Research on Cooling Action and Simulation of Temperature Distribution with Water Vapor as Coolants and Lubricants in Green Cutting

2007 ◽  
Vol 10-12 ◽  
pp. 276-280
Author(s):  
Jun Yan Liu ◽  
Rong Di Han ◽  
Yang Wang
Keyword(s):  
Water Vapor ◽  
Temperature Distribution ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Convection Heat Transfer ◽  
Force Convection ◽  
The Finite Element Method ◽  
Convection Heat Transfer Coefficient ◽  
Dry Cutting ◽  
Vapor Lubrication

Water vapor is a good, pollution-free and economical coolants and lubricants in green machining. In order to research the cutting temperature distributions with water vapor as coolants and lubricants in machining, the experiments conducted under the conditions of water vapor as coolants and lubricants and dry cutting. The cutting temperatures are studied by metal cutting theory, and then by employing the finite element method (FEM), the temperature distribution of cutting region is simulated with application of water vapor as coolants and lubricants and dry cutting conditions. The results show that the water vapor jet flow has high force-convection heat transfer coefficient and directly cooling action to reduce cutting temperature, and the stress, the length of tool-chip interface are reduced with application of water vapor lubrication. So that the cutting thermal is decreased and water vapor has indirect cooling action. Under the conditions of indirect and direct cooling action, the cutting temperature is reduced obviously with application of water vapor as coolants and lubricants.

Experiment Study of Oil-Air Lubrication on Cooling of Turning Tools

2011 ◽  
Vol 189-193 ◽  
pp. 3187-3190 ◽  
Author(s):  
Jin Li Wang ◽  
Lin Cai ◽  
Hong Tao Zheng
Keyword(s):  
Metal Cutting ◽  
Research Work ◽  
Cutting Temperature ◽  
Cost Savings ◽  
Machining Process ◽  
Dry Cutting ◽  
Air Lubrication ◽  
Temperature Contrast ◽  
Cooling Technology ◽  
Lubrication Conditions

When lubricants are used according to special requirements, it is possible to achieve considerable cost savings. Compared to conventional coolant cooling technology used in metal cutting, oil-air lubrication increases cooling performance, avoids environmental pollution, reduces running and maintenance costs. The cutting temperature contrast experimental research was based on close to practice 45# steel in dry cutting, wet cutting and oil-air lubrication conditions. The research work concentrated on the superiority of oil-air lubrication cooling and the influence of cutting amount on temperature. The experimental results show that oil-air lubrication is more effective in reducing the cutting temperature than wet cutting or dry cutting, this paper details the cutting temperature curves at several different tests provides a basis for industrial production, improves the level of machining process and the significance was being reported.

Investigations of Tool Wear with Water Vapor as Coolant and Lubricant in Green Cutting

2011 ◽  
Vol 317-319 ◽  
pp. 556-559
Author(s):  
Yue Zhang ◽  
Tong Jiang ◽  
Li Han ◽  
Qi Dong Li ◽  
Tai Li Sun ◽  
...  
Keyword(s):  
Water Vapor ◽  
Tool Wear ◽  
Metal Cutting ◽  
Boundary Layer Theory ◽  
Cutting Fluids ◽  
Potential Solution ◽  
Dry Cutting ◽  
Lubricating Film ◽  
Study Results ◽  
Generating System

Green cutting is one of the developing tends 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, a special generating system is developed to produce suitable water vapor, and a simulation to the velocity of water vapor jet flow is presented. Then tool wear was investigated and a new capillary model is proposed, based on the experimental results. According to the boundary-layer theory, the kinetics equations of flow were solute. The velocity and flux of molecule are presented. In the capillary, the adsorption of tool-chip interface results in boundary lubricating film; the conical shape of capillary limits the depth of coolant and lubricant penetrating; and the negative press is the motility for coolant and lubricant penetrating. The study results show water vapor can decrease tool wear about 10% times and 20% comparing to cutting fluids and dry cutting, and water vapor could be a potential solution of green cutting.

Water Vapor Cooling Effects in Turning by Finite Element Modeling

2011 ◽  
Vol 189-193 ◽  
pp. 1631-1634
Author(s):  
Fan Yang ◽  
Jian Long Huang
Keyword(s):  
Finite Element ◽  
Water Vapor ◽  
Geometric Modeling ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Fem Simulation ◽  
Cutting Process ◽  
Finite Element Software ◽  
Aisi 1045 ◽  
Cooling Effects

In order to correctly analyze the effect of water vapor cooling in metal cutting process, the turning process of AISI 1045 in the water vapor cooling condition is simulated using a commercial finite element software Deform-2D, including geometric modeling, meshing, boundary condition setting and material modeling, etc. The cutting temperature in different cooling conditions are then analyzed and discussed. The experimental validation showed a good agreement with simulation results. Thus, FEM simulation of cutting process can be considered as a promising and reliable tool for machining development within the near future.

