Investigation on Cutting Force Reduction of Eco-friendly Cutting Fluids with Castor Oil and Additives in Broaching

2021 ◽  
Author(s):  
Lihua He ◽  
Jinlei Shi ◽  
Jing Ni ◽  
Kai Feng
Keyword(s):  
Cutting Force ◽  
Castor Oil ◽  
Cutting Fluids ◽  
Force Reduction

Design, Development and Performance Evaluation of Bio-Degradable Nano Cutting Fluid

2018 ◽  
Vol 24 (8) ◽  
pp. 5485-5489
Author(s):  
C Venkatesh ◽  
S Balasubramani ◽  
R. Boopathy Pradeep
Keyword(s):  
Cutting Force ◽  
Castor Oil ◽  
Metal Cutting ◽  
Experimental Studies ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Design Development ◽  
Nano Fluid ◽  
Machining Properties

Various cutting fluids are available in cutting fluid market to provide good machining performances for metal cutting industries. Incidentally, most of the cutting fluids are synthetic and semi synthetic in nature, though they are beneficial to the industries but they are posing health and environmental issues. Even if these cutting fluids have the sufficient properties required for good machining, the major constraints associated with these fluids are their nature of non-biodegradability and non-friendliness to the environment. To overcome these difficulties, intense research is carried out to develop the biodegradable and effective cutting fluid. In this research, a novel castor oil based cutting fluid infused with nano molybdenum (MoS2) particles has been developed and its various machining properties have been investigated. Various important cutting parameters like surface roughness, tool life, cutting force were investigated using this newly developed biodegradable nano fluid as a cutting fluid. Comparative experimental studies have also been done with sunflower oil blend and conventional synthetic oil. Observed results validated that the newly developed castor oil based nano fluid improves the surface finish, too life by minimizing the cutting force developed to the considerable extent.

Development and Performance Evaluation of Bio-Degradable Nanocutting Fluid

2018 ◽  
Vol 18 (06) ◽  
pp. 1850036
Author(s):  
C. Venkatesh ◽  
J. Baskaran
Keyword(s):  
Cutting Force ◽  
Tool Life ◽  
Castor Oil ◽  
Metal Cutting ◽  
Experimental Studies ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Oil Blend ◽  
Machining Properties

Various cutting fluids are available in the cutting fluid market to provide good machining performances for metal cutting industries. Incidentally, most of the cutting fluids are synthetic and semisynthetic in nature, and although they are beneficial to the industries, they are posing health and environmental issues. Even if these cutting fluids have sufficient properties required for good machining, the major constraints associated with these fluids are their nature of nonbiodegradability and nonfriendliness to the environment. To overcome these difficulties, intense research is carried out to develop biodegradable and effective cutting fluids. In this research, a novel castor oil-based cutting fluid infused with nanomolybdenum (MoS2) particles has been developed and its various machining properties have been investigated. Various important cutting parameters like surface roughness, tool life, and cutting force were investigated using this newly developed biodegradable nanofluid as a cutting fluid. Comparative experimental studies have also been undertaken with sunflower oil blend and conventional synthetic oil. Observed results validated that the newly developed castor oil-based nanofluid improves the surface finish and tool life by minimizing the cutting force developed to the considerable extent.

Studying the lubricity of new eco-friendly cutting oil formulation in metal working fluid

2018 ◽  
Vol 70 (9) ◽  
pp. 1569-1579 ◽  
Author(s):  
M.R. Noor El-Din ◽  
Marwa R. Mishrif ◽  
Satish V. Kailas ◽  
Suvin P.S. ◽  
Jagadeesh K. Mannekote
Keyword(s):  
Surface Morphology ◽  
Corrosion Inhibitor ◽  
Castor Oil ◽  
Cutting Fluid ◽  
Working Fluid ◽  
Cutting Fluids ◽  
Metal Working ◽  
Content Type ◽  
Metalworking Fluid ◽  
3D Profilometer

