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1

Influence of Aluminium Oxide Nanoparticles Mass Concentrations on the Tool Wear Values During Turning of Titanium Alloy Under Minimum Quantity Lubrication Conditions

Szczotkarz Natalia, Adamczuk Krzysztof, Dębowski Daniel, Gupta Munish Kumar

Advances in Science and Technology. Research Journal

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2024

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Vol. 18, no 1

76--88

EN

Recently, environmental consciousness has led to the quest for ways to minimise negative elements in machining operations that threaten operator health and the environment. Titanium alloys are hard to cut, thus cooling the cutting zone is essential to reduce tool wear. Variations in Al2O3 nanoparticle concentrations supplied to the MQL cutting fluid affect cutting wedge wear during Ti6Al4V alloy turning. A diameter of 15 nm nanoparticles were utilised at 0.25, 0.5, 0.75, and 1 wt% mass concentrations. In the experiments, the flank face wear band width VBB and crater width KB were measured. Comparisons were also made using dry-cutting tools and the MQL approach without nanoparticles. X-ray microanalysis was used to quantify and qualitatively assess the chemical composition of chosen rake surface micro-areas. Studies showed that Al2O3 nanoparticle mass concentration affects tool wear when turning a hard-to-cut alloy. 0.5 and 0.75 wt% mass concentrations had the lowest flank and rake wear of the four mass concentrations. The SEM examination showed that 0.5 wt% mass concentration decreased adhesive wear the most.

2

Influence of Minimum Quantity Lubrication Using Vegetable-Based Cutting Fluids on Surface Topography and Cutting Forces in Finish Turning of Ti-6Al-4V

Lisowicz Joanna, Habrat Witold, Krupa Krzysztof

Advances in Science and Technology. Research Journal

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2022

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Vol. 16, no 1

95--103

EN

Titanium alloys are included in the group of difficult-to-cut materials. The use of different methods to reduce the temperature of the machining zone is one of the factors influencing the performance of the machining. The most commonly used method is flood cooling. On the basis of recent research, the conventionally used cutting fluids can cause some health problems for machine operators. Moreover, it was found that they can cause some problems for the environment during storage and disposal. Therefore, in recent years, the aspects of the use of biodegradable fluids and the reduction of the number of metalworking fluids used in machining processes have received much more attention. In this study, the effect of the application of three different vegetable oil-based cutting fluids was evaluated for minimum quantity lubrication (MQL) in finishing the Ti-6Al-4V titanium alloy on surface topography and cutting force components. The same tests were conducted for dry cutting conditions and the results were compared with those after machining with MQL. It was found that the best surface roughness was obtained with the use of the mixture of 50% vegetable oil and 50% diester (1PR20) under all the cutting parameters considered. The biggest differences in the values of the Sa and Sz parameters can be noticed for the lowest feed rate. For the feed rate f = 0.1 mm/rev, the Sa parameter values were approximately 32% and 24% lower for MQL with 1PR20 compared to MQL to LB2000 and dry cutting conditions, respectively. In terms of cutting force components, the lowest values were obtained for the MQL with 1PR20 machining. The values of the main cutting force were about 15% lower compared to the MQL with LB2000 cutting conditions for all the cutting parameters considered.

3

Nowe osiągnięcia w technikach chłodzenia przy obróbce superstopów

Jemielniak Krzysztof

Mechanik

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2021

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R. 94, nr 7

6--16

EN

The paper presents an update of the recent literature on advances in cooling techniques for machining of difficult to machine materials such as nickel and titanium-based alloys used in aero-engine and aerostructure applications. The review covers: cryogenic machining, minimum quantity lubrication, the combination of MQL and cryogenic cooling, and high-pressure lubricoolant supply. Examples of applications in industrial processes are also given.

PL

W artykule przedstawiono najnowsze osiągnięcia w technikach chłodzenia przy obróbce materiałów trudnoobialnych, takich jak stopy niklu i stopy tytanu, stosowanych w silnikach i konstrukcjach lotniczych. Przegląd obejmuje: chłodzenie kriogeniczne i minimalne, połączenie tych technik, czyli kriogeniczne chłodzenie minimalne, oraz chłodzenie pod wysokim ciśnieniem. Przedstawiono również przykłady zastosowań przemysłowych.

