scholarly journals Experimental Investigation on Effects of MQL on Surface Finish and Tool Wear in Turning of SAE 1018

2018 ◽  
Vol 7 (2) ◽  
pp. 67-69
Author(s):  
Sandeep Kumar ◽  
Sukhpal Singh Chatha ◽  
Rutash Mittal
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Metal Cutting ◽  
Substantial Reduction ◽  
Minimum Quantity Lubrication ◽  
Environmental Safety ◽  
Work Piece ◽  
Cutting Fluids ◽  
Nose Radius ◽  
Machining Processes

In all machining processes, tool wear is a major problem and it leads to tool failure. In metal industries, the use of cutting fluids affects both employee’s health and environmental pollution. But the use of cutting fluids becomes necessary to keep tight tolerances and to maintain the work-piece surface properties without damages. Researchers are trying to reduce the use of coolant lubricant fluids in metal cutting to obtain environmental safety. So, to minimize the use of cutting fluids new cutting techniques are investigated. Minimal quantity of Lubrication (MQL) is a recent technique introduced in machining to obtain less tool wear and environment safety. The minimum quantity lubrication was provided with a spray of mixture of air and vegetable oil at suitable pressure. MQL machining was performed much superior compared to dry and wet machining due to substantial reduction in tool wear and cutting zone temperature and a better surface finish. MQL provides neat and clean environment avoiding health hazards due to smoke, fumes and gases etc. In this study work-piece of SAE 1018 were prepared to investigate their Surface finish under turning with coated tool bits. Wear of nose radius of tool bits were analyzed by SEM which results in less wear in MQL process as compared to flood cooling.

Application of tri-hybridized carbonaceous nanocutting fluids in an end milling operation by the minimum quantity lubrication technique

2021 ◽  
pp. 135065012110438
Author(s):  
S. Vignesh ◽  
U. Mohammed Iqbal
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
End Milling ◽  
Hexagonal Boron Nitride ◽  
Coconut Oil ◽  
Minimum Quantity Lubrication ◽  
Work Piece ◽  
Cutting Fluids ◽  
Minimum Quantity ◽  
Milling Operations

This paper is concentrated on the exploration of carbonaceous nanocutting fluids with the concept of tri-hybridization with improved lubricative and cooling properties by using multi-walled carbon nanotubes, hexagonal boron nitride , and graphene nanoparticles with neat cold-pressed coconut oil in a fixed volumetric proportion. The rheological properties of the nanofluids were studied to assess their performance in real-time end milling operations using an AA7075 work piece on a CNC lathe machine under a minimum quantity lubrication environment. At the outset, the carbonaceous nanofluids gave good performance when compared to conventional cutting fluids. Furthermore, the surfaces of the tribo-pairs and the chips formed were analyzed using a profilometer and high-end microscopes. The results obtained from the experiments confirm that the tri-hybridized carbonaceous nanolubricant has reduced the cutting force, tool wear, and surface roughness when correlated to monotype nanofluids. The scanning electron microscope images of the surface and tool were studied and it was found that the surface quality was maintained while end milling with tri-hybridized carbonaceous nanofluid. Improvement of ∼17%, 20% and 25% in cutting forces, surface roughness and tool wear was found in tri-hybrid fluid when compared to other fluids. Thus, the present work indicates that the addition of carbon-based nanoparticles with coconut oil has offered better performance and is found to be a credible alternative to existing conventional cutting fluids.

scholarly journals Minimum Quantity Lubrication (MQL) and its Effect on Tool Wear During Miniature Drilling :an Experimental Study

2016 ◽  
Vol 1 (2) ◽  
pp. 65-70
Author(s):  
Norsalawani Binti Mohamad ◽  
Rubina Bahar
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
High Speed Steel ◽  
Minimum Quantity Lubrication ◽  
Limiting Factors ◽  
Work Piece ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Tool Condition ◽  
Overall Performance

