Investigating the effects of liquid atomization and delivery parameters of minimum quantity lubrication on the grinding process of Al2O3 engineering ceramics

Minimum quantity lubrication (MQL) is a cost-effective and environmentally friendly alternative to flood cooling. MQL spray jet has been shown to have potential to be applied successfully in different machining processes. Since the amount of lubricating liquid employed in MQL jet is very low, it is necessary to generate and apply the MQL spray efficiently. However, efficient application of MQL is not only related to spray atomization characteristics and delivery parameters but is also affected by machining conditions. The present paper demonstrates a theoretical and experimental investigation on the spray atomization and delivery parameters in the grinding process of Al₂O₃ engineering ceramics. The spray atomization characteristics studied are carrier gas velocity, liquid droplet size and liquid droplet velocity. Experiments were performed to verify the delivery parameters of MQL spray including nozzle angle, nozzle distance, lubricant flow rate and gas flow rate in the case of Al₂O₃ ceramics grinding. The experimental results confirm the theoretical outcomes and indicate that by applying optimal spray delivery parameters efficient lubrication takes place. Moreover, efficient lubrication of Al₂O₃ ceramics grinding can decrease the challenges existing in ceramics grinding processes by reducing grinding forces and surface roughness.     

Analytical model of metalworking fluid penetration into the flank contact zone in orthogonal cutting

Metalworking fluids (MWFs) are used widely in machining process to dissipate heat, lubricate moving surfaces, and clear chips. They have also been linked to a number of environmental and worker health problems. To reduce these impacts, minimum quantity lubrication (MQL) sprays of MWF delivered in air or CO₂ have been proposed. MQL sprays can achieve performance comparable with conventional water-based or straight oil MWFs while only delivering a small fraction of the fluid. This performance advantage could be explained by the enhanced penetration into the cutting zone that results from delivering MWF in high pressure and precise sprays. To explore this hypothesis, an analytical model of MWF penetration into the flank face of the cutting zone is developed and validated using experimental data. The model is based on a derivation of the Navier–Stokes equation and the Reynolds equation for lubrication and applied to an orthogonal cutting geometry under steady-state conditions. A solution to the model is obtained using a numerical strategy of discretizing the analytical scheme with two-dimensional centered finite difference method. Penetration into the cutting zone is estimated for MQL sprays delivered in air, CO₂ and N₂ as well as two conventional MWFs, straight oil and semi-synthetic emulsion. The model suggests that conventional MWFs, do not penetrate the cutting zone fully and fail to provide direct cooling to the flank zone where wear is most likely to occur. MQL sprays do penetrate the cutting zone completely. Using convective heat transfer coefficients from a previous study, a finite element heat balance is carried out on the tool to understand how each fluid impacts temperature near the flank tip of the tool. The results of the modeling effort are consistent with experimental measurements of tool temperature during turning of titanium (6AL4V) using a K313 carbide tool. The prediction of temperature near the flank indicates that MQL sprays do suppress temperatures near the flank effectively. These results help explain the low levels of tool wear observed for some MQL sprays, particularly those based on high pressure CO₂. This modeling framework provides valuable insight into how lubricant delivery characteristics such as speed, viscosity, and cutting zone geometry can impact lubricant penetration.     

Micro-flood (MF) technology for sustainable manufacturing operations that are coolant less and occupationally friendly

This paper presents a new technology for minimizing the use of metalworking fluids (MWFs) during the machining process that is atomization-less and occupational friendly. Micro-flood (MF) technology utilizes direct contact between the cutting tool and the MWF without the interaction of a gas medium. Experiments were conducted in high volume mass production environment turning HSLA (high strength low alloy) SAE 070Y steel. Machining performance and total air mass particulates were investigated in dry machining, Near dry machining (NDM) via atomized spray mist and MF technology. Open-atmosphere air monitoring indicated that total mass particulates behaved in an almost linear fashion with respect to gas atomization pressure, whereas the MWF flow rate demonstrated logarithmic trends in NDM applications using an atomized spray. Nozzle orientations directed upward into the air also produced higher mg/m³ concentrations (such as flank) than chip and rake face orientations that were directed down. Greater separation existed at higher gas atomization pressures, MWF flow rates and by changing the MWF type. At extreme limits, nozzle orientation affected mg/m³ concentration as much as 4–5 mg/m³ for water-miscible MWFs and 15–22 mg/m³ for non-water-miscible MWFs. Tool-life performance varied greatly among MWF type and flow rate, and in all cases MF technology performed better than NDM using an atomized spray mist. Direct and consistent MWF penetration to cutting zone using MF technology lowered tool-wear on the average of 12–75% compared to NDM at the same MWF flow rate. Compared to dry machining, NDM improved tool-wear on the average by 20–243%. In one case, tool-wear performance was improved by 616% at 0.15 mm using MF technology compared to dry machining at a nominal 0.925 mm tool-wear. Overall, a large mass reduction of particulates can be achieved employing MF technology that would have been unrealistic for an open-atmosphere machining environment employing an atomized spray mist. On the average, MF technology can maintain a total air mass particulate of less than 0.4 mg/m³ in the occupational work zone using MWF flow rates up to 1260 ml/h, regardless of the MWF classification. Atomized spray mist applications are capable meeting the 5 mg/m³ OSHA limit if MWF flow rates are less than 160 ml/h, air pressures are less than 0.137 MPa (20 psi) using water-miscible MWFs and air pressures are less than 0.0344 MPa (5 psi) using non-water-miscible MWFs.     

Measurement of tool internal temperatures in the tool–chip contact region by embedded micro thin film thermocouples

Sensors capable of providing fast and reliable feedback signals for monitoring and control of existing and emerging machining processes are an important research topic, that has quickly gained academic and industrial interest in recent years. Generally, high-precision machining processes are very sensitive to variation in local machining conditions at the tool–workpiece interface and lack a thorough understanding of fundamental thermomechanical phenomena. Existing sensors to monitor the machining conditions are not suitable for robust in-process control as they are either destructively embedded and/or do not possess the necessary spatial and temporal resolution to monitor local tool internal temperatures during machining at the cutting tip/edge effectively. This paper presents a novel approach for assessing transient tool internal temperature fields in the close vicinity of less than 300 μm of the tool cutting edge. A revised array layout of 10 micro thin film micro thermocouples, fabricated using adapted semiconductor microfabrication methods, has been embedded into polycrystalline cubic boron nitride (PCBN) cutting inserts by means of a modified diffusion bonding technique. Scanning electron microscopy was used to examine material interactions at the bonding interface and to determine optimal bonding parameters. Sensor performance was statically and dynamically characterized. They show good linearity, sensitivity and very fast response time. Initial machining tests on aluminum alloys are described herein. The tests have been performed to demonstrate the functionality and reliability of tool embedded thin film sensors, and are part of a feasibility study with the ultimate goal of applying the instrumented insert in hard machining operations. The microsensor array was used for the acquisition of tool internal temperature profiles very close to the cutting tip. The influence of varying cutting parameters on transient tool internal temperature profiles was measured and discussed. With further study, the described instrumented cutting inserts could provide more valuable insight into the process physics and could improve various aspects of machining processes, e.g. reliability, tool life, and workpiece quality.     

Macro-level environmental comparison of near-dry machining and flood machining

This paper focuses on investigating several aspects of the machining process from an ecological perspective, the result being a macro-level analysis. The analysis presented here considers not only the environmental impact of the material removal process itself, but also the impact of the associated processes such as the material preparation, and the scrap processing. A macro-level assessment of the comparative life cycle environmental performance of the near-dry machining (NDM) using TiN-coated carbide tools and the flood machining (FM) is performed by a case study referring to the gear milling. The assessment, using the SimaPro 7.1.5 software and the ecoinvent1.5 database, includes combined Life Cycle Assessment (LCA) of the workpiece material, the scrap processing, the use of lubrication, and the energy consumption.     

The effect of spindle speed,feed-rate and machining time to the surface roughness and burr formation of Aluminum Alloy 1100 in micro-milling operation

This paper describes the characteristics and the cutting parameters performance of spindle speeds (n, rpm) and feed-rates (f, mm/s) during three interval ranges of machining times (t, minutes) with respect to the surface roughness and burr formation, by using a miniaturized micro-milling machine. Flat end-mill tools that have two-flutes, made of solid carbide with Mega-T coated, with 0.2 mm in diameter were used to cut Aluminum Alloy AA1100. The causal relationship among spindle speeds, feed-rates, and machining times toward the surface roughness was analyzed using a statistical method ANOVA. It is found that the feed-rate (f) and machining time (t) contribute significantly to the surface roughness. Lower feed-rate would produce better surface roughness. However, when machining time is transformed into total cut length, it is known that a higher feed-rate, that consequently giving more productive machining since produce more cut length, would not degrade surface quality and tool life significantly. Burr occurrence on machined work pieces was analyzed using SEM. The average sizes of top burr for each cutting parameter selection were analyzed to find the relation between the cutting parameters and burr formation. In this research, bottom burr was found. It is formed in a longer machining time compare the formation of top burr, entrance burr and exit burr. Burr formation is significantly affected by the tool condition, which is degrading during the machining process. This knowledge of appropriate cutting parameter selection and actual tool condition would be an important consideration when planning a micro-milling process to produce a product with minimum burr.     

