Effect of MQL flow rate on machinability of AISI 4140 steel

Abstract

Many studies were performed about the influence of minimum quantity lubrication (MQL) technique on cutting performance in the literature, but there is no paper examining the effect of different MQL flow rates and cutting parameters on machinability of AISI 4140 material as a whole. In this study, the effects of different MQL flow rates and cutting parameters on surface roughness, main cutting force and cutting tool flank wear (VB), with great importance among the machinability criteria, and forming as a result of the machining of AISI 4140, were revealed. At the end of the experiments, it was determined that rise of flow rate affected main cutting forces positively to a certain extent; yet, it exhibited no significant effect on surface roughness, but reduced VB. Also, it was observed that both main cutting force and surface roughness increased with the increase of feed, while generally decreased with the increase of cutting speed. It was seen that flank wear was positively affected by the increase in flow rate; and this decreased with the increase in flow rate. R² values obtained as 99.8% and 99.9% for main cutting forces and surface roughness values modeled statistically with the help of quadratic equations, respectively.     

Investigation into the performance of eco-friendly graphite nanofluid as lubricant in MQL grinding

In this study, the lubrication and cooling properties of eco-friendly graphite nanofluids in MQL grinding were investigated. Grinding forces, subsurface temperature of workpiece, surface roughness, micro-hardness and metallographic observations of ground surfaces were employed to evaluate the performance of synthesized nanofluids as lubricant under different grinding parameters. The results were also compared with grinding in dry, pure MQL and flood cooling conditions. The results showed that the tangential forces and force ratios in grinding using graphite nanofluid MQL are lower than that of other lubricating methods especially at extreme cutting parameters. Also, application of graphite nanofluid MQL reduced the grinding temperature at high velocities of workpiece. These reductions could be attributed to the formation of a tribofilm on the ground surface by the present of graphite nanoparticles in the wheel-workpiece interface. Additionally, the presence of this tribofilm in the contact area generated a smooth surface even at high depth of cut and velocity of workpiece. Furthermore, the micro-hardness of ground surfaces increased in graphite nanofluid MQL grinding because of infiltration of graphite nanoparticles in the grinding surface and the plastic deformation of subsurface of workpiece.     

微量润滑技术对切削Ti-6Al-4V组织性能的影响

通过温度采集、力学性能检测和组织形貌分析,系统研究了微量润滑切削TC4钛合金时不同润滑油用量对冷却效果、切削性能和组织性能的影响规律。试验结果表明:同一切削条件下,润滑油用量Q在一定范围内值越大,冷却效果、切削性能越佳,加工后材料显微组织尺寸越小,显微硬度越大;当Q取值35-40ml/h时,各性能趋于最优。然而,Q超过40ml/h后,冷却效果、切削性能和工件的组织性能反而降低。     

内冷刀具低温微量润滑切削试验

低温微量润滑切削是一种新型的绿色切削技术。利用自行设计的内冷结构刀具进行低温微量润滑切削试验。将切削后试件的表面粗糙度、切屑形态及刀具耐用度与普通刀具的干切削、湿切削的相关试验数据进行对比和分析。试验结果表明,内冷刀具适用于低温冷风切削方式,在降低表面粗糙度,改善其断屑性能,有效提高刀具的耐用度等方面有一定的优势。     

The influence of the cutting tool microgeometry on the machinability of hardened AISI 4140 steel

The aim of this work is to define the cutting conditions that allow the dry drilling of carbon fiber reinforced epoxy (CFRE) composite materials taking into consideration the quality of the drilled holes (the exit delamination factor and the cylindricity error) and the optimum combination of drilling parameters. A further aim is to use grey relational analysis to improve the quality of the drilled holes. The machining parameters were measured according to 3³ full factorial parameter designs (27 experiments with independent process variables). The experiments were carried out under various cutting parameters with different spindle speeds and feed rates. Drilling tests were done using WC carbide, high-speed steel (HSS), and TiN-coated carbide drills. The experiment design was accomplished by application of the statistical analysis of variance (ANOVA). Results show that the thrust force is mainly influenced by the tool materials and the feed rate, which has a strong influence on the exit delamination factor. On the other hand, the spindle speed particularly affects the cylindricity error of the holes. Correlations were established between spindle speed/feed rate and the various machining parameters so as to optimize cutting conditions. These correlations were found by quadratic regression using response surface methodology (RSM). Finally, tests were carried out to check the concordance of experimental results.     

