Eco-green machining of superalloy A286: Assessment of tool wear morphology and surface topology

Musavi, Seyed Hasan; Davoodi, Behnam; Niknam, Seyed Ali

doi:10.1177/0954405421995618

Cited by 17 publications

(3 citation statements)

References 37 publications

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“…Tool wear morphology is the main machinability aspect [41,42]. Therefore, novel research about the accurate conception of the in uences of nano uid-based lubricants on machining e ciency is asked.…”

Section: -2-1-tool Wear Morphology and Surface Chemistrymentioning

confidence: 99%

A challenging study on compatibility or incompatibility of vegetable-based lubricant with human health

Musavi,

Davoodi

2024

Int J Adv Manuf Technol

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More than 70% of industrial lubricant waste releases into nature after a period of utilization without any ltration stage. Knowing environmental concerns and increasing regulations over pollution, the request to use risk-free lubricant is irrefutable. One of these lubricants is vegetable-based cutting uid (VBCF), which has recently attracted attention. The present work has tried to study the compatibility or incompatibility of VBCF with human health and provide a method for eliminating or reducing their potential risks. To achieve this goal, a study on one of the most known, destructive, and accessible microbes (Pseudomonas) in the workshop environment was performed. The results showed that Pseudomonas could multiply in solid and liquid mediums, and its colonies could quickly propagate in VBCF. Therefore, as a signi cant achievement in this study, unreinforced VBCF is not a suitable selection from a health point of view. Although these cutting uids are introduced as a compatible lubricant with humans and the environment, bacteria and mold can multiply swiftly without apparent alterations. It was also observed that using nanoparticles like copper-oxide with a speci c volume fraction (0.4%) could ght with the bio lm of Pseudomonas to destroy the colonies at the initial time of their formation. Scanning Electron Microscope (SEM) images and Energy-Dispersive X-ray spectroscopy (EDX) analysis also studied the machinability attributes. The machining tests indicated that the nano uid also greatly impacts the control of tool wear mechanisms and surface quality in A286 superalloy machining. 1-IntroductionSigni cant heat is produced during the machining of superalloys and other di cult-to-cut materials, drastically decreasing the tool life [1, 2]. Therefore, cutting uid (CF) is utilized to reduce the cutting temperature during the process [3, 4]. In general, cutting uid is applied to improve the e ciency and performance of cutting operations [5]. The main advantages of cutting uid application are reducing the heat, increasing tool life, improving surface nish, preventing adhered-chip formation on the tool face (especially in alloys of which adhesive wear is the dominant mechanism), and facilitating chip removal of the cutting area [6]. Though different CFs utilized in the machining industry, mineral-based cutting uids (MBCFs-approximately 85% of used oil) are the most widely used ones. Some scientists reported the worldwide consumption of 2.4 million tons of different cutting uids per year [7, 8]. Besides, the annual consumption of MBCFs in the European Union is around 320 thousand tons. Furthermore, more than twothirds of the used oils deliver to nature without a ltration process [9]. However, the use of cutting uids creates some di culties and limitations, including environmental issues, operator health problems, as well as high costs (purchase and maintenance) due to unstable crude oil derivatives (approximately 17% of the total cost of cutting processes) [10,11].In practice, all CFs utilized in machining industries are...

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Section: -2-1-tool Wear Morphology and Surface Chemistrymentioning

confidence: 99%

A challenging study on compatibility or incompatibility of vegetable-based lubricant with human health

Musavi,

Davoodi

2024

Int J Adv Manuf Technol

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“…Wear behavior of cutting tool is an important indicator for evaluating the machinability of workpiece material, which is also the focus of researches in the field of processing. [16][17][18][19] Then wear behaviors, such as the abrasive wear, adhesive wear, diffusion wear, and oxidation wear on the rake face and flank face of cutting tools, are usually experimentally studied. [20][21][22] Scanning electron microscope (SEM) and energy dispersion spectrum (EDS) are usually conducted to analyze the micrograph of worn area.…”

Section: Introductionmentioning

confidence: 99%

Study on the tool life analysis for free-cutting steels

Zhang

Yang

Tang

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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Experimental study and theoretical calculation on the tool lives of free-cutting steels with different additions were carried out in terms of the friction characteristics, chip deformation, and normal stress distribution. The average friction coefficient, shear angle, and maximum normal stress were then calculated, and the influence of them on tool life was analyzed and discussed carefully. The free-cutting steel with Bi addition (MB) presented the best tool life of about 9200 and 5200 s at the speed of 150 and 200 m/min, respectively, which was mainly due to the combined effect of the lower average friction coefficient, maximum normal stress, and higher shear angle. When the cutting speed increased to 300 m/min, the tool life decreased rapidly, which was mainly caused by the serious tool wear behavior dominated by the high cutting temperature. Differing from the calculated results of shear angles based on Lee and Shaffer’s assumption, the measured shear angles decreased with the cutting speed ranging from 150 to 250 m/min, resulting from the thermal softening of workpiece material during machining. Moreover, the present findings indicated that the cutting process became unstable when the maximum normal stress on the tool nose was larger than 2 GPa, where catastrophic failures occurred, resulting in accelerated fracture of the tool. The research findings not only give more insight into the effect of friction characteristics, chip deformation, and normal stress distribution on the tool lives, but also have significance for the machining of free-cutting steels.

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“…Although cutting fluids present significant benefits, it can not always be considered the first solution for tool wear reduction. Using cutting fluid in the machining of soft materials (e.g., aluminum alloys) may change the angle of cutting edges by creating a built-up edge [7,8].…”

Section: Introductionmentioning

confidence: 99%

Study the Effects of Micro-Textured Cutting Tool on Surface Quality and Tool Wear when Machining Aluminium Alloy 7075-T6

Musavi

Sepehrikia

Niknam

et al. 2021

Preprint

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Due to the wide applications of aluminum alloy in numerous industrial sectors and products, significant attention has been paid by many researchers to improve the production and manufacturing aspects of aluminium alloys and related products. One of the main concerns in this regard is the cutting tool life when machining aluminium alloys. This work aims to present the capability and performance of a new strategy of life improvement in the tungsten carbide inserts by creating micro-textured grooves on their surface. For this purpose, the laser was used to create the different morphologies of textures on the insert surfaces. The grooves were created with different distances in parallel to the cutting edge on the tool rake face. The effects of fabricated grooves on the tool wear attributes were discussed in three directions, including the main edge (x-direction), side edge (y-direction), and radial (in the direction of 45 degrees) and the effect of these grooves/textures on the surface roughness attributes were also studied. To that end, experimental works were performed under dry and minimum quantity lubrication (MQL), as well as three levels of cutting speed, feed rate, and grooves distance. The experimental results were compared with those measured under non-textured inserts. Finally, the obtained results were statistically analyzed, and the empirical models were formulated. Experimental results indicated that micro-textured inserts in both MQL and dry conditions led to surface quality and tool wear as compared to readings made under non-textured inserts.

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Eco-green machining of superalloy A286: Assessment of tool wear morphology and surface topology

Cited by 17 publications

References 37 publications

A challenging study on compatibility or incompatibility of vegetable-based lubricant with human health

A challenging study on compatibility or incompatibility of vegetable-based lubricant with human health

Study on the tool life analysis for free-cutting steels

Study the Effects of Micro-Textured Cutting Tool on Surface Quality and Tool Wear when Machining Aluminium Alloy 7075-T6

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