scholarly journals Non-Traditional Machining Process of Composite Materials using Renewable Lubricants

2020 ◽  
Vol 9 (1) ◽  
pp. 929-933
Keyword(s):  
Thermal Conductivity ◽  
Sunflower Oil ◽  
Metal Cutting ◽  
Machining Process ◽  
Cutting Fluid ◽  
Metal Nitrides ◽  
Cutting Fluids ◽  
Dry Machining ◽  
Carbon Nano Tubes ◽  
Oil Sunflower

The global increasing alertness of the environmental and health problems linked to the use of mineral based metal cutting fluids in machining is lead industry to develop alternative fluid. The fluid should be environmentally friendly and sustainable like vegetable oil with suspended nanoparticle. The low thermal conductivity of cutting fluids of natural based oil requires the addition of nanoparticles. The most common nanoparticle that suitable to be added to cutting fluid are non-metals, carbide, oxide, Carbon Nano Tubes (CNTs) and metal nitrides. In this paper, a comparison had made of dry machining and machining with cutting coolant oil, sunflower oil+MoS2, Sunflower, oil Graphene. The study concludes that, the addition of such minerals to the cutting fluids increased the thermal conductivity of cutting fluids.

scholarly journals Machinability Investigations of Inconel-800 Super Alloy under Sustainable Cooling Conditions

Materials ◽  
2018 ◽  
Vol 11 (11) ◽  
pp. 2088 ◽  
Author(s):  
Munish Gupta ◽  
Catalin Pruncu ◽  
Mozammel Mia ◽  
Gurraj Singh ◽  
Sunpreet Singh ◽  
...  
Keyword(s):  
Chip Morphology ◽  
Surface Characteristics ◽  
Machining Process ◽  
Cutting Fluid ◽  
Critical Parameters ◽  
Chemical Components ◽  
Cutting Fluids ◽  
Dry Machining ◽  
Manufacturing Method ◽  
Inconel 800

With regard to the manufacturing of innovative hard-machining super alloys (i.e., Inconel-800), a potential alternative for improving the process is using a novel cutting fluid approach. Generally, the cutting fluids allow the maintenance of a better tool topography that can generate a superior surface quality of machined material. However, the chemical components of fluids involved in that process may produce harmful effects on human health and can trigger environmental concerns. By decreasing the cutting fluids amount while using sustainable methods (i.e., dry), Near Dry Machining (NDM) will be possible in order to resolve these problems. This paper discusses the features of two innovative techniques for machining an Inconel-800 superalloy by plain turning while considering some critical parameters such as the cutting force, surface characteristics (Ra), the tool wear rate, and chip morphology. The research findings highlight the near-dry machining process robustness over the dry machining routine while its great potential to resolve the heat transfer concerns in this manufacturing method was demonstrated. The results confirm other benefits of these methods (i.e., NDM) linked to the sustainability aspects in terms of the clean process, friendly environment, and permits as well as in terms of improving the manufacturing characteristics.

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

Dry Machining of T6061 Aluminium Alloy Using Titanium Carbonitride (TiCN) Coated Tools

2013 ◽  
Vol 652-654 ◽  
pp. 2129-2133
Author(s):  
Tasnim Firdaus Ariff ◽  
Nur Najwa Sofian ◽  
Nor Hayati Che Mat
Keyword(s):  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Machining Process ◽  
Titanium Carbonitride ◽  
Cutting Fluids ◽  
Dry Machining ◽  
Coated Tools ◽  
Percentage Difference ◽  
Optimum Cutting

In metal cutting process, the use of cutting fluids, cooling and easy chip removal causes long-term effects of cutting fluids disposal into environment. Research has also proven the health hazards on manufacturing workers who coming in direct contact with cutting fluids. Currently it is highly competitive or end-user of metal workings fluid to reduce cost and improve productivity. Considering the high cost and problems associated with health and safety, it would be desirable if the use of cutting fluids be omitted. This study investigates the flank wear behavior of coated Titanium Carbonitride (TiCN) coated tools in dry and wet machining of T6061 Aluminum alloy with the aim of obtaining the optimum cutting speed for dry and wet machining respectively. By using specific depths of cut 0.2 and 0.6 mm with feed rates of 0.4 and 0.8 mm/rev respectively, the wear was investigated for 3 different high cutting speeds; 290, 360 and 446 mm/min. Results of dry machining was compared with traditional wet machining process. The temperature of tool tip, machining time and tool wear were recorded. Wear rate of the tool increases with the increasing cutting speed and parameters for both dry and wet machining. Wear percentage difference for dry machining was found to be 21-37 % (d = 0.2 mm and f = 0.4 mm/rev) and 41 - 58% (d = 0.6 mm and f = 0.8 mm/rev) higher than wet machining. The optimum cutting speed for both cutting parameters is 446 m/min for dry and wet machining. Tool tip temperature for dry machining is found to be 14 - 16 % higher than wet machining for both cutting parameters. It is observed that dry machining is suitable for high speed intermittent cutting operations.

Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

2020 ◽  
Vol 38 (11A) ◽  
pp. 1593-1601
Author(s):  
Mohammed H. Shaker ◽  
Salah K. Jawad ◽  
Maan A. Tawfiq
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

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.

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.

Influência do Avanço da Ferramenta e do Uso de Fluido de Corte na Rugosidade em Usinagem de Torneamento Cilíndrico Externo de Alumínio

2018 ◽  
Vol 13 (13) ◽  
pp. 13
Author(s):  
Clauber Roberto Melo Marques ◽  
Paulo Henrique Castagnel
Keyword(s):  
Mass Spectrometry ◽  
Cutting Speed ◽  
Tool Material ◽  
Chemical Characterization ◽  
Surface Characteristics ◽  
Cutting Parameters ◽  
Machining Process ◽  
Cutting Fluid ◽  
Dry Machining ◽  
Average Roughness

As características superficiais de uma peça usinada são resultantes de vários fatores, entre eles pode-se citar o material da ferramenta utilizada, geração de calor e parâmetros de corte. Este trabalho teve como objetivo principal verificar a influência do avanço da ferramenta e do uso de fluido de corte em usinagem analisando a rugosidade de superfícies de peças de alumínio usinadas por torneamento cilíndrico externo, em um equipamento CNC Romi Centur 30D com comando Siemens, variando-se a velocidade de avanço da ferramenta, assim como a usinagem a seco e com fluido de corte. Foi realizada uma análise da caracterização química por Espectrometria de Massa para identificar a constituição do material utilizado. Foi executado o processo de usinagem em 10 peças de alumínio, com velocidade de corte de 220 m/min em todos os testes, variando-se o avanço da ferramenta (0,1, 0,15, 0,2, 0,25, 0,30 mm/rot), e para cada valor de avanço diferente foi realizado um ensaio à seco e um com fluido de corte. Após a usinagem as peças foram analisadas utilizando-se um rugosímetro Mitutoyo modelo SJ-310, para medição da Rugosidade Média (Ra) resultante. Concluiu-se que para valores de avanço de ferramenta de até 0,25 mm/rot, com velocidade de corte de 220 m/min, a presença do fluido de corte na usinagem não apresentou melhoria no resultado final. Somente com avanço de 0,30 mm/rot a presença do fluido de corte se mostrou mais eficiente que a usinagem a seco.Palavras-chave: Usinagem. Alumínio. Rugosidade. AbstractThe surface characteristics of a machined part is the result of several factors, among them the tool material used, heat generation and cutting parameters. This work had as main objective the analysis of the surface roughness of aluminum parts machined by external cylindrical turning in a CNC Romi Centur 30D equipment with Siemens command, varying the speed of tool advance, as well as the dry machining and with cutting fluid. An analysis of the chemical characterization was performed by Mass Spectrometry to identify the constitution of the material used. The machining process was carried out in 10 pieces of aluminum, with a cutting speed of 220 m/min in all tests. The tool advance (0,1, 0,15, 0,2, 0,25, 0,30 mm/rot), and for each different feed rate a dry test and one with cutting fluid were performed. After machining, the parts were analyzed using a Mitutoyo model SJ-310 rugosimeter to measure the resulting Average Roughness (Ra). It was concluded that for tool feed values up to 0.25 mm/rot, with a cutting speed of 220 m/min, the presence of the cutting fluid in the machining did not show improvement in the final result. Only with an advance of 0.30 mm/rot the presence of the cutting fluid was more efficient than the dry machining. Keywords: Machining, Aluminum, Roughness.

