Continuous Monitoring of Metal Working Fluid Quality in Machining Processes

2016 ◽  
Vol 139 (4) ◽  
Author(s):  
Benjamin Glasse ◽  
Udo Fritsching
Keyword(s):  
Process Monitoring ◽  
Measurement Techniques ◽  
Life Time ◽  
Spectroscopic Measurement ◽  
Machining Process ◽  
Working Fluid ◽  
Metal Working ◽  
Machining Processes ◽  
Stability Change ◽  
Tool Performance

Metal working fluid (MWF) emulsions are utilized as coolants and lubricants in machining processes like turning or drilling. During their operation life time cycle, MWFs change their properties due to impacting stresses which may influence the machining and tool performance. A frequent refreshing or renewal of MWFs in machining process is thus necessary. This investigation discusses measurement techniques of MWF emulsions to be used for MWF quality assessment and process monitoring. By means of optical spectroscopic measurement techniques (turbidimetry and laser diffraction), the evaluation of the temporal change of the wavelength exponent and the MWF emulsion droplet size is related to the MWF stability. The in-process monitoring of the MWFs in machining during several weeks of operation is shown. Thus, it will be demonstrated that optical spectroscopic measurement techniques may be applied to determine stability change of the emulsion system.

An extensive review on sustainable developments of dry and near-dry electrical discharge machining processes

2021 ◽  
pp. 1-37
Author(s):  
Sampath Boopathi
Keyword(s):  
Electrical Discharge ◽  
Electrical Discharge Machining ◽  
Optimization Techniques ◽  
Machining Process ◽  
Working Fluid ◽  
Dielectric Fluid ◽  
Extensive Literature ◽  
Machining Processes ◽  
Research Activities ◽  
Dry Edm

Abstract Electrical discharge machining (EDM) is very essential unconventional electro-thermal machining process to machine the contour profile of hard materials in modern production industries. The liquid dielectric fluid has been replaced by the gas and minimum quantity of liquid mixed with gas (gas-mist) to encourage the green machining processes. The various gases and gas-mist have been used as the working fluid in dry and near-dry EDM respectively. The research-contextual, various dielectric fluids, sustainable and innovative developments, process parameters, machining characteristics, and optimization techniques applied in various dry and near-dry EDM have been illustrated through an extensive literature survey. Future research opportunities in both dry and near-dry EDM have been summarized to promote eco-friendly EDM research activities.

scholarly journals Influence of metal working fluid on chip formation and mechanical loads in orthogonal cutting

2021 ◽  
Author(s):  
Berend Denkena ◽  
Alexander Krödel ◽  
Lars Ellersiek
Keyword(s):  
Chip Formation ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Machining Process ◽  
Working Fluid ◽  
Rake Face ◽  
Metal Working ◽  
Mechanical Loads ◽  
Working Fluids ◽  
Process Forces

AbstractMetal working fluids are used in machining processes of many hard-to-cut materials to increase tool life and productivity. Thereby, the metal working fluids act on the thermal and on the mechanical loads of the tool. The changing mechanical loads can mostly be attributed to the changing friction between rake face and chip and changes in the chip formation, e.g., the contact length between rake face and chip. However, analyzing those effects is challenging, since a detailed look at the chip formation process is prevented by the metal working fluid. In this paper, a novel planing test rig is presented, which enables high-speed recordings of the machining process and process force measurements while using metal working fluids. Experiments reveal that process forces are reduced with increasing pressure of the metal working fluid. However, the average friction coefficient only changes slightly, which indicates that the reduced process forces are mainly the result of reduced contact lengths between rake face and chip.

Fuzzy Modeling on the Basis of FCM Technique: A Case Study Aiming at Process Supervision

2001 ◽  
Author(s):  
Rodolfo E. Haber Guerra ◽  
Rodolfo Haber Haber ◽  
Angel Alique ◽  
Clodeinir R. Peres ◽  
Salvador Ros
Keyword(s):  
Fuzzy Model ◽  
Main Idea ◽  
Nonlinear Behavior ◽  
Milling Process ◽  
Machining Process ◽  
Machining Processes ◽  
Complex Processes ◽  
Tool Performance ◽  
Process Supervision

Abstract The nonlinear behavior and complexity of machining processes have motivated researchers to use fuzzy model to effect process supervision. The main idea of this paper concerns the application of fuzzy logic and clustering techniques to develop a fuzzy model of the milling process aiming at the optimization of machine-tool performance and the overall machining process. A brief description of the algorithm employed is given, focused on the fuzzy c-mean technique (FCM). The results indicate that the FCM criterion is suitable for modeling complex processes such as the milling process. The fuzzy model obtained serves as foundation to develop complex supervisory systems.

scholarly journals Nano-enhanced biolubricant in sustainable manufacturing: From processability to mechanisms

Friction ◽  
2022 ◽  
Author(s):  
Yanbin Zhang ◽  
Hao Nan Li ◽  
Changhe Li ◽  
Chuanzhen Huang ◽  
Hafiz Muhammad Ali ◽  
...  
Keyword(s):  
Molecular Structure ◽  
Heat Transfer ◽  
Physicochemical Properties ◽  
Future Development ◽  
Sustainable Manufacturing ◽  
Machining Process ◽  
Working Fluid ◽  
Metal Working ◽  
Relationship Analysis ◽  
Quality Aspects

