Reduction In Flank Wear Research Articles

Performance assessment of graphene oxide based nano-cutting fluids during sustainable hard turning through synthesis, characterization and machinability investigation

Achieving sustainability in manufacturing necessitates the implementation of eco-friendly solutions by adopting environmentally friendly coolants with cost-effective, energy-efficient and cleaner production processes without posing any risk to the operator's health. In this current work, mineral oil-based graphene oxide (GO) nano-cutting fluids of different concentration (0.05, 0.1, 0.2, 0.3, 0.4, 0.5 % wt.) are synthesized and their characteristics such as rheological, thermo-physical and tribological properties along with their stability and toxicology impact are thoroughly investigated. Further, the influence of nano-cutting fluid concentration on machinability and sustainability aspects during hard turning such as flank wear, surface integrity, power consumption, cutting temperature, carbon and noise emissions are investigated. According to the result an enhancement of 28.83 % and 29.54 % in viscosity and thermal conductivity have been recorded when concentration of nanofluid increases from 0.05 % to 0.5 %. GO nano-cutting fluids shows anti wear and friction reduction properties by providing excellent lubricious properties, as a result coefficient of friction has been reduced up to 28.36 % at 0.5 % wt. GO compared to plane mineral oil. A notable reduction in flank wear, cutting temperature, surface roughness, cutting temperature, power consumption, carbon emission and noise emission were noticed to be 25.96 %, 27.82 %, 23.86 %, 25.22 %, 11.66 % and 2.72 % respectively when the concentration of GO nanoparticles increases from 0.05 % to 0.5 % wt. Smoother surface with minimal defect has been noticed from the SEM and AFM image of machined workpiece at highest concentration (0.5 % wt.) of GO due to the synergetic effect of GO nano-cutting fluid and dual nozzle MQL system.

A sustainable approach for the preparation and stability of mono and hybrid nanofluids in the milling of Nickel based superalloy

This work is focused on enhancing the sustainability and machinability in finish end-milling of Nimonic 90 superalloy using nanofluid-assisted machining. The research deals with the preparation and analysis of the stability of hybrid nanofluids for the machining of Nimonic 90. The UV–visible absorption of prepared mono and hybrid nanofluids are examined and based on the absorption curves, and 1% of the weight of the nanoparticles is chosen. The samples have been used to estimate the ideal ultrasonication time and its behaviour with various ionic and non-ionic surfactants have been determined. By examining the UV–visible absorption curves, the shelf life of the hybrid nanofluid is obtained, and it is found to be equivalent to that of the freshly prepared nanofluid. When preparing nanofluids based on alumina and hBN, tween 80 and Sodium Dodecyl Sulfate (SDS) has proved to be to be superior surfactants, respectively. Furthermore, toxicity test has revealed that the well-dispersed nanofluid are non-toxic in nature, with hybrid nanofluid exhibiting 84% cell viability. The hybrid nanofluid possesses a zeta potential of −30.8 mV. Additionally, has been observed that all the prepared nanofluids exhibited Newtonian behaviour and that their viscosities are 15%–20% higher than those of the base fluid. During the nanofluid assisted machining with hybrid nanofluid, the machining results of Nimonic 90 superalloy demonstrate the synergistic influence of both nanoparticles. Compared to dry machining, the hybrid nanofluid has a 48.80% reduction in cutting forces, 72.66% reduction in cutting temperature, 63.63% reduction in surface roughness, and 46.03% reduction in flank wear. Additionally, a Pugh matrix assessment score of 9 compared to the score of −5 for dry machining indicates that the usage of hybrid nanofluid as a cutting condition has substantial potential for future sustainable machining methods.

