The Jatropha curcas vegetable base soluble cutting oil as a renewable source in the machining of aluminum alloy 7050-T7451

2015 ◽  
Vol 67 (2) ◽  
pp. 181-195 ◽  
Author(s):  
Carlos Alberto Schuch Bork ◽  
Janaina Fracaro Souza Gonçalves ◽  
Jefferson Oliveira Gomes
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Cutting Tool ◽  
Sustainable Manufacturing ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Cutting Fluid ◽  
Process Conditions ◽  
Renewable Source ◽  
Content Type

Purpose – This article aims to collect data on the aluminum alloy 7050-T7451 machinability used in the manufacturing of aeronautical structures, using the combination of the jatropha vegetable-base soluble cutting oil in relation to the canola vegetal and semisynthetic mineral oils and the technique to apply cutting fluid by flood in relation to the Minimum Quantity Lubrication (MQL) in the milling process (HSM – high-speed machining). Design/methodology/approach – It was observed that the jatropha vegetal cutting oil presented the best results in relation to requirements for lubrication, superficial mean roughness (index Ra) and shape errors in relation to the other oils in both the techniques to apply fluid which were tested. Comparing the application techniques, the jatropha vegetal oil offered an increase in the life span of the cutting tool, using the flood technique, exceeding in almost six times the machined length of the cutting tool in relation to the MQL technique in the same process conditions. Findings – The Jatropha vegetable-base cutting oil, besides being produced from a renewable source, has inherent characteristics that can help attain a sustainable manufacturing, mainly with the use of the flood technique to apply cutting fluid in the aluminum alloy 7050-T7451 machining. Originality/value – The Jatropha (vegetable) oil, in relation to its physicochemical properties, appeared to be the best one fit for being used in the machining of aluminum alloys 7050-T7451 because it did not interfere with any of the elements involved in the formation of intergranular corrosion and/or pitting, which are not allowed in the aeronautical production of parts. Jatropha (vegetable) cutting oil, besides being produced from a clean and renewable source, has the inherent characteristics that can help attain a sustainable manufacturing.

Simulation on Cutting Temperature during High-Speed Milling Aluminum Alloy 7055

2013 ◽  
Vol 328 ◽  
pp. 486-490 ◽  
Author(s):  
Liang Tan ◽  
Chang Feng Yao ◽  
Wei Zuo ◽  
Dao Xia Wu
Keyword(s):  
Aluminum Alloy ◽  
Theoretical Basis ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Element Model ◽  
Milling Process ◽  
High Speed Milling ◽  
Milling Parameters

To optimize the parameters of high-speed milling of aluminum alloy 7055 and provide a theoretical basis for cutting temperature control, a finite element model of high-speed milling process of aluminum alloy 7055 was developed with AdvantEdge. Based on these models, the effect of milling parameters on cutting temperature is investigated by single factor experiments. And the temperature distribution of workpiece and cutting tool is predicted. The results show that the highest temperature occurs at close to the tool tip in the rack face, the temperature increases with an increase in cutting speed and feed per tooth, while other parameters have a less significant effect on cutting temperature.

Analytical Calculation of Cutter/Workpiece Engagements for Helical Hole Milling

2009 ◽  
Author(s):  
Jue Wang ◽  
Derek Yip-Hoi
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Analytical Calculation ◽  
Milling Process ◽  
Helical Milling ◽  
Helicoidal Surface ◽  
Swept Volume ◽  
Intersection Geometry ◽  
Intersection Curves ◽  
Solid Modeler

Helical milling is a 3-axis machining operation where a cutting tool is feed along a helix. This operation is used in ramp-in and ramp-out moves when the cutting tool first engages the workpiece, for contouring and for hole machining. It is increasingly finding application as a means for roughing large amounts of material during high speed machining. Simulating the helical milling process requires Cutter/Workpiece Engagement (CWE) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. For hole milling an additional complication comes from self-intersections that occur with the tool swept volume. This makes the generation of the instantaneous in-process workpiece needed for finding the CWE difficult. In this paper we present an analytical approach for finding the engagement geometry that utilizes the intersection curves between a cylinder representing a flat end mill and the helicoidal surface generated by the bottom of the tool as it feeds downwards along the helix. This technique can be integrated into a solid modeler based approach for machining simulation. It has the advantage of not require instantaneous updates of the workpiece as is typically the case in finding CWEs.

