Performance evaluation of Ti–6Al–4V machining using nano-cutting fluids under minimum quantity lubrication

Hegab, Hussien; Umer, Usama; Deiab, Ibrahim; Kishawy, Hossam A.

doi:10.1007/s00170-017-1527-z

Cited by 127 publications

(43 citation statements)

References 40 publications

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“…It can be concluded that the proposed nano-fluids are atomized using the MQL device, under employment of a certain amount of compressed air. Consequently, a fine mist, walled with a vegetable oil layer is formed (see Figure 4) [16][17][18]32,33]. This mist is capable of penetrating into the tool-workpiece interfere area and creating a tribofilm which has a significant role in reducing the generated cutting heat, as well as decreasing the coefficient of friction.…”

Section: Resultsmentioning

confidence: 99%

“…Nano-cutting fluids technology, has been used in previous studies to enhance the machining process performance, for example, micro-drilling of aluminum 6061 [13] sing nano-diamond particles; micro-grinding of tool steel using aluminum oxide-nano-particles [14]; and micro-end-milling of Ti-6Al-4V using MQL-nano-fluid with chilly CO 2 gas [15]. In addition, previous studies obtained better results when using MQL-nano-fluid compared to the classical MQL; for example, better surface quality [16] and flank wear [17] results were noticed when machining Ti-6Al-4V using MWCNTs-MQL. Furthermore, MWCNTs-MQL showed improvements in the tool wear behavior when turning Inconel 718 [18].…”

Section: Introductionmentioning

confidence: 94%

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Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

Hegab

Kishawy

2018

JMMP

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Difficult-to-cut materials have been widely employed in many engineering applications, including automotive and aeronautical designs because of their effective properties. However, other characteristics; for example, high hardness and low thermal conductivity has negatively affected the induced surface quality and tool life, and consequently the overall machinability of such materials. Inconel 718, is widely used in many industries including aerospace; however, the high temperature generated during machining is negatively affecting its machinability. Flood cooling is a commonly used remedy to improve machinability problems; however, government regulation has called for further alternatives to reduce the environmental and health impacts of flood cooling. This work aimed to investigate the influence of dispersed multi-wall carbon nanotubes (MWCNTs) and aluminum oxide (Al 2 O 3 ) gamma nanoparticles, on enhancing the minimum quantity lubrication (MQL) technique cooling and lubrication capabilities during turning of Inconel 718. Machining tests were conducted, the generated surfaces were examined, and the energy consumption data were recorded. The study was conducted under different design variables including cutting speed, percentage of added nano-additives (wt.%), and feed velocity. The study revealed that the nano-fluids usage, generally improved the machining performance when cutting Inconel 718. In addition, it was shown that the nanotubes additives provided better improvements than Al 2 O 3 nanoparticles.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 94%

Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

Hegab

Kishawy

2018

JMMP

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“…The results obtained also revealed the reduction in both tool wear and surface roughness due to the lubricating effect of MoS 2 nanoparticles. Hegab, H. et al [21,22] studied the turning performance of Ti-6Al-4V alloy under the MQL technique using nano-cutting fluids. By using multi-walled carbon nanotubes (MWCNTs) suspended in vegetable oil, the MQL heat capacity was improved and the power consumption, as well as flank wear, reduced significantly with the nano concentration of 2 wt %.…”

Section: Introductionmentioning

confidence: 99%

Performance Evaluation of MQL Parameters Using Al2O3 and MoS2 Nanofluids in Hard Turning 90CrSi Steel

2019

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Hard machining has gained much attention to be an alternative solution for many traditional finish grinding operations due to high productivity, ease to adapt to complex part contours, the elimination of cutting fluids, good surface quality, and the reduction of machine tool investment. However, the enormous amount of heat generated from the cutting zone always requires the high-grade inserts and limits the cutting conditions. The MQL technique with nanofluids assisted for hard machining helps to improve the cutting performance while ensuring environmentally friendly characteristics. This paper focuses on the development of MQL technique by adding Al2O3 and MoS2 nanoparticles to the base fluids (soybean oil and water-based emulsion) for the hard turning of 90CrSi steel (60÷62 HRC). The analysis of variance (ANOVA) is used to evaluate the performance of MQL parameters in terms of cutting forces and surface roughness. The study reveals that a better performance of coated carbide inserts is observed by using MQL with Al2O3 and MoS2 nanofluids. In addition, the fluid type, nanoparticles and nanoparticle concentration have a strong effect on cutting performance. The interaction influence among the investigated variables is also studied in order to provide the technical guides for further studies using Al2O3 and MoS2 nanofluids.

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“…Maruda et al applied a cemented carbide tool to cut AISI 1045 and found that MQCL with extreme pressure anti-wear additive can form a thin friction film layer on the tool surface during the cutting process, enhancing the wear resistance of the tool [6]. Hegab et al used a nano-additive to improve the cold cutting efficiency of titanium alloy on the basis of micro-lubrication [7]. Compared with micro-lubrication, nanofluids improve the lubrication property of the rake and flank face of the tool, enabling it to have better cutting performance and better energy consumption performance.…”

Section: Introductionmentioning

confidence: 99%

Tribological Performance of Micro-Groove Tools of Improving Tool Wear Resistance in Turning AISI 304 Process

Zhan

Lin

et al. 2020

Materials

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AISI 304 has good physical and chemical properties and thus is widely used. However, due to the low thermal diffusivity, the cutting temperature of AISI 304 is high accelerating the wear of the tool. Therefore, tool wear is a major problem in machining hard cutting materials. In this study, we developed a new type of micro-groove tool whose rake surface was distributed with micro-groove by powder metallurgy based on the finite element temperature field morphology. We compared the wear of the proposed micro-groove tool with an untreated one by using a scanning electron microscope (SEM) and an X-ray energy spectrum. The abrasive, adhesive, and oxidation wear of the rake and the flank face of the micro-groove tool were lower than that of the untreated one. Due to the micro-groove on the rake face of the tool, the contact length between the tool and chip was reduced, leaving more extension space. Furthermore, chip extrusion deformation was avoided, and the energy caused by chip deformation was reduced. After 70 min of cutting, the counterpart reached the specified wear amount while the main cutting force, the feed resistance, and the cutting depth resistance of the proposed micro-groove tool were reduced by 16.1%, 33.9%, and 40.1%, respectively. With regard to steady state, the cutting temperature was reduced by 17.2% and the wear width of the flank face was reduced by 36.7%.

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Performance evaluation of Ti–6Al–4V machining using nano-cutting fluids under minimum quantity lubrication

Cited by 127 publications

References 40 publications

Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

Performance Evaluation of MQL Parameters Using Al2O3 and MoS2 Nanofluids in Hard Turning 90CrSi Steel

Tribological Performance of Micro-Groove Tools of Improving Tool Wear Resistance in Turning AISI 304 Process

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