Temperature In Cutting Zone Research Articles

Improving the Performance of the Machining Process by Using Ultra‐Advanced Tools in a Clean Turning of Inconel 686 Using the Minimum Quantity Lubrication Method

ABSTRACTThe high tensile strength and high resistance of nickel‐based superalloy 686 against high temperatures and corrosion rates have made it a widely used in important applications such as the aerospace industry, high pollution‐ and corrosion‐resistance equipment manufacturing and petrochemical industry. Therefore, the machining of this advanced alloy with its unique properties is extremely important and can be challenging. Significant increase in input parameters levels, reduction of machining costs, improvement of surface and subsurface properties and clean production are among the issues that should be considered in dealing with Inconel 686 turning operations. Simultaneous application of advanced tools such as polycrystalline diamond (PCD) and polycrystalline cubic boron nitride (PCBN) and optimised minimum quantity lubrication (MQL) method and evaluating the results obtained with a wide range of output parameters related to machining process performance and tribological properties can be proposed as an innovation and a solution to this problem in this article. This study analyses several output parameters with different speeds and feeds to evaluate the effect of cutting insert type on machining process performance and tribological properties. The output parameters include tool wear, residual stress, cutting zone temperature, surface smoothness, machining forces and workpiece surface defects. The results indicated that using the optimised MQL method reduces the size of lubricant droplets and increases the surface covered by cooling. With these changes, the performance of the machining process and the parameters related to the surface integrity increase significantly. Among the parameters associated with the performance of the machining process, the PCD tool reduces the cutting zone temperature by 23%, the tool wear by 19% and the machining forces by 18% compared to the PCBN tool. In the parameters related to surface integrity, this method reduces the residual stress by 19% and the surface roughness by 9% compared to the PCBN tool. From the production index perspective, the PCD tool can significantly increase the cutting speed and feed rate, reducing production time and costs.

The Effect of Rake Angle and Cutting Edge Radius on the Orthogonal Cutting Process of Ti6Al4V Alloy

This paper investigates the effect of rake angle, α, cutting edge radius, r, and feed rate, f, on the cutting force and cutting zone temperature during orthogonal dry cutting of Ti6Al4V. A numerical model representative of the 2D orthogonal cutting process is developed using ABAQUS/Explicit software. Johnson-Cook, (JC) constitutive material model is used to describe material plasticity. JC damage model and energy-based fracture criterion are used to describe damage initiation and evolution. Using Minitab-19 software, Taguchi L9 orthogonal array (3 × 3) is implemented to plan simulation trails. Assuming a constant cutting speed of 500 mm/min, three levels for each factor are considered α (-5°, 0°, 5°), <em>r</em> (0.02, 0.04, 0.06 mm) and <em>f</em> (0.1, 0.2, 0.3 mm). The cutting force and cutting zone temperature are analyzed using ANOVA. Based on a 90% Confidence Interval (90% CI), the results show that only feed rate significantly affects the cutting force. However, rake angle, cutting edge radius, and feed rate do not substantially affect cutting zone temperature.

A review of the use of cryogenic coolant during machining titanium alloys

Titanium alloys are considered difficult-to-machine materials, and much effort has been made to improve their machinability through various approaches. The use of cryogenic coolants during machining, sometimes referred to as cryogenic machining, is a popular environmentally friendly technique that promises to reduce cutting zone temperatures, reduce friction, and enhance tool life during machining operations. This review article explores the use of cryogenic coolants during titanium machining and presents an overview of research progress and knowledge gaps. The various coolants and methods for cryogenic machining are reviewed, along with the effectiveness of these methods in terms of key machinability criteria, including tool wear, tribological properties, and heat transfer. Issues in sustainability are also explored.

Comparison of turning process performance using modified cutting inserts under minimum quantity lubrication

ABSTRACT While machining of high-strength alloy steel materials, poor surface quality and decreased tool life are result by an increase in the cutting zone temperature close to the machining region. To overcome this, surface texture with green manufacturing environment is an alternate path to enhancing machining performance. In the present work, novel Parallel Grooved Textured Tools (PGT) was developed and studied the performance of so developed tools. Further, the Untextured Tool (UT) and PGT performance was compared while machining EN24 alloy steel under Minimum Quantity Lubrication (MQL) condition. It was perceived from result that textured tools reduced the cutting temperature (CT), rake wear (RW), flank wear (FW), surface roughness (Ra) and cutting force (CF) up to 18.96%, 18.79%, 24.31%, 12.69%, and18.96% respectively compared to UT.

