Property and Recyclability Change of Corrosion-Inhibition-Improved Amine-Free Water-Soluble Cutting Fluid with Repeated Recycling

2017 ◽  
Vol 749 ◽  
pp. 65-69
Author(s):  
Kenji Yamaguchi ◽  
Kazuo Ogawa ◽  
Tsuyoshi Fujita ◽  
Yasuo Kondo ◽  
Satoshi Sakamoto ◽  
...  
Keyword(s):  
Corrosion Inhibition ◽  
Metal Cutting ◽  
Free Water ◽  
Water Soluble ◽  
Cutting Fluid ◽  
Water Recovery ◽  
Recycled Water ◽  
Recycling System ◽  
Inhibition Performance ◽  
Cooling And Lubrication

Cutting fluid is commonly used during metal cutting process for cooling and lubrication. Fluid types are generally classified into mineral or fatty oils and water miscible oils. In Japan, the former is called water-insoluble coolants, and the latter is called water-soluble coolants. Water-insoluble coolants are specified as dangerous material by the Japanese law due to its flammability. Therefore, the water-insoluble coolants are not appropriate for unmanned operation of machine tools. Therefore, the usage rate of water-soluble coolants is increasing. Water soluble coolants are diluted with a water by several ten times. The waste management of the water-soluble coolant become important for environment-conscious green manufacturing. We have been developing a recycling system for water-soluble coolants. In the recycle system, water is extracted from the waste coolant and the water is then reutilized as a diluent of a new coolant. We have developed various types of chemical or bio-chemical water recovery methods for recycling systems. We found a commercially available amine-free water-soluble coolant is suitable for the recycling system. The processing time, processing cost, and the biochemical and chemical oxygen demand of the extracted water are improved by the amine-free water soluble coolant compared with a conventional amine-containing coolant. However, its corrosion inhibition performance was poor in general machining applications. Our cooperative company developed a prototype of a corrosion-inhibition-improved amine-free water-soluble cutting coolant. The prototype coolant showed a good stability and cooling and lubricating performances, and its recyclability was as good as that of conventional amine-free coolants. In this study, we focused on repeated recycling of the prototype coolant. We repeatedly applied the water recycling process to the recycled coolant. The recyclability of the prototype coolant was not affected by repeated recycling; however, process residues increased with the number of recycles, and a deterioration was noticed in the corrosion-inhibition performance of the coolant diluted with recycled water.

Recyclability and Performance Stability of Corrosion Inhibition Improved Amine-Free Water-Soluble Cutting Coolant

2016 ◽  
Vol 1136 ◽  
pp. 104-109 ◽  
Author(s):  
Kenji Yamaguchi ◽  
Tsuyoshi Fujita ◽  
Yasuo Kondo ◽  
Satoshi Sakamoto ◽  
Subaru Tsukano ◽  
...  
Keyword(s):  
Corrosion Inhibition ◽  
Waste Treatment ◽  
Free Water ◽  
Water Soluble ◽  
Environmental Load ◽  
Machining Processes ◽  
Recycling System ◽  
Treatment Processes ◽  
And Performance ◽  
Inhibition Performance

The concern for environmental problems has been increasing rapidly in recent years. Water-soluble coolants are widely used in machining processes. To reduce management costs and the environmental load of water-soluble coolants, the authors studied a recycling system for water-soluble coolants. With this recycling system, water is extracted from a waste coolant by chemical or biochemical treatment; the recovered water is re-utilized as a diluent for a new coolant. Coolant recyclability depends on the coolant type. Most water-soluble coolants contain alkanolamines for corrosion inhibition and maintenance of putrefaction prevention. However, alkanolamines are difficult to eliminate from water-soluble coolants by chemical and physical waste treatment processes. Some amine-free, water-soluble coolants have been developed and are commercially available. The reduction of environmental load in the treatment of waste coolants is anticipated for amine-free coolants. We applied the recycling process to a commercially available amine-free, water-soluble coolant. The amine-free coolant showed good recyclability and lubricating performance. However, the corrosion inhibition performance of the coolant was inadequate for use in general machining. Recently, our cooperative company developed a prototype amine-free, water-soluble coolant with improved corrosion inhibition. In this study, we experimentally examined the recyclability and performance stability of this newly developed coolant. The experimental results showed that the new amine-free coolant has good corrosion inhibition equivalent to conventional amine-containing coolants. In addition, the recyclability, stability, and cooling and lubricating performance of the coolant are equal to conventional amine-free coolants. The amine-free, water-soluble coolant with improved corrosion inhibition has the advantage that it can be used in the recycling system for water-soluble coolants.

