A sustainability comparison between conventional and high-speed machining

Al‐Ghamdi, Khalid A.; Iqbal, Asif

doi:10.1016/j.jclepro.2015.05.132

Cited by 29 publications

(11 citation statements)

References 30 publications

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“…Lastly, the average power required to drive the employed MQL system at the air pressure, oil mixing rate, and air flow rate of 0.6 MPa, 30 mL/h, and 0.4 L/s, respectively, is 418 Watts. The details regarding the calculations can be seen in Reference [35]. By adding the above calculated values of power requirements, the SCE values ranged from 57.6 to 82 J/mm 3 , 74.5 to 131 J/mm 3 , and 5.2 to 8.3 J/mm 3 , respectively, for CO 2 snow, LN 2 , and micro-lubrication.…”

Section: Specific Cutting Energy and Machining Forcesmentioning

confidence: 99%

“…Lastly, the effect of cutting speed on process cost was not very clear, as this predictor asserted its effects on all five constituents of PC in different ways. With regard to a continuous cutting process, it was reported that high-speed machining of Ti-6Al-4V yielded better surface finish and caused lower consumption of specific energy than conventional machining, but fared poorly with respect to the sustainability measures of tool life and process cost [35]. The graphs highlight a phenomenon that sets apart the cryogenic fluids from micro-lubrication.…”

Section: Process Costmentioning

confidence: 99%

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Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

Iqbal

Suhaimi

Zhao

et al. 2020

Metals

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Ti-6Al-4V, the most commonly used alloy of titanium, possesses excellent mechanical properties and corrosion resistance, which is the prime reason for the continual rise in its industrial demand worldwide. The extraordinary mechanical properties of the alloy are viewed as a hindrance when it comes to its shaping processes, and the process of milling is no exception to it. The generation of intense heat flux around the cutting zones is an established reason of poor machinability of the alloy and unacceptably low sustainability of its machining. The work presented in this paper attempts to enhance sustainability of milling Ti-6Al-4V by investigating the effects of milling orientation, cutter's helix angle, cutting speed, and the type of cryogenic coolant and lubricant on the sustainability measures, such as tool damage, cutting energy consumption, process cost, milling forces, and work surface roughness. It was found that micro-lubrication is more effective than the two commonly used cryogenic coolants (carbon dioxide snow and liquid nitrogen) in reducing tool wear, work surface roughness, process cost, and energy consumption. Furthermore, down-milling enormously outperformed up-milling with respect to tool wear, work surface quality, and process cost. Likewise, the high levels of cutter's helix angle and cutting speed also proved to be beneficial for milling sustainability.Metals 2020, 10, 258 2 of 25 environmentally [3]. The problem is generally negotiated either by lowering the material removal rates or by applying emulsion-based coolants, neither of which actually offers a sustainable solution.With regard to quashing the intense heat flux around the cutting areas, the application of cryogenic fluids, especially liquid nitrogen (LN 2 ), fares very well. The fluids offer a viable solution because of extremely low operational temperatures, no waste generation, and controllable flow rates. Additionally, application of micro-lubrication, also known as minimum quantity of lubrication (MQL), also proved to be very beneficial in enhancing tool life and improving surface quality in machining of titanium alloys conducted at medium cutting speeds [4,5]. MQL is a near-dry machining method in which a miniscule quantity of lubricating oil is pulverized into a stream of air, and the resulting aerosol is applied onto the cutting areas [6].Although steady progress is being made regarding quantification of the effects of cryogenic coolants with regard to the continuous machining processes, not much effort is being put up concerning interrupted machining processes, such as milling. Cryogenic milling is distinct from continuous machining processes performed under cryogenic environment in the sense that the cutting teeth of a milling tool periodically and rapidly engage and disengage with the work material, leading to cyclic heating (caused by thermal energy released by work material's plastic deformation) and cooling (caused by interaction with the incoming cryogenic fluid) of the cutting edges. Such a course is expected to induce...

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Section: Specific Cutting Energy and Machining Forcesmentioning

confidence: 99%

Section: Process Costmentioning

confidence: 99%

Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

Iqbal

Suhaimi

Zhao

et al. 2020

Metals

Self Cite

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“…They have described that texture features of the graylevel co-occurrence matrix appearing on machined part are strongly related to the machining time of the cutting tool. AlGhamdi and Iqbal (2015) have put forward a comparison between the phenomena of conventional machining and high-speed machining in the perspective of sustainability metrics such as tool life, specific energy consumption, productivity, process cost, and machining forces. It was reported that high-speed machining outperformed conventional machining in respect of productivity and energy consumption but could not perform better with respect to the other metrics.…”

Section: Literature Reviewmentioning

confidence: 99%

“…In this context, the current work aims to study the effects of using three levels of flank wear as tool life criterion in conjunction with those of cutting speed, feed rate, work material temper state, and MQL on the sustainability metrics, namely energy consumption, productivity, work surface finish, and process cost in milling of a cold work tool steel. The current work uses the same metrics, except machining forces, for evaluation of the process's sustainability as were used in the previous work (Al-Ghamdi and Iqbal, 2015). However, as the process investigated in this work is an intermittent cutting process, as compared to the continuous cutting process used in the previous work, the evaluation of the metrics is altogether different.…”

Section: Literature Reviewmentioning

confidence: 99%

Effects of tool life criterion on sustainability of milling

Iqbal

Al‐Ghamdi

Hussain

2016

Journal of Cleaner Production

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“…The authors in another work have presented a multi-objective analysis of energy consumption, process cost, and work surface roughness of a machining process based on optimization of cutting speed, feed rate, and depth of cut [3]. In a recent work, a comparison between tool life, process cost, productivity, and specific energy consumption has been provided [4]. Another work presents a model that optimizes cutting parameters for maximization of profit per unit energy consumption in a single pass turning process [5].…”

Section: Introductionmentioning

confidence: 99%

Revamping Grooving Process for Sustainability using Fuzzy Expert System

Iqba

2016

MATEC Web of Conferences

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Abstract. The article presents an application of a fuzzy expert system for renovating a metal cutting process to cope with the sustainability requirements. The work seeks a sustainable balance between energy consumption, productivity and tool damage. Cylindrical grooving experiments were performed to generate data related to quantification of the effects of material hardness, cutting speed, width of cut and feed rate on the aforementioned sustainability measures. A fuzzy knowledge-base was developed that suggests the most suitable adjustments of the controlled variables that would lead to achievement of various combinations of the objectives.

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A sustainability comparison between conventional and high-speed machining

Cited by 29 publications

References 30 publications

Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

Sustainable Milling of Ti-6Al-4V: Investigating the Effects of Milling Orientation, Cutter′s Helix Angle, and Type of Cryogenic Coolant

Effects of tool life criterion on sustainability of milling

Revamping Grooving Process for Sustainability using Fuzzy Expert System

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