Progressive Tool Wear in Cryogenic Machining: The Effect of Liquid Nitrogen and Carbon Dioxide

Kaynak, Yusuf; Gharibi, Armin

doi:10.3390/jmmp2020031

Cited by 31 publications

(10 citation statements)

References 30 publications

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“…It is seen that cryogenic cooling (180 N) increases the thrust forces by 45% and 16% compared to wet machining (125 N) and dry machining (155 N) conditions, respectively. Reduction in cooling temperature to subzero conditions causes an increase in strength of the workpiece material and, hence, higher thrust force, and agrees with the reported literature [ 9 , 25 , 26 ]. Sudden cooling could promote the hardening of the magnesium matrix and enhance its brittleness.…”

Section: Resultssupporting

confidence: 92%

Cryogenic Drilling of AZ31 Magnesium Syntactic Foams

et al. 2020

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Machined surface quality and integrity affect the corrosion performance of AZ31 magnesium composites. These novel materials are preferred for temporary orthopedic and vascular implants. In this paper, the drilling performance of AZ31-magnesium reinforced with hollow alumina microsphere syntactic foam under LN2 cryogenic, dry, and Almag® Oil is presented. Cutting tests were conducted using TiAlN physical vapor deposition (PVD) coated multilayer carbide and K10 uncoated carbide twist drills. AZ31 magnesium matrices were reinforced with hollow alumina ceramic microspheres with varying volume fractions (5%, 10%, 15%) and average bubble sizes. Experimental results showed that the drilling thrust forces increased by 250% with increasing feed rate (0.05 to 0.6 mm/tooth) and 46% with the increasing volume fraction of alumina microspheres (5% to 15%). Cryogenic machining generated 45% higher thrust forces compared to dry and wet machining. The higher the volume fraction and the finer the average size of hollow microspheres, the higher were the thrust forces. Cryogenic machining (0.42 µm) produced a 75% improvement in surface roughness (Ra) values compared to wet machining (1.84 µm) with minimal subsurface machining-induced defects. Surface quality deteriorated by 129% with an increasing volume fraction of alumina microspheres (0.61 µm to 1.4 µm). Burr height reduction of 53% was achieved with cryogenic machining (60 µm) compared to dry machining (130 µm). Overall, compared to dry and wet machining methods, cryogenic drilling can be employed for the machining of AZ31 magnesium syntactic foams to achieve good surface quality and integrity.

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Section: Resultssupporting

confidence: 92%

Cryogenic Drilling of AZ31 Magnesium Syntactic Foams

et al. 2020

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“…In recent years, other important aspects were also considered, such as health care of operators, environment, and the cost of liquids, which is between 7.5% and 17% of the cost of a machining part [3]. The present trend is to use alternative techniques, such as dry machining [4], electrocutting [5], cryogenic [6], cold compressed air [7], or minimum quantity of lubricant (MQL) [8], with the aim to reduce environmental impacts.…”

Section: Introductionmentioning

confidence: 99%

Wear and MnS Layer Adhesion in Uncoated Cutting Tools When Dry and Wet Turning Free-Cutting Steels

Krähmer

Hameed

Egea

et al. 2019

Metals

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Free-cutting steels are developed to produce large quantities of parts with low mechanical behavior, mainly for automotive sector. These alloys contain phosphorous, lead, sulfur, and manganese that help to improve the machinability and surface roughness. However, due to the toxicity of lead, steel mills in recent years have been focusing on non-toxic steels to produce minimum environmental pollution and better machinability. The present work investigates the tool wear during dry and wet turning of free-cutting steels (SAE 1212, SAE 12L14, and SAE 1215) by using uncoated hard metal inserts at three cutting speeds. Additionally, a EDS analysis was performed to determine the presence of Mn and S elements at the rake face of the cutting tool that can induce a higher adhesion of manganese sulfide (MnS). The results show that the SAE 12L14 steel has the best performance in terms of tool life at different cutting speeds. This difference is maximum at the lowest cutting speed, which gradually decreases with the increase of the cutting speed. The wear behavior is evaluated in the three steel alloys at each cutting speed and, consequently, the tool wear exhibits a slightly better performance in the dry machining condition for higher cutting speeds (180 and 240 m/min), independent of the steel alloy. Finally, EDS analysis confirms the presence of Mn and S elements at the rake face of the inserts machined in dry condition. Hence, MnS is expected to interpose between the machined surface and cutting tool surface to behave similar to tribofilm by reducing the wear on the cutting edge.

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“…This results in a higher number of production stops and, therefore, in a dramatic increase of production time. Thus, the chip formation process and chip control using combined cryogenic and minimum quantity lubrication [19,20], applying cryogenic lubrication [7,21], high pressure coolant [2,11] ultrasonic-assisted vibration [15,17], optimization of the processing parameters [10,[22][23][24], and chip breakers [10,14,16] as well as their limitations [25], have been widely studied, both experimentally and by means of simulation. It is widely accepted that the contribution of chip breakers in enhancing the chip fragmentation process is significant.…”

Section: Introductionmentioning

confidence: 99%

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

2019

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Chip evacuation is a critical issue in metal cutting, especially continuous chips that are generated during the machining of ductile materials. The improper evacuation of these kinds of chips can cause scratching of the machined surface of the workpiece and worsen the resultant surface quality. This scenario can be avoided by using a properly designed chip breaker. Despite their relevance, chip breakers are not in wide-spread use in polycrystalline diamond (PCD) cutting tools. This paper presents a systematic methodology to design chip breakers for PCD turning inserts through finite element modelling. The goal is to evacuate the formed chips from the cutting zone controllably and thus, maintain surface quality. Particularly, different scenarios of the chip formation process and chip curling/evacuation were simulated for different tool designs. Then, the chip breaker was produced by laser ablation. Finally, experimental validation tests were conducted to confirm the ability of this chip breaker to evacuate the chips effectively. The machining results revealed superior performance of the insert with chip breaker in terms of the ability to produce curly chips and high surface quality (Ra = 0.51–0.56 µm) when compared with the insert without chip breaker that produced continuous chips and higher surface roughness (Ra = 0.74–1.61 µm).

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Progressive Tool Wear in Cryogenic Machining: The Effect of Liquid Nitrogen and Carbon Dioxide

Cited by 31 publications

References 30 publications

Cryogenic Drilling of AZ31 Magnesium Syntactic Foams

Cryogenic Drilling of AZ31 Magnesium Syntactic Foams

Wear and MnS Layer Adhesion in Uncoated Cutting Tools When Dry and Wet Turning Free-Cutting Steels

Tailored Chip Breaker Development for Polycrystalline Diamond Inserts: FEM-Based Design and Validation

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