Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

Monitoring of Cutting Conditions with Dry Cutting on CNC Turning Machine

2010 ◽  
Vol 443 ◽  
pp. 382-387 ◽  
Author(s):  
Somkiat Tangjitsitcharoen ◽  
Suthas Ratanakuakangwan
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Temperature ◽  
Cutting Conditions ◽  
Cutting Condition ◽  
Nose Radius ◽  
Dry Cutting ◽  
Cnc Turning ◽  
Coated Carbide

This paper presents the additional work of the previous research in order to verify the previously obtained cutting condition by using the different cutting tool geometries. The effects of the cutting conditions with the dry cutting are monitored to obtain the proper cutting condition for the plain carbon steel with the coated carbide tool based on the consideration of the surface roughness and the tool life. The dynamometer is employed and installed on the turret of CNC turning machine to measure the in-process cutting forces. The in-process cutting forces are used to analyze the cutting temperature, the tool wear and the surface roughness. The experimentally obtained results show that the surface roughness and the tool wear can be well explained by the in-process cutting forces. Referring to the criteria, the experimentally obtained proper cutting condition is the same with the previous research except the rake angle and the tool nose radius.

Effect of minimum quantity lubrication and vortex tube cooling on laser-assisted micromilling of a difficult-to-cut steel

2020 ◽  
Vol 234 (11) ◽  
pp. 1422-1432 ◽  
Author(s):  
Pushparghya Deb Kuila ◽  
Shreyes Melkote
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Vortex Tube ◽  
Minimum Quantity Lubrication ◽  
Dimensional Accuracy ◽  
Burr Formation ◽  
Workpiece Material ◽  
Minimum Quantity ◽  
Tool Condition ◽  
Cooling Methods

Laser-assisted micromilling is a promising micromachining process for difficult-to-cut materials. Laser-assisted micromilling uses a laser to thermally soften the workpiece in front of the cutting tool, thereby lowering the cutting forces, improving the dimensional accuracy, and reducing the tool wear. Thermal softening, however, causes the workpiece material to adhere to the tool and form a built-up edge. To mitigate this problem and to enhance micromachinability of the workpiece in laser-assisted micromilling, this article investigates the following lubrication and cooling methods: (1) minimum quantity lubrication and (2) vortex tube cooling. Experiments utilizing the two methods are carried out on a difficult-to-cut stainless steel (A286), and the surface morphology, tool condition, burr formation, groove dimensional accuracy, surface finish, and cutting forces are analyzed. Results show that the combination of laser-assisted micromilling and minimum quantity lubrication yields the least amount of tool wear, lower resultant force, better groove dimensional accuracy, and no built-up edge. While vortex tube cooling with laser-assisted micromilling produces smaller burrs compared to minimum quantity lubrication, it yields larger changes in groove dimensions and is characterized by built-up edge formation. Possible physical explanations for the experimental observations are given.

Wear Mechanisms of Ceramic Tools in High-Speed Turning of Superalloy GH2132

2013 ◽  
Vol 589-590 ◽  
pp. 23-27 ◽  
Author(s):  
Dong Wang ◽  
Jun Zhao ◽  
Xiao Xiao Chen ◽  
Yong Hui Zhou
Keyword(s):  
Tool Wear ◽  
Wear Mechanisms ◽  
High Speed ◽  
Cutting Tool ◽  
Element Distribution ◽  
Cutting Condition ◽  
Dry Cutting ◽  
High Speed Turning ◽  
Ceramic Cutting Tool ◽  
Tool Wear Mechanisms

An experimental investigation of wear mechanisms in high-speed turning of superalloy GH2132 with Al2O3-based ceramic was conducted under dry cutting condition. The tool wear mechanisms were characterized by observation of tool wear morphology using scanning electron microscopy (SEM) and detection of the element distribution of the worn tool surface utilizing energy dispersive X-ray spectroscopy (EDS). The results of turning experiments indicated that the major wear mechanisms of the ceramic cutting tool were synergistic interaction between abrasive wear and adhesive wear, and meanwhile the micro-chipping was also observed. It is also shown that cutting distance of the Al2O3-TiC ceramic cutting tool at the speed of 420 m/min was higher than that of the speed of 360 m/min and 540 m/min.

scholarly journals Experimental Examination of Tool Wear During Turning of Ti-Grade 2 Alloy in Dry and Minimum Quantity Lubrication (MQL)

