Wear analysis when machining AISI 304 with ethylene glycol/TIO2 nanoparticle-based coolant

Abstract

This paper discuss the tool life and wear mechanism in the end-milling of AISI304 stainless steel using a TiN-coated carbide insert with water-soluble coolant and nanoparticle-based coolant (TiO 2 /EG). The cutting variables are cutting speed, feed rate, and axial depth. The end-milling operation using nanoparticle-based coolant (TiO 2 /EG) obtains a high tool life compared with the end-milling operation using water-soluble coolant. In general, the tool failure when milling with water-soluble coolant was flank wear, cracking, chipping, and fracture at a cutting distance of 720 mm, but the milling process with nanoparticle-based coolant (TiO 2 / EG) showed chipping and fracture at a cutting distance of 1200 mm. According to ISO 8688-2-1989 (E), the wear criterion for milling with water-soluble coolant is reached at an average cutting distance of 800 mm, but milling with nanoparticle-based coolant (TiO 2 /EG) reached the ISO 8688-2-1989 (E) wear criterion at a cutting distance of 1300 mm. The SEM and EDX spectra show that there are nanolayers of Ti nanoparticles from the nanofluid embedded in and filling the holes in the insert, forming a layer which acts as a thermal bridge for the cutting insert. Attrition and oxidation at the cutting edge were the main tool wear mechanisms present during the end-milling operation with nanoparticlebased coolant (TiO 2 /EG). An oxide layer formed during the oxidation wear which shielded the cutting tool from impact during the milling process.

Toward TiO2 Nanofluids—Part 2: Applications and Challenges

“…Then, the hard oxidation layer can protect the tool from micro-cracking and chipping wear because it could not be easily detached despite under the severe impact of the milling force and took parts of the tool surface from the workpiece.

Fig. 12SEM and EDX of cutting edge [122]. At a cutting speed of 1500 rpm, feed rate of 0.02-mm tooth, and axial depth of 0.1 mm using nanoparticle-based coolant at a cutting distance of 180 mm (×60 magnification).

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Effects of sintering schedule on the characteristics of Fe-based powder compacts formed through warm compaction route

“…However, when compared to the sample sintered at 600°C for 30 mins, a more dispersed pattern can be observed, with all the elements fused together. Also, the formation of new structures can be seen among the grain boundaries in the sample sintered at 750°C for 90 mins [33]. A good dispersion of elements can be seen in the samples sintered at 900°C.…”

Optimisation of process parameters for minimum volumetric wear rate on AA7075-TiC metal matrix composite

“…It can be seen that the grooves are deeper in the matrix alloy as compared to the composites tested under similar conditions (19.62 N, 2.61 m/s and 3 km) owing to the absence of hard TiC particles. The examination of the wear surface of the AA7075 matrix alloy tested under the above conditions was characterised by smearing and scratches, typical characteristics of sliding wear (Figure 5a) [35].However, the worn surfaces shown in Figures 5b-c reveal that the grooves are much shallower in the composites than those of the matrix alloy owing to the presence of TiC particles [36,37]. Furthermore, it is evident from Figure 5c exhibits a comparatively smooth worn surface and grooves are much finer and more closely spaced in the AA7075/8 wt.% TiC sample owing to the sliding action of a larger number of hard particles and debris.…”