Enhancing surface quality and tool life in SLM-machined components with Dual-MQL approach

Selective laser melting (SLM) can produce complex metal components with high densities, thereby surpassing the limitations of traditional machining methods. However, achieving accurate dimensions, geometries, and acceptable surface states in parts fabricated through SLM remains a concern as they often fall short compared to traditionally machined components. As a solution, a hybrid additive-subtractive manufacturing (HASM) method was developed to effectively utilize the advantages of both techniques. In this study, SLM-made 316 L stainless steel was machined under distinct cooling conditions to investigate the effects of roughness and tool wear. After a thorough investigation, the dual-MQL strategy was evaluated and compared with dry and MQL cutting strategies. The findings showed that the dual-MQL condition led to a significant reduction in flank wear by 54–56% and 29–34%, respectively, associated with dry and MQL cutting techniques, making it a highly promising key for machining SLM-made steel components. Machine learning techniques are potential tools for prediction and classification capabilities in machining processes. For milling SLM-made 316 L SS, multilayer perceptron (MLP) proved to be the most effective prediction model and for classification MLP and Random forest performed better.

A sustainable cooling/lubrication method focusing on energy consumption and other machining characteristics in high-speed turning of aluminum alloy

Understanding energy implications and machining performance standards is vital as industries move toward sustainability. Modern machining techniques including high-speed turning are used in the study on aluminum alloy materials. Therefore, this study focuses on the energy consumption and in-depth analysis of machinability criteria in the context of eco-friendly high-speed turning of aluminum alloy. The experiments were performed under ecofriendly cutting conditions dry and minimum quantity lubrication (MQL) conditions and the intricate relationship between machining parameters and cooling conditions was investigated in terms of energy consumption, tool wear, surface roughness and chips morphology. The result reveal that the Ra values exhibited 2.4 times increase in dry machining and an average increase of 2.3 times in MQL machining when the feed rate was increased from 0.2 to 0.4 mm/rev. Moreover, the MQL cooling is helpful in lowering the energy consumption as well as tool wear and surface roughness during the machining operations. MQL machining resulted in a 35% reduction in flank wear and 20% reduction in energy consumption compared to dry machining.

Carboxylated cellulose nanofibrils based on banana rachis as additive in oil-based emulsion coolant for effective flank wear reduction in lathe operation

Nitro-oxidized carboxylated cellulose nanofibrils (NOCNFs) from the banana rachis are employed in oil-emulsion coolant as an additive. The concentrations of NOCNF were 0.1, 0.2, 0.3 wt. %. The cutting parameters include the spindle speeds and depth of cut. The temperature and wear reduction were significant. The temperature at the tool flank decreased from 119°C to 76°C, corresponding to an 11% reduction in wear at the depth of cut co. 2 mm and spindle speed of 1330 rpm. The viscosity of the nanofluid and the corrosion of the low-carbon mild steel specimen are discussed. Arguably, a stable NOCNF nanofluid suspension is good against wear even at elevated temperatures. Interestingly, these results occurred at a lower NOCNF concentration co. 0.3% wt. compared to 1–2 wt. % from Al2O3 nanoparticles in literature. In this paper, banana rachis nanofibrils are attractive for developing of effective and environmentally friendly additives from biomass.

Influence of V concentration in TiAlSiVN coating on self-lubrication, friction and tool wear during two-pass dry turning of austenitic steel 316 L

The present work investigates the performance of TiAlSiVN coating with 5 and 11 at% of V concentration deposited on the Al2O3/SiC cutting tools during dry turning of austenitic 316 L stainless steel. The maximum flank wear reduction compared to the uncoated tool for coated tools with 11% and 5% V concentration was 85% and 67%, respectively. The Raman analysis indicated the formation of V2O5 in the cutting zone, which helps to reduce friction and machining forces for the coated tools. Overall, the presence of higher V content (11 at%) enhances the self-lubrication behaviour of the TiAlSiVN coating, accounting to lower fluctuations in cutting forces, superior surface finish, and lower flank wear when compared to the TiAlSiV5N coated and uncoated cutting tools.

Prediction and classification of tool wear and its state in sustainable machining of Bohler steel with different machine learning models

Machine learning has numerous advantages, especially in the rapid digitization of the manufacturing industry that combines data from manufacturing processes and quality measures. Predictive quality allows manufacturers to make informed predictions about the quality of their products by analyzing data gathered during production. The quality of the machining, the total cost and the computation time need to be improved using contemporary production processes. With this concern, a series of experiments were carried out on Bohler steel both in dry, Minimum Quantity Lubrication (MQL) and nano-MQL conditions in varying quantities to explore the tool wear. In comparison to dry conditions, the utilization of MQL in machining processes demonstrates significantly enhanced efficacy in mitigating flank wear. The reduction in flank wear ranges from around 5% to 20% to 25%, contingent upon the application of MQL on the flank face, rake face, or both faces simultaneously. After that, the results of the tests were evaluated with the models of machine learning (ML) to determine which environment was optimal for cutting under both real and artificial circumstances.

