scholarly journals Nano-enhanced biolubricant in sustainable manufacturing: From processability to mechanisms

Friction ◽  
2022 ◽  
Author(s):  
Yanbin Zhang ◽  
Hao Nan Li ◽  
Changhe Li ◽  
Chuanzhen Huang ◽  
Hafiz Muhammad Ali ◽  
...  

AbstractTo eliminate the negative effect of traditional metal-working fluids and achieve sustainable manufacturing, the usage of nano-enhanced biolubricant (NEBL) is widely researched in minimum quantify lubrication (MQL) machining. It’s improved tool wear and surface integrity have been preliminarily verified by experimental studies. The previous review papers also concluded the major influencing factors of processability including nano-enhancer and lubricant types, NEBL concentration, micro droplet size, and so on. Nevertheless, the complex action of NEBL, from preparation, atomization, infiltration to heat transfer and anti-friction, is indistinct which limits preparation of process specifications and popularity in factories. Especially in the complex machining process, in-depth understanding is difficult and meaningful. To fill this gap, this paper concentrates on the comprehensive quantitative assessment of processability based on tribological, thermal, and machined surface quality aspects for NEBL application in turning, milling, and grinding. Then it attempts to answer mechanisms systematically considering multi-factor influence of molecular structure, physicochemical properties, concentration, and dispersion. Firstly, this paper reveals advanced lubrication and heat transfer mechanisms of NEBL by quantitative comparison with biolubricant-based MQL machining. Secondly, the distinctive filmformation, atomization, and infiltration mechanisms of NEBL, as distinguished from metal-working fluid, are clarified combining with its unique molecular structure and physical properties. Furtherly, the process optimization strategy is concluded based on the synergistic relationship analysis among process variables, physicochemical properties, machining mechanisms, and performance of NEBL. Finally, the future development directions are put forward aiming at current performance limitations of NEBL, which requires improvement on preparation and jet methods respects. This paper will help scientists deeply understand effective mechanism, formulate process specifications, and find future development trend of this technology.

Author(s):  
Berend Denkena ◽  
Alexander Krödel ◽  
Lars Ellersiek

AbstractMetal working fluids are used in machining processes of many hard-to-cut materials to increase tool life and productivity. Thereby, the metal working fluids act on the thermal and on the mechanical loads of the tool. The changing mechanical loads can mostly be attributed to the changing friction between rake face and chip and changes in the chip formation, e.g., the contact length between rake face and chip. However, analyzing those effects is challenging, since a detailed look at the chip formation process is prevented by the metal working fluid. In this paper, a novel planing test rig is presented, which enables high-speed recordings of the machining process and process force measurements while using metal working fluids. Experiments reveal that process forces are reduced with increasing pressure of the metal working fluid. However, the average friction coefficient only changes slightly, which indicates that the reduced process forces are mainly the result of reduced contact lengths between rake face and chip.


2010 ◽  
Vol 133 (3) ◽  
Author(s):  
Jay C. Rozzi ◽  
John K. Sanders ◽  
Weibo Chen

Cutting fluids have been used in machining processes for many years to decrease the temperature during machining by spraying the coolant into the machining zone directly on the cutting tool and the part. This has the effect of decreasing the tool temperature, which increases tool life and improves the part quality. These benefits come with significant drawbacks. Cutting fluids are environmentally unfriendly, costly, and potentially toxic. An alternative that has been evaluated in this paper is an internal cooling system (ICS) for lathe turning, which cools the cutting tool using a very small amount of an inert, cryogenic working fluid routed through a microchannel heat exchanger (MHX) that is mounted beneath the cutting tool insert. The working fluid absorbs the heat generated during the machining process after which it is harmlessly vented to the environment. This indirect cooling technique results in an environmentally friendly machining process that uses no cutting fluids, enables increased processing speed, and reduces manufacturing costs. An approximate heat transfer model was developed and used to predict the tool life as a function of the tool cooling approach for various speeds. Machining experiments were completed to validate the heat transfer model and confirm that the ICS can significantly improve tool life relative to conventional flood cooling. The validated model was then used to evaluate alternative cooling approaches using the ICS. It was found that the use of a cryogenic working fluid can significantly improve tool life at all cutting speeds but that the latent heat capacity of the working fluid should exceed the expected maximum heat transfer rate into the tool. This work established that the ICS approach is an effective means to increase tool life without the disadvantages associated with external cryogenic cooling methods.


Author(s):  
Benjamin Glasse ◽  
Udo Fritsching

Metal working fluid (MWF) emulsions are utilized as coolants and lubricants in machining processes like turning or drilling. During their operation life time cycle, MWFs change their properties due to impacting stresses which may influence the machining and tool performance. A frequent refreshing or renewal of MWFs in machining process is thus necessary. This investigation discusses measurement techniques of MWF emulsions to be used for MWF quality assessment and process monitoring. By means of optical spectroscopic measurement techniques (turbidimetry and laser diffraction), the evaluation of the temporal change of the wavelength exponent and the MWF emulsion droplet size is related to the MWF stability. The in-process monitoring of the MWFs in machining during several weeks of operation is shown. Thus, it will be demonstrated that optical spectroscopic measurement techniques may be applied to determine stability change of the emulsion system.


2020 ◽  
Vol 92 (3) ◽  
pp. 30901
Author(s):  
Suvanjan Bhattacharyya ◽  
Debraj Sarkar ◽  
Ulavathi Shettar Mahabaleshwar ◽  
Manoj K. Soni ◽  
M. Mohanraj

The current study experimentally investigates the heat transfer augmentation on the novel axial corrugated heat exchanger tube in which the spring tape is introduced. Air (Pr = 0.707) is used as a working fluid. In order to augment the thermohydraulic performance, a corrugated tube with inserts is offered. The experimental study is further extended by varying the important parameters like spring ratio (y = 1.5, 2.0, 2.5) and Reynolds number (Re = 10 000–52 000). The angular pitch between the two neighboring corrugations and the angle of the corrugation is kept constant through the experiments at β = 1200 and α = 600 respectively, while two different corrugations heights (h) are analyzed. While increasing the corrugation height and decreasing the spring ratio, the impact of the swirling effect improves the thermal performance of the system. The maximum thermal performance is obtained when the corrugation height is h = 0.2 and spring ratio y = 1.5. Eventually, correlations for predicting friction factor (f) and Nusselt number (Nu) are developed.


2001 ◽  
Author(s):  
K. Bartlett ◽  
J. Phipps ◽  
K. Kulhankova ◽  
P. Thorne
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