Effect of MQL and nanofluid on the machinability aspects of hardened alloy steel

Abstract

The current research comprises of various machinability aspects of 4340 hardened alloy steel which are scrutinized with in context of improvements in main cutting force, tool flank wear, crater wear, surface roughness, micro-hardness, machined surface morphology, chip morphology, chip reduction coefficient and apparent coefficient of friction under three different cutting fluid applications i.e. compressed air, water soluble coolant and nanofluid (using eco-friendly radiator coolant as the base fluid and Al₂O₃ as the nanoparticle) using uncoated cermet cutting inserts and a comparative assessment was performed to select which fluid performed better in terms of various machining attributes among three cutting fluids. The minimum quantity lubrication technique (MQL) was used in which a smaller volume of coolant sprinkled at high pressure. This method is found as the most effective alternative to minimize health risks and machining costs, which is quite high in other setups. The test specimen was machined at three different cutting speeds i.e. 100, 120 and 140?m/min along with two machining parameters i.e. feed and depth of cut were kept constant respectively at 0.2?mm/rev and 0.4?mm. Outcomes made a conclusion that Al₂O₃ enriched ecofriendly nanocoolant outperformed both compressed air and water soluble coolant in terms of every machinability aspects.     

Experimental Investigations of Machinability in the Turning of Compacted Graphite Iron using Minimum Quantity Lubrication

Unique mechanical properties of the compacted graphite iron (CGI) attracted attention of manufacturers and suppliers mainly in automotive industry in last decades. However due to the low machinability of the CGI material, more efficient machining strategies need to be implemented. Improvement in the cost-effective and environmentally sensitive processing of compacted graphite iron (CGI) is one of the major concerns of the manufacturing world because of the allure of CGI's mechanical properties. This study assesses the efficiency of minimum quantity lubrication (MQL) in CGI turning when compared to the dry-cutting condition. The turning tests were conducted across a wide range of cutting parameters: three different cutting speeds (100, 200, 300 m/min) and three different feed rates (0.1, 0.2, 0.3 mm/rev), all at a constant depth of cut (1 mm). The MQL efficiency is evaluated through cutting force and surface roughness measurements, optical and SEM analyses of chip formation and tool-wear analysis. The results showed that MQL usage provided a reduction in the resultant cutting forces by 2–5%, a reduction in surface roughness by 25%. The SEM analysis also revealed much clearer and smoother cutting edges on tool surfaces used in the MQL tests.     

Molecular dynamics simulation of multi-groove nano-milling

This article investigates the nano-milling of multi-grooves on single crystalline copper. To explore the material removal mechanisms, molecular dynamics (MD) simulations were carried on both sequential and simultaneous nano-milling processes. It was found that to obtain quality grooves; a simultaneous multi-grooving requires a larger wall thickness between two adjacent grooves. Under sequential nano-millings or a simultaneous nano-milling with same rotational direction of the tools, the minimum wall thickness can be identified by residual stress distribution analysis. Under a simultaneous nano-milling with opposite rotational direction of the tools, this requirement of minimum wall thickness is better identified by strain rate distribution analysis. Overall, the simultaneous nano-milling with opposite rotational direction of the tools gives the best groove quality. A detailed machinability analysis showed that the groove quality by nano-milling can be improved by increasing the depth of cut and wall thickness between two adjacent grooves.     

Influence of High-Pressure Coolant Assistance on the Machinability of the Titanium Alloy Ti555–3

The origin of this article is the quantification of productivity gains and the improvement in surface integrity seen for a recent titanium alloy that is seeing increasing use in the aeronautical industry. The Ti555–3 titanium alloy, which is starting to find greater application in the aeronautical field, exhibits certain difficulties in terms of machining. High Pressure Coolant (HPC) assisted turning consists of projecting a high pressure coolant jet between the chip and the tool. Comparisons are made between assisted turning using variable jet pressure and conventional turning (dry and classical lubrication). It is shown that it is possible to improve productivity by using HPC-assisted machining. The results highlight good chip fragmentation and a great improvement of tool life with HPC assistance. Surface integrity is also shown to be improved, through surface roughness parameters that decrease, and surface residual stresses that become more compressive. These effects have been attributed to the thermo-mechanical action of the coolant jet resulting in lower cutting forces, lower coefficient of friction and lower temperature in the cutting zone.     

