scholarly journals Effect of Boric Acid Mixture as Solid Lubricant towards Machining Processes

2013 ◽  
Vol 651 ◽  
pp. 372-377
Author(s):  
S. Sulaiman ◽  
M.K.A.M. Ariffin ◽  
T.S. Hong ◽  
N.A. Mustafa
Keyword(s):  
Boric Acid ◽  
Manufacturing Industry ◽  
Solid Lubricant ◽  
Metal Removal ◽  
Cutting Fluid ◽  
Acid Mixture ◽  
Machining Processes ◽  
Feasible Alternative ◽  
And Performance ◽  
Cutting Processes

Milling is widely used metal removal process in manufacturing industry that involves generation of high cutting forces and temperature. Lubricants become important to reduce the cutting force and temperature for better machining processes and performances. Conventional cutting fluid has some limitations. The applications of conventional cutting fluid create some techno-environmental problems like environmental pollution, biological problems to operators and water pollution. Application of solid lubricant in milling has proved to be a feasible alternative to the conventional cutting fluids. The present work investigates the effect of boric acid as solid lubricant towards machining performances such as tool wear and surface roughness. The results indicate that boric acid can improve the cutting processes and performance compared to conventional cutting fluid.

scholarly journals Tribological behavior of the boric acid and titanium dioxide based nanofluid in machining of EN24 steel

2020 ◽  
Vol 37 (1−2) ◽  
Author(s):  
Ravi Kant Avvari ◽  
Shreenivasa Rao Penta ◽  
PVJ Mohan Rao
Keyword(s):  
Titanium Dioxide ◽  
Boric Acid ◽  
Cutting Forces ◽  
Solid Lubricant ◽  
Heat Dissipation ◽  
Metal Removal ◽  
Tribological Behavior ◽  
Cutting Fluid ◽  
Work Piece ◽  
Tungsten Carbide Tool

Turning operation is a widely recognized metal removal process in the industry. If the machining were not run efficiently, it may affect the performance of the tool and the work piece by generating higher cutting forces and the temperature as in hard steel. To minimize these effects, lubrication has to be effective in reducing these forces and lowering the tool temperature. In the present study, machining experiments were conducted on EN24 steel with the application of nano sized boric acid (50 nm) as the solid lubricant that is mixed with titanium dioxide (100 µm) in SAE 40 oil. Turning tests are conducted using tungsten carbide tool inserts under dry, wet and MQL conditions to measure and compare the cutting forces, tool temperatures and roughness of the work piece. Results indicate that boric acid enables significant reduction in the cutting forces which in combination with the titanium dioxide helps to improve the heat dissipation; an advantage that makes such lubricants an effective cutting fluid. H3BO3 and TiO2 based nanofluid resulted in reducing the surface roughness of up to 2.7 µm that is a re-duction by ~15%.

scholarly journals The Role of Surfactant Structure on the Development of a Sustainable and Effective Cutting Fluid for Machining Titanium Alloys

Metals ◽  
2020 ◽  
Vol 10 (10) ◽  
pp. 1388 ◽  
Author(s):  
Elisabet Benedicto ◽  
Eva María Rubio ◽  
Diego Carou ◽  
Coral Santacruz
Keyword(s):  
Titanium Alloys ◽  
Chain Length ◽  
Cutting Tools ◽  
Hydrocarbon Chain ◽  
Cutting Fluid ◽  
Machining Processes ◽  
Produce Water ◽  
Hydrocarbon Chain Length ◽  
Metalworking Fluid ◽  
And Performance

In cutting operations of titanium alloys, most of the problems are related to the high consumption of cutting tools due to excessive wear. An improvement of metalworking fluid (MWF) technology would increase the productivity, sustainability, and quality of machining processes by lubricating and cooling. In this research article, the authors varied the surfactant’s charge, the hydrocarbon chain length, and the ethoxylation degree. Surfactants were dispersed at 1.2 mM in water and trimethylolpropane oleate to produce water-based MWF. Infrared reflection absorption spectroscopy and total organic carbon analysis were used to study the influence of surfactant structure on the film forming ability of the emulsion and performance was studied on Ti6Al4V using tapping torque test. The results showed that by changing the molecular structure of the surfactant, it is possible to vary the affinity between the ester and the substrate and reach an optimal combination, which improves the formation of a tribofilm. The mixture with anionic surfactants has good tribology performance, while non-ionic surfactants shorten the tool’s life. Moreover, the increase in the hydrocarbon chain length and the number of ethoxylations of surfactants promotes the adhesion of ester onto the metal surface, improving the lubricity properties of environmentally friendly MWF.

Investigation to Study the Applicability of Solid Lubricant in Turning AISI 1040 steel

2006 ◽  
Vol 129 (3) ◽  
pp. 520-526 ◽  
Author(s):  
Deep Mukhopadhyay ◽  
Sankha Banerjee ◽  
N. Suresh Kumar Reddy
Keyword(s):  
Surface Quality ◽  
Solid Lubricant ◽  
Metal Removal ◽  
Chip Thickness ◽  
Industrial Applications ◽  
Experimental Setup ◽  
Machining Processes ◽  
Novel Concept ◽  
Machining Fluids ◽  
Zone Temperature

Machining of materials has received substantial attention due to the increasing use of machining processes in various industrial applications. The research in this area is intended mainly to improve the machining of process so as to achieve the required surface quality. Machining processes, though employed widely as in metal removal process, have their own share of problems, such as high machining zone temperature, which may lead to poor surface quality. Machining fluids are applied in different forms to control such a high temperature, but they are partially effective within a narrow working range; recent studies also indicate their polluting nature. Solid lubricant assisted machining is a novel concept to control the machining zone temperature without polluting the environment. Solid lubricant, if employed properly, could control the machining zone temperature effectively by intensive removal of heat from the machining zone. A new experimental setup has been envisaged and built. Experiments have been carried out to study the effect of solid lubricant on surface finish and chip thickness. Results indicate that the effectiveness of solid lubricant is substantial through the experimental domains.