Lubricating property of MQL grinding of Al2O3/SiC mixed nanofluid with different particle sizes and microtopography analysis by cross-correlation

With the increased requirements for environmental protection, energy conservation, and low consumption, nanofluid minimal quantity lubrication (MQL) grinding, which is an environment-friendly machining method, has been paid increasing attention. Improving the lubricating property of nanofluids effectively is currently a main research trend. Meanwhile, optimizing mixed nanoparticle (NP) size ratio is an effective way for enhancing the lubricating property of MQL grinding. In the experiment, different sizes (30, 50, and 70 nm) of Al₂O₃ and SiC NPs were mixed, and nanofluids were prepared at 2% (volume fraction) mixed NPs and base oil. The prepared nanofluids were then used in MQL grinding on a hard Ni-based alloy (inconel 718). The experiment was then evaluated by specific grinding force, removal rate of workpiece, surface roughness, morphology of grinding debris, and contact angle. The effect of the sizes of the Al₂O₃/SiC mixed NPs on MQL grinding performance was discussed in accordance with the period and amplitude, as well as cross-correlation coefficient, of the workpiece surface cross-correlation function curve profile. Experimental results suggest that different Al₂O₃/SiC mixed NP sizes affect the nanofluid MQL grinding performance variably. The highest removal rate of the workpiece [189.05 mm³/(s N)] and the lowest RSm (0.0381 mm) were achieved when the Al₂O₃/SiC mixed NP size ratio was 70:30. The lowest Ra (0.298 μm) was obtained at 50:30. Meanwhile, the highest length ratio of the profile support (90%), the best morphology of abrasive dusts, and the largest wetting area of liquid drops were acquired at 30:70. Furthermore, a cross-correlation analysis of the workpiece surface profile curve under three size ratios (30:70, 50:30, and 70:30) was carried out. The cross-correlation function curve of the workpiece surface profile under 30:70 attained the shortest period, the largest amplitude, and the largest cross-correlation coefficient (0.67), thereby indicating good workpiece surface quality. Therefore, 30:70 was the best size ratio of the Al₂O₃/SiC mixed nanofluid.     

镍基合金Inconel718可切削加工性的试验研究

Inconel718是一种高强度耐热镍基合金,具有优良的高温强度、高温硬度和耐蚀性,在高温条件下能长期工作,已被广泛地应用于宇航工业、航空工业的涡轮发动机和相关零件的制造。分析Inconel718的机械性能、微观组织结构及其对切削加工性能的影响并进行了相关的试验验证,在试验数据的基础上,研究Inconel718中含碳量对切削过程中刀具磨损的影响。试验结果表明,Inconel718中含碳量在刀具后刀面磨损中起着非常重要的作用,Inconel718合金中含碳量越高,合金中所含的细微硬质夹杂物也越多,在切削过程中使刀具产生严重的后刀面磨粒磨损,从而降低材料的切削加工性。     

Effect of modifier elements on machinability of Al-20%Mg2Si metal matrix composite during dry turning

The principle aim of this study was to observe the effect of machining parameters as well as the separate additions of 0.4 wt% bismuth, 0.01 wt% strontium, and 0.8 wt% antimony on the machinability of Al-20%Mg₂Si in situ metal matrix composite. Microstructure alteration, surface roughness, main cutting force, and chip morphology were taken into account as indices to examine the effect of modifiers and machinability during dry turning. It was found that the additives modify the Mg₂Si_P particles by changing the particle shape from coarse primary to polygonal shape and decrease the particle size and aspect ratio as well as increase the particle density. Results show that the modified work-pieces present adequate machinability with respect to cutting force and surface roughness. The smaller reinforcements enable lower surface roughness values to be obtained even if they are pulled out, fractured, or elongated. In addition, the modified work-pieces encourage lower surface roughness values in comparison with unmodified work-piece due to less built-up-edge formation. A scenario for surface roughness of Al-Mg₂Si composite with respect to the size and aspect ratio of reinforcement particles is proposed in this study.     

