The Impact of Cooling System on Surface Quality in Milling

2015 ◽  
Vol 809-810 ◽  
pp. 135-140 ◽  
Author(s):  
Bogdan Alexandru Chirita ◽  
Nicolae Catalin Tampu
Keyword(s):  
Heat Dissipation ◽  
Cooling System ◽  
Minimum Quantity Lubrication ◽  
Production Costs ◽  
Cutting Fluids ◽  
Cryogenic Machining ◽  
Machining Processes ◽  
Dry Cutting ◽  
Environment Quality ◽  
The Impact

In the last years there has been an increased demand to lower the impact of industrial activities on environment quality. Cutting fluids, among other products, are an important pollutant but they have often been associated with the need for a higher productivity of machining processes. Cutting fluids are a mean of reducing temperature in the cutting area, friction and tool wear but they also represent 7% to 17% of the production costs. Other problems raised by cutting fluids are: microorganism infestation, which can cause pulmonary and dermatological diseases and poor lubrication or corrosion caused by some of the chemicals. Dry cutting is regarded as the cleanest cooling method, but it has a reduced heat dissipation efficiency and practically there is no lubrication. Other relatively new green solutions concern the use of minimum quantity lubrication (MQL) and cryogenic machining.

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 Development of a Low Cost Eco-Friendly Minimum Quantity Lubrication System for Machining Processes

2021 ◽  
Vol 8 ◽  
pp. 37-47
Author(s):  
Arunachalam Ramanathan ◽  
Sumaya Al Rumhi ◽  
Noor Al Hamimi ◽  
Shurooq Al Ajmi
Keyword(s):  
Quality Function Deployment ◽  
Cooling System ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Lower Surface ◽  
Machining Processes ◽  
Decision Matrix ◽  
Minimum Quantity ◽  
Lathe Machine ◽  
Mql System

Recently all environmental worries are calling for reducing the usage of fluids in machining operations. One of the promising solutions that appeared lately is minimum quantity lubrication (MQL). This research aimed to develop an eco-friendly cooling system for a lathe machine and assess its performance. After considering the customer needs, the needs were translated into engineering specifications in the conceptual design phase, and then the quality function deployment was developed. Three concepts were generated and evaluated considering the selection criteria, and a final concept was selected using the decision matrix method. Following this, a detailed design and fabrication of the subsystems such as the oil tank and a structure accommodate all the components. The developed system was tested on six different workpiece samples to compare the MQL system with the conventional one. In general, the MQL system resulted in lower surface roughness values as well as lower tool wear.

scholarly journals Experimental Investigation on Effects of MQL on Surface Finish and Tool Wear in Turning of SAE 1018

2018 ◽  
Vol 7 (2) ◽  
pp. 67-69
Author(s):  
Sandeep Kumar ◽  
Sukhpal Singh Chatha ◽  
Rutash Mittal
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Metal Cutting ◽  
Substantial Reduction ◽  
Minimum Quantity Lubrication ◽  
Environmental Safety ◽  
Work Piece ◽  
Cutting Fluids ◽  
Nose Radius ◽  
Machining Processes

In all machining processes, tool wear is a major problem and it leads to tool failure. In metal industries, the use of cutting fluids affects both employee’s health and environmental pollution. But the use of cutting fluids becomes necessary to keep tight tolerances and to maintain the work-piece surface properties without damages. Researchers are trying to reduce the use of coolant lubricant fluids in metal cutting to obtain environmental safety. So, to minimize the use of cutting fluids new cutting techniques are investigated. Minimal quantity of Lubrication (MQL) is a recent technique introduced in machining to obtain less tool wear and environment safety. The minimum quantity lubrication was provided with a spray of mixture of air and vegetable oil at suitable pressure. MQL machining was performed much superior compared to dry and wet machining due to substantial reduction in tool wear and cutting zone temperature and a better surface finish. MQL provides neat and clean environment avoiding health hazards due to smoke, fumes and gases etc. In this study work-piece of SAE 1018 were prepared to investigate their Surface finish under turning with coated tool bits. Wear of nose radius of tool bits were analyzed by SEM which results in less wear in MQL process as compared to flood cooling.

scholarly journals Study of the Tool Wear Process in the Dry Turning of Al–Cu Alloy

Metals ◽  
2019 ◽  
Vol 9 (10) ◽  
pp. 1094 ◽  
Author(s):  
Batista ◽  
Del Sol ◽  
Gomez-Parra ◽  
Ramirez-Peña ◽  
Salguero
Keyword(s):  
Tool Wear ◽  
Cutting Conditions ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Dry Cutting ◽  
Wear Process ◽  
Cutting Geometry ◽  
Cu Alloy ◽  
Adhesion Wear ◽  
Increase Tool Life

Light alloy machining is a widely implemented process that is usually used in the presence of cutting fluids to reduce wear and increase tool life. The use of coolants during machining presents negative environmental impacts, which has increased interest in reducing and even eliminating their use. In order to obtain ecofriendly machining processes, it will be necessary to suppress the use of cutting fluids, in a trend called “dry machining”. This fact forces machines to work under aggressive cutting conditions, producing adhesion wear that affects the integrity of the parts’ surfaces. This study describes cutting tool wear mechanisms in machining of UNS A92024 samples under dry cutting conditions. Energy dispersive spectroscopy (EDS) analysis shows the different compositions of the adhered layers. Roughness is also positively affected by the change of the cutting geometry produced in the tool.

scholarly journals An Independent Internal Cooling System for Promoting Heat Dissipation during Dry Cutting with Numerical and Experimental Verification

