Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718

Hegab, Hussien; Umer, Usama; Soliman, Mahmoud S.; Kishawy, Hossam A.

doi:10.1007/s00170-018-1825-0

Cited by 189 publications

(66 citation statements)

References 38 publications

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“…In addition, previous studies obtained better results when using MQL-nano-fluid compared to the classical MQL; for example, better surface quality [16] and flank wear [17] results were noticed when machining Ti-6Al-4V using MWCNTs-MQL. Furthermore, MWCNTs-MQL showed improvements in the tool wear behavior when turning Inconel 718 [18]. Moreover, lower cutting forces and better surface quality were noticed when turning EN 31, using MWCNTs-MQL [19].…”

Section: Introductionmentioning

confidence: 86%

“…It can be concluded that the proposed nano-fluids are atomized using the MQL device, under employment of a certain amount of compressed air. Consequently, a fine mist, walled with a vegetable oil layer is formed (see Figure 4) [16][17][18]32,33]. This mist is capable of penetrating into the tool-workpiece interfere area and creating a tribofilm which has a significant role in reducing the generated cutting heat, as well as decreasing the coefficient of friction.…”

Section: Resultsmentioning

confidence: 99%

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Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

Hegab

Kishawy

2018

JMMP

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Difficult-to-cut materials have been widely employed in many engineering applications, including automotive and aeronautical designs because of their effective properties. However, other characteristics; for example, high hardness and low thermal conductivity has negatively affected the induced surface quality and tool life, and consequently the overall machinability of such materials. Inconel 718, is widely used in many industries including aerospace; however, the high temperature generated during machining is negatively affecting its machinability. Flood cooling is a commonly used remedy to improve machinability problems; however, government regulation has called for further alternatives to reduce the environmental and health impacts of flood cooling. This work aimed to investigate the influence of dispersed multi-wall carbon nanotubes (MWCNTs) and aluminum oxide (Al 2 O 3 ) gamma nanoparticles, on enhancing the minimum quantity lubrication (MQL) technique cooling and lubrication capabilities during turning of Inconel 718. Machining tests were conducted, the generated surfaces were examined, and the energy consumption data were recorded. The study was conducted under different design variables including cutting speed, percentage of added nano-additives (wt.%), and feed velocity. The study revealed that the nano-fluids usage, generally improved the machining performance when cutting Inconel 718. In addition, it was shown that the nanotubes additives provided better improvements than Al 2 O 3 nanoparticles.

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Section: Introductionmentioning

confidence: 86%

Section: Resultsmentioning

confidence: 99%

Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

Hegab

Kishawy

2018

JMMP

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“…These effects were combined using the concept of velocity-modified temperature, and it was suggested that the flow stress for a particular material at a given strain can be assumed to be a unique function of this parameter. Hegab with his research team [29] investigated the effects of two types of nano-cutting fluids on tool performance and chip morphology during the turning of Inconel 718. Similarly, Adekunle et al [30] dealt with the chip morphology and behavior of tool temperature during the turning of AISI 301steel using different biodegradable oils.…”

Section: State Of the Artmentioning

confidence: 99%

Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels

Monková

Monka

Sekerakova

et al. 2019

Metals

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One of the phenomena that accompanies metal cutting is extensive plastic deformation and fracture. The excess material is plastically deformed, fractured, and removed from the workpiece in the form of chips, the formation of which depends on the type of crack and their propagation. Even in case of the so-called 'continuous' chip formation there still has to be a fracture, as the cutting process involves the separation of a chip from the workpiece. Controlling the chip separation and its patterning in a suitable form is the most important problem of the current industrial processes, which should be highly automated to achieve maximal production efficiency. The article deals with the chip root evaluation of two EN C45 and EN 16MnCr5 steels, focusing on the shear angle measuring and built-up edge observation as important factors influencing the machining process, because a repeated formation and dislodgement of built-up edge unfavorably affects changes in the rake angle, causing fluctuation in cutting forces, and thus inducing vibration, which is harmful to the cutting tool. Consequently, this leads to surface finish deterioration. The planing was selected as a slow-rate machining operation, within which orthogonal and oblique cutting has been used for the comparative chips' root study. The planned experiment was implemented at three levels (lower, basic, and upper) for the test preparation and the statistical method, and regression function was used for the data evaluation. The mutual connections among the four considered factors (cutting speed, cutting depth, tool cutting edge inclination, and rake angle) and investigated by the shear angle were plotted in the form of graphical dependencies. Finally, chips obtained from both steels types and within both cutting methods were systematically processed from the microscopic (chip root) and macroscopic (chip pattern) points of view.Metals 2019, 9, 956 2 of 27 of a machined surface are in many cases not achievable by mechanical working or casting processes, because the surfaces of the parts are adversely affected. This is why machining is needed.[3] Controlling the chip separation and its patterning in a suitable form is the most important problem of the current industrial processes, which should be highly automated to achieve maximal production efficiency.One of the phenomena that accompanies metal cutting is extensive plastic deformation and fracture. The excess material is plastically deformed, fractured, and removed from the workpiece in the form of chips, the formation of which depends on the type of crack and their propagation. Even in the case of so-called 'continuous' chip formation there still has to be a fracture, as the cutting process involves the separation of a chip from the workpiece. Chips at the machining are formed due to tearing and shearing, the workpiece material adjacent to the tool face is compressed and a crack runs ahead of the cutting tool and towards the body of the workpiece. Cutting takes place intermittently and there is no movement of the w...

