Dry Machining Conditions Research Articles

EVALUATION OF ENERGY CONSUMPTION, CUTTING FORCE, SURFACE ROUGHNESS AND VIBRATION IN MACHINING TOOLOX 44 STEEL USING TAGUCHI-BASED GRAY RELATIONAL ANALYSIS

This paper presents the Toolox 44 steel’s experimental and statistical machinability optimizations conducted for achieving minimum output parameters (energy consumption ([Formula: see text]), cutting force ([Formula: see text]), surface roughness ([Formula: see text]), and vibration (Vib)). Turning experiments have been performed under dry machining conditions on a CNC lathe at different cutting parameters according to the Taguchi L27 orthogonal array. Taguchi-based gray relational analysis (GRA) has also been used to optimize output parameters simultaneously. Moreover, analysis of variance (ANOVA) has been applied to determine the effects of cutting parameters on output parameters. As a result, the lowest Ec was measured 0.06 kW at the 1.5 mm depth of cut, 220 m/min cutting speed and 0.4 mm/rev feed rate. At 0.5 mm depth of cut, 220 m/min cutting speed and 0.1 mm/rev feed rate, the lowest [Formula: see text], [Formula: see text] and Vib are measured at 132.28 N, 0.69 [Formula: see text]m and 2.25 m/s2, respectively. According to GRA, the best machining combination in terms of energy consumption ([Formula: see text]), cutting force ([Formula: see text]), surface roughness ([Formula: see text]), and vibration (Vib) was A1B3C1, and the percentage of improvement in the gray relational degree has been calculated to be 25.25%. Validation test results showed that the optimization of cutting parameters was successful in the machining process of Toolox 44 steel according to the multiple output parameter values.

Optimization of Cutting Parameter for Machining Ti-6Al-4V Titanium Alloy

Titanium alloy Ti-6Al-4V, has been broadly used in industries, primarily medical manufacturing, and aerospace, due to their considerable mechanical properties. Aerospace structural components made of titanium alloy (Ti-6Al-4V) material, a difficult-to-machine material which results in massive cutting force, steep cutting temperature, and significant tool wear. In this research, carbide insert tool is used to cut a Ti-6Al-4V titanium block at constant depth of cut of 0.50 mm using the method of dry machining is investigated with the aim of estimating the effects of two manipulated cutting parameters, which are spindle speed (140 and 150 m/min), and feed rate (0.1 and 0.2). This was done to observe their effects on the tool wear of the insert. The objective of this study is to study the machinability performance of coated carbide insert tool under dry machining condition, and to optimize the cutting parameter to machine Ti-6Al-4V using dry machining method. It was found in this research that lowest valued parameter, Parameter 1 (140 m/min, 0.1 mm/rev) caused the most flank wear, and the roughest surface on the Ti-6Al-4V block. Lower speeds can possibly inflict higher shocking force, which leads to higher wear propagation.

An insight into the effect surface morphology, processing, and lubricating conditions on tribological properties of Ti6Al4V and UHMWPE pairs

The effects of surface topography, processing, and environment conditions during tribological contact between Ti6Al4V titanium alloy and UHMWPE friction pairs were systematically evaluated. Hence, in this research the polyethylene samples (blocks) having a constant surface roughness were rubbed against counter-bodies (rollers) made of titanium alloy with different roughness of surfaces. The counter-samples were manufactured using either dry machining and/or minimum quantity lubrication (MQL) conditions. Such cutting conditions are harmless to humans and the environment. Simulated body fluid (SBF) and distilled water was used to simulate the tribological trials. We have noted that the lubricant applied to protect the integrity of machined parts, the rollers, have only minor impact on the tribological features of the friction pairs tested. Further, the samples produced with dry machining demonstrated a slightly lower momentary friction coefficient and temperature. In contrast, the MQL method enable reduced friction surface and significant wear accumulation. Further, it was found that the minimum and maximum values of the Sa texture parameter associated to tribological parameters do not exceed 21% and 4%, when is used dry and MQL methods, respectively. Nevertheless, the distilled water revealed a much better wear resistance when comparing to SBF, and the later one trigger as well as an accentuated wear progress with different patterns. The results of the study are important in the design of new biomedical components produced by finish turning.

