting Forces and Surface Roughness in Milling of Carbon Fibre Composite (CFC) With Conventional and and Pressurized CO2 Cutting Fluids

2015 ◽  
Author(s):  
Aishah Najiah Dahnel ◽  
Christopher Kibbler ◽  
Stuart Barnes ◽  
Helen Ascroft
Keyword(s):  
Surface Roughness ◽  
Carbon Fibre ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Dry Milling ◽  
Carbon Fibre Composites ◽  
Cutting Speeds

Carbon Fibre Composites (CFC) are commonly used in aerospace, automotive and civil industries to manufacture high performance products which require high strength with low weight. They are usually produced to near net shape, however machining such as milling is frequently performed to achieve dimensional accuracy. This paper presents the effect of using conventional (water-based) and carbon dioxide (CO2) cutting fluids during milling of CFC on cutting forces, temperature and surface roughness in comparison to dry milling. Milling experiments were conducted using uncoated tungsten carbide milling routers at a constant feed rate and depth of cut of 0.025 mm/rev and 5 mm, respectively. Cutting speeds used were 100, 150 and 200 m/min. Cutting forces were measured using a dynamometer, temperatures during milling were measured at the workpiece by thermocouples and surface roughness (Ra) of the milled surfaces were measured using a surface profilometer. Milling with conventional and CO2 cutting fluids resulted in higher cutting forces than dry milling at all cutting speeds used. This was attributed to cooling of the CFC, which retained the strength of polymer matrix during machining. Cutting temperatures were the highest and reached beyond 100°C during dry milling. The use of conventional cutting fluid during milling provided significant cooling to the workpiece, in which cutting temperatures were maintained below 30°C at all cutting speeds used. Cooling the workpiece during milling with CO2 cutting fluid resulted in cutting temperatures within the range of 65–86°C. Even though the application of cutting fluids during milling generated higher cutting forces than dry milling, it produced favourable results in terms of surface finish. The use of cutting fluid during machining CFC is shown to be highly effective in sustaining the strength of CFC materials as a result of low cutting temperature.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

scholarly journals Experimental Investigation on Properties and Machining Performance of CNT Suspended Vegetable oil Nanofluids

2018 ◽  
Vol 15 (4) ◽  
pp. 5957-5975
Author(s):  
P. V. Krishna ◽  
R. R. Srikant ◽  
N. Parimala
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Microbial Contamination ◽  
Cutting Temperature ◽  
Coconut Oil ◽  
Minimum Quantity Lubrication ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Performance

This work is motivated by environmentally conscious machining and focus on the basic properties and applicability of nano cutting fluids in machining. Cutting fluids are formulated by dispersing carbon nanotubes (CNT) in coconut oil (CC) with varying percentage of nanoparticle inclusions (NPI). The properties such as density, heat transfer coefficient, dynamic viscosity and thermal conductivity are determined before their application. The formulated nanofluids are applied during machining through minimum quantity lubrication (MQL) technique. Microbial contamination and biodegradability tests are conducted to assess the quality of nanocutting fluids. Viscosity is found to decrease with increase in temperature where, as specific heat slightly decreased with an increase in NPI for CNT dispersed fluids. It is observed that nanofluids in MQL upshot in the reduction of cutting force, cutting temperature, tool wear and surface roughness. CNT dispersed cutting fluids at 0.5% NPI and speed of 60 m/min, 0.131 mm/rev feed and 0.5 mm depth of cut (DOC) shown better performance in the selected range of parameters. Machining performance is more influenced by the percentage of nanoparticles and then the depth of cut, speed and feed respectively. For the cutting conditions, the influence of DOC in obtaining minimum cutting forces and reducing cutting temperatures is found to be 85% and 45% respectively for nBA dispersed fluids. The extent of influence of %NPI is found to be 35.19% for CNT dispersed fluids to obtain reduced cutting forces, cutting temperatures, tool wear and surface roughness according to GRA analysis. Microbial contamination is observed to be the least for 0.5% NPI dispersed fluids. It is also identified that nano cutting fluids used in this work are biodegradable and biologically treatable for disposal as well.