切削液对光学玻璃SF6在金刚石切削加工中可加工性的影响(英文)

本文研究了切削液对光学玻璃SF6在金刚石切削加工中可加工性的影响.首先对SF6进行了维氏压痕试验,并分析切削液(处理液)浸泡试件前后,SF6材料的硬度及断裂韧性的变化.进而进行了SF6试件的变切深刻划试验,采用共聚焦显微镜检测SF6材料的临界切削深度,试验结果表明,与未采用切削液的刻划相比,以碳酸钠为切削液的刻划使SF6的临界切削深度增加了35.6%;最后以压痕及刻划试验的结果为基础,进行了SF6试件的金刚石切削加工试验,由原子力显微镜(AFM)检测可知有切削液作用的切削试验中获得工件的表面粗糙度值比无切削液作用试验中的粗糙度值降低超过50%.试验结果表明,以碳酸钠溶液为切削液可显著改善光学玻璃SF6的可加工性.     

PcBN刀具车削镍基高温合金切削性能研究

本文研究了刀尖圆弧半径、负倒棱参数、切削速度、PcBN材质及干湿切削对PcBN刀具车削镍基高温合金GH4169切削性能的影响.试验结果表明:增大刀尖圆弧半径、负倒棱角度或减小负倒棱宽度均会使刀具磨损相应减小;PcBN的磨损随切削速度的提高而增大;DBW85的切削性能优于BZN6 000和BTN100,且其高速下的磨损量...     

易切削变形Zn-Cu-Bi合金的显微组织与性能

采用力学性能测试、光学显微镜、扫描电镜和能谱分析技术及切削性能测试对自行研制的含Bi易切削变形Zn-Cu合金铸态及挤压态的组织与性能进行研究.结果表明:Mn在Zn-Cu合金中易形成大而硬的块状相,对于提高锌合金的综合力学性能作用不明显,且可能产生不良影响;低熔点Bi相在Zn-Cu合金中铸态时以针状弥散分布,挤压态时以点状弥散分布,改善了Zn-Cu合金的切削性能;自行配制的Zn- 1.2％Cu-0.5％Bi-X合金,切削性能良好,抗拉强度达到405 MPa,伸长率为19.0％,表现出较优的综合性能,可作为部分铜合金替代材料,用于制造轴承、连接件、五金和家电等结构件.     

基于AFM氮化硅探针刻蚀方法制作聚碳酸酯纳米光栅

基于原子力显微镜(AFM)探针的纳米机械刻蚀技术以其成本低、分辨率高的优势被广泛应用于各种纳米元器件的制造中.为了得到最优的光栅结构,首先通过单次刻蚀实验定量分析了刻蚀方向、加载力和刻蚀速率等3个主要加工参数对所得纳米沟槽形貌和尺寸的影响,给出了普通氮化硅探针对聚碳酸酯(PC)的加工特性及加工效率.然后通过改变沟槽间距(100~500 nm)得到了不同周期的纳米光栅结构,并确定了这种探针与样品的组合对间距的要求及最佳加工参数:沿垂直于微悬臂长轴向右刻蚀,加载力2.3μN,刻蚀速率2.6μm/s.最后利用该技术对实验室已有原子光刻技术所得周期为213 nm的一维Cr原子光栅结构进行了复制加工,得到了均匀的213 nm一维光栅,证明这种基于AFM探针的纳米机械刻蚀技术可被广泛应用于纳米加工.     

可加工氮化硅/氮化硼复相陶瓷的制备

以硅(Si)粉、六方氮化硼(h-BN)为原料,在氮气(N2)中用燃烧合成(combustion synthesis,CS)气固反应法,原位生成可加工氮化硅/氮化硼(Si3N4/h-BN)复相陶瓷.考察了h-BN不同体积分数(下同)对Si3N4/h-BN复相陶瓷可加工性的影响.结果表明:在实验条件下,Si粉氮化完全,不存在残余的游离Si.Si3N4/h-BN复相陶瓷中以柱状β-Si3N4为主相,β-Si3N4晶粒之间为针状h-BN相.随着h-BN相含量的增加,Si3N4/h-BN复相陶瓷的可加工性提高,抗弯强度先减小后增加.h-BN含量为25%时,Si3N4/h-BN复相陶瓷的抗弯强度最低.     

A novel approach to fixture layout optimization on maximizing dynamic machinability

In the aerospace industry, the reasonable layout of fixture can efficiently suppresses machining vibration of thin-walled aerospace structure during machining. Based on the analysis of typical structural components encountered in the aerospace industry, a general frame-structure workpiece with fixture constraints can be equivalent as Mindlin plates with simultaneous elastic edges and internal supports. On basis of the equivalent models, the powerful pb-2 Ritz method defined by the product of a two-dimensional polynomial and basic functions can be introduced to be taken as trial functions. Substituting displacement functions into energy functional and minimizing total energy by differentiation leads to eigenfrequency equations of the workpiece–fixture system. Consequently, a novel nonlinear programming problem based on the frequency sensitivity can be built to optimize the layout of fixture supports to maximize the fundamental nature frequency of the workpiece–fixture system. The feasibility of the proposed approach is validated by a machining case.