Tool life prediction by RSM for cryogenic milling of inconel 718

2019 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Nurul Hayati Binti Abdul Halim ◽  
Che Hassan Che Haron ◽  
Jaharah A. Ghani ◽  
Muammar Faiq Azhar
Keyword(s):  
Tool Life ◽  
Inconel 718 ◽  
High Speed ◽  
Metal Cutting ◽  
Milling Process ◽  
Average Error ◽  
Depth Of Cut ◽  
Content Type ◽  
Radial Depth ◽  
Ball Nose Milling

Purpose The purpose of this study is to present the tool life optimization of carbide-coated ball nose milling inserts when high-speed milling of Inconel 718 under cryogenic CO2 condition. The main aims are to analyze the influence level of each cutting parameter on the tool life and to identify the optimum parameters that can lengthen the tool life to the maximum. Design/methodology/approach The experimental layout was designed using Box–Behnken RSM where all parameters were arranged without combining their highest and lowest values of each factor at the same time. A total of 29 milling experiments were conducted. Then, a statistical analysis using ANOVA was conducted to identify the relationship between the controlled factors on tool life. After that, a predictive model was developed to predict the variation of tool life within the predetermined parameters. Findings Results from the experimental found that the longest tool life of 22.77 min was achieved at Vc: 120 m/min, fz: 0.2 mm/tooth, ap: 0.5 mm and ae: 0.2 mm. ANOVA suggests the tool life of 23.4 min can be reached at Vc: 120.06 m/min, fz: 0.15 mm/tooth, ap: 0.66 mm and ae: 0.53 mm. All four controlled factors have influenced the tool life with the feed rate and radial depth of cut (DOC) as the major contributors. The developed mathematical model accurately represented the tool life at an average error of 8.2 per cent when compared to the actual and predicted tool life. Originality/value These experimental and statistical studies were conducted using Box–Behnken RSM method under cryogenic CO2 condition. It is a proven well-known method. However, the cooling method used in this study is a new technique and its effects on metal cutting, especially in the milling process of Inconel 718, has not yet been explored.

Geometric Modeling of Cutter/Workpiece Engagements for Helical Milling With Flat End Mills

2007 ◽  
Author(s):  
Eyyup Aras ◽  
Derek Yip-Hoi
Keyword(s):  
Geometric Modeling ◽  
High Speed ◽  
Tool Path ◽  
Cutting Tool ◽  
Milling Process ◽  
Helical Milling ◽  
Mapping Technique ◽  
Depth Of Cut ◽  
Modeling Methodology ◽  
End Mills

Helical milling is a 3-axis machining operation where a cutting tool is feed along a helix. This operation is used in ramp-in and ramp-out moves when the cutting tool first engages the workpiece, for contouring and for hole machining. It is increasingly finding application as a means for roughing large amounts of material during high speed machining. Modeling the helical milling process requires cutter/workpiece engagements (CWEs) geometry in order to predict cutting forces. The calculation of these engagements is challenging due to the complicated and changing intersection geometry that occurs between the cutter and the in-process workpiece. In this paper we present a geometric modeling methodology for finding engagements during helical milling with flat end mills. A mapping technique has been developed that transforms a polyhedral model of the removal volume from Euclidean space to a parametric space defined by location along the tool path, engagement angle and the depth-of-cut. As a result, intersection operations are reduced to first order plane-plane intersections. This approach reduces the complexity of the cutter/workpiece intersections and also eliminates robustness problems found in standard polyhedral modeling and improves accuracy over the Z-buffer technique. The reported method has been implemented and tested using a combination of commercial applications. This paper highlights ongoing collaborative research into developing a Virtual Machining System.

Evaluation of Tool Wear Suppressive Ability of Lubricants Usein in Minimum Quantity Lubrication Application in High Speed Machining of Cast Aluminum Alloys

2005 ◽  
Author(s):  
Alexander Bardetsky ◽  
Helmi Attia ◽  
Mohamed Elbestawi
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tool ◽  
Minimum Quantity Lubrication ◽  
Metalworking Fluids ◽  
High Speed Machining ◽  
Cast Aluminum ◽  
Tool Wear Rate ◽  
Cast Aluminum Alloys ◽  
Lubricant Composition

The disadvantages of conventional metalworking fluids such as disposal problems, health problems and economic factors have led to the development of strategies to reduce their amount in metalworking. Recently, Minimum Quantity Lubrication (MQL) technology was developed and it seems to be a suitable alternative for economically and environmentally compatible production. It combines the functionality of lubrication with an extremely low consumption of lubricant and has a potential to replace metalworking fluids application in machining operations. The MQL lubricants are formulated with two major groups of additives; anti-wear (AW) additives and extreme pressure (EP) additives. When such lubricants are applied to the cutting zone, protective layers are formed on the interacting surfaces of the workpiece and the cutting tool. These layers prevent direct contact between the tool and chip surfaces, and, therefore reduce friction forces and tool wear. In order to utilize MQL to its full potential, it is essential to select appropriate lubricant composition for particular work material and machining parameters. The experimental study of different compositions of MQL lubricants is reported. The effectiveness of the lubricants are determined in terms of their ability to protect the cutting tool in high speed machining of cast aluminum alloys, which are widely used in automotive industry. The main objective of this research is to quantitatively evaluate the ability of lubricant’s additive composition to reduce the tool wear. This is reached through the comparison between the tool wear rate measured during the machining of aluminum cast alloy with the application of MQL, and the tool wear rate obtained in dry machining of the same alloy. Two kinds of the lubricants are evaluated; vegetable and synthetic. The content of AW and EP additives in each kind of lubricant was varied on three levels in order to capture the effect of the lubricant’s composition on tool wear. The result of the MQL lubricants evaluation is discussed and the recommendations for optimal lubricant composition are made.

Study on Chip Breaking of HSS Tool with Convex Stripe

2014 ◽  
Vol 685 ◽  
pp. 90-93
Author(s):  
Zhong Liang Wu ◽  
Jie Zhao ◽  
Yan Lin Wang
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Cutting Tool ◽  
Experimental Results ◽  
Manufacturing Processes ◽  
Cutting Depth ◽  
Chip Breaking ◽  
On Chip ◽  
Tool Cutting ◽  
Cutting Experiments

Chip breaking is important during manufacturing processes. A method of chip breaking is described. Common high speed tool was selected as cutting tool. The convex stripe was made by the laser instrument on the rake of cutting tool. Cutting experiments of aluminum alloy were carried out with this kind of tools. Experimental results show that chip breaking of tools with convex stripe is easier than ordinary tools. And the chip shape is always arc. The chip created by tools with convex stripe breaks more easily when cutting depth is less than 0.5mm. There is no damage on cutting tool with this method which is simple for manufacture.

scholarly journals Progressing towards Sustainable Machining of Steels: A Detailed Review

Materials ◽  
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.

scholarly journals Analysis of tool wear and surface roughness in high-speed milling process of aluminum alloy Al6061

2021 ◽  
pp. 71-84
Author(s):  
Nhu-Tung Nguyen ◽  
Dung Hoang Tien ◽  
Nguyen Tien Tung ◽  
Nguyen Duc Luan
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Tool Wear ◽  
Feed Rate ◽  
High Speed ◽  
Cutting Speed ◽  
Milling Process ◽  
Face Milling ◽  
Depth Of Cut ◽  
High Speed Milling

In this study, the influence of cutting parameters and machining time on the tool wear and surface roughness was investigated in high-speed milling process of Al6061 using face carbide inserts. Taguchi experimental matrix (L9) was chosen to design and conduct the experimental research with three input parameters (feed rate, cutting speed, and axial depth of cut). Tool wear (VB) and surface roughness (Ra) after different machining strokes (after 10, 30, and 50 machining strokes) were selected as the output parameters. In almost cases of high-speed face milling process, the most significant factor that influenced on the tool wear was cutting speed (84.94 % after 10 machining strokes, 52.13 % after 30 machining strokes, and 68.58 % after 50 machining strokes), and the most significant factors that influenced on the surface roughness were depth of cut and feed rate (70.54 % after 10 machining strokes, 43.28 % after 30 machining strokes, and 30.97 % after 50 machining strokes for depth of cut. And 22.01 % after 10 machining strokes, 44.39 % after 30 machining strokes, and 66.58 % after 50 machining strokes for feed rate). Linear regression was the most suitable regression of VB and Ra with the determination coefficients (R2) from 88.00 % to 91.99 % for VB, and from 90.24 % to 96.84 % for Ra. These regression models were successfully verified by comparison between predicted and measured results of VB and Ra. Besides, the relationship of VB, Ra, and different machining strokes was also investigated and evaluated. Tool wear, surface roughness models, and their relationship that were found in this study can be used to improve the surface quality and reduce the tool wear in the high-speed face milling of aluminum alloy Al6061

Automatic In-Process Chatter Avoidance in the High-Speed Milling Process

2010 ◽  
Vol 132 (3) ◽  
Author(s):  
N. J. M. van Dijk ◽  
E. J. J. Doppenberg ◽  
R. P. H. Faassen ◽  
N. van de Wouw ◽  
J. A. J. Oosterling ◽  
...  
Keyword(s):  
High Speed ◽  
Control Strategies ◽  
Detection Algorithm ◽  
Milling Process ◽  
Process Conditions ◽  
High Speed Milling ◽  
Milling Operations ◽  
Milling Operation ◽  
Automatic Adaptation ◽  
And Control

High-speed milling is often used in industry to maximize productivity of the manufacturing of high-technology components, such as aeronautical components, mold, and dies. The occurrence of chatter highly limits the efficiency and accuracy of high-speed milling operations. In this paper, two control strategies are presented that guarantee a chatter-free high-speed milling operation by automatic adaptation of spindle speed and feed. Moreover, the proposed strategies are robust for changing process conditions (e.g., due to heating of the spindle or tool wear). An important part of the control strategy is the detection of chatter. A novel chatter detection algorithm is presented that automatically detects chatter in an online fashion and in a premature phase such that no visible marks on the workpiece are present. Experiments on a state-of-the-art high-speed milling machine underline the effectiveness of the proposed detection and control strategies.

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