The Experts below are selected from a list of 4131 Experts worldwide ranked by ideXlab platform

Mozammel Mia - One of the best experts on this subject based on the ideXlab platform.

  • investigation of surface modification and tool wear on milling nimonic 80a under hybrid Lubrication
    Tribology International, 2021
    Co-Authors: Nimel Sworna Ross K, Munish Kumar Gupta, G Manimaran, Saqib Anwar, Azizur M Rahman, Mehmet Erdi Korkmaz, Abdullah Alfaify, Mozammel Mia
    Abstract:

    Abstract Friction at cutting interfaces deteriorates the nascent surfaces and influences the wear of tool (tool life) that causes the cost of manufacturing. Hybrid Cooling/Lubrication has been used to machine Nimonic 80A which is challenging to machine conventionally due to its poor heat diffusivity and superior chemical attraction. The focus was on the surface modification (roughness, topography, residual stress, microhardness) and wear phenomenon of the tools under the hybrid cryogenic minimum quantity Lubrication (CMQL) approach. Compressive residual stress, increased microhardness (4–9%), and less tool wear (22–71%) were few benefits of CMQL compared to the traditional approach. Concurrent action of chilling and Lubrication enabled lower temperatures, higher compressive residual stress, microhardness, and surface quality. Abrasion and adhesion were dominant wear modes.

  • evaluating the sustainability pillars of energy and environment considering carbon emissions under machining ofti 3al 2 5 v
    Sustainable Energy Technologies and Assessments, 2020
    Co-Authors: Rupinder Singh, Munish Kumar Gupta, J S Dureja, Manu Dogra, Muhammad Jamil, Mozammel Mia
    Abstract:

    Abstract This paper investigates the turning of Ti-3Al-2.5 V with coated carbide tools under different Cooling/lubricating environments to identify the sustainable and improved Cooling/Lubrication technology. Five different Cooling/Lubrication conditions (dry, pressurized compressed air-assisted wet Cooling, Cooling with Ranque-Hilsch-vortex-tube (RHVT), conventional MQL, and wet oil Cooling) were selected and turning performance was evaluated in terms of air quality of the worker’s breathable/working zone, energy consumption, carbon emissions, tool wear, surface roughness, and chips analysis. From experimentation, it was found that under MQL the value of tool wear and surface roughness was lowest as compared to other Cooling/lubricating conditions. But the generation of particulate matter of PM2.5 (150–305 mg/m3) under MQL was on alarming scale as compared to other Cooling/lubricating environments. Further, energy consumption and carbon emissions with MQL was found to be lowest followed by RHVT, which was mainly due to effective Cooling/Lubrication provided by the lubricant in MQL and chilled air under RHVT. The comparison of RHVT and MQL environments indicate just 1.6–1.4% increment in energy consumed with the use of RHVT under both tested speeds. Further, under RHVT state 45%–56% reduction in carbon emission (at both MRR) in contrast to dry turning was observed. The generation trend of average PM2.5 particles under RHVT was comparable with that achieved under dry conditions. Results of the study clearly indicates that RHVT can act as sustainable Cooling/Lubrication techniques in terms of environmental, economic and technological aspects for turning of Ti-3Al-2.5 V.

  • ecological economical and technological perspectives based sustainability assessment in hybrid Cooling assisted machining of ti 6al 4 v alloy
    Sustainable Materials and Technologies, 2020
    Co-Authors: Munish Kumar Gupta, Mozammel Mia, Murat Sarikaya, Muhammad Jamil, Qinghua Song, Zhanqiang Liu, Vinod Kushvaha, Anil Kumar Singla
    Abstract:

    Abstract Ti-6Al-4 V alloy is a well-acknowledged standard material for the application of modern aerospace, surgical equipment, and prosthetic body parts owing to its stable thermo-physical properties at elevated temperature. However, this structure stability imparts its low thermal conductivity that leads to buildup of heat at tool-workpiece interface during machining which subsequently has a damaging effect on the tool cutting edge. Several biodegradable cutting fluids have already been attempted controlling the heat generation, environmental footprints to improve the overall machinability. In this endeavor, the effectiveness of dry, liquid nitrogen (LN2) and hybrid cryogenic and minimum quantity Lubrication (LN2 + MQL) conditions was evaluated in terms of important machinability indicators for instance surface roughness, cutting forces and temperature. The environmental parameters such as total cycle time, productivity, economic analysis, energy consumption and carbon emissions were also analyzed under these Cooling conditions. Lastly, the sustainability assessment of process parameters was calculated with the help of the Analytic Hierarchy Process (AHP) coupled with the Technique for Order Preference Based on Similarity to Ideal Solution (TOPSIS) techniques. Findings have exhibited superior Cooling/Lubrication effect under LN2 + MQL conditions lowering the machining as well as environmental indices. The improvement in cycle time and productivity of LN2 and LN2 + MQL was appeared to be 29.01% and 34.21% as compared with dry turning. The sustainability assessment results also revealed that the lower cutting parameters under LN2 + MQL produced best results to achieve the overall sustainability index.

  • Multi-Objective Optimization of Energy Consumption and Surface Quality in Nanofluid SQCL Assisted Face Milling
    MDPI AG, 2019
    Co-Authors: Aqib Mashood Khan, Mozammel Mia, Muhammad Jamil, Konstantinos Salonitis, Shoaib Sarfraz, Wei Zhao, Guolong Zhao
    Abstract:

    Considering the significance of improving the energy efficiency, surface quality and material removal quantity of machining processes, the present study is conducted in the form of an experimental investigation and a multi-objective optimization. The experiments were conducted by face milling AISI 1045 steel on a Computer Numerical Controlled (CNC) milling machine using a carbide cutting tool. The Cu-nano-fluid, dispersed in distilled water, was impinged in small quantity Cooling Lubrication (SQCL) spray applied to the cutting zone. The data of surface roughness and active cutting energy were measured while the material removal rate was calculated. A multi-objective optimization was performed by the integration of the Taguchi method, Grey Relational Analysis (GRA), and the Non-Dominated Sorting Genetic Algorithm (NSGA-II). The optimum results calculated were a cutting speed of 1200 rev/min, a feed rate of 320 mm/min, a depth of cut of 0.5 mm, and a width of cut of 15 mm. It was also endowed with a 20.7% reduction in energy consumption. Furthermore, the use of SQCL promoted sustainable manufacturing. The novelty of the work is in reducing energy consumption under nano fluid assisted machining while paying adequate attention to material removal quantity and the product’s surface quality

  • An approach to cleaner production for machining hardened steel using different Cooling-Lubrication conditions
    Journal of Cleaner Production, 2018
    Co-Authors: Mozammel Mia, Grzegorz Krolczyk, