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Journal ArticleDOI

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

29 Jul 2011-Wear (Elsevier)-Vol. 271, Iss: 9, pp 2412-2416
TL;DR: In this paper, 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, is reported.
About: This article is published in Wear.The article was published on 2011-07-29. It has received 63 citations till now. The article focuses on the topics: Tool wear & Machining.
Citations
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Journal ArticleDOI
TL;DR: 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..

349 citations

Journal ArticleDOI
TL;DR: In this paper, 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.

260 citations

Journal ArticleDOI
TL;DR: In this paper, the authors have reviewed the current state of the art in MQL with a particular focus on drilling, turning, milling and grinding machining operations and concluded that MQL has huge potential as a substitute for conventional flood cooling.
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.

155 citations


Cites background or result from "Study of dry and minimum quantity l..."

  • ...- 19 Figure 11: Effect of cooling conditions on (a) average torque, (b) average force, (c) average surface roughness and (d) flank wear width [88]....

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  • ...drilling of ADI was conducted under dry, flood and MQL conditions by Meena and Mansori [88] with MQL being found to offer good machining performance in terms of average torque, average thrust force, average surface roughness and flank wear width, although not to the same extent as those obtained from conventional flood cooling (Figure 11)....

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Book ChapterDOI
01 Jan 2013
TL;DR: This chapter has also focused on environmental conscious machining such as dry cutting, machining with minimum quantity lubricant and especially machine with vegetable based cutting fluids including other types of 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

98 citations


Cites background from "Study of dry and minimum quantity l..."

  • ...It was found in the literature that surface roughness, torque, force and tool wear of MQL drilling of austempered ductile iron were lower than that of dry drilling but higher than flooding [45]....

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Journal ArticleDOI
TL;DR: In this article, 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.

73 citations

References
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Journal ArticleDOI
TL;DR: In this paper, the authors present an investigation into various methods of cutting fluid application with the objective of deriving the optimum cutting condition for the drilling of cast aluminium alloys, under varying conditions of cutting speed and feed.

218 citations

Journal ArticleDOI
TL;DR: In this article, the authors used a heat treatment process consisting of austempering and subsequent isothermal tempering below the inter critical (A 1 ) temperature of ductile cast iron, which resulted in a fully ferritic microstructure.
Abstract: The primary goal of this investigation was to create austempered ductile cast iron (ADI) with a fully ferritic microstructure without compromising its mechanical properties. This was achieved by applying a novel heat treatment process. This process consists of austempering and subsequent isothermal tempering below the inter critical ( A 1 ) temperature of ductile cast iron. Ductile cast iron samples were initially austenitized at 927 °C (1700 °F) for 2 h and then austempered at three different temperatures 260 °C (500 °F), 316 °C (600 °F) and 385 °C (725 °F) and finally isothermally tempered at 484 °C (900 °F) for 2 h. This resulted in a fully ferritic microstructure. The effect of this tempering on the physical and mechanical properties of the material was examined and compared with conventionally processed ADI. Tests results show that when ADI is austempered at 260 °C (500 °F) and subsequently tempered at 484 °C (900 °F) it has significantly better mechanical properties than the samples initially austempered at other two temperatures (i.e. 316 °C (600 °F) and 385 °C (725 °F)).

78 citations

Journal Article
TL;DR: In this paper, the role of minimum quantity lubrication (MQL) on cutting temperature, tool wear, surface roughness and dimensional deviation in turning of AISI-4340 steel at industrial speed-feed combinations by uncoated carbide insert was investigated.
Abstract: Normal 0 21 false false false TR X-NONE X-NONE MicrosoftInternetExplorer4 In all machining processes, tool wear is a natural phenomenon and it leads to tool failure. The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Metal cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions but the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. 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. Due to these problems, 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 lubrication (MQL). This paper deals with the experimental investigation on the role of MQL on cutting temperature, tool wear, surface roughness and dimensional deviation in turning of AISI-4340 steel at industrial speed-feed combinations by uncoated carbide insert. The encouraging results include significant reduction in tool wear rate, dimensional inaccuracy and surface roughness by MQL mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction. Key Words : MQL, tool wear, surface roughness and dimensional deviation

76 citations

Journal ArticleDOI
TL;DR: In this paper, a series of multi-layered interfaces consisting of TiAl, TiN and TiAlN was investigated to improve the adhesion strength of (Ti,Al)N deposited on high-speed steel substrates.
Abstract: With improved microhardness and high temperature resistance, the advanced (Ti,Al)N hard coating has now been successfully applied to carbide tools for high speed machining, although problems with adhesion at the interface are inevitable when the (Ti,Al)N hard coating is applied to high-speed steel cutting tools. This study investigated a series of multi-layered interfaces consisting of TiAl, TiN and TiAlN in an effort to improve the adhesion strength of (Ti,Al)N deposited on high-speed steel substrates. Deposition of both interlayer and (Ti,Al)N films was conducted sequentially in a single batch process, while cathodic arc evaporation was selected as the deposition method for its superior plasma intensity and the flexibility of multiple target arrangement. Microstructure and tribological properties were analyzed by scanning electron microscopy/electron diffraction spectroscopy, particle analyzer, microhardness and wear testers. Results indicated that a combination of TiN and TiAlN interlayers provided an adhesion strength of 50 N between (Ti,Al)N and M2 substrates. The tribological performance of (Ti,Al)N thin films on high-speed steel cutting tools was significantly improved.

63 citations

Journal ArticleDOI
TL;DR: In this paper, the authors demonstrate that the data of ADI from numerous sources have a similar trend and demonstrate that a key factor controlling the stability of the retained austenite can be evaluated soundly using the thermodynamics principles.

41 citations