Influence of CO2-snow and subzero MQL on thermal aspects in the machining of Ti-6Al-4V

Jamil, Muhammad; Khan, Aqib Mashood; Gupta, Munish Kumar; Mia, Mozammel; He, Ning; Li, Liang; Sivalingam, Vinothkumar

doi:10.1016/j.applthermaleng.2020.115480

Cited by 62 publications

(14 citation statements)

References 37 publications

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“…To test the dynamometer performance for in-process measurement, milling forces were measured at high rotational speeds (10,000 r/min~18,000 r/min). Down milling experiments were conducted out on a Mikron UPC 710, which is a five-axis machining center with a maximum rotational speed of 18,000 rpm, a feed rate up to 20 m/min, and a rated power of 15 kW [27]. The end mills are uncoated solid carbide tools with 2 flutes, 10 mm diameter, 0.5 mm nose radius, and 30 • helix angle.…”

Section: Experimental Settingmentioning

confidence: 99%

Development and Testing of a High-Frequency Dynamometer for High-Speed Milling Process

Lyu

Jamil

et al. 2021

Machines

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Cutting forces are strongly associated with the mechanics of the cutting process. Hence, machining forces measurements are very important to investigate the machining process, and numerous methods of cutting forces measurements have been applied. Nowadays, a dynamometer is the most popular tool for cutting forces measurements. However, the natural frequency of a dynamometer has a direct impact on the accuracy of measured cutting forces in the machining process. Therefore, few dynamometers are appropriate and reliable to measure the cutting forces at high frequencies. In this work, a new strain-gauge-based dynamometer (SGBD) with a special structure was designed, manufactured, and put to the test to ensure the measurement of high-frequency dynamic forces in the milling process. The main structure of the SGBD is symmetrical and mainly consists of a center quadrangular prism surrounded by four force sensing elastic elements, an upper support plate, and a lower support plate. The dynamic identification test was conducted and indicated that the SGBD′s natural frequency could be stabilized at a high value of 9.15 kHz. To automatically obtain the milling force data with a computer during high rotational speed milling, a data acquisition system was devised for the dynamometer. To reduce the effects of cross-sensitivity and acting point of force, an innovative model based on a conversion matrix was established for the dynamometer. Furthermore, the cutting tests were conducted at high rotational speeds (10,000–18,000 rpm), and it was found that the difference of cutting forces between the SGBD and a Kistler dynamometer are 2.3–5.8% in the X direction and 3.5–8.8% in the Y direction. The experimental findings disclosed that the new kind of dynamometer is reliably for the measurement of high-frequency dynamic forces in milling at high rotational speeds.

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Section: Experimental Settingmentioning

confidence: 99%

Development and Testing of a High-Frequency Dynamometer for High-Speed Milling Process

Lyu

Jamil

et al. 2021

Machines

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“…Conventional flood cooling is "ineffective" method to remove heat properly as heat evacuation is mainly dependent on the temperature difference. The emulsion remains in the liquid state during cooling, therefore it stays in contact with the heater or the workpiece surface for a longer time [11,12]. An enhanced heat transfer during cutting is necessary to reduce the high cutting temperature and result in improved machining performance.…”

Section: High Performance Cooling Techniques 21 Cryogenic Machiningmentioning

confidence: 99%

Review of new developments in machining of aerospace materials

Jemielniak¹

2021

Journal of Machine Engineering

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The paper presents an update of the recent literature on advances in machining of difficult to machine materials such as nickel and titanium-based alloys, and composites used in aeroengine and aerostructure applications. The review covers the following issues: advances in high-performance cooling techniques as cryogenic machining, minimum quantity lubrication, the combination of MQL and cryogenic cooling, and high-pressure lubricoolant supply and hybrid cutting processesvibration assisted machining (both low and high frequency), laser, plasma and EDM assisted machining. Examples of applications in industrial processes are also given.

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“…As a result, this phenomenon lowers the coating thickness, reduces its strength, and accelerates coating peeling [29]. The mist carrying hybrid nano-additives penetrated well at the tool-chip interface due to air pressure, formed a tribo-film.…”

Section: Flank Wearmentioning

confidence: 99%

Tribological and Machinability Performance of Hybrid Al2O3 -MWCNTs MQL for Milling Ti-6Al-4V

Jamil¹,

He²,

Zhao³

et al. 2021

Preprint

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Recent burgeoning development in nanotechnology unfold an avenue in the manufacturing industry. Owing to the superior heat transfer potential of nanoadditives mentioned recently, it could be interesting to improve the heat transfer and tribological capability of metal cutting fluids by mixing nanofluids in emulsions properly. In order to attain high-performance cutting of difficult-to-cut alloys, hybrid nanofluids assisted Minimum Quantity Lubrication (MQL) system is applied with the anticipation of efficient lubrication and heat transfer. Taguchi based L16(43) orthogonal array is used involving nanofluids concentrations of alumina-multiwalled carbon nanotubes (Al2O3-MWCNTs) air pressure and cooling flow rate at constant cutting conditions in the milling of Ti-6Al-4V. The resultant cutting force (FR), cutting temperature (T), and surface roughness (Ra) is considered as key machining responses. Besides, tool wear, chip analysis, and surface topography are also analyzed under the effect of hybrid nanofluids. Findings have shown the minimum resultant force, cutting temperature and surface roughness of 24.3N, 148.7oC, and 0.67µm respectively at nanofluids concentration of 0.24vol%, 120ml/h of flow rate at 0.6MPa of air pressure. The microscopic analysis of the end-mill depicted minor thermal damage, chip-welding, and coating peeling. Also, chip analysis depicts the clean back surface and less melting of saw-tooth chip edges. The surface topography confirms the less micro-adhesion of chips and material debris. The summary showed that appropriately chosen MQL parameters have improved the lubrication/cooling performance by providing oil film and enhancing the milling performance measures. The outcomes of the proposed study are useful for the manufacturing industry for the enhancement of process performance.

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Influence of CO2-snow and subzero MQL on thermal aspects in the machining of Ti-6Al-4V

Cited by 62 publications

References 37 publications

Development and Testing of a High-Frequency Dynamometer for High-Speed Milling Process

Development and Testing of a High-Frequency Dynamometer for High-Speed Milling Process

Review of new developments in machining of aerospace materials

Tribological and Machinability Performance of Hybrid Al2O3 -MWCNTs MQL for Milling Ti-6Al-4V

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