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Journal ArticleDOI

Grinding of Ti-6Al-4V Under Small Quantity Cooling Lubrication Environment Using Alumina and MWCNT Nanofluids

06 Jan 2017-Materials and Manufacturing Processes (Taylor & Francis)-Vol. 32, Iss: 6, pp 608-615
TL;DR: In this paper, a small quantity cooling lubrication (SQCL) technology using nanofluids, namely, multiwalled carbon nanotube (MWCNT) and alumina nanofluid, was used for reciprocating surface grinding using a vitrified SiC wheel.
Abstract: Ti-6Al-4V is a difficult-to-grind material as chips tend to adhere to the grit materials of an abrasive wheel due to its chemical affinity. In the present work, it has been attempted to improve the grindability by application of small quantity cooling lubrication (SQCL) technology using nanofluids, namely, multiwalled carbon nanotube (MWCNT) and alumina nanofluid. The suitability of nanofluids was experimentally evaluated in reciprocating surface grinding using a vitrified SiC wheel. Substantial improvement in grindability under the influence of MWCNT nanofluid (SQCL) could be achieved compared to soluble oil (flood). Reduction of specific grinding forces and specific energy was observed due to the combined effect of superior heat dissipation and lubrication abilities; when the latter one was realized through on-site rolling of MWCNT strands, inter-tubular slip and solid lubrication of the film adhered onto the wheel surface. These outperforming characteristics of MWCNT nanofluid helped in retaini...
Citations
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Journal ArticleDOI
TL;DR: In this article, an attempt has been made to evaluate the effectiveness of two cooling and lubrication techniques namely cryogenic cooling and hybrid nanoadditive-based minimum quantity lubrication (MQL).
Abstract: Owing to superior physio-chemical characteristics, titanium alloys are widely adopted in numerous fields such as medical, aerospace, and military applications. However, titanium alloys have poor machinability due to its low thermal conductivity which results in high temperature during machining. Numerous lubrication and cooling techniques have already been employed to reduce the harmful environmental footprints and temperature elevation and to improve the machining of titanium alloys. In this current work, an attempt has been made to evaluate the effectiveness of two cooling and lubrication techniques namely cryogenic cooling and hybrid nanoadditive–based minimum quantity lubrication (MQL). The key objective of this experimental research is to compare the influence of cryogenic CO2 and hybrid nanofluid–based MQL techniques for turning Ti–6Al–4V. The used hybrid nanofluid is alumina (Al2O3) with multi-walled carbon nanotubes (MWCNTs) dispersed in vegetable oil. Taguchi-based L9 orthogonal-array was used for the design of the experiment. The design variables were cutting speed, feed rate, and cooling technique. Results showed that the hybrid nanoadditives reduced the average surface roughness by 8.72%, cutting force by 11.8%, and increased the tool life by 23% in comparison with the cryogenic cooling. Nevertheless, the cryogenic technique showed a reduction of 11.2% in cutting temperature compared to the MQL-hybrid nanofluids at low and high levels of cutting speed and feed rate. In this regard, a milestone has been achieved by implementing two different sustainable cooling/lubrication techniques.

170 citations

Journal ArticleDOI
TL;DR: In this article, the effects of two types of nano-cutting fluids on tool performance and chip morphology during turning of Inconel 718 were investigated, and it was found that MWCNT nano-fluid has shown better performance than Al2O3 nanofluid.
Abstract: Flood cooling is a typical cooling strategy used in industry to dissipate the high temperature generated during machining of Inconel 718. The use of flood coolant has risen environmental and health concerns which call for different alternatives. Minimum quaintly lubricant (MQL) has been successfully introduced as an acceptable coolant strategy; however, its potential to dissipate heat is much lower than the one achieved using flood coolant. MQL-nano-cutting fluid is one of the suggested techniques to further improve the performance of MQL particularly when machining difficult-to-cut materials. The main objective of this study is to investigate the effects of two types of nano-cutting fluids on tool performance and chip morphology during turning of Inconel 718. Multi-walled carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles have been utilized as nano-additives. The novelty here lies on enhancing the MQL heat capacity using different nano-additives-based fluids in order to improve Inconel 718 machinability. In this investigation, both nano-fluids showed better results compared to the tests performed without any nano-additives. Significant changes in modes of tool wear and improvement in the intensity of wear progression have been observed when using nano-fluids. Also, the collected chips have been analyzed to understand the effects of adding nano-additives on the chip morphology. Finally, it has been found that MWCNT nano-fluid has shown better performance than Al2O3 nano-fluid.

158 citations

Journal ArticleDOI
TL;DR: In this paper, the machining and sustainability characteristics of minimum quantity lubrication (MQL), nanofluids-MQL, Ranque-Hilsch vortex tube MQL (RHVT + MQL), cryogenic MQL as alternative to flood cooling applications in the cutting of light-weight materials are presented.

75 citations

Journal ArticleDOI
TL;DR: In this article, the authors investigated the effects of multi-walled-carbon nanotubes (MWCNTs) cutting fluid during cutting of Ti-6Al-4V.
Abstract: Titanium alloys are the primary candidates in several applications due to its promising characteristics, such as high strength to weight ratio, high yield strength, and high wear resistance. Despite its superior performance, some inherent properties, such as low thermal conductivity and high chemical reactivity lead to poor machinability and result in premature tool failure. In order to overcome the heat dissipation challenge during machining of titanium alloys, nano-cutting fluids are utilized as they offer higher observed thermal conductivity values compared to the base oil. The objective of this work is to investigate the effects of multi-walled-carbon nanotubes (MWCNTs) cutting fluid during cutting of Ti-6Al-4V. The investigations are carried out to study the induced surface quality under different cutting design variables including cutting speed, feed rate, and added nano-additive percentage (wt%). The novelty here lies on enhancing the MQL heat capacity using nanotubes-based fluid in order to improve Ti-6Al-4V machinability. Analysis of variance (ANOVA) has been implemented to study the effects of the studied design variables on the machining performance. It was found that 4 wt% MWCNTs nano-fluid decreases the surface roughness by 38% compared to the tests performed without nano-additives, while 2 wt% MWCNTs nano-fluids improve the surface quality by 50%.

