Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids

Shokrani, Alborz; Dhokia, Vimal; Newman, Stephen T.

doi:10.1016/j.ijmachtools.2012.02.002

Cited by 724 publications

(293 citation statements)

References 136 publications

(308 reference statements)

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“…Additionally, in the recent years, the increased environmental awareness and growing costs have led to a critical re-consideration of conventional cooling lubrication used in machining processes. The costs related to cutting fluids in a manufacturing operation range from 10% to 20% of the total costs of the manufactured workpiece, whereas some researchers have claimed that the costs associated with cutting fluids are higher than the cost of cutting tools (Shokrani et al, 2012). Most of these costs are primarily due to environmental requirements: handling of cutting fluids as well as their disposal must obey the strict rules of environmental protections.…”

mentioning

confidence: 99%

Analysis of a free machining α+β titanium alloy using conventional and ultrasonically assisted turning

Muhammad

Hussain

Maurotto

et al. 2014

Journal of Materials Processing Technology

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• This is the author's version of a work that was accepted for publication in the Journal of Materials Processing Technology. Changes resulting from the publishing process, such as peer review, editing, corrections, structural formatting, and other quality control mechanisms may not be reflected in this document. Changes may have been made to this work since it was submitted for publication.A definitive version was subsequently pub- enhanced machinability generating short chips during metal cutting, which prevents entanglement with cutting tools improving productivity. To further enhance the machinability of this material, a novel hybrid machining technique called ultrasonically assisted turning (UAT) was used. Experimental investigations were carried out to study the machinability, chip shapes, cutting forces, temperature in the process zone and surface roughness for conventional and ultrasonically assisted turning of both alloys. UAT shows improved machinability with reduced nominal cutting forces, improved surface roughness of the machined workpiece and generation of shorter chips when compared to conventional machining conditions.

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confidence: 99%

Analysis of a free machining α+β titanium alloy using conventional and ultrasonically assisted turning

Muhammad

Hussain

Maurotto

et al. 2014

Journal of Materials Processing Technology

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“…Titanium based alloys such as Ti-6Al-4V is readily regarded as difficult-to-machine or hard-to-cut materials (Shokrani et al, 2012). Ti-6Al-4V titanium alloy is often used in the aircraft industry due to the good compromise between mechanical resistance and tenacity, together with its low density and excellent corrosion resistance.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation on friction drilling of titanium alloy

Dehghan¹,

Ismail²,

Ariffin³

et al. 2018

10.5267/j.esm

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Friction drilling is a green hole-making process that zealously utilizes the heat generated from the friction between the rotating conical tool and workpiece to create a bushing without generating chip. The difficult-to-machine materials with unique metallurgical properties have been developed to meet the demands of extreme applications. However, the major challenges of friction drilling on difficult-to-machine materials are the hole diameter accuracy, petal formation and tool wear. In this study, the effects of process parameters such as spindle speed and feed rate on bushing height and shape, hardness and tool wear in friction drilling of titanium alloy Ti-6Al-4V were experimentally investigated using tungsten carbide tool. Optical photographs have also been analyzed for better understanding of the chipless friction drilling process for different parametric settings. Experimental results indicated that the spindle speed has great influences for achieving better bushing formation and prolong the tool life. It was confirmed that the low spindle speed and low feed rate have great influences for achieving better bushing shape and height, prolong tool life and lower hardness that located adjacent to the hole wall. It also was discovered that the low thermal conductivity of Ti-6Al-4V caused to improper increment of frictional heat and surface temperature. This disadvantage leads to unsatisfactory bushing formation. This work demonstrated the performances of chipless friction drilling used on difficult-to-machine material that can offer a great prospective for a new product design and manufacturing.

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“…Some of the alternative techniques, which can reduce or eliminate the use of the cutting fluids, are minimum quantity lubrication (MQL), cryogenic cooling and dry cutting [4]. In MQL, a small amount of air-cutting fluid blend, called aerosol, is fed onto the machining zone.…”

Section: Introductionmentioning

confidence: 99%

“…The cryogenic machining uses coolants in the form liquefied gases. Each of these techniques has advantages and limitations [4]. MQL shows good thermal stability and lubrication effects, but poor cooling capability.…”

Section: Introductionmentioning

confidence: 99%

“…Cryogenic cooling is environment friendly but, results in changes in the properties of tool and work piece materials. In dry cutting the use of the cutting fluids is completely eliminated, thus it is an environment-friendly technique [2,4]. Due to certain advantages and limitations of each of these cooling techniques, the choice of the technique is dependent on several economical, ecological factors.…”

Section: Introductionmentioning

confidence: 99%

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Optimization of Process Parameters During End Milling and Prediction of Work Piece Temperature Rise

Bhirud¹,

Gawande²

2017

Archive of Mechanical Engineering

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During the machining processes, heat gets generated as a result of plastic deformation of metal and friction along the tool-chip and tool-work piece interface. In materials having high thermal conductivity, like aluminium alloys, large amount of this heat is absorbed by the work piece. This results in the rise in the temperature of the work piece, which may lead to dimensional inaccuracies, surface damage and deformation. So, it is needed to control rise in the temperature of the work piece. This paper focuses on the measurement, analysis and prediction of work piece temperature rise during the dry end milling operation of Al 6063. The control factors used for experimentation were number of flutes, spindle speed, depth of cut and feed rate. The Taguchi method was employed for the planning of experimentation and L 18 orthogonal array was selected. The temperature rise of the work piece was measured with the help of K-type thermocouple embedded in the work piece. Signal to noise (S/N) ratio analysis was carried out using the lower-the-better quality characteristics. Depth of cut was identified as the most significant factor affecting the work piece temperature rise, followed by spindle speed. Analysis of variance (ANOVA) was employed to find out the significant parameters affecting the work piece temperature rise. ANOVA results were found to be in line with the S/N ratio analysis. Regression analysis was used for developing empirical equation of temperature rise. The temperature rise of the work piece was calculated using the regression equation and was found to be in good agreement with the measured values. Finally, confirmation tests were carried out to verify the results obtained. From the confirmation test it was found that the Taguchi method is an effective method to determine optimised parameters for minimization of work piece temperature.

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Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids

Cited by 724 publications

References 136 publications

Analysis of a free machining α+β titanium alloy using conventional and ultrasonically assisted turning

Analysis of a free machining α+β titanium alloy using conventional and ultrasonically assisted turning

Experimental investigation on friction drilling of titanium alloy

Optimization of Process Parameters During End Milling and Prediction of Work Piece Temperature Rise

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