Health Effects of Oil Mists: A Brief Review

1989 ◽  
Vol 5 (3) ◽  
pp. 429-440 ◽  
Author(s):  
Carl R. Mackerer
Keyword(s):  
Health Effects ◽  
Metal Cutting ◽  
Human Cancer ◽  
Health Effect ◽  
Skin Irritation ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Potential Health ◽  
Skin Contact

Metal cutting/grinding fluids are of three basic types: straight oil (insoluble), oil-in-water emulsions (soluble) and synthetic/semi-synthetic. All contain a variety of additives to improve performance. Human exposure occurs primarily by direct skin contact with the liquid or by skin and respiratory contact after fluid misting. Dermatitis caused by primary or direct skin irritation is the most prevalent health effect of exposure to cutting fluids. Occasionally allergic dermatitis is seen which is related to the development of sensitization to one or more of the additive components. Recent studies indicate that long-term exposure to cutting fluids does not result in increased incidences of lung cancer, urinary bladder cancer, gastrointestinal cancer, or death from non-malignant respiratory diseases. Long-term exposure to certain cutting fluids, however, is believed to have resulted in certain types of skin cancer, especially scrotal cancer. It is likely that these carcinogenic responses were caused by contact with polycyclic aromatic compounds (PCA) of 3–7 rings. Modern base oils which are severely refined have very low levels of PCA, are not carcinogenic in animal bioassays, and are unlikely to be carcinogenic in man. This is not necessarily true for re-refined oils which may contain significant levels of PCA and polychlorinated biphenyls derived from coming-ling used cutting oils with used engine oils and transformer oils. Cutting oils, themselves, generally do not accumulate significant levels of carcinogenic PCA during use. Additives, in theory, can cause a variety of health effects either directly or through the generation of reaction products such as nitrosamines. In actual use, adverse health effects appear to be limited to occasional instances of allergic contact dermatitis. Nitrosamines are extremely carcinogenic in test animals; although no human cancer cases directly attributable to nitrosamine contamination have been observed, nitrosating agents and amines should not be combined in cutting fluid formulations. It is difficult to anticipate or predict the potential toxicity of a particular cutting fluid formulation because of the presence of variable amounts of proprietary additives which, themselves, are often complex reaction mixtures. Thus, each additive and final formulation must be evaluated on a case by case basis to appropriately assess potential health hazards.

scholarly journals Effect of Some Thermodynamic Properties of Cutting Fluids on Machinability of Carbon Steel

2020 ◽  
Vol 5 (2) ◽  
Author(s):  
Sulaiman Abdulkareem ◽  
Moshood A Babatunde ◽  
Temitayo S Ogedengbe ◽  
Isaac K Adegun
Keyword(s):  
Surface Roughness ◽  
Carbon Steel ◽  
Thermodynamic Properties ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Engine Oil ◽  
Cutting Fluids ◽  
Dry Machining ◽  
Used Engine Oil ◽  
Average Improvement

Cutting fluids are used to reduce heat generated during machining, however some have been discovered to pose health challenges hence the search for viable alternatives. In this paper, three machining conditions (dry machining, wet machining with soluble oil and wet machining with used-engine oil) were conducted on high carbon steel, with a sole aim of investigating the suitability of engine oil as an alternative to soluble oil. Measurements related to effective use of oil as metal cutting fluids were determined and the machining parameters used were cutting speed (750 – 1750 rpm), feed rate (40 – 120 mm/rev), and depth of cut (0.1 – 0.3 mm). The experimental procedure was formulated using Minitab software version 18 and the machining responses investigated were maximum temperature at the cutting interface, surface roughness, and tool wear rate (TWR). Thermodynamic properties investigated include, flashpoint, specific heat capacity, viscosity and density. The experimental results showed that cutting temperature reduced from an average of 440oK during dry machining to 369.8oK (16% improvement) during machining with used-engine oil and 362.6oK (18% improvement) during machining with soluble oil. The surface roughness produced was generally higher while machining with used-engine oil with an average improvement of 39% in surface integrity. However, when soluble oil was used as cutting fluid, average improvement in surface integrity increased to 70%. Hence, used-engine oil offered impressive lubricating and cooling properties and could replace soluble oil as a cutting fluid during machining.Keywords—Cutting Fluid, Cutting Speed, Machining, Surface Roughness, Tool Wear

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