Evaluation of the Effect of Application of Air Jet Cooling and Cooled-Air Jet Cooling on Machining Characteristics of St 60 Steel

2014 ◽  
Vol 493 ◽  
pp. 468-472
Author(s):  
Rusnaldy ◽  
Norman Iskandar ◽  
Yusuf Umardani ◽  
Paryanto ◽  
Susilo Adi Widyanto
Keyword(s):  
Tool Life ◽  
Machining Process ◽  
Cutting Fluid ◽  
Air Cooling ◽  
Machining Processes ◽  
Dry Cutting ◽  
Liquid Coolant ◽  
Cooling Medium ◽  
Jet Cooling ◽  
Air Jet

The use of cutting fluid is to reduce the friction between tool and workpiece, reduce and dissipate generated heat. The application of cutting fluid is also to improve the surface quality of workpiece and increase the tool life. On the other side, cutting fluid contains chemical carcinogens that causes serious health risks for machine operators and have inherent waste disposal concern on the environment. Due to these problems, some alternative have been sought to minimize or avoid the use of cutting fluid in machining processes. Air cooling techniques were proposed as alternative cooling mediums, i.e air jet cooling (AJC) and cooled-air jet cooling (CAJC), the liquid less method. In this work, air cooling techniques were investigated to be a possible solution of machining problem for cooling medium. This studi was also motivated by economics point of view that the application of AJC and CAJC would be more efficient than liquid method. The purpose of this study is to investigate the effect of AJC and CAJC on turning process of St 60 steel because it is used widely for production of components especially in small and medium enterprises in Indonesia. The tool tip temperatures, surface roughness and tool wear were measured for a range of cutting times. For a comparison purposes, experiments were also carried out with using traditional liquid coolant and without any cooling applied to the tool tip (dry cutting method). Experiments have shown that air cooling technques (AJC, and CAJC) can be used as cooling medium in machining process. Experimental results show that machining with CAJC have shorter tool life compare to machining with AJC and dry cutting, but liquid coolant in this studi is still the best cooling medium for machining of St 60 steel..

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 Influence of Bio-Oils as Cutting Fluids on Chip Formation and Tool Wear during Drilling Operation of Mild Steel

2019 ◽  
Vol 8 (2) ◽  
pp. 3328-3330
Keyword(s):  
Tool Wear ◽  
Mild Steel ◽  
Tool Life ◽  
Machining Process ◽  
Cutting Fluid ◽  
Work Piece ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Steel Work ◽  
On Chip

The importance of health and environment has forced Machining Industries to reduce the application of Petroleum-based cutting fluid. But to ease the machining process and to increase the tool life, cutting fluids must be used. Research has been done on vegetable oils as cutting fluids which is easy for disposal and does not affect the environment and the operator’s health [1] . This paper discusses the machinability and tool life during drilling of a mild steel work piece using Neem, Karanja, blends of 50%Neem-50%Karanja, 33.3%Neem-66.6%Karanja, 66.6%Neem-33.3%Karanja as cutting fluid. Results obtained using petroleum-based oil are compared with the results obtained by using above mentioned combination of oils and also with dry cutting conditions.

Späne- und Stauberfassung bei der CFK-Zerspanung*/Extraction of chips and dust in machining operations of CFRP. Investigation on CFRP dry machining in industrial applications

2018 ◽  
Vol 108 (06) ◽  
pp. 473-478
Author(s):  
A. Gebhardt ◽  
M. Schneider
Keyword(s):  
Industrial Applications ◽  
Machining Process ◽  
Dry Machining ◽  
Machining Processes ◽  
Dry Cutting ◽  
Clamping System ◽  
Cutting Processes ◽  
Machining Operations

Bauteile aus CFK (kohlenstofffaserverstärkte Kunststoffe) werden meist spanend endbearbeitet. Diese Bearbeitung kann unter Überflutung durch KSS (Kühlschmierstoffe) oder trocken stattfinden. Die hier vorgestellte Studie zeigt für die Trockenzerspanung, wie die notwendige Erfassung von Stäuben und Spänen stattfindet, welche Technologien eingesetzt werden und wie eine Maschinen- und Bauteilreinigung aussieht.   A machining process is mostly used as a last step in the production of workpieces made of CFRP. In this machining process lubricants may be used or dry cutting processes are applicated. The here presented study shows for dry machining processes, which technologies are used for the dust and chip extraction. Furthermore, the techniques for the cleaning of the machine, the clamping system and workpiece are presented.

scholarly journals EFFECT OF MINIMUM QUANTITY LUBRICATION ON SURFACE ROUGHNESS IN TOOL-BASED MICROMILLING

2017 ◽  
Vol 18 (1) ◽  
pp. 147-154
Author(s):  
Mohammad Yeakub Ali ◽  
Wan Norsyazila Jailani ◽  
Mohamed Rahman ◽  
Muhammad Hasibul Hasan ◽  
Asfana Banu
Keyword(s):  
Surface Roughness ◽  
Feed Rate ◽  
Spindle Speed ◽  
Machining Process ◽  
Depth Of Cut ◽  
Microfluidic Channels ◽  
Machining Parameters ◽  
Machining Processes ◽  
Dry Cutting ◽  
Minimum Quantity

