Influence of nanolubricant particles’ size on flank wear in hard turning

This paper presents the effects of cutting speed, nanoparticles’ size, and their concentration in water-based TiO₂ nanofluid on the magnitude of tool flank wear and tool wear rate. The types of nanoparticles and base fluid, nanoparticle size, and nanoparticle concentration can affect the tribological and heat transfer properties of nanofluids, and thereupon, these parameters can affect the cutting forces and temperatures during the metal cutting process, thereby affecting tool wear and nanolubricant consumption. According to the achieved results, with an increase in the size of nanoparticles from 10 to 50 nm, the average decrease in cutting tool flank wear reduces from 46.2% to 34.8%.     

Experimental Investigation on Sialon Ceramic Inserts for Ultra-high-speed Milling of Inconel 718

A series of milling aerospace material Inconel 718 experiments were conducted with a sialon ceramic tool to investigate chip evolution, cutting force, and tool wear at different cutting speeds. Round inserts were used at ultra-high-speeds under dry cutting conditions. A scanning electron microscopy and an optical microscope were used to observe the worn surfaces and to reveal the wear mechanisms of the inserts. The experiment results showed that the macroscopic shape of the chips was small scraps and fan-shaped. With the increase in the cutting speed, the plastic deformation of the chips was increasingly serious. The minimal average cutting forces were obtained at v_c = 700 m/min. The rise of cutting temperature was resulted from the increase in cutting deformation work and friction work with cutting speed. The combined effect of thermal stress and mechanical stress contributed to the tool chipping, flaking, microcrack propagation, abrasion, and adhesion which were the primary reasons of the sialon ceramic tool wear.     

On the calculation of cutting forces and chip-tool contact interaction characteristics in cutting ductile metals

Based on a comparative analysis of experimental and calculated (by two different relations) cutting forces, the tangential stresses in the reference shear plane during chip formation has been found to be equal to the true ultimate stress of the workpiece material in mechanical tests. The author puts forward the methods for assessment of forces and stresses separately on the areas of plastic and elastic contact between the chip and the tool and some other chip formation characteristics from the measured chip reduction coefficient K _l . The angle of action of the cutting force is proposed to be determined as a sum of angles $\omega = \left( {\frac{\pi } {4} - \Phi } \right) + \Delta \omega$ , where Δω decreases with increasing tool rake at γ ≥ 0 but has almost no effect on the accuracy of assessment of the principal cutting force component P _z . The paper gives examples of cutting force determination in machining steel 10 and steel 08Kh18N10T using a tool with γ = 0 and 20°.     

Machining Parameters Optimization of Titanium Alloy using Response Surface Methodology and Particle Swarm Optimization under Minimum-Quantity Lubrication Environment

The present paper depicts an application of response surface methodology (RSM) and particle swarm optimization (PSO) technique for optimizing the machining factors in turning of titanium (Grade-II) alloy using cubic boron nitride insert tool under minimum quantity lubricant (MQL) environment. The three machining factors, i.e., cutting speed (V_c), feed rate (f) and side cutting edge angle (approach angle π), are designed as three factors by using RSM design, which is withal subject to several constraints including tangential force (F_c), tool wear (V_Bmax), surface roughness (R_a) and tool-chip contact length (L). The multiple regression technique was used to establish the interaction between input parameters and given responses. Moreover, the results have been presented and optimized process parameters are acquired through multi-response optimization via desirability function as well as the PSO technique. The lower values of V_c (200 m/min), f (0.10 mm/rev) and higher values of ? (90°) are the optimum machining factors for minimizing the aforementioned responses. It was also observed that the selected responses predicated on PSO are much closer as that of the values acquired in view of the desirability function approach. Henceforth, PSO has the potential to cull appropriate machining factors while turning titanium (Grade-II) alloys under MQL conditions.     

Progress of Nanofluid Application in Machining: A Review

A colloidal mixture of nanometer-sized (<100 nm) metallic and non-metallic particles in conventional cutting fluid is called nanofluid. Nanofluids are considered to be potential heat transfer fluids because of their superior thermal and tribological properties. Therefore, nano-enhanced cutting fluids have recently attracted the attention of researchers. This paper presents a summary of some important published research works on the application of nanofluid in different machining processes: milling, drilling, grinding, and turning. Further, this review article not only discusses the influence of different types of nanofluids on machining performance in various machining processes but also unfolds other factors affecting machining performance. These other factors include nanoparticle size, its concentration in base fluid, lubrication mode (minimum quantity lubrication and flood), fluid spraying nozzle orientation, spray distance, and air pressure. From literature review, it has been found that in nanofluid machining, higher nanoparticle concentration yields better surface finish and more lubrication due to direct effect (rolling/sliding/filming) and surface enhancement effect (mending and polishing) of nanoparticles compared to dry machining and conventional cutting fluid machining. Furthermore, nanofluid also reduces the cutting force, power consumption, tool wear, nodal temperature, and friction coefficient. Authors have also identified the research gaps for further research.     