Environmental, technological and economical aspects of cryogenic assisted hard machining operation of inconel 718: A step towards green manufacturing

It is critical in today's modern manufacturing era to have a machining system that is both environmentally and economically beneficial. It is therefore necessary in many ways to illustrate a relationship between technological, economic and sustainability measures in the machining of Inconel 718. In present investigation, the experimental studies are incorporated by the use of the dry and MQL (minimum quantity lubrication) environments, as well as cryogenic-LN2 and cryogenic-CO2 environments. In terms of technological, sustainability, and economic metrics, the results show that cryogenic-LN2 performed better, followed by cryogenic-CO2, MQL, and dry conditions. As turning Inconel 718, LN2 assisted machining reduce total machining costs and energy usage considerably when compared to dry, MQL, cryogenic-CO2 environments. In addition, the LN2 cooling environment has been shown to significantly reduce machining outputs such as cutting force, tool wear, and surface roughness. LN2 conditions was found to be most promising as it has decreased the cutting force by 32.1%, tool flank wear by 33.33% and total energy consumption by 18% compared to dry machining conditions. It's worth noting that modern lubri-cooling technologies help the aerospace sector be more sustainable by decreasing resource consumption, enhancing environmental advantages, and improving machining features.

Experimental investigations on the wear behaviour of micro-EDM-fabricated textured tools during dry turning of Ti6Al4V

PurposeThis paper aims to focus on analysing the wear characteristics of tungsten carbide tools on which various micro patterns are fabricated to study its effect on the machinability of Ti-6Al-4V at dry turning conditions.Design/methodology/approachMicro-patterns such as dimples, linear grooves and a novel combination of dimples and linear grooves were fabricated on rake faces of uncoated tools by micro-EDM process. Impact of these patterns on tool wear and chip morphology characteristics under dry machining conditions were analysed, and their performances were compared with the non-textured tool (NTT).FindingsEncouraging results in terms of minimal tool wear and favourable chip morphology characteristics were observed in case of all the textured tools, which demonstrated better tribological characteristics in contrast to NTT. The average flank wear was reduced by 43.5, 32 and 24.7% in dimple textured tool (DTT), linear textured tool (LTT) and hybrid textured tool (HTT), respectively, as compared to NTT. The average chip curl diameters measured for NTT, DTT, LTT, and HTT were observed to be 6.60, 3.51, 4.0 and 4.31 mm, respectively.Originality/valueThe contribution of this work lies in fabricating innovative patterns using cost-effective micro-EDM process and analysing how the patterns, depending upon their dimensional area and wear debris accumulation characteristics, influence the machinability of Ti-6Al-4V in the absence of any lubrication mediums.

The effect of carbon nanotube amount in machining of ZA-27 matrix carbon nanotube reinforced nano composite

In recent years, the usage area of nano material reinforced composites has been increasing gradually. Accordingly, machining of metal matrix and nano material reinforced composite materials becomes important. In this study, the effect of carbon nanotube (CNT) on the machining of CNT-reinforced ZA-27 (zinc-aluminum) nano composite was investigated. For this purpose, 0.5%, 1.0%, 1.5%, 3.0% CNTreinforced ZA-27 based composites were produced by powder metallurgy method. Firstly, SEM images of composites were taken. Then, hardness measurements were made and pore amounts were determined. At the last stage, the machinability tests of nano composites have been carried out. Machinability tests were carried out by turning method to determine the cutting forces and surface roughness amounts. The tests were carried out with cemented carbide cutting tools under dry cutting conditions. Cutting speeds of 75, 125, 175, 225 m/min, feed values of 0.05, 0.10, 0.20 mm/rev and constant cutting depth of 1.0 mm were chosen as test parameters. The data obtained as a result of the tests were interpreted together with microstructure, porosity and hardness values. Hardness values decreased and the pore amounts increased with the increase in the CNT-reinforcement ratio within the composite structure.Cutting forces and the surface roughness amounts increased with the increase in feed value. Cutting forces and surface roughness amounts decreased together with increase in cutting speed. CNT-reinforcement material in the composite structure caused a decrease in cutting forces. However, surface roughness values showed an increase with the increase of CNTreinforcement ratio. It has been determined that CNT-reinforcement material facilitates machining by lubricating effect in dry machining conditions. Built-up edge (BUE) was observed on all cutting tool bits used in machining tests. BUE amounts increased in itself with the increase in CNT ratios and feed rates.