4

Nanofluid assistance in machining processes – properties, mechanisms and applications: a review

Grzesik Wit

Journal of Machine Engineering

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2021

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Vol. 21, No. 2

75--90

EN

A special group of hybrid assisted processes termed media-assisted processes which apply liquid media with special additives in the form of nanoparticles supplied to the cutting zone is overviewed. Special attention is paid to minimum quantity lubrication (MQL) technique with the use of nanofluids. In this review paper some important thermal and tribological effects resulting from the applications of various nanoparticles are outlined and compared. The MQL-nano cutting fluid mechanisms (rolling and ploughing) are described. In particular, some important quantitative effects concerning thermal and tribological behaviour of the cutting process as well as surface quality are presented.

5

Dysza do minimalnego smarowania podczas obróbki materiałów trudnoobrabialnych

Jemielniak Krzysztof

Mechanik

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2020

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R. 93, nr 11

10

PL

Podczas obróbki materiałów trudnoobrabialnych, takich jak stopy tytanu czy niklu, konieczne jest stosowanie cieczy chłodząco-smarujących, jednak stanowi to poważne obciążenie dla środowiska. Bardziej ekologiczne jest smarowanie minimalne (MQL), gdzie ilość chłodziwa jest zredukowana, zwłaszcza z wykorzystaniem olejów roślinnych. Jednakże przenikalność medium do strefy skrawania i właściwości chłodzące są w tym przypadku niskie, co jest najbardziej odczuwalne przy frezowaniu szybkościowym. Sytuację poprawia dodanie do oleju dwusiarczku molibdenu (WS2) oraz zastosowanie specjalnej dyszy.

6

Hybrydowe procesy skrawania wspomagane mediami technologicznymi

Grzesik W.

Mechanik

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2018

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R. 91, nr 12

1050--1056

PL

Przedstawiono hybrydowe sposoby skrawania, wykorzystujące wspomaganie mediami technologicznymi (media-assisted machining – MAM). Omówiono zasady i możliwości technologiczne intensywnego chłodzenia CCS pod dużym ciśnieniem (high pressure cutting – HPC), minimalnego chłodzenia (minimum quantity cooling/lubrication – MQC/MQL), chłodzenia kriogenicznego (cryogenic machining – CM) oraz integracji tych oddziaływań w procesie skrawania w różnych zastosowaniach przemysłowych – zwłaszcza w przypadku kształtowania elementów z materiałów trudnoskrawalnych. Opisano sposoby zasilania mediami technologicznymi oraz rozwiązania narzędzi/systemów narzędziowych i wyposażenie obrabiarek hybrydowych CNC. Podano przykład optymalizacji obróbki MAM z uwzględnieniem chłodzenia kriogenicznego.

EN

A special group of hybrid assisted processes termed media-assisted processes which various liquid and gaseous media supplied to the cutting zone is highlighted. Special attention is paid on such cooling techniques as high-pressure machining (HPC), high-pressure jet assisted machining (HPJAM), minimum quantity cooling/lubrication (MQC/MQL) and a group of cryogenically cooled machining including such cryogenic media as CO2 snow and liquid nitrogen (LN2). Some important effects resulting from the various cooling strategies are outlined and compared. In particular, quantitative effects concerning chip breaking, thermal and tribological behavior of the cutting process as well as burr reduction, surface quality and subsurface layer are presented. The optimization procedure concerning both energy consumption and machining costs in terms of material removal rate (MRR) is presented.

7

Assessment of surface roughness in MQL assisted turning process of titanium alloy with application of TOPSIS-AHP method

Bartoszuk M., Gupta M. K.

Journal of Machine Engineering

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2018

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Vol. 18, No. 2

97--105

EN

The optimization of surface roughness values considered as one of the most significant issues regarding turning process of titanium alloys with the use of minimum quantity lubrication (MQL) method. With such an aim in mind, the application of TOPSIS-AHP method is implemented in order to establish the most favourable cutting parameters for the following values of surface roughness: Ra, Rq and Rz in machining of titanium alloys regarding MQL conditions. The proposed methodology consists of the two stages. At the beginning, tests on turning process were performed on CNC lathe, taking feed rate, approach angle, and cutting speed as input parameters. Then, the TOPSIS-AHP method was applied on the given experimental data and the optimum machining parameters were determined. The findings from current investigations showed that, lower values of cutting speed, feed rate and middle value of approach angle shows the optimal results.