Cryogenic Drilling of Ti–6Al–4V Alloy Under Liquid Nitrogen Cooling

This article is focused on experimental study of the effects of cryogenic liquid nitrogen (LN₂) coolant during drilling of Ti–6Al–4V alloy material with three different levels of cutting speed (V_c) and feed rate (f) at a constant depth. Cutting temperature (T), thrust force (F_z), torque (M_z), surface roughness (R_a), and hole quality are the output responses investigated by using cryogenic LN₂ coolant compared with a wet coolant. Tool wear and chip morphology were examined with the changes in cryogenic LN₂ coolant. It is found that cryogenic LN₂ coolant results in lowering cutting zone temperature which helps more removal of heat from the cutting zone. Lower thrust forces and surface roughness were observed due to less friction and better chip breaking in cryogenic LN₂ condition. Also better chipping results in improvement in hole quality, viz., circularity and cylindricity in cryogenic LN₂ condition. Less serration and uniform segmentation results in better chip morphology and no damage to the cutting inserts resulted in improved tool life in cryogenic LN₂ condition. The main application of cryogenic LN₂ coolant in the cutting zone provides better lubrication and is more effective than wet coolant. The effects of this investigation show that cryogenic LN₂ coolant is an alternative approach for a wet coolant in the drilling process.     

Investigation on Stability and Optical Properties of Titanium Dioxide and Aluminum Oxide Water-Based Nanofluids

Water is regarded as a poor absorber of solar energy. This affects the efficiency of solar thermal systems. The addition of nanoparticles to heat transfer fluids used in solar thermal systems can enhance their optical properties. These new-generation heat transfer fluids are known as nanofluids. The present study investigates the stability and optical properties of three nanofluids, including aluminum oxide (13 nm and <50 nm) and titanium dioxide (21 nm) nanofluids. The stability of the nanofluids was observed through a photo-capturing method and zeta potential measurements. Ultraviolet–visible (UV–Vis) spectrophotometer was used to measure the absorbance and transmittance of the prepared nanofluids. The effect of factors such as type of particle, type of surfactant, and pH of the solution on the optical properties of the nanofluids was also investigated. We found that the titanium dioxide nanofluid had better optical properties but lower stability compared to aluminum oxide nanofluids.     

Investigation on Some Machinability Aspects of Inconel 825 During Dry Turning

In the current study, attempt has been made to investigate the influence of cutting speed (Vc) (51, 84, and 124 m/min) on various machining characteristics like chip morphology, chip thickness ratio, tool wear, surface, and sub-surface integrity during dry turning of Inconel 825. Comparable study was carried out using uncoated and commercially available chemical vapor deposition multilayer coated (TiN/TiCN/Al₂O₃/ZrCN) cemented carbide (ISO P30 grade) insert. Chip morphology consists of chip forms obtained at different cutting conditions. Serrated chips were observed when machining Inconel 825 with both types of tool with more serration in case of uncoated insert. The chip thickness ratio increased as cutting speed was increased. Use of multilayer coated tool also resulted in increase in chip thickness ratio. Rake and flank surfaces were examined with scanning electron microscope and optical microscope. Abrasion, adhesion, and diffusion wears were found to be dominating tool wear mechanism during dry machining of Inconel 825. The beneficial effect of coated tool over its uncoated counterpart was most prominent during machining at high cutting speed (Vc = 124 m/min). The surface and sub-surface integrity obtained with coated tool were superior to that while machining Inconel 825 with uncoated tool.     

Determination of effective specific heat of nanofluids

The effective specific heat of several types of nanofluids are measured by transient double hot-wire technique. Sample nanofluids are prepared by suspending 1–5 volume percentages of titanium dioxide (TiO₂), aluminium oxide (A1₂O₃) and aluminium (Al) nanoparticles in various base fluids, such as deionised water, ethylene glycol and engine oil. The effective specific heats of these nanofluids were found to decrease substantially with increased volume fraction of nanoparticles. Besides particle volume fraction, particle materials and base fluids also have influence on the effective specific heat of nanofluids. Except Al/engine oil-based nanofluid, predictions of the effective specific heat of nanofluids by the volume fraction mixture rule-based model showed reasonably good agreement with the experimental results. Based on the calibration results obtained for the base fluids, the measurement error is estimated to be within 2.77%.     