Prediction of polycrystalline materials texture evolution in machining via Viscoplastic Self-Consistent modeling

The crystallographic orientation or anisotropy is one of the main microstructural attributes strongly affecting the mechanical properties of materials. It is also an influential parameter to be considered during the manufacturing process especially for ultra-precision machining since it affects part quality, tool performance, and process productivity through material properties. In this study, a prediction toolset constituted of a Viscoplastic Self-Consistent model and machining process mechanics model is used to predict the texture evolution on the machined surface. The VPSC (Viscoplastic Self-Consistent) methodology which uses the mechanisms of slip and twinning that are active in single crystals of arbitrary symmetry was used. For this, an analytical model for the process mechanics is derived to understand the forces and stresses generated by the cutting tool at each workpiece point, then the strain and strain rate to capture the rate at which the material is deforming and finally the crystallographic orientations under various machining conditions. Experiments were performed on the orthogonal cutting of aluminum alloy AA-7075-T651 and the texture results were compared to model predictions.     

An analytical force model for orthogonal elliptical vibration cutting technique

The elliptical vibration cutting (EVC) technique has been found to be a promising technique for ultraprecision machining of various materials. In each overlapping EVC cycle, the thickness of cut (TOC) of work material, and the tool velocity get continuously varied. These two inherent phenomena, in fact, introduce transient characteristics into its cutting mechanics, which are considered to be different from the one applied for conventional cutting technique. Recently, a few theoretical models have been developed to understand the material removal mechanism with the EVC technique; however, in those studies, the transient phenomena were not considered. In the present research, an analytical force model for the orthogonal EVC process was developed in order to fully understand the EVC mechanism, and to more accurately predict the transient cutting force values. Three important factors: (i) transient TOC, (ii) transient shear angle, and (iii) transition characteristic of friction reversal were investigated and analyzed mainly based on geometric modeling and the Lee and Shaffer's slip-line solution. Mathematical evaluation shows that they may have significant influence on EVC process, and thus on its output performance. In order to validate the proposed force model, a series of low-frequency orthogonal EVC tests were conducted. The experimental transient cutting force values were compared with the predicted values calculated using the proposed model, and they are found to be in a good agreement with each other.     

AFM probe based nano mechanical scribing of soda-lime glass

In recent years, demands for miniature components have increased due to their reduced size, weight and energy consumption. In particular, brittle materials such as glass can provide high stiffness, hardness, corrosion resistance and high-temperature strength for various biomedical and high-temperature applications. In this study, cutting properties and the effects of machining parameters on the ductile cutting of soda-lime glass are investigated through the nano-scale scratching process. In order to understand the fundamentals of the material removal mechanism at the atomic scale, such as machined surface quality, cutting forces and the apparent friction, theoretical investigation along with experimental study are needed. Scribing tests have been performed using a single crystal diamond atomic force microscope (AFM) probe as the scratching tool, in order to find the cutting mechanism of soda-lime glass in the nano-scale. The extended lateral force calibration method is proposed to acquire accurate lateral forces. The experimental thrust and cutting forces are obtained and apparent friction coefficients are deduced. The effects of feed rates and the ploughing to shearing transition of soda-lime glass have been investigated.     

Ball end milling mechanistic model based on a voxel-based geometric representation and a ray casting technique

Prediction of machining forces involved in complex geometry can be valuable information for machine shops. This paper presents a mechanistic cutting force simulation model for ball end milling processes, using ray casting and voxel representation methods used in 3D computer graphics field. Using this method, instantaneous uncut chip cross sectional areas can be extracted, which can be used in cutting pressure coefficient extraction and machining simulation including machining forces and geometry of the workpiece. The major advantage of the proposed scheme is that it can simulate milling processes with arbitrary cutting tool geometry on a workpiece with complex geometry, using an algorithm with constant time complexity. A series of cutting experiments were carried out to validate the model.     

