Effect of Minimum Quantity Lubrication to Prediction of Cutting Temperature Distribution in Turning Material AISI-1045

2020 ◽  
Vol 902 ◽  
pp. 97-102
Author(s):  
Tran Trong Quyet ◽  
Pham Tuan Nghia ◽  
Nguyen Thanh Toan ◽  
Tran Duc Trong ◽  
Luong Hong Sam ◽  
...  
Keyword(s):  
Temperature Distribution ◽  
Shear Zone ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
The Difference ◽  
Secondary Shear Zone ◽  
Cutting Model

This paper presents a prediction of cutting temperature in turning process, using a continuous cutting model of Johnson-Cook (J-C). An method to predict the temperature distribution in orthogonal cutting is based on the constituent model of various material and the mechanics of their cutting process. In this method, the average temperature at the primary shear zone (PSZ) and the secondary shear zone (SSZ) were determined for various materials, based on a constitutive model and a chip-formation model using measurements of cutting force and chip thicknes. The J-C model constants were taken from Hopkinson pressure bar tests. Cutting conditions, cutting forces and chip thickness were used to predict shear stress. Experimental cutting heat results with the same cutting parameters using the minimum lubrication method (MQL) were recorded through the Testo-871 thermal camera. The thermal distribution results between the two methods has a difference in value, as well as distribution. From the difference, we have analyzed some of the causes, finding the effect of the minimum quantity lubrication parameters on the difference.

Temperature Distribution Simulation, Prediction and Sensitivity Analysis of Orthogonal Cutting of Cortical Bone

2021 ◽  
pp. 095441192110498
Author(s):  
Quanwei Wang ◽  
Heqiang Tian ◽  
Xiaoqing Dang ◽  
Jingbo Pan ◽  
Yu Gao ◽  
...  
Keyword(s):  
Temperature Distribution ◽  
Cortical Bone ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Maximum Temperature ◽  
Model Parameters ◽  
Feed Speed ◽  
Milling Temperature ◽  
Cutting Model

Bone cutting plays an important role in spine surgical operations. The power devices with high speed employing in bone cutting usually leads to high cutting temperature of the bone tissue. This high temperature control is important in improving cutting surface quality and optimizing the cutting parameters. In this paper, the bone-cutting model was appropriately simplified for finite element (FE) based modeling of 2D orthogonal cutting to discuss the change law of cutting temperature of cortical bones for cervical vertebra, and to study the orthogonal cutting mechanism of the anisotropic cortical bone, a 3D FE simulation model had been also established in which longitudinal, vertical, and transversal cutting types were accomplished to investigate the effect of osteons orientation. Secondly, this response surface method was used to regress the simulation results, and establishes the prediction model of maximum temperature on cutting depth, cutting speed, and feed speed. Then, the Sobol method was used to analyze the sensitivity of the milling temperature prediction mathematical model parameters, in order to clarify and quantitatively analyze the influence of input milling parameters on the output milling temperature. Finally, the cutting temperatures obtained with the simulations were compared with the corresponding experimental results obtained from the bone milling tests. This study verifies the influence of key variables and the cutting parameters on thermo mechanical behavior of the bone cutting. The obtained cutting temperature distribution for the bone surfaces could be employed to establish a theoretical foundation for research on thermal damage control of bone tissues.

Model-based sensitivity analysis of machining-induced residual stress under minimum quantity lubrication

2015 ◽  
Vol 231 (9) ◽  
pp. 1528-1541 ◽  
Author(s):  
Xia Ji ◽  
Steven Y Liang
Keyword(s):  
Residual Stress ◽  
Sensitivity Analysis ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Mixture Ratio ◽  
Minimum Quantity

This article presents a sensitivity analysis of residual stress based on the verified residual stress prediction model. The machining-induced residual stress is developed as a function of cutting parameters, tool geometry, material properties, and lubrication conditions. Based on the residual stress predictive model, the main effects of the cutting force, cutting temperature, and residual stress are quantitatively analyzed through the cosine amplitude method. The parametric study is carried out to investigate the effects of minimum quantity lubrication parameters, cutting parameters, and tool geometry on the cutting performances. Results manifest that the cutting force and residual stress are more sensitive to the heat transfer coefficient and the depth of cut, while the cutting temperature is more sensitive to the cutting speed. Large maximum compressive residual stress is obtained under a lower flow rate of minimum quantity lubrication, small depth of cut, and the proper air–oil mixture ratio. This research can support the controlling and optimization of residual stress in industrial engineering by strategically adjusting the application parameters of minimum quantity lubrication.

Calculating of the Temperature Distribution of Primary Shear Zone in Orthogonal High Speed Cutting Based on the Non-Uniform Volume Moving Heat Source

2009 ◽  
Vol 626-627 ◽  
pp. 105-110 ◽  
Author(s):  
Guo He Li ◽  
Min Jie Wang
Keyword(s):  
Temperature Distribution ◽  
Heat Source ◽  
Shear Zone ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Constitutive Relationship ◽  
Moving Heat Source ◽  
High Speed Cutting ◽  
Strain And Strain Rate

A method was presented for calculating the temperature distribution of primary shear zone in orthogonal high speed cutting based on the non-uniform volume moving heat source. The temperature distribution of primary shear zone in orthogonal high speed cutting was calculated by the dynamic plastic constitutive relationship and the distribution of strain and strain rate of primary shear zone. The results show that the temperature distribution of primary shear zone is uneven, from the original plane to the cutoff plane, the cutting temperature increases continuously. In the middle of primary shear zone, the change of cutting temperature is larger, at the position near to original plant and cutoff plane, the change of cutting temperature is smaller. The cutting temperature increases with the increase of cutting speed and cutting depth, but decreases with the increase of rake angle. The comparison with existing method shows that the method presented in this paper is not only available, but also simple, convenient and more accord with the fact of orthogonal high speed cutting.

Analysis on the Temperature Rise Produced by Plastic Deformation Heat for Nanoscale Orthogonal Cutting of Copper Workpiece

2012 ◽  
Author(s):  
Zone-Ching Lin ◽  
Ying-Chih Hsu ◽  
Liang-Kuang Chen
Keyword(s):  
Plastic Deformation ◽  
Temperature Distribution ◽  
Temperature Rise ◽  
Calculation Method ◽  
Orthogonal Cutting ◽  
Equivalent Stress ◽  
Equivalent Strain ◽  
Perfect Crystal ◽  
Molecular Statics ◽  
Cutting Model

The quasi-steady molecular statics nanoscale orthogonal cutting model developed by this paper not only can calculate cutting force, equivalent stress and equivalent strain, but also can calculate the temperature rise of the cut perfect crystal copper workpiece. This paper considers that during nanoscale orthogonal cutting, the temperature rise of the cut perfect crystal copper workpiece is produced by plastic deformation heat only. The calculation method of equivalent stress and equivalent strain uses three-dimensional quasi-steady molecular statics nanocutting model to calculate and simulate the phenomenon. The model for plastic deformation heat developed by this paper can be used to calculate the equivalent stress and equivalent strain of the cut copper workpiece. Furthermore, the calculation method of temperature rise of the cut workpiece produced by plastic deformation heat is developed. Afterwards the analysis of temperature distribution is also conducted. And the obtained temperature distribution of the cut copper workpiece computed by this paper is qualitatively compared with the temperature distribution obtained by molecular dynamics method in the reference.

Predictive Modeling of Minimum Quantity Lubrication: Cutting Force, Temperature and Residual Stress

2013 ◽  
Vol 365-366 ◽  
pp. 1181-1184 ◽  
Author(s):  
Xia Ji ◽  
Xue Ping Zhang ◽  
Bei Zhi Li ◽  
Steven Y. Liang
Keyword(s):  
Residual Stress ◽  
Cutting Force ◽  
Predictive Modeling ◽  
Analytical Approach ◽  
Orthogonal Cutting ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
Machining Force ◽  
Tc4 Alloy ◽  
Cooling Effects

This paper presents an analytical approach to predict the machining force, temperature and residual stress under minimum quantity lubrication (MQL) condition. Both the lubrication and cooling effects are considered to change the tribological and thermal properties in the modified Oxleys model, which is capable to predict the cutting force and temperature in MQL machining directly from cutting conditions. The machining-induced residual stress is predicted by modified McDowell hybrid algorithm. The predicted cutting forces and residual stresses are verified by orthogonal cutting tests for C45 steel and TC4 alloy steel.

