Safe and Economically Efficient Use of Metal Working Fluids in Mechanical Processing of Magnesium Alloys

2007 ◽  
Author(s):  
Stefan Joksch ◽  
Rene´ Schwerin
Keyword(s):  
Magnesium Alloys ◽  
Large Scale ◽  
Manufacturing Industry ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Mechanical Processing ◽  
Metal Working ◽  
Working Fluids ◽  
Research Activities ◽  
Fluid Systems

Magnesium, a light-weight metal, has been used as a construction material since the early days of the 20th century. Excellent availability and low specific weight are the main benefits for applications in the aerospace and automotive fields. Because of a vast increase of Magnesium machining applications in the mobile equipment manufacturing industry over the last 10 years, there is an increasing demand for specially adapted cutting fluid systems for the machining of Magnesium parts. This paper will provide an overview on the latest research activities in Germany to develop new cutting fluid systems for a safe and economically efficient use of metal working fluids in mechanical processing of Magnesium alloys. Laboratory results and field applications with new innovative water-miscible cutting fluids are demonstrating that it is possible to control the huge problems of the past, such as hydrogen formation, emulsion split and corrosion. Based on experiences in the biggest european magnesium Machining project, the “Al/Mg Hybrid Crank Case” (Fig. 1), problems and solutions specific for large scale machining of Magnesium alloys with water-mixed cutting fluids are shown.

Studying the lubricity of new eco-friendly cutting oil formulation in metal working fluid

2018 ◽  
Vol 70 (9) ◽  
pp. 1569-1579 ◽  
Author(s):  
M.R. Noor El-Din ◽  
Marwa R. Mishrif ◽  
Satish V. Kailas ◽  
Suvin P.S. ◽  
Jagadeesh K. Mannekote
Keyword(s):  
Surface Morphology ◽  
Corrosion Inhibitor ◽  
Castor Oil ◽  
Cutting Fluid ◽  
Working Fluid ◽  
Cutting Fluids ◽  
Metal Working ◽  
Content Type ◽  
Metalworking Fluid ◽  
3D Profilometer

PurposeThis paper aims to formulate a new metal working fluid (MWF) composition including some eco-friendly emulsifiers, corrosion inhibitor, biocide, and non- edible vegetable oil (castor oil) as the base oil. To achieve this aim, five MWFs with different hydrophilic–lipophilic balance (HLB) value as 10, 9.5, 9, 8.5 and 8 were prepared to identify the optimum HLB value that gives a highly stable oil-in-water emulsion. The performance of castor oil based MWF was evaluated using tool chip tribometer and drill dynamometer. The surface morphology of steel disc and friction pin was performed using scanning electron microscope (SEM) and 3D profilometer. The results revealed that the use of the prepared cutting fluid (E1) caused the cutting force to decrease from 500 N for dry high-speed steel sample to 280N, while the same value for a commercial cutting fluid (COM) was recorded as 340 N at drilling speed and cutting feed force as 1120 rpm and 4 mm/min., respectively.Design/methodology/approachA castor oil-based metalworking fluid was prepared using nonionic surfactants. The composition of the metalworking fluid was further optimized by adding performance-enhancing additives. The performance of castor oil based MWF was analyzed using Tool chip tribometer and Drill dynamometer. The surface morphology of steel ball and a disc was done using 3D profilometer and SEM.FindingsStudies revealed that castor oil-based MWF having Monoethanolamine (MEA) as corrosion inhibitor was found to be highly stable. The drilling dynamometer and tool chip tribometer studies showed that castor oil-based MWF performance was comparable to that of commercial MWF.Research limitations/implicationsThis study aims to explore the performance of the castor oil based metalworking fluid (MWF) using tool chip tribometer and drill dynamometer.Practical implicationsThe conventional MWFs are petroleum derives and are unsustainable. Use of non-edible plant-based oils for preparing the MWF will not only be conserved environment but also add value addition to agricultural crops.Social implicationsThe social Implications is aiming to decrease the environmental impact that results from the using of mineral cutting fluids.Originality/valueThe originality of this work is to replace the mineral oil and synthetic oil based cutting fluids with more eco-friendly alternatives one. In addition, the investigation will focus on developing functional additives required for cutting fluids which are environmentally benign.

