Experimental analysis of system parameters for minimum cutting fluid consumption when machining Ti-6Al-4V using a novel supply system

Abstract

This paper presents the development of a new controlled cutting fluid impinging supply system (Cut-list) to deliver an accurate quantity of cutting fluid into machining zones through precisely oriented coherent round nozzles. The performance of the new system was evaluated against a conventional system during the step shoulder milling of Ti-6Al-4V using a water-miscible vegetable oil-based cutting fluid, which was phase 1 in this comprehensive study. The use of Cut-list resulted in a significant reduction up to 42% in cutting fluid consumption as well as reductions in cutting force, tool flank wear, average surface roughness (R a ) and burr height (Gariani et al. in Appl Sci 7(6):560, 2017). This paper details phase 2 of the study which was aimed to investigate the effects of working conditions, nozzle positions/angles and impinging distances on key process measures including cutting forces, workpiece temperature, tool wear, burr formation and average surface roughness of the machined surface. Feed rate showed a significant effect on mean values of cutting force, burr formation and surface roughness, whereas average workpiece temperature and flank wear values are very sensitive to cutting speed. Nozzle position at a 15°angle in the feed direction and 45°/60°against feed direction assisted in minimising workpiece temperature. An impinging distance of 55/75 mm is also necessary to control burr formation, workpiece temperature and average surface roughness. It can be concluded that Cut-list gave promising results compared to conventional flood cooling systems in terms of the evaluated machining outputs. Therefore, the new system can be considered as a feasible, efficient and ecologically beneficial solution, giving less fluid consumption in machining processes.

Influence of Minimum Quantity Lubrication Using Vegetable-Based Cutting Fluids on Surface Topography and Cutting Forces in Finish Turning of Ti-6Al-4V

“…The main functions of metalworking fl uids are lubrication and cooling. Moreover, they reduce the build-up edge, protect both machined elements and machine parts against corrosion, and facilitate the removal of chips from the machining zone [3]. On the other hand, conventionally used cutting fl uids can cause some health problems for machine operators, such as dermatitis [4], work-related asthma [5] and cancer at several sites (e.g.…”

Investigating the pulse short electric arc milling of Ti6Al4V alloy

“…However, these alloys have some drawbacks such as signi cant chemical activity at high temperatures and low thermal conductivity. In conventional mechanical methods for cutting the specimens made of titanium alloy, the cutting tool is prone to contact wear and stick at high temperatures, thereby reducing the tool life [1][2][3].…”

Preparation and efficiency of environmentally friendly metal working fluid (MWFs) from chemical modification of waste cooking oil

“…Perpetually, the cutting fluid will get defiled with use, should be arranged to the climate. It was apparent from the writing that cutting fluids involve 16.9% of machining cost [2]. The report by National Institute of Occupational Safety and Health [3] shows that inward breath of oilbased metalworking fluid vaporizers may aggravate the throat, nose, and lung and has been related with chronic bronchitis, asthma and worsening of previous respiratory issues.…”