Experimental investigation of cutting temperature and surface roughness for different cutting fluids during turning of Duplex stainless steel-2205 under minimum quantity lubrication technique

2021 ◽  
Vol 15 (2) ◽  
pp. 8042-8056
Author(s):  
Prashantha Kumar S T ◽  
Thirtha Prasada HP
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Deionized Water ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Minimum Quantity

Duplex stainless steel (DSS)-2205 comes under hard to machine material owing to its inherent properties but more applications in severe working conditions hence, selection of turning process parameters and suitable cutting fluids of DSS-2205 is essential. In the present work, investigate the performance of Deionized water, neat cut oil, and emulsified fluid on cutting temperature and surface roughness during turning of duplex stainless steel-2205 under minimum quantity lubrication technique. Based on a face-centered composite design, 20 experiments were conducted with varying speed, feed, and depth of cut in three levels for three different fluids. Analysis of variance (ANOVA) is used to identify significant parameters that affect the response. Numerical optimization was carried out under Desirability Function Analysis (DFA) for cutting temperature during deionized water cutting fluid for surface roughness during emulsified cutting fluid. Depth of cut is the significant factor for cutting temperature contribution is 74.83% during Deionized water as a fluid, and feed is the significant factor for surface roughness contribution is 93.57% during emulsified fluid. The optimum cutting parameters were determined for speed (50m/min), feed (0.051mm/rev) and depth of cut (0.4mm). Experimental results revealed that Deionized water gives better results for reduced the cutting temperature and emulsified fluid for surface roughness reduction.

Cutting Performance of Fiber Laser Textured Tools in Face Milling of Titanium Alloys

2017 ◽  
Vol 1142 ◽  
pp. 250-253
Author(s):  
Ze WU ◽  
You Qiang Xing ◽  
Peng Huang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloys ◽  
Fiber Laser ◽  
Cutting Forces ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Face Milling ◽  
Laser Machining ◽  
Dry Milling ◽  
Temperature Surface

Textured self-lubricating tools were fabricated by fiber laser machining. Dry milling of titanium alloys was carried out with these textured tools and conventional one for comparison. The cutting forces, cutting temperature, surface roughness of processed workpiece and tool flank wear were measured. Results show that the textured tools can reduce the cutting forces, cutting temperature and surface roughness of workpiece, as a result, present superior wear-resistance compared to the untextured tool.

scholarly journals Performance evaluation of rubber seed oil based cutting fluid in turning mild steel

2021 ◽  
Vol 40 (4) ◽  
pp. 648-659
Author(s):  
A.O. Osayi ◽  
S.A. Lawal ◽  
M.B. Ndaliman ◽  
J.B. Agboola
Keyword(s):  
Surface Roughness ◽  
Seed Oil ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Mineral Oil ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Rubber Seed Oil ◽  
Water Emulsion ◽  
Rubber Seed

Due to the negative effects associated with the wide use of mineral oil, the desire for eco-friendly cutting fluids as alternative to mineral oil has become a global issue. In this study, rubber seed oil was used to formulate oil-in-water emulsion cutting fluid. Full factorial design was used for the formulation of the oil-in-water emulsion cutting fluid. The optimal process parameters obtained were used for the formulation of the novel cutting fluid and the cutting fluid was characterised. The characteristics of the formulated cutting fluid shows viscosity of 4.25 mm2/s, pH value of 8.3, high stability and corrosion resistant. Box-Behnken design was used for the turning operation and the performance of the rubber seed oil cutting fluid was compared with mineral oil. The input parameters were cutting speed, feed rate and depth of cut, while the responses were surface roughness and cutting temperature. Coated carbide insert was used as cutting tool. The ANOVA results show that the feed rate had the most significant effect on the surface roughness and cutting temperature followed by the cutting speed and depth of cut during the turning process. It was observed that the rubber seed oil based cutting fluid reduced surface roughness and cutting temperature by 9.79% and 1.66% respectively and therefore, it can be concluded that the rubber seed oil based cutting fluid performed better than the mineral oil in turning of mild steel.

An Experimental Evaluation of an Atomization-Based Cutting Fluid Application System for Micromachining

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Martin B. G. Jun ◽  
Suhas S. Joshi ◽  
Richard E. DeVor ◽  
Shiv G. Kapoor
Keyword(s):  
Cutting Forces ◽  
End Milling ◽  
Cutting Temperature ◽  
Lower Surface ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Droplet Impingement ◽  
Application System ◽  
Fluid Properties ◽  
Micro End Milling

An atomization-based cutting fluid application system is developed for micro-end milling. The system was designed to ensure spreading of the droplets on the workpiece surface based on the analysis of the atomized droplet impingement dynamics. The results of the initial experiments conducted to examine the viability of the system show that the cutting forces are lower and tool life is significantly improved with the atomized cutting fluids when compared to dry and flood cooling methods. Also, application of atomized cutting fluid is found to result in good chip evacuation and lower cutting temperature. Experiments were also conducted to study the effect of fluid properties on cutting performance, and the results show that cutting fluids with lower surface tension and higher viscosity perform better in terms of cutting forces.