Examining the Effect of Various Vegetable Oil-Based Cutting Fluids on Surface Integrity in Drilling Steel - A Review

2013 ◽  
Vol 845 ◽  
pp. 809-813 ◽  
Author(s):  
A.Z. Sultan ◽  
S. Sharif ◽  
Denni Kurniawan
Keyword(s):  
Vegetable Oil ◽  
Surface Integrity ◽  
Manufacturing Industry ◽  
Mineral Oil ◽  
Cutting Fluid ◽  
Health Impacts ◽  
Metalworking Fluids ◽  
Drilling Process ◽  
Cutting Fluids ◽  
Industrial Activities

Increased attention on environmental and health impacts by industrial activities forces the manufacturing industry to reduce the mineral oil-based metalworking fluids as a cutting fluid. The advantages of using vegetable oil-based cutting fluids on tool wear and the cutting force have been reported in the literature, but those reporting the effects of their use on the surface finish of the workpiece are still lacking. This mini-review gives an overview of the influence of vegetable oil-based cutting fluids on surface integrity of steel during drilling process. Effect of the different cooling strategies on surface integrity is also presented.

Effect of cutting fluid on precision machined surface integrity of heat-resistant stainless steel

2016 ◽  
Vol 232 (9) ◽  
pp. 1535-1548 ◽  
Author(s):  
Pei Yan ◽  
Yiming Rong ◽  
Xibin Wang ◽  
Junyi Zhu ◽  
Li Jiao ◽  
...  
Keyword(s):  
Surface Integrity ◽  
Manufacturing Industry ◽  
Service Performance ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Machined Surface ◽  
Surface Work ◽  
Machined Surface Integrity ◽  
Machined Surfaces

The machined surface integrity of blades is of utmost importance in the power equipment manufacturing industry. Recently, many blade accidents have been attributable to the misuse of cutting fluids that were necessary in the actual machining of difficult-to-cut materials, but the effect of the cutting fluid on surface integrity and service performance has been persistently neglected. In this article, an investigation into the effect of cutting fluids on the surface quality of a typical blade material was undertaken, combined with properties of two universal cutting fluids. Element composition, surface morphology, residual stress and hardness of the machined surfaces were investigated. The results indicated that cutting fluids could not reduce cutting forces in precision machining. There were some places where local and irregular elemental Cr loss was incurred when machined with the additive Cl, and the depth of Cr loss was 1–2 µm. The machined surface under CF-206 was smooth, and the roughness of CF-210 was the highest. The tensile residual stresses of dry cutting were the highest, whereas those of CF-210 were the lowest. Surface work hardening under cutting fluids was higher, with depths of 20–30 µm. These results are significant for the control of precision machined surfaces and subsurfaces of blades with high integrity and service performance.

COMPARATIVE ANALYSIS OF PERFORMANCE BETWEEN CONVENTIONAL CUTTING FLUIDS AND VEGETABLE GLYCERINE BASED CUTTING FLUID IN STEEL 1020 TURNING OPERATION

2017 ◽  
Author(s):  
Gustavo Fernandes ◽  
Sanderson Clayton ◽  
Bernardo Jakitsch ◽  
Luis Henrique Andrade Maia ◽  
Mariana Gomes ◽  
...  
Keyword(s):  
Comparative Analysis ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Turning Operation ◽  
Steel 1020 ◽  
Analysis Of Performance

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.

