Influence of Minimum Quantity Lubrication on Friction Coefficient and Work-Material Adhesion During Machining of Cast Aluminum With Various Cutting Tool Substrates Made of Polycrystalline Diamond, High Speed Steel, and Carbides

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Pierre Faverjon ◽  
Joël Rech ◽  
René Leroy
Keyword(s):  
Friction Coefficient ◽  
Aluminum Alloys ◽  
High Speed ◽  
Cutting Tool ◽  
High Speed Steel ◽  
Minimum Quantity Lubrication ◽  
Polycrystalline Diamond ◽  
Dry Machining ◽  
Minimum Quantity ◽  
Work Material

Due to the increasing emphasis on environmental constraints, industry works on how to limit the massive use of lubricants by using the micro-pulverization of oil in machining processes and, especially, in the machining of aluminum alloys for the automotive industry. The success of a machining operation is dependent on a friction coefficient and weak adhesion with the tool-work material interface. This paper aims at identifying the influence of cutting tool substrates (high speed steel (HSS), carbide, polycrystalline diamond (PCD)) and of minimum quantity lubrication (MQL) on the friction coefficient and on adhesion in tribological conditions corresponding to the ones observed in the cutting of aluminum alloys (sliding velocity: 20-1500 m/min). An open ball-on-cylinder tribometer, especially designed to simulate these tribological conditions through Hertz contact, has been used. It has been shown that HSS and carbide substrates lead to large friction coefficients (0.8–1) and substantial adhesion in dry conditions, whereas PCD substrates would lead to lower average friction coefficient values (0.4–0.5) and very limited adhesion, which proves the necessity of using PCD tools in the dry machining of aluminum. It has also been shown that the application of MQL leads to a large decrease of the friction coefficient (0.1–0.2) and eliminates almost all traces of adhesions on pins for any substrates, which shows that MQL is an interesting compromise between dry machining and flood cooling.

STUDY ON THE TRIBOLOGICAL BEHAVIOR OF CUTTING TOOLS COATED WITH FILMS

2011 ◽  
Vol 25 (31) ◽  
pp. 4261-4264 ◽  
Author(s):  
MANABU YASUOKA
Keyword(s):  
Friction Coefficient ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
High Speed Steel ◽  
Frictional Properties ◽  
Coated Tool ◽  
Significant Difference ◽  
The Difference ◽  
Pin On Disk

A hard film coat can improve a tool's performance. In this study, the frictional properties of an uncoated tool and a coated tool with TiN were measured against that of SCM440 (42 CrMo 4) steel. The results showed there was no significant difference between the friction coefficient of the high-speed steel tool and the tool coated with TiN but the friction coefficient of uncoated tool was slightly lower than that of the steel. In the second part of the study, coats of TiN , TiC , CrN , and TiAlN were deposited on high-speed steel and the wear characteristics were determined with a pin-on-disk wear examination. The differences in the friction coefficients were attributed to the difference in the wear of the slipping material. There were large differences in the adhesion characteristics on the surface of the slipping material. The author suggest that these differences influence the characteristics of the cutting tool.

scholarly journals Cutting Performance Analysis of Surface Textured Tools in Dry Turning: Optimisation of process parameters

2021 ◽  
Vol 309 ◽  
pp. 01164
Author(s):  
Rima Singha Roy ◽  
Sushmita Dash ◽  
Trupti Ranjan Mahapatra ◽  
Debadutta Mishra ◽  
Sanjib Jaypuria
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
Removal Rate ◽  
High Speed Steel ◽  
Optimum Process ◽  
Pure Aluminium ◽  
Rake Face ◽  
Dry Machining ◽  
Dry Cutting ◽  
Dry Turning

Owing to minimum quantity or no use of toxic coolants, the dry machining technique has been evidenced to be a versatile sustainable method. However, during dry machining of ductile alloys, the severe tool wear and metal adhesion on the rake face of the cutting tool has been a matter of great concern. In the present work, an attempt has been made to assess the improvement in the tribological conditions in dry cutting by providing surface texturing on the rake face of High-Speed Steel (HSS) cutting tool. Dimples were produced on the rake surface of the HSS tool using pulsed Nd: YAG Laser and dry turning of pure aluminium is performed using the textured tool based on Taguchi’s L9 orthogonal array (OA) experimental design. The dry cutting of pure aluminium was also performed using the conventional/un-textured tool and the obtained results are used for comparison purpose. Improved turning performance in terms of material removal rate and surface roughness is found from the conformation tests using optimum process parameter determined by the Taguchi analysis. The ANOVA results suggests the effectiveness of using the textured tools during dry machining is significantly affected by feed and speed.

scholarly journals Minimum Quantity Lubrication (MQL) and its Effect on Tool Wear During Miniature Drilling :an Experimental Study

2016 ◽  
Vol 1 (2) ◽  
pp. 65-70
Author(s):  
Norsalawani Binti Mohamad ◽  
Rubina Bahar
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Minimum Quantity Lubrication ◽  
Limiting Factors ◽  
Work Piece ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Tool Condition ◽  
Overall Performance

Miniature drilling is widely used in industries including electronics and reconstructive surgeries to create small sized holes. Chip removal and effective supply of coolant are the two limiting factors that make the process more complex compared to other meso scale machining processes and also contribute to the tool wear. The tool wear in the process is mainly caused by the interaction, motion and chip production between the tool and work piece. Uniform supply of coolant must be ensured to reach the drilled cavity to keep the tool wear to a minimal level. This study includes experimental investigation of the tool condition after applying Minimum Quantity Lubrication (MQL) system as a greener approach as the name indicates. The tool condition with MQL has also been compared with dry and flood cooling. Two different types of drill bit materials (High Speed Steel and Carbide) have been tested under same experimental condition to drill through Aluminum Alloy 6061 and it has been found that overall performance in terms of tool condition after applying MQL was better compared to the other two methods. The overall wear propagation area was measured for both the conditions. It was seen, the wear propagation covered minimal area with MQL while for flood and dry condition wear was spread over a bigger area on flank. 