Influence of different parameters and their coupled effects on the stability of alumina nanofluids by a fractional factorial design approach

Nanofluids have been introduced as new-generation fluids able to improve energy efficiency in heat exchangers. However, stability problems related to both agglomeration and sedimentation of nanoparticles have limited industrial-level scaling. A fractional factorial experimental 2^k?1 design was applied in order to evaluate the effects of nanoparticle concentration, surfactant type and concentration, ultrasonic amplitude as well as ultrasonic time on the stability of alumina (Al₂O₃) nanofluids. Commercial alumina nanoparticles (particle diameter <50 nm) were dispersed in deionized water using ultrasonic probe dispersion equipment. Sodium dodecylbenzenesulfonate (SDBS) and cetyltrimethylammonium bromide (CTAB) were used as surfactants. The stability of the nanofluids in static mode was monitored by visual inspection and UV visible spectroscopy. The results of the experimental design showed that the coupled effects between surfactant type and surfactant concentration and between ultrasonication tip amplitude and ultrasonication time had the most pronounced effects on nanofluid stability. The experimental conditions providing the best stability were 0.5 wt% of Al₂O₃, CTAB, critical micelle surfactant concentration, 30% ultrasonic amplitude and 30 min of ultrasonication.     

Experimental Study on Hybrid Cryogenic and Plasma-Enhanced Turning of 17-4PH Stainless Steel

This article presents machinability of 17-4PH stainless steel using a hybrid technique composed of plasma-enhanced turning and cryogenic turning. First of all, using some primary experimental tests and nonlinear regression, a mathematical model was developed for surface temperature of uncut chip as a function of plasma current and cutting parameters. Then, the influence of cutting speed (V_c), feed (f), and surface temperature of uncut chip (T_sm) was studied on surface roughness (R_a), cutting force (F_z), and tool flank wear (V_B). The results show that hybrid turning (HYT) is able to lower the main cutting force and tool flank wear in comparison with conventional turning. In addition, surface roughness was improved except for high level of surface temperature of uncut chip. However, hardness measurement of machined workpiece showed that HYT does not change the hardness of machined surface.     

Free convection of hybrid Al2O3-Cu water nanofluid in a differentially heated porous cavity

Hybrid nanofluids are a new type of enhanced working fluids, engineered with enhanced thermo-physical properties. The hybrid nanofluids profit from the thermo-physical properties of more than one type of nanoparticles. The present study aims to address the free convective heat transfer of the Al₂O₃-Cu water hybrid nanofluid in a cavity filled with a porous medium. Two types of important porous media, glass ball and aluminum metal foam, are considered for the porous matrix. The experimental data show dramatic enhancement in the thermal conductivity and dynamic viscosity of the synthesized hybrid nanofluids, and hence, these thermophysical properties could not be modeled using available models of nanofluids. Thus, the actual available experimental data for the thermal conductivity and the dynamic viscosity of hybrid nanofluids are directly utilized in the present theoretical study. Various comparison with results published previously in the literature are performed and the results are found to be in excellent agreement. In most cases, the average Nusselt number Nu_l is decreasing function of the volume fraction of nanoparticles. The results show the reduction of heat transfer using nanoparticles in porous media. The observed reduction of the heat transfer rate is much higher for hybrid nanofluid compared to the single nanofluid.     

Thermal Conductivity and Viscosity Measurements of Water-Based TiO<Subscript>2</Subscript> Nanofluids

In this study, the thermal conductivity and viscosity of TiO₂ nanoparticles in deionized water were investigated up to a volume fraction of 3% of particles. The nanofluid was prepared by dispersing TiO₂ nanoparticles in deionized water by using ultrasonic equipment. The mean diameter of TiO₂ nanoparticles was 21 nm. While the thermal conductivity of nanofluids has been measured in general using conventional techniques such as the transient hot-wire method, this work presents the application of the 3ω method for measuring the thermal conductivity. The 3ω method was validated by measuring the thermal conductivity of pure fluids (water, methanol, ethanol, and ethylene glycol), yielding accurate values within 2%. Following this validation, the effective thermal conductivity of TiO₂ nanoparticles in deionized water was measured at temperatures of 13 °C, 23 °C, 40 °C, and 55 °C. The experimental results showed that the thermal conductivity increases with an increase of particle volume fraction, and the enhancement was observed to be 7.4% over the base fluid for a nanofluid with 3% volume fraction of TiO₂ nanoparticles at 13 °C. The increase in viscosity with the increase of particle volume fraction was much more than predicted by the Einstein model. From this research, it seems that the increase in the nanofluid viscosity is larger than the enhancement in the thermal conductivity.     