Experimental studies and mathematical modelling of Inconel 600 with CVD coated TiN/TiCN/Al2O3/ZrCN inserts under dry machining Conditions

Inconel 600 is a nickel-based super alloy with applications in the field of Aerospace, Nuclear energy, Heat treatment, and chemical processing industries, and is a difficult to cut material due to its high hot hardness and strength. Coated carbide inserts can improve the machinability of alloys like Inconel 600 and other super alloys. This work is about the machinability characteristics study on Inconel 600 alloy under dry turning environment with high speed machining using CVD coated TiN/TiCN/Al2O3/ZrCN cutting tool insert. Cutting speed (200, 250, and 300 m/min), feed rate (0.05, 0.1, 0.15 mm/rev), and back rake angle (-7, -5, -3°) are considered as machining process parameters. Full factorial design of experiments were performed to evaluate the performance of process parameters on surface roughness and material removal rate. It was found that surface roughness decreased with increase in cutting speed and increases with increase in feed rate. Surface roughness increases with increase in rake angle in negative direction. Material removal rate increases with increase in both cutting speed and the feed rate whereas rake angle had minimal influence. Mathematical modelling was done on the obtained results and found that Rˆ2 value for surface roughness and material removal rate were 99.14% and 98.69% respectively. Analysis of Variance on surface roughness found that feed rate* feed rate is the most influencing parameter with maximum contribution of 34.16% whereas feed rate* cutting speed parameter has maximum influence on material removal rate with contribution of 83.03 %.

Analyze the Effect of Crater Cutting Tool Wear Modeling in the Machining of Aluminium Composite

The present investigation is used to analyze the effect of crater wear modeling in the machining of aluminium composite. Response surface methodology (RSM) is one of the best optimization technique used to bring out the optimal values of speed, feed and depth of cut for attain minimum surface roughness, cutting tool temperature and tool wear. AA7075 alloy with 15wt% of silicon carbide has been investigated in the dry machining condition. The double layered TiCN/Al2O3 coated tool was preferred. The worn surface analysis in coated tool was concentrated. The outcomes of the machining conditions were expected to improve surface finish. Novel approach of this investigation is to analyze the surface morphology to visualize the surface peak and valley profile of the coated tool and analyzed with various surface parameters that decide the surface roughness of the profile.

Evaluation of Machinability on duplex stainless steel 2205 under dry and Wet condition

The examination of machinability in terms of surface roughness on duplex stainless steel under dry and wet machining conditions with a TiAlN coated solid carbide drill is presented in this paper. The experiments were carried out utilizing a CNCNC milling machine for drilling and a Taguchi design L8 set of orthogonal array(OA) for parametric optimization. Following the experimental optimization, it was discovered that dry machining produces a better surface quality than wet machining, with an R2 value of 0.990 for surface roughness. Finally, it was discovered that dry machining produces a superior surface finish than wet machining, and that the ideal process parameter for surface roughness (Ra) is a dry machining environment, a high spindle speed (900 RPM), and a low feed rate (0.03). After confirmation test were conducted for validation of experimental results and it was observed that experimental results and model results are close to each other.