TATMO V-N

Alloy Digest ◽  
1985 ◽  
Vol 34 (12) ◽  
Keyword(s):  
High Speed ◽  
Cutting Tool ◽  
High Speed Steel ◽  
High Hardness ◽  
Heat Treating ◽  
Nitrogen Addition ◽  
Aisi Type ◽  
End Mills ◽  
Red Hardness ◽  
Edge Toughness

Abstract TATMO V-N is an AISI Type M7 high-speed steel modified by alloy balancing and a nitrogen addition to develop superior hardness response in heat treatment. It is an excellent grade for many cutting-tool applications requiring an optimum balance of red hardness, edge toughness and wear resistance, such as drills, taps, end mills, reamers and milling cutters. Its combination of outstanding properties and high hardness makes Tatmo V-N a logical alternate for cobalt high-speed steels in many cutting-tool applications. This datasheet provides information on composition, physical properties, hardness, and elasticity. It also includes information on forming, heat treating, machining, and surface treatment. Filing Code: TS-452. Producer or source: Latrobe Steel Company.

Study on the Effects of Abrasive and Coolant-Lubricant Types on Minimum Quantity Lubrication-MQL Grinding

2011 ◽  
Vol 325 ◽  
pp. 231-237 ◽  
Author(s):  
Taghi Tawakoli ◽  
M.J. Hadad ◽  
A. Daneshi ◽  
M.H. Sadeghi ◽  
B. Sadeghi
Keyword(s):  
Surface Quality ◽  
Minimum Quantity Lubrication ◽  
Dry Machining ◽  
Grinding Forces ◽  
Minimum Quantity ◽  
Mql Grinding ◽  
Air Jet ◽  
Dry Grinding ◽  
Surface Damages ◽  
Minimum Quantity Lubricant

In dry grinding, as there is no coolant lubricant to transfer the heat from the contact zone, generation of surface damages are not preventable. Promising alternatives to conventional flood coolant applications are also Minimum Quantity Lubricant (MQL) or Near Dry Machining (NDM) or Semi Dry Machining (SDM). This research has been conducted to study the influence of the abrasive and coolant-lubricant types on the minimum quantity lubrication (MQL) grinding performance. One type of CBN and three types of conventional wheels (corundum) were tested. The tests were carried out in presence of fluid, air jet and eleven types of coolant-lubricants, as well as in dry condition. The results indicate that the finest surface quality and the lowest grinding forces could be obtained when grinding with CBN wheels. In the case of conventional wheels, the coarser wheel induces much proper grinding results.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

scholarly journals Stability analysis for a single-point cutting tool deflection in turning operation

2019 ◽  
Vol 11 (6) ◽  
pp. 168781401985318
Author(s):  
Amon Gasagara ◽  
Wuyin Jin ◽  
Angelique Uwimbabazi
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Cutting Tool ◽  
Single Point ◽  
Three Dimensional ◽  
High Speed Steel ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Beam Model ◽  
Tool Deflection

In this article, a new model of regenerative vibrations due to the deflection of the cutting tool in turning is proposed. The previous study reported chatter as a result of cutting a wavy surface of the previous cut. The proposed model takes into account cutting forces as the main factor of tool deflection. A cantilever beam model is used to establish a numerical model of the tool deflection. Three-dimensional finite element method is used to estimate the tool permissible deflection under the action of the cutting load. To analyze the system dynamic behavior, 1-degree-of-freedom model is used. MATLAB is used to compute the system time series from the initial value using fourth-order Runge–Kutta numerical integration. A straight hard turning with minimal fluid application experiment is used to obtain cutting forces under stable and chatter conditions. A single-point cutting tool made from high-speed steel is used for cutting. Experiment results showed that for the cutting parameters above 0.1mm/rev feed and [Formula: see text]mm depth of cut, the system develops fluctuations and higher chatter vibration frequency. Dynamic model vibration results showed that the cutting tool deflection induces chatter vibrations which transit from periodic, quasi-periodic, and chaotic type.

scholarly journals An Experimental Investigation on Bushing Geometrical Properties and Density in Thermal Frictional Drilling

2018 ◽  
Vol 8 (12) ◽  
pp. 2658
Author(s):  
Zülküf Demir ◽  
Cebeli Özek ◽  
Muhammed Bal
Keyword(s):  
Experimental Investigation ◽  
Aluminum Alloys ◽  
Wall Thickness ◽  
High Speed ◽  
High Speed Steel ◽  
Volume Ratio ◽  
Geometrical Properties ◽  
Friction Drilling ◽  
Tool Diameter ◽  
Geometrical Dimensions

In thermal friction drilling (TFD) operations, the geometrical dimensions of bushing shape, height and wall thickness are the most vital consequences, since these increase the connecting length and strength. In this paper, AA7075-T651 aluminum alloys with 2, 4, 6, 8, and 10 mm thicknesses were drilled with the TFD process in order to investigate density, volume ratio, and height and wall thickness of the bushings. The experiments were conducted at constant spindle speed and feed rate conditions by using High Speed Steel (HSS) conical tools of 5, 10, 15, and 20 mm in diameter. It was experimentally found that the bushing height and the wall thickness had a tendency to increase linearly with the increase in both material thickness and tool diameter. The effect of tool diameter was found to have more influence on the measurable values than the thickness of the drilled material. The density of the bushing changed trivially. Approximately 70–75 percent of the evacuated material formed the bushing shape in TFD operations.

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