Machining in high pressure coolant environment – a strategy to improve machining performance: a review

Shete, Hanmant; Sohani, M. S.; Todkar, A. S.

doi:10.1504/ijmtm.2019.104551

Cited by 3 publications

(2 citation statements)

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“…Conventional machining mostly uses one mechanical mechanism, but HPC is usually comprised of three systems: mechanical, thermal, and tribological controls, which makes it impressive and valuable in high-speed machining [ 180 ]. High-speed machining is useful in the following conditions, (i) difficult to machine materials, (ii) high speed and feed, (iii) deep-hole drilling, (iv) continuous chips production [ 181 ]. HPC generally provides high pressure to the coolant, which allows the deep flow of the fluid between the work-electrode spaces or contact regions of tools and chips, as specified in Figure 34 [ 182 ].…”

Section: Sustainable Techniquesmentioning

confidence: 99%

Progressing towards Sustainable Machining of Steels: A Detailed Review

et al. 2021

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Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.

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Section: Sustainable Techniquesmentioning

confidence: 99%

Progressing towards Sustainable Machining of Steels: A Detailed Review

et al. 2021

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“…The literature survey revealed that, study pertaining to the HPC drilling has been limited to the use of a constant high-pressure coolant and pinpointed on the necessity of investigation on the effect of HPC in drilling process using design of experiment [17]. Hence, present study aims to determine the effect of variation of high pressure of coolant, spindle speed, feed rate and peck depth on the surface roughness of hole in drilling using Taguchi Technique.…”

Section: Introductionmentioning

confidence: 99%

Effect of Process Parameters on Surface Roughness in HPC Drilling of AISI 1055 Steel

Shete¹,

Sohani²

2020

JMechE

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Data regarding the influence of high-pressure coolant on the performance of drilling process using design of experiment has been limitedly available. This paper presents the effect of higher coolant pressures along with spindle speed, feed rate and peck depth on the surface roughness of hole using Taguchi technique. Experimental set up was developed consisting of specially manufactured high-pressure coolant system and high-pressure adapter assembly attached to vertical machining center. Developed experimental set up has optimized utilization of non-through coolant vertical machining center in a small-scale industry. Experiments were conducted on AISI 1055 steel with TiAIN coated drill on the vertical machining center. Taguchi technique was used for design of experiment and analysis of results. Results revealed that the surface roughness improve till coolant pressure reaches to an optimum value of 13.5 bar and there after it decreases. Coolant pressure and spindle speed was the significant process parameters for the hole surface roughness. Surface roughness at the top of hole was considerably lower than the bottom of hole, under the action of all process parameters. Supply of coolant at high pressure has resulted in lower surface roughness even with large peck depth; which indicate that, manufacturing cost can be reduced with the use of high-pressure coolant in drilling.

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