Performance Assessment of Minimum Quantity Castor-Palm Oil Mixtures in Hard-Milling Operation

The necessity to progress towards sustainability has inspired modern researchers to examine the lubrication and cooling effects of vegetable oils on conventional metal cutting operations. Consequently, as an eco-friendly vegetable product, castor oil can be the right choice as Minimum quantity lubrication (MQL) base fluid. Nonetheless, the high viscosity of castor oil limits its flowability and restricts its industrial application. Conversely, palm oil possesses superior lubricity, as well as flowability characteristics. Hence, an attempt has been made to improve the lubrication behavior of castor oil. Here, six castor-palm mixtures (varying from 1:0.5–1:3) were utilized as MQL-fluid, and the values of machining responses viz. average surface roughness, specific cutting energy, and tool wear were evaluated. Furthermore, an integrated Shannon’s Entropy-based Technique for order preference by similarity to ideal solution (TOPSIS) framework was employed for selecting the most suitable volume ratio of castor-palm oil mixture. The rank provided by the TOPSIS method confirmed that 1:2 was the best volume ratio for castor-palm oil mixture. Afterward, a comparative analysis demonstrated that the best castor-palm volume fraction resulted in 8.262 and 16.146% lowering of surface roughness, 5.459 and 7.971% decrement of specific cutting energy, 2.445 and 3.155% drop in tool wear compared to that of castor and palm oil medium, respectively.

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Laser-Assisted Machining of a Fiber Reinforced Metal Matrix Composite

ASME 2009 International Manufacturing Science and Engineering Conference, Volume 2 ◽

10.1115/msec2009-84013 ◽

2009 ◽

Cited By ~ 4

Author(s):

Chinmaya R. Dandekar ◽

Yung C. Shin

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Metal Matrix ◽

Material Removal ◽

Volume Fraction ◽

Cutting Speed ◽

Surface Damage ◽

Specific Cutting Energy ◽

Cutting Energy ◽

Multi Phase

Metal matrix composites due to their excellent properties of high specific strength, fracture resistance and corrosion resistance are highly sought after over their non-ferrous alloys, but these materials also present difficulty in machining. Excessive tool wear and high tooling costs of diamond tools makes the cost associated with machining of these composites very high. This paper is concerned with machining of high volume fraction long-fiber MMC’s, which has seldom been studied. The composite material considered for this study is an Al-2%Cu aluminum matrix composite reinforced with 62% by volume fraction alumina fibers (Al-2%Cu/Al2O3). Laser-machining is utilized to improve the tool life and the material removal rate while minimizing the sub-surface damage. The effectiveness of the laser-assisted machining process is studied by measuring the cutting forces, specific cutting energy, surface roughness, sub-surface damage and tool wear under various material removal temperatures. A multi-phase finite element model is developed in ABAQUS/Standard to identify and assist in selection of cutting parameters such as; tool rake angle, cutting speed and material removal temperature. The multi-phase model is also successful in predicting the damage depth on machining. The optimum material removal temperature is established as 300°C at a cutting speed of 30 m/min. LAM provides a 65% reduction in the surface roughness, specific cutting energy, the tool wear rate and minimum sub-surface damage over conventional machining using the same cutting conditions.

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Feasibility of Supercritical Carbon Dioxide Based Metalworking Fluids in Micromilling

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4023375 ◽

2013 ◽

Vol 135 (2) ◽

Cited By ~ 1

Author(s):

S. D. Supekar ◽

B. A. Gozen ◽

B. Bediz ◽

O. B. Ozdoganlar ◽

S. J. Skerlos

Keyword(s):