Effects of Cutting Fluids on Surface Roughness in Single-Point Diamond Turning of Rapidly Solidified Aluminium (RSA 431)

2020 ◽  
Vol 853 ◽  
pp. 18-23
Author(s):  
F.A Oyekunle ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Rapidly Solidified

Single-point diamond turning is a technique of ultra-high precision machining that provides excellent quality of surface for mirrors, spherical and aspherical components. In SPDT just like other machining processes, cutting fluid plays an important role in metal removal and tool condition which largely influence the surface of diamond turned surface. In this paper, the surface roughness of diamond turned RSA 431 was studied by investigating the effect of kerosene mist and water as cutting fluids. Higher order response surface of Box-Behnken design was generated using fewer runs than a normal factorial technique. The cutting parameters that were varied for both experiments were depth of cut, feed and, speed. Taylor Hobson PGI Dimension XL surface Profilometer was used to measure the surface roughness after each experimental run. The results show that water when used as cutting fluid during machining, produces better surface roughness than kerosene mist. Predictive models for surface roughness were developed for each experiment. Values from the Mean Absolute Percent Error (MAPE) was used to evaluate and compare the two models to determine the accuracy. RSM also proved to be a better methodology of predicting surface roughness.

Cutting Forces and Tool Wear in Dry Milling of Ti6Al4V

2012 ◽  
Vol 565 ◽  
pp. 454-459 ◽  
Author(s):  
Yun Chen ◽  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Milling ◽  
Workpiece Material ◽  
Tool Wear Mechanism ◽  
Coated Carbide ◽  
Carbide Inserts ◽  
Cutting Speeds

Titanium alloys are difficult-to-cut materials. This paper presents an experimental study of the effects of different cutting conditions and tool wear on cutting forces in dry milling Ti6Al4V with coated carbide inserts. The experimental results show that the peak forces increase with the increase in the feed rate and depth of cut. With the cutting speed increment in the range from 50 m/min to 150 m/min the peak forces decrease, while at further higher cutting speeds investigated peak forces increase. The decrease of the peak forces is due to thermal softening of the workpiece material and the increase is because of the strain hardening rate of Ti6Al4V. The tool wear experiment reveals that the major tool wear mechanism is the flank wear. The variations of the peak forces are caused by both the tool wear propagation and the thermal effects.

scholarly journals Experimental Investigation of Nano Fluid in Machining Process to Enhance the Performance

2021 ◽  
Vol 9 (VII) ◽  
pp. 1940-1944
Author(s):  
Gaurav Tandekar
Keyword(s):  
Surface Roughness ◽  
Sodium Dodecyl ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machining Process ◽  
Nano Particles ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Nano Fluid ◽  
Machining Parameter

The surface roughness is paying a very dominant role in manufacturing industries. It is one of the parameters that cannot be avoided in machining process. Investigation was done on turning titanium alloy grade 2 with uncoated carbide insert in a CNC lathe. During machining on titanium, the high cutting temperature found, because of that friction in tool causes, for that purpose we are carry more cutting fluid, cutting tool & actual machining parameter. The present work shows the concentration of multi-walled carbon nanotube (MWCNT) & Graphene nano-particles are in used. The Nano fluid is prepared by using various ratios of nano-particles (MWCNT & Graphene), rice bran oil and blended oil as a base fluid. sodium dodecyl benzene sulfonate (SDBS) Surfactant added in cutting-fluid to provide better lubricant properties. The statistical planning of the experiment is done by using Taguchi method. The process parameters considered in the study are cutting speed, feed rate, depth of cut and surface roughness is considered as a response parameter.

scholarly journals Experimental investigations of vibration and acoustics signals in milling process using kapok oil as cutting fluid

2020 ◽  
Vol 21 (5) ◽  
pp. 521
Author(s):  
Subramaniam Shankar ◽  
Murugasamy Manikandan ◽  
Gunasekaran Raja ◽  
Alokesh Pramanik
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Feed Rate ◽  
Sound Pressure ◽  
Flank Wear ◽  
Milling Process ◽  
Cutting Fluid ◽  
Experimental Investigations ◽  
Depth Of Cut ◽  
Cutting Fluids

Vegetable oils are found as the feasible alternative for conventional minerals oils. There has been many environmental and health issues which are spotted with the use of conventional cutting fluids. There has been a great demand for developing new environmentally friendly vegetable based cutting fluids to reduce these harmful effects. In this present study, vegetable based kapok oil is used as a cutting fluid during milling to study its consequences over other conventional oils. The process parameters such as spindle speed, depth of cut and feed rate were optimized with respect to the flank wear (Vb) and surface roughness (Ra) respectively with the use of central composite design in response surface methodology (RSM). Further an attempt has been made to monitor the tool condition by measuring the cutting force, vibration and sound pressure simultaneously. Three different tool conditions such as dull, fresh and working were analyzed and their consequences were also reported. Also, the performance of the kapok oil is compared with the palm oil and mineral oil (SAE 20W 40). The feed rate has the major contribution for surface roughness and flank wear. It is found that the cutting force (F), sound pressure (p) and vibration (V) increases with the tool wear.

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