Achieving clean production with nanostructured coated milling tools dry machining low carbon steel

Jackson, M.J.; Robinson, G.M.; Whitt, M.D.; da Silva, R.B.; da Silva, M.B.; Machado, A.R.

doi:10.1016/j.jclepro.2023.138523

Cited by 6 publications

(1 citation statement)

References 49 publications

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“…The introduction of new technologies in the field of base material processing has led to a significant improvement in the physical and mechanical characteristics of processed workpieces. The new technology based on cathode-arc evaporation, although it does not completely exclude the possibility of droplets appearing in films, still plays an important role in surface modification [40][41][42]. These features make it possible to create interfaces for automated drill design systems without additional processing of working surfaces.…”

Section: Introductionmentioning

confidence: 99%

Computer-aided design system for a drill with an improved shape of the flunk surface

Pivkin,

Ershov,

Grechishnikov

et al. 2023

Advanced Laser Processing and Manufacturing VII

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In this paper, a new system for designing drills with a full parametric cycle of connection of the main parameters of the rear surface of the drill, based on the identified functional relationships between the parameters of the original tool surface and the kinematics of the movement of the drill tooth. For the first time, a mechanism for determining the shape of the back surface of a three-tooth drill with the possibility of regrinding by various methods has been established. This work will allow not only to develop design support for tool production, but also to create a system for the automatic production of three-tooth drills and writing control programs for CNC machines. The work is the first to propose an analytical mathematical model for solving the solve problem of profiling the helical groove of a twist drill and cutting edges, which is the main stage in the design of a new class of drills with a toroidal cutting surface. For the first time, a study of the field of change in the rake angle and the normal rake angle in the region of the generating surface was carried out. As a result, it was found that in the f range from [-1.2; 1] the normal rake angle γN for almost the entire length of the section takes values in the range [20°; 32°], with a displacement of the cutting edge f by a distance of 2.8 mm, it will be possible to obtain the geometry of the helical surface on the cutting surface in a constant range from 32° with a tolerance range of 2°.

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Section: Introductionmentioning

confidence: 99%

Computer-aided design system for a drill with an improved shape of the flunk surface

Pivkin,

Ershov,

Grechishnikov

et al. 2023

Advanced Laser Processing and Manufacturing VII

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Investigating the performance of the pressurized injection lubrication technique in the turning process

Elsadek

2024

Int J Adv Manuf Technol

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Efficient lubrication and cooling are crucial in machining operations to enhance tool life and workpiece quality. Sustainable methods like minimum quantity lubrication (MQL) and dry cutting often face limitations in cooling efficiency and chip evacuation, especially under high-speed conditions or when machining difficult-to-cut materials such as stainless steel. This study introduces the novel pressurized injection lubrication (PIL) technique designed to address these challenges by optimizing lubrication, cooling, and chip evacuation during the turning operations of stainless steel 304. Using flaxseed oil as the lubricant, the PIL system employs a 0.26 mm stream diameter at a pressure of 16 bar to provide the necessary cooling and lubrication to the cutting zone. Cutting temperature and surface roughness were selected as the primary responses. Experimental runs were designed using the Taguchi L9 method. Analysis of variance showed that the lubrication method significantly affected the cutting temperature, with a contribution percentage approaching 94%. The experimental results demonstrated that PIL reduced the cutting temperature by up to 55%, while MQL reduced it by about 48%, both compared to dry cutting at the highest utilized speed. The lubrication method was also found to be the most significant factor affecting surface roughness, with a contribution percentage of 72.8%. Experimentally, PIL improved surface roughness by a maximum of 16.2% compared to MQL. Additionally, PIL maintained low oil consumption (0.9 l/h) and energy usage (< 0.017 kWh). The cost-effective PIL setup, priced under 65 USD, underscores its potential as a sustainable and efficient alternative for machining processes. The system’s components are readily available, facilitating easy integration into existing metal-cutting machines. Finite element analysis (FEA) modeling was used to predict residual stresses under different lubrication methods. The FEA model indicated that PIL and MQL reduced residual stresses by about 81.2% and 76.6%, respectively, compared to dry cutting at a speed of 500 rpm. These findings suggest that PIL can significantly enhance machining performance and sustainability, offering a viable solution to modern manufacturing challenges.

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Machinability performance of bio-degradable hybrid nano-cutting fluid for sustainable manufacturing: analytical and soft computing modelling

Chenrayan,

Shahapurkar,

Manivannan

et al. 2024

Int J Adv Manuf Technol

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Achieving clean production with nanostructured coated milling tools dry machining low carbon steel

Cited by 6 publications

References 49 publications

Computer-aided design system for a drill with an improved shape of the flunk surface

Computer-aided design system for a drill with an improved shape of the flunk surface

Investigating the performance of the pressurized injection lubrication technique in the turning process

Machinability performance of bio-degradable hybrid nano-cutting fluid for sustainable manufacturing: analytical and soft computing modelling

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