Tool wear induced burr formation and concomitant reduction in MQL wetting capability in micro-milling

Saha, Suman; Deb, Sankha; Bandyopadhyay, P.P.

doi:10.1016/j.ijmecsci.2022.108095

Cited by 21 publications

(4 citation statements)

References 79 publications

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“…In addition, Saha et al [302] investigated the reachability of MQL oil droplets and the subsequent decline in the wetting efficiency at a constant MQL oil flow rate, attributed to the enlargement of top burrs due to tool wear during micro-milling of Ti-6Al-4V at varying aspect ratios. At an axial depth of 200 µm, the height of the burr increased from 21 to 190 µm over a cutting length of 125 mm, resulting in a decrease in the wetted area from 1036 to 3776 µm 2 .…”

Section: Minimum Quantity Lubrication-assisted Millingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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Section: Minimum Quantity Lubrication-assisted Millingmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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“…Tis section discusses the research eforts undertaken to explore phenomena associated with cutting tools. Te employment of machine learning methods in these attempts demonstrates variability, with some studies using such algorithms and others do not [17][18][19]. Tese phenomena have a substantial impact on various difculties, including the reduction of dimensional accuracy in the cut surface, tool breakage, and machine downtime.…”

Section: Related Workmentioning

confidence: 99%

“…Song et al [17] proposed a predictive model for estimating cutting forces in carbon fber reinforced polymer (CFRP) materials based on nonlinear regression analysis. Saha et al [18] presented an energy-based model for the prediction of cutting forces in machine operations. Authors aimed to examine the factors that contribute to the onset of adhesion in the context of progressive tool wear.…”

Section: Related Workmentioning

confidence: 99%

Forecasting the Friction Coefficient of Rubbing Zirconia Ceramics by Titanium Alloy

Salah,

Fathalla,

Eldesouky

et al. 2023

International Journal of Intelligent Systems

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The thermal issues generated from friction are the key obstacle in the high-performance machining of titanium alloys. The friction between the workpiece being cut and the cutting tool is the dominant parameter that affects the heat generation during the machining processes, i.e., the temperature inside the cutting zone and the consumed cutting energy. Besides, the complexity is associated with the nature of the friction phenomenon. However, there are limited efforts to forecast the friction coefficient during the machining operations. In this work, the friction coefficients between the titanium alloy against zirconia ceramics lubricated by minimum quantity lubrication were recorded and measured using a universal mechanical tester pin-on-disc tribometer. Then, we proposed two models for forecasting the friction coefficient which are trained and tested on the recorded data. The two predictive models are based on autoregressive integrated moving average and gated recurrent unit deep neural network methods. The proposed models are evaluated through a set of exhaustive experiments. These experiments demonstrated that the proposed models can efficiently be used to reduce power consumption dedicated to monitoring the friction coefficients. Besides, they can reduce or avoid surface thermal damage by predicting the high level of friction coefficients in advance, which can be used as an alert to enable or readjust the lubrication parameters (fluid pressure, fluid flow rate, etc.) to maintain lower ranges of friction coefficients and power consumption.

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“…Generally, grooves can be manufactured by computer numerical control (CNC) milling, laser machining or electrical discharge machining (EDM) with some limitations, but large-scale grooves and the high strength of materials such as nickel-based superalloys limit the efficiency of conventional mechanical machining. CNC milling always suffers from serious tool wear [7][8][9], machining defects and low surface integrity [10], and nonconventional processes that use high thermal energy lead to limited processing accuracy and degraded material functionality; laser machining results in heat-affected zones, cracks on the surface of the machined structure and molten spatter around the grooves [11,12], and EDM suffers from similar defects [13][14][15][16][17][18]. Therefore, mainstream processes cannot satisfy all manufacturing demands and are not always suitable, especially in the aerospace industry, where preserving material properties is critical for the functionality of parts.…”

Section: Introductionmentioning

confidence: 99%

Formation and reduction of taper in electrochemical single-pass milling grooves

Chen

Qiu

et al. 2023

International Journal of Mechanical Sciences

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Tool wear induced burr formation and concomitant reduction in MQL wetting capability in micro-milling

Cited by 21 publications

References 79 publications

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Forecasting the Friction Coefficient of Rubbing Zirconia Ceramics by Titanium Alloy

Formation and reduction of taper in electrochemical single-pass milling grooves

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