73 citations

Journal ArticleDOI
TL;DR: A previous general assessment algorithm has been implemented to find the optimal and sustainable process parameters levels during machining Inconel 718 with MQL-nano-fluids and it has been found that the assessment algorithm results were in agreement with the physical findings of the conducted experimental results.

69 citations

References
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Journal ArticleDOI
TL;DR: In this article, the authors investigated the increase of thermal conductivity with temperature for nano fluids with water as base fluid and particles of Al 2 O 3 or CuO as suspension material.
Abstract: Usual heat transfer fluids with suspended ultra fine particles of nanometer size are named as nanofluids, which have opened a new dimension in heat transfer processes. The recent investigations confirm the potential of nanofluids in enhancing heat transfer required for present age technology. The present investigation goes detailed into investigating the increase of thermal conductivity with temperature for nano fluids with water as base fluid and particles of Al 2 O 3 or CuO as suspension material. A temperature oscillation technique is utilized for the measurement of thermal diffusivity and thermal conductivity is calculated from it

2,177 citations


"Grinding of Ti-6Al-4V Under Small Q..." refers background in this paper

  • ...Their thermal properties were also found to be more effective as compared to synthetic and mineral oil based lubricants; Al2O3 nanofluid in particular was found to have temperature-dependent properties that proved to be effective at elevated temperatures generated while grinding ductile cast iron [22]....

    [...]

Journal ArticleDOI
TL;DR: In this article, the main problems associated with the machining of titanium as well as tool wear and the mechanisms responsible for tool failure are discussed. But no equivalent development has been made for cutting titanium alloys due primarily to their peculiar characteristics.

1,417 citations


"Grinding of Ti-6Al-4V Under Small Q..." refers background in this paper

  • ...To deal with these challenges, operators are forced to maintain benign grinding parameters [1], unless special measures are taken....

    [...]

  • ...Reduced tool life and poor grinding ratio have been observed by multiple researchers over the years [1,2]....

    [...]

Journal ArticleDOI
TL;DR: In this paper, a detailed analysis and adaptation of cutting parameters, cutting tools, machine tools and the production environment is mandatory to ensure an efficient process and successfully enable dry machining.

812 citations


"Grinding of Ti-6Al-4V Under Small Q..." refers background in this paper

  • ...A major step toward this is the effort to ensure minimal consumption of metal working fluid, which often poses to be a disposal problem and hence an environmental and health hazard [4,5]....

    [...]

Journal ArticleDOI
TL;DR: Together, these results imply that the geometry, agglomeration state, and surface resistance of nanoparticles are the main variables controlling thermal conductivity enhancement in nanofluids.
Abstract: In recent years many experimentalists have reported an anomalously enhanced thermal conductivity in liquid suspensions of nanoparticles. Despite the importance of this effect for heat transfer applications, no agreement has emerged about the mechanism of this phenomenon, or even about the experimentally observed magnitude of the enhancement. To address these issues, this paper presents a combined experimental and theoretical study of heat conduction and particle agglomeration in nanofluids. On the experimental side, nanofluids of alumina particles in water and ethylene glycol are characterized using thermal conductivity measurements, viscosity measurements, dynamic light scattering, and other techniques. The results show that the particles are agglomerated, with an agglomeration state that evolves in time. The data also show that the thermal conductivity enhancement is within the range predicted by effective medium theory. On the theoretical side, a model is developed for heat conduction through a fluid containing nanoparticles and agglomerates of various geometries. The calculations show that elongated and dendritic structures are more efficient in enhancing the thermal conductivity than compact spherical structures of the same volume fraction, and that surface (Kapitza) resistance is the major factor resulting in the lower than effective medium conductivities measured in our experiments. Together, these results imply that the geometry, agglomeration state, and surface resistance of nanoparticles are the main variables controlling thermal conductivity enhancement in nanofluids.

700 citations


"Grinding of Ti-6Al-4V Under Small Q..." refers background in this paper

  • ...But this lubrication mechanism seemed to be impaired in the test results due to its tendency to form agglomerates having fractal/dendritic shapes over time, which happened without compromising the stability of the nanofluid [27]....

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Journal ArticleDOI
TL;DR: An experimental study of the shear-banding phenomenon in the concentrated wormlike micellar system CTAB at 20wt.% in D2O confirms the studies performed previously and investigates possible causes for three-dimensional instability.
Abstract: We report on an experimental study of the shear-banding phenomenon in the concentrated wormlike micellar system CTAB at 20 wt. % in D2O. Time-resolved velocity profiles are recorded using ultrasonic velocimetry simultaneously to global rheological data. Our results confirm the studies performed previously by Fischer and Callaghan (Phys. Rev. E 64, 011501 2001). Time averaged velocity profiles display an unsheared “nematic gel.” In the range of applied shear rate, the flow field exhibits very fast temporal fluctuations. Suspicions for the presence of three-dimensional flow are evidenced and possible causes for a three-dimensional instability are discussed together with the coupling of wall slip to bulk dynamic.

349 citations