Anil Meena

Bio: Anil Meena is an academic researcher from Indian Institute of Technology Madras. The author has contributed to research in topic(s): Tool wear & Machining. The author has an hindex of 7, co-authored 17 publication(s) receiving 193 citation(s). Previous affiliations of Anil Meena include Arts et Métiers ParisTech & ParisTech.

Study of dry and minimum quantity lubrication drilling of novel austempered ductile iron (ADI) for automotive applications

Abstract: Coolants and lubricants for machining can improve the machinability of the workpiece, increase productivity, and extend tool life by reducing tool wear. However, for environmental and economic reasons, recent research in industry and academia has sought ways to reduce the use of machining fluids. This paper reports the use of dry and minimum quantity lubrication (MQL) to drill austempered ductile iron (ADI), a new class of materials used for light weight automotive components like connecting rods and crankshafts. In this study, ADI is produced by a novel processing technique known as continuous casting-heat treatment process. The novel technique is developed by the integration of casting (in die casting) and heat treatment processes in the foundry to save energy and time. This paper deals with an experimental investigation on the role of MQL drilling on the cutting forces, tool wear and surface roughness of newly produced ADI at industrial speed-feed combinations by TiAlN-coated tungsten carbide tool. MQL drilling, performance is then compared with the dry and conventional drilling process under the same experimental conditions and environment. The results include significant reduction in tool wear, cutting forces and surface roughness by MQL drilling, mainly through reduction in the cutting zone temperature.

Influence of micro scale textured tools on tribological properties at tool-chip interface in turning AISI 316 austenitic stainless steel

Abstract: Friction at the tool-chip interface and tool-chip adhesion causes severe problems during machining, which reduces the tool life and deteriorate the machined surface quality. To improve the tribological properties at the tool-chip interface and to decrease the tool-chip adhesion, surface texturing of the tools could be a better solution. Therefore, the present study is mainly focused on the cutting performance of the textured carbide tools while turning AISI 316 austenitic stainless steel. The textures were developed on the rake face of WC/Co carbide tools by laser machining. The effect of different lay directions of the texture with respect to the chip flow was studied. The cutting performance of the textured tools is compared with the conventional carbide tools in terms of cutting forces, tool wear and chip morphology. SEM and EDS analyses have been performed to better understand both the tool and chip surface characteristics. Results show that the texture modifies the adhesion of chips on the rake face as compared to the conventional tool and reduces the cutting forces. Moreover, the texture lay angle significantly affects the effectiveness of lubrication and tool-chip contact length. Therefore, by texturing the tools, friction force at the tool-chip interface can be minimized.

Specific cutting force, tool wear and chip morphology characteristics during dry drilling of austempered ductile iron (ADI)

Abstract: Dry machining is being recognized as ecological machining due to its less environmental impact and manufacturing cost. However, the choice of dry machining is mainly influenced by the workpiece material properties, machining operation and cutting conditions. The recent emergence of austempered ductile iron (ADI) can be considered a significant economic advantage to the increasing industrial demand for cost- and weight-efficient materials. However, due to its microstructure-induced inherent properties, ADI is considered hard-to-machine material. Thus, the dry drilling of ADI is investigated in this paper. The ADI material used in the present study is produced using an innovative process route for near net shape casting production. Drilling experiments are conducted on a DMU80P Deckel Maho five-axis machining centre using PVD-coated carbide tools under dry cutting environment. The dry drilling of ADI under different cutting conditions is evaluated in terms of specific cutting force and tool wear analysis. The influence of cutting conditions on chip morphology and surface roughness is also investigated. The experimental results revealed that the combination of the low feed rate and higher cutting speed leads to the higher mechanical and thermal loads on the tool's cutting edge, resulting in higher specific cutting force values. This behaviour is further supported by the chip morphology analysis, which revealed the formation of segmented chips at higher cutting speed with segment spacing increase with an increase in feed rate. Depending upon the cutting parameters, different modes of tool failures including crater wear, flank wear, chipping, breakage and built-up edge were observed. Surface roughness analysis revealed the influence of tool wear and chip morphology on the machined surface finish.