8

Methods of minimalization of coolant flow rate in the grinding processes - the review

Czapiewski W.

Journal of Mechanical and Energy Engineering

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2017

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Vol. 1, No 2

117--122

EN

The article describes the role and types of cooling lubricants used in grinding processes. Conventional methods of coolants delivery into the grinding zone were described, such as: flood method, high-pressure jet method, centrifugal coolant provision method as well as methods method to minimize coolant flow rate: minimum quantity lubrication (MQL), minimum quantity cooling (MQC) and minimum quantity cooling lubrication (MQCL). Against this background, a methods were presented to completely eliminate grinding fluid from the grinding process (dry grinding) like: impregnated grinding wheels and cold air guns (CAG).

9

Influence of cooling lubricants on the surface roughness and energy efficiency of the cutting machine tools

Jersák J., Simon S.

International Journal of Applied Mechanics and Engineering

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2017

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Vol. 22, no. 3

779--787

EN

The Technical University of Liberec and Brandenburg University of Technology Cottbus-Senftenberg investigated the influence of cooling lubricants on the surface roughness and energy efficiency of cutting machine tools. After summarizing the achieved experimental results, the authors conclude that cooling lubricants extensively influence the cutting temperature, cutting forces and energy consumption. Also, it is recognizable that cooling lubricants affect the cutting tools lifetime and the workpiece surface quality as well. Furthermore, costs of these cooling lubricants and the related environmental burden need to be considered. A current trend is to reduce the amount of lubricants that are used, e.g., when the Minimum Quantity Lubrication (MQL) technique is applied. The lubricant or process liquid is thereby transported by the compressed air in the form of an aerosol to the contact area between the tool and workpiece. The cutting process was monitored during testing by the three following techniques: lubricant-free cutting, cutting with the use of a lubricant with the MQL technique, and only utilizing finish-turning and finish-face milling. The research allowed the authors to monitor the cutting power and mark the achieved surface quality in relation to the electrical power consumption of the cutting machine. In conclusions, the coherence between energy efficiency of the cutting machine and the workpiece surface quality regarding the used cooling lubricant is described.

10

Obróbka stopu miedzi CuZn40Pb2 w warunkach minimalnego smarowania

Karolczak P., Waszczuk K.

Mechanik

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2016

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R. 89, nr 8-9

1062--1063

PL

Zaprezentowano wyniki badań toczenia stopu miedzi o oznaczeniu CuZn40Pb2 z wykorzystaniem minimalnego smarowania. Ukazują one wpływ zastosowania MQL na chropowatość powierzchni stopu miedzi przy obróbce rombowymi płytkami powlekanymi i niepowlekanymi. Ponadto określono efektywne zakresy stosowania MQL w toczeniu wzdłużnym stopu miedzi ze względu na otrzymaną chropowatość powierzchni.

EN

The article presents the results of use the minimum quantity lubrication in the copper alloy turning. The results show the effects of applying an MQL on the surface roughness CuZn40Pb2 material with the use of the uncoated and coated diamond cutting edge. In addition, the article sets the effective fields of application MQL in longitudinal turning of a copper alloy, due to the resulting of surface roughness.

11

Wpływ posuwu wzdłużnego na zużycie frezu ślimakowego i siły skrawania podczas frezowania obwiedniowego z minimalnym wydatkiem cieczy obróbkowej (MQL)

Stachurski W.

Zeszyty Naukowe. Transport / Politechnika Śląska

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2015

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z. 89

155--161

PL

W artykule dokonano oceny wpływu zmiany posuwu wzdłużnego podczas frezowania obwiedniowego kół zębatych z minimalnym wydatkiem cieczy obróbkowej (metoda MQL) na zużycie frezu ślimakowego oraz siły skrawania. Badania wykonano frezując stal C45 frezem ślimakowym ze stali szybkotnącej HS6-5-2 bez pokryć przeciwzużyciowych. Dla porównania przeprowadzono próby podczas frezowania „na mokro”. W trakcie badań wykorzystano dwa posuwy przy stałej prędkości skrawania. Koła frezowano na pełną głębokość wrębów. Podczas frezowania mierzono siłę skrawania. Zużycie narzędzia mierzono w sposób bezpośredni jako szerokość starcia na powierzchni przyłożenia (nie zaobserwowano istotnego zużycia na powierzchni natarcia). Przyjęto, że parametrem kryterialnym dla zużycia będzie stała długość frezowania. Wyniki badań przedstawiono w postaci wykresów zmian zużycia dla najbardziej obciążonego zęba frezu oraz wykresów przebiegów sił skrawania. Na podstawie uzyskanych wyników ustalono, że metoda MQL może być alternatywną metodą podawania cieczy obróbkowej podczas frezowania obwiedniowego.

EN

In the paper evaluation of the influence of axial feed on the hob wear in hobbing with minimal quantity lubrication technique has been done. As a work material C45 carbon steel has been investigated. Wear resistance of the hob made from high speed steel HS6-5-2 without coating has been investigated. For comparison tests with conventional fluid supply method have been carried out. Gears have been generated with full depth of cut and with two axial feed with constant cutting speed value. During hobbing cutting forces have been measured by experimental stand. Tool wear has been measured directly as a width of flank wear land of the hob cutter teeth. During investigation any significant wear changes on the rake faces haven’t been detected, so those results haven’t been taken into consideration. A constant length of cut parameter has been established as a criteria value. Results of investigation have been presented in the form of graphs describing changes of wear land width parameter in comparison to the most loaded tooth wear land parameter. Also changes of cutting forces in time are presented too. On the base of obtained results conclusion has been formulated that MQL technique might be used as an alternative solution for supplying cutting fluid into the cutting zone during hobbing process.

12

The grinding of titanium alloys

Wójcik R.

Archives of Mechanical Technology and Automation

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2013

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Vol. 33, no. 4

49--60

EN

The results of studies of the grinding process of titanium alloys by the grinding wheels with chrome electrocorundum aluminum oxide, silicon carbide, CBN and GP were presented in the article. During the grinding of surfaces propylene glycol and commercial cutting fluids were applied, dedicated used to passing with minimum flow into the cutting zone. The results were com¬pared with those of dry grinding.

PL

W artykule zaprezentowano badania procesu szlifowania stopów tytanu ściernicami z elektrokorundu chromowego, węglika krzemu, cBN oraz GP. Podczas szlifowania płaszczyzn zastosowano glikol propylenowy i handlowe płyny obróbkowe, podawane z minimalnym przepływem do strefy skrawania. Wyniki badań odniesiono do szlifowania na sucho

13

Research On The Influence Of Cooling And Lubrication On The Surface Layer Selected Properties

Leppert T.

Journal of Polish CIMAC

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2009

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Vol. 4, no 3

57-63

EN

The paper presents the structure and selected results of the BW 13/2007 research conducted in the Production Engineering Department. It describes the conditions and application range of dry and MQL cutting, as well as the results of an analysis into the machined surface geometrical structure, cutting forces and residual stresses in the surface layer.

14

Dry cutting gear hobbing in modul range m≥4 mm with HSS tools

Lierath F., Knoche H.J., Herzhoff P., Streubel A.

Zeszyty Naukowe Politechniki Rzeszowskiej. Mechanika

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2002

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z. 58 [193]

227-231

EN

In line with the project the high work potential of dry cutting and minimum quantity lubrication (MQL) with coated HSS-gear hobs will be shown in order to realize an economical and reliable method for gear hobbing of toothed systems with bigger modules, which works completely without or nearly without cooling fluids respectively. For the investigations was used common material for gears in a module range from 4 mm to 7 mm and progressive cutting values similar to industrial applications. It was demonstrated that industrial produced gear hobs from powder metallurgical HSS with TiAlN coatings by using methods of dry cutting and MQL can resist the occurring process charges due to the bigger modules and gear width. In comparison to the state of technical knowledge which is wet cutting was ascertained an enormous increase of tool life by using this method of dry cutting and MQL.