Preliminary Experimental Study on Effect of Cutting Fluid on Milled Surface Quality of Iron-Base Superalloy

As the development of new materials and high speed machining, cutting fluid becomes more and more important because of its functions of cooling, lubrication, corrosion protection and cleaning. The main purposes of cutting fluid are decreasing temperature, reducing friction, extending tool life and improving machining efficiency. In precision machining, high machined surface integrity is the most important. In this paper, a preliminary experimental study on effect of two different cutting fluids on milled surface quality of iron-base superalloy was taken. The surface morphology, roughness, micro hardness and residual stress of the machined surface were investigated. The results showed that the material properties and geometric characteristics of the machined surface were significantly affected by cutting fluid conditions. The effect of cutting fluid on machined surface quality and service performance will become an important research direction. This paper also suggests the main contents of the further research on effect of cutting fluids on machined surface.

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PROCESSING AND CHARACTERIZATION OF ECO-FRIENDLY CUTTING FLUID WITH NANO ADDITIVES FOR TURNING OPERATION

Surface Review and Letters ◽

10.1142/s0218625x21500578 ◽

2021 ◽

pp. 2150057

Author(s):

M. K. MARICHELVAM ◽

S. SENTHIL MURUGAN ◽

K. MAHESWARAN ◽

D. SHYAMPRASAD VARMA

Keyword(s):

Boric Acid ◽

Environmental Sustainability ◽

Coconut Oil ◽

Cutting Fluid ◽

Interface Temperature ◽

Test Flash ◽

Cutting Fluids ◽

Machined Surface ◽

Turning Operation

Machining quality depends on numerous factors such as speed, feed rate, quality of the materials, the cutting fluids used and so on. The quality of machining components can also be improved by using appropriate cutting fluids. In this study, the three different types of eco-friendly cutting fluids based on coconut oil with nano boric acid particles were synthesized with nanoadditives and characterized during the lathe-turning operation of mild steel. The obtained results were compared between the dry/plain turning (without the cutting fluid) and the turning with the cutting fluids like coconut oil and mineral oil with nanoparticles. In industries, a wide variety of cutting fluids are used; however, most of these cutting fluids are made up of synthetic materials which may affect the environment significantly. Hence, it is essential to develop eco-friendly cutting fluids for environmental sustainability. Here, the cutting fluids were characterized by the morphological study on nanoparticles (400[Formula: see text]nm) and the machined surface using scanning electron microscope (SEM), viscosity test, flash and fire point, surface roughness on machined part, tool tip-workpiece interface temperature, cutting force and flank wear measurement. The results showed that cutting fluids with 0.5% of boric acid had better performance.

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The Effect of One Directional Ultrasonic Vibration Assistance in High Speed Meso-Scale Milling Process

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.447-448.41 ◽

2010 ◽

Vol 447-448 ◽

pp. 41-45 ◽

Cited By ~ 1

Author(s):

Jeong Hoon Ko ◽

Kah Chuan Shaw ◽

Han Kwang Chua ◽

Rong Ming Lin

Keyword(s):

Surface Quality ◽

Ultrasonic Vibration ◽

High Speed ◽

Cutting Speed ◽

Milling Process ◽

Air Bearing ◽

Machined Surface ◽

Machined Surface Quality ◽

Milled Surface ◽

Vibration Assistance

One-directional ultrasonic vibration assisted milling system is designed and its performance is investigated in terms of machined surface quality under 135,000 rpm. The ultrasonic vibration generator excites the workpiece with a frequency around 40 kHz and amplitude of a few micro meters. The milling tool’s cutting speed is controlled by an air-bearing spindle system. Both feed-directional and cross-feed directional ultrasonic vibration assistance are considered in order to understand the mechanism of ultrasonic vibration assistance for surface roughness generation. A comparison is done on a milled surface which is generated with and without ultrasonic vibration assistance. The experimental results show that ultrasonic vibration assistance can improve the machined surface quality which depended on the cutting edge radius and the feed per tooth.

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Experimental study of single cubic boron nitride grains in the ultrasound-assisted high-speed grinding

Advances in Mechanical Engineering ◽

10.1177/1687814017693543 ◽

2017 ◽

Vol 9 (2) ◽

pp. 168781401769354 ◽

Cited By ~ 1

Author(s):

Dao-hui Xiang ◽

Zhong-yun Liu ◽

Zhi-kun Zhou ◽

Yun-long Yao

Keyword(s):

Experimental Study ◽

Boron Nitride ◽

Surface Quality ◽

High Speed ◽

Cubic Boron Nitride ◽

Grinding Force ◽

Abrasive Particles ◽

Ultrasonic Assisted ◽

High Speed Grinding

The kinematic characteristics, grinding force, surface quality of workpiece surface, and wear of abrasive particles were studied by theoretical analysis and experimental study on the single cubic boron nitride abrasive particles under ultrasonic-assisted high-speed grinding. Under the condition of the same grinding parameters, the motion characteristics and the grinding forces of the two machining modes of general grinding and ultrasonic-assisted grinding are compared and analyzed. Research shows that the ultrasonic vibration is applied in the common external circular grinding on grinding particle movement characteristics changed obviously, grinding particle trajectory of variable length, cutting groove width wider, thereby improving the grinding efficiency and the grinding removal rate; ultrasonic assisted under high speed grinding, the grinding force is higher than that of common grinding force is small, efficiency of grinding under ultrasonic processing mode is much higher than ordinary grinding, the surface quality of the workpiece has improved markedly.

