Surface roughness and cutting force prediction in MQL and wet turning process of AISI 1045 using design of experiments

This paper presents an investigation into the MQL (minimum quantity lubrication) and wet turning processes of AISI 1045 work material with the objective of suggesting the experimental model in order to predict the cutting force and surface roughness, to select the optimal cutting parameters, and to analyze the effects of cutting parameters on machinability. Fractional factorial design and central composite design were used for the experiment plan. Cutting force and surface roughness according to cutting parameters were measured through the external cylindrical turning based on the experiment plan. The measured data were analyzed by regression analysis and verification experiments were conducted to confirm the results. From the experimental results and regression analysis, this research project suggested the experimental equations, proposed the optimal cutting parameters, and analyzed the effects of cutting parameters on surface roughness and cutting force in the MQL and wet turning processes.     

EFFECTS OF COOLANT SUPPLY METHODS AND CUTTING CONDITIONS ON TOOL LIFE IN END MILLING TITANIUM ALLOY

Titanium machining poses a great challenge to cutting tools due to its severe negative influence on tool life primarily due to high temperature generated and strong adhesion in the cutting area. Thus, various coolant supply methods are widely used to improve the machining process. On account of this, tool life and cutting force are investigated based on dry cutting, flood cooling, and minimum quantity lubrication (MQL) techniques. The experimental results show that MQL machining can remarkably and reliably improve tool life, and reduce cutting force due to the better lubrication and cooling effect.     

EFFECTS OF COOLANT SUPPLY METHODS AND CUTTING CONDITIONS ON TOOL LIFE IN END MILLING TITANIUM ALLOY

Titanium machining poses a great challenge to cutting tools due to its severe negative influence on tool life primarily due to high temperature generated and strong adhesion in the cutting area. Thus, various coolant supply methods are widely used to improve the machining process. On account of this, tool life and cutting force are investigated based on dry cutting, flood cooling, and minimum quantity lubrication (MQL) techniques. The experimental results show that MQL machining can remarkably and reliably improve tool life, and reduce cutting force due to the better lubrication and cooling effect.     

Cryogenic minimum quantity lubrication machining: from mechanism to application

Cutting fluid plays a cooling–lubrication role in the cutting of metal materials. However, the substantial usage of cutting fluid in traditional flood machining seriously pollutes the environment and threatens the health of workers. Environmental machining technologies, such as dry cutting, minimum quantity lubrication (MQL), and cryogenic cooling technology, have been used as substitute for flood machining. However, the insufficient cooling capacity of MQL with normal-temperature compressed gas and the lack of lubricating performance of cryogenic cooling technology limit their industrial application. The technical bottleneck of mechanical–thermal damage of difficult-to-cut materials in aerospace and other fields can be solved by combining cryogenic medium and MQL. The latest progress of cryogenic minimum quantity lubrication (CMQL) technology is reviewed in this paper, and the key scientific issues in the research achievements of CMQL are clarified. First, the application forms and process characteristics of CMQL devices in turning, milling, and grinding are systematically summarized from traditional settings to innovative design. Second, the cooling–lubrication mechanism of CMQL and its influence mechanism on material hardness, cutting force, tool wear, and workpiece surface quality in cutting are extensively revealed. The effects of CMQL are systematically analyzed based on its mechanism and application form. Results show that the application effect of CMQL is better than that of cryogenic technology or MQL alone. Finally, the prospect, which provides basis and support for engineering application and development of CMQL technology, is introduced considering the limitations of CMQL.     

Performance and evaluation of MoS2 based machining using PVD-TiAlN coated tool

A recent trend on turning of difficult-to-machine (DTM) materials using environmentally friendly vegetable oil has became popular due to its immense machinability aids. Conventional cutting oils fail to give cooling/lubrication at higher cutting speed-feed combination and create environmental pollution. The present work investigated the effect of molybdenum disulphide nanoparticle (nMoS2) dispersed in castor oil, as a cutting fluid, sprayed using minimum quantity lubrication (MQL) technique on turning of AISI O1 cold worked tool steel. The machining was carried out by varying the speed ranging from 110–170 m/min, a feed rate of 0.02-0.08 mm/rev and depth of cut of 0.7 mm. PVD-TiAlN coated tungsten carbide insert was used for the experimentation. The experimental results of nMQL condition were compared with the dry and wet condition. The results proved that application nMQL has given 15–49 % enhanced tool life with better surface finish as compared with dry and wet condition, respectively. No major phase change occurs in nMQL when compared with other conditions because of their low cutting temperature.