Carbon Dioxide ◽

Surface Roughness ◽

Stainless Steel ◽

Supercritical Carbon Dioxide ◽

Tool Wear ◽

304 Stainless Steel ◽

Metalworking Fluids ◽

Burr Formation ◽

Specific Cutting Energy ◽

Cutting Energy

This article investigates the feasibility of using supercritical carbon dioxide based metalworking fluids (scCO2 metalworking fluids (MWFs)) to improve micromachinability of metals. Specifically, sets of channels were fabricated using micromilling on 304 stainless steel and 101 copper under varying machining conditions with and without scCO2 MWF. Burr formation, average specific cutting energy, surface roughness, and tool wear were analyzed and compared. Compared to dry machining, use of scCO2 MWF reduced burr formation in both materials, reduced surface roughness by up to 69% in 304 stainless steel and up to 33% in 101 copper, tool wear by up to 20% in 101 copper, and specific cutting energy by up to 87% in 304 stainless steel and up to 40% in 101 copper. The results demonstrate an improvement in micromachinability of the materials under consideration and motivate future investigations of scCO2 MWF-assisted micromachining to reveal underlying mechanisms of functionality, as well as to directly compare the performance of scCO2 MWF with alternative MWFs appropriate for micromachining.

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Statistical analysis of energy consumption, tool wear and surface roughness in machining of Titanium alloy (Ti-6Al-4V) under dry, wet and cryogenic conditions

Mechanical Sciences ◽

10.5194/ms-10-561-2019 ◽

2019 ◽

Vol 10 (2) ◽

pp. 561-573 ◽

Cited By ~ 2

Author(s):

Muhammad Ali Khan ◽

Syed Husain Imran Jaffery ◽

Mushtaq Khan ◽

Muhammad Younas ◽

Shahid Ikramullah Butt ◽

...

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Effective Means ◽

Sustainable Manufacturing ◽

Cutting Speed ◽

Depth Of Cut ◽

Machining Parameters ◽

Specific Cutting Energy ◽

Cutting Energy ◽

Positive Effect

Abstract. Productivity and economy are key elements of any sustainable manufacturing system. While productivity is associated to quantity and quality, economy focuses on energy efficient processes achieving an overall high output to input ratio. Machining of hard-to-cut materials has always posed a challenge due to increased tool wear and energy loss. Cryogenics have emerged as an effective means to improve sustainability in the recent past. In the present research the use of cooling conditions has been investigated as an input variable to analyze its effect on tool wear, specific cutting energy and surface roughness in combination with other input machining parameters of feed rate, cutting speed and depth of cut. Experimental design was based on Taguchi design of experiment. Analysis of Variance (ANOVA) was carried out to ascertain the contribution ratio of each input. Results showed the positive effect of coolant usage, particularly cryogenic, on process responses. Tool wear was improved by 33 % whereas specific cutting energy and surface roughness were improved by 10 % and 9 % respectively by adapting the optimum machining conditions.

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Laser-Assisted Machining of a Fiber Reinforced Metal Matrix Composite

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4002548 ◽

2010 ◽

Vol 132 (6) ◽

Cited By ~ 27

Author(s):

Chinmaya R. Dandekar ◽

Yung C. Shin

Keyword(s):

Tool Wear ◽

Metal Matrix ◽

Material Removal ◽

Volume Fraction ◽

Cutting Speed ◽

Subsurface Damage ◽

Matrix Composites ◽

Specific Cutting Energy ◽

Laser Assisted Machining ◽

Cutting Energy

Metal matrix composites, due to their excellent properties of high specific strength, fracture resistance, and corrosion resistance, are highly sought after over their nonferrous alloys, but these materials also present difficulty in machining. Excessive tool wear and high tooling costs of diamond tools make the cost associated with machining of these composites very high. This paper is concerned with the machining of high volume fraction long-fiber metal matrix composites (MMCs), which has seldom been studied. The composite material considered for this study is an Al–2% Cu aluminum matrix composite reinforced with 62% by volume fraction alumina fibers (Al–2% Cu/Al2O3). Laser-assisted machining (LAM) is utilized to improve the tool life and the material removal rate while minimizing the subsurface damage. The effectiveness of the laser-assisted machining process is studied by measuring the cutting forces, specific cutting energy, surface roughness, subsurface damage, and tool wear under various material removal temperatures. A multiphase finite element model is developed in ABAQUS/STANDARD to assist in the selection of cutting parameters such as tool rake angle, cutting speed, and material removal temperature. The multiphase model is also successful in predicting the damage depth on machining. The optimum material removal temperature is established as 300°C at a cutting speed of 30 m/min. LAM provides a 65% reduction in the surface roughness, specific cutting energy, tool wear rate, and minimum subsurface damage over conventional machining using the same cutting conditions.

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