scholarly journals Progressing towards Sustainable Machining of Steels: A Detailed Review

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5162
Author(s):  
Kashif Ishfaq ◽  
Irfan Anjum ◽  
Catalin Iulian Pruncu ◽  
Muhammad Amjad ◽  
M. Saravana Kumar ◽  
...  
Keyword(s):  
Skin Diseases ◽  
Cryogenic Treatment ◽  
Sustainable Manufacturing ◽  
Health And Safety ◽  
Minimum Quantity Lubrication ◽  
Solid Lubricants ◽  
Cryogenic Cooling ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
Sustainable Machining

Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

The Jatropha curcas vegetable base soluble cutting oil as a renewable source in the machining of aluminum alloy 7050-T7451

2015 ◽  
Vol 67 (2) ◽  
pp. 181-195 ◽  
Author(s):  
Carlos Alberto Schuch Bork ◽  
Janaina Fracaro Souza Gonçalves ◽  
Jefferson Oliveira Gomes
Keyword(s):  
Aluminum Alloy ◽  
High Speed ◽  
Cutting Tool ◽  
Sustainable Manufacturing ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Cutting Fluid ◽  
Process Conditions ◽  
Renewable Source ◽  
Content Type

Purpose – This article aims to collect data on the aluminum alloy 7050-T7451 machinability used in the manufacturing of aeronautical structures, using the combination of the jatropha vegetable-base soluble cutting oil in relation to the canola vegetal and semisynthetic mineral oils and the technique to apply cutting fluid by flood in relation to the Minimum Quantity Lubrication (MQL) in the milling process (HSM – high-speed machining). Design/methodology/approach – It was observed that the jatropha vegetal cutting oil presented the best results in relation to requirements for lubrication, superficial mean roughness (index Ra) and shape errors in relation to the other oils in both the techniques to apply fluid which were tested. Comparing the application techniques, the jatropha vegetal oil offered an increase in the life span of the cutting tool, using the flood technique, exceeding in almost six times the machined length of the cutting tool in relation to the MQL technique in the same process conditions. Findings – The Jatropha vegetable-base cutting oil, besides being produced from a renewable source, has inherent characteristics that can help attain a sustainable manufacturing, mainly with the use of the flood technique to apply cutting fluid in the aluminum alloy 7050-T7451 machining. Originality/value – The Jatropha (vegetable) oil, in relation to its physicochemical properties, appeared to be the best one fit for being used in the machining of aluminum alloys 7050-T7451 because it did not interfere with any of the elements involved in the formation of intergranular corrosion and/or pitting, which are not allowed in the aeronautical production of parts. Jatropha (vegetable) cutting oil, besides being produced from a clean and renewable source, has the inherent characteristics that can help attain a sustainable manufacturing.

scholarly journals Performance Assessment and Chip Morphology Evaluation of Austenitic Stainless Steel under Sustainable Machining Conditions

Metals ◽  
2021 ◽  
Vol 11 (12) ◽  
pp. 1931
Author(s):  
Anshuman Das ◽  
Smita Padhan ◽  
Sudhansu Ranjan Das ◽  
Mohammad S. Alsoufi ◽  
Ahmed Mohamed Mahmoud Ibrahim ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Performance Assessment ◽  
Sustainable Manufacturing ◽  
Minimum Quantity Lubrication ◽  
Chip Morphology ◽  
Compressed Air ◽  
Ceramic Tool ◽  
Sustainable Machining ◽  
Minimum Quantity

Sustainable manufacturing has received great attention in the last few decades for obtaining high quality products with minimal costs and minimal negative impacts on environment. Sustainable machining is one of the main sustainable manufacturing branches, which is concerned with improving environmental conditions, reducing power consumption, and minimizing machining costs. In the current study, the performance of three sustainable machining techniques, namely dry, compressed air cooling, and minimum quantity lubrication, is compared with conventional flood machining during the turning of austenitic stainless steel (Nitronic 60). This alloy is widely used in aerospace engine components, medical applications, gas power industries, and nuclear power systems due to its superior mechanical and thermal properties. Machining was performed using SiAlON ceramic tool with four different cutting speeds, feeds and a constant depth of cut. Consequently, various chip characteristics such as chip morphology, chip thickness, saw tooth distance and chip segmentation frequency were analyzed with both optical and scanning electron microscopes. Performance assessment was performed under the investigated cutting conditions. Our results show that the tool life under MQL machining are 138%, 72%, and 11% greater than dry, compressed air, and flooded conditions, respectively. The use of SiAlON ceramic tool results is more economically viable under the MQL environment as the overall machining cost per component is lower ($0.27) as compared to dry ($0.36), compressed air ($0.31), and flooded ($0.29) machining conditions. The minimum quantity lubrication technique outperformed the other investigated techniques in terms of eco-friendly aspects, economic feasibility, and technical viability to improve sustainability.