Material Characterization of Austempered Ductile Iron (ADI) Produced by a Sustainable Continuous Casting–Heat Treatment Process

Abstract: Selecting a suitable manufacturing process is one way of achieving sustainability of a product by diminishing energy consumption during its production cycle and improving material efficiency. The article attempts to explore the new processing technology for direct manufacturing of lightweight austempered ductile iron (ADI) casting in a permanent mold. The new processing technology is based on the innovative integrated approach toward casting and heat-treatment process. In this technology, the ductile iron samples obtained using the permanent mold are first austenized immediately after solidification process followed by austempering heat treatment in the fluidized bed and then air cooled at room temperature to obtain ADI material. The influence of austempering time on the microstructural characteristics, mechanical properties, and strain-hardening behavior of ADI was studied. Optical microscopy, scanning electron microscopy (SEM), and X-ray diffraction (XRD) analyses were performed to correlate the mechanical properties with microstructural characteristics. It was observed that the mechanical properties of resulting ADI samples were influenced by the microstructural transformations and varied retained austenite volume fractions obtained due to different austempering time. The results indicate that the strain-hardening behavior of the ADI material is influenced by the carbon content of retained austenite.

Drilling performance of green austempered ductile iron (ADI) grade produced by novel manufacturing technology

Abstract: Machinability study on drilling of green austempered ductile iron (ADI) grade was conducted using a TiAlN-coated tungsten carbide drill. The green ADI grade was produced by a novel manufacturing technology known as continuous casting-heat treatment technology to save energy and time in foundry. However, in spite of good combination of strength, toughness and enhanced wear resistance, the microstructural properties of ADI sometimes lead to machinability issues. The effect of cutting parameters on cutting force coefficients, chip morphology, and surface integrity of the drilled surface were discussed. Results showed that the strength properties of novel ADI are comparable to that of ASTM grade 1 ADI, whereas percent elongation is comparable to that of ASTM grade 2 ADI. Results obtained also showed that the combined effect of cutting speed at its higher values and feed rate at its lower values can result in increasing cutting force coefficients and specific cutting energy. At higher cutting speed, hardness values increases at the subsurface layer of the drilled surface due to plastic deformation.

Effects of Minimum Quantity Lubrication (MQL) in machining processes using conventional and nanofluid based cutting fluids: A comprehensive review

Abstract: In any metal cutting operation, the cutting fluid plays a vital role by cooling the surface of the work piece and the cutting tool, removing chips from the cutting zone and by lubricating the tool–work piece interface. However, misuse of the cutting fluid and wrong methods of its disposal can affect human health and the environment badly. Also, it accounts for 16–20% of the total cost of manufacturing in the production industry. Among various techniques available on application of the coolant, researchers, of late, have been focussing on Near Dry Machining (NDM)/Minimum Quantity Lubrication (MQL) as it minimizes the use of coolant by spraying the mixture of compressed air and cutting fluid in an optimized manner instead of flood cooling. The MQL technique has proved to be suitable because it complies with the requirements of ‘green’ machining. This paper presents a review of the important research papers published regarding the MQL-based application of mineral oils, vegetable oils and nanofluid-based cutting fluids for different machining processes, such as, drilling, turning, milling and grinding, etc. The paper explains the mechanism of the MQL technique. In a systematic manner, the present work also discusses its effect on the performance parameters of different machining processes. Most of the experimental studies have shown that application of MQL produces surface better than dry machining and similar to that as produced under wet machining. Its application also reduces cutting forces, cutting zone temperature, tool wear, friction coefficient in comparison to dry and wet machining. Therefore, MQL technique has proved to be a viable alternative to the flood lubrication under similar performance parameters.