An investigation on surface grinding of hardened stainless steel S34700 and aluminum alloy AA6061 using minimum quantity of lubrication (MQL) technique

In grinding process, the abrasives plunge and slide against the workpiece during material removal with high specific energy consumption and high grinding zone temperature. To improve process efficiency, lubrication becomes an important requirement of the grinding fluids, along with chip removal and cooling the grinding zone. Grinding fluids have negative influences on the working environment and machining cost in terms of the health of the machine operator, pollution, the possibility of explosion (for oil), filtering, and waste disposal. The use of minimum quantity of lubrication (MQL) with an extremely low consumption of lubricant has been reported as a technologically and environmentally feasible alternative to flood cooling. This paper deals with an investigation of the grindability of hardened stainless steel (UNS S34700) and aluminum alloy AA6061 using dry, MQL, and conventional fluid techniques. One type of SiC and five types of Al₂O₃ wheels (corundum) as well as vegetable and synthetic ester MQL oils have been tested. The influences of wheel and coolant–lubricant types have been studied on the basis of the grinding forces, surface topography, and surface temperature. Synthetic ester MQL oil was found to give better grinding performance than the vegetable MQL oils. It was argued that the improved performance of the ester oil is caused by the formation of tribo-films on the abrasives and the workpiece, which enhances lubrication by inhibiting metal–abrasive interaction. Also, the grindability of the machined specimens was found to increase substantially by using the MQL grinding process with soft and coarse wheels. In MQL grinding of AA6061 alloy, the use of vegetable oil resulted in the lowest surface roughness, whereas using synthetic ester additives lead to highest surface roughness because of higher chip loading on the grinding wheel and consequently more redeposited material on the workpiece surface.     

Computational fluid dynamics analysis of MQL spray parameters and its influence on superalloy grinding

The application of emulsion for combined heat extraction and lubrication requires continuous monitoring of the quality of emulsion to sustain a desired grinding environment; this is applicable to other grinding fluids as well. To sustain a controlled grinding environment, it is necessary to adopt an effectively lubricated wheel–work interface. The present work aims to develop a numerical model to replicate the mist formation in minimum quantity lubrication (MQL) grinding using a fluent-based computational fluid dynamics (CFD) flow solver. The MQL parameters considered for this study are air pressure and the mass flow rate. Simulation of the atomization under turbulent conditions was done in a discrete phase model (DPM) owing to the fact that oil mass flow rates are very low and oil acts as a discrete medium in air. Jet velocity and droplet diameters were also obtained under different input conditions to find the optimum value of air pressure and mass flow rate of oil to achieve the desired results (lower cutting force and surface roughness) in MQL grinding of superalloy (Inconel 751). It is seen that medium size (around 16.3 µm) of droplet plays a significant role in improved performance by the way of reduction in cutting force and surface roughness.     

考虑质量扩散的瘤内磁流体分布对磁热疗影响研究

通过比较磁纳米颗粒在体内的理想均匀分布和真实实验分布,研究了不同纳米流体分布对治疗温度的影响,其中真实分布来源于实验结果经本文所提出方法处理后的图像分布.同时,还进一步研究了纳米流体扩散行为对浓度分布的影响,以及研究了温度依赖性的血液灌注率和传统定值灌注率对治疗温度分布影响的差异.本研究基于热等效应剂量的角度,通过43...     

微量润滑系统油雾调控及雾粒特性研究

微量润滑油雾调控及雾粒传输方式直接影响油雾状态的变化,进而影响喷射至切削区域的雾粒特性。基于内置式微量润滑雾化技术和油雾内部传输应用特点,研究了不同微量润滑雾化参数和雾粒传输方式条件下油量调控性能和调控规律,并结合传输管路油雾出口雾粒特征,揭示了油雾传输管路内径和传输行程对雾粒特性的影响规律。研究结果表明,雾化室压差在传输油雾量调控上比进气压力作用显著,需要结合压差和进气压力二者影响来考虑雾化器开启数量以对传输油雾量进行调节,在传输过程中传输管路尺寸与行程是影响油雾雾粒特性的重要因素。     

Effect of magnetic field on forced convection between two nanofluid laminar flows in a channel

This paper provides a numerical study of forced convection between hot and cold nanofluid laminar flows that are separated by a thin membrane, in a horizontal channel. Outer surface of channels' walls are thermally insulated and divide into two parts; namely NMP and MP. NMP is the channel's wall from the entrance section to the middle section of channel that is not influenced by magnetic field. MP is the channel's wall from the middle section to the exit section of channel which is influenced by a uniform-strength transverse magnetic field.The governing equations for both hot and cold flows are solved together using the SIMPLE algorithm. The effects of pertinent parameters, such as Reynolds number(10≤Re≤500), Hartman number(0≤Ha≤60) and the solid volume fraction of copper nano-particles(0≤?≤0.05), are studied. The results are reported in terms of streamlines, isotherms, velocity and temperature profiles and local and average Nusseltnumber.The results of the numerical simulation indicate that the increase in Reynolds number and the solid volume fraction lead to increase in Nusselt number. Meanwhile, the results also show that the rate of heat transfer between the flows increases as the Hartmann number increases, especially at higher values of the Reynolds number.     