     

Experimental evaluation on the effect of electrostatic minimum quantity lubrication (EMQL) in end milling of stainless steels

The machining of stainless steels is very challenging owing to their high toughness and low thermal conductivity, causing high cutting temperatures and rapid tool wear. Conventionally, metalworking fluids in flood form are used during the process to improve surface quality and tool life; however, their use raises issues including environmental pollution and economic concerns. Therefore, an electrostatic minimal quantity lubrication (EMQL) technology was developed to reduce the consumption of metalworking fluids. EMQL is a near-dry machining technology utilizing the synergetic effects between electrostatic spraying and minimum quantity lubrication (MQL), wherein the lubricant is to apply in a form of fine, uniform and highly penetrable and wettable mist droplets directly to the cutting zone. This study investigates the effect of EMQL in end milling of AISI 304 stainless steel in comparison with dry, wet and MQL machining. The results suggest that EMQL reduces tool wear and cutting force, prolongs tool life considerably and enhances surface finish compared with conventional wet and MQL machining. scanning electron microscopy and Energy-dispersive X-ray spectroscopy analyses show that EMQL considerably reduces adhesive and abrasive wear on the flank face because of the lower friction and heat generation resulting from more efficient entry of the lubricant into the cutting interfaces.     

多壁碳纳米管/油酸复合物纳米流体车削GCr15钢的性能研究

针对切削液不易渗入到切削区起润滑作用的问题,提出利用内部填充油酸(OA)的多壁碳纳米管(MWCNTs)复合物为添加剂制备纳米流体,该纳米流体更易渗入到切削区,且复合物可在切削时释放油酸起增强润滑的作用。首先测试了纳米流体的热物理性能,考察了它在微量润滑(MQL)条件下车削GCr15钢的性能,然后研究了切削过程中复合物的冷却润滑特性。结果表明：与普通MWCNTs相比,复合物能更好地提高纳米流体的分散稳定性、传热性和润湿性;与普通乳化液相比,复合物纳米流体车削时的切削力减小约15%,切削温度降低约25%,工件表面粗糙度值减小16%,刀具耐用度提高了22%。     

Study on minimum quantity lubrication in micro-grinding

This paper discusses the performance of the minimum quantity lubrication (MQL) in micro-grinding based on ground surface roughness and tool life. The effects of grinding and lubricating parameters on machining performance are studied. Experiments for dry grinding and grinding with pure air are also conducted for comparison. It is observed that surface roughness and tool life are improved with the application of MQL in micro-grinding. Experimental results show that efficient chip removal from the cutting zone in micro-grinding is important for achieving good surface finish and adequate tool life. The application of a small amount of cutting oil in MQL can significantly extend the tool life. In this study, the tool life in MQL is seven times longer than that in dry grinding and five times longer than that in grinding with air cooling. If the oil flow is surplus to requirements or the air flow is inadequate, excess oil will stay on the grinding tool after the grinding test. As a result, poor surface roughness is observed. The optimal lubrication conditions in this experimental exploration are the combination of an oil flow of 1.88?ml/h and an air flow of 25?L/min.     

Chatter and dynamic cutting force prediction in high-speed ball end milling

Machine tool chatter is a serious problem which deteriorates surface quality of machined parts and increases tool wear, noise, and even causes tool failure. In the present paper, machine tool chatter has been studied and a stability lobe diagram (SLD) has been developed for a two degrees of freedom system to identify stable and unstable zones using zeroth order approximation method. A dynamic cutting force model has been modeled in tangential and radial directions using regenerative uncut chip thickness. Uncut chip thickness has been modeled using trochoidal path traced by the cutting edge of the tool. Dynamic cutting force coefficients have been determined based on the average force method. Several experiments have been performed at different feed rates and axial depths of cut to determine the dynamic cutting force coefficients and have been used for predicting SLD. Several other experiments have been performed to validate the feasibility and effectiveness of the developed SLD. It is found that the proposed method is quite efficient in predicting the SLD. The cutting forces in stable and unstable cutting zone are in well agreement with the experimental cutting forces.     

Evaluation of Minimal of Lubricant in End Milling

When considering machinability parameters, the use of coolant is indispensable in metal cutting operations. However, stricter environmental regulations are making the use of an ample amount of conventional coolant impossible because of its negative impact on the environment. Consequently, the use of minimal quantities of lubricant (MQL) can be regarded as an alternative solution in which the functionality of cooling and lubrication can be achieved by a tiny amount of cutting oil. In this study, flood coolant (42 l min _1) was used compared to the MQL amount of 8.5 ml h_1 and the comparative effectiveness was investigated in terms of cutting force, tool wear, surface roughness, and chip shape. Unlike the catastrophic tool failure in flood cooling, the use of MQL resulted in the cutting edge remaining intact, in spite of a higher flank width. The findings of this study show that MQL may be considered to be an economical and environmentally compatible lubrication technique.     