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“…The comprised dry, wet, and minimum quantity lubrication (MQL) method was identified as the best cooling method for minimum tool wear and surface roughness [9]. Moreover, the fluid's content used in MQL has an influence on the chip morphology and tool performance [10]. In addition, changing tool materials is the most important way to improve tool performance.…”

Section: Introductionmentioning

confidence: 99%

Failure and Control of PCBN Tools in the Process of Milling Hardened Steel

Wang

Zhou

et al. 2019

Metals

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The polycrystalline cubic boron nitride (PCBN) milling tool can be used in the mold industry to replace cemented carbide tools to improve machining efficiency and quality. It is necessary to study the tool wear and failure mechanism to increase machining efficiency and extend tool life. Cr12MoV is used to analyze the failure form of PCBN tools in the interrupted cutting of hardened steels at low and high speed conditions in milling experiments. Experimental results show that the failure forms of PCBN tools include chipping and flank wear at low speed, and the failure modes at high speed are flank wear, the surface spalling of the rake face, and the fatigue failure on the flank face. The failure mechanism of different failure forms is analyzed by observing the surface morphology of the tool and using the theory of fracture mechanics. The results show that a high cutting speed should be selected to avoid the early damage of low speed and achieve better application of PCBN tools. At high cutting speed, tool failure is mainly caused by mechanical wear, diffusion wear, and oxidation wear. Moreover, a fatigue crack will occur at the cutting edge on the chamfered tool under thermal-mechanical coupling because of the intergranular fracture of the CBN grain and binder. A large area of accumulated fatigue damage may appear due to the influence of alternating mechanical stress and thermal stress. Finally, the control method to avoid tool failure is presented.Metals 2019, 9, 885 2 of 15 nitride (PCBN) cutting tools are the preferred tool material due to excellent mechanical properties of higher hardness strength and wear resistance than other tool materials at high temperature. They are frequently used in the turning of hard and wear-resistant materials, such as hardened steels, superalloy, and even ceramics [11][12][13][14]. Numerous studies investigate the machining performance and tool life in PCBN hard turning [15][16][17]. Progressive flank wear, micro-chipping, and tool breakage easily occur due to critical crater wear [18]. For different cutting tools and workpiece materials, cutting speed is the main factor affecting the tool life, and it usually has a critical value after which the tool life of the cemented carbide tool will be lower than the PCBN cutting tool.In recent years, scholars have focused on the research of milling using the PCBN cutting tool. The results show that with a smaller cutting force [19], better surface quality [20], and a higher volume of metal removal [21] can be obtained by using PCBN tools compared with carbide-coated tools in processing hardened steel materials.It is observed that surface roughness (Ra) is in the range of 0.2 to 0.3 µm using a PCBN ball end tool, compared with 0.4 to 0.6 µm using the cemented tungsten carbide tool, at the cutting speed of 400 m/min in the milling of DIEVAR tool steel [22]. For milling, there is still a speed below which the tool life of cemented carbide is less than the tool life of PCBN. The life of cemented carbide tools can be higher than that of PCBN to...

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Effects of nano-cutting fluids on tool performance and chip morphology during machining Inconel 718

Cited by 189 publications

References 38 publications

Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels

Failure and Control of PCBN Tools in the Process of Milling Hardened Steel

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