Research on Cutting Force and Surface Roughness in Face Milling Ni-Based Superalloy

2012 ◽  
Vol 588-589 ◽  
pp. 1698-1701
Author(s):  
Hui Wang ◽  
Feng Zhou ◽  
Rong Di Han
Keyword(s):  
Surface Roughness ◽  
Water Vapor ◽  
Environmental Pollution ◽  
Metal Cutting ◽  
Face Milling ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Milling Force ◽  
Oil Emulsion ◽  
Nickel Based Superalloy

The machinability of Nickel-based superalloy GH4169 is poor, the traditional methods to machining is application of cutting fluids with the active additives which cause environmental pollution and health problems. In this paper, the water vapor was applied on milling instead of cutting fluids for the aim of green milling GH4169. The effects of water vapor, oil emulsion and dry cutting on milling force and the surface roughness have been examined with carbide tools YG6A. The results of experiments indicated that application of water vapor produced lower milling force, the values were reduced about 7 percent compared to dry cutting, and it is advantage in surface roughness. The research results show that clean production was achieved in metal cutting associated with water vapor cooling and lubricating.

Prediction of Temperature Distribution in High-Speed End Mill Assisted by Heat Pipe Cooling

2011 ◽  
Vol 311-313 ◽  
pp. 2371-2374
Author(s):  
Hua Wei Ju ◽  
Wei Xiao Tang ◽  
Qing Hua Song ◽  
Hong Liang Zhou
Keyword(s):  
Temperature Distribution ◽  
Heat Pipe ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Dimensional Accuracy ◽  
Machining Process ◽  
Clear Understanding ◽  
End Mill ◽  
Heat Transfer Theory

The cutting temperature is a key factor which directly affects thermal distortion, the machined part’s dimensional accuracy, as well as the tool wear in machining process. Aiming to effectively remove the cutting heat yields in machining process, the cutting tool with heat pipe cooling has been developed in recent years. This research focuses on developing a clear understanding of the temperature distribution in end mill embedded with heat pipe. Mathematical model is developed based on the heat transfer theory and the metal-cutting theory. 3-D finite element models are set up. The thermal boundary conditions are properly set, and contrasts of the temperature field in end mill with and without embedded heat pipes by numerical simulations are given.

scholarly journals Effect of Built-Up Edge Formation on Residual Stresses Induced by Dry Cutting of Normalized Steel

2014 ◽  
Vol 996 ◽  
pp. 603-608
Author(s):  
Johannes Kümmel ◽  
Jens Gibmeier ◽  
Volker Schulze ◽  
Alexander Wanner
Keyword(s):  
Surface Layer ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Wear Behaviour ◽  
Dry Cutting ◽  
Workpiece Material ◽  
Workpiece Surface

The tool and workpiece surface layer states of the tribosystem uncoated WC-Co cutting tools vs. normalised SAE 1045 workpiece material are studied in detail for a dry metal cutting process. Within the system the cutting parameters (cutting speed, feed rate, cutting depth) determine the wear state of the cutting tool and the resulting surface layer state (residual stress) in the workpiece. As the built-up edge can be used as a possible wear protecting layer [1] the influence of built-up edge and wear behaviour of the cutting tool was examined with respect to the workpiece surface layer state for knowledge based metal cutting processing. Small compressive stresses (-60-80 MPa) are induced in the surface layer, that are nearly homogeneous for the highest built-up edge, which lead to the lowest tool wear in combination with lowest cutting temperature.

Study of High Efficiency in Green Cutting Nickel-Based Superalloy GH4169

2010 ◽  
Vol 33 ◽  
pp. 555-559
Author(s):  
Rong Di Han ◽  
Hui Wang ◽  
Y. Zhang ◽  
Q.W. Yao
Keyword(s):  
Water Vapor ◽  
Tool Wear ◽  
Cutting Force ◽  
Surface Quality ◽  
Tool Life ◽  
Cutting Temperature ◽  
Dry Cutting ◽  
Machined Surface ◽  
Nickel Based Superalloy ◽  
Machined Surface Quality