OPTIMAL MQL AND CUTTING CONDITIONS DETERMINATION FOR DESIRED SURFACE ROUGHNESS IN TURNING OF BRASS USING GENETIC ALGORITHMS

The evolving concept of minimum quantity of lubrication (MQL) in machining is considered as one of the solutions to reduce the amount of lubricant to address the environmental, economical and ecological issues. This paper investigates the influence of cutting speed, feed rate and different amount of MQL on machining performance during turning of brass using K10 cemented carbide tool. The experiments have been planned as per Taguchi's orthogonal array and the second order surface roughness model in terms of machining parameters was developed using response surface methodology (RSM). The parametric analysis has been carried out to analyze the interaction effects of process parameters on surface roughness. The optimization is then carried out with genetic algorithms (GA) using surface roughness model for the selection of optimal MQL and cutting conditions. The GA program gives the minimum values of surface roughness and the corresponding optimal machining parameters.     

Comparative assessment of cooling conditions,including MQL technology on machining factors in an environmentally friendly approach

Manufacturers need to continuously improve productivity and reduce the most disadvantages. In the current work, an experimental study has been carried out in order to evaluate the influence of different cutting parameters on the various machining factors such as surface roughness, cutting force, cutting power, metal removal rate, and tool wear during turning of X210Cr12 steel using a multilayer-coated tungsten carbide insert with various nose radii (r). Tests are designed according to Taguchi’s L₁₈ (2¹ × 3⁴) orthogonal array. ANOVA has been performed to determine the effect of the cutting conditions, and mathematical models have been developed through response surface methodology (RSM). The results indicate that the feed rate and the tool nose radius are the main affecting factors on surface roughness while both tangential force and cutting power are affected mainly by the depth of cut followed by the feed rate and the nose radius. Other special tests of long term have been established in order to study the wear evolution and consequently to determine the tool life. The results indicate also that minimum quantity lubrication (MQL) leads to an important improvement in terms of the cutting tool life by a gain of 23~40% compared to wet and dry machining. It has been found that the MQL is an interesting way to minimize lubrication cost and protect operator health and the environment while keeping better machining quality.     

Influence of minimum quantity lubrication parameters on tool wear and surface roughness in milling of forged steel

The minimum quantity of lubrication (MQL) technique is becoming increasingly more popular due to the safety of environment.Moreover,MQL technique not only leads to economical benefits by way of saving ...     

Predictive modeling of residual stress in minimum quantity lubrication machining

Residual stress is one of the critical characteristics for assessing the surface integrity of machined components as it poses a strong bearing on the service quality, functionality, and life of the machined components. The machined-in residual stresses can be affected by cutting parameters, tool geometry, material properties, and lubrication conditions. A physics-based relationship between residual stresses and processing conditions could support process planning in achieving desirable part quality and functionality. This paper presents an analytical model that predicts the residual stresses in machining under minimum quantity lubrication (MQL) condition as functions of cutting parameters, tool geometry, material properties as well as MQL application parameters. Both the lubrication and cooling effects caused by MQL air–oil mixture contribute to changes in friction due to boundary lubrication as well as changes in the thermal stress due to heat loss. The cutting force and cutting temperature are coupled into a thermal–mechanical model which incorporates the kinematic hardening and strain compatibility to predict the resulting residual stress under lubricated conditions. The residual stress prediction model is verified for orthogonal tube facing of TC4 alloy. The predicted residual stresses captured the measured results well in terms of the trend and magnitude.     

Performance profiling of minimum quantity lubrication in machining

This study develops the analytical understanding of mechanical and environmental effects of minimum quantity lubrication (MQL) in machining and profiles the MQL performance as functions of machining and fluid application parameters. Physics-based predictive models are formulated to quantitatively describe the resulting contact stress and temperature distributions under completely dry, MQL (under boundary lubrication), and flood cooling conditions in cylindrical turning. On that basis, the air quality effects in terms of cutting fluid aerosol emission rate and droplet size distribution have been derived through the modeling of evaporation, runaway aerosol atomization, and dissipation processes. Additionally, the abrasion, adhesion, and diffusion wear mechanisms under time-evolving cutter geometry have been quantitatively evaluated for the development of a tool wear and tool life relationship with the fluid application condition. Experimental measurements of force, temperature, aerosol concentration, and tool flank wear rate in dry, MQL, and fluid cooling cases has also been pursued to calibrate and validate the predictive models. The MQL performance profile is assessed through the sensitive analysis of tool utilization, power consumption, and air quality with respect to MQL application parameters; and it serves as a basis to support the overall optimization of machining process by incorporating both mechanical and environmental considerations.     