Optimization of Dry Electrical Discharge Machining of Stainless Steel using Big Data Analytics

Big data (datasets accessible through the Internet) coupled with machine learning arrangements constitute big data analytics, which is heavily resource-depended and creates inequality-only large organizations can sustain or utilize big data analytics, and medium and small organizations fall behind. This article presents a novel inequality-free big data analytics for process planning in medium and small enterprises. Big data, search mechanism, control and evaluation variables relevant datasets, uncertainty quantification using possibility distributions, and decision rules are the components of the proposed analytics. This article reports the characteristics of the analytics applied to optimizing dry electrical discharge machining conditions of stainless steel.

Evaluation and Comparison of Turning Process Performance during Machining of D2 Steel Material under Two Sustainable Machining Techniques

In the present work, two sustainable machining techniques namely Minimum Quantity Lubrication (MQL) and dry machining were investigated during turning of AISI D2 steel material using tungsten carbide tools. Cutting velocity, feed rate and depth of cut were considered as turning process variables whereas cutting temperature, tool rake wear, tool flank wear and surface roughness were taken as turning process performance characteristics for investigation purpose. Based on the obtained results it was found that MQL machining technique significantly controlled the cutting temperature, tool rake wear, tool flank wear and surface roughness values to a maximum of 46%, 22%, 23% and 35% when compared to dry machining condition. It was noticed that MQL cooling technique uses tiny quantity of coolant and contributes for sustainable requirements in present industry. Further, it was observed that more chip entanglement marks as major surface defectives and edge chipping as major tool wear mechanism in dry machining.

Study on the Wear of Cutting-Tools Used in Dry Machining of Cu-10wt%Al-5wt%Ni-5wt%Fe Alloy

Aluminium bronze alloys are special copper alloys that have a machinability rate from 20 to 40% compared to free cutting brasses, so the cutting parameters and type of tools suitable for machining of these materials may be very different for other copper alloys. Also, due to the relative high costs of the raw material, the absence of contamination of the chips by cutting fluids improve its intrinsic resales value and encourage the use of machining process without coolant. The aim of this work is to evaluate the tool wear mechanisms in the finishing machining of the Cu-10wt%Al-5wt%Ni-5wt%Fe aluminium-bronze alloy with carbide and cermet inserts at different cutting speeds under dry machining condition. The turning of material showed lower surface roughness in higher speed conditions and better dimensional stability at lower speeds. It was observed the formation of continuous chips, but of little volume occupied. The scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) analyses of tool wear show the adhesion as the main tool wear mechanism, followed by abrasion. At the lower cutting speed, the adhesion wears affected significantly the surface finish, reducing the tool life in comparison to the higher speeds.

Eco-friendly precision turning of superalloy Inconel 718 using MQL based vegetable oils: Tool wear and surface integrity evaluation

This work reports on the performance of eco-friendly spray-based approach employing vegetable oils to precision machine nickel based superalloy Inconel 718. Taguchi L9 (33) orthogonal array was used to evaluate two vegetable oils namely sunflower and castor oil for turning operation and their performance was compared with dry machining mode. Three levels of cutting speed (30, 50, 70 m/min.), feed rate (0.168, 0.281, 0.393 mm/rev.) and air pressure (2, 3.5, 5 bar) were used while keeping constant depth of cut (1) mm and spray standoff settings (50 mm). Tool wear, surface roughness and machined surface integrity were taken as response parameters. Tool wear analysis was further supplemented with scanning electron microscopy (SEM). The effects of the input variables on response parameters were quantified by analysis of variance (ANOVA). It was found that feed rate is the most contributing factor for surface roughness with a contribution of 95.71%, 97.86% and 93.19% for MQLSO, MQLCO and dry machining conditions respectively. As for the tool wear, cutting speed is the most contributing factor with a contribution of 76.55%, 80.87% and 69% for MQLSO, MQLCO and dry machining conditions respectively. Minimum tool wear was obtained with sunflower oil with lowest feed rate (0.168 mm/rev.) and cutting speed (30 m/min.) combination. Further insight on worst and least tool wear conditions via SEM images indicate grooving, incidences of adhered material and attrition/chipping to be observable for dry machining condition. On the other hand, lesser incidences of adhered chips and uniform wear which extended up-to the tool nose was observed for least tool wear condition obtained with MQLSO indicting its effectiveness. The minimum values for tool wear (116 μm) and surface roughness (0.43 μm) as obtained with MQLSO, were 26% and 52.09% better (respectively) when compared to the dry machining at same conditions. In the context of surface integrity, a strain hardened layer extending up to the depth of 270 μm was observed at optimum machining parameters. Approximately, 16% higher hardness value was observed closer to the machined surface, than that of bulk material.