Experimental investigation of nanofluids in minimum quantity lubrication during turning of EN-24 steel

2019 ◽  
Vol 234 (5) ◽  
pp. 712-729
Author(s):  
Archana Thakur ◽  
Alakesh Manna ◽  
Sushant Samir
Keyword(s):  
Comparative Analysis ◽  
Desirability Function ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Hybrid Nanofluid ◽  
Machining Performance ◽  
Optimization Of Parameters ◽  
Minimum Quantity ◽  
Response Optimization ◽  
Hybrid Nanofluids

The present work evaluates the performance of different machining environments such as dry, wet, minimum quantity lubrication, Al2O3 nanofluids based minimum quantity lubrication, CuO nanofluids based minimum quantity lubrication and Al–CuO hybrid nanofluids based minimum quantity lubrication on machining performance characteristics during turning of EN-24. The nanofluids and hybrid nanofluids were prepared by adding the Al2O3, CuO and Al2O3/CuO to the soluble oil with different weight percentages (0.5 wt.%, 1 wt.%, 1.5 wt.%). The thermal and tribological properties of hybrid nanofluid and nanofluids were analyzed. The comparative analysis of different turning environments has been done. From comparative analysis it is clearly observed that the nanofluids and hybrid nanofluid shows better performance during turning of EN-24 steel. So there is a need for optimization of parameters during turning of EN-24 under Al2O3 nanofluids based minimum quantity lubrication, CuO nanofluids based minimum quantity lubrication and Al–CuO hybrid nanofluids based minimum quantity lubrication. The optimization of parameters has been done by response surface methodology. The significance of developed model was identified from analysis of variance. Multi-response optimization was done using desirability function approach. To verify the accuracy of developed models, confirmatory experiments were performed. The experimental results reveal that Al–CuO hybrid nanofluids based minimum quantity lubrication significantly improves surface quality, reduces cutting temperature and cutting forces.

Selection of Minimum Quantity Lubrication (MQL) Parameters in Milling of Ti-6Al-4V

2012 ◽  
Vol 426 ◽  
pp. 139-142 ◽  
Author(s):  
Zhi Qiang Liu ◽  
X.J. Cai ◽  
Ming Chen ◽  
Qing Long An
Keyword(s):  
Cutting Force ◽  
End Milling ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Minimum Quantity ◽  
Nozzle Position ◽  
Mql System ◽  
End Milling Process ◽  
Selection Of

Different parameters of Minimum Quantity Lubrication (MQL) system, including air pressure, oil quantity, nozzle position, might have different influences on the cutting force and the cutting temperature. This paper presents an experiment of end-milling titanium alloy with MQL system. The objective of the experiment is to investigate the influences of MQL parameters in milling of Ti-6Al-4V. The results of experiment show that there are different effects on the cutting force and the cutting temperature with different MQL parameters, which will help to select different parameters in the end-milling process of Ti-6Al-4V.

Effect of the alumina nanofluid concentration on minimum quantity lubrication hard machining for sustainable production

2019 ◽  
Vol 233 (17) ◽  
pp. 5977-5988 ◽  
Author(s):  
Tran Minh Duc ◽  
Tran The Long ◽  
Pham Quang Dong
Keyword(s):  
Thermal Conductivity ◽  
Soybean Oil ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Research Trend ◽  
Hard Machining ◽  
Negative Effects ◽  
Hard Milling ◽  
Minimum Quantity ◽  
New Research

The use of vegetable oil-based nanofluids for minimum quantity lubrication hard machining has become a new research trend, proven to bring out very promising results and attained much attention to reduce the negative effects of using cutting fluids on the environment. The enhancement of thermal conductivity and viscosity of nanofluids helps to reduce the values of the friction coefficient, and the cooling lubricant properties are significantly improved when compared to the base fluids. In this paper, a set of optimized minimum quantity lubrication hard milling parameter combinations is obtained by using response surface methodology. Based on the optimized results, the study of the concentration effect of Al2O3 soybean oil-based nanofluid used for minimum quantity lubrication hard milling performance of 60Si2Mn hardened steel is investigated to validate and make further observations. It is noted that the appropriate nanoconcentration (1.0–1.5 wt%) and cutting conditions are observed to improve the cutting performance using soybean oil-based nanofluid. Increasing the nanoparticle concentration enhances the thermal conductivity and viscosity of the base fluids, which lead to reduce the cutting temperature and cutting forces and prolong the tool life from 80 to 115 min (increasing about 43.8%). Especially, the surface roughness ( Ra, Rz) improves and remains stable during hard cutting. Hence, the application of soybean oil-based nanofluid in minimum quantity lubrication hard machining is enlarged without losing anti-toxic, economic, and environment-friendly properties.

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