Performance Stability of Recycle Amine-Free Water-Soluble Coolant in Long Term Operation

2014 ◽  
Vol 625 ◽  
pp. 530-535
Author(s):  
Kenji Yamaguchi ◽  
Yasuo Kondo ◽  
Satoshi Sakamoto ◽  
Mitsugu Yamaguchi ◽  
Ryoichi Nakazawa
Keyword(s):  
Environmental Effect ◽  
Free Water ◽  
Water Soluble ◽  
Water Recovery ◽  
Machining Processes ◽  
Cooling Performance ◽  
Recycling System ◽  
Term Operation ◽  
The Stability

Recently, the concern for the environment has been increasing rapidly. In machining processes, the treatment of water-soluble coolants waste has caused environmental problems. Water-soluble coolants contain surfactants, preservatives, and corrosion inhibitors for maintaining the stability and performance of the coolants. To reduce the management cost and environmental effect of water-soluble coolants, the authors have been studying a recycling system for water-soluble coolants. In the recycling system, oil-free recycle water is isolated from the coolant waste and reused as a diluent of the new coolant. The authors have been developing different types of water recovery methods for the recycling system, and the recovered water from the coolant waste has potential as a diluent for a new coolant. In this report, we focused on the amine (alkanolamine) -free water-soluble coolant. Some amine-free water-soluble coolants have been developed and are commercially available. A reduction in the environmental effect in the waste treatment of coolants is expected with amine-free coolants. We have demonstrated that the amine-free water-soluble coolant has equal or better cooling and lubricating performance compared with the conventional amine-containing coolant. In addition, the amine-free coolant shows good recyclability for the recycling system. The processing time of the recycling treatment of the amine-free coolant has been decreased by half with our recycling process compared with the conventional amine-containing coolant. In this report, we examined the stability, cooling performance and lubricating performance of the recycle amine-free water-soluble coolant in long term operation. The recycle amine-free water-soluble coolant is operated in a 3-axis machining center for several months. We observed concentration, pH, corrosion inhibition performance, cooling performance, and lubricating performance of the coolant. The results from these experiments show the amine-free water-soluble coolant has the advantage to use in the recycling system for water-soluble coolant.

scholarly journals Water-Soluble and Biodegradable Pectin-Grafted Polyacrylamide and Pectin-Grafted Polyacrylic Acid: Electrochemical Investigation of Corrosion-Inhibition Behaviour on Mild Steel in 3.5% NaCl Media

2014 ◽  
Vol 2014 ◽  
pp. 1-9 ◽  
Author(s):  
R. Geethanjali ◽  
A. Ali Fathima Sabirneeza ◽  
S. Subhashini
Keyword(s):  
Electron Microscopy ◽  
Mild Steel ◽  
Corrosion Inhibition ◽  
Polyacrylic Acid ◽  
Water Soluble ◽  
Electrochemical Investigation ◽  
Grafted Polymers ◽  
Tafel Polarization ◽  
Inhibition Performance ◽  
Scanning Electron

Pectin-g-polyacrylamide (denoted as Pec-g-PAAm) and pectin-g-polyacrylic acid (denoted as Pec-g-PAA) were synthesized using pectin, acrylamide, and acrylic acid as starting materials. The grafted polymers were characterized using Fourier transform infrared spectroscopy (FTIR), thermogravimetric analyser (TGA), and scanning electron microscopy (SEM). The corrosion inhibition behaviour of the grafted polymers on mild steel in 3.5% NaCl was evaluated electrochemically through Tafel polarization and impedance studies. The corrosion inhibition performance of both the polymers was found to be around 85%.