Multi-response optimization of process parameters for sustainable machining of AISI 1018 steel with palm kernel oil-assisted minimum quantity lubrication technique

AbstractIn this study, palm kernel oil, an eco-friendly oil, was extracted from its seeds and then examined for thermal and physiochemical characterization. Subsequently, the performance of palm kernel oil was evaluated in comparison with standard mineral oil during the milling of AISI 1018 steel with a double milling tool using the MQL technique. The influence of cutting conditions such as feed rate, spindle speed, and DOC on response variables (cutting temperature and surface roughness) was studied using a Taguchi L9 orthogonal array. Using the TOPSIS approach (a compensatory method that provides a more realistic form of modeling than non-compensatory methods, and allows trade-offs between criteria, where a poor result in one criterion can be voided by a good result in another criterion) an integrated structure for modeling and optimizing the process was developed. The findings showed that palm kernel oil had a 54% oil yield. In terms of machining, palm kernel oil performed much better than mineral oil lubricants. From the results obtained, palm kernel oil reduced the surface roughness by about 15.6% over mineral oil. Effective cooling in palm kernel oil led to reduced cutting zone temperatures, which in turn extended tool life and improved cutting stability. Additionally, ANOVA was used to show the parameters' significant influence on the output responses. The findings showed that feed rate and depth of cut had the greatest impact on the responses for palm kernel oil and mineral oil, respectively.

Performance evaluation of WC, SiAlON and SiCw + Al2O3 tools in dry machining of Inconel 617

Despite the fact that Inconel 617 has prominent industrial applications, the machining characteristics of the same alloy are relatively unknown. The present study, therefore, aims at comparative evaluation of performance of WC, SiAlON and SiCw + Al2O3 tools under different cutting parameters during dry machining of Inconel 617. Solid solution strengthening due to Ni-Cr-Mo-Co phases and precipitation strengthening due to M23C6 carbide present in Inconel 617 specifically lead to rapid rate of tool wear. Finite element (FE) simulation is carried out to predict cutting zone temperature and tool wear followed by experimental validation. The results indicate that WC tool performs well in terms of cutting force, temperature and surface roughness under the condition of low cutting speed of 50 m/min due to low tool wear. The effectiveness of WC tool rapidly deteriorates under high cutting speeds of 150 and 250 m/min. Ceramic tools outperform WC under the condition of higher cutting speeds in terms of greater resistance to crater and flank wear, cutting force, temperature and surface roughness. However, depth-of-cut notch and nose chipping are the predominant modes of tool wear for ceramic tools during machining of Inconel 617.

The influence of a newly developed refrigeration cycle based workpiece cooling method in milling AISI 304 stainless steel

Machining stainless steel produces a high temperature in the cutting zone, leads to a decrease in the tool's longevity and also adversely affects the surface quality of the workpiece. Conventional cooling techniques are not effective in achieving better surface finish and less tool wear formation. This research introduces a novel refrigeration cycle-based workpiece cooling process to improve the machinability of AISI 304 stainless steel. The influence of this method in cutting zone temperature, surface roughness, tool wear formation and workpiece microstructure were compared with those of dry machining. The experimental results demonstrate that the proposed method provides a better surface finish, reducing roughness by 9 %, lowering the cutting zone temperature by 24 %–60 %, and minimizing wear on cutting tools under specific machining conditions. These findings can offer valuable insights for the manufacturing industry.