An Evaluation of the Tool Wear of Ceramic and Coated Carbide Inserts in Finishing Turning under the Influence of Age-Strengthening Gray Cast Iron

Gray cast iron (GCI) is a common material in the automotive industry due to its mechanical characteristics, which change primarily for materials employed for the foundry and cooling rate of material. According to the workpiece, the material of the cutting tool and cutting parameters are analyzed to improve the machining and to increment the lifetime of the tools. In this research, the foundry and machining process of an automotive component using ceramic and coated carbide tools were the study case, and the effect that they have on the age strengthening of GCI on the tool wear of the cutting tools was studied. Both inserts have the capability to machine the material with a rough surface between 1.5 to 2.0 μm. The wear mechanism of inserts and the microstructure of GCI were characterized with microscopy techniques, atomic force microscope (AFM), and energy dispersive X-ray spectroscopy (EDS). The microstructure of the workpiece shows a casting with flake graphite morphology that is linked with the induction of microcracks in the material. The experimental analysis shows that the GCI with 12 days of aging has an increased tensile strength. This improves the tool life of ceramic and coated carbide tools. There is a 50% reduction in flank wear with inserts that are machined with the GCI within five days of aging, compared with the material within twelve days. The rake face and flank wear show that abrasive and adhesive wear are the main mechanisms of ceramic inserts due to the high cutting speed. Meanwhile, adhesive and oxidative wear in the flank were the predominant type of wear for coated carbide tools.

A Supervised Machine Learning Model for Tool Condition Monitoring in Smart Manufacturing

In the current industry 4.0 scenario, good quality cutting tools result in a good surface finish, minimum vibrations, low power consumption, and reduction of machining time. Monitoring tool wear plays a crucial role in manufacturing quality components. In addition to tool monitoring, wear prediction assists the manufacturing systems in making tool-changing decisions. This paper introduces an industrial use case supervised machine learning model to predict the turning tool wear. Cutting forces, the surface roughness of a specimen, and flank wear of tool insert are measured for corresponding spindle speed, feed rate, and depth of cut. Those turning test datasets are applied in machine learning for tool wear predictions. The test was conducted using SNMG TiN Coated Silicon Carbide tool insert in turning of EN8 steel specimen. The dataset of cutting forces, surface finish, and flank wear is extracted from 200 turning tests with varied spindle speed, feed rate, and depth of cut. Random forest regression, Support vector regression, K Nearest Neighbour regression machine learning algorithms are used to predict the tool wear. R squared, the technique shows the random forest machine learning model predicts the tool wear of 91.82% of accuracy validated with the experimental trials. The experimental results exhibit flank wear is mainly influenced by the feed rate followed by the spindle speed and depth of cut. The reduction of flank wear with a lower feed rate can be achieved with a good surface finish of the workpiece. The proposed model may be helpful in tool wear prediction and making tool-changing decisions, which leads to achieving good quality machined components. Moreover, the machine learning model is adaptable for industry 4.0 and cloud environments for intelligent manufacturing systems.

Role of sustainable cooling/lubrication conditions in improving the tribological and machining characteristics of Monel-400 alloy

Due to its strong corrosion resistance, high hardness, and ability to maintain its strength at high temperatures, Monel-400 is utilized in the marine, aerospace, and power plant sectors. Monel-400 alloy is hard to machine owing to quick tool wear that causes poor dimensional accuracy. Therefore, an advanced measurement system is required to monitor the insight of machining performance of difficult-to-machine alloys like Monel-400. In the present work, a new cutting technique is presented to increase the efficiency of cryogenic carbon dioxide (CO2) and minimum quantity lubrication (MQL) in the high-performance machining of Monel-400. The combination of both CO2 + MQL (CMQL) is an efficient approach that is supplied to the rake side and compared with dry, CO2 and MQL. Tool wear, surface roughness, temperature, chip morphology and microhardness measurements were performed to enumerate the influence of distinct cutting environments. Based on the findings of the systematic trials, CMQL was found to be the finest effective cooling technique, reducing friction to the greatest possible extent and creating the best possible surface. Under CMQL condition, the flank wear reduction was found to be 51–55 %, 37–47 % and 26–33 % compared to dry, MQL and CO2 conditions, respectively. Even though CMQL effectively reduces friction, the cryo medium outperformed and increased the machined face hardness.

Machining performance evaluation and tool wear analysis of dry cutting austenitic stainless steel with variable-length restricted contact tools

Austenitic stainless steel during machining still faces several challenges in terms of poor machinability and severe tool wear. In this work, different rake surface restricted contact tools with an inconstant tool-chip contact length are designed and fabricated. An in-depth investigation is then performed to comprehend the influence of the variable-length restricted contact tools on the machining performance and tool wear during dry cutting of AISI 316L austenitic stainless steel. The results indicate that considerable improvements in tribological properties and tool life are achieved with the developed tools. The cutting force, cutting temperature, chip curl radius, and chip thickness decrease compared to traditional restricted contact tools. A dramatic reduction in flank wear of up to 44.18% is obtained in variable-length restricted contact tools compared with traditional restricted contact tools. Variable-length restricted contact structures also reduce the adhesion rate and abrasion damage of tool wear processes. The insights in this study exhibit an efficient method of dry machining stainless steel and may provide a basis for designing cutting tools for green machining of difficult-to-cut materials.

Design, fabrication and characterization of a self-lubricated textured tool in dry machining

The manufacturing industry nowadays is facing various environmental regulations and is in the process of development of new technologies to minimize use of these lubricants during machining. One such trend is noticed in terms of surface texturing in different shapes on rake or flank face of tool which resulted in decrease in tool temperature, wear rate etc. Currently, the machining without lubricant (dry machining) is increasingly useful. This paper deals with one of the promising ways to minimize the use of cutting fluid by the development of self-lubricated tool. By this virtue, a low friction film between the working interfaces were generated during the machining. Molybdenum disulphide (MoS 2 ) powder is employed as the solid lubricant in this work. Micro textures were made on the different faces of the tool using the Epilog Fiber Laser (30Watt pulsed) and the solid lubricant (MoS 2 ) is filled in them for the purpose of self lubrication. Dry plain turning tests were conducted on Al6061-T6 alloy under different machining times and cutting speeds. The performance of textured cutting tool was investigated in terms of interfacial tool temperature and flank wear and also compared with conventional dry tool. The developed textured cutting tool with solid lubricant (MoS 2 ) generated 21–40% less cutting temperature compared to that of the dry cutting tool. This textured cutting tool also exhibited 24–35% reduction in flank wear at different cutting speeds. SEM images show significant improvement in microstructure and wear behavior of self-lubricated textured tool in comparison to the conventional dry tool.

Vibration, tool wear and surface roughness characteristics in turning of Inconel 718 alloy with ceramic insert under LN2 machining

Liquid nitrogen (LN2) machining is considered as a safe, clean, and environmentally friendly machining process. This paper aims to investigate the vibration, tool wear and surface roughness mechanism of the ceramic insert during turning of Inconel 718 alloy under dry machining and LN2 machining. The experiments were performed at three cutting speeds (100, 150, 200 m/min), feed rates (0.04, 0.08, 0.12 mm/rev) and depths of cut (0.2, 0.4, 0.6 mm). The experiment results show better machinability and longer tool life in LN2 machining. The vibration acceleration is reduced by 14–32%. A 17–34% reduction of workpiece surface roughness is observed. Flank wear and notch are the predominant wear forms both in LN2 machining and dry machining, and 16–34% reduction of flank wear is noted in LN2 machining.

