scholarly journals Development of an enhanced single point milling procedure to screen metalworking cutting fluid performance in terms of tool wear when machining aerospace alloys

2020 ◽  
pp. 095440542096815
Author(s):  
Thawhid Khan ◽  
Matthew Broderick ◽  
Syed Ashir Sajid ◽  
Jack Secker ◽  
Chris M Taylor
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Low Cost ◽  
Single Point ◽  
Cutting Fluid ◽  
Screening Tests ◽  
Metalworking Fluids ◽  
Suitable Candidate ◽  
Aerospace Alloys ◽  
Machining Test

Metalworking fluids (MWFs) can greatly improve the machinability of materials and increase cutting tool life. There are a range of MWF products available on the market, however there are very few reliable low cost machining based fluid screening tests which can help select the most suitable candidate. This study developed a novel and rigorous single point milling (SPM) procedure carried out under controlled conditions, which would provide fluid performance differentiation for a range of typical aerospace alloys. The use of a single insert with a controlled geometry reduced machining variance and ensured performance repeatability. Tool life curves were used to determine optimum machining surface speeds for Inconel 718 (In718) of 80 m/min and Ti-6Al-4V (Ti64) of 160 m/min. Carrying out trials using five different cutting fluid products within a controlled tool life window clearly demonstrated that the SPM machining test was able to differentiate performance on both In718 and Ti64 material. Overall a 65% and 53% performance difference in tool life behaviour was observed between the best and worst performing fluids for In718 and Ti64, respectively.

Calculation of Tool Life of a Single Point Cutting Tool under Different Metallic Coatings

2019 ◽  
Vol 6 (4) ◽  
pp. 8-11
Author(s):  
Chandra Mouli Anumula ◽  
Kiran Datta Talluri ◽  
Vikram Sinha ◽  
Annamareddy Srinadh
Keyword(s):  
Tool Life ◽  
Cutting Tool ◽  
Single Point ◽  
Metallic Coatings

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.

scholarly journals Optimisation of cutting fluid concentration and operating parameters based on RSM for turning Ti–6Al–4V

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

AbstractThe 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 and 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.

Different Methods of Cutting Fluid Application on Turning of a Difficult-to-Machine Steel

2012 ◽  
Vol 628 ◽  
pp. 476-481
Author(s):  
L.E.A. Sanchez ◽  
G.L. Palma ◽  
L.J. Nalon ◽  
A.E. Santos ◽  
D.L. Modolo
Keyword(s):  
High Pressure ◽  
Cutting Force ◽  
Conventional Method ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Fluid ◽  
Pressure System ◽  
Minimum Quantity ◽  
Machine Steel ◽  
Set Up

Different methods of cutting fluid application are used on turning of a difficult-to-machine steel (SAE EV-8). A semi-synthetic cutting fluid was applied using a conventional method, minimum quantity of cutting fluid (MQCF), and pulverization. By the minimum quantity method was also applied a lubricant of vegetable oil (MQL). Thereafter, a cutting fluid jet under high pressure (3.0 MPa) was singly applied in the following regions: chip-tool interface; top surface of the chip; and tool-workpiece contact. Two other methods were used: an interflow between conventional application and chip-tool interface jet and, finally, three jets simultaneously applied. In order to carry out these tests, it was necessary to set up a high pressure system using a piston pump for generating a cutting fluid jet, a Venturi for fluid application (MQCF and MQL), and a nozzle for cutting fluid pulverization. The output variables analyzed included tool life, surface roughness, cutting tool temperature, cutting force, chip form, chip compression rate and machined specimen microstructure. It can be observed that the tool life increases and the cutting force decreases with the application of cutting fluid jet, mainly when it is directed to the chip-tool interface. Excluding the methods involving jet fluid, the conventional method seems to be more efficient than other methods of low pressure.

Application of Minimum Quantity Lubrication for Drum High Clutch in Turning Process

2019 ◽  
Vol 947 ◽  
pp. 160-166
Author(s):  
Nutrada Khumjeen ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Turning Process ◽  
Minimum Quantity

The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.

Experimental Investigations on the Effect of Vegetable Based Cutting Fluid in Turning AISI 1040 Steel

2014 ◽  
Vol 541-542 ◽  
pp. 368-373
Author(s):  
Durwesh Jhodkar ◽  
M. Amaranth ◽  
H. Chelladurai ◽  
J. Ramkumar
Keyword(s):  
Cutting Tool ◽  
Flank Wear ◽  
Single Point ◽  
Coconut Oil ◽  
Good Alternative ◽  
Cutting Fluid ◽  
Experimental Investigations ◽  
Crater Wear ◽  
Turning Operation ◽  
Cutting Tool Insert

Application of petroleum based cutting fluids in machining operation may cause many problems such as eye burn and skin inflation etc. Vegetables oils are good alternative to overcome such issues. In this work, experiments were carried out to study the influence of coconut oil on the performance of single point cutting tool insert in turning operation. Three cutting conditions viz. dry, wet and coconut oil were considered to evaluate the tool wear. Results obtained from the experiments highlighted the advantages of coconut oil, a considerable reduction in flank wear, crater wear and auxiliary wear was observed in the turning operation.

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