Sustainable cooling strategies to reduce tool wear, power consumption and surface roughness during ultrasonic assisted turning of Ti-6Al-4V

Airao, Jay; Nirala, Chandrakant K.; Bertolini, Rachele; Królczyk, Grzegorz M.; Khanna, Navneet

doi:10.1016/j.triboint.2022.107494

Cited by 96 publications

(28 citation statements)

References 47 publications

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“…In addition, there was an increase of more than 10% in the carrying share of the Mr1 vertices. The results obtained are in line with literature reports, which indicate that an effectively operating cooling system produces workpiece surface roughness [14,15,16].…”

Section: Resultssupporting

confidence: 91%

Testing of Air-Cooling Efficiency of the Underside of a Turning Tool Carbide Insert in EN-GJL 250 Cast Iron Turning Operations

Bartoszuk¹,

Prażmowski²,

Hurey³

2022

Adv. Sci. Technol. Res. J.

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This article shows the results of research on the eff ectiveness of operation of an original tool air cooling system in cutting. A case of turning EN-GJL 250 cast iron with TH10 tungsten carbide cutting inserts without protective coatings was selected for testing. The paper gives constructional details of the tested tool cooling system and discusses the principle of its operation. The research carried out has shown that this way of cooling the cutting insert causes a signifi cant decrease in temperature in all sub-areas of the cutting zone. In addition, air cooling has been proven to signifi cantly reduce cutting tool wear and slightly improve the roughness of the machined surface. The results obtained showed that the proposed method of cooling can be successfully used in the treatment of grey cast iron.In the future, it may serve as a basis for the construction of a professional cooling system for industrial applications.

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Section: Resultssupporting

confidence: 91%

Testing of Air-Cooling Efficiency of the Underside of a Turning Tool Carbide Insert in EN-GJL 250 Cast Iron Turning Operations

Bartoszuk¹,

Prażmowski²,

Hurey³

2022

Adv. Sci. Technol. Res. J.

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“…Tool wear affects vibration, cutting forces, energy consumption and Ra . 36 In this part of this experimental study, the change in vibration, power consumption and Ra was investigated as the machining time increased. Under coolant, 0.2 mm a , 175 m/min v and 0.1 mm/rev f was preferred as cutting parameters.…”

Section: Resultsmentioning

confidence: 99%

“…In addition, in studies with other materials, it was stated that by increasing tool wear, 19,37 vibration, 38 energy consumption increased and Ra increased. 36,39…”

Section: Resultsmentioning

confidence: 99%

“…In addition, in studies with other materials, it was stated that by increasing tool wear, 19,37 vibration, 38 energy consumption increased and Ra increased. 36,39 Supplementary Figure 8 shows the material removal rate and the crater wear on the tool. It is seen that the wear on the tool increases by increasing machining time.…”

Section: Relationship Between Machining Time Vibration Power Consumpt...mentioning

confidence: 99%

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Investigation of machinability properties of AISI H11 tool steel for sustainable manufacturing

Şahinoğlu

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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In this experimental study, vibration, energy consumption, power consumption and surface roughness values that occur in the machining of AISI H11 tool steel under CO2, coolant and dry cutting conditions were investigated. The effects of different cutting parameters and cooling systems on machinability were investigated. Analysis of variance was done. Regression equations were obtained. Relationships between power consumption, vibration and surface roughness are explained with mathematical equations. Finally, the optimum CC were determined by the multiple optimization methods. According to the test results, while the instantaneous power consumption increases by increasing cutting parameters, energy consumption decreases as the processing time is shortened. Vibration value increases by increasing cutting parameters. The highest vibration value occurs in cutting with CO2. Compared to dry and CO2 cutting, the vibration is lowest in coolant cutting. The friction decreases with the coolant and the vibration value decreases. There is a similar relationship between vibration and surface roughness value. The most effective parameter on the surface roughness value is the feed rate. It was seen that the most suitable CC for the most efficient cutting, the lowest energy consumption, vibration and surface roughness value, under coolant cutting, 0.2 mm depth of cut, 175 m/min cutting speed and 0.119 mm/rev feed rate. With optimum CC, the vibration value was reduced by 5.18%, the surface roughness value by 37.12%, energy consumption by 36.19% and the machine efficiency was increased by 7.16%.

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“…Airao and Nirala [ 50 ] observed the increased shear angle and decreased tool-workpiece contact ratio when ultrasonic vibration amplitude and frequency increased in the machining of SS 304. Meanwhile, Airao et al [ 51 ] applied ultrasonic vibration with minimum quantity lubrication and liquid carbon dioxide in the machining of Ti6Al4V and found a significant reduction of specific cutting energy. In an overview of the mentioned research, the transient cutting force in UVC was not completely modeled, and a fully transient cutting force model would promote an in-depth understanding of the reduced cutting force and cutting energy.…”

Section: Introductionmentioning

confidence: 99%

An Analytical and Experimental Study on Cutting Characteristics and Transient Cutting Force Modeling in Feed Directional Ultrasonic Vibration-Assisted Cutting of High Strength Alloys

Chen

Tang²,

Shao³

et al. 2022

Materials

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Ultrasonic vibration-assisted cutting (UVC) is progressively being used in machining as it can significantly promote the fabrication process. However, the ultrasonic vibration affecting the cutting process is still controversial. The full-transient cutting process is proposed in this study to analyze the affecting mechanism induced by ultrasonic vibration in the cutting process. This novel model is the first developed based on the fact that ultrasonic vibration would change mechanical behaviors and the cutting process. For example, the reduction of shear flowing stress in the primary shear zone and alteration of the shear angle in the UVC process. Then, considering those coupled effects, a novel model is proposed to determine the average and transient cutting forces. Here, insight and understanding into the physical phenomenon in UVC are provided. The effectiveness of the proposed model is verified by comparison with experimental results and analytical models available in the literature, with cutting parameters varying from macro to micro-scale. The results show that the ultrasonic vibration affects the cutting process in a complicated way, which is determined by transient characteristics, acoustic softening, thermal softening, plowing, and friction. Those effects on cutting performances in the UVC process under various cutting scenarios are investigated and discussed systematically. The average deviation of cutting forces between experiments and values predicted by the proposed model for Ti6Al4V, AISI 1045, and Al6063 is about 7%, 10.2%, and 11%, respectively. The deviation decreases with the increase of cutting speed in the machining of Ti6Al4V, which is different from the machining of other materials. This is contributed by the varied effect of ultrasonic vibration on the cutting process.

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Sustainable cooling strategies to reduce tool wear, power consumption and surface roughness during ultrasonic assisted turning of Ti-6Al-4V

Cited by 96 publications

References 47 publications

Testing of Air-Cooling Efficiency of the Underside of a Turning Tool Carbide Insert in EN-GJL 250 Cast Iron Turning Operations

Testing of Air-Cooling Efficiency of the Underside of a Turning Tool Carbide Insert in EN-GJL 250 Cast Iron Turning Operations

Investigation of machinability properties of AISI H11 tool steel for sustainable manufacturing

An Analytical and Experimental Study on Cutting Characteristics and Transient Cutting Force Modeling in Feed Directional Ultrasonic Vibration-Assisted Cutting of High Strength Alloys

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