Comparison between Nitrogen-Oil-Mist and Air-Oil-Mist Condition when Turning of Hardened Tool Stainless Steel

2014 ◽  
Vol 660 ◽  
pp. 18-22
Author(s):  
Mohamed Handawi ◽  
Amad Elddein Issa Elshwain ◽  
Mohd Yusof Noordin ◽  
Norizah Redzuan ◽  
Denni Kurniawan
Keyword(s):  
High Speed ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Dry Cutting ◽  
Nitrogen Gas ◽  
Cutting Zone ◽  
Oil Mist ◽  
Coated Carbide

Minimum quantity lubrication (MQL) or as it’s called semi dry cutting is a technique which spray a small value of lubricant flow rate to the cutting zone area. MQL has been used in many machining process with different cutting tools and workpiece materials due to its green environments and economically advantageous. MQL has become an attractive option to dry and flood cutting in terms of reduce the temperature in the cutting zone and reduce the cost of the product. However, in MQL seems to be machining limited by cutting temperature, because at high speed the effect of oil mist becomes evaporated. Therefore another alternative cooling approach was used with oil mist in this research. This research presents study the performance of nitrogen gas as a coolant and oil mist as lubricant in turning of hardened stainless tool steel (STAVAX ESR) with hardness 48 HRC. Using a gas as coolant with oil mist is a new solution for enhancing machinability. Turning experiments are carried out on CNC turning machine. The cutting insert grade is KC5010 (PVD-TiAlN wiper coated carbide). The experimental results were: 1) nitrogen gas with oil mist prolongs tool life compare with air with oil mist. 2) better product surface finish by using nitrogen gas with oil mist.

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.

CFD Analysis on the Flow Field of Minimum Quantity Lubrication during External Thread Turning

2012 ◽  
Vol 723 ◽  
pp. 113-118 ◽  
Author(s):  
Ming Chen ◽  
Li Jiang ◽  
Bo Wen Shi ◽  
Zhi Qiang Liu ◽  
Qing Long An
Keyword(s):  
Flow Field ◽  
Flow Rate ◽  
Great Influence ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Droplet Breakup ◽  
Machining Process ◽  
Minimum Quantity ◽  
Cutting Zone ◽  
Oil Mist

Minimum quantity lubrication (MQL) is a new cooling technology used in machining process, which is friendly to environment and lower cost. This paper applied computational fluid dynamics (CFD) to analyze flow field of MQL in thread turning. Comprehensively applying droplet breakup method and capillary method, flow field of MQL in cutting zone were analyzed in detail. The results showed that oil mist could enter into cutting zone from sides of chip. And two vortexes existed around cutting zone which could reduce cutting temperature by accelerating heat exchange. Furthermore, flow rate of compressed air had great influence on velocity and diameter of droplets, velocity and pressure distribution of flow field. The effects of different flow rates indicated the larger flow rate was benefit for entering into cutting zone of oil mist.

Control of Machining Process for Titanium Alloy Based on Green Cooling and Lubricating Technology

2012 ◽  
Vol 580 ◽  
pp. 7-11
Author(s):  
Yue Zhang ◽  
Li Han ◽  
You Jun Zhang ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Small Diameter ◽  
Machining Process ◽  
Machined Surface ◽  
Cutting Zone ◽  
Cutting Experiments ◽  
Special Control

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.

scholarly journals Mekanisme Pembentukan Burr pada Pemesinan Frais Mikro Ti 6Al- 4V ELI dalam Keadaan Kering

2020 ◽  
Vol 11 (3) ◽  
pp. 307-312
Author(s):  
Endra Saputra ◽  
◽  
Gusri Akhyar Ibrahim ◽  
Suryadiwansa Harun ◽  
Eko Agus Supriyadi ◽  
...  
Keyword(s):  
High Speed ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Machining Process ◽  
Micro Milling ◽  
Burr Formation ◽  
Depth Of Cut ◽  
Hard Metals ◽  
Titanium Material ◽  
Cutting Zone

One of the ingredients that are popular now is titanium, but titanium is a material that is difficult to process using conventional milling machining because of the poor thermal conductivity of the material so that the high-temperature machining process produced in the cutting zone causes plastic deformation in cutting tools and increased chemical reactivity in titanium. High-speed micro-milling machining can be used for micromachining of hard metals or alloys that are difficult to achieve at low speeds. Micro milling machining in titanium material 6Al-4V ELI with variations in milling knife diameter 1 and 2 mm, spindle speed 10.000 and 15.000 rpm, feed 0,001 and 0,005 mm / rev, depth of cut 100 and 150 μm, which then do data processing using the method Taguchi full factorial and theoretical analysis. The results showed that the diameter of the tool and into the cut had the greatest effect on burr formation, the greater the diameter of the milling blade resulted in the formation of shorter and smaller burrs, the use of a 1 mm diameter milling blade and a 150 μm depth cut gave rise to long burr formations and tight, while the use of a 2 mm diameter milling blade and a cutting depth of 100 μm give rise to a short and slight burr formation.