Effect of hBN Solid Lubricant Concentration on Machinability of Titanium (Ti-6Al-4V) Alloy

2015 ◽  
Vol 830-831 ◽  
pp. 87-90 ◽  
Author(s):  
S. Santosh ◽  
K. Rajkumar ◽  
A. Gnanavelbabu
Keyword(s):  
Solid Lubricant ◽  
Hexagonal Boron Nitride ◽  
Sustainable Manufacturing ◽  
Minimum Quantity Lubrication ◽  
Solid Lubricants ◽  
Aerospace Applications ◽  
Dry Conditions ◽  
Cutting Zone ◽  
Cutting Zone Temperature ◽  
Zone Temperature

The prime rationale for designers to choose titanium in their designs for aerospace applications is its relative low weight for a given strength level and its relative resistance to high temperature. Excellent biocompatibility makes titanium as ideal material for many biomedical applications. Even though the titanium products are either sintered or cast into required shape, there is a need for machining in order to produce intricate shapes. However machining of titanium alloys poses many serious problems owing to the reactivity of titanium at high cutting temperatures and rapid tool wear. An alternative method to overcome this is by reducing the cutting zone temperature. This can be achieved by the addition of solid lubricants to regular cutting liquids and using it as minimum quantity lubrication (MQL) strategy. In this study, hexagonal boron nitride (hBN) powder with different concentrations (5, 10, 15 wt %) was mixed with water and used as a lubricant. Turning experiments were performed with TiAlN coated Tungsten carbide insert for a constant speed and variable feed rates. For comparison purpose, machining was carried out under dry conditions. Results indicate that the cutting zone temperature reduced drastically on addition of solid lubricant hBN with water. MQL conditions showed that cutting zone temperature decreased by several folds when compared to dry machining. However there was no significant decrease in temperature between 10 and 15 wt% hBN additions which indicates that 10% hBN addition proves to be optimal. This type of machining thereby paves way for sustainable manufacturing.

Development of A New Cutting Fluid Supply System for Near Dry Machining Process

2008 ◽  
Vol 389-390 ◽  
pp. 175-180
Author(s):  
Motoki Yamashita ◽  
Yasuhiro Kakinuma ◽  
Tojiro Aoyama ◽  
Mitsuho Aoki
Keyword(s):  
High Speed ◽  
Minimum Quantity Lubrication ◽  
Working Environment ◽  
Machining Process ◽  
Cutting Fluid ◽  
Experimental Result ◽  
Video Observation ◽  
Lubrication System ◽  
Dry Cutting ◽  
Oil Mist

Large amount of cutting oil consumption is one of the issues for environment. The Minimum Quantity Lubrication (MQL) technique has been applied to the near-dry cutting process. However, MQL technique generates oil mist which is harmful to the working environment and the health of factory workers. In this study, a new lubrication system called Direct Oil Shot Lubrication System (DOS) was developed and applied to milling processes. The performances of DOS technique was evaluated by measuring the floating oil mist and carrying out the cutting tests. The amount of floating oil mist of DOS system was considerably reduced compared to the MQL. The behavior of small oil drops supplied from DOS nozzle to cutting edge was analyzed by means of a high speed video observation, and the optimum setting for DOS was obtained. The experimental result shows developed DOS system realized the smaller density of oil mist floating than the MQL technique while the DOS attained the almost same lubrication effect in milling process as the MQL technique.

Robust Design of Using MWCNTs in Minimum Quantity Lubrication

2014 ◽  
Vol 670-671 ◽  
pp. 11-21 ◽  
Author(s):  
Wei Tai Huang ◽  
Der Ho Wu ◽  
Shih Pin Lin ◽  
Jian Ting Chen
Keyword(s):  
Robust Design ◽  
High Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
High Speed Milling ◽  
High Speed Cutting ◽  
Thermal Wear ◽  
Cutting Effect ◽  
A New Technique

This objective of this article is to present a new technique of nanofluids/MQL in high speed milling by using MWCNTs. In the past, studies have shown the MQL process can improve tool life and surface accuracy in high speed cutting. The purpose of using carbon nanotubes is to increase the thermal conductivity of cutting fluid and to reduce the temperature during the cutting and decrease the thermal wear of tool. The proposed study is to investigate the characterization of the MWCNTs/ nanofluids combined with MQL during the high speed milling of AISI 1050 and AISI P21 experimentally. The Taguchi robust design was also used to optimize the parameters of nozzle with respect to tool feed direction, such as spraying distance, angle of ejection, and relative locations for improving the MWCNTs/MQL cutting effect. Experimental results showed the MWCNTs/ nanofluid had the benefits of improving surface roughness and reducing wear of tool in high speed milling. The results were compared to dry cutting, and wet cutting in detail.