Experimental investigation of dry,wet and cryogenic boring of AA 7075 alloy

In this research work, an attempt has been carried out to examine (investigate) and study the dry, wet and cryogenic boring of AA 7075 alloy, which is predominantly used in transport applications in defense (aeronautical parts), oceanic and automaker industries. To ensure direct supply of the coolant, and real-time measurement of cutting temperature a modified boring bar is used (modification is carried out using EDM to accommodate placement of a thermocouple to obtain real-time measurement of temperature readings during the boring cycle). It is observed that during cryogenic boring of AA 7075 alloy there is a considerable reduction in the cutting force (F_c), cutting temperature (T_c) and surface roughness (R_a) by 56.16%, 84.70%, 58.98% compared to dry boring and 48.43%, 80.70%, 34.70% compared to wet boring, respectively. Decrease in F_c and T_c leads to a reduction in high stresses at localized points during machining and in turn curtail wear in workpiece and tool. Lubrication provided by cryogenic fluids also plays a sizable role in reduction of F_c and T_c. Reduction in lower F_c and T_c has a glaring effect on the surface characteristics of the hole produced during the boring process. Tool wear is reduced in cryogenic boring by 36.96% and 17.57% compared to dry and wet boring, respectively. Taguchi and ANOVA was carried out which helped in determining feed as an important parameter with respect to F_c and R_a during boring of AA 7075 under dry, wet and cryogenic conditions whereas speed as an important parameter in determining T_c in dry and wet conditions and feed for T_c in cryogenic boring condition. TOPSIS analysis highlighted speed of 770 rpm and feed of 0.055 mm/min as the most closest to ideal solution for all three different cutting conditions. Surface morphology study after boring of AA 7075 highlighted better surface characteristics in cryogenic bored surface compared to dry and wet boring. Roughness measured in AFM for tool used in boring highlighted a decrease in 86.79% and 66.01% in cryogenic boring in juxtaposition with dry and wet boring, respectively. A surge in compressive residual stress is observed in cryogenic bored surface by 10.41% and 3.5% in juxtaposition with dry and wet boring, respectively, highlighting an abatement in tensile residual stress and better workpiece integrity as compared to dry and wet boring conditions.     

Study of viscosity and specific heat capacity characteristics of water-based Al2O3 nanofluids at low particle concentrations

In this paper, the specific heat capacity and viscosity properties of water-based nanofluids containing alumina nanoparticles of 47 nm average particle diameter at low concentrations are studied. Nanofluids were prepared with deionised water as base fluid at room temperature by adding nanoparticles at low volume concentration in the range of 0.01%–1% to measure viscosity. The effect of temperature on viscosity of the nanofluid was determined based on the experiments conducted in the temperature range of 25°C to 45°C. The results indicate a nonlinear increase of viscosity with particle concentration due to aggregation of particles. The estimated specific heat capacity of the nanofluid decreased with increase of particle concentration due to increase in thermal diffusivity. Generalised regression equations for estimating the viscosity and specific heat capacity of nanofluids for a particular range of particle concentration, particle diameter and temperature are established.     

Experimental studies on the cryogenic machining of biodegradable ZK60 Mg alloy using micro-textured tools

Reducing the contact area between the cutting tool rake surface and chip promotes the machining performance of the work material and increases the tool life. Magnesium alloys are ductile-lightweight materials that form continuous chips during machining. The present investigation discusses the orthogonal turning of ZK60 magnesium alloy with linearly textured cutting inserts under both dry and liquid nitrogen (LN₂) cooling conditions. Linear grooves that are parallel and perpendicular to chip flow direction were created using Nd-YAG laser on the tungsten carbide cutting inserts. The effect of texturing combined with the application of LN₂ cooling is studied by evaluating the machining temperature and forces, microhardness, surface roughness and tool wear. Textured tools considerably minimize the liaison area of the chip with the rake plane compared to non-textured tools, which resulted in favorable effects in machinability. In case of cryogenic machining, textured tools substantially minimize the friction by the coupled effect of micro-pool lubrication and the formation of thin-film lubrication between the tool–chip/tool–work interfaces. Parallel-textured tools aided with cryogenic cooling exhibit superior performance during machining among the different types of tools employed in the present investigation.     