scholarly journals Kekasaran permukaan pada pemesinan frais mikro Ti 6Al- 4V ELI (extra low intertitial)

2020 ◽  
Vol 8 (2) ◽  
Author(s):  
Gusri Akhyar Ibrahim ◽  
Endra Saputra ◽  
Suryadiwansa Harun ◽  
Eko Agus Supriyanto ◽  
Armulani Patihawa
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Chemical Reactivity ◽  
Cutting Tools ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Titanium Material ◽  
Cutting Zone ◽  
Tool Diameter

One of the ingredients that are popular now is titanium, but titanium is a material that is difficult to process using conventional milling machining because of the poor thermal conductivity of the material so that the high-temperature machining process produced in the cutting zone causes plastic deformation in cutting tools and increased chemical reactivity in titanium. High-speed micro-milling machining can be used for micro machining of hard metals or alloys that are difficult to achieve at low speeds. Micro milling machining in titanium material 6Al-4V ELI with variations in milling tool diameter 1 and 2 mm, spindle speed 10.000 and 15.000 rpm, feed 0,001 and 0,005 mm/rev, depth of cut 100 and 150 μm, which then do data processing using the method taguchi full factorial and theoretical analysis. The results showed that the diameter of the tool and into the depth of cut the most effect on surface roughness, the greater the tool diameter of the milling produced a smaller roughness value, this is inversely proportional to the depth of the cut. The lowest roughness value is 0,26 and the highest roughness value is 0,9. Keywords: Micro milling machining, titanium 6Al-4V ELI, surface roughness.

scholarly journals Sustainable High-Speed Finishing Turning of Haynes 282 Using Carbide Tools in Dry Conditions

Metals ◽  
2019 ◽  
Vol 9 (9) ◽  
pp. 989 ◽  
Author(s):  
Antonio Díaz-Álvarez ◽  
José Díaz-Álvarez ◽  
José Luis Cantero ◽  
Henar Miguélez
Keyword(s):  
Mechanical Properties ◽  
Tool Life ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Fluids ◽  
Dry Conditions ◽  
Cutting Zone ◽  
Favorable Conditions ◽  
Coated Carbide ◽  
Cutting Speeds

Nickel-based superalloys exhibit an exceptional combination of corrosion resistance, enhanced mechanical properties at high temperatures, and thermal stability. The mechanical behavior of nickel-based superalloys depends on the grain size and the precipitation state after aging. Haynes 282 was developed in order to improve the creep behavior, formability, and strain-age cracking of the other commonly used nickel-based superalloys. Nevertheless, taking into account the interest of the industry in the machinability of Haynes 282 because of its great mechanical properties, which is not found in other superalloys like Inconel 718 or Waspaloy, more research on this alloy is necessary. Cutting tools suffer extreme thermomechanical loading because of the high pressure and temperature localized in the cutting zone. The consequence is material adhesion during machining and strong abrasion due to the hard carbides included in the material. The main recommendations for finishing turning in Haynes 282 include the use of carbide tools, low cutting speeds, low depth of pass, and the use of cutting fluids. However, because of the growing interest in sustainable processes and cost reduction, dry machining is considered to be one of the best techniques for material removal. During the machining of Haynes 282, at both the finishing and roughing turning, cemented carbide inserts are most commonly used and are recommended all over the industry. This paper deals with the machining of Haynes 282 by means of coated carbide tools cutting fluids (dry condition). Different cutting speeds and feeds were tested to quantify the cutting forces, quality of surface, wear progression, and end of tool life. Tool life values similar to those obtained with a lubricant under similar conditions in other studies have been obtained for the most favorable conditions in dry environments.

scholarly journals EFFECT OF HIGH PRESSURE COOLANT JET ON CUTTING TEMPERATURE, TOOL WEAR AND SURFACE FINISH IN TURNING HARDENED (HRC 48) STEEL

2015 ◽  
Vol 45 (1) ◽  
pp. 1-6 ◽  
Author(s):  
Mozammel Mia ◽  
Nikhil Ranjan Dhar
Keyword(s):  
High Pressure ◽  
Tool Wear ◽  
Cutting Forces ◽  
High Speed ◽  
Hard Turning ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Beneficial Effects ◽  
Coated Carbide ◽  
High Pressure Coolant