PCD coating polishing effect on the tool wear in high-speed milling of graphite

The manufacture of molds with increasingly shorter deadlines and costs requires tool manufacturers to improve their manufacturing processes. One of the ways is improving their electrode machining, because this process will affect directly in the result of the dimensional precision and production time of the mold. The usage of graphite as raw material for electrodes is known to be highly satisfactory since the graphite has the advantage of machining faster and allowing a great variety of geometrical forms; however, its main disadvantage is that the graphite also has a high level of wearing during the machining process. The cutting-edge preparations are used in order to reduce the effects of this problem, increasing the durability of the tools. In that interest, this paper has researched the effect of edge preparations, through the polishing of the PCD coating, on the wear of tools, in milling of graphite electrodes. Therefore, experimental tests were performed with untreated and polished tools, with abrasive brushes, and by drag finishing. The tests consisted in machining electrodes with analysis of tool wear, roughness, and characterization of the tools. The findings indicate that the edge preparation results in modifications on the coating surface, reducing the roughness value by a mean of 23%, and in the case of drag finishing process, a variation of the values reduction, since this process is more reliable and reproducible. With regard to the tools’ wear, gains such as reduction of flank wear and a cutting length increase of up to 63% were noticed, in comparison with the original tools.

Investigation of the influence of MWCNTs mixed nanofluid on the machinability characteristics of PH 13-8 Mo stainless steel

In recent years, advances in nanotechnology have been positively reflected in the manufacturing industry, as in many other fields. Owing to their physical and chemical aspects, the nano-sized solid lubricants can help to improve the tribological and thermal properties when added to aerosols, suspensions and emulsions. In order to achieve high efficiency in machining operations, this phenomenon provides an opportunity to perform the tasks expected from a coolant/lubricant. Therefore, this study aimed to investigate the influence of cutting fluid reinforced by multi-walled carbon nanotubes (MWCNTs) into vegetable based cutting fluid on machinability characteristics of PH 13-8 Mo stainless steel that has excellent mechanical properties. For this, Taguchi's L27 (33) orthogonal array involving three factors and their three levels such as cutting speed of 120, 180, 240 m/min, feed rate of 0.1, 0.15 and 0.2 mm/rev and three C/L environment i.e., dry, pure-MQL (0 vol% of nano-additives) and MWCNTs mixed nanofluid-MQL were taken as process parameters. In this experimental design, surface roughness and peak temperature in cutting zone were considered as responses. Moreover, to analyze only the influence C/L environment on tool wear, wear mechanisms and surface topography, a series of experiments were conducted by preserving other machining parameters. As a result, approximately 5% and 12% lower surface roughness was achieved with pure-MQL and nanofluid-MQL, respectively. The reduction in flank wear was found to be 40.2% and 69% under cutting environment, i.e., pure-MQL and MWCNTs mixed nanofluid-MQL.

Investigation of machining Ti-6Al-4V with graphene oxide nanofluids: Tool wear, cutting forces and cutting vibration

This paper investigated experimentally the machining of Ti-6A-4V with a new graphene based cutting fluid. Three different types of graphene oxide (GO) nanofluids with various GO concentrations were applied in a series of cutting experiments. Tool wear, cutting force and the vibration in turning titanium alloy with the new nanofluids as well as conventional coolant were analysed. The working mechanism and different cutting effects caused by the variation of GO concentration and coolant pressure were discussed. The results show that the cutting force was reduced by 50.83 % when GO nanofluids were used. The vibration in the turning Ti-6Al-4 V with GO nanofluids was significantly lower than that in using base fluids. While the Build-up-Edge (BUE) and adhered layers on the rake face were less than those formed in using conventional coolant, the reduction of flank wear was up to 44.1 %, 53.9 % and 71.3 % respectively when GO nanofluids with the concentration of 0.1 wt.% GO, 0.3 wt.% GO and 0.5 wt.% GO were applied.

Effect of cryogenic coolant on turning performance: a comparative study

In the recent years, environmental regulations became stringent in terms of disposal of chemically contaminated conventional coolants. Cryogenic cooling is an alternative technique to the conventional cooling technique with conventional coolants. In this work, new findings were reported in turning of 17-4 precipitation hardenable stainless steel (PH SS) at varying feed rate conditions under cryogenic cooling and the results were compared with the minimum quantity lubrication (MQL), conventional wet and dry cutting conditions, respectively. Turning performance considered in this work includes cutting temperature, surface roughness and tool wear. From the findings, it was noticed that a maximum of 24%, 26% and 69% reduction in surface roughness was observed in cryogenic machining when compared to MQL, wet and dry environments, respectively. Also, the maximum flank wear reduction found in cryogenic machining was 42%, 48% and 53%, respectively, over the MQL, wet and dry environments. Overall, it was concluded that cryogenic machining is a feasible method for improving the turning performance characteristics in machining of 17-4 PH SS.