2019 ◽  
Vol 8 (12) ◽  
pp. 4768-4771
Keyword(s):  
Tool Wear ◽  
Tungsten Carbide ◽  
Manufacturing Industry ◽  
Wear Behavior ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Depth Of Cut ◽  
Experimental Examination ◽  
Machine Material ◽  
Minimum Quantity

In any manufacturing industry cost and productivity are the major concerns to be taken care. There are several factors which can be used to control these factors and while it comes to machining tool wear plays a major role in deciding the productivity and cost of the machining process. Recently many studies have been done on the different alloys of titanium and it is found to be very useful and difficult to machine material as well. In this work turning of one of the titanium alloys is used to study the tool wear behavior during dry and minimum quantity lubrication (MQL) machining conditions. In the current work tungsten carbide (WC) insert is used for machining process. After the machining Taguchi’s analysis is used to analyze the results obtained after the machining. In this work spindle speed, feed, and depth of cut are taken as the input parameters along with the machining condition. From the results it is found that MQL provides the better results to minimize the tool wear

scholarly journals Tool Wear and Formation Mechanism of White Layer When Hard Milling H13 Steel under Different Cooling/Lubrication Conditions

2014 ◽  
Vol 6 ◽  
pp. 949308 ◽  
Author(s):  
Song Zhang ◽  
Jianfeng Li ◽  
Honggang Lv
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Formation Mechanism ◽  
White Layer ◽  
Minimum Quantity Lubrication ◽  
Cutting Condition ◽  
H13 Steel ◽  
Dry Cutting ◽  
Hard Milling ◽  
Cooling And Lubrication

The present work aims at revealing the formation mechanism of white layer and understanding the effects of tool wear and cooling/lubrication condition on white layer when hard milling H13 steel with coated cutting tools. Hard milling experiments were carried out, and tool wear and its effect on formation of white layer were investigated. Compared to dry cutting condition, CMQL (cryogenic minimum quantity lubrication) technique can obviously reduce tool wear and prolong tool life owing to its good cooling and lubrication properties. The optical images of the subsurface materials indicate that the formation of white layer is related to tool wear; moreover, the thickness of white layer increases with the increase of tool wear. SEM (scanning electron microscope) images and XRD (X-ray diffraction) analysis confirm that the formation of white layer is mainly due to the mechanical effect rather than the thermal effect. It also proves that white layer is partly decreased or can be totally eliminated by optimizing process parameters under CMQL cutting condition. CMQL technique has the potential to be used for achieving prolonged tool life and enhanced surface integrity.

scholarly journals Physics-Based Simulations of Chip Flow over Micro-Textured Cutting Tool in Orthogonal Cutting of Alloy Steel

2021 ◽  
Vol 5 (3) ◽  
pp. 65
Author(s):  
Kaushalendra V. Patel ◽  
Krzysztof Jarosz ◽  
Tuğrul Özel
Keyword(s):  
Tool Wear ◽  
Alloy Steel ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
State Variables ◽  
Process Variables ◽  
Dry Cutting ◽  
Chip Flow

Physics-based process simulations have the potential to allow virtual process design and the development of digital twins for smart machining applications. This paper presents 3D cutting simulations using the finite element method (FEM) and investigates the physical state variables that are fundamental to the reduction in cutting forces, friction, and tool wear when micro-textured cutting tools are employed. For this goal, textured cemented carbide cutting tool inserts are designed, fabricated, and tested in the orthogonal dry cutting of a nickel-chromium-molybdenum alloy steel. Cutting forces and friction coefficients are compared against the non-textured tool, revealing the effects of texture parameters. Chip flow over the textured tool surface and process variables at the chip-tool contact are investigated and compared. The results reveal the fundamental sources of such improvements. Archard’s wear rate as a composition of process variables is utilized to compare experimental and simulated wear on the textured cutting tools. The effects of texture and cutting conditions on tool wear and adhesion characteristics are further discussed on the simulation results with experimental comparisons. It was found that the results obtained from these simulations provide further fundamental insights about the micro-textured cutting tools.