Hard turning of harder material differs from conventional turning because of its larger specific cutting forces requirements. The beneficial effects of hard turning can be offset by excessive temperature generation which causes rapid tool wear or premature tool failure if the brittle cutting tools required for hard turning are not used properly. Under these considerations, the concept of high-pressure coolant (HPC) presents itself as a possible solution for high speed machining in achieving slow tool wear while maintaining cutting forces at reasonable levels, if the high pressure cooling parameters can be strategically tuned. This paper deals with an experimental investigation of some aspects of the turning process applied on hardened steel (HRC48) using coated carbide tool under high-pressure coolant, comparing it with dry cut. The results indicate that the use of high-pressure coolant leads to reduced surface roughness, delayed tool flank wear, and lower cutting temperature, while also having a minimal effect on the cutting forces.

Machining Process of Titanium Alloy Based on Green Cooling and Lubricating Technology

2010 ◽  
Vol 139-141 ◽  
pp. 681-684
Author(s):  
Yue Zhang ◽  
Li Han ◽  
Qi Dong Li ◽  
Tai Li Sun ◽  
Xi Chuan Zhang
Keyword(s):  
Titanium Alloy ◽  
Water Vapor ◽  
High Speed ◽  
Cutting Temperature ◽  
Small Diameter ◽  
Machining Process ◽  
Machined Surface ◽  
Surface Appearance ◽  
Cutting Zone ◽  
Special Control

The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface appearance. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy instead of cutting floods.

Application of Minimum Quantity Lubrication when Drilling Nickel-Based Superalloy at High Cutting Speed

2009 ◽  
Vol 407-408 ◽  
pp. 612-615 ◽  
Author(s):  
Erween Abdul Rahim ◽  
Hiroyuki Sasahara
Keyword(s):  
Feed Rate ◽  
High Speed ◽  
Failure Modes ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Minimum Quantity Lubrication ◽  
Machined Surface ◽  
Minimum Quantity ◽  
Coated Carbide

Nowadays, an increase on demands of aerospace components has led to implementation of high speed machining (HSM). The principal factors in the performance of aerospace materials are strength-to-weight ratio, fatigue life, fracture toughness, survivability and of course, reliability. However, when HSM is coupled with dry or near dry machining, it will present considerable technical challenges to the manufacturing sector especially when the integrity of the machined surface is concerned. In this investigation, the effect of high speed drilling (HSD) conditions on the performance and surface integrity of Inconel 718 were studied. Hole was drilled individually using TiAlN coated carbide insert drill (14 mm in diameter) under minimum quantity of lubrication (MQL) condition. Results showed that uniform flank wear and chipping were the dominant tool failure modes. Moreover, the results showed an increase in cutting temperature with increasing cutting speed and feed rate. Thrust force and torque decreased linearly with the increasing cutting speed but significantly increased when higher feed rate is employed. Cutting speed significantly influenced the distribution of surface roughness value. Variations of hardness readings were recorded beneath the machined surfaces, they were due to the hardening effects caused by concentration of high temperature and stresses on the workpiece.

Experimental Investigation of Hard Turning Mechanisms by PCBN Tooling Embedded Micro Thin Film Thermocouples

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Linwen Li ◽  
Bin Li ◽  
Xiaochun Li ◽  
Kornel F. Ehmann
Keyword(s):  
Thin Film ◽  
Hard Turning ◽  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Cutting Insert ◽  
Thin Film Thermocouples ◽  
Cutting Zone

Temperature-distribution measurements in cutting tools during the machining process are extremely difficult and remain an unresolved problem. In this paper, cutting temperature distributions were measured by thin film thermocouples (TFTCs) embedded into polycrystalline cubic boron nitride (PCBN) cutting inserts in the immediate vicinity of the tool-chip interface. The embedded TFTC array provides temperature measurements with a degree of spatial resolution (100 μm) and dynamic response (150 ns) that is not possible with currently employed methods due to the micro-scale junction size of the TFTCs. Using these measurements during hard turning, steady-state, dynamic, as well as chip morphology and formation process analyses were performed based on the cutting temperature and cutting force variations in the cutting zone. It has been shown that the temperature changes in the cutting zone depend on the shearing band location in the chip and the thermal transfer rate from the heat generation zone to the cutting tool. Furthermore, it became evident that the material flow stress and the shearing bands greatly affect not only the chip formation morphology but also the cutting temperature field distributions in the cutting zone of the cutting insert.

Sign in / Sign up

Export Citation Format

Share Document