Miniature drilling is widely used in industries including electronics and reconstructive surgeries to create small sized holes. Chip removal and effective supply of coolant are the two limiting factors that make the process more complex compared to other meso scale machining processes and also contribute to the tool wear. The tool wear in the process is mainly caused by the interaction, motion and chip production between the tool and work piece. Uniform supply of coolant must be ensured to reach the drilled cavity to keep the tool wear to a minimal level. This study includes experimental investigation of the tool condition after applying Minimum Quantity Lubrication (MQL) system as a greener approach as the name indicates. The tool condition with MQL has also been compared with dry and flood cooling. Two different types of drill bit materials (High Speed Steel and Carbide) have been tested under same experimental condition to drill through Aluminum Alloy 6061 and it has been found that overall performance in terms of tool condition after applying MQL was better compared to the other two methods. The overall wear propagation area was measured for both the conditions. It was seen, the wear propagation covered minimal area with MQL while for flood and dry condition wear was spread over a bigger area on flank. 

scholarly journals INFLUENCE OF THE USE OF CARAPA GUIANENSIS OIL (ANDIROBA OIL) COMPARED WITH COMMERCIAL CUTTING FLUID IN THE TURNING PROCESS OF THE ABNT 1045 STEEL GRADES

2019 ◽  
Vol 16 (33) ◽  
pp. 21-29
Author(s):  
T. I. M. BOTELHO ◽  
G. S. FIGUEIREDO ◽  
F. M. PRAXEDES ◽  
J. V. U. TEIXEIRA ◽  
E. B. MONTEIRO
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Turning Process ◽  
Machining Processes ◽  
Carapa Guianensis ◽  
1045 Steel

The increasing technological advances obtained both in the development of new materials and of machine tools increased the demand for the machining processes and in addition, the use of increased cutting fluids. However, it’s necessary to have characteristics that don’t harm the environment and the operator. In machining processes, cutting fluids, when properly chosen and applied, may reflect benefits during the manufacturing process. This work evaluated the performance of a commercial cutting fluid by comparing it with vegetable oil extracted from carapa guianensis in the abnt 1045 steel turning process. The cutting speed (vc), tool feed (f) and depth (ap) and the influence of the use of both of them on the metal was verified with the following variables: chip analysis, surface finish, cutting temperature and tool wear. It was observed that with the use of andiroba oil, better chip was generated for the safety of the operator, higher cutting temperatures in the piece, higher tool wear and better surface finish with a difference of 23% compared to commercial cutting fluid. Thus, the fluid from andiroba based on the conventional application demonstrated a viable alternative in the turning process of abnt 1045 steel, because it’s biodegradable and reduces petroleum-based cutting fluids.

scholarly journals INFLUENCE OF THE USE OF CARAPA GUIANENSIS OIL (ANDIROBA OIL) COMPARED WITH COMMERCIAL CUTTING FLUID IN THE TURNING PROCESS OF THE ABNT 1045 STEEL GRADES

2019 ◽  
Vol 16 (33) ◽  
pp. 927-935
Author(s):  
T. I. M. BOTELHO ◽  
G. S. FIGUEIREDO ◽  
F. M. PRAXEDES ◽  
J. V. U. TEIXEIRA ◽  
E. B. MONTEIRO
Keyword(s):  
Tool Wear ◽  
Surface Finish ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Turning Process ◽  
Machining Processes ◽  
Carapa Guianensis ◽  
1045 Steel

The increasing technological advances obtained both in the development of new materials and of machine tools increased the demand for the machining processes and in addition, the use of increased cutting fluids. However, it’s necessary to have characteristics that don’t harm the environment and the operator. In machining processes, cutting fluids, when properly chosen and applied, may reflect benefits during the manufacturing process. This work evaluated the performance of a commercial cutting fluid by comparing it with vegetable oil extracted from carapa guianensis in the abnt 1045 steel turning process. The cutting speed (vc), tool feed (f) and depth (ap) and the influence of the use of both of them on the metal was verified with the following variables: chip analysis, surface finish, cutting temperature and tool wear. It was observed that with the use of andiroba oil, better chip was generated for the safety of the operator, higher cutting temperatures in the piece, higher tool wear and better surface finish with a difference of 23% compared to commercial cutting fluid. Thus, the fluid from andiroba based on the conventional application demonstrated a viable alternative in the turning process of abnt 1045 steel, because it’s biodegradable and reduces petroleum-based cutting fluids.

