Metal cutting lubricants and cutting tools: a review on the performance improvement and sustainability assessment

Abdelrazek, Ali H.; Choudhury, Imtiaz Ahmed; Nukman, Y.; Kazi, S.N.

doi:10.1007/s00170-019-04890-w

Cited by 69 publications

(37 citation statements)

References 134 publications

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“…In various industries, hydrogen [30,31] is widely applied as a high-performance gaseous cooling medium since its thermal conductivity is higher than all other gases. In addition, helium gas [32] or hydrogen [33] can also be applied as cooling media in gas-cooled nuclear reactors since its low tendency to absorb neutrons. Sulfur hexafluoride [34,35] is also widely applied to cool some high-voltage power systems, such as circuit breakers, transformer, or switches.…”

Section: Resultsmentioning

confidence: 99%

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Kuo

Zhu

et al. 2022

Polymers

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Metal additive manufacturing techniques are frequently applied to the manufacturing of injection molds with a conformal cooling channel (CCC) in order to shorten the cooling time in the injection molding process. Reducing the cooling time in the cooling stage is essential to reducing the energy consumption in mass production. However, the distinct disadvantages include higher manufacturing costs and longer processing time in the fabrication of injection mold with CCC. Rapid tooling technology (RTT) is a widely utilized technology to shorten mold development time in the mold industry. In principle, the cooling time of injection molded products is affected by both injection mold material and coolant medium. However, little work has been carried out to investigate the effects of different mold materials and coolant media on the cooling performance of epoxy-based injection molds quantitatively. In this study, the effects of four different coolant media on the cooling performance of ten sets of injection molds fabricated with different mixtures were investigated experimentally. It was found that cooling water with ultrafine bubble is the best cooling medium based on the cooling efficiency of the injection molded parts (since the cooling efficiency is increased further by about 12.4% compared to the conventional cooling water). Mold material has a greater influence on the cooling efficiency than the cooling medium, since cooling time range of different mold materials is 99 s while the cooling time range for different cooling media is 92 s. Based on the total production cost of injection mold and cooling efficiency, the epoxy resin filled with 41 vol.% aluminum powder is the optimal formula for making an injection mold since saving in the total production cost about 24% is obtained compared to injection mold made with commercially available materials.

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Section: Resultsmentioning

confidence: 99%

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Kuo

Zhu

et al. 2022

Polymers

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“…As reported by Abdelrazek et al in [1], cryogenic machining is one of the sustainable and profitable alternatives to conventional cooling for processing titanium and other heatresistant alloys HRA. Jawahir et al [2] carried out an exhaustive analysis of the state of art on cryogenics in manufacturing.…”

Section: Introductionmentioning

confidence: 99%

Experimental investigation of the effects of cryogenic cooling on tool life in Ti6Al4V milling

Albertelli

Mussi

Strano

et al. 2021

Int J Adv Manuf Technol

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In this paper, the results of an experimental campaign of cryogenic milling are presented and discussed. For this purpose, a specific experimental setup that allowed to feed the liquid nitrogen LN through the tool nozzles was used. Tool life tests were carried out at different cutting speeds. The tool duration data were collected and used to identify the parameters of the Taylor’s model. Different end-of-life criteria for the tool inserts were even investigated. The achieved results are compared to those obtained using conventional cooling. It was observed that at low cutting velocity, conventional cooling still assures longer tool lives than in cryogenic condition. Since in cryogenic milling the increasing of the cutting velocity is not so detrimental as in conventional cutting, at high cutting speed (from 125 m/min) longer tool durations can be achieved. Statistical analyses on the model parameters were carried out to confirm the presented findings. The analysis of the effect of the cooling approach on the main wear mechanisms was also reported. At low cutting speed, adhesion and chipping phenomena affected the tool duration mainly in cryogenic milling.

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“…However, the drawbacks of low melting point and high ductility tend to bring out a limitation in tool machinability, which make chips more likely to adhere on the tool surface, lowering tool resistance and the quality of products [1,2]. Therefore, in order to alleviate the defects, a variety of approaches in enhancement of cutting tools in the recent years have been a 2 pplied to reduce friction and wear between the tool and chip, such as cutting fluid [3], PVD coatings [4], surface texturing [5,6].…”

Section: Introductionmentioning

confidence: 99%

Effect of Hybrid Texture on Cutting Performance of WC/Co-based Coated Tools Turning Aluminum Alloy

Zhou

Yang

et al. 2021

Preprint

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When cutting aluminum alloy with WC/Co coated tools, severe adhesion and wear exist on the tool-chip contact interface, which are the major factors leading to failure of cutting tools. To address this problem and extend service life of cutting tools, this study introduced surface textures into coated tools, trying to integrate the anti-friction properties of micro-textures with the wear resistance properties of coatings to improve tribological characteristics of tools surface. Firstly, hybrid texture consisting of micro-scale pits and micro-scale grooves were fabricated on the rake surface close to the main cutting edge of carbide tools by picosecond laser. Subsequently, the textured tools were deposited with hard-coatings CrAlN via physical vapor deposition (PVD) technology and the hybrid textured CrAlN coated tool (MPG-T) was obtained eventually. Other texture combinations included micro-scale pits and micro-scale grooves distributed in the tool-chip contact zone. Wet cutting experiments were carried out on these prepared tools. Results showed that compared with micro-scale pitted coated tool (MP-T), micro-scale grooved (MG-T) and conventional coated tool (CCT), MPG-T tool performed better in cutting forces, friction coefficient, tool adhesion and wear on the rake face and the flank face, chip morphology. Moreover, the corresponding synergistic mechanisms of hybrid texture and coatings were proposed. It’s suggested that applying the results to actual industries can enhance the cutting performance of coated tools in machining of aluminum alloy.

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Metal cutting lubricants and cutting tools: a review on the performance improvement and sustainability assessment

Cited by 69 publications

References 134 publications

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Effects of Different Mold Materials and Coolant Media on the Cooling Performance of Epoxy-Based Injection Molds

Experimental investigation of the effects of cryogenic cooling on tool life in Ti6Al4V milling

Effect of Hybrid Texture on Cutting Performance of WC/Co-based Coated Tools Turning Aluminum Alloy

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