AbstractTo eliminate the negative effect of traditional metal-working fluids and achieve sustainable manufacturing, the usage of nano-enhanced biolubricant (NEBL) is widely researched in minimum quantify lubrication (MQL) machining. It’s improved tool wear and surface integrity have been preliminarily verified by experimental studies. The previous review papers also concluded the major influencing factors of processability including nano-enhancer and lubricant types, NEBL concentration, micro droplet size, and so on. Nevertheless, the complex action of NEBL, from preparation, atomization, infiltration to heat transfer and anti-friction, is indistinct which limits preparation of process specifications and popularity in factories. Especially in the complex machining process, in-depth understanding is difficult and meaningful. To fill this gap, this paper concentrates on the comprehensive quantitative assessment of processability based on tribological, thermal, and machined surface quality aspects for NEBL application in turning, milling, and grinding. Then it attempts to answer mechanisms systematically considering multi-factor influence of molecular structure, physicochemical properties, concentration, and dispersion. Firstly, this paper reveals advanced lubrication and heat transfer mechanisms of NEBL by quantitative comparison with biolubricant-based MQL machining. Secondly, the distinctive filmformation, atomization, and infiltration mechanisms of NEBL, as distinguished from metal-working fluid, are clarified combining with its unique molecular structure and physical properties. Furtherly, the process optimization strategy is concluded based on the synergistic relationship analysis among process variables, physicochemical properties, machining mechanisms, and performance of NEBL. Finally, the future development directions are put forward aiming at current performance limitations of NEBL, which requires improvement on preparation and jet methods respects. This paper will help scientists deeply understand effective mechanism, formulate process specifications, and find future development trend of this technology.

6. Evaluation of Five Extraction Protocols for Determination of Endotoxin in Metal Working Fluid Aerosol

2001 ◽  
Author(s):  
K. Bartlett ◽  
J. Phipps ◽  
K. Kulhankova ◽  
P. Thorne
Keyword(s):  
Working Fluid ◽  
Metal Working

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

scholarly journals Temperature monitoring in the subsurface during single lip deep hole drilling

2020 ◽  
Vol 87 (12) ◽  
pp. 757-767
Author(s):  
Robert Wegert ◽  
Vinzenz Guski ◽  
Hans-Christian Möhring ◽  
Siegfried Schmauder
Keyword(s):  
Cutting Parameters ◽  
Drill Hole ◽  
Machining Process ◽  
Hole Drilling ◽  
Drilling Process ◽  
Deep Hole ◽  
Machining Processes ◽  
Deep Hole Drilling ◽  
Feed Force ◽  
Cutting Zone

AbstractThe surface quality and the subsurface properties such as hardness, residual stresses and grain size of a drill hole are dependent on the cutting parameters of the single lip deep hole drilling process and therefore on the thermomechanical as-is state in the cutting zone and in the contact zone between the guide pads and the drill hole surface. In this contribution, the main objectives are the in-process measurement of the thermal as-is state in the subsurface of a drilling hole by means of thermocouples as well as the feed force and drilling torque evaluation. FE simulation results to verify the investigations and to predict the thermomechanical conditions in the cutting zone are presented as well. The work is part of an interdisciplinary research project in the framework of the priority program “Surface Conditioning in Machining Processes” (SPP 2086) of the German Research Foundation (DFG).This contribution provides an overview of the effects of cutting parameters, cooling lubrication and including wear on the thermal conditions in the subsurface and mechanical loads during this machining process. At first, a test set up for the in-process temperature measurement will be presented with the execution as well as the analysis of the resulting temperature, feed force and drilling torque during drilling a 42CrMo4 steel. Furthermore, the results of process simulations and the validation of this applied FE approach with measured quantities are presented.

scholarly journals Influence of a closed-loop controlled laser metal wire deposition process of S Al 5356 on the quality of manufactured parts before and after subsequent machining

2021 ◽  
Author(s):  
Dina Becker ◽  
Steffen Boley ◽  
Rocco Eisseler ◽  
Thomas Stehle ◽  
Hans-Christian Möhring ◽  
...  
Keyword(s):  
Wall Thickness ◽  
Closed Loop ◽  
Deposition Process ◽  
Metal Wire ◽  
Machining Process ◽  
Machining Processes ◽  
Initial State ◽  
Additive Process ◽  
Shape Accuracy ◽  
Loop Control

AbstractThis paper describes the interdependence of additive and subtractive manufacturing processes using the production of test components made from S Al 5356. To achieve the best possible part accuracy and a preferably small wall thickness already within the additive process, a closed loop process control was developed and applied. Subsequent machining processes were nonetheless required to give the components their final shape, but the amount of material in need of removal was minimised. The effort of minimising material removal strongly depended on the initial state of the component (wall thickness, wall thickness constancy, microstructure of the material and others) which was determined by the additive process. For this reason, knowledge of the correlations between generative parameters and component properties, as well as of the interdependency between the additive process and the subsequent machining process to tune the former to the latter was essential. To ascertain this behaviour, a suitable test part was designed to perform both additive processes using laser metal wire deposition with a closed loop control of the track height and subtractive processes using external and internal longitudinal turning with varied parameters. The so manufactured test parts were then used to qualify the material deposition and turning process by criteria like shape accuracy and surface quality.

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