Development of a virtual sensor for the comparison of heat partitions in milling under cryogenic cooling lubrication and high-pressure cutting fluid supply

AbstractHigh-pressure cutting fluid supply is a proven technology for chip breaking when turning difficult-to-cut materials, such as Inconel 718. However, the technology is usually not suitable for the finish turning of safety-critical parts in aero engines. The acting force of the cutting fluid jet on the back of the chip causes chip breaking. The broken chips are then accelerated by the cutting fluid jet towards the workpiece surfaces where they cause damage on impact. One approach to minimize surface damage is a specific increase in the chip length. The center of gravity of the chips with an adjusted length is shifted out of the focus where the cutting fluid jet hits the chips. Hence, the already finished surface is subjected to fewer impacts of the chips. In this study, the adjustment of the chip length by pulsating high-pressure cutting fluid supply to prevent surface damage was investigated. A valve unit was used to generate two alternating cutting fluid supply pressure levels in certain time intervals. During the low-pressure stage, the force of the cutting fluid jet does not lead to chip breakage and the chip length increases until the valves switch and the high-pressure stage is released. The focus of this work was the analysis of the relationship between the duration of the low-pressure and high-pressure time intervals and the chip length. Additionally, the influence of the depth of cut, the feed, and the cutting speed on the chip length during pulsating high-pressure cutting fluid supply was investigated. Finally, a case study was carried out to evaluate the effectiveness of the pulsating high-pressure cutting fluid supply technology. Therefore, the shoulder surface of a demonstrator part was finished by face turning. Following, the cylindrical surface was finished with a continuous and pulsating high-pressure cutting fluid supply with varied supply parameters. Microscopic analyses of the surface prove that the pulsating high-pressure cutting fluid supply prevents the surface from being damaged by the impacts of chips.

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Robust and accurate prediction of thermal error of machining centers under operations with cutting fluid supply

CIRP Annals ◽

10.1016/j.cirp.2021.04.074 ◽

2021 ◽

Author(s):

Toru Kizaki ◽

Shinji Tsujimura ◽

Yuya Marukawa ◽

Shigeo Morimoto ◽

Hisashi Kobayashi

Keyword(s):

Thermal Error ◽

Accurate Prediction ◽

Cutting Fluid ◽

Fluid Supply

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Energy Efficient Cutting Fluid Supply: The Impact of Nozzle Design

Procedia CIRP ◽

10.1016/j.procir.2016.11.192 ◽

2017 ◽

Vol 61 ◽

pp. 564-569 ◽

Cited By ~ 3

Author(s):

Nadine Madanchi ◽

Marius Winter ◽

Sebastian Thiede ◽

Christoph Herrmann

Keyword(s):

Energy Efficient ◽

Cutting Fluid ◽

Nozzle Design ◽

Fluid Supply ◽

The Impact

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A Novel Experimental Test Bench to Investigate the Effects of Cutting Fluids on the Frictional Conditions in Metal Cutting

Journal of Manufacturing and Materials Processing ◽

10.3390/jmmp4020045 ◽

2020 ◽

Vol 4 (2) ◽

pp. 45 ◽

Cited By ~ 1

Author(s):

Thomas Lakner ◽

Marvin Hardt

Keyword(s):

Experimental Test ◽

Metal Cutting ◽

Test Bench ◽

Cutting Fluid ◽

Cutting Fluids ◽

Machining Processes ◽

Workpiece Material ◽

Fluid Supply ◽

Frictional Forces ◽

Experimental Test Bench

The tribological effect of cutting fluids in the machining processes to reduce the friction in the cutting zone is still widely unknown. Most test benches and procedures do not represent the contact conditions of machining processes adequately, especially for interrupted contacts. This results in a lack of knowledge of the tribological behavior in machining processes. To close this knowledge gap, a novel experimental test bench to investigate the effects of cutting fluids on the frictional conditions in metal cutting under high-pressure cutting fluid supply was developed and utilized within this work. The results show that there is a difference between the frictional forces in interrupted contact compared to continuous contact. Furthermore, the cutting fluid parameters of supply pressure, volumetric flow rate, and impact point of the cutting fluid jet influence the frictional forces, the intensities of which depend on the workpiece material. In conclusion, the novel test bench allows examining the frictional behavior in interrupted cuts with an unprecedented precision, which contributes to a knowledge-based design of the cutting fluid supply for cutting tools.

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Progressing towards Sustainable Machining of Steels: A Detailed Review

Materials ◽

10.3390/ma14185162 ◽

2021 ◽

Vol 14 (18) ◽

pp. 5162

Author(s):

Kashif Ishfaq ◽

Irfan Anjum ◽

Catalin Iulian Pruncu ◽

Muhammad Amjad ◽

M. Saravana Kumar ◽

...

Keyword(s):

Skin Diseases ◽

Cryogenic Treatment ◽

Sustainable Manufacturing ◽

Health And Safety ◽

Minimum Quantity Lubrication ◽

Solid Lubricants ◽

Cryogenic Cooling ◽

Cutting Fluid ◽

Dry Cutting ◽

Sustainable Machining

Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

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