State of the art review on the sustainable dry machining of advanced materials for multifaceted engineering applications: progressive advancements and directions for future prospects

Abstract

In this article, the comprehensive review on the application, and indeed, a comparative analysis on dry machining of different types of materials (Inconel, steel, aluminum, cast iron, magnesium and advanced materials) used in machining (turning, drilling and milling operations) were carried out in the light of utmost works published in the literature. The work describes the scientific findings of the past twenty years, including sustainable methods (surface texture, solid lubricants, vibration-assisted machining, laser-assisted machining), tool coatings, and geometry of tools. Vibration-assisted machining is another direction that researchers have investigated without the use of cutting coolants, where the complete disposal of coolants is not possible. Various researchers have carried out rigorous experimental work on milling, drilling, and turning operations under dry conditions to machine numerous materials. A significant proportion of experimental data about tool wear, tool wear machining, surface quality, surface integrity, etc., has been analyzed under dry conditions. However, the critical analysis of dry machining for different conventional machining operations for a variety of industrial materials is still lacking for establishing dry machining as a sustainable process for industrial applications. Thus, the critical analysis of various machining parameters and their consequences on tool wear and the surface quality of machined work was carried out in this work. Finally, scientific recommendations based on critical findings were proposed for industrial implementation of dry machining.

A novel study on the influence of graphene-based nanofluid concentrations on the response characteristics and surface-integrity of Hastelloy C-276 during minimum quantity lubrication

“…However, friction due to sliding and rotary motion of chip has created the abrasion marks on the top surface of cutting tool where the lubricant media is not accessible due to high sliding velocity and lower cutting area. Hence, dual lubrication nozzle should be the good option for to reduce the same [ [82] , [83] , [84] ].…”

Comparative Machining Performance Analysis between Taguchi’s Method and Random Forest Model

“…The tool holder used for holding the tool is PSBNL 25 25 M12. Singh et al (12) determined from their study that PVD coated (TiAlN) is best suited for dry machining. TH 1000 is a PVD coated tool with a Ti-Al-Si-N nanolaminate coating.…”

“…From Figure 3 (i) it can be concluded that "P c " was higher for 80 m/min for all "DoC" when compared to other "V c ". Singh et al (12) concluded from their review that dry machining showed promising results and reduced the excess cost that comes with the usage of cutting fluid, employing coating technology is the best scope for dry machining and PVD coated (TiAlN) is best suited for dry machining. In agreement with the current study, Emrah Şahin et al (14) , Raman Kumar et al (15) , Sivaiah et al (16) , Rajarajan et al (17) and Sarvam Patel et al (18) have concluded from their studies that "R a " decreases with the increase in cutting speed, and an increase in feed leads to an increase in "R a ".…”

Turning of Al 7075-T6 aerospace alloy under different sustainable metalworking fluid strategies by coated carbide tools

“…RHVT MF strategy reduces flank wear due to the cooling effect of air and less amount of work material deposit on the tool. Furthermore, reduced tool wear has been found at 200 m min −1 in comparison to 150 m min −1 due to high speed with low feed results in reduced tool wear [50]. The fact that tool wear is mainly determined by the temperature generated at the cutting zone explains the ability of the RHVT MF strategy to reduce tool flank wear [51].…”