scholarly journals Influence of Graphene Nanosheets on Thermo-Physical and Tribological Properties of Sustainable Cutting Fluids for MQL Application in Machining Processes

2021 ◽  
Author(s):  
Vitor Baldin ◽  
Leonardo R Ribeiro da Silva ◽  
Rogério Valentim Gelamo ◽  
Adres Bustillo Iglesias ◽  
Rosemar Batista da Silva ◽  
...  
Keyword(s):  
Tribological Properties ◽  
Graphene Nanosheets ◽  
Milling Process ◽  
Graphene Sheets ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Cemented Carbide Tool ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Abstract This study investigates the effects of applying two vegetable and one mineral-based cutting fluids with 0.05 %wt and 0.1 %wt dispersion of graphene sheets on the tribosystem generated at the interface between the cemented carbide tool and the AISI 1045 steel workpiece. The fluids are firstly characterized (viscosity, thermal conductivity and diffusivity, and wettability) and tested in reciprocating and ramp milling tests. The results show that the graphene sheets alter the thermo-physical and tribological properties of the cutting fluids; in this case, vegetable-based cutting fluids, even in minimum quantities and with graphene nanoparticles, have a high potential for increasing the efficiency and sustainability of the milling process.

scholarly journals Effect of Graphene Addition in Cutting Fluids Applied by MQL in End Milling of AISI 1045 Steel

Lubricants ◽  
2021 ◽  
Vol 9 (7) ◽  
pp. 70
Author(s):  
Vitor Baldin ◽  
Leonardo Rosa Ribeiro da Silva ◽  
Celso Ferraz Houck ◽  
Rogério Valentim Gelamo ◽  
Álisson Rocha Machado
Keyword(s):  
Tool Life ◽  
Wear Mechanisms ◽  
End Milling ◽  
Fatigue Cracks ◽  
Graphene Sheets ◽  
Cutting Fluids ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Cemented Carbide

The cutting fluids applied to the machining processes by the MQL process aim to reduce the machining temperatures and tool wear as well as improve the surface and dimensional finishing of the parts. To increase the efficiency of these fluids, graphene lubricating platelets are added. This work investigated the performance of three different cutting fluids with graphene sheets added and applied via MQL, considering the tool life, wear, and wear mechanisms acting on TiAlN-coated cemented carbide cutting tools in the end milling of AISI 1045 steel. We evaluated two vegetable- (MQL15 and LB1000) and one mineral-based (MQL14) neat oils and the same fluids with the addition of 0.05 and 0.1%wt graphene nanoplatelets. Dry cuts were also performed and investigated for comparison. The experiments were conducted under fixed cutting conditions (vc = 250 m/min, fz = 0.14 mm/tooth, ap = 1 mm, and ae = 20 mm). The end-of-tool-life criterion followed the guidelines of ISO 8688-1 (1989). To analyze the results, ANOVA and Tukey’s test were applied. The addition of graphene sheets in the vegetable-based cutting fluids effectively increased the lubricating properties, partially reducing the wear mechanisms acting on the tools. In addition, there was a predominance of thermal fatigue cracks and mechanical cracks as well as adhesive and abrasive wear mechanisms on the tools used in the cutting with the MQL15 and MQL14 fluids, indicating greater cyclical fluctuations in temperature and surface stresses.

Synthesis, characterization and tribological behavior of oleic acid-capped core-shell lanthanum borate-SiO2 composites

2014 ◽  
Vol 66 (1) ◽  
pp. 1-8 ◽  
Author(s):  
Zhengfeng Jia ◽  
Yan-qiu Xia ◽  
Xin Shao ◽  
San-ming Du
Keyword(s):  
Oleic Acid ◽  
Tribological Properties ◽  
Friction And Wear ◽  
Thermo Gravimetric Analysis ◽  
Core Shell ◽  
Gravimetric Analysis ◽  
Content Type ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Purpose – The purpose of this paper is to investigate the tribological properties of poly-alpha-olefin (PAO) with nano/microstructure core-shell lanthanum borate-SiO2 composites (OCLS). Design/methodology/approach – Oleic acid-capped core-shell lanthanum borate-SiO2 composites were synthesized by an easy way. The composites were characterized by means of Fourier transform-infrared spectroscopy (FT-IR), transmission electron microscopy (TEM) and thermo gravimetric analysis (TGA). The friction and wear behaviors of the quenched AISI 1045 steel specimens sliding against AISI 52100 steel under the lubrication of PAO containing OCLS were comparatively investigated with PAO containing SiO2 additive on an Optimol SRV reciprocating friction and wear tester. On the other hand, the tribological properties of the PAO containing OCLS were also investigated on four-ball tester. Findings – The diameter of OCLS was about 20 nm, and the thickness of the SiO2 shell was less than 5 nm. The ratio of oleic acid (OA) is about 15 percent. The PAO containing OCLS possesses much better tribological properties than that of pure PAO and PAO containing SiO2 additive. Originality/value – The PAO+OCLS possess a better friction reducing and antiwear properties than pure PAO. The new additive can improve the tribological ability of machinery.