Effects of Cutting Fluids on Surface Roughness in Single-Point Diamond Turning of Rapidly Solidified Aluminium (RSA 431)

2020 ◽  
Vol 853 ◽  
pp. 18-23
Author(s):  
F.A Oyekunle ◽  
Khaled Abou-El-Hossein
Keyword(s):  
Surface Roughness ◽  
Metal Removal ◽  
Single Point ◽  
Cutting Parameters ◽  
Diamond Turning ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Processes ◽  
Rapidly Solidified

Single-point diamond turning is a technique of ultra-high precision machining that provides excellent quality of surface for mirrors, spherical and aspherical components. In SPDT just like other machining processes, cutting fluid plays an important role in metal removal and tool condition which largely influence the surface of diamond turned surface. In this paper, the surface roughness of diamond turned RSA 431 was studied by investigating the effect of kerosene mist and water as cutting fluids. Higher order response surface of Box-Behnken design was generated using fewer runs than a normal factorial technique. The cutting parameters that were varied for both experiments were depth of cut, feed and, speed. Taylor Hobson PGI Dimension XL surface Profilometer was used to measure the surface roughness after each experimental run. The results show that water when used as cutting fluid during machining, produces better surface roughness than kerosene mist. Predictive models for surface roughness were developed for each experiment. Values from the Mean Absolute Percent Error (MAPE) was used to evaluate and compare the two models to determine the accuracy. RSM also proved to be a better methodology of predicting surface roughness.

scholarly journals A Novel Technique to Assess the Effect of Machining and Subsurface Microstructure on the Fatigue Performance of Ti-6Al-2Sn-4Zr-6Mo

2020 ◽  
Vol 321 ◽  
pp. 04012
Author(s):  
Daniel Suárez-Fernández ◽  
Bradley P. Wynne ◽  
Pete Crawforth ◽  
Katharine Fox ◽  
Martin Jackson
Keyword(s):  
Structural Integrity ◽  
Metal Removal ◽  
Microstructural Analysis ◽  
Development Stage ◽  
Cnc Machining ◽  
Machining Process ◽  
Machining Parameters ◽  
Machining Processes ◽  
Novel Approach ◽  
And Performance

Aerospace titanium components are manufactured under the strictest standards in order to ensure the highest quality. To develop highly efficient machining processes, extensive research and investment is necessary. For the specific case of rotating titanium critical components, large quantities of forged workpieces are machined to determine the effects of the different machining parameters on tool wear characteristics and component structural integrity and performance. However, testing the different permutations of metal removal parameters and tool combinations is expensive and time consuming at the development stage. The novel approach developed and presented here, enables the machining of smaller titanium parts that can be compared 1-to-1 to parts extracted from industrial machined disc components. This approach not only reduces cost, but ultimately accelerates the research and development process due to more rapid feedback between different iterations of the machining parameters. The proposed technique specifically replicates the face turning operation performed in rotational critical titanium components, such as compressor discs, using small coupons machined in a standard CNC machining centre. The machined coupons can be fatigue tested through a 4-point bending and microstructural analysis can be performed on the tested coupons to directly study the effects of the machining process on the surface and underlying microstructure.

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 Investigation of the Cutting Uid'S Ow and its Thermomechanical Effect on the Cutting Zone Based on Uid-Structure Interaction (FSI) Simulation

2021 ◽  
Author(s):  
Hui Liu ◽  
Markus Meurer ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Metal Cutting ◽  
Negative Impact ◽  
Orthogonal Cutting ◽  
Fluid Simulation ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Thermomechanical Effect ◽  
Dimensional Simulation ◽  
On Chip ◽  
Cutting Processes

Abstract Cutting fluids are an important part of today's metal cutting processes, especially when machining aerospace alloys. They offer the possibility to extend tool life and improve cutting performance. However, the equipment and handling of cutting fluids also raises manufacturing costs. To reduce the negative impact of the high cost of cutting fluids, cooling systems and strategies are constantly being optimized. In most existing works, the influences of different cooling strategies on the relevant process parameters, such as tool wear, cutting forces, chip breakage, etc., are empirically investigated. Due to the limitations of experimental methods, analysis and modeling of the working mechanism has so far only been carried out at a relatively abstract level. For a better understanding of the mechanism of cutting fluids, a thermal coupled two-dimensional simulation approach for the orthogonal cutting process was developed in this work. This approach is based on the Coupled Eulerian Lagrangian (CEL) method and provides a detailed investigation of the cutting fluid’s impact on chip formation and tool temperature. For model validation, cutting tests were conducted on a broaching machine. The simulation resolved the fluid behavior in the cutting area and showed the distribution of convective cooling on the tool surface. This work demonstrates the potential of CEL based cutting fluid simulation, but also pointed out the shortcomings of this method.

Sign in / Sign up

Export Citation Format

Share Document