EBS Behaviour Immediately After Repository Closure in a Clay Host Rock: The HE-E Experiment (Mont Terri URL)

2011 ◽  
Author(s):  
Irina Gaus ◽  
Klaus Wieczorek ◽  
Juan Carlos Mayor ◽  
Thomas Trick ◽  
Jose´-Luis Garcia` Sin˜eriz ◽  
...  
Keyword(s):  
Thermal Conductivity ◽  
Host Rock ◽  
Large Scale ◽  
Process Models ◽  
Research Activities ◽  
Hydraulic Behaviour ◽  
Validation Experiment ◽  
Engineered Barrier ◽  
Mont Terri

The evolution of the engineered barrier system (EBS) of geological repositories for radioactive waste has been the subject of many research programmes during the last decade. The emphasis of the research activities was on the elaboration of a detailed understanding of the complex thermo-hydro-mechanical-chemical processes, which are expected to evolve in the early post closure period in the near field. It is important to understand the coupled THM-C processes and their evolution occurring in the EBS during the early post-closure phase so it can be confirmed that the safety functions will be fulfilled. Especially, it needs to be ensured that interactions during the resaturation phase (heat pulse, gas generation, non-uniform water uptake from the host rock) do not affect the performance of the EBS in terms of its safety-relevant parameters (e.g. swelling pressure, hydraulic conductivity, diffusivity). The 7th Framework PEBS project (Long Term Performance of Engineered Barrier Systems) aims at providing in depth process understanding for constraining the conceptual and parametric uncertainties in the context of long-term safety assessment. As part of the PEBS project a series of laboratory and URL experiments are envisaged to describe the EBS behaviour after repository closure when resaturation is taking place. In this paper the very early post-closure period is targeted when the EBS is subjected to high temperatures and unsaturated conditions with a low but increasing moisture content. So far the detailed thermo-hydraulic behaviour of a bentonite EBS in a clay host rock has not been evaluated at a large scale in response to temperatures of up to 140°C at the canister surface, produced by HLW (and spent fuel), as anticipated in some of the designs considered. Furthermore, earlier THM experiments have shown that upscaling of thermal conductivity and its dependency on water content and/or humidity from the laboratory scale to a field scale needs further attention. This early post-closure thermal behaviour will be elucidated by the HE-E experiment, a 1:2 scale heating experiment setup at the Mont Terri rock laboratory, that started in June 2011. It will characterise in detail the thermal conductivity at a large scale in both pure bentonite as well as a bentonite-sand mixture, and in the Opalinus Clay host rock. The HE-E experiment is especially designed as a model validation experiment at the large scale and a modelling programme was launched in parallel to the different experimental steps. Scoping calculations were run to help the experimental design and prediction exercises taking the final design into account are foreseen. Calibration and prediction/validation will follow making use of the obtained THM dataset. This benchmarking of THM process models and codes should enhance confidence in the predictive capability of the recently developed numerical tools. It is the ultimate aim to be able to extrapolate the key parameters that might influence the fulfilment of the safety functions defined for the long term steady state.

scholarly journals Formulation of Sustainable Water-Based Cutting Fluids with Polyol Esters for Machining Titanium Alloys

Metals ◽  
2021 ◽  
Vol 11 (5) ◽  
pp. 773
Author(s):  
Elisabet Benedicto ◽  
Eva María Rubio ◽  
Laurent Aubouy ◽  
María Ana Sáenz-Nuño
Keyword(s):  
Molecular Structure ◽  
Tool Wear ◽  
Titanium Alloys ◽  
Film Formation ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Lubricating Film ◽  
Wear Protection ◽  
Oil In Water ◽  
Polyol Esters

The machinability of titanium alloys still represents a demanding challenge and the development of new clean technologies to lubricate and cool is greatly needed. As a sustainable alternative to mineral oil, esters have shown excellent performance during machining. Herein, the aim of this work is to investigate the influence of esters’ molecular structure in oil-in-water emulsions and their interaction with the surface to form a lubricating film, thus improving the efficiency of the cutting fluid. The lubricity performance and tool wear protection are studied through film formation analysis and the tapping process on Ti6Al4V. The results show that the lubricity performance is improved by increasing the formation of the organic film on the metal surface, which depends on the ester’s molecular structure and its ability to adsorb on the surface against other surface-active compounds. Among the cutting fluids, noteworthy results are obtained using trimethylolpropane trioleate, which increases the lubricating film formation (containing 62% ester), thus improving the lubricity by up to 12% and reducing the torque increase due to tool wear by 26.8%. This work could be very useful for fields where often use difficult-to-machine materials—such as Ti6Al4V or γ-TiAl – which require large amounts of cutting fluids, since the formulation developed will allow the processes to be more efficient and sustainable.