Machining evaluation of a hybrid MQL-CO2 grinding technology

Although there are already successful industrial experiences in other machining industries with the elimination of coolants, this is not so in the grinding industry due to the large amounts of generated heat that must be evacuated from the contact zone. In this work, a new approach to the elimination of fluids in grinding is presented. The technology is based on the use of a hybrid Minimum Quantity of Lubricant (MQL)-low temperature CO₂ system that reduces lubrication consumption. Abrasive grits are protected by the layer of frozen oil, resulting in a significant improvement in grinding wheel life and surface quality of the machined component. Although the cooling action is reduced with respect to the conventional coolant, no thermal damage was observed on the workpiece.     

Analysis of machined surface quality in a single-pass of ball-end milling on Inconel 718

The ball-end milling process is widely used for generating three-dimensional sculptured surfaces with definite curvature. In such cases, variation of surface properties along the machined surface curvatures is not well understood. Therefore, this paper reports the effect of machining parameters on the quality of surface obtained in a single-pass of a ball-end milling cutter with varying chip cross-sectional area. This situation is analogous to generation of free form cavities, pockets, and round fillets on mould surfaces. The machined surfaces show formation of distinct bands as a function of instantaneous machining parameters along the periphery of cutting tool edge, chip compression and instantaneous shear angle. A distinct variation is also observed in the measured values of surface roughness and micro-hardness in these regions. The maximum surface roughness is observed near the tool tip region on the machined surface. The minimum surface roughness is obtained in the stable cutting zone and it increases towards the periphery of the cutter. Similar segmentation was observed on the deformed chips, which could be correlated with the width of bands on the machined surfaces. The sub-surface quality analysis in terms of micro-hardness helped define machining affected zone (MAZ). The parametric effects on the machining induced shear and residual stresses have also been evaluated.     

Modulation-assisted high speed machining of compacted graphite iron (CGI)

The application of controlled, low-frequency modulation (～100 Hz) superimposed onto the cutting process in the feed-direction – modulation-assisted machining (MAM) – is shown to be quite effective in reducing the wear of cubic boron nitride (CBN) tools when machining compacted graphite iron (CGI) at high machining speeds (>500 m/min). The tool life is at least 20 times greater than in conventional machining. This significant reduction in wear is a consequence of the multiple effects realized by MAM, including periodic disruption of the tool–workpiece contact, formation of discrete chips, enhanced fluid action and lower cutting temperatures. The propensity for thermochemical wear of CBN, the principal wear mode at high speeds in CGI machining, is thus reduced. The tool wear in MAM is also found to be smaller at the higher cutting speeds (730 m/min) tested. The feed-direction MAM appears feasible for implementation in industrial machining applications involving high speeds.     

Laser tempering based turning process for efficient machining of hardened AISI 52100 steel

Cost-effective machining of hardened steel components such as a large wind turbine bearing has traditionally posed a significant challenge. This paper presents an approach to machine hardened steel parts efficiently at higher material removal rates and lower tooling cost. The approach involves a two-step process consisting of laser tempering of the hardened workpiece surface followed by conventional machining at higher material removal rates with lower cost ceramic tools to efficiently remove the tempered material. The laser scanning parameters that yield the highest depth of tempered layer are obtained from a kinetic phase change model. Machining experiments are performed to demonstrate the possibility of higher material removal rates and improved tool wear behavior compared to the conventional hard turning process. Tool wear performance, cutting forces, and surface finish of Cubic Boron Nitride (CBN) tools as well as low cost ceramic tools are compared in machining of hardened AISI 52100 steel (~63 HRC). In addition, cutting forces and surface finish are compared for the laser tempering based turning and conventional hard turning processes. Experimental results show the potential benefits of the laser tempering based turning process over the conventional hard turning process.     

Machining Performance and Health Effects of Cutting Fluid Application in Drilling of A390.0 Cast Aluminum Alloy

Environmental issues in machining have led to a push to curtail the use of cutting fluids. However, cutting fluid effects on part quality, process planning, and operator exposure to aerosols need to be first studied. The effects of cutting fluid application on hole accuracy and mist generation have been studied for blind-hole drilling of A390.0 aluminum alloy. Different cutting fluid types and application modes were tested under varying conditions of cutting speed, feed, and hole depth. The cooling and chip-transporting ability of cutting fluids was found to have the maximum effect on dimensional accuracy. Dry cutting yielded holes with the least accuracy, while mist lubrication was found to give superior dimensional accuracy to dry cutting but had the worst aerosol concentration. Flooding with synthetic cutting fluid gave the best overall results.     