Investigation of the effect of minimum quantity lubrication and Ranque–Hilsch vortex tube cooling on cutting forces, surface roughness and cutting zone temperature in turning Al 6082 T4 alloy

Aluminium alloys are widely utilized, particularly in the automotive and aerospace industries, because of their great corrosion resistance, high strength/density ratio and propensity to increase mechanical qualities during ageing. With this widespread use, there are also various machining problems. Therefore, in this study, the cutting forces, average surface roughness and cutting zone temperature of different cooling conditions in turning Al 6082 T4 alloy were investigated. In the experiments, three different cutting conditions (Ranque–Hilsch vortex tube (RHVT), minimum quantity lubrication (MQL), and dry) were used in the experiments. As cutting parameters, three cutting speeds and feed rates (500, 625 and 800 m/min and 0.1, 0.125 and 0.15 mm/rev) were chosen. Taguchi-based grey relation analysis was applied to the data obtained after the experiments. As a result, it has been observed that MQL and RHVT methods positively affect the cutting forces, average surface roughness and cutting zone temperature values. As a result of Taguchi-grey relational analysis, optimum results were obtained with RHVT cooling, 800 cutting speed and 0.1 feed rate.

A review on minimum quantity lubrication (MQL) assisted machining processes using mono and hybrid nanofluids

PurposeBecause many cutting fluids contain hazardous chemical constituents, industries and researchers are looking for alternative methods to reduce the consumption of cutting fluids in machining operations due to growing awareness of ecological and health issues, government strict environmental regulations and economic pressures. Therefore, the purpose of this study is to raise awareness of the minimum quantity lubrication (MQL) technique as a potential substitute for environmental restricted wet (flooded) machining situations.Design/methodology/approachThe methodology adopted for conducting a review in this study includes four sections: establishment of MQL technique and review of MQL machining performance comparison with dry and wet (flooded) environments; analysis of the past literature to examine MQL turning performance under mono nanofluids (M-NF); MQL turning performance evaluation under hybrid nanofluids (H-NF); and MQL milling, drilling and grinding performance assessment under M-NF and H-NF.FindingsFrom the extensive review, it has been found that MQL results in lower cutting zone temperature, reduction in cutting forces, enhanced tool life and better machined surface quality compared to dry and wet cutting conditions. Also, MQL under H-NF discloses notably improved tribo-performance due to the synergistic effect caused by the physical encapsulation of spherical nanoparticles between the nanosheets of lamellar structured nanoparticles when compared with M-NF. The findings of this study recommend that MQL with nanofluids can replace dry and flood lubrication conditions for superior machining performance.Practical implicationsMachining under the MQL regime provides a dry, clean, healthy and pollution-free working area, thereby resulting the machining of materials green and environmentally friendly.Originality/valueThis paper describes the suitability of MQL for different machining operations using M-NF and H-NF.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0131/

EFFECTS OF VIBRATION CONDITIONS ON MACHINABILITY OF AISI 52100 BEARING STEEL

This study focused on determining the effects of the cooling condition in the conventional and ultrasonic-assisted turning of AISI 52100 steel. AISI 52100 steel has been widely used in the bearing, mold, and automotive industries because of its superior wear resistance and mechanical properties. However, its high wear resistance caused poor machinability in conventional machining methods. Low surface quality, rapid tool wear, high cutting temperature, and high cutting force are the main difficulties in the conventional machining of AISI 52100 steel. On the other hand, ultrasonic-assisted machining has become widely used in the past decades for the machining of materials that have low machinability in conventional methods. Conventional turning and ultrasonic-assisted turning were selected as machining methods. Ultrasonic-assisted turning experiments were conducted under 20 and 30 kHz vibration frequencies. Cubic Boron Nitride (CBN) cutting tools were used in machining experiments. In machining operations 50, 100, and 150 m/min cutting speeds were selected, and feed rate (0.1 mm/rev) and depth of cut (0.5 mm) were kept constant in experiments. Minimum quantity lubrication technique which used 1% Al2O3 nanoparticle additives cutting fluid and dry cooling methods were used. CBN insert was used as a cutting tool. The effects of cutting speed, cutting method, and cooling condition on surface quality, cutting force, cutting zone temperature, and cutting tool wear were studied experimentally. Analysis of Variance (ANOVA) was carried out to determine the significance of the effects of input variables on process outputs. As a result of this study, it is determined that combined UAT and nanoMQL have significant effects on the process outputs.

Effect of vibration and cutting zone temperature on surface topography during hybrid cooling/lubrication assisted machining of Vanadis 10

Abstract New alloy materials developed to meet the increasing technological needs of people come into our lives with some difficulties in terms of machinability. New cooling and lubrication techniques have been developed to facilitate the workability of such difficult-to-process materials and protect the world ecologically and the quality of the produced product. The workpiece used in this study, Vanadis 10 SuperClean, is a high vanadium alloyed powder metallurgy tool steel offering a unique combination of excellent abrasive wear resistance in combination with a good chipping resistance. The present study investigated the effects of dry, cryo, and CryoMQL cutting conditions on cutting tool vibration amplitude, cutting temperature, surface roughness, tool wear, and tool life in turning of Vanadis 10 tool steel used in the automotive industry. The experiments were performed using TiCN/Al2O3/TiN coated cemented carbide tools and cutting parameters as the constant depth of cut (1 mm), feed rates (0.08, 0.1, 0.12 mm rev−1), and cutting speeds (80, 100, 120 m min−1). The results obtained from experiments showed that spraying liquid nitrogen into the cutting zone provided significant improvements on cutting temperature, tool wear, cutting tool vibration amplitude, and surface roughness. The best results in terms of all output were achieved in the CryoMQL cutting environment. CryoMQL environment has reduced surface roughness up to 65.03 %, flank wear 56.99 %, cutting temperature 32.77 %, and cutting tool vibration amplitude up to 42.76 % compared to dry machining.

Development of Cutting Temperature Model Based on Experiment and Analysis of its Influencing Factors in Cutting ADI

Austempered ductile iron (ADI) is a difficult material with severe tool wear during machining, due to the high cutting temperatures in the cutting zone. In this paper, the mathematical model of the cutting temperature is developed based on the turning experiment, and the impact of cutting speed, feeding speed, and cutting depth on the cutting temperature of turning ADI is studied. When the cutting speed and the feed speed increase, a large amount of heat cannot be dissipated, and the cutting zone temperature increases. When the cutting depth increases, the increase of the heat dissipation area makes the cutting temperature change not obvious. This research has important engineering significance for studying the cutting mechanism of ADI and improving cutting efficiency.

Machinability analysis of Ti-6Al-4V under cryogenic condition

Aerospace alloys are termed as hard to cut materials owing to their low thermal conductivity, high temperature strength and elevated chemical reactivity. Cryogenic conditions can be effectively deployed to improve the machinability and productivity while addressing environmental and sustainability concerns connected with high tool wear and the use of conventional cutting fluids. Current work was undertaken to develop a novel tool wear map under cryogenic condition using cutting speed and feed rate as input variables. The developed map was demarcated into regions of low, moderate and high tool wear zones in addition to an unusually high wear zone, termed as avoidance zone existing between cutting speeds of 65–95 m/min and feed rates of 0.18–0.22 mm/rev. Characterization of developed map in terms of tool chip contact length revealed its direct relationship with cutting speed and feed rate accounting for the formation of different wear regions. Elemental analysis of avoidance zone detected high presence of TiN which results in larger tool chip contact length owing to its higher thermal conductivity. Chip morphology characterization highlighted an increase in chip compression ratio and decrease in shear angle due to the reduction of effective tool rake angle, further elevating the cutting zone temperature promoting wear. SEM and EDS spot analysis indicated the presence of adhesive and diffusion-dissolution wear mechanisms as the tool wear progresses. Comparative analysis with dry condition indicated that tool life is enhanced up to 100% using cryogenic media. Analysis of cryogenic tool wear map underscored the importance of careful choice of machining parameters in terms of increase in MRR up to 36% and tool life up to 58%. Overall, cryogenic tool wear map presents graphical interpretation of the machinability of Ti–6Al–4V in terms of tool wear.

Eco-friendly MoS2/waste coconut oil nanofluid for machining of magnesium implants

Abstract The cost of the coolant and its disposal cost are significant issues in metal machining processes. In biocompatible magnesium alloy-based medical implants and instrument manufacturing, the cost hikes are owing to the use of unconventional machining processes and computerised numerical control machines. This research aims to improve machinability performance and optimize process parameters for biocompatible magnesium implant manufacturing for biomedical applications using eco-friendly nanofluid of MoS2 nanoparticles suspended in waste coconut oil. The nanofluid was prepared from the multiple times used waste coconut oil (waste) and was mixed with MoS2 nanoparticles. The orthogonal array L16, Taguchi analysis, and analysis of variance were employed in experimental design and statistical optimization. The machinability performance was determined by measuring and comparing the responses like cutting force, feed force, surface roughness, cutting zone temperature, and tool wear. They were compared with machining using a nanofluid and conventional commercial coolant. The results reveal that the proposed method of machining improved machinability performance appreciably; therefore, the observations of the proposed method were used and the process parameters were optimized. Mathematical models were developed for the prediction of process parameters. The proposed method exhibited the average reduction of the cutting force by 68.23167 N, feed force requirements by 34.180 N, the cutting zone temperature by 60.435°C, the surface roughness by 0.118908 µm, and the tool wear by 039938 mg·h−1.