Mathematical Modeling & Multi Response Optimization for Improving Machinability of Alloy Steel Using RSM, GRA and Jaya Algorithm

In order to minimise the difficulties associated in selecting conventional coolants in any machining, cutting fluids like vegetable based oils can serve as a viable alternative. Vegetable based oils when used in combination with eco-friendly techniques like MQL/NDM can have a major impact in any machining. In the present paper, performance characteristics of surface roughness and tool wear in machining of EN 36 steel alloy under Near Dry machining conditions/ Minimum quantity lubrication using vegetable based oil lubricant is studied. The input parameters like MQL flow rate, speed, feed and depth of cut for 5 levels are used in the CCD approach of Response surface methodology. For improving the machinability of alloy steel and to predit the values a regression equation is designed and developed between the input parameter and the output parameters. A multi-response optimum model for the output responses was also developed using RSM, GRA and JAYA algorithm, It was observed from the experiment results that JAYA algorithm has been proved the best multi-response optimization technique when compared to grey relational analysis and RSM.

Multi-spindle drilling of Al2024 alloy and the effect of TiAlN and TiSiN-coated carbide drills for productivity improvement

High precision drilling is required to ensure the structural integrity of the aircraft. Therefore, strict quality controls are required to ensure optimum hole quality since hundreds of thousands of holes are drilled into different aircraft structures. The large number of holes required for riveting means that their installation must be carried out in a fast and precise manner. This can be achieved using multi-head drilling tools that can drill several holes simultaneously. The current study investigated the use of a multi-spindle drill head that can produce three holes simultaneously. Uncoated carbide and TiAlN-coated and TiSiN-coated carbide drills were used to assess cutting forces, hole surface roughness, burr formations and tool condition when machining Al2024 aerospace alloy under dry machining conditions. Analysis of variance was employed for estimating the relationships between the input parameters (spindle speed, feed and tool coating) and the studied hole quality metrics. Furthermore, a regression model was developed with a regression coefficient (R2) of more than 90% for the prediction of measured responses. Interestingly, better results in lower thrust force and surface roughness were obtained using the uncoated carbide drills compared with TiAlN and TiSiN, while the performance of TiAlN was found to be better than those obtained from TiSiN.

Numerical investigations of cutting temperature and cutting forces in cryogenic assisted turning of magnesium alloy

Magnesium alloys are biocompatible materials that are not only used in biomedical implants but also in many engineering load-bearing applications due to their high strength to density ratio. However, machining of these alloys is somehow challenging, for example, magnesium alloy (AZ31B) is prone to ignition risk at relatively low temperatures during various machining processes. This ignition risk can be avoided by performing machining under cryogenic conditions. In the present research work, 2D finite element-based analysis of orthogonal cutting process of magnesium alloy (AZ31B) is performed considering both cryogenic and dry machining environments. Finite element simulations are performed by varying the cutting speed and uncut chip thickness. A widely employed, damage-based Johnson-Cook flow stress model is exploited to perform coupled thermo-mechanical cutting simulations. Cutting forces and temperatures are the major output parameters of interest in the work. The resultant cutting forces predicted by FE analysis for cutting speed of 100 m/min and for uncut chip thickness of 0.1 mm vary by 19% and 16% for cryogenic and dry machining conditions, respectively, when compared with available experimental results from literature, whereas, in the workpiece body, temperature variations of 14% and 2% have been found for cryogenic and dry machining conditions, respectively. Promising results of numerical model may help to further investigate and optimize the process.

