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A comprehensive review on minimum quantity lubrication (MQL) in machining processes using nano-cutting fluids
The cutting fluid is significant in any metal cutting operation, for cooling the cutting tool and the surface of the workpiece, by lubricating the tool-workpiece interface and removing chips from the cutting zone. Recently, many researchers have been focusing on minimum quantity lubrication (MQL) among the numerous methods existing on the application of the coolant as it reduces the usage of coolant by spurting a mixture of compressed air and cutting fluid in an improved way instead of flood cooling. The MQL method has been demonstrated to be appropriate as it fulfills the necessities of ‘green’ machining. In the current study, firstly, various lubrication methods were introduced which are used in machining processes, and then, basic machining processes used in manufacturing industries such as grinding, milling, turning, and drilling have been discussed. The comprehensive review of various nanofluids (NFs) used as lubricants by different researchers for machining process is presented. Furthermore, some cases of utilizing NFs in machining operations have been reported briefly in a table. Based on the studies, it can be concluded that utilizing NFs as coolant and lubricant lead to lower tool temperature, tool wear, higher surface quality, and less environmental dangers. However, the high cost of nanoparticles, need for devices, clustering, and sediment are still challenges for the NF applications in metalworking operations. At last, the article identifies the opportunities for using NFs as lubricants in the future. It should be stated that this work offers a clear guideline for utilizing MQL and MQL-nanofluid approaches in machining processes. This guideline shows the physical, tribological, and heat transfer mechanisms associated with employing such cooling/lubrication approaches and their effects on different machining quality characteristics such as tool wear, surface integrity, and cutting forces.
Journal Article
Research status and development trend of tungsten alloy cutting
Tungsten alloy has excellent performance and has been widely used in military, aerospace and nuclear energy, and other cutting-edge industries. However, tungsten alloy has large hardness, high strength, and poor plastic deformation ability, which resulted in high cutting force and serious tool wear during the cutting process, leading to low surface quality of the workpiece after molding. Therefore, it is of great significance to strengthen the research on tungsten alloy cutting technology to promote the development of tungsten alloy application. Firstly, the research progress of tungsten alloy cutting process technology has been systematically reviewed, and the current status of cutting parameters optimization, new cutting methods and devices, and cutting fluid technology have been emphatically reviewed. Secondly, the types of tungsten alloy cutting tools, the relevant tool micro-texture, and tool coatings technology have been briefly described, and the composite cutting technology such as cryogenic cutting, electroplastically assisted cutting, and ultrasonic vibration assisted cutting and the effect of cutting performance prediction technology on tungsten alloy machining performance have been summarized. Finally, the development prospect of tungsten alloy cutting technology has been prospected.
Journal Article
The Influence of Surface Texturing of Ceramic and Superhard Cutting Tools on the Machining Process—A Review
Machining is an indispensable manufacturing process for a wide range of engineering materials, such as metals, ceramics, and composite materials, in which the tool wear is a serious problem, which affects not only the costs and productivity but also the quality of the machined components. Thus, the modification of the cutting tool surface by application of textures on their surfaces is proposed as a very promising method for improving tool life. Surface texturing is a relatively new surface engineering technology, where microscale or nanoscale surface textures are generated on the cutting tool through a variety of techniques in order to improve tribological properties of cutting tool surfaces by reducing the coefficient of friction and increasing wear resistance. In this paper, the studies carried out to date on the texturing of ceramic and superhard cutting tools have been reviewed. Furthermore, the most common methods for creating textures on the surfaces of different materials have been summarized. Moreover, the parameters that are generally used in surface texturing, which should be indicated in all future studies of textured cutting tools in order to have a better understanding of its effects in the cutting process, are described. In addition, this paper proposes a way in which to classify the texture surfaces used in the cutting tools according to their geometric parameters. This paper highlights the effect of ceramic and superhard textured cutting tools in improving the machining performance of difficult-to-cut materials, such as coefficient of friction, tool wear, cutting forces, cutting temperature, and machined workpiece roughness. Finally, a conclusion of the analyzed papers is given.