基于四阶矩法车削颤振可靠性研究*

再生颤振是影响加工质量、加速刀具磨损、刀具破坏的主要原因。以车削加工为研究对象,针对具有不确定参数的车削加工颤振预测问题,研究车削加工系统结构动态特性参数具有随机特性的情况下颤振可靠性建模及求解问题。定义车削加工过程不出现颤振的概率为颤振可靠度,建立车削加工系统可靠性模型,研究四阶矩法求解可靠度的问题,提出利用颤振可靠性叶瓣图方法进行颤振预测。通过模态试验对一车床进行频响函数测试,采用四阶矩法计算获得了颤振可靠度,并与蒙特卡洛法获得的可靠度相比较。结果表明四阶矩法计算获得的可靠度与蒙特卡洛仿真结果一致性很好,但是四阶矩法计算精度高而且计算耗时远小于蒙特卡洛法。进行颤振可靠性切削试验,通过观察振纹和分析噪声功率谱识别颤振,对典型参数进行验证,试验结果与分析结果一致。     

A new process damping model for chatter vibration

This paper presents a new analytical process damping model (PDM) and calculation of Process Damping Ratios (PDR) for chatter vibration for low cutting speeds in turning operations. In this study a two degree of freedom complex dynamic model of turning with orthogonal cutting system is considered. The complex dynamic system consists of dynamic cutting system force model which is based on the shear angle (φ) oscillations and the penetration forces which are caused by the tool flank contact with the wavy surface. Depending on PDR, the dynamic equations of the cutting system are described by a new mathematical model. Variation and quantity of PDR are predicted by reverse running analytical calculation procedure of traditional Stability Lobe Diagrams (SLD). Developed mathematical model is performed theoretically for turning operations in this study and simulation results are verified experimentally by cutting tests.     

Micro-drilling of Ti–6Al–4V alloy: The effects of cooling/lubricating

This paper presents a series of experimental investigations of the effects of various machining conditions [dry, flooded, minimum quantity lubrication (MQL), and cryogenic] and cutting parameters (cutting speed and feed rate) on thrust force, torque, tool wear, burr formation, and surface roughness in micro-drilling of Ti–6Al–4V alloy. A set of uncoated carbide twist drills with a diameter of 700 μm were used for making holes in the workpiece material. Both machining conditions and cutting parameters were found to influence the thrust force and torque. The thrust force and torque are higher in cryogenic cooling. It was found that the MQL condition produced the highest engagement torque amplitude in comparison to the other coolant–lubrication conditions. The maximum average torque value was obtained in the dry drilling process. There was no substantial effect of various coolant–lubrication conditions on burr height. However, it was observed that the burr height was at a minimum level in cryogenic drilling. Increasing feed rate and decreasing spindle speed increased the entry and exit burr height. The minimum surface roughness values were obtained in the flood cooling condition. In the dry drilling process, increased cutting speed resulted in reduced hardness on the subsurface of the drilled hole. This indicates that the surface and subsurface of the drilled hole were subject to softening in the dry micro-drilling process. The softening at the subsurface of drilled holes under different cooling and lubrication conditions is much smaller compared to the dry micro-drilling process.     

EXPERIMENTAL STUDY ON LUBRICATION MECHANISM IN MQL INTERMITTENT CUTTING PROCESS

Effects and mechanisms in MQL aluminium cutting are investigated by use of an intermittent turning process and by a friction test apparatus this is designed for measuring friction force between a freshly formed surface and tool material in plastic contact condition. Cutting tests are conducted using two types of lubricants that have differences in lubricity, and in speed ranges from 100 m/min to 400 m/min. Experimental results suggest that the lubrication mechanism of the MQL aluminium cutting considerably changes, depending upon the lubricant types and the temperature on the tool face. If an ester-type lubricant is used and tool surface temperature can be suppressed below a certain transition temperature of friction, a large reduction in a frictional force can be obtained at an initial stage of intervals of intermittent cutting.     

Deformation behaviour of sintered silicon–copper steel preforms of various aspect ratios during cold upsetting

This paper presents the optimization of the face milling process of 7075 aluminum alloy by using the gray relational analysis for both cooling techniques of conventional cooling and minimum quantity lubrication (MQL), considering the performance characteristics such as surface roughness and material removal rate. Experiments were performed under different cutting conditions, such as spindle speed, feed rate, cooling technique, and cutting tool material. The cutting fluid in MQL machining was supplied to the interface of work piece and cutting tool as pulverize. An orthogonal array was used for the experimental design. Optimum machining parameters were determined by the gray relational grade obtained from the gray relational analysis.