Cutting zone temperature reduction in by using novel nanofluid in SAE1144 machining

CNC Lathe is generally utilized for motor shaft machining. The cost of machining is high as it is machined in CNC machining as well as high cutting speed employed whereas heat generation is more. High cutting zone temperature causes thermal defects in the products. This research focused to create novel nanofluids with the use of waste cooking oil and Molybdenum disulfide Nanoparticles for cutting fluid for machining the SAE 1144 steel shaft. Two independent groups with Taguchi L16 experimental design were employed in this research. This investigation aims to make a shift from CNC-based machining to conventional machining practices without compromising the quality requirements by the reduction of cutting zone temperature with the use of a Novel nanofluid to provide cooling and lubrication at the cutting zone. This study investigates the effect of Molybdenum disulfide Nanoparticles’ concentration on waste cooking oil (Nanofluid) to reduce Cutting zone temperature while machining SAE1144 shaft. The observations were statistically validated. The base fluid is waste cooking oils from the largest sweets and savouries manufacturer as well as a widespread hotel network source. Green machining principles are compared with the findings. The results pass the statistical threshold for validity. That is the proposed clean machining practices reduced the average cutting zone temperature from 271.06 °C (dry/ green machining) to 194.94 °C. A low concentration of 0.1% gives better results at low as well as high cutting speeds. The cutting zone temperature is highly influenced by cutting speed.

Evaluation of Nano Fluids with Minimum Quantity Lubrication in Turning of Ni-Base Superalloy UDIMET 720

This article focuses on turning superalloy Udimet 720, which is difficult to work with, using different coolant/lubricant methods. The study includes delivering Graphene and Multi-Walled Carbon Nanotubes nanopowders homogeneously dispersed in vegetable oil to the cutting area with the minimum quantity lubrication (MQL) method. Experiments at different cutting speeds and feed rates were repeated in four different cutting environments. Compared to dry turning, the cutting zone temperature of the cutting fluid delivered to the cutting zone by MQL methods decreased. In addition, thanks to the nanopowders, it formed an oil film by better penetrating the cutting tool-chip interface and reducing the cutting tool’s wear. With the reduced cutting tool wear, the cutting tool could maintain its form for a longer period of time, so better quality surfaces were obtained on the workpiece surface. As a result of the study, it was found that cutting zone temperature improved by 30%, tool wear by 51.8% and surface roughness by 43.9%.

Performance evaluation of African star seed (chrysophyllum albidum) oil as a cutting lubricant in milling of ASTM A36 steel

ABSTRACT Due to the harmful effects that conventional mineral oils have on human health and the environment, vegetable oils are becoming more and more dominant as cutting fluids in metal-cutting operations. In terms of cutting temperature and surface roughness, this paper examines the comparative advantages of minimum quantity lubrication (MQL) with a cutting fluid based on vegetable oil to fully dry machining and MQL machining with mineral oil during the milling of ASTM A36 steel. MQL machining with African star oil performed significantly better than dry cutting and mineral oil due to a significant drop in cutting zone temperature that enabled favourable chip-tool interaction. The findings also showed that the surface finish improved significantly with the use of African star oil as a lubricant. African star oil can undertake the same tasks as foreign-made lubricants when it comes to the milling of ASTM A36 steel, as evidenced by its efficiency when compared to the common cutting lubricant.

