Performance study of uncoated and AlTiN-coated tungsten carbide tools in micromilling of Ti6Al4V using nano-MQL

Roushan, Ashutosh; Rao, U. S.; Sahoo, Priyabrata; Patra, Karali

doi:10.1007/s40430-022-03997-8

Cited by 8 publications

(3 citation statements)

References 41 publications

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“…23(b). GNP NPECs further improve the surface quality of the workpiece compared with PMQL conditions because the excellent tribological properties of the GNP nano-enhanced phase improve the cooling performance of the lubricant film [218].…”

Section: Surface Qualitymentioning

confidence: 99%

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Hu,

Li,

Zhou

et al. 2023

Front. Mech. Eng.

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Nanoparticle-enhanced coolants (NPECs) are increasingly used in minimum quantity lubrication (MQL) machining as a green lubricant to replace conventional cutting fluids to meet the urgent need for carbon emissions and achieve sustainable manufacturing. However, the thermophysical properties of NPEC during processing remain unclear, making it difficult to provide precise guidance and selection principles for industrial applications. Therefore, this paper reviews the action mechanism, processing properties, and future development directions of NPEC. First, the laws of influence of nano-enhanced phases and base fluids on the processing performance are revealed, and the dispersion stabilization mechanism of NPEC in the preparation process is elaborated. Then, the unique molecular structure and physical properties of NPECs are combined to elucidate their unique mechanisms of heat transfer, penetration, and antifriction effects. Furthermore, the effect of NPECs is investigated on the basis of their excellent lubricating and cooling properties by comprehensively and quantitatively evaluating the material removal characteristics during machining in turning, milling, and grinding applications. Results showed that turning of Ti–6Al–4V with multi-walled carbon nanotube NPECs with a volume fraction of 0.2% resulted in a 34% reduction in tool wear, an average decrease in cutting force of 28%, and a 7% decrease in surface roughness Ra, compared with the conventional flood process. Finally, research gaps and future directions for further applications of NPECs in the industry are presented.

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Section: Surface Qualitymentioning

confidence: 99%

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Hu,

Li,

Zhou

et al. 2023

Front. Mech. Eng.

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show abstract

“…13 Although the uncoated WC tools may provide with the desired performance results, the cutting edges are directly exposed to the vigorous machining conditions and hence they need to be effectively shielded to prolong the life of the tool as the tools can experience catastrophic tool failure due to micro-chipping. 14 It has been observed in previous studies that development of coating by pre-conditioning technique may be viewed as a long-term solution for machining hard to cut category of alloys because of its effectiveness and simplicity in the coating method. The AlSi-10Mg coating has been shown to minimize the generation of BUE generation and subsequently also improve the surface integrity of the work specimen owing to its dampening properties along the contact interfaces which facilitates reduced frictional characteristics.…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

George

Sahu

Dhanish

et al. 2023

Proceedings of the Institution of Mechanical Engineers, Part C:

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Machinability of Ti-6Al-4V, despite its numerous applications, is challenging owing to its poor thermal conductivity, severe chemical affinity and strain hardening characteristics. Although various coating techniques and expensive lubrication strategies have been tried, a significant improvement in tool life characteristics are yet to be achieved. Hence this work aims at suggesting a novel cost-effective and ecofriendly tool treatment technique by exploring the impact of a dual combination of an AlSi-10Mg coating developed by an emerging pre-conditioning technique with the incorporation of micro-textures on tool face to observe significant improvements in tool life and machinability characteristics of the alloy. It was analyzed from the results that while the micro-textures played a vital role in reducing the severe contact stress and machining temperature due to its improved heat transfer by convection, AlSi-10Mg film effectively shielded the cutting edges of the tool by providing a dampening effect along the edges, thereby ensuring improved tool life and enhanced machinability characteristics at the same time. The proposed tool combination was observed to be successful in significantly reducing the flank wear by 35%, 43% and 30% where 75, 253, and 371 µm were observed at 80, 100, and 120 m/min as compared to 117, 449, and 531 µm in the case of uncoated non-textured tool at the same operating conditions. Surface roughness of Ti-6Al-4V also reduced by 25%, 34%, and 37% where 1394, 1168, and 872 nm as compared to plain tool where 1840, 1770, and 1370 nm were recorded. Moreover, average chip curl diameter was observed to be 2.62, 3.36, and 6.49 mm as compared to chips generated by uncoated tools which recorded values of 4.33, 11.9, and 18.87 mm at 80, 100, and 120 m/min respectively.

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Performance evaluation of cold plasma and h-BN nano-lubricant multi-field coupling assisted micro-milling of aluminum alloy 6061-T651

Duan,

Wang,

et al. 2024

Alexandria Engineering Journal

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Performance study of uncoated and AlTiN-coated tungsten carbide tools in micromilling of Ti6Al4V using nano-MQL

Cited by 8 publications

References 41 publications

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Nanoparticle-enhanced coolants in machining: mechanism, application, and prospects

Tool surface modification methodology to improve the machinability of Ti6Al4V through combination of micro-EDM texturing and AlSi-10Mg soft coating techniques in dry turning

Performance evaluation of cold plasma and h-BN nano-lubricant multi-field coupling assisted micro-milling of aluminum alloy 6061-T651

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