Nano-lubricant influence on surface residual stresses in hard milling

2021 ◽  
pp. 095440892110047
Author(s):  
Omid Rohani Raftar ◽  
Mahdi Kaveh ◽  
Mohsen Khajehzadeh ◽  
Abdolreza Rahimi ◽  
Mohammad Reza Razfar
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Mechanical Loading ◽  
Metal Cutting ◽  
Water Soluble ◽  
Machining Process ◽  
Nano Particles ◽  
Cutting Fluid ◽  
Machining Processes ◽  
Surface Residual Stresses

Residual stress could be induced by machining processes like milling which can greatly affect the fatigue life of fabricated parts, especially in dynamic loading conditions. In metal cutting operations, machining induced residual stresses can be explained in the terms of machining forces and temperatures of the cutting zones. This thermo mechanical loading along with the resulted metallurgical changes are the main sources of residual stresses generation at the surface of machined workpiece. Researchers have proved the superior properties of nanofluids over the conventional coolants to reduce the intensity of thermo mechanical loading in machining process which will affect the residual stresses caused by machining. Therefore, in this paper, silver nanoparticles in the water-soluble oil have been used for reducing the mechanical and thermal loads in the milling process. The cutting forces, temperature of the cutting zone, surface roughness and the residual stress of machined surface have been measured experimentally in milling of hardened steel AISI 4140 for various nanoparticle’s concentration, feeds and cutting speeds. Results show that increasing the concentration of Nano-particles in base fluid from 0.5 to 3.0% wt., will make machining surface residual stresses more compressive averagely by about 66.67% compared to conventional cutting fluid.

scholarly journals Evaluation of subcooled MQL in cBN hard turning of powder-based Cr-Mo-V tool steel using simulations and experiments

2021 ◽  
Author(s):  
Sampsa V.A. Laakso ◽  
Dinesh Mallipeddi ◽  
Peter Krajnik
Keyword(s):  
Tool Steel ◽  
Cutting Forces ◽  
Hard Turning ◽  
Metal Cutting ◽  
Cooling Capacity ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Workpiece Surface ◽  
Residual Strains ◽  
Cooling And Lubrication

AbstractMetal cutting fluids for improved cooling and lubrication are an environmental risk and a health risk for workers. Minimizing water consumption in industry is also a goal for a more sustainable production. Therefore, metal cutting emulsions that contain hazardous additives and consume considerable amounts of water are being replaced with more sustainable metal cutting fluids and delivery systems, like vegetable oils that are delivered in small aerosol droplets, i.e., via minimum quantity lubrication (MQL). Since the volume of the cutting fluid in MQL is small, the cooling capacity of MQL is not optimal. In order to improve the cooling capacity of the MQL, the spray can be subcooled using liquid nitrogen. This paper investigates subcooled MQL with machining simulations and experiments. The simulations provide complementary information to the experiments, which would be otherwise difficult to obtain, e.g., thermal behavior in the tool-chip contact and residual strains on the workpiece surface. The cBN hard turning simulations and experiments are done for powder-based Cr-Mo-V tool steel, Uddeholm Vanadis 8 using MQL subcooled to −10 °C and regular MQL at room temperature. The cutting forces and tool wear are measured from the experiments that are used as the calibration factor for the simulations. After calibration, the simulations are used to evaluate the thermal effects of the subcooled MQL, and the surface residual strains on the workpiece. The simulations are in good agreement with the experiments in terms of chip morphology and cutting forces. The cutting experiments and simulations show that there is only a small difference between the subcooled MQL and regular MQL regarding the wear behavior, cutting forces, or process temperatures. The simulations predict substantial residual plastic strain on the workpiece surface after machining. The surface deformations are shown to have significant effect on the simulated cutting forces after the initial tool pass, an outcome that has major implications for inverse material modeling.

Study on Metabolic System for Water-Soluble Coolant — Machining Performance and Long-Term Stability of Recycled Coolant

2009 ◽  
Vol 407-408 ◽  
pp. 313-316 ◽  
Author(s):  
Kenji Yamaguchi ◽  
Yasuo Kondo ◽  
Satoshi Sakamoto ◽  
Shu Kohira
Keyword(s):  
Tap Water ◽  
Water Soluble ◽  
Environmental Load ◽  
Water Recovery ◽  
Recycled Water ◽  
Machining Performance ◽  
Metabolic System ◽  
Term Stability ◽  
Long Term Stability

