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

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

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.

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

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

Environmentally Friendly Machining: Vegetable Based Cutting Fluids

Role of textured tool in improving machining performance: A review

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

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

Microstructure attributes and tool wear mechanisms during high-speed machining of Ti-6Al-4V

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.

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

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.

Anil Meena

Papers

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

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

Microstructure attributes and tool wear mechanisms during high-speed machining of Ti-6Al-4V

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

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