Cooling improvement for the machining process with the inclusion of nanoparticles using the experimental approach

Machining of hard materials has always experienced challenges in their production process owing to several elements such as surface roughness, dimensional and geometrical tolerances, machining forces, longevity of the tools, and the generated heat during the operation. In order to tackle these technical problems, cutting tools, cutting fluids, and chipping strategies have undergone precise evaluation to facilitate the machining challenges. The current study is fixated on the assessment of cutting fluids and their significant efficacy on turning process. The desirable quality of a production part in machining processes is contingent upon the effectiveness of lubrication and cooling process during the turning operation. Hence, the tests have been done under various conditions regarding the cutting fluid for the cooling purpose. This study evaluates the efficacy of dispersion in the base fluid with volume fractions of 1.5 % and 3 % on temperature of the cutting tool in Mo40 steel turning operation, compared to the conditions utilizing coolant oil and conventional dry condition. Nanofluid minimum quantity lubrication (NMQL) strategy, as the main hindrance for immoderate use of cutting fluid, has been applied within the machining phenomena of Mo40 steel. Cutting speed and feed rates have been selected as the variable input parameters, for which the tests were performed and compared. The obtained results of this work revealed that employing nanofluid in machining operation led the cutting tool to experience an average reduction of about 60 % in the temperature range. Notable to mention, the growth in concnetration of the nanofluid intensifies temperature decrement of the cutting tool. In detail, the cutting zone temperature for 3 % volume concentration found to be 2 °C less than that of 1.5 %. Furthermore, using nanoparticles improved the roughness quality of the workpiece, and tool wear. Tool geometry, tool coating, along with various nanofluids are other factors, for which the experiment can be implemented as the future study.

Cutting temperature measurement using a novel near-infrared two-color pyrometer under dry and wet cutting of Ti‐6Al‐4V alloy

Due to the poor thermal properties of titanium alloys, heat generated and accumulated in the cutting area significantly affects tool life and workpiece quality. Although some methods have been proposed to measure the cutting temperature during machining titanium alloys, there still exist disadvantages including low spatial-temporal resolution, low measuring accuracy, restricted usage environment, etc. In this paper, a novel near-infrared two-color pyrometer system is developed and applied to measure the cutting zone temperature under dry and wet cutting of Ti‐6Al‐4V alloy. The developed pyrometer can eliminate the emissivity effect and shows a good linear relationship between the output signal ratio and the calibrated temperature. Meanwhile, the developed pyrometer exhibits good dynamic response and high measuring accuracy when measuring tool edge temperature and chip temperature in dry cutting conditions. In addition, a reliable sealing for cutter assembly is developed to overcome the influence of cutting fluid on the optic-fiber probe and the developed pyrometer can measure the tool edge temperature quickly and accurately in wet cutting conditions. In summary, the novel near-infrared two-color pyrometer system is validated to be quick responsiveness, high measuring accuracy, and good working stability when monitoring the cutting zone temperature under dry and wet cutting of Ti‐6Al‐4V alloy.

Influence of tribological properties of Zr-ZrN-(Zr,Cr,Al)N and Zr-ZrN-(Zr,Mo,Al)N multilayer nanostructured coatings on the cutting properties of coated tools during dry turning of Inconel 718 alloy

The article studies the tribological properties of multicomponent nanostructured coatings of Zr-ZrN-(Zr,Cr,Al)N and Zr-ZrN-(Zr,Mo,Al)N, as well as the wear resistance and fracture behaviour of cutting tools with the mentioned coatings during the turning of Inconel 718 alloy. The Ti–TiN-(Ti,Cr,Al)N coating was also considered as a reference coating. While the Ti–TiN-(Ti,Cr,Al)N coating is characterized by high hardness, it also demonstrated high coefficients of friction (COF) at temperatures of 600 °C and above (i.e., at temperatures in the cutting zone). The Zr-ZrN-(Zr,Mo,Al)N coating has a balanced combination of high hardness and low COF at cutting zone temperatures. As a result, the Zr-ZrN-(Zr,Mo,Al)N-coated tool demonstrated wear resistance 2.4 times higher than that of the Ti–TiN-(Ti,Cr,Al)N-coated tool. During the process of cutting, zirconium (Zr) and chromium (Cr) oxides are formed in the Zr-ZrN-(Zr,Cr,Al)N coating, and the formation of zirconium and molybdenum (Mo) oxides is detected in the Zr-ZrN-(Zr,Mo,Al)N coating, which can have a positive effect on cutting conditions. Under the cutting conditions, the oxidizing action caused an almost complete transformation of a nitride coating structure into an oxide structure, while the nanolayer structure was partially preserved.