Tribological Properties of Cr Coating Lubricated with Different Lubricants

2013 ◽  
Vol 651 ◽  
pp. 470-473
Author(s):  
Xin Feng ◽  
Xiang Yu Ge
Keyword(s):  
Tribological Properties ◽  
Liquid Paraffin ◽  
Wear Volume ◽  
Pure Liquid ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Aisi 52100 Steel ◽  
Cr Coating ◽  
Steel Substrates ◽  
1045 Steel

In this paper, Cr coatings were prepared onto AISI 1045 steel substrates using medium frequency magnetic sputtering process, and were analyzed using the X-ray diffraction (XRD). Five kinds of lubricants were chosen and evaluated as lubricants for Cr coatings/AISI 52100 steel contacts at room temperature. The tribological properties of the lubricants were investigated using a ball-on-disk type UMT reciprocating friction tester. The results indicated that the 1-ethyl-3-hexylimidazolium hexafluorophosphate (L-P206) ILs has excellent friction-reducing properties, the friction coefficient kept at a relatively stable value of 0.036, however pure liquid paraffin has the lowest wear volume value. The Cr coatings using different lubricants show different tribology properties. The worn surfaces of Cr coatings were observed and analyzed using a scanning electron microscope (SEM).

A Parametric Study of the Modeling of Orthogonal Machining Using the Smoothed Particle Hydrodynamics Method

2015 ◽  
Author(s):  
Chinmay S. Avachat ◽  
Harish P. Cherukuri
Keyword(s):  
Finite Element ◽  
Smoothed Particle Hydrodynamics ◽  
Chip Morphology ◽  
Machining Processes ◽  
Orthogonal Machining ◽  
Particle Hydrodynamics ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Smoothed Particle ◽  
1045 Steel

Modeling machining processes with conventional finite element methods (FEM) is challenging due to the severe deformations that occur during machining, complex frictional conditions that exist between the cutting tool and the workpiece, and the possibility of self contact due to chip curling. Recently, the Smoothed Particle Hydrodynamics (SPH) method has emerged as a potential alternative for modeling machining processes due to its ability to handle severe deformations while avoiding mass and energy losses encountered by traditional FEM. The method has been implemented in several commercial finite element packages such as ABAQUS and LS-DYNA for solving problems involving localized severe deformations. Numerous control parameters are present in a typical SPH formulation. The purpose of this work is to evaluate the effect of the three most important parameters, namely, the smoothing length, particle density, and the type of SPH formulation. The effects of these parameters on the chip morphology and stress distribution in the context of orthogonal machining of AISI 1045 steel are investigated. The LS-DYNA finite element package along with Johnson-Cook material model is used for this purpose. Results from the parametric study are presented and compared with the previously reported results in the literature. In addition, the sensitivity of chip morphology and stresses to Johnson-Cook parameters for AISI 1045 steel is also investigated by considering five different sets of values reported in the literature for this steel.

scholarly journals Effect of Cutting Conditions on the Residual Stresses Induced by Milling of AISI 1045 Steel

2019 ◽  
Vol 8 (2) ◽  
pp. 1462-1465 ◽  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Diffraction Method ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Machined Surface ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

The nature of residual stresses caused by machining processes has been relevant to the study of component performance for decades. The concept that cutting parameters affect the magnitude and nature of residual stress is well known. In order to reduce the residual stresses on a machined surface, it is important to identify the extent of the effect of cutting conditions. This paper presents the effect of depth of cut and tool speed on milling induced residual stresses. Speed and depth of cut were varied when milling several AISI 1045 Steel specimens. Stresses were measured with the X-ray diffraction method and corroborated with mathematical modelling on an FEA software. A relationship between tool speed and residual stress, and depth of cut and residual stress was thus obtained.

