scholarly journals Investigation of the Cutting Uid'S Ow and its Thermomechanical Effect on the Cutting Zone Based on Uid-Structure Interaction (FSI) Simulation

2021 ◽  
Author(s):  
Hui Liu ◽  
Markus Meurer ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Metal Cutting ◽  
Negative Impact ◽  
Orthogonal Cutting ◽  
Fluid Simulation ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Thermomechanical Effect ◽  
Dimensional Simulation ◽  
On Chip ◽  
Cutting Processes

Abstract Cutting fluids are an important part of today's metal cutting processes, especially when machining aerospace alloys. They offer the possibility to extend tool life and improve cutting performance. However, the equipment and handling of cutting fluids also raises manufacturing costs. To reduce the negative impact of the high cost of cutting fluids, cooling systems and strategies are constantly being optimized. In most existing works, the influences of different cooling strategies on the relevant process parameters, such as tool wear, cutting forces, chip breakage, etc., are empirically investigated. Due to the limitations of experimental methods, analysis and modeling of the working mechanism has so far only been carried out at a relatively abstract level. For a better understanding of the mechanism of cutting fluids, a thermal coupled two-dimensional simulation approach for the orthogonal cutting process was developed in this work. This approach is based on the Coupled Eulerian Lagrangian (CEL) method and provides a detailed investigation of the cutting fluid’s impact on chip formation and tool temperature. For model validation, cutting tests were conducted on a broaching machine. The simulation resolved the fluid behavior in the cutting area and showed the distribution of convective cooling on the tool surface. This work demonstrates the potential of CEL based cutting fluid simulation, but also pointed out the shortcomings of this method.

The Effect of Superheated Water Vapor as Coolant and Lubricant on Chip Formation of Difficult-to-Cut Materials in Green Cutting

2008 ◽  
Vol 375-376 ◽  
pp. 172-176 ◽  
Author(s):  
Rong Di Han ◽  
Yue Zhang ◽  
Yang Wang ◽  
Guo Fan Cao ◽  
Jie Liu
Keyword(s):  
Water Vapor ◽  
Chip Formation ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Contact Length ◽  
Cutting Fluid ◽  
Environment Friendly ◽  
Cutting Zone ◽  
On Chip ◽  
Deformation Coefficient

Green cutting is ecologically desirable and have been a tendency in the industry field. Water vapor can be introduced in metal cutting as coolant and lubricant due to its pollution-free, generating easily and unneeded disposal. Therefore, water vapor is an environment-friendly coolant and lubricant in machining. This study attempts to understand the effect of water vapor as coolant and lubricant on chip formation. In the comparison experiments to dry and wet cutting, water vapor jet flow from a developed generator is applied into cutting zone directly. When YG8 (K20 in ISO) tools are used to turn titanium alloy TC4 (Ti-6Al-4V), Ni-based super alloy GH3030 and stainless steel 1Cr18Ni9Ti in orthogonal cutting, through quick-stop tests, the photos of polished chip sections microstructure were obtained. And the results suggest that the application of water vapor produces the least BUE, tool-chip contact length but the largest deformation coefficient and shear angle. The water vapor as coolant and lubricant could be a substitution of cutting fluid to carry out green cutting in the machining of difficult-to-cut materials.

Computational Methods for the Assessment of Nanofluids in Abrasive Processes

2017 ◽  
Vol 261 ◽  
pp. 201-206
Author(s):  
Nikolaos E. Karkalos ◽  
Angelos P. Markopoulos
Keyword(s):  
Temperature Profile ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Fluid ◽  
Environmental Concerns ◽  
Cutting Fluids ◽  
Fluid Type ◽  
Cooling Fluid ◽  
Cutting Processes ◽  
The Cost

Metal cutting processes such as machining or abrasive processes are related to the production of relatively large amounts of heat, as a result of the intense contact of workpiece and cutting tool. For that reason, it is often necessary to employ a cooling fluid in order to alleviate the intense and usually undesired heat-induced effects on the workpiece. Due to the cost and environmental concerns regarding cutting fluids, the heat absorbing efficiency and quantity of cutting fluids employed is always a concern. In the present work, the effect of cutting fluid type in the temperature profile of the workpiece during grinding is investigated and useful conclusions are drawn, concerning the efficiency of nanofluids as cutting fluids.