Green Manufacturing - Textured Novel Cutting Tool for Sustainable Machining: A Review

2020 ◽  
Vol 899 ◽  
pp. 135-143
Author(s):  
Awais Farooqi ◽  
Nukman bin Yusoff
Keyword(s):  
Sustainable Manufacturing ◽  
Cutting Tools ◽  
Minimum Quantity Lubrication ◽  
Green Manufacturing ◽  
Machining Process ◽  
Machining Processes ◽  
Sustainable Machining ◽  
Nano Fluid ◽  
Prime Objective ◽  
Removal Processes

Green manufacturing concept has become a cutting edge in the field of sustainable machining. The prime objective of the philosophy is to find a technique in machining or material removal processes that are environmentally friendly, with minimal wastage, energy efficient and optimal condition for the machining processes. This review paper discusses the significance of textured novel cutting tools, is one of the promising technologies and process. It discusses the Dry Machining process to capture green sustainable manufacturing practices. The study may answer of how it stands among other methods including minimum quantity lubrication and nano fluid lubricant. This paper also presents the importance of advanced manufacturing tools to match the sustainable future needs with an idea of proposed methodology to conduct a research on textured novel cutting tools for sustainable machining.

scholarly journals Eco-Friendly Cutting Fluids in Minimum Quantity Lubrication Assisted Machining: A Review on the Perception of Sustainable Manufacturing

2019 ◽  
Vol 8 (1) ◽  
pp. 249-280 ◽  
Author(s):  
Binayak Sen ◽  
Mozammel Mia ◽  
G. M. Krolczyk ◽  
Uttam Kumar Mandal ◽  
Sankar Prasad Mondal
Keyword(s):  
Vegetable Oil ◽  
Review Paper ◽  
Recent Trend ◽  
Sustainable Manufacturing ◽  
Minimum Quantity Lubrication ◽  
Sustainable Machining ◽  
Minimum Quantity ◽  
Engineering Alloys ◽  
Published Research ◽  
Mql System

AbstractIn modern days, the conception of sustainability has progressively advanced and has begun receiving global interest. Thus, sustainability is an imperative idea in modern research. Considering the recent trend, this review paper presents a summary of the previously published research articles on minimum quantity lubrication (MQL) assisted machining. The requirement to stir towards sustainability motivated the researchers to revise the effects of substitute lubrication methods on the machining. Conventional lubri-cooling agents are still extensively employed when machining of engineering alloys, but the majority of the recent papers have depicted that the utilization of vegetable oil, nanofluids, and nanoplatelets in MQL system confers superior machining performances as compared to conventional lubrication technology. In actual, the definite principle of this manuscript is to re-examine modern advancements in the MQL technique and also explore the benefits of the vegetable oil and nanofluid as a lubricant. In brief, this paper is a testimony to the advancing capabilities of eco-friendly MQL technique which is a viable alternative to the flood lubrication technology, and the outcomes of this review work can be contemplated as a movement towards sustainable machining.

The Influence of the Lubrication Method and the Cutting Regime on the Surface Roughness when Milling 7175 Aluminum Alloy

2013 ◽  
Vol 371 ◽  
pp. 28-32 ◽  
Author(s):  
Vlad Diciuc ◽  
Mircea Lobonțiu ◽  
Gheorghe Bran ◽  
Vasile Lazar
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Feed Rate ◽  
Ecological Impact ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Lubrication Conditions

In the current paper, some aspects regarding the quality of the surface machined under different lubrication conditions is being assessed: cutting under a jet of cutting fluid, minimum quantity lubrication cutting, dry cutting. The objective was to assess the results obtained after MQL cutting in comparison with dry cutting and cutting under a jet of cutting fluid. The variables of the cutting regime were the feed rate and the type of milling (climb and conventional). This study has an important ecological impact over the use of cutting fluids.

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