PurposeThis paper aims to formulate a new metal working fluid (MWF) composition including some eco-friendly emulsifiers, corrosion inhibitor, biocide, and non- edible vegetable oil (castor oil) as the base oil. To achieve this aim, five MWFs with different hydrophilic–lipophilic balance (HLB) value as 10, 9.5, 9, 8.5 and 8 were prepared to identify the optimum HLB value that gives a highly stable oil-in-water emulsion. The performance of castor oil based MWF was evaluated using tool chip tribometer and drill dynamometer. The surface morphology of steel disc and friction pin was performed using scanning electron microscope (SEM) and 3D profilometer. The results revealed that the use of the prepared cutting fluid (E1) caused the cutting force to decrease from 500 N for dry high-speed steel sample to 280N, while the same value for a commercial cutting fluid (COM) was recorded as 340 N at drilling speed and cutting feed force as 1120 rpm and 4 mm/min., respectively.Design/methodology/approachA castor oil-based metalworking fluid was prepared using nonionic surfactants. The composition of the metalworking fluid was further optimized by adding performance-enhancing additives. The performance of castor oil based MWF was analyzed using Tool chip tribometer and Drill dynamometer. The surface morphology of steel ball and a disc was done using 3D profilometer and SEM.FindingsStudies revealed that castor oil-based MWF having Monoethanolamine (MEA) as corrosion inhibitor was found to be highly stable. The drilling dynamometer and tool chip tribometer studies showed that castor oil-based MWF performance was comparable to that of commercial MWF.Research limitations/implicationsThis study aims to explore the performance of the castor oil based metalworking fluid (MWF) using tool chip tribometer and drill dynamometer.Practical implicationsThe conventional MWFs are petroleum derives and are unsustainable. Use of non-edible plant-based oils for preparing the MWF will not only be conserved environment but also add value addition to agricultural crops.Social implicationsThe social Implications is aiming to decrease the environmental impact that results from the using of mineral cutting fluids.Originality/valueThe originality of this work is to replace the mineral oil and synthetic oil based cutting fluids with more eco-friendly alternatives one. In addition, the investigation will focus on developing functional additives required for cutting fluids which are environmentally benign.

scholarly journals Performance of Volcano-Like Laser Textured Cutting Tools: An Experimental and Simulative Investigation

Lubricants ◽  
2018 ◽  
Vol 6 (4) ◽  
pp. 98 ◽  
Author(s):  
Zhengyang Kang ◽  
Yonghong Fu ◽  
Xingyu Fu ◽  
Martin Jun
Keyword(s):  
Cutting Force ◽  
Cutting Tools ◽  
Surface Texturing ◽  
Temperature Fields ◽  
Small Scale ◽  
Rake Face ◽  
Forming Process ◽  
Force Reduction ◽  
And Performance ◽  
Distribution Of Stress

In recent years, surface texturing in micro-scale has been attempted on the surface of cutting tools for multiple purposes, e.g., cutting force reduction, prolonging life-span, anti-adhesion, etc. With respect to machinability and performance, micro-groove texture (MGT) has dominated in this field compared to other textured patterns. In this study, a novel volcano-like texture (VLT) was fabricated on the rake face of cemented carbide inserts (WC-Co, YG6) by fiber laser. The following cutting experiment tested the flat, MGT and VLT tools in turning aluminum alloy 6061. The effects of coolant and cutting conditions were investigated. In addition, a validated FEM model was employed to explore the distribution of stress and temperature fields in the tool-chip interface. The initial forming process of adhesion layer on rake face was investigated as well. The results indicated that lower cutting force and less adhesion can be achieved by small scale VLT. This study not only introduced VLT on cutting tools but also revealed its comprehensive performance.

Punching Force Reduction with Wave-Formed Tools

2007 ◽  
Vol 344 ◽  
pp. 209-216 ◽  
Author(s):  
Jussi A. Karjalainen ◽  
Kari Mäntyjärvi ◽  
Martti Juuso
Keyword(s):  
Cutting Force ◽  
Experimental Work ◽  
Tool Geometry ◽  
Material Strength ◽  
Test Results ◽  
Electro Discharge Machining ◽  
Lateral Forces ◽  
Circular Holes ◽  
Hole Geometry ◽  
Force Reduction

Flat-end tools are the most general types used in sheet metal punching and nibbling. They are geometrically simple and easy to sharpen but, on other hand, their cutting forces are relatively large, and hence the cutting process is frequently noisy. In order to reduce both cutting force and noise tools with one-way or two-way shearing have been utilised. The major drawbacks of these tools are the asymmetry of cutting easily causing non-circular holes with round tools, lateral forces with one-way shearing, excessive forming during cutting and more complex tool geometry to maintain. Here a new geometry for a punch is employed. The shearing edge is a sinus curve with several peaks making the cutting edge circularly symmetric and the phenomenon totally balanced. This means smaller forming forces, particularly in cases when also the radial form is concave. The geometry is without doubt more complex compared to the flat-end tool but rather easy to produce by multi-axis milling and electro-discharge machining. In the current work a set of experimental punches has been designed, manufactured and tested. A simple analytical theory for cutting force has also been derived and compared with the test results. The results show that the new geometry produces very precise hole geometry with a lower cutting force compared to conventional flat-end tools. Of course, more theoretical and experimental work is required to optimise the tool geometry including the tool clearance for each pair of material strength and thickness.

