High-speed machining of aluminium alloy using vegetable oil based small quantity lubrication:
16 Jun 2020-pp 095440542092978
TL;DR: In an attempt to investigate the effectiveness of vegetable oil based small quantity lubrication in high-speed machining of aluminium, this paper found that its usefulness is more significant in an...
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...
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TL;DR: The most important aspect of sustainability in manufacturing is the preservation of energy and natural resources as discussed by the authors , which can be achieved by increasing energy efficiency through low, clean, and renewable energy consumption.
Abstract: The most important aspect of sustainability in manufacturing is the preservation of energy and natural resources. For modern production, optimized processes that minimize negative impacts on the environment are becoming increasingly important. This can be achieved by increasing energy efficiency through low, clean, and renewable energy consumption. There are many ways to produce less pollution, emissions, and waste in machining: by using more environmentally friendly cooling methods; by applying methods that reduce or eliminate the need for utilization of cooling lubrication; improving the energy efficiency of machining operations; determining the optimal cutting conditions that save resources by increasing machining productivity or reducing the metal removal rate (MRR); minimizing power consumption; and reducing carbon dioxide emissions. This article gives an idea of modern manufacturing with a focus on analyzing the current state of machining operations in terms of saving production resources and ensuring more environmentally friendly production using greener cooling methods of machining such as Dry, Conventional cooling systems, Minimum quantity of lubricant (MQL), Minimum quantity of cooling lubrication (MQCL), Nanofluids, Biodegradable Vegetable Oils, Cryogenic Lubrication, and High-Pressure Cooling (HPC). Finally, the important modern trends of providing resource-saving and environmentally efficient technologies in modern sustainable manufacturing are discussed in this paper.
29 citations
TL;DR: In this article, the performance of AA7075 T6 alloy with uncoated and MT-CVD TiCN-Al2O3-coated carbide inserts is evaluated with regard to tangential cutting force, tool tip temperature and depth of flank wear.
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.
8 citations
TL;DR: In this article, the authors investigated tribo-phenomena at sliding interface of Al2124-17SiCp disc and WC-6Co pin and explored suitability of nano-oil aerosols as lubricants.
7 citations
12 Apr 2022-Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture
TL;DR: In this article , the effects of strontium (Sr) and magnesium (Mg) elements in certain rates added to Al-9Si alloy manufactured using permanent mold casting technique on the structural, mechanical, and machinability properties of these alloys were investigated.
Abstract: In this study, the effects of strontium (Sr) and magnesium (Mg) elements in certain rates added to Al-9Si alloy manufactured using permanent mold casting technique on the structural, mechanical, and machinability properties of these alloys were investigated. While microstructural images of the alloys were obtained with an optical microscope, hardness, tensile strength, and elongation to fracture were determined by conventional methods. The resultant cutting force (F) and average surface roughness (Ra) were measured as experimental outputs in the turning process. It was observed that Al-9Si alloy comprised of α-Al, eutectic Al-Si, β, and primary Si phases. The addition of Sr to the Al-9Si alloy led to the formation of the Al4Sr phase and the transformation of the β phase into the δ phase. The addition of Mg to Al-9Si-0.1Sr alloy caused the δ phase to transform into the π phase. The hardness of the tested alloy increased significantly with the Mg addition. The yield strength and tensile strength of them increased with both Sr and Mg additions. On the other hand, elongation to fracture value of the Al-9Si alloy increased with Sr addition while it decreased with the Mg addition. The F and Ra values obtained from the Al-9Si alloy increased with Sr addition in the turning process while decreased with Mg addition. The results obtained from turning tests were discussed based on the mechanical properties of alloys.
3 citations
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TL;DR: In this article, the effects of carbide materials on cutting edge fracture mechanism of micro end mill in aluminum alloy 7075 machining are investigated, and the results showed that the Co content and WC grain size of cemented carbides have significant effects on tool wear and cutting performance.
Abstract: The effects of cemented carbide materials on cutting edge fracture mechanism of micro end mills in aluminum alloy 7075 machining are investigated. A series of micro milling experiments on the tool wear were conducted. The surface morphologies of micro end mills were observed, and the end teeth flank wear length and tool total cutting edge length reduction were measured. The results showed that the Co content and WC grain size of cemented carbides have significant effects on tool wear and cutting performance of the micro end mill. With increase of WC grain size, the tool end teeth flank wear length increases and the total cutting edge length reduction of the mill obviously increases. Thus, the micro end mill with finer grain size presents better wear resistance. However, with increase of Co content, the micro end mill exhibits less wear resistance. This can be explained that the adsorption energy between Co atom and Al atom become larger based on first principle calculation of adsorption energy between cemented carbides and aluminum alloy. The Co binder of tool material is dragged off by frequent fall off of built-up edge, resulting in more loss of Co element. Thus, the strength of the tool is decreased.
10 citations
TL;DR: Results of this research show that the more volume of cutting tool involved into the workpiece, the smaller the SCE produced, and optimal setting for sustainability target could be obtained through the established model.