Cutting fluid plays an important role in machining processes to achieve dimensional accuracy in reducing tool wear and improving the tool life. Conventional flood cooling method in machining processes is not cost effective and consumption of huge amount of cutting fluids is not healthy and environmental friendly. In micromachining, flood cooling is not recommended to avoid possible damage of the microstructures. Therefore, one of the alternatives to overcome the environmental issues to use minimum quantity of lubrication (MQL) in machining process. MQL is eco-friendly and has economical advantage on manufacturing cost. However, there observed lack of study on MQL in improving machined surface roughness in micromilling. Study of the effects of MQL on surface roughness should be carried out because surface roughness is one of the important issues in micromachined parts such as microfluidic channels. This paper investigates and compares surface roughness with the presence of MQL and dry cutting in micromilling of aluminium alloy 1100 using DT-110 milling machine. The relationship among depth of cut, feed rate, and spindle speed on surface roughness is also analyzed. All three machining parameters identified as significant for surface roughness with dry cutting which are depth of cut, feed rate, and spindle speed. For surface roughness with MQL, it is found that spindle speed did not give much influence on surface roughness. The presence of MQL provides a better surface roughness by decreasing the friction between tool and workpiece.

Tool Wear Investigation on Dry Electrostatic Cooling in Turning Titanium Alloy Ti6Al4V

2010 ◽  
Vol 97-101 ◽  
pp. 2058-2061 ◽  
Author(s):  
Hui Wang ◽  
Rong Di Han ◽  
Yang Wang
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
Set Up ◽  
Titanium Alloy Ti6al4v ◽  
Emulsion Oil

The machinability of Titanium Alloy Ti6Al4V 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 dry electrostatic cooling was applied instead of cutting fluid for the aim of green cutting Ti6Al4V. The ionized device and gas supply system was set up, the effects of dry electrostatic cooling, emulsion oil and dry cutting on tool wear have been examined in turning of Ti6Al4V with carbide tools YG8, the curve between tool flank wear and cutting time was proposed, and the equation between cutting speed and tool life was set up. The results of experiments indicated that application of dry electrostatic cooling reduced the tool wear and increased the tool life. The research results show that clean production was achieved in metal cutting associated with dry electrostatic cooling.

Predictive Modeling and Optimization of High Performance Machining

2007 ◽  
Vol 10-12 ◽  
pp. 842-849
Author(s):  
Steven Y. Liang ◽  
Binti M. Abraham
Keyword(s):  
Tool Life ◽  
Process Parameters ◽  
High Performance ◽  
Manufacturing Systems ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Analytical Models ◽  
Machining Performance ◽  
Machining Processes ◽  
Workpiece Material

High performance machining refers to the material removal operation that delivers the maximum achievable part quality, process competitiveness, and ecological compatibility through strategic utilization of cutters, machine tools, operation configuration, and process parameters. It is rapidly emerging as a prerequisite to productivity and profitability of machining operations and associated manufacturing systems. To accomplish high performance machining, a thorough understanding of the underlying mechanics that affect the performance attributes such as tool life, part integrity, air quality, etc., and how it is attributed to tooling conditions, operation configuration, and process parameters, is required. This paper reviews and summarizes a series of analytical methodologies by coupling with studies performed at the Georgia Institute of Technology for the quantitative modeling of fundamental mechanics of machining in the context of thermal, mechanical, tribological, and metallurgical effects and their interactions. In this study, cutting stresses, residual stress and tool life are explicitly described as functions of tool geometries, cutting speed, chip load, cutting fluid properties, interface tribological conditions, and the cutter/workpiece material constants. These analytical models facilitate the prediction of machining performance thereby allowing the optimal planning of machining processes in pursuing maximum performance. An array of experimental cutting data is also presented in comparison to model-based predictions for the validation of all aspects of the machining mechanics analysis.

Relative Effects of Cooling and Lubrication in Micro-Milling of Aluminum and the Design of Atomization Cooling and Lubrication Systems

2012 ◽  
Author(s):  
Shawn E. Nevala ◽  
Van T. Wifvat ◽  
Samuel A. Johnson ◽  
John E. Wentz
Keyword(s):  
Deionized Water ◽  
Statistical Testing ◽  
Cutting Fluid ◽  
Micro Milling ◽  
Micro Machining ◽  
Machining Processes ◽  
Dry Cutting ◽  
Rolled Aluminum ◽  
Collision Force ◽  
Cooling And Lubrication

Accelerated tool wear and tool breakage are significant problems in micro-machining processes such as micro-milling. Traditional flood cooling processes are unsuitable for micro-milling due to the excessive collision force between the fluid stream and the tool being large enough to affect the accuracy of the cutting process. In this research an atomization-based cooling and lubrication system is presented that delivers atomized cutting fluids to a micro-milling tool through the use of an original nozzle design based on two orthogonally-directed streams. The system and nozzle is used to investigate the relative importance of cooling and lubrication on micro-milling of 6061 T6 cold-rolled aluminum with a 0.508 mm diameter two-fluted end mill. Six cutting conditions are experimentally evaluated based on cutting forces and tool life. Lubrication is investigated through two concentrations (10% and 25%) of a semi-synthetic cutting fluid. Cooling is investigated through the use of atomized deionized water as well as dry cutting with cooling provided by a Ranque-Hilsch vortex tube. Dry cutting was used as a control. Statistical testing revealed the importance of lubrication relative to cooling when machining on the micro-scale as deionized water performed the worst of all tests conducted. Based on the experimental results, recommendations are made for the design of future micro-machining cooling and lubrication systems.