Selection of Optimal Tool Geometry and Cutting Conditions in End Milling With Graphite as a Solid Lubricant

2004 ◽  
Author(s):  
N. Suresh Kumar Reddy ◽  
P. Venkateswara Rao
Keyword(s):  
Solid Lubricant ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Cutting Fluids ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

Coolants dissipate the heat generated during machining and hence improve productivity, machinability, etc. However, the use of cutting fluids in machining operations may seriously degrade the quality of environment. So, in recent years researchers have started machining with the use of solid lubricants with the aim of improving machining performance and overcome some of the limitations that arise with the use of cutting fluids or while machining dry. This paper deals with an investigation on using graphite as a solid lubricant to reduce the heat generated at the milling zone for improving the surface roughness of the machined AISI 1045 steel. An experimental setup has been developed to maintain constant flow rate of graphite powder continuously on to the workpiece and tool interface zone. The experimental studies have been conducted to see the effect of tool geometry (radial rake angle and nose radius) and cutting conditions (cutting speed and feed rate) on the machining response such as surface finish in solid lubricant assisted machining using four fluted solid TiAlN coated carbide cutters. Results indicate that there is a considerable improvement in the performance of milling AISI 1045 steel using graphite as a solid lubricant when compared with machining with cutting fluids. An attempt has also been made to select optimum tool geometry and cutting conditions in end milling with graphite as a solid lubricant by using the prediction model obtained from these experimental results.

Hybrid Modelling and Optimization of the Oblique Cutting of AISI 1045 Steel

2018 ◽  
Vol 8 (4) ◽  
pp. 1-22 ◽  
Author(s):  
Iván La Fé Perdomo ◽  
Ramón Quiza ◽  
Marcelino Rivas ◽  
Veena Ramtahalsing
Keyword(s):  
Hybrid Approach ◽  
Search Space ◽  
Wide Sense ◽  
Machining Processes ◽  
Oblique Cutting ◽  
Conflicting Objectives ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Competitive Products ◽  
1045 Steel

Optimization is a very important issue in mechanical industry, especially in machining processes, where different aspects must be considered. Thus, selecting the most proper cutting conditions plays a key role for obtaining efficient and competitive products. This article proposes a hybrid approach for modelling and optimizing the oblique turning processes. Analytical modelling and statistical regressions are combined for predicting the values of the most important parameters involved in the oblique cutting process. The predictions of the model were validated by using experimental data, showing coincidence for a 95%-confidence level. Then, an a posteriori multi-objective optimization is carried out by using a genetic algorithm. Two important and conflicting objectives are simultaneously considered: unit cutting time and tool wear rate, which describe the productivity and tool waste, respectively. The outcome of the optimization process is a set of non-dominated solutions, which are optimal in the wide sense that no other solution in the search space can improve one objective without worsen the other one. Finally, the decision-maker chooses the most convenient solution depending on the actual workshop conditions.

Tribology of Coated Tools in High-Speed Machining: A Tool Wear and “Equivalent Toolface” Geometry Based Study

2005 ◽  
Author(s):  
A. K. Balaji
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Tool Geometry ◽  
Machining Processes ◽  
Coated Tools ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Rough Turning

Predicting tool-wear (and thereby, tool-life) and selecting proper coated tools along with appropriate tool geometry still remains a major concern for industries trying to achieve increased productivity using automated machining processes. This study is focused upon aggressive high-speed rough turning of AISI 1045 steel. The wear patterns in different coated tools (one mono-layer PVD and two multi-layer CVD coatings) are correlated to changes in nominal tool geometry. This study focuses on the role of tooling geometry (inclination and rake angles) and their importance in dictating the behavior, performance, and wear of coated tools. Using an ‘equivalent toolface’ (ET) model, this study correlates the nominal tool geometry to an equivalent geometry, thereby introducing a new methodology for characterizing the complex effects of multilayer coatings in terms of simple effective tool geometry. The ET approach provides a new angle for understanding the tribological effects of coatings in machining.

Application of Biodegradable Cutting Fluids in High Speed Turning

2011 ◽  
Vol 381 ◽  
pp. 20-24 ◽  
Author(s):  
Hong Jie Pei ◽  
Wen Jie Zheng ◽  
Gui Cheng Wang ◽  
Hu Qiang Wang
Keyword(s):  
High Speed ◽  
National Standards ◽  
Cutting Fluids ◽  
Dry Machining ◽  
High Consumption ◽  
Metal Machining ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Better Than

Large quantities of coolant-lubricants are still widely used in metal working industry, generating high consumption and discard costs and impacting the environment. An alternative to current practices is to use biodegradable cutting fluids that doesn’t pollute environment or require new setups. In current study, biodegradable base oils, synthetic ester and castor oil, are chosen and compounded into cutting fluids which correspond with the national standards. The tests have been performed to high speed turn AISI 1045 steel in ester-based fluid, castor-based emulsion, kerosene and dry condition. The results indicate that the application of cutting fluids is inevitable in metal machining and can not be replaced by dry machining. The lubricating and cooling properties of the ester-based fluid and castor-based emulsion are better than kerosene and can wholly replace mineral oil.

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