2017 ◽  
Vol 7 (4) ◽  
pp. 332 ◽  
Author(s):  
Bin Yao ◽  
Weifang Sun ◽  
Binqiang Chen ◽  
Xiaojin Yu ◽  
Yuchao He ◽  
...  
Keyword(s):  
Experimental Verification ◽  
Heat Dissipation ◽  
Cooling System ◽  
Internal Cooling ◽  
Dry Cutting

scholarly journals Application of Eco-Friendly Cutting Fluids Through Small Quantity Lubrication Technique: A Study

2018 ◽  
Vol 7 (2) ◽  
pp. 116-120
Author(s):  
Amrit Pal ◽  
Hazoor Singh Sidhu
Keyword(s):  
Minimum Quantity Lubrication ◽  
Colloidal Suspensions ◽  
Nano Particles ◽  
Cutting Fluid ◽  
Superior Performance ◽  
Cutting Fluids ◽  
Machining Performance ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Nano Fluids

Owing to environmental concerns and growing regulations over contamination and pollution, the demand for renewable and biodegradable cutting fluids is rising. The aim of this paper is to review the eco-friendly and user-friendly minimum quantity lubrication (MQL) technique using vegetable-based oil and solid lubricant in different machining processes. It has been reported in various literature that the minimum quantity lubrication (MQL) method using vegetable oil-based cutting fluid shows superior performance as compared to dry and wet machining. The major benefits of MQL are reduction of consumption of cutting fluid, cost saving, reduction of impact to the environment and improved overall performances in cutting operation and the surface quality. To achieve improved thermal conductivity researchers focused attention on nano fluids. Nano fluids are nano-metered sized colloidal suspensions in the base fluid like water, oil, glycol, etc. The application of nano fluid controls the tool wear by reducing the temperature. Impingement of the nano-particles with high pressure in MQL enables entry of nano-particles at the tool chip interface. Thus it reduces the coefficient of friction and improves machining performance significantly.

Influence of Minimum Quantity Lubrication on Friction Characterizing Tool–Aluminum Alloy Contact

2016 ◽  
Vol 138 (2) ◽  
Author(s):  
Frédéric Cabanettes ◽  
Julian Rolland ◽  
Florian Dumont ◽  
Joël Rech ◽  
Zlate Dimkovski
Keyword(s):  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Minimum Quantity Lubrication ◽  
Operating Conditions ◽  
Experimental Results ◽  
Lower Amount ◽  
Cutting Fluids ◽  
Machining Processes ◽  
The Real ◽  
Minimum Quantity

The possibility to reduce the amount of cutting fluids from machining processes is actively studied by the industrialists and researchers. Minimum quantity lubrication (MQL) is a solution toward cutting fluids reduction. This paper investigates the consequences on friction coefficient induced by the use of MQL. A tribometer is used in order to experimentally simulate the local tribological conditions encountered during machining. As the relative sliding speed increases, a lower amount of oil is deposited on the rough surfaces. Depending on the MQL operating conditions and sliding velocities, it is plausible to reach starvation by leaving the real rough contact partly dry. A model computing a starvation percentage by filling an estimated oil amount in a deformed topography correlates with the experimental results.

scholarly journals Environmental Analysis of Sustainable and Traditional Cooling and Lubrication Strategies during Machining Processes

2020 ◽  
Vol 12 (20) ◽  
pp. 8462 ◽  
Author(s):  
Amr Salem ◽  
Connor Hopkins ◽  
Mohamd Imad ◽  
Hussien Hegab ◽  
Basil Darras ◽  
...  
Keyword(s):  
Vegetable Oils ◽  
Positive Impact ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Process Efficiency ◽  
Cutting Fluids ◽  
Machining Performance ◽  
Machining Processes ◽  
Cooling Strategies ◽  
Cooling And Lubrication

Due to rising demands of replacing traditional cooling strategies with sustainable cooling strategies, the development of sustainable strategies such as minimum quantity lubrication (MQL) of nano-cutting fluids (NCFs) is on the rise. MQL of NCFs has received a lot of attention due to its positive impact on machining process efficiency. However, environmental and human health impacts of this strategy have not been fully investigated yet. This work aims to investigate the impacts of MQL of molybdenum disulfide (MoS2), multi-walled carbon nanotubes (MWCNTs), titanium dioxide (TiO2), and aluminum oxide (Al2O3) NCFs by employing a cradle-to-gate type of life cycle assessment (LCA). Besides, this paper provides a comparison of the impacts and machining performance when utilizing MQL of NCFs with other cooling strategies such as traditional flood cooling (TFC) of conventional cutting fluids and MQL of vegetable oils. It was found that NCFs have higher impacts than conventional cutting fluids and vegetable oils. The impacts of TiO2-NCF and MoS2-NCF were lower than the impacts of MWCNTs-NCF and Al2O3-NCF. MQL of NCFs presented higher impacts by 3.7% to 35.4% in comparison with the MQL of vegetable oils. TFC of conventional CFs displayed the lowest impact. However, TFC of conventional cutting fluids is contributing to severe health problems for operators. MQL of vegetable oils displayed higher impacts than TCFs of conventional cutting fluids. However, vegetable oils are considered to be environmentally friendly. According to the findings, the MQL of vegetable oils is the most sustainable strategy for machining processes with associated low/medium cutting temperatures. While MQL of TiO2 and MoS2 NCFs are the sustainable strategy for machining processes associated with high cutting temperatures.

A comprehensive review on minimum quantity lubrication (MQL) in machining processes using nano-cutting fluids

2019 ◽  
Vol 105 (5-6) ◽  
pp. 2057-2086 ◽  
Author(s):  
Zafar Said ◽  
Munish Gupta ◽  
Hussien Hegab ◽  
Neeti Arora ◽  
Aqib Mashood Khan ◽  
...  
Keyword(s):  
Minimum Quantity Lubrication ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Comprehensive Review ◽  
Minimum Quantity
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