Correlation of Cutting Force and Power Consumption for Ultrasonic-Vibration-Assisted Cutting of Label Paper Stacks

2012 ◽  
Author(s):  
Karl-Robert Deibel ◽  
Jens Boos ◽  
Sascha Weikert ◽  
Konrad Wegener
Keyword(s):  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Quality Parameters ◽  
Cutting Edge ◽  
Pull Out ◽  
Edge Quality ◽  
Force Reduction ◽  
Cutting Speeds ◽  
Guillotine Cutting

Experiments comparing conventional and ultrasonic vibration assisted guillotine cutting of paper stacks have been performed on plain and aluminum coated label paper. It is shown that ultrasonic vibration assisted cutting reduces the cutting force for both paper species. Reduction of the cutting force allows the down holder force to be decreased and lowers the compression of the paper stack necessary to prevent pull-out of the top sheets of paper. Using a higher amplitude setting on the ultrasonic generator further decreases the cutting force for the paper stack. For three different cutting speeds, it is shown that ultrasonic vibration assisted cutting force reduction depends on the average speed of the tool for both paper species. A linear regression with present experimental data is done to obtain an equation for the relation between input generator power and resulting cutting force. Finally, the quality of the cutting edge is examined, quality parameters are defined, and according to these the cutting edge quality is assessed.

Performance evaluation method for cutting fluids using cutting force in micro-feed end milling

2020 ◽  
Vol 62 ◽  
pp. 232-243
Author(s):  
Tomohiko Kitamura ◽  
Ryutaro Tanaka ◽  
Yasuo Yamane ◽  
Katsuhiko Sekiya ◽  
Keiji Yamada
Keyword(s):  
Performance Evaluation ◽  
Cutting Force ◽  
Evaluation Method ◽  
End Milling ◽  
Cutting Fluids ◽  
Performance Evaluation Method

Machinability investigation and sustainability analysis of minimum quantity lubrication–assisted micro-milling process

2020 ◽  
Vol 234 (11) ◽  
pp. 1388-1401
Author(s):  
Xueming Yang ◽  
Xiang Cheng ◽  
Yang Li ◽  
Guangming Zheng ◽  
Rufeng Xu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Sustainability Assessment ◽  
Minimum Quantity Lubrication ◽  
Production Quality ◽  
Milling Process ◽  
Micro Milling ◽  
Cutting Fluids ◽  
Thin Wall ◽  
Minimum Quantity

Machining conditions such as cutting fluids exert a crucial function in micro-milling, which removes chips from the cutting area and lubricates the interface between the tool and workpiece. Therefore, it is necessary to identify suitable cutting fluids for processing different materials. In this article, the effects of cutting fluids (dry, flood cooling, minimum quantity lubrication, and jet cold air) on tool wear, surface roughness, and cutting force were studied. The Pugh matrix environmental approach was used to compare different cutting fluids in terms of sustainable production. In addition, a curved thin wall was processed to demonstrate the value of minimum quantity lubrication in industry. The experimental results illustrated that the minimum quantity lubrication can not only effectively reduce tool wear and cutting force but also improve the finished surface quality. According to the sustainability assessment results, minimum quantity lubrication was superior to other cutting fluids in terms of environmental impact and production quality. The curved thin wall size error was only 2.25% under minimum quantity lubrication condition. This indicated minimum quantity lubrication was particularly suitable for micro-milling of H59 brass and 6061 aluminum compared to other cutting fluids.

scholarly journals Assessment of water-based cutting fluids with green additives in broaching

Friction ◽  
2019 ◽  
Vol 8 (6) ◽  
pp. 1051-1062 ◽  
Author(s):  
Jing Ni ◽  
Kai Feng ◽  
Lihua He ◽  
Xiaofan Liu ◽  
Zhen Meng
Keyword(s):  
Castor Oil ◽  
Linear Alkylbenzene Sulfonate ◽  
Green Manufacturing ◽  
Cutting Edge ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Linear Alkylbenzene ◽  
Oil In Water ◽  
Water Based ◽  
Alkylbenzene Sulfonate

Abstract In order to improve the cutting performance in broaching, the lubrication and cleaning effects offered by water-based cutting fluids with green additives need to be studied from the viewpoint of green manufacturing. Therefore, water-based solutions with castor oil, surfactant (linear alkylbenzene sulfonate, LAS), and nanographite were prepared by ultrasonic agitation and sprayed into the zone of broaching via atomization. The performances of the cutting fluids, in terms of the viscosity, specific heat, wetting angle, and droplet size, were evaluated to discuss their effects on the broaching load. Among the fluids, the addition of LAS into oil-in-water (WO-S), where its cutting fluid with 10 wt.% castor oil and 1.5 wt.% surfactant, exhibited the lowest broaching force. With regard to the lubricating and cleaning mechanisms, WO-S has good wettability and permeability, and hence, can lubricate the cutting edge of the tool to decrease the cutting load, cool the cutting edge to keep it sturdy, and clean the surface of the cutting edge to keep it sharp. The results reveal that the simultaneous addition of castor oil and LAS had remarkable effects on the lubrication and cleaning, and resulted in a broaching load reduction of more than 10% compared to commercial cutting fluids. However, the addition of nanographite could not improve the lubrication owing to its agglomeration.

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