Machining Ti-6Al-4V Alloy Using Nano-Cutting Fluids: Investigation and Analysis

Abdelkrem Eltaggaz,Ibrahim Deiab,Ibrahim Nouzil

doi:10.3390/jmmp5020042

Abdelkrem Eltaggaz, Ibrahim Deiab + Show 1 more

Open Access

https://doi.org/10.3390/jmmp5020042

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Abstract

Minimum Quantity Lubrication nanofluid (MQL-nanofluid) is a viable sustainable alternative to conventional flood cooling and provides very good cooling and lubrication in the machining of difficult to cut materials such as titanium and Inconel. The cutting action provides very difficult conditions for the coolant to access the cutting zone and the level of difficulty increases with higher cutting speeds. Furthermore, high compressive stresses, strain hardening and high chemical activity results in the formation of a ‘seizure zone’ at the tool-chip interface. In this work, the impact of MQL-nanofluid at the seizure zone and the corresponding effects on tool wear, surface finish, and power consumption during machining of Ti-6Al-4V was investigated. Aluminum Oxide (Al2O3) nanoparticles were selected to use as nano-additives at different weight fraction concentrations (0, 2, and 4 wt.%). It was observed that under pure MQL strategy there was significant material adhesion on the rake face of the tool while the adhesion was reduced in the presence of MQL-nanofluid at the tool-chip interface, thus indicating a reduction in the tool chip contact length (TCCL) and reduced seizure effect. Furthermore, the flank wear varied from 0.162 to 0.561 mm and the average surface roughness (Ra) varied from 0.512 to 2.81 µm. The results indicate that the nanoparticle concentration and the reduction in the seizure zone positively influence the tool life and quality of surface finish.

Highlights

Many applications in the field of automotive and aeronautical industries utilize the difficult to cut materials such as titanium and Inconel due to their effective properties such as high corrosion resistance and better strength-to-weight ratio [1]
Three machining outputs were investigated in this study: machined surface quality, tool life, and power consumption
It was observed that employing the minimum quantity lubrication (MQL)-nanofluid strategy reduced the seizure zone

Summary

Introduction

Many applications in the field of automotive and aeronautical industries utilize the difficult to cut materials such as titanium and Inconel due to their effective properties such as high corrosion resistance and better strength-to-weight ratio [1]. There are characteristics including low thermal conductivity and workpiece material hardness, which have negative effect on the machined surface roughness and tool life. Several studies have been conducted with an aim to specify the optimal machining variables and select a better coolant strategy as machining of difficult to cut materials is still facing different problems, in the machining of ceramics, titanium alloys, polymers, nickel-based alloys, composite based materials and hardened steels [1,2,3,4]. The disposal of the generated heat during the machining is not suitable due to the low heat conductivity of these alloys [6,7]

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