To reduce the management cost and environmental load of water-soluble coolant, authors have been studying on a metabolic system for water-soluble coolant. More than 90% of waste water-soluble coolant is composed of water phase. If the oily additives and contaminants can be isolated from the waste coolant, the amount of waste coolant decreases remarkably because the recycled water can be reutilized as a diluent of renewal coolant. Authors has been developed some types of water recovery methods for the metabolic system. To complete the metabolic system for water-soluble coolant, the coolant diluted with recovered water should have the same machining performance and long-term stability as those of coolant diluted with tap water. In this report, we examined the machining performance and ability change of water-soluble coolant diluted with recycled water under operations encountered in machine tool.

scholarly journals Evaluation of Subcooled MQL in cBN Hard Turning of powder-based Cr-Mo-V Tool Steel Using Simulations and Experiments

2021 ◽  
Author(s):  
Sampsa Vili Antero Laakso ◽  
Dinesh Mallipeddi ◽  
Peter Krajnik
Keyword(s):  
Cutting Forces ◽  
Hard Turning ◽  
Metal Cutting ◽  
Wear Behavior ◽  
Cooling Capacity ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Workpiece Surface ◽  
Residual Strains ◽  
Cooling And Lubrication

Abstract Metal cutting fluids for improved cooling and lubrication are an environmental risk and a health risk for workers. Minimizing water consumption in industry is also a goal for a more sustainable production. Therefore, metal cutting emulsions that contain hazardous additives and consume considerable amounts of water are being replaced with more sustainable metal cutting fluids and delivery systems, like vegetable oils that are delivered in small aerosol droplets, i.e. via minimum quantity lubrication (MQL). Since the volume of the cutting fluid in MQL is small, the cooling capacity of MQL is not optimal. In order to improve the cooling capacity of the MQL, the spray can be subcooled using liquid nitrogen. This paper investigates subcooled MQL with machining simulations and experiments. The simulations provide complementary information to the experiments, which would be otherwise difficult to obtain, e.g. thermal behavior in the tool-chip contact and residual strains on the workpiece surface. The cBN hard turning simulations and experiments are done for powder-based Cr-Mo-V tools steel, Uddeholm Vanadis 8 using MQL subcooled to -10 °C and regular MQL at room temperature. The cutting forces and tool wear are measured from the experiments, that are used as the calibration factor for the simulations. After calibration, the simulations are used to evaluate the thermal effects of the subcooled MQL, and the surface residual strains on the workpiece. The simulations are in good agreement with the experiments in terms of chip morphology and cutting forces. The cutting experiments and simulations show that there is only a small difference between the subcooled MQL and regular MQL regarding the wear behavior, cutting forces or process temperatures. The simulations predict substantial residual plastic strain on the workpiece surface after machining. The surface deformations are shown to have significant effect on the simulated cutting forces after the initial tool pass, an outcome that has major implications for inverse material modelling.

scholarly journals Experimental Investigation on Ultrasonic Atomization Assisted Turning of Titanium Alloy

Micromachines ◽  
2020 ◽  
Vol 11 (2) ◽  
pp. 168 ◽  
Author(s):  
Jianbing Meng ◽  
Bingqi Huang ◽  
Xiaojuan Dong ◽  
Yizhong Hu ◽  
Yugang Zhao ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Tool Life ◽  
Chip Morphology ◽  
Contact Length ◽  
Water Soluble ◽  
Cutting Fluid ◽  
Ultrasonic Atomization ◽  
Cooling And Lubrication

There are high cutting temperatures, large tool wear, and poor tool life in conventional machining, owing to the superior strength and low thermal conductivity of titanium alloy. In this work, ultrasonic atomization assisted turning (UAAT) of Ti6Al4V was performed with a mixed water-soluble oil-based cutting fluid, dispersed into tiny droplets by the high frequency vibration of a piezoelectric crystal. Different cutting speeds and two machining environments, dry and ultrasonic atomization assisted machining, were considered in the investigation of tool life, tool wear morphology, surface roughness, and chip morphology. In comparison with dry machining, UAAT shows lower tool wear and longer tool life due to the advantages of cooling and lubrication. Furthermore, better surface roughness, smoother chip edges, and shorter tool-chip contact length were obtained with UAAT.

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