Preparation,characterization, viscosity,and thermal conductivity of nitrogen-doped graphene aqueous nanofluids

Nanofluids perform a crucial role in the development of newer technologies ideal for industrial purposes. In this study, Nitrogen-doped graphene (NDG) nanofluids, with varying concentrations of nanoparticles (0.01, 0.02, 0.04, and 0.06 wt%) were prepared using the two-step method in a 0.025 wt% Triton X-100 (as a surfactant) aqueous solution as a base. Stability, zeta potential, thermal conductivity, viscosity, specific heat, and electrical conductivity of nanofluids containing NDG particles were studied. The stability of the nanofluids was investigated by UV–vis over a time span of 6 months and concentrations remain relatively constant while the maximum relative concentration reduction was 20 %. The thermal conductivity of nanofluids was increased with the particle concentration and temperature, while the maximum enhancement was about 36.78 % for a nanoparticle loading of 0.06 wt%. These experimental results compared with some theoretical models including Maxwell and Nan’s models and observed a good agreement between Nan’s model and the experimental results. Study of the rheological properties of NDG nanofluids reveals that it followed the Newtonian behaviors, where viscosity decreased linearly with the rise of temperature. It has been observed that the specific heat of NDG nanofluid reduced gradually with the increase of concentration of nanoparticles and temperature. The electrical conductivity of the NDG nanofluids enhanced significantly due to the dispersion of NDG in the base fluid. This novel type of fluids demonstrates an outstanding potential for use as innovative heat transfer fluids in medium-temperature systems such as solar collectors.     

Experimental investigations on cryogenic cooling by liquid nitrogen in the end milling of hardened steel

Milling of hardened steel generates excessive heat during the chip formation process, which increases the temperature of cutting tool and accelerates tool wear. Application of conventional cutting fluid in milling process may not effectively control the heat generation also it has inherent health and environmental problems. To minimize health hazard and environmental problems caused by using conventional cutting fluid, a cryogenic cooling set up is developed to cool tool–chip interface using liquid nitrogen (LN₂). This paper presents results on the effect of LN₂ as a coolant on machinability of hardened AISI H13 tool steel for varying cutting speed in the range of 75–125 m/min during end milling with PVD TiAlN coated carbide inserts at a constant feed rate. The results show that machining with LN₂ lowers cutting temperature, tool flank wear, surface roughness and cutting forces as compared with dry and wet machining. With LN₂ cooling, it has been found that the cutting temperature was reduced by 57–60% and 37–42%; the tool flank wear was reduced by 29–34% and 10–12%; the surface roughness was decreased by 33–40% and 25–29% compared to dry and wet machining. The cutting forces also decreased moderately compared to dry and wet machining. This can be attributed to the fact that LN₂ machining provides better cooling and lubrication through substantial reduction in the cutting zone temperature.     

Residual surface stress: comparing traditional and modulated tool path machining processes

Traditional machining processes, where material is removed by a cutting tool from a workpiece, can introduce residual stresses at the surface of machined pieces. This paper provides an examination of an alternative machining methodology called modulated tool path machining. The ultimate objective of this research is to determine the effects of modulated tooling path machining processes, as applied to control chip geometry, on the surface stress of selected materials. Residual stresses in machined samples were characterised through the use of X-ray diffraction by comparing the modulated path method with a more traditional material removal technique (i.e. constant surface speed and constant contact).

This paper is part of a Themed Issue on Measurement, modelling and mitigation of residual stress.     

Environment Friendly Machining of Ni–Cr–Co Based Super Alloy using Different Sustainable Techniques

In order to eradicate the use of mineral based cutting fluid, the machining of Ni–Cr–Co based Nimonic 90 alloy was conducted using environment friendly sustainable techniques. In this work, uncoated tungsten carbide inserts were employed for the machining under dry (untreated and cryogenically treated), MQL, and cryogenic cutting modes. The influence of all these techniques was examined by considering tool wear, surface finish, chip contact length, chip thickness, and chip morphology. It was found that the cryogenically treated tools outperformed the untreated tools at 40 m/min. At cutting speed of 80 m/min, MQL and direct cooling with liquid nitrogen brought down the flank wear by 50% in comparison to dry machining. Similarly at higher cutting speed, MQL and cryogenic cooling techniques provided the significant improvement in terms of nose wear, crater wear area, and chip thickness value. However, both dry and MQL modes outperformed the cryogenic cooling machining in terms of surface roughness value at all the cutting speeds. Overall cryotreated tools was able to provide satisfactory results at lower speed (40 m/min). Whereas both MQL and cryogenic cooling methods provided the significantly improved results at higher cutting speeds (60 and 80 m/min) over dry machining.