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Study on Arithmetic of Surface Damage Ratio in High Speed Machining of Graphite Based on Matlab Image Processing

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.652-654.2196 ◽

2013 ◽

Vol 652-654 ◽

pp. 2196-2199

Author(s):

Li Zhou ◽

Yu Zhong Li ◽

Cheng Yong Wang

Keyword(s):

Image Processing ◽

Surface Quality ◽

High Speed ◽

Quantitative Description ◽

Surface Damage ◽

Projection Area ◽

High Speed Machining ◽

Machined Surface ◽

Stereo Microscope

The surface quality of graphite cannot be completely evaluated only by the roughness value Ra measured by profilometer. The surface damage ratio Sc is presented to give quantitative description of surface quality of graphite, which was calculated as the ratio of the projection area of fracture craters to the overall area of free surface. The machined surface was observed and taken photo by use of the stereo microscope with CCD image acquisition system. Matlab image processing tool was used to convert the color photo to binary image, in which fracture craters were shown as black pixels and the other surfaces as white pixels. The surface damage ratio is the result of the sum of black pixels divided by the overall pixels. Under the same conditions of high speed machining experiments for verification, the surface damage ratio was calculated in comparison with the Ra values measured by profilometer. The variation tendency of surface damage ratios exhibited good coherence to the measured roughness.

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Research on Machined Surface Quality of High Speed Hard Machining for Harden Steel

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.500.82 ◽

2012 ◽

Vol 500 ◽

pp. 82-88 ◽

Cited By ~ 1

Author(s):

Cai Xu Yue ◽

Xian Li Liu ◽

Da Wei Sun ◽

Ming Yang Wu

Keyword(s):

Surface Quality ◽

High Speed ◽

Cutting Parameters ◽

Hardened Steel ◽

Machining Process ◽

Machined Surface ◽

High Speed Cutting ◽

Machined Surface Quality ◽

Side Flow

For its good processing flexible, economic and environmental protection performance, hardened steel GCr15 is used widely in car and energy industry. Although surface quality in machining process is not controlled well, that restricts application of hardened steel GCr15 extensive to a certain degree. Therefore, this study revealed the effect of cutting parameters on surface roughness. Also influence of cutting conditions on surface morphology and organization generation mechanism of subsurface were stuied for high-speed cutting hardened steel GCr15. Appear reasons of plastic side flow on surface was researched. Also, effect of tool wear on surface quality was studied as well. The research results provided theoretical basis for rational choice for high speed hardened steel cutting process.

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Effect of High Speed Dry End Milling on Surface Roughness and Cutting Forces of Ti-6Al-4V ELI

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.493.546 ◽

2014 ◽

Vol 493 ◽

pp. 546-551 ◽

Cited By ~ 3

Author(s):

Safian Sharif ◽

Habib Safari ◽

Sudin Izman ◽

Denni Kurniawan

Keyword(s):

Surface Roughness ◽

Surface Quality ◽

Cutting Forces ◽

High Speed ◽

End Milling ◽

Cutting Speed ◽

Machined Surface ◽

Milled Surface ◽

Cemented Carbide Tools ◽

Cutting Speeds

The surface quality generated when high speed dry end milling (HSDEM) Ti-6Al-4V-ELI titanium alloy with coated and uncoated carbide tools were investigated. Evaluation was conducted using TiAlN+TiN coated and uncoated cemented carbide tools under different high cutting speeds and feed rates conditions. Surface roughness and cutting forces were measured when using new tools. The milled surface quality and corresponding alteration were characterized through electron microscopy. Within the investigated conditions high quality surface finish was obtained on the machined surface. Increasing cutting speed from 200 to 300 m/min during the process improved the surface finished particularly under lower feed rates. In term of generated surface quality, uncoated H25 grade carbide tools out performed coated F40M grade specifically at the higher cutting conditions. The main damages observed after HSDEM on the surface for all machining conditions contain redeposited materials, feed marks, and tool edge marks. Under both tested feed rates the resultant cutting force decreased by increasing the cutting speeds and uncoated carbide tools provide the lower cutting forces compared to coated types.

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Experimental study on machined surface quality of turning superalloy Inconel625

Ferroelectrics ◽

10.1080/00150193.2017.1391591 ◽

2018 ◽

Vol 522 (1) ◽

pp. 9-19

Author(s):

Erliang Liu ◽

Hongwei Xing ◽

Xudong Wei ◽

Ning Wang ◽

Jin Qi ◽

...

Keyword(s):

Experimental Study ◽

Surface Quality ◽

Machined Surface ◽

Machined Surface Quality

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Vibration Analysis Based on AR Trispectrum in Milling Process

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.97-101.1895 ◽

2010 ◽

Vol 97-101 ◽

pp. 1895-1901

Author(s):

Yu Yan Jiang ◽

Yi Jian Huang ◽

Xiu Cheng Ye

Keyword(s):

Surface Quality ◽

Vibration Analysis ◽

Metal Cutting ◽

Cutting Parameters ◽

Milling Process ◽

Cutting Fluid ◽

Depth Of Cut ◽

Machined Surface ◽

Machined Surface Quality

This paper presents the use of vibration analysis based on autoregressive (AR) trispectrum in milling process to indicate the relationship between machined surface quality of workpiece and spectrum character under a variety of different cutting parameter settings, such as the depth of cut, the feed rate and the spindle speed. The metal cutting experiments were performed on steel A3 material without using any cutting fluid. The experimental results for slices analysis of trispectra indicated that the spectral peaks were abundant as the milling process went smoothly. The roughness value measured reflects the machined surface quality of workpice. According to the changes for spectral peak and roughness value, a conclusion was made that the proposed trispectrum slices method for choosing cutting parameters and monitoring the machined surface quality in milling process was practicable.

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