Abstract: Sustainability is a growing interest in basic industry. The ultimate goal for manufacturing industry is environmental releases, and sustainable development. By reducing energy consumption, economic and environmental performance can be significantly improved for the manufacturing systems. In this paper, the cutting force and specific cutting energy (SCE) consumption are evaluated based on the calculated material removal volume. Three different cutting tool geometries, including the C-, D-, and T-shaped turning indexable tools, are examined to investigate how cutting tool geometry affects the cutting force and SCE. Experimental research and theoretical modeling analysis have been conducted. Statistical analysis for theoretical and experimental SCE has been conducted to extract the effect of each factor on variation. Results of this research show that the more volume of cutting tool involved into the workpiece, the smaller the SCE produced. Optimal setting for sustainability target in terms of minimum cutting energy being consumed could be obtained through the established model.
10 citations
TL;DR: In this article, a small-diameter polycrystalline diamond (PCD) end-mill was fabricated and utilized in micro-milling, and the wear characteristics of the rake face and flank face were analyzed using scanning electron microscope (SEM) and energy dispersive X-ray (EDX) spectroscopy.
Abstract: Small-diameter end-mill is a key element for micro-machining technique. It is a new attempt to manufacture a small-diameter tool with polycrystalline diamond (PCD), which is also a hot issue in the research area of micro-manufacturing. PCD end-mills with small-diameter were fabricated and utilized in micro-milling. With a contact simulation model, the stress distribution and potential crack propagation of the PCD tool was revealed via 2D finite element (FE) analysis of 2Al2 aluminum alloy acting on the tool surface. Thereafter, a series of machining experiments on 2A12 micro-part were carried out with the PCD small-diameter end-mill. The wear characteristics of the rake face and flank face were analyzed, and the wear mechanisms of small-diameter end-mills were carefully investigated by using scanning electron microscope (SEM) and energy dispersive X-ray (EDX) spectroscopy. Three typical breakage morphologies of PCD end-mills were demonstrated while machining the aluminum alloy workpiece, i.e., the breakage of the tool tip, the edge chipping, and the peeling off of PCD layer. The consequent experiment results showed that abrasive wear, adhesive wear, and oxidative wear were the predominant characteristics in the damage region of PCD small-diameter end-mill. The effect mechanisms of various wear characteristics were also analyzed and revealed in detail. The experimental results were discussed according to the simulation results and effects on failure behavior of the PCD tool. The research can provide a better understanding for the wear and breakage behaviors of the downsized PCD tool in machining aluminum alloy and underpin the development of micro-milling process with diamond tool.
8 citations
TL;DR: In this article, the influence of cutting parameters (speed, feed and depth of cut) and its effect on the cutting force and the surface finish was presented. But, machining of Al and its alloy and finding the suitable tool is really a big challenge because of its formation of BUE (Built-up Edge) and BUL (Builtup Layer).
Abstract: Aluminium (Al) is the suitable material for aerospace and automotive industries due its light weight, corrosion resistance, weldability, non-magnetic and mechanical properties. But, machining of Al and its alloy and finding the suitable tool is really a big challenge because of its formation of BUE (Built-up Edge) and BUL (Built-up Layer). This paper presents the influence of cutting parameters (speed, feed and depth of cut) and its effect on the cutting force and the surface finish. Five different advanced cutting tool inserts (SPUN WC, SPGN WC, PCD, WC + TiN and WC + Ti(C, N) TiN + Al2O3) at different cutting speed (Vc) ranging between 300 m/min and 700 m/min and feed rate (f) of 0.045, 0.06, 0.09 and 0.125 mm/rev at a depth of cut of 0.2 mm (constant throughout the experiment) were taken for the experiment. Tool inserts were characterized by Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) analysis. The cutting forces were measured using Kistler force dynamometer. Amongst all tools, PCD provided a better result in all aspects but surprisingly WC tool provided a better surface finish with lesser tool wear. For all cutting conditions, high speed (670 m/min) and low feed rate (0.045 mm/rev) were recommended.
6 citations
TL;DR: In this paper, the machining performance of diamond-coated end mills was analyzed in the light of coating morphology, difference in intra-bond orbital hybridization, wettability and anti-frictional characteristics.
Abstract: The current study analyses machining performance of diamond coated end mills in the light of coating morphology, difference in intra-bond orbital hybridization, wettability and anti-frictional characteristics. Three different classes of diamond coatings, including a new generation nanocrystalline (NCD) coating, were chosen so that they do contain different intensity of sp 2 and sp 3 hybridisation in C C covalent bonding. The machining experiments were carried out in slot machining mode accomplished by two-fluted endmills and on aluminium and a silicon-free aluminium alloy, AA2024. sp 2 -rich hydrogenated DLC coating demonstrated outperformance in anti-frictional characteristics over its counter parts when tested against a sliding aluminium disc. The tribological performance of the sp 3 -rich NCD coating was superior to the sp 3 -hybridized microcrystalline diamond coating (MCD) but could not excel H-DLC coating. The difference in the hybridization level did not influence wettability towards the molten aluminium. However, the end mills having new generation NCD coating outperformed its counterparts at high speed machining conditions, establishing the supremacy over H-DLC coating, even over the MCD coating. The coating morphology including roughness played the most influencing role in favour of the machining performance, considering the ability to arrest built up layer (BUL) formation and to produce high surface finish of the machined work-surface.
6 citations