Comparison of surface integrity, tool wear and chip morphology in CO2 cryogenic and dry milling of 304 stainless steel

In this study, dry and CO2 cryogenic milling conditions on 304 stainless steel is investigated. The cutting speeds of (60, 100, 140 m min−1), feed rates of (0.1, 0.13, 0.16 mm tooth−1) and axial depth of cuts of (0.5, 1, 1.5 mm) are considered in the L9 Taguchi array to design both dry and cryogenic slot milling tests. In cryogenic milling, defects in surface topography and tool wear (flank wear, built up edge and tool chipping) reduced significantly compared to dry machining conditions. Cryogenic milling improved the surface roughness from 4% to 71% compared to the corresponding dry conditions. In dry milling, more serrated chips and more discontinuities are seen in the lateral sides of the chips than cryogenic. In cryogenic compared to dry milling, the surface hardness of the workpiece decreased from at least 8% to a maximum of 12%. Also, the hardness of dry milling surface, increased from 43% to 102% compared to the bulk material. The maximum depth of hardening in cryogenic milling is 23% lower than that of dry condition. Increasing cutting parameters or dry machining will intensify the plastic deformation and compressing the microstructural grains adjacent to the machining surface, as in the deformed surface zone, the grain boundaries are indistinguishable. The maximum reduction in the thickness of the deformed layer was about 16% in the cryogenic milling compared to the corresponding dry condition. Considering XRD diagrams for dry and cryogenic milling compared to non-machined condition, no significant metallurgical phase transformation has occurred in the workpiece material.

Evaluation of the clean nano-cutting fluid by considering the tribological performance and cost parameters

In this study, the tribological performance of cutting fluid developed with canola oil and nano-silver was investigated. Within the scope of the study, AA7075-T6 material was milled under the conditions of dry machining, boron oil, canola oil, and nano-silver added canola oil. As a result of the experiments, surface roughness, cutting forces, cutting temperature, chip morphologies, and tool wear were investigated. Nano-lubricant caused a slight increase in the machining forces, but it provided high performance in terms of surface roughness, cutting temperature, chip morphology and tool wear. As a result of the optimisation, the nano-silver added cutting fluid was determined to be optimum in terms of surface roughness and cutting temperature.

Investigations on the effect of Machining parameters on Machining force and roughness in Micro-Milling of Titanium Gr5 and Gr12 alloys under dry Machining conditions using carbide tool

In the present research steady, an attempt has been made to explore the inspiration of process parameters on micro-machining of Titanium Grade-5 and Grade-12 alloys with cemented carbide cutting tool. The experimental trials are conducted under dry machining with several cutting parameters. The objective of the research is to identify the inspiration of machining parameters on surface superiority and force generation in titanium alloys micro-machining. The surface superiority and force generation were quantify through each cutting conditions. The obtained results indicated that the roughness (Ra) and cutting force reductions with upsurge in speed and intensifications with rise in feed rate. The results revealed that the speed have predominant inspiration on force generation and roughness whereas depth of cut is least significant during micro-milling of Titanium alloys. Chip formation shows the various segment and broken chips during machining process.

Comparison of conventional drilling and helical milling for hole making in Ti6Al4V titanium alloy under sustainable dry condition

Hole drilling in Ti6Al4V titanium alloy is challenging due to its poor machinability resulting from high-temperature strength and low thermal conductivity. Therefore, an evaluation of the helical milling process is carried out by comparing the thrust force, surface roughness, machining temperature, burr size, and hole diametrical accuracy with the conventional drilling process. The results indicate the advantage of the helical milling in terms of the lower magnitude of thrust force. The holes generated using helical milling displayed a superior surface finish at lower axial feed conditions, while higher axial feed conditions result in chatter due to the tool deformation. Also, the absence of a heat-affected zone (HAZ) under dry helical milling conditions indicates the work surface formation without thermal damage. Besides, a significant reduction in the size of the burrs is noted during helical milling due to lower machining temperature. Analysis of the hole diameter reinforces the capability of the helical milling process for processing H7 quality holes. Consequently, helical milling can be considered a sustainable alternative to mechanical drilling, considering its ability to machine quality holes under dry machining conditions.