Controlled Contact Cutting Tools

1959 ◽  
Vol 81 (2) ◽  
pp. 139-147 ◽  
Author(s):  
B. T. Chao ◽  
K. J. Trigger
Keyword(s):  
Shear Stress ◽  
Surface Finish ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Tools ◽  
Substantial Reduction ◽  
Cutting Fluids ◽  
Dynamic Shear ◽  
Effective Utilization ◽  
High Speed Cutting

A substantial reduction in power consumption, an increase in tool life, more effective utilization of cutting fluids, and improved surface finish on the machined workpiece have been achieved by suitably controlling the length of tool-chip contact. Reasons for these findings are discussed in terms of basic variables in chip formation mechanics. Artificially restricted contact tools open new avenues for metal cutting research. Machining data obtained with such tools provide further evidence of the invariant behavior of the dynamic shear stress of metals under high-speed cutting conditions, and unfold interesting information on the intricate nature of tool-chip contact.

Tool Wear Analysis in Turning Using Different Inserts and Different Lubrication Systems

2015 ◽  
Vol 813-814 ◽  
pp. 404-409
Author(s):  
R. Panneer ◽  
Kesaraju Venkata Sai Pavan
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Fluids ◽  
Control Factors ◽  
Optimization Of Process Parameters ◽  
Cutting Inserts

In metal cutting, increasing cutting spped and feed achieve higher productivity, but it will affect dimensional accuracy and surface integrity of the work surface, wear resistance and life of tool. Cutting fluids when appropriately chosen and applied will minimize these problems. This work deals with the optimization of process parameters in turning of EN24 and SS316L Steels with different cutting fluids with different cutting inserts under different machining conditions using Taguchi’s Robust Design Methodology. The control factors selected are machining environment, cutting speed, feed, depth of cut, work piece material and type of tool. Investigations are carried out on conventional lathe using the prefixed cutting conditions. Tool Wear and Surface Roughness are measured and anlysed using ANOVA and appropriate conclusions are derived.

scholarly journals Effect of Minimum Quantity Lubrication in Machining Using Different Vegetable Oils

2018 ◽  
Vol 7 (2) ◽  
pp. 70-72
Author(s):  
Satwinder Kaur ◽  
Kulwinder Garg ◽  
Rutash Mittal
Keyword(s):  
Tool Wear ◽  
Vegetable Oils ◽  
Surface Finish ◽  
Metal Cutting ◽  
Minimum Quantity Lubrication ◽  
Economic Benefits ◽  
Cutting Fluid ◽  
Tool Performance ◽  
Surface Damages

In metal industries and researchers are trying to reduce the use of coolant lubricant fluid in metal cutting to give the better performance, health safety, economic benefits and reduction in environmental pollution. Lubrication is necessary for the cutting operations to avoid the surface damages. The MQL gives better result over the conventional flood cooling as it effectively reduce the tool wear through mixture of air and lubricant and also impairs the surface finish of product. The minimization of cutting fluid leads to saving the lubrication cost and also saves machine cleaning time. This study deals with experimental investigation on role of different vegetable oils tool wear and surface finish. Experiments were carried out by plain turning of round bar of SAE 1018. The aerosol based on different vegetable oils was used to evaluate the tool performance and surface finish at different speed combinations. It was observed that Aerosol consist of Canola oil gives less tool wear and comparative surface finish as compared to Sunflower and Soybean oil. SEM results also analyzed in terms of tool wear.

