Effect of fluid concentration in titanium machining with an atomization-based cutting fluid (ACF) spray system

2013 ◽  
Vol 15 (4) ◽  
pp. 419-425 ◽  
Author(s):  
Chandra Nath ◽  
Shiv G. Kapoor ◽  
Anil K. Srivastava ◽  
Jon Iverson
Keyword(s):  
Cutting Fluid ◽  
Spray System ◽  
Titanium Machining ◽  
Fluid Concentration

On Cutting Temperature Measurement During Titanium Machining With an Atomization-Based Cutting Fluid Spray System

2015 ◽  
Vol 137 (2) ◽  
Author(s):  
Alexander C. Hoyne ◽  
Chandra Nath ◽  
Shiv G. Kapoor
Keyword(s):  
Cutting Temperature ◽  
Cutting Fluid ◽  
Dry Machining ◽  
Temperature Level ◽  
Spray System ◽  
Titanium Machining ◽  
Dry Conditions ◽  
System Temperature ◽  
Cutting Zone ◽  
Fluid Penetration

The poor thermal conductivity and low elongation-to-break ratio of titanium lead to the development of extreme temperatures (in excess of 550 °C) localized in the tool–chip interface during machining of its alloys. At such temperature level, titanium becomes highly reactive with most tool materials resulting in accelerated tool wear. The atomization-based cutting fluid (ACF) spray system has recently been demonstrated to improve tool life in titanium machining due to good cutting fluid penetration causing the temperature to be reduced in the cutting zone. In this study, the cutting temperatures are measured both by inserting thermocouples at various locations of the tool–chip interface and the tool–work thermocouple technique. Cutting temperatures for dry machining and machining with flood cooling are also characterized for comparison with the ACF spray system temperature data. Findings reveal that the ACF spray system more effectively reduces cutting temperatures over flood cooling and dry conditions. The tool–chip friction coefficient indicates that the fluid film created by the ACF spray system also actively penetrates the tool–chip interface to enhance lubrication during titanium machining.

Cutting Temperature Measurement During Titanium Machining With an Atomization–Based Cutting Fluid (ACF) Spray System

2013 ◽  
Author(s):  
Alexander C. Hoyne ◽  
Chandra Nath ◽  
Shiv G. Kapoor
Keyword(s):  
Temperature Gradient ◽  
Cutting Temperature ◽  
Cutting Fluid ◽  
Extreme Temperatures ◽  
Dry Machining ◽  
Lubrication Mechanism ◽  
Spray System ◽  
Titanium Machining ◽  
System Temperature ◽  
Cooling And Lubrication

The poor thermal conductivity and low elongation–to–break ratio of titanium lead to the development of extreme temperatures localized in the tool–chip interface during machining of its alloys and cause accelerated tool wear. The atomization–based cutting fluid (ACF) spray system has recently been demonstrated to improve tool life in titanium machining. In order to understand the cooling and lubrication mechanism of the ACF spray system, it is important to determine the temperature gradient developed inside the entire tool–chip interface. The objective of this work is to measure the cutting temperatures at various locations inside the tool–chip interface during titanium machining with the ACF spray system. The temperature gradient and mean cutting temperature are measured using the inserted and the tool–work thermocouple techniques, respectively. Cutting temperatures for dry machining and machining with flood cooling are also characterized for comparison with the ACF spray system temperature data. Findings reveal that the ACF spray system more effectively reduces cutting temperatures over flood cooling. The tool–chip friction coefficient data indicate that the fluid film created by the ACF spray system also actively penetrates the tool–chip interface to enhance lubrication during titanium machining, especially as the tool wears.

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.

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.

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.

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.

Design and evaluation of an atomization-based cutting fluid spray system in turning of titanium alloy

2012 ◽  
Vol 14 (4) ◽  
pp. 452-459 ◽  
Author(s):  
Chandra Nath ◽  
Shiv G. Kapoor ◽  
Richard E. DeVor ◽  
Anil K. Srivastava ◽  
Jon Iverson
Keyword(s):  
Titanium Alloy ◽  
Cutting Fluid ◽  
Spray System

The Influence of Cutting Fluid Concentration on Surface Integrity of VP80 Steel and the Influence of Cutting Fluid Flow Rate on Surface Roughness of VPATLAS Steel After Grinding

2017 ◽  
Vol 139 (12) ◽  
Author(s):  
Raphael Lima de Paiva ◽  
Rosemar Batista da Silva ◽  
Mark J. Jackson ◽  
Alexandre Mendes Abrão
Keyword(s):  
Surface Roughness ◽  
Flow Rate ◽  
Surface Integrity ◽  
Ground Surface ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Fluid Concentration ◽  
Grinding Conditions ◽  
Temperature Levels ◽  
Grinding Operations

The application of cutting fluid in grinding operations is crucial to control temperature levels and prevent thermal damage to the workpiece. Water-based (emulsions and solutions) coolants are used in grinding operations owing to their excellent cooling capability and relatively lower cost compared to neat oils. However, the cutting fluid efficiency is not only dependent on its type, but also on other parameters including its concentration and flow rate. In this context, this work aims to analyze the influence of the coolant concentration and flow rate on the grinding process. Two different workpiece materials for the production of plastic injection moulds were machined: VP80 and VPATLAS steel grades. Six grinding conditions (combinations of depth of cut values of 5, 15, and 25 μm with coolant concentration of 3% and 8%, respectively) were employed in the former, while two grinding conditions were used for the latter. The output parameter used to assess the influence of coolant concentration and flow rate on the grinding operation focused on the integrity of the workpiece materials (surface roughness and microhardness below the ground surface). The results showed that the surface integrity of VP80 after grinding was more sensitive to depth of cut than to cutting fluid concentration. Furthermore, the highest coolant concentration outperformed the lowest one when grinding under more severe conditions. With regard VPATLAS steel, no influence of the coolant flow rate on surface roughness was observed.

scholarly journals Optimisation of Cutting Fluid Concentration and Operating Parameters based on RSM for Turning Ti–6Al–4V

2021 ◽  
Author(s):  
Salah Gariani ◽  
Mahmoud Elsayed ◽  
Islam Shyha
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Feed Rate ◽  
Linear Models ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Operating Parameters ◽  
Cutting Condition ◽  
Fluid Concentration

Abstract The paper details experimental and optimisation results for the effect of cutting fluid concentration and operating parameters on the average surface roughness (Ra) and tool flank wear (VB) when flooded turning of Ti-6Al-4V using water-miscible vegetable oil-based cutting fluid. Cutting fluid concentration, cutting speed, feed rate and cutting tool were the control variables. Response Surface Methodology (RSM) was employed to develop an experimental design and optimise Ra and VB using linear models. The study revealed that cutting fluid concentration has a little influence on Ra and VB performance while Ra was strongly affected by feed rate and cutting tool type. The developed empirical model also suggested that the best parameters setting to minimise Ra and VB are 5%, 58 m/min, 0.1 mm/rev for cutting fluid concentration, cutting speed and feed rate, respectively, using H13A tool. At this setting, the predicted surface roughness and tool wear were 0.48 and 30 µm, respectively. In the same vein, tool life and micro-hardness tests were performed at the suggested optimum cutting condition with different cutting speeds. A notable decrease in tool life (82.3%) was obtained when a higher cutting speed was used.

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