Ecological trends in machining as a key factor in sustainable production – A review

Abstract: A comprehensive analysis of literature pertaining to ecological trends in machining processes of difficult-to-cut materials (e.g. hard steels, Ti-based alloys, Ni-based alloys) has been performed. The paper focuses on the improvement of machining processes with a balanced attention onthe reduction of pollution generated by coolants and emulsions. Here, the specific areas of interest are: Dry cutting; Minimum Quantity Lubrication/Minimum Quantity Cooling Lubrication; Cryogenic Cooling; High-Pressure Coolant and Biodegradable Vegetable Oils. The proposed approach of sustainable and cleaner production for the above-mentioned areas involves the minimized use of coolant/lubricants, employment of appropriate cutting tool's grade and machining conditions that leads to the reduction of total cost, cutting force, energy consumption, temperature but improvements of surface quality, volume of material removed, as well as the prolongation of tool life. In addition, the qualitative judgments like impact on human operator's health, atmospheric air, chip removal from machining area etc. are taken into account. The study presented in the paper is such a vast compendium of knowledgeregarding multi-directional critical analysis of machined parts, tools, chips under state-of-art cooling/lubrication systems that it will help the next generation scientists to find recent advances as well as future avenues of research on ecological aspects of machining for sustainability.

A review identifying the effectiveness of minimum quantity lubrication (MQL) during conventional machining

Abstract: Government legislation and public opinion are the main drivers behind the movement of manufacturing companies towards sustainable production. Fundamentally, companies want to avoid future financial penalties and the industry is therefore under pressure to adapt new techniques and practices in order to become environmentally friendly. The cost efficiency of metal cutting operations is highly dependent on accuracy, excellent surface finish and minimized tool wear and, to this end, has traditionally made abundant use of cutting fluid in machining operations. However, these cutting fluids have been a major contributor to environmental and health issues. In recent years, an enormous effort to eradicate these adverse effects has been made with one important focus being the implementation of minimum quantity lubrication (MQL). In the present work, the authors have reviewed the current state of the art in MQL with a particular focus on drilling, turning, milling and grinding machining operations. Overall, it is concluded that MQL has huge potential as a substitute for conventional flood cooling.

Environmentally Friendly Machining: Vegetable Based Cutting Fluids

Abstract: A wide variety of cutting fluids are commercially available in the cutting fluid suppliers in order to provide machining performances for a number of industries In machining, mineral, synthetic and semi-synthetic cutting fluids are widely used but, recently, uses of vegetable based cutting fluids have been increased Although, these cutting fluids are beneficial in the industries, their uses are being questioned nowadays as regards to health and environmental issues Cutting fluids are contaminated with metal particles and degradation products which diminish the effectiveness of cutting fluids To minimize the adverse environmental effects associated with the use of cutting fluids, the hazardous components from their formulations have to be eliminated or reduced to the acceptable level In addition, mineral based cutting fluids are going to be replaced with vegetable based cutting fluids since they are environmentally friendly Today to diminish the negative effects associated with cutting fluids, researchers have developed new bio based cutting fluids from various vegetable oils This chapter has also focused on environmental conscious machining such as dry cutting, machining with minimum quantity lubricant and especially machining with vegetable based cutting fluids including other types of cutting fluids Literatures associated with types of cutting fluids have also been presented in this chapter

Performance evaluation of aluminium 6063 drilling under the influence of nanofluid minimum quantity lubrication

Abstract: For environmental and economic reasons, recent research in industry and academia has sought ways to reduce the use of machining fluids. New cutting techniques are to be investigated to achieve this objective. Minimal quantity of lubrication (MQL) is a recent technique introduced in machining to obtain safe, environmental and economic benefits, reducing the use of coolant lubricant fluids in metal cutting. The objective of this work is to compare the performance of different lubrication conditions (dry, flooded, pure MQL and nanofluid MQL) with respect to the cutting forces (thrust force and torque), tool wear and surface roughness in the drilling of aluminium 6063 alloy by using HSS drill tools. In both MQL methods (pure MQL and MQL with nano-particles) oil supply rate is fixed at 200 ml/h and air pressure is fixed at 70 Psi. The nano-particles (Al2O3) of 20 nm in size are considered for the nanofluid with volumetric concentration of 1.5% in base oil (soya bean oil). The experimental results show that the nanofluid MQL (NFMQL) significantly increases the number of drilled holes and reduces the drilling torques and thrust forces as compare to other coolant-lubrication conditions. Superior results of NFMQL may be attributed to the reason that NFMQL produces low friction force at the tool/chip and tool/workpiece interfaces due to its rolling effect of nano-particles and superior cooling performance. In addition, the nanofluid MQL effectively eliminates chips and burrs to enhance the surface quality of holes and also increases the tool life by obtained lowest tool wear.