Synergetic Concept of Software Control of Machining Processes on Metal-Cutting Machines

2021 ◽  
pp. 24-36
Author(s):  
V.L. Zakovorotny ◽  
V.E. Gvindzhiliya
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Wear Testing ◽  
External Control ◽  
Machining Processes ◽  
Cutting Zone ◽  
Output Characteristics ◽  
The Cost ◽  
And Control ◽  
Cutting System

High precision metal-cutting machines ensure that the programmed machine actuator trajectories correspond to the real ones. For lathes these are the trajectories of the longitudinal and transverse calipers of the system, as well as the spindle. The purpose of processing is to produce parts of a given quality while minimizing the manufacturing costs. The condition of the dynamic cutting system, determined by the trajectories of forces and deformations, affects the quality indicators of parts and the cutting efficiency, which depends on the intensity of tool wear. The properties of the system change depending on the phase trajectory of the power of irreversible transformations of the energy supplied to the cutting zone by the work performed. Their changes related with the evolution of the parameters of the dynamic link formed by cutting are manifested in the development of tool wear and changes in the quality of the part. Thus, the power of irreversible energy transformations is one of the internal factors causing changes in the output characteristics of processing and the state of the process. In this regard, when processing on machine tools, there is a problem of synergistic coordination of external control (for example, the CNC program) with internal one, the source of which is the irreversible transformation of the energy supplied to the cutting zone. The article considers the problem of synergetic coordination of external and internal controls during cutting process, the solution of which will allow increasing the efficiency of processing on CNC machines. A mathematical model of a controlled dynamic cutting system and control algorithms are proposed to improve the efficiency of processing parts of a given quality while minimizing the intensity of tool wear. Testing of the developed algorithms has shown that their use reduces the cost of manufacturing parts by 1.2.

Investigations of Tool Wear with Water Vapor as Coolant and Lubricant in Green Cutting

2011 ◽  
Vol 317-319 ◽  
pp. 556-559
Author(s):  
Yue Zhang ◽  
Tong Jiang ◽  
Li Han ◽  
Qi Dong Li ◽  
Tai Li Sun ◽  
...  
Keyword(s):  
Water Vapor ◽  
Tool Wear ◽  
Metal Cutting ◽  
Boundary Layer Theory ◽  
Cutting Fluids ◽  
Potential Solution ◽  
Dry Cutting ◽  
Lubricating Film ◽  
Study Results ◽  
Generating System

Green cutting is one of the developing tends in the industry field. Water vapor can be introduced in metal cutting as coolant and lubricant due to its pollution-free, generating easily and unneeded disposal. Therefore, a special generating system is developed to produce suitable water vapor, and a simulation to the velocity of water vapor jet flow is presented. Then tool wear was investigated and a new capillary model is proposed, based on the experimental results. According to the boundary-layer theory, the kinetics equations of flow were solute. The velocity and flux of molecule are presented. In the capillary, the adsorption of tool-chip interface results in boundary lubricating film; the conical shape of capillary limits the depth of coolant and lubricant penetrating; and the negative press is the motility for coolant and lubricant penetrating. The study results show water vapor can decrease tool wear about 10% times and 20% comparing to cutting fluids and dry cutting, and water vapor could be a potential solution of green cutting.

Machining

2013 ◽  
pp. 213-270
Keyword(s):  
Electron Beam ◽  
Tool Wear ◽  
Electrical Discharge ◽  
Cutting Fluids ◽  
Machining Parameters ◽  
Machining Processes ◽  
Wire Cutting ◽  
Grinding Operations ◽  
Conventional Machining

Abstract This chapter covers the practical aspects of machining, particularly for turning, milling, drilling, and grinding operations. It begins with a discussion on machinability and its impact on quality and cost. It then describes the dimensional and surface finish tolerances that can be achieved through conventional machining methods, the mechanics of chip formation, the factors that affect tool wear, the selection and use of cutting fluids, and the determination of machining parameters based on force and power requirements. It also includes information on nontraditional machining processes such as electrical discharge, abrasive jet, and hydrodynamic machining, laser and electron beam machining, ultrasonic impact grinding, and electrical discharge wire cutting.

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