Application of Minimum Quantity Lubrication for Drum High Clutch in Turning Process

2019 ◽  
Vol 947 ◽  
pp. 160-166
Author(s):  
Nutrada Khumjeen ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Turning Process ◽  
Minimum Quantity

The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.

scholarly journals An Experimental Investigation on Vegetable Oils as a Cutting Fluid under Minimum Quantity Lubrication: A Sustainable Machining Approach

2021 ◽  
Vol 23 (04) ◽  
pp. 143-155
Author(s):  
Shrikant U. Gunjal ◽  
◽  
Sudarshan B. Sanap ◽  
Nilesh C. Ghuge ◽  
Satish Chinchanikar ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Vegetable Oils ◽  
Cutting Forces ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Fluid ◽  
Interface Temperature ◽  
Cutting Fluids ◽  
Minimum Quantity

Cutting fluid is a vital part of the machining process. Cutting fluid is significantly applied tolower the friction and heat generated in the machining zone. It also helps in easy chip removal, protection against oxidation, tool life improvement, and an overall improvement in the quality of the product. The current industrial practices are majorly emphasized on mineral-based oil application under flood lubrication to achieve superior quality. However, these oils and techniques are toxic and environmentally unfriendly. Machining under dry or with minimum quantity lubrication (MQL) has been mostly preferred to eliminate the use of abundant oil. The current research work has established the promising potential for vegetable oils as a cutting fluid under MQL during turning of AISI 4130 steel. The results inferred that vegetable-based cutting fluids performed better over mineral-based cutting fluids in terms of lower values of machined surface roughness, tool wear, cutting forces, and chip-tool interface temperature. The MQL machining performance in terms of cutting forces, surface roughness and tool life has been observed better in comparison to machining under flood and dry cutting conditions.

Online Cutting Tool Wear Monitoring Using I-Kaz Method and New Regression Model

2010 ◽  
Vol 126-128 ◽  
pp. 738-743 ◽  
Author(s):  
Jaharah A. Ghani ◽  
Muhammad Rizal ◽  
Mohd Zaki Nuawi ◽  
Che Hassan Che Haron ◽  
Mariyam Jameelah Ghazali ◽  
...  
Keyword(s):  
Tool Wear ◽  
Regression Model ◽  
Cutting Force ◽  
Cutting Tool ◽  
Machining Process ◽  
Cutting Condition ◽  
Tool Wear Monitoring ◽  
Cutting Tool Wear ◽  
Graphic Presentation ◽  
Wear Monitoring

This study presents a new method for detecting the cutting tool wear based on the measured cutting force signals using the regression model and I-kaz method. The detection of tool wear was done automatically using the in-house developed regression model and 3D graphic presentation of I-kaz 3D coefficient during machining process. The machining tests were carried out on a CNC turning machine Colchester Master Tornado T4 in dry cutting condition, and Kistler 9255B dynamometer was used to measure the cutting force signals, which then stored and displayed in the DasyLab software. The progression of the cutting tool flank wear land (VB) was indicated by the amount of the cutting force generated. Later, the I-kaz was used to analyze all the cutting force signals from beginning of the cut until the rejection stage of the cutting tool. Results of the I-Kaz analysis were represented by various characteristic of I-kaz 3D coefficient and 3D graphic presentation. The I-kaz 3D coefficient number decreases as the tool wear increases. This method can be used for real time tool wear monitoring.

Performance analysis of cryogenically treated plus tempered carbide inserts in turning of Inconel 718 using cryogenic minimum quantity lubrication cooling technique

2019 ◽  
Vol 233 (12) ◽  
pp. 1810-1819 ◽  
Author(s):  
Venkat Pradeep Allu ◽  
D Linga Raju ◽  
S Ramakrishna
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Minimum Quantity Lubrication ◽  
Chip Morphology ◽  
Cryogenic Cooling ◽  
Superior Performance ◽  
Minimum Quantity ◽  
Carbide Inserts ◽  
Cryogenic Minimum Quantity Lubrication

The present study deals with performance investigation of cryogenically treated plus tempered carbide inserts during machining of Inconel 718. A novel cooling approach of combined minimum quantity lubrication with cryogenic coolant, cryogenic minimum quantity lubrication is examined to improve the machinability of Inconel 718 and compared with dry, wet, minimum quantity lubrication, and cryogenic cooling conditions. Tool wear, cutting forces, and chip morphology were analyzed to evaluate the effect of cooling under different conditions. The results revealed that minimum quantity lubrication and cryogenic conditions exhibited superior performance than wet and dry conditions. However, severe tool fracture and cutting forces were observed in cryogenic machining which is an outcome of hardened surface of nickel alloy due to cryogenic fluid. Cryogenic minimum quantity lubrication was understood to be the best machining condition generating least cutting force and tool wear. Furthermore, examining chip morphology under scanning electron microscopy revealed that cryogenic minimum quantity lubrication performed stable machining.

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