Green Manufacturing - Textured Novel Cutting Tool for Sustainable Machining: A Review

2020 ◽  
Vol 899 ◽  
pp. 135-143
Author(s):  
Awais Farooqi ◽  
Nukman bin Yusoff
Keyword(s):  
Sustainable Manufacturing ◽  
Cutting Tools ◽  
Minimum Quantity Lubrication ◽  
Green Manufacturing ◽  
Machining Process ◽  
Machining Processes ◽  
Sustainable Machining ◽  
Nano Fluid ◽  
Prime Objective ◽  
Removal Processes

Green manufacturing concept has become a cutting edge in the field of sustainable machining. The prime objective of the philosophy is to find a technique in machining or material removal processes that are environmentally friendly, with minimal wastage, energy efficient and optimal condition for the machining processes. This review paper discusses the significance of textured novel cutting tools, is one of the promising technologies and process. It discusses the Dry Machining process to capture green sustainable manufacturing practices. The study may answer of how it stands among other methods including minimum quantity lubrication and nano fluid lubricant. This paper also presents the importance of advanced manufacturing tools to match the sustainable future needs with an idea of proposed methodology to conduct a research on textured novel cutting tools for sustainable machining.

scholarly journals Improvement of Machining Processes: A Case Study

2019 ◽  
Vol 2 (3) ◽  
pp. 634-641
Author(s):  
Hakan Gökçe ◽  
Ramazan Yeşilay ◽  
Necati Uçak ◽  
Ali Teke ◽  
Adem Çiçek
Keyword(s):  
Material Removal ◽  
Current Practice ◽  
Complex Geometry ◽  
Vital Role ◽  
Machining Process ◽  
Machining Processes ◽  
Machining Time ◽  
Machining Strategy ◽  
Removal Processes

In material removal processes, determination of optimal machining strategy is a key factor to increase productivity. This situation is gaining more importance when machining components with complex geometry. The current practice in the determination of machining strategy mostly depends on the experience of the machine operator. However, poorly designed machining processes lead to time-consuming and costly solutions. Therefore, the improvement of machining processes plays a vital role in terms of machining costs. In this study, the machining process of a boom-body connector (GGG40) of a backhoe loader was improved. Improvements of toolpaths and cutting conditions of 22 different material removal processes were checked through a CAM software. According to the simulation results, the process plan was rearranged. Besides, some enhancements in casting model were conducted to decrease in the number of machining operations. When compared to current practice, a reduction of 55% in machining time was achieved.

scholarly journals Progressing towards Sustainable Machining of Steels: A Detailed Review

Materials ◽  
2021 ◽  
Vol 14 (18) ◽  
pp. 5162
Author(s):  
Kashif Ishfaq ◽  
Irfan Anjum ◽  
Catalin Iulian Pruncu ◽  
Muhammad Amjad ◽  
M. Saravana Kumar ◽  
...  
Keyword(s):  
Skin Diseases ◽  
Cryogenic Treatment ◽  
Sustainable Manufacturing ◽  
Health And Safety ◽  
Minimum Quantity Lubrication ◽  
Solid Lubricants ◽  
Cryogenic Cooling ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
Sustainable Machining

Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

scholarly journals A Composite Evaluation Model of Sustainable Manufacturing in Machining Process for Typical Machine Tools

Processes ◽  
2019 ◽  
Vol 7 (2) ◽  
pp. 110 ◽  
Author(s):  
Lishu Lv ◽  
Zhaohui Deng ◽  
Tao Liu ◽  
Linlin Wan ◽  
Wenliang Huang ◽  
...  
Keyword(s):  
Energy Efficiency ◽  
Machine Tools ◽  
Manufacturing Industry ◽  
Orthogonal Experiment ◽  
Evaluation Model ◽  
Sustainable Manufacturing ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Carbon Efficiency

Machine tool is the basic manufacturing equipment in today’s mechanical manufacturing industry. A considerable amount of energy and carbon emission are consumed in machining processes, the realization of sustainable manufacturing of machine tools have become an urgent problem to be solved in the field of industry and academia. Therefore, five types of machine tools were selected for the typical machining processes (turning, milling, planning, grinding and drilling). Then the model of the energy efficiency, carbon efficiency and green degree model were established in this paper which considers the theory and experiment with the resource, energy and emission modeling method. The head frame spindle and head frame box were selected to verify the feasibility and practicability of the proposed model, based on the orthogonal experiment case of the key machining process. In addition, the influence rules of machining parameters were explored and the energy efficiency and green degree of the machine tools were compared. Finally, the corresponding strategies for energy conservation and emission reduction were proposed.

