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Journal ArticleDOI

High-speed machining of aluminium alloy using vegetable oil based small quantity lubrication:

16 Jun 2020-pp 095440542092978

Abstract: In an attempt to investigate the effectiveness of vegetable oil based small quantity lubrication in high-speed machining of aluminium, this study finds that its usefulness is more significant in an...
Topics: Aluminium alloy (57%), Lubrication (56%), Aluminium (55%), Vegetable oil (55%), Machining (54%)
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Journal ArticleDOI
Sarthak Prasad Sahoo1, Saurav Datta1Institutions (1)
Abstract: The present study examines dry machining performance of AA7075 T6 alloy using uncoated and MT-CVD TiCN–Al2O3-coated carbide inserts. Machining performance is assessed with regard to tangential cutting force, tool tip temperature and depth of flank wear. The performance of coated tool is compared to that of uncoated insert. In addition, different modes of tool wear and chip morphology are studied in detail. It is experienced that coated tool causes lower tool tip temperature and lesser flank wear than untreated counterpart. Apart from abrasion, adhesion and built-up layer formation; attrition wear is distinctly visible in case of uncoated tool. On the contrary, in addition to common wear modes, coated tool also experiences diffusion wear.

2 citations

Journal ArticleDOI
Balakrushna Guntreddi1, Amitava Ghosh1Institutions (1)
Abstract: Current study investigates tribo-phenomena at sliding interface of Al2124-17SiCp disc and WC-6Co pin and explores suitability of nano-oil aerosols as lubricants They form chip-tool tribo-pair in machining Ploughing, adhesion, abrasion were predominant under dry sliding Adhesion and friction-coefficient (COF) were severer with higher normal load and lower sliding velocity Aerosol of palm-oil arrested adhesion of aluminium on carbide pin and reduced COF by 80–82% through film-lubrication but at low load conditions Diamond/graphite nanoparticles (1 wt%) suspension helped palm-oil sustain film-lubrication at sliding interface even in extreme conditions, reducing COF further and arresting adhesion phenomenon Rolling of near-spherical nano-diamonds or basal-plane shearing within graphite nano-platelets caused additional reduction in friction Graphite nano-aerosol was superior and similarly effective in high-speed milling as SQL-medium

1 citations

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Journal ArticleDOI
01 Jan 2004-CIRP Annals
Abstract: Modern machining processes face continuous cost pressures and high quality expectations. To remain competitive a company must continually identify cost reduction opportunities in production, exploit economic opportunities, and continuously improve production processes. A key technology that represents cost saving opportunities related to cooling lubrication, and simultaneously improves the overall performance of cutting operations, is dry machining. The elimination of, or significant reduction in, cooling lubricants affects all components of a production system. 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.

731 citations

Journal ArticleDOI
Abstract: This paper presents the effects of minimum quantity lubrication (MQL) by vegetable oil-based cutting fluid on the turning performance of low alloy steel AISI 9310 as compared to completely dry and wet machining in terms of chip–tool interface temperature, chip formation mode, tool wear and surface roughness. The minimum quantity lubrication was provided with a spray of air and vegetable oil. MQL machining was performed much superior compared to the dry and wet machining due to substantial reduction in cutting zone temperature enabling favorable chip formation and chip–tool interaction. It was also seen from the results that the substantial reduction in tool wears resulted in enhanced the tool life and surface finish. Furthermore, MQL provides environment friendliness (maintaining neat, clean and dry working area, avoiding inconvenience and health hazards due to heat, smoke, fumes, gases, etc. and preventing pollution of the surroundings) and improves the machinability characteristics.

327 citations

Journal ArticleDOI
Abstract: In metal industries, the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. But the use of cutting fluid generally causes economy of tools and it becomes easier to keep tight tolerances and to maintain workpiece surface properties without damages. Because of them some alternatives has been sought to minimize or even avoid the use of cutting fluid in machining operations. Some of these alternatives are dry machining and machining with minimum quantity of lubrication (MQL). This paper deals with experimental investigations in the role of MQL on cutting temperature, chip formation and product quality in turning AISI-1040 steel at different industrial speed-feed combinations by uncoated carbide insert. The results have been compared with dry machining and machining with soluble oil as coolant. The experimental results indicate that such MQL enables substantial reduction in the cutting temperature, dimensional inaccuracy depending upon the levels of the cutting velocity and feed rate. It was also noted that the chip formation and chip–tool interaction become more favorable under MQL condition. Therefore, it appears that MQL, if properly employed, not only provides environment friendliness but can also improve the machinability characteristics.

295 citations

Journal ArticleDOI
Abstract: The increasing attention to the environmental and health impacts of industrial activities by governmental regulations and by the growing awareness level in the society is forcing industrialists to reduce the use of mineral oil-based metalworking fluids as cutting fluid. Cutting fluids have been used extensively in metal cutting operations for the last 200 years. In the beginning, cutting fluids consisted of simple oils applied with brushes to lubricate and cool the machine tool. As cutting operations became more severe, cutting fluid formulations became more complex. There are now several types of cutting fluids in the market and the most common types can be broadly categorized as cutting oils or water-miscible fluids. In this review, the applicability of vegetable oil-based metalworking fluids in machining of ferrous metals has been undertaken. The advantages of metalworking fluids and its performances with respect to the cutting force, surface finish of work piece, tool wear and temperature at the cutting zone have been investigated. It has been reported in various literature that metalworking fluids, which are vegetable oil-based, could be an environmentally friendly mode of machining with similar performance obtained using mineral oil-based metalworking fluids.

246 citations

Journal ArticleDOI
P. S. Sreejith1Institutions (1)
31 Jan 2008-Materials Letters
Abstract: This paper reports on the effect of different lubricant environments when 6061 aluminium alloy is machined with diamond-coated carbide tools. The effect of dry machining, minimum quantity of lubricant (MQL), and flooded coolant conditions was analyzed with respect to the cutting forces, surface roughness of the machined work-piece and tool wear. The three types of coolant environments are compared. It is found that MQL condition will be a very good alternative to flooded coolant/lubricant conditions. Therefore, it appears that if MQL properly employed can replace the flooded coolant/lubricant environment which is presently employed in most of the cutting/machining applications, thereby not only the machining will be environmental friendly but also will improve the machinability characteristics.

176 citations