Nano-lubricant influence on surface residual stresses in hard milling

2021 ◽  
pp. 095440892110047
Author(s):  
Omid Rohani Raftar ◽  
Mahdi Kaveh ◽  
Mohsen Khajehzadeh ◽  
Abdolreza Rahimi ◽  
Mohammad Reza Razfar
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Mechanical Loading ◽  
Metal Cutting ◽  
Water Soluble ◽  
Machining Process ◽  
Nano Particles ◽  
Cutting Fluid ◽  
Machining Processes ◽  
Surface Residual Stresses

Residual stress could be induced by machining processes like milling which can greatly affect the fatigue life of fabricated parts, especially in dynamic loading conditions. In metal cutting operations, machining induced residual stresses can be explained in the terms of machining forces and temperatures of the cutting zones. This thermo mechanical loading along with the resulted metallurgical changes are the main sources of residual stresses generation at the surface of machined workpiece. Researchers have proved the superior properties of nanofluids over the conventional coolants to reduce the intensity of thermo mechanical loading in machining process which will affect the residual stresses caused by machining. Therefore, in this paper, silver nanoparticles in the water-soluble oil have been used for reducing the mechanical and thermal loads in the milling process. The cutting forces, temperature of the cutting zone, surface roughness and the residual stress of machined surface have been measured experimentally in milling of hardened steel AISI 4140 for various nanoparticle’s concentration, feeds and cutting speeds. Results show that increasing the concentration of Nano-particles in base fluid from 0.5 to 3.0% wt., will make machining surface residual stresses more compressive averagely by about 66.67% compared to conventional cutting fluid.

scholarly journals Cold Zone Exploration Using Position of Maximum Nusselt Number for Inclined Air Jet Cooling

2017 ◽  
Vol 64 (4) ◽  
pp. 533-549 ◽  
Author(s):  
Sunil B. Ingole ◽  
K. K. Sundaram
Keyword(s):  
Reynolds Number ◽  
Nusselt Number ◽  
Leading Edge ◽  
Jet Impingement ◽  
Target Surface ◽  
Air Cooling ◽  
Cold Zone ◽  
Jet Cooling ◽  
Air Jet ◽  
Cold Spots

Abstract Inclined jet air cooling can be effectively used for cooling of electronics or other such applications. The non-confined air jet is impinged and experimentally investigated on the hot target surface to be cooled, which is placed horizontally. Analysis and evaluations are made by introduction of a jet on the leading edge and investigated for downhill side cooling to identify cold spots. The jet Reynolds number in the range of 2000 ≤ Re ≤ 20 000 is examined with a circular jet for inclination (Θ) of 15 < Θ < 75 degree. Also, the consequence of a jet to target distance (H) is explored in the range 0:5 ≤ H/D ≤ 6.8. For 45 degree jet impingement, the maximum Nusselt number is widely spread. Location of maximum Nusselt number is studied, which indicates cold spots identification. At a higher angle ratio, the angle is the dominating parameter compared to the Reynolds Number. Whereas at a lower angle ratio, the inclined jet with a higher Reynolds number is giving the cooling point away from leading edge. It is observed that for a particular angle of incident location of maximum Nusselt Number, measured from leading edge of target, is ahead than that of stagnation point in stated conditions.

scholarly journals A Scientific Approach of using the DMAIC Methodology to Investigate the Effect of Cutting Tool Life on Product Quality and Process Economics: A Case Study of a Saudi Manufacturing Plant

2021 ◽  
Vol 11 (1) ◽  
pp. 6799-6805
Author(s):  
A. B. E. Aichouni ◽  
H. Abdullah ◽  
F. Ramlie
Keyword(s):  
Process Improvement ◽  
Tool Life ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Machining Process ◽  
Real Field ◽  
Manufacturing Plant ◽  
Manufacturing Companies ◽  
Machining Processes ◽  
Process Economics

One of the major priorities for manufacturing companies in the globalized economy is the ability to offer high-quality products to customers at the lowest production cost. Globally, process improvement methods and techniques are used to reduce waste and improve product and service quality. This paper aims to propose a systematic model based on process improvement methodologies and tools to help the manufacturing companies decide on cutting tool life and other manufacturing issues. This research seeks to prove that some common industry practices, such as changing cutting tools in machining processes, can significantly affect the economics of production and the overall performance of the plant. The research is mainly based on analyzing real field data using the DMAIC methodology to identify improvements in order to achieve a balance between economy and quality in a Saudi manufacturing plant. Although the study was concerned only with changing cutting tools in the machining process in an air conditioning plant, its findings and conclusions can be generalized to all manufacturing processes.

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