Some Effects of Cutting Fluids on Chip Formation in Metal Cutting

1965 ◽  
Vol 87 (1) ◽  
pp. 36-38 ◽  
Author(s):  
H. S. Rama Iyengar ◽  
R. Salmon ◽  
W. B. Rice
Keyword(s):  
Chip Formation ◽  
Metal Cutting ◽  
Cooling Effect ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Steel Tubing ◽  
Internally Cooled ◽  
Higher Temperature ◽  
Temperature Equilibrium ◽  
On Chip

In cutting dry AISI C-1025 steel tubing, with a variety of cutting fluids, and with an internally cooled tool, two distinct equilibria were discerned. Chip temper colors indicate that these are thermal equilibria. The establishment of the second, higher temperature equilibrium is delayed or prevented by using cutting fluids and delayed by using an internally cooled tool. It is concluded that the cooling effect of a cutting fluid is of primary importance.

scholarly journals A Novel Experimental Test Bench to Investigate the Effects of Cutting Fluids on the Frictional Conditions in Metal Cutting

2020 ◽  
Vol 4 (2) ◽  
pp. 45 ◽  
Author(s):  
Thomas Lakner ◽  
Marvin Hardt
Keyword(s):  
Experimental Test ◽  
Metal Cutting ◽  
Test Bench ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Workpiece Material ◽  
Fluid Supply ◽  
Frictional Forces ◽  
Experimental Test Bench

The tribological effect of cutting fluids in the machining processes to reduce the friction in the cutting zone is still widely unknown. Most test benches and procedures do not represent the contact conditions of machining processes adequately, especially for interrupted contacts. This results in a lack of knowledge of the tribological behavior in machining processes. To close this knowledge gap, a novel experimental test bench to investigate the effects of cutting fluids on the frictional conditions in metal cutting under high-pressure cutting fluid supply was developed and utilized within this work. The results show that there is a difference between the frictional forces in interrupted contact compared to continuous contact. Furthermore, the cutting fluid parameters of supply pressure, volumetric flow rate, and impact point of the cutting fluid jet influence the frictional forces, the intensities of which depend on the workpiece material. In conclusion, the novel test bench allows examining the frictional behavior in interrupted cuts with an unprecedented precision, which contributes to a knowledge-based design of the cutting fluid supply for cutting tools.

scholarly journals A COMPREHENSIVE REVIEW ON EVALUATION OF ENVIRONMENTAL FRIENDLY MACHINABILITY, CUTTING FLUIDS AND TECHNIQUES IN METAL CUTTING OPERATION

2021 ◽  
Vol 9 (04) ◽  
pp. 223-235
Author(s):  
Rajeev Sharma ◽  
◽  
Binit Kumar Jha ◽  
Vipin Pahuja ◽  
◽  
...  
Keyword(s):  
Metal Cutting ◽  
Cost Effective ◽  
Machining Process ◽  
Cutting Fluid ◽  
Work Piece ◽  
Cutting Fluids ◽  
Environmental Friendly ◽  
Different Types ◽  
Two Factors ◽  
Cutting Operation

Todays, due to the environmental concerns, growing contamination and pollution regulations, the demand for renewable and biodegradable cutting fluids is increasing day by day. Environmental friendly machining is one of the latest approach which is economical and also eco-friendly that improve the machinability. Different types of environmental friendly machining techniques are available e.g. MQL machining, cryogenic machining, dry machining and high pressure cooling approach. In this article, an attempt is made regarding environmental friendly machining processing, including different types of cutting fluids and machining techniques. The Knowledge of cutting fluid and its processing conditions is of critically importance to maximize the efficiency of cutting fluids in any machining process. In general, the generation of heat in the cutting zone due to friction at the tool-chip interface and the friction between the safety surface of the tool and the work piece is always the deciding factor on the quality of the work piece surface. In any manufacturing industries or company two factors play important role in machinability and productivity e.g. surface quality and tool wear. The main objective of this review article that analysis the different environmental friendly machining techniques and encourages the cooling approach in metal cutting operation. So finally, after the literature survey found that environmental friendly machining approach is cost effective machining process and also eco-friendly machining process.

scholarly journals Review on Performance Evaluation of Machining Characteristics using Vegetable-based Cutting Fluids – An approach towards Green Manufacturing

2021 ◽  
Vol 58 (2) ◽  
pp. 6358-6365
Author(s):  
Mohd. Asif I. Gandhi
Keyword(s):  
Vegetable Oil ◽  
Metal Cutting ◽  
Harmful Effect ◽  
Green Manufacturing ◽  
Machining Process ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Machining Characteristics ◽  
Disposal Cost ◽  
Lubricating Properties