Evaluating Process Design through Quality Function Deployment for Environment

2010 ◽  
Vol 97-101 ◽  
pp. 2377-2380
Author(s):  
Yong Ming Wu ◽  
Zhou Hui Yang
Keyword(s):  
Product Design ◽  
Process Design ◽  
Quality Function Deployment ◽  
Green Manufacturing ◽  
Design Tool ◽  
Machining Process ◽  
Machining Processes ◽  
Quality Function ◽  
Know How ◽  
Design Engineers

Quality Function Deployment for Environment (QFDE) is an effective eco-design tool to transform the voices of customer and environment into the engineering metrics for evaluating product design. From the viewpoint of green manufacturing, machining process design is focused on by many manufacturers and it is necessary to evaluate its environmental impact. The QFDE method is developed to evaluate machining process design with the new house of quality. According to the evaluation, design engineers can identify which part characteristics and their machining processes should be focused on and then know how to improve the product design. A case of an engine is studied to illustrate the proposed method.

Hard Turning of AISI D2 Steel In CNC Machining: An Overview

2018 ◽  
Vol 3 (1) ◽  
pp. 17-20
Author(s):  
Navriti Gupta ◽  
◽  
A.K Agrawal, ◽  
R.S Walia ◽  
Ranganath Singari
Keyword(s):  
Metal Removal ◽  
Cnc Machining ◽  
Machining Process ◽  
Tungsten Carbides ◽  
Machining Processes ◽  
Manufacturing Operations ◽  
Aisi D2 ◽  
Removal Processes ◽  
Tough Steel ◽  
D2 Steel

D2 steel is an industrial tool steel. It is widely used in the tool and die industry for making cutting tool inserts, bending inserts, restriking inserts, etc. which can be taken out after their tool life. D2 steel is a very tough steel and difficult to machine also. High generations tool bits like Tungsten carbides and Titanium carbides are required to machine them. The heat treatment follows the machining process. Their machinability is very low. CNC machines are often used to finish them. Often they are machined using programs on UG-NX Uni Graphics(CAM) and DELCAM. And they have to be machined in three steps. Roughing operations, followed by Semi-Finish machining and the last step is finish machining.CNC machining centers are versatile in their applications in metal removal processes. Often they are so modernized that just like many manufacturing operations, metal removal can be automated too. The need for CNC machining arises due to extensive finishing requirements in the aerospace, automotive industries. However, the CNC or Computer and Numerically controlled machining process usage is not limited to these industries only. Tool and Die industry also is heavily dependent on CNC material removal and machining processes as now replaceable inserts are widely used in this industry.

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 and Application of Coated Ceramic Cutting Tools

2006 ◽  
Vol 45 ◽  
pp. 1155-1162 ◽  
Author(s):  
E. Uhlmann ◽  
T. Hühns ◽  
S. Richarz ◽  
Walter Reimers ◽  
S. Grigoriev
Keyword(s):  
Cutting Tools ◽  
Substrate Material ◽  
Machining Process ◽  
Machining Processes ◽  
Ceramic Substrates ◽  
Pvd Coating ◽  
High Temperature Alloys ◽  
Pre Treatment ◽  
Process Measurements ◽  
Comprehensive Measurement

Ceramics are characterized by their special wear and temperature resistance. Thus, they are especially suited for the cutting of high-temperature alloys and difficult-to-cut materials. Due to their low ductility, they show brittle-hard properties during the process, which lead to a sudden failure of the tool. But it is possible to create composite materials that counteract the brittle-hard behavior of the substrate material by PVD-coating. The objective of the investigations is to increase the process stability of coated ceramic indexable inserts made of aluminum oxide and silicon nitride through the optimisation of the mechanical pre-treatment of the substrate materials. To this end, the ceramic substrates are pre-treated by different abrasive machining processes. Comprehensive measurement evaluations show the influence of the machining process and strategy on the formation of surface and subsurface. The workpieces ground and lapped in different ways are subsequently coated by an especially developed PVD process. Measurements show the influence of the pre-treatment on the surface structure and on the mechanical properties of the composite material. The application of the developed and manufactured tools in cutting tests verifies the results of the measurements.

Laboratory Experiment of New Cutting Materials in Milling Processes

2014 ◽  
Vol 611 ◽  
pp. 467-471 ◽  
Author(s):  
Igor Vilček ◽  
Jozef Kováč ◽  
Jaroslava Janeková
Keyword(s):  
Cubic Boron Nitride ◽  
Cutting Tools ◽  
High Hardness ◽  
Hardened Steel ◽  
Production Costs ◽  
Machining Processes ◽  
Hard Materials ◽  
Removal Processes ◽  
Conventional Machining ◽  
Cutting Tool Materials

The development of manufacturing technology is mostly given by economics, environmental trends and the development of cutting materials and machine tools. Manufacturing is a significant part of the worldwide economy. Machining (material removal processes) represents major part of production costs. This paper yield inquiries into the hard and precise milling with a focus on force effects in experimental machining, tool wear and final surface qualities (roughness, micro hardness). The precision machining of hardened steel differs from conventional machining in terms of the hardness of the workpiece materials and the cutting tool materials that are required. Hard materials are characterized by high hardness (> 45 HRC) and abrasiveness. Machining processes require cutting tools of much higher hardness and also higher resistance of the abrasive wear. Recently developed cubic boron nitride (CBN) and coated sintered carbides cutting tools are considered to have the ability of cutting such as steel. CBN cutting tools show good performance during machining of the hardened steel because of their hot hardness and good fracture toughness.

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