Experimental investigation of turning AISI 1045 steel using cryogenic carbon dioxide as the cutting fluid

The intensive temperatures in high speed machining not only limit the tool life but also impair the machined surface by inducing tensile residual stresses, microcracks and thermal damage. This problem can be handled largely by reducing the cutting temperature. When the conventional coolant is applied to the cutting zone, it fails to remove the extent of the heat effectively. Hence, a cryogenic coolant is highly recommended for this purpose. In this paper, an attempt has been made to use cryogenic carbon dioxide (CO₂) as the cutting fluid. Experimental investigations are carried out by turning AISI 1045 steel in which the efficiency of cryogenic CO₂ is compared to that of dry and wet machining with respect to cutting temperature, cutting forces, chip disposal and surface roughness. The experimental results show that the application of cryogenic CO₂ as the cutting fluid is an efficient coolant for the turning operation as it reduced the cutting temperature by 5%–22% when compared with conventional machining.It is also observed that the surface finish is improved to an appreciable amount in the finished work piece on the application of cryogenic CO₂. The surface finish is improved by 5%–25% in the cryogenic condition compared with wet machining.     

From large-scale to micromachining: A review of force prediction models

In this paper, a review of work performed in the area of force modelling in metal cutting processes is presented. Past and present trends are described and criticised to compare their relevance with current requirements. Several approaches are reviewed, such as empirical, mechanistic and analytical models. The models’ ability to predict forces, from rough machining to finish machining, is analysed.     

Application of FEM simulation of chip formation to stability analysis in orthogonal cutting process

Models for chatter prediction in machining often use a mechanistic force model that calculate the force as the product of a material dependent cutting constant and chip area. However, in reality, the forces are the result of complex interaction between the tool and the chip, and are affected by many factors. The effects of these complex, and often nonlinear, factors on the machining dynamics may only be included in chatter prediction if the chip formation process is simulated concurrently with simulation of the machining dynamics. In this paper, finite element simulation of the chip formation process is combined with simulation of chatter dynamics and the inter-relationship between the chip formation process and the chatter phenomenon is investigated. Mesh adaptation technique is used to simulate the chip formation within an FEM elastoplastic analysis with dynamic effects and frictional contact. The combined modeling predicts the occurrence of process damping at low cutting speeds, which other models are generally unable to predict.     

Analytical process damping stability prediction

This paper describes an analytical solution for turning and milling stability that includes process damping effects. Comparisons between the new analytical solution, time-domain simulation, and experiment are provided. The velocity-dependent process damping model applied in the analysis relies on a single coefficient similar to the specific cutting force approach to modeling cutting force. The process damping coefficient is identified experimentally using a flexure-based machining setup for a selected tool-workpiece pair (carbide insert-AISI 1018 steel). The effects of tool wear and cutting edge relief angle are also evaluated. It is shown that a smaller relief angle or higher wear results in increased process damping and improved stability at low spindle speeds.     

Experimental investigation,intelligent modeling and multi-characteristics optimization of dry WEDM process of Al–SiC metal matrix composite

Dry wire electrical discharge machining (WEDM) is an environmentally friendly modification of the oil WEDM process in which liquid dielectric is replaced by a gaseous medium. In the present work, parametric analysis has been fulfilled while dry WEDM of Al–SiC metal matrix composite. Experiments were designed and conducted based on L₂₇ Taguchi's orthogonal array to study the effect of pulse on time, pulse off time, gap voltage, discharge current, wire tension and wire feed on cutting velocity (CV) and surface roughness (SR). Firstly, a series of exploratory experiments has been conducted to identify appropriate gas and wire material based on the values of cutting velocity. After selection of best gas and best wire, they were used for later stage of experiments. Analysis of variances (ANOVA) has been performed to identify significant factors. In order to correlate relationship between process inputs and responses, an adaptive neuro-fuzzy inference system (ANFIS) has been employed to predict the process characteristics based on experimental observation. At the end, an artificial bee colony (ABC) algorithm has been associated with ANFIS models to maximize CV and minimize SR, simultaneously. Then the optimal solutions that obtained through ANFIS-ABC technique have been compared with numbers of confirmatory experiments. Results indicated that oxygen gas and brass wire guarantee superior cutting velocity. Also, according to ANOVA, pulse on time and discharge current were found to have significant effect on CV and SR. In modeling of CV and SR by ANFIS, it was resulted that the proposed method has superiority in prediction of them in the ranges of factors beyond the training condition. Also, association of ANFIS with ABC can find the optimal combination of process parameters accurately according to the confirmatory experiments.