Temperature effects on the Ti6Al4V machinability using cooled gaseous nitrogen in semi-finishing turning

More and more stringent environmental concerns and regulations over contamination and pollution are driving the research to alternative cooling strategies that are more environmental friendly but still offer the same advantages of the conventional cutting fluids during machining operations. Even if some solutions, such as Liquid Nitrogen (LN2) or air cooling, have been proved to perform well, they are still rarely used in industrial applications due to their high operating costs, safety issues, and scarce availability of data about their effects on the alloy machinability. In this context, the object of the work is to evaluate the performances of a new cooling method using gaseous Nitrogen (N2) cooled by LN2 in a range of temperature between 0° and −150°C. The method was applied in semi-finishing turning of the titanium alloy Ti6Al4V. Different tests were conducted in order to evaluate the temperature effects on the Ti6Al4V machinability and identify the cooling condition that guaranteed the best performances in terms of both tool wear and machined surface integrity. The study proved that the coolant temperature influenced the alloy machinability and that a critical temperature existed below which no additional improvements were detected compared to the wet and LN2 cooling strategies used as baseline. The best solution was highlighted using N2 cooled at −150°C, which induced significant reduction of the rake and flank wear reduction compared to LN2 and wet condition, as well as the improvement of the surface integrity. Furthermore, the coolants cooling capacity was analytically modelled to explain the obtained experimental results.

Fundamental Research on Hobbing and Finish-Hobbing in Dry and with MQL System

This paper deals with hobbing and finish-hobbing that considers the machine environment when using various hard hob materials. Experiments were conducted by simulating hobbing by fly tool cutting on a milling machine. The results are summarized as follows. (1) Under the condition of hobbing with TiN-coated tools in dry cutting and with a minimal quantity of lubricant (MQL) system, P20 and P30 hob materials as the substrate show stable cutting and do not cause tool failure. The flank wear obtained with P30 is less than that obtained with P10 and P20 in the case of the coated TiAlN film tool. The MQL system shows flank wear reduction compared with dry cutting. (2) Under the condition of finish-hobbing, when using the TiN-coated tool, the flank wear obtained with dry cutting is smaller than that obtained with the MQL system. The flank wear increases in the order of P10, P20 and P30 hob materials, and the P10 hob material is effective. The TiAlN-coated P30 tool decreases flank wear and is suitable for finish-hobbing in dry cutting and with the MQL system. (3) Under the condition of hobbing, the finished surface roughness obtained with the MQL system when using TiN-and TiAlN-coated tools is smaller than that obtained by dry cutting. (4) Under the condition of finish-hobbing, the finished surface roughness obtained with TiN-and TiAlN-coated P30 is small in dry cutting and with the MQL system.

Effects of magnetic assistance on improving tool wear resistance and cutting mechanisms during steel turning

This paper provides a novel magnetic assisted turning mechanism for machining steel alloy specimens by HSS tools. The presented setup reduces air gap on a closed magnetic circuit and applies the magnetic field on both tool and workpiece, simultaneously. The usage of closed magnetic field contributes to using the magnetic field advantages at lower magnetic intensity. Using the design of experiments method, full factorial technique, 33×2 tests were conducted to study the influence of effective parameters i.e., magnetic field, depth of cut, feed rate and spindle speed. The flank wear and the cutting force were measured to quantitatively investigate the effect of magnetic treatment on machining process. The results were investigated by the analysis of variance (ANOVA) method and the magnetic field was revealed as the most pivotal factor. The analysis of variance results, micrographs of tool wear and dynamometer's force diagrams proved the advantages of the proposed method. Through this technique, a maximum 94% reduction in flank wear and 66% improvement of cutting force were achieved.