The machinability of nickel-based superalloy GH4169 is very poor, the traditional machining of GH4169 using the cutting fluids with the active additives causes environmental and health problems, which is out of the request of the sustainable development strategy. In this paper a new green cutting technology with overheated water vapor as coolants and lubricants was proposed to achieve the aim of green cutting and high productivity. Cutting experiments and tool wear tests using carbide tool YG6 under dry cutting, emulsion and water vapor were performed. The cutting force, cutting temperature, machined surface quality and tool life were investigated; the curve of flank tool wear and relation between tool life and cutting velocity was carried out. The results of experiments indicated that during water vapor condition, the cutting force and cutting temperature was reduced, the machined surface roughness was improved, and the tool life was longed, respectively, and the higher velocity was taken during the some tool wear condition compared to dry cutting. The research results show that green cutting was achieved associated with overheated water vapor cooling and lubricating, at he same time the machined surface quality and production efficiency was increased.

FEM Analysis of Temperature in High Speed Cutting of TiAl6V4 Alloys

2012 ◽  
Vol 522 ◽  
pp. 201-205
Author(s):  
You Xi Lin ◽  
Cong Ming Yan ◽  
Zheng Ying Lin
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Fem Analysis ◽  
Element Model ◽  
Maximum Temperature ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Radial Depth

mprovements in modeling and simulation of metal cutting processes are required in advanced manufacturing technologies. A three dimensional fully thermal mechanical coupled finite element model had been applied to simulate and analyze the cutting temperature for high speed milling of TiAl6V4 titanium alloy. The temperature distribution induced in the tool and the workpiece was predicted. The effects of the milling speed and radial depth of cut on the maximum cutting temperature in the tool was investigated. The results show that only a rising of temperature in the lamella of the machined surface is influenced by the milling heat. The maximum temperature in the tool increases with increasing radial depth of cut and milling speed which value is 310°C at a speed of 60 m/min and increases to 740°C at 400m/min. The maximum temperature is only effective on a concentrated area at the cutting edge and the location of the maximum temperature moves away from the tool tip for higher radial depths of milling. The predicted temperature distribution during the cutting process is consistent with the experimental results given in the literature. The results obtained from this study provide a fundamental understanding the process mechanics of HSM of TiAl6V4 titanium alloys.

Experimental Investigation on Green Cutting GH4169 with Ionized Air Cooling and Lubricating

2010 ◽  
Vol 426-427 ◽  
pp. 279-283 ◽  
Author(s):  
Hui Wang ◽  
Rong Di Han ◽  
Yan Li Tang ◽  
Yang Wang
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Green Manufacturing ◽  
Air Cooling ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Metal Machining ◽  
Manufacturing Techniques ◽  
Ionized Air

The machinability of Nickel-based superalloy GH4169 is poor, the traditional methods to machining is application of cutting fluids with the active additives which will cause environmental and health problems. In recent years, environmental concerns call for the reduced of cutting fluids in metal machining. The green manufacturing techniques are to be investigated to achieve this objective. In this paper, the ionized air was applied instead of cutting fluids for the aim of green cutting. The effects of ionized air on cutting force, cutting temperature and chip formation have been examined in turning of GH4169 with carbide tools K20. The results of experiments indicated that application of ionized air produced lower cutting force and cutting temperature, the values were reduced about 7 percent and 9 percent compared to dry cutting respectively, and it is advantage in forming acceptable chips. The research results show that clean production was achieved in metal cutting associated with ionized air cooling and lubricating.

Experimental Study of Green High-Speed Turning Nickel-Based Superalloy GH4169

2010 ◽  
Vol 26-28 ◽  
pp. 1132-1136
Author(s):  
Jun Zhou ◽  
Rong Di Han
Keyword(s):  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Operating Conditions ◽  
Dry Cutting ◽  
Machined Surface ◽  
High Speed Turning ◽  
Nickel Based Superalloy ◽  
Cooling Lubricant ◽  
Lubricant Application

Knowing the stringent operating conditions to which superalloys are subjected to in automobile, aerospace and gas turbine industries, the machinability of nickel-based superalloy GH4169 is very poor, the traditional cutting fluids in GH4169 machining pollutes environments. The purpose of this study is to clarify the possibility of the turning in high speed (vc＞50m/min)[1]. In particular, the effects of the overheat water vapor with 130°C as cooling lubricant application were examined, through observation and measurement of the shape of the generated chips, machined surface integrity, cutting force and cutting temperature in a series of experiments with dry cutting or overheat water vapor with 130°C as cooling lubricant. As a result of these experiments, it was possible to measure and confirm the effects of the overheat water vapor with 130°C as cooling lubricant in high speed turning.

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