Evaluation of machinability according to the changes in machine tools and cooling lubrication environments and optimization of cutting conditions using Taguchi method

This study analyze the effect of machine tools, cooling lubrication environments and cutting conditions on surface roughness and cutting force, and propose the combination of cutting conditions which minimizes the effect of machine tool variables on the dispersion of cutting force and surface roughness by treating the changes in machine tool itself and the installation environments as a noise factors. To do so, the Taguchi method is used to establish an experiment plan, and flat end milling is carried out to measure cutting force and surface roughness. The research results show that in the case of cutting force, the effect of cutting conditions is dominant, and changes in machine tools and cooling lubrication environments barely have effect on cutting force. However, in the case of surface roughness, all of the cutting conditions, machine tool and cooling lubrication environment variables have impact. In order to select a combination of cutting conditions insensible to changes in machine tools, considerations for feed per revolution and axial depth of cut turn out most important in the aspect of cutting force, and considerations for feed per revolution is most important in the surface roughness.     

Theoretical and experimental study of the chatter vibration in wet and MQL machining conditions in turning process

Turning is one of the most commonly used cutting processes for manufacturing components in production engineering. The turning process, in some cases, is accompanied by intense relative movements between tool and workpiece, which is called chatter vibrations. Chatter has been identified as a detrimental problem that adversely impacts surface finish, tool life, process productivity, and dimensional accuracy of the machined part. Cooling/Lubrication in the turning process is normally done for some reasons, including friction and force reduction, temperature decrement, and surface finish improvement. Wet cooling is a traditional cooling/lubrication process that has been used in machining since the past. Besides, a variety of new cooling and lubricating approaches have been developed in recent years, such as the minimum quantity lubrication (MQL), cryogenic cooling, nanolubrication, etc., due to ecological issues. Despite the importance of cooling/lubrication in machining, there is a lack of research on chatter stability in the presence of cutting fluid in cutting processes. In this study, the chatter vibration in turning process for two cooling/lubrication conditions of conventional wet and MQL is investigated. An integrated theoretical model is used to predict both the metal cutting force and the chatter stability lobe diagram (SLD) in turning process. This model involves deriving a math equation for predicting metal cutting force for both wet and MQL conditions using experimental training force data and a Genetic Expression Programming (GEP)-based regression model. Also, the traditional single degree of freedom chatter model is used here for predicting the SLDs. The chatter model is discussed and verified with experimental tests. Then, the experimental results of the tool's acceleration signal, work surface texture, surface roughness, chip shape, and tool wear are presented and compared for wet and MQL conditions. The results of this study show that the cooling/lubrication systems such as wet or MQL have a considerable effect on the SLDs. Also, the predicted results of metal cutting force and SLD for both wet and MQL techniques are in good agreement with the experimental data. Therefore, it is recommended that for each lubrication condition including wet, or MQL, the SLD be determined to achieve higher machinability.     

Experimental investigations on machinability aspects in finish hard turning of AISI 4340 steel using uncoated and multilayer coated carbide inserts

The present work deals with some machinability studies on flank wear, surface roughness, chip morphology and cutting forces in finish hard turning of AISI 4340 steel using uncoated and multilayer TiN and ZrCN coated carbide inserts at higher cutting speed range. The process has also been justified economically for its effective application in hard turning. Experimental results revealed that multilayer TiN/TiCN/Al₂O₃/TiN coated insert performed better than uncoated and TiN/TiCN/Al₂O₃/ZrCN coated carbide insert being steady growth of flank wear and surface roughness. The tool life for TiN and ZrCN coated carbide inserts was found to be approximately 19 min and 8 min at the extreme cutting conditions tested. Uncoated carbide insert used to cut hardened steel fractured prematurely. Abrasion, chipping and catastrophic failure are the principal wear mechanisms observed during machining. The turning forces (cutting force, thrust force and feed force) are observed to be lower using multilayer coated carbide insert in hard turning compared to uncoated carbide insert. From 1st and 2nd order regression model, 2nd order model explains about 98.3% and 86.3% of the variability of responses (flank wear and surface roughness) in predicting new observations compared to 1st order model and indicates the better fitting of the model with the data for multilayer TiN coated carbide insert. For ZrCN coated carbide insert, 2nd order flank wear model fits well compared to surface roughness model as observed from ANOVA study. The savings in machining costs using multilayer TiN coated insert is 93.4% compared to uncoated carbide and 40% to ZrCN coated carbide inserts respectively in hard machining taking flank wear criteria of 0.3 mm. This shows the economical feasibility of utilizing multilayer TiN coated carbide insert in finish hard turning.     

Effect of elasto-plastic loading on the magnetic characteristics of steel 20 hardened with gas case-hardening

The evolution of the magnetic characteristics of case-hardened Steel 20 under the influence of elasto-plastic tensile, compressive, and torsional strains is analyzed. The field dependence of the differential magnetic permeability is shown to reflect a three-layer nature of the obtained micro-structure: a hardened surface layer, a transition zone, and a ferrite-pearlite core. It is proposed to evaluate the level of the applied stresses on the basis of the peak field and the height of the differential magnetic permeability peaks of corresponding layers of the case-hardened steel.     

Effect of hardening on the machinability of C22 steel under drilling operations using twist HSS drill bit

For metallic or composite materials, the judicious choice of cutting conditions depends on several factors that may be of such objectives (time, cost of production, material removal rate, etc.) or constraints (cutting force, temperature in the machining area, consumed power, etc.). The quality of the results depends on the optimization method and the efficiency of the algorithm involved. In this paper, graphical and particle swarm optimization (PSO) methods are proposed. They aim to determine the optimal cutting conditions (cutting speed and feed per tooth) in slotting of multidirectional carbon fiber reinforced plastic laminate (CFRP), referenced G803/914, with three knurled tools having different geometries. The experiences that led to the measures of roughness, temperature, cutting efforts, and consumed power are made in the same working conditions with cutting speed ranging from 80 to 200 m/min and feed per tooth from 0.008 to 0.060 mm/rev/tooth. The results illustrate that for the graphical method, the optimum cutting speed depends on the performance “maximum total removal rate” and is the same for all the studied knurled tools while optimum feed per tooth depends on the “roughness” performance: its value depends on the tool geometry. For the PSO technique, optimum cutting speed and feed per tooth values are variable and depend on the tool geometry.     

Effect of lapping on the fatigue strength of a hardened 13Cr-0.34C stainless steel

Reversed plane-bending fatigue tests were carried out on 13Cr-0.34C stainless steels, heated treated to two hardness levels. Their surfaces were prepared by grinding and lapping according to the procedure actually used in the production of compressor valves. It was found that the larger compressive residual stresses in the subsurfaces produced by lapping raised the fatigue strength in spite of the increased surface roughness and the embedding of lapping particles, the latter being effective in reducing wear.     

Experimental investigation and economic analysis of surfactant (Span-20) in powder mixed electrical discharge machining (PMEDM) of AISI D2 hardened steel

Abstract

Powder mixed EDM (PMEDM) is recognized as an advanced and innovative technique with enhanced performance and limited drawbacks in comparison to conventional EDM method. This study investigates the effect of powder particle size, various powder concentrations (C_p), and surfactant concentrations (C_s) on the performance of EDM. Since the machining characteristics are highly dependent on the dielectric performances, significant attention has been directed to introduce Cr powder and Span-20 surfactant into the dielectric fluid to achieve higher productivity and enhanced surface integrity. The EDM machining was carried out on AISI D2 hardened steel through ´Plug & Plaý dielectric circulating system attached to the main machine in order to evaluate the machining performances (i.e. MRR, EWR, and R_a). Interestingly, machining performance was improved with combination of Cr powder mixed and span-20 surfactant. By comparing the performance of span-20 surfactant and micro-nano chromium, the result within selected parameters shows that the span-20 surfactant and nano-chromium is the better choice for the EDM of AISI D2 hardened steel. In the machinability studies, the EDM machining of AISI D2 hardened steel by using span-20 surfactant and nano-chromium has exhibited the excellent machining performances, which led to 45.08% MRR enhancement and 68.89% R_a enhancement comparing to micro-chromium powder and span-20 surfactant led to 35.28% MRR and 28.96% R_a. Furthermore, cost analysis revealed that the nano-Cr powder size was approximately 4 times more economical than micro-Cr powder in machining of AISI D2 hardened steel, although the price for 1?kg is quite expensive.