Wet-mechanical processing of a plastic-rich two-dimensional-fraction from mixed wastes for chemical recycling

2021 ◽  
pp. 0734242X2199643
Author(s):  
Möllnitz Selina ◽  
Bauer Markus ◽  
Schwabl Daniel ◽  
Sarc Renato
Keyword(s):  
Large Scale ◽  
Sewage Treatment Plant ◽  
Treatment Plant ◽  
Process Water ◽  
Chemical Recycling ◽  
Mechanical Processing ◽  
Municipal Solid Wastes ◽  
Core Element ◽  
Metal Levels ◽  
Mixed Wastes

The recycling of source separated polyolefins (POs) (e.g., light weight packaging waste) is already state of the art. Therefore, further plastic materials contained in mixed wastes have become more important due to increasing legal pressure. Mixed commercial and municipal solid wastes contain large quantities of POs. These mixed wastes would usually be treated in waste incinerators or processed to refuse-derived fuel for cement plants. Large-scale experiments were conducted to assess the potential of such POs from these waste streams for recycling processes. The potential and applicability of a dry-mechanical and subsequently wet-mechanical (Wet-mechanical) processing with the aim of generating a PO concentrate for chemical recycling purposes was assessed. These investigations’ focus was put on the centrifugal force separator technology as the core element of Wet-mechanical processing. In addition to the input material, all output materials and process water streams were chemically and physically characterized to estimate potential treatment or recycling paths. Results demonstrate that a two-stage purification is necessary to produce POs with sufficient purity out of both wastes. Chlorine and heavy metal levels are simultaneously reduced. The increased quantity of impurities only slightly changes the density of the process waters. Process water analyses show that wastewater treatment is necessary before discharge into a receiving water or sewage treatment plant. The sediment does not fulfil any hazard-relevant properties, and different thermal treatment options are possible.

scholarly journals Spatial Agglomeration of China’s Forest Products Manufacturing Industry: Measurement, Characteristics and Determinants

Forests ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 1006
Author(s):  
Zhenhuan Chen ◽  
Hongge Zhu ◽  
Wencheng Zhao ◽  
Menghan Zhao ◽  
Yutong Zhang
Keyword(s):  
Spatial Distribution ◽  
Spatial Data ◽  
Large Scale ◽  
Manufacturing Industry ◽  
Economies Of Scale ◽  
Forest Products ◽  
Spatial Data Analysis ◽  
Forest Protection ◽  
Spatial Agglomeration ◽  
Continuous Space

China’s forest products manufacturing industry is experiencing the dual pressure of forest protection policies and wood scarcity and, therefore, it is of great significance to reveal the spatial agglomeration characteristics and evolution drivers of this industry to enhance its sustainable development. Based on the perspective of large-scale agglomeration in a continuous space, in this study, we used the spatial Gini coefficient and standard deviation ellipse method to investigate the spatial agglomeration degree and location distribution characteristics of China’s forest products manufacturing industry, and we used exploratory spatial data analysis to investigate its spatial agglomeration pattern. The results show that: (1) From 1988 to 2018, the degree of spatial agglomeration of China’s forest products manufacturing industry was relatively low, and the industry was characterized by a very pronounced imbalance in its spatial distribution. (2) The industry has a very clear core–periphery structure, the spatial distribution exhibits a “northeast-southwest” pattern, and the barycenter of the industrial distribution has tended to move south. (3) The industry mainly has a high–high and low–low spatial agglomeration pattern. The provinces with high–high agglomeration are few and concentrated in the southeast coastal area. (4) The spatial agglomeration and evolution characteristics of China’s forest products manufacturing industry may be simultaneously affected by forest protection policies, sources of raw materials, international trade and the degree of marketization. In the future, China’s forest products manufacturing industry should further increase the level of spatial agglomeration to fully realize the economies of scale.

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