Lubricants play a major role in decreasing friction and wear during the machining process. Commercial metal cutting fluids are non-renewable and also produces the harmful effect to the environment as well as the operators. The preparation and disposal cost of mineral oil is an expensive one. To promote sustainable and green manufacturing eco-friendly cutting fluid is the need of an hour. Vegetable oil is preferred as an alternative tocommercial cutting fluid owing to its environmentally friendly, biodegradability, renewable, and less toxic, as well as exceptional lubricating properties. This article discusses the influence of various vegetable oil used for the material removal process and its performance. Vegetable oils significantly enhance the machining characteristics in terms of cutting force, tool wear, and surface quality

3D Finite Element Simulation on the Orthogonal Cutting Processes with Different Commercial Codes

2011 ◽  
Vol 188 ◽  
pp. 555-560
Author(s):  
Zhao Yu Mou ◽  
Peng Fei Gao ◽  
Wei Fang Wang ◽  
Dong Hui Wen
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Orthogonal Experiment ◽  
Orthogonal Cutting ◽  
Friction Model ◽  
Element Simulation ◽  
Cutting Experiment ◽  
Type Boundary ◽  
Cutting Processes ◽  
Type Boundary Condition

The purpose of this paper is to compare different simulation model of orthogonal cutting process using three different FEM commercial codes as well as with the results of orthogonal experiment. For one thing, element type, boundary condition and friction model between the chip and tool commercial have been compared when the numerical model established in implicit finite element code, Deform3D and the explicit code ANSYS/LS-DYNA and Thirdwave AdvantEdge. For another, main and thrust cutting forces, shear angles, chip thicknesses and contact lengths by three codes are compared with the orthogonal metal cutting experiment by Movahhedy and Altintas.

scholarly journals Dislocation Density Based Flow Stress Model Applied to the PFEM Simulation of Orthogonal Cutting Processes of Ti-6Al-4V

Materials ◽  
2020 ◽  
Vol 13 (8) ◽  
pp. 1979 ◽  
Author(s):  
Juan Manuel Rodríguez ◽  
Simon Larsson ◽  
Josep Maria Carbonell ◽  
Pär Jonsén
Keyword(s):  
Dislocation Density ◽  
Constitutive Model ◽  
Manufacturing Industry ◽  
Metal Cutting ◽  
Deformation Behaviour ◽  
Orthogonal Cutting ◽  
Constitutive Models ◽  
Shear Zones ◽  
Cutting Processes ◽  
Mechanical Cutting

Machining of metals is an essential operation in the manufacturing industry. Chip formation in metal cutting is associated with large plastic strains, large deformations, high strain rates and high temperatures, mainly located in the primary and in the secondary shear zones. During the last decades, there has been significant progress in numerical methods and constitutive modeling for machining operations. In this work, the Particle Finite Element Method (PFEM) together with a dislocation density (DD) constitutive model are introduced to simulate the machining of Ti-6Al-4V. The work includes a study of two constitutive models for the titanium material, the physically based plasticity DD model and the phenomenology based Johnson–Cook model. Both constitutive models were implemented into an in-house PFEM software and setup to simulate deformation behaviour of titanium Ti6Al4V during an orthogonal cutting process. Validation show that numerical and experimental results are in agreement for different cutting speeds and feeds. The dislocation density model, although it needs more thorough calibration, shows an excellent match with the results. This paper shows that the combination of PFEM together with a dislocation density constitutive model is an excellent candidate for future numerical simulations of mechanical cutting.

Effect of Cutting Fluid Supply Strategies on Surface Finish of Turned Parts

2011 ◽  
Vol 383-390 ◽  
pp. 4576-4584 ◽  
Author(s):  
M.N. Islam ◽  
N. H. Rafai ◽  
B. C. Heng
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Negative Impact ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Anova Analysis ◽  
Fluid Supply ◽  
Steel Aisi ◽  
Turned Parts

This paper presents the experimental and analytical results of different cutting fluid supply strategies—dry, minimum quantity lubrication (MQL) and flood turning in terms of the surface finish of turned parts. Subsequently, the influence of independent input parameters on surface finish is investigated in order to optimize their effects. Three techniques—traditional analysis, Pareto ANOVA analysis, and the Taguchi method—are employed. Initially mild steel AISI 1030 has been selected as the work material. The results indicate that the cutting fluid supply strategy has insignificant influence on the surface finish of turned parts. However, the amount of cutting fluid in MQL showed some influence. Further research on two additional materials, aluminum 6061 and alloy steel AISI 4340, reveals that the surface roughness for different work materials is influenced differently by the cutting fluid supply strategies and there is a scope for optimizing the cutting fluid supply strategy in terms of both method and the amount of cutting fluid. This will reduce the amount of cutting fluids used and consequently, their negative impact on the environment, by avoiding unnecessary applications.

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