Journal Article
Investigation of Fracture Damage and Breaking Energy Consumption of Hard Rock Repeatedly Cut by Abrasive Water Jet
Abrasive water jet is widely used in the field of deep hard rock cutting. To accurately and quantitatively evaluate the implementation effect of repeated cutting hard rock by jet, the ratio of the jet cutting speed to the cutting times is defined as an index to evaluate the rock-breaking effect and efficiency, and laboratory experiments of repeated cutting granite by abrasive water jet under different horizontal stress are carried out. The obtained results show that the increase of rock horizontal stress leads to a rougher cutting surface of the abrasive jet, the average growth rate of roughness is 34.8 and 15.8%, respectively, and increases the specific energy consumption rate of the rock breaking, the average growth rate of specific energy consumption is 11.8 and 38.9%, respectively. When the repeated cutting method is used to break rock, as the ratio of the cutting speed to the cutting times increases, the cutting surface roughness and the specific energy consumption of rock breaking decrease first and then increase. When the cutting speed is 9 mm/s and the cutting is repeated for 3 times, the breaking effect and efficiency are the best. Under the combined action of axial high-speed impact, radial rotary grinding, and water wedge cracking, the local mineral particles in the slot may undergo trans-granular or inter-granular fracture, which eventually evolves into spalling and macro-damage of mineral particles.HighlightsThe variation of geometric parameters of slot cut by abrasive water jet with different horizontal stress and repeated cutting times is analyzed.The surface roughness changes after repeated jet cutting were analyzed using three-dimensional morphological scanning.The micro morphological characteristics of the slot surface under repeated cutting by abrasive water jet are described.The results could provide theoretical basis and production guidance for hydraulic cutting and breaking of deep hard rock.
Journal Article
Cutting performance and tool wear mechanism of corrugated helical PCD tool in milling Cf/SiC composites
C
f
/SiC composites are widely utilized in the aerospace industry due to their excellent properties. However, C
f
/SiC composites are notoriously challenging to machine. The substantial cutting force and severe tool wear during machining often result in poor surface quality and low machining efficiency. This paper presented a corrugated helical PCD (polycrystalline diamond) tool, featuring a helical structure and an arc array micro-groove on the primary cutting edge, and these micro-groove structures are staggered, facilitating continuous material removal during the machining of C
f
/SiC composites. The study investigated the milling force variations of the corrugated helical PCD tool when machining C
f
/SiC composites under different milling parameters. A comparative study was conducted on the milling force, surface quality, and tool wear of corrugated helical PCD tool and commercial PCD tools. The experiment revealed that the milling force initially decreases and then increases with rising spindle speed and increases with higher feed rates per tooth, milling depth, and width. The newly designed tool exhibited lower milling force, superior machining surface quality, and extended tool life, approximately 0.7 times that of commercial PCD tools. The cutting performance of the corrugated helical PCD tool proved superior. Additionally, it was confirmed that the primary wear mechanism for the corrugated helical PCD tool cutting C
f
/SiC composites was abrasive wear.
Journal Article
Performance Evaluation of Vegetable Oil-Based Nano-Cutting Fluids in Environmentally Friendly Machining of Inconel-800 Alloy
Recently, the application of nano-cutting fluids has gained much attention in the machining of nickel-based super alloys due their good lubricating/cooling properties including thermal conductivity, viscosity, and tribological characteristics. In this study, a set of turning experiments on new nickel-based alloy i.e., Inconel-800 alloy, was performed to explore the characteristics of different nano-cutting fluids (aluminum oxide (Al2O3), molybdenum disulfide (MoS2), and graphite) under minimum quantity lubrication (MQL) conditions. The performance of each nano-cutting fluid was deliberated in terms of machining characteristics such as surface roughness, cutting forces, and tool wear. Further, the data generated through experiments were statistically examined through Box Cox transformation, normal probability plots, and analysis of variance (ANOVA) tests. Then, an in-depth analysis of each process parameter was conducted through line plots and the results were compared with the existing literature. In the end, the composite desirability approach (CDA) was successfully implemented to determine the ideal machining parameters under different nano-cutting cooling conditions. The results demonstrate that the MoS2 and graphite-based nanofluids give promising results at high cutting speed values, but the overall performance of graphite-based nanofluids is better in terms of good lubrication and cooling properties. It is worth mentioning that the presence of small quantities of graphite in vegetable oil significantly improves the machining characteristics of Inconel-800 alloy as compared with the two other nanofluids.
Journal Article
Experimental research into alternative abrasive material for the abrasive water-jet cutting of titanium
Experimental research on high-pressure abrasive water-jet cutting of a popular titanium alloy, grade 5 (Ti6Al4V), is presented. Three types of abrasive material, garnet, olivine, and a cheaper alternative—crushed glass abrasive, were investigated. The influence of basic cutting parameters such as traverse speed and concentration of abrasive on cutting depth was shown, as was the effect of the ratio of the diameter of the water nozzle to the diameter of the focusing tube on the cutting depth. A slower traverse speed resulted in a deeper depth of cut for all abrasive materials. The variation of cutting depth became irrelevant when the concentration of the jet was increased. On basic regression analysis, the cutting depth control models were formulated. The cutting efficiency and the focusing tube wear for all abrasives were compared in order to determine the degree of effectiveness for each abrasive.
Journal Article
Abrasive Waterjet Machining
The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A description of this process and its influencing parameters are first presented in this paper, along with process models for the AWJ tool itself and also for the jet–material interaction. The AWJ material removal process occurs through the high-velocity impact of abrasive particles, whose tips micromachine the material at the microscopic scale, with no thermal or mechanical adverse effects. The macro-characteristics of the cut surface, such as its taper, trailback, and waviness, are discussed, along with methods of improving the geometrical accuracy of the cut parts using these attributes. For example, dynamic angular compensation is used to correct for the taper and undercut in shape cutting. The surface finish is controlled by the cutting speed, hydraulic, and abrasive parameters using software and process models built into the controllers of CNC machines. In addition to shape cutting, edge trimming is presented, with a focus on the carbon fiber composites used in aircraft and automotive structures, where special AWJ tools and manipulators are used. Examples of the precision cutting of microelectronic and solar cell parts are discussed to describe the special techniques that are used, such as machine vision and vacuum-assist, which have been found to be essential to the integrity and accuracy of cut parts. The use of the AWJ machining process was extended to other applications, such as drilling, boring, milling, turning, and surface modification, which are presented in this paper as actual industrial applications. To demonstrate the versatility of the AWJ machining process, the data in this paper were selected to cover a wide range of materials, such as metal, glass, composites, and ceramics, and also a wide range of thicknesses, from 1 mm to 600 mm. The trends of Industry 4.0 and 5.0, AI, and IoT are also presented.
Journal Article
Micro-milling tool wear monitoring under variable cutting parameters and runout using fast cutting force coefficient identification method
Extracting discriminative tool wear features is of great importance for tool wear monitoring in micro-milling. However, due to the dependency on tool runout and cutting parameters, the traditional tool wear features are incompetent to monitor the tool wear condition in micro-milling with significant tool runout and varied cutting parameter interactions. In this study, micro-milling cutting force is represented by a parametric model including variable cutting parameters, tool runout, and tool wear. The cutting force coefficient in the model, which is not only discriminative to the tool wear condition but also independent to the tool runout and cutting parameters, is extracted as the micro-milling tool wear feature. To reduce the computation cost, a fast neural network–based method is proposed to identify the tool runout and the cutting force coefficient from the cutting force signal. Experimental results show that the proposed cutting force coefficient–based approach is efficient to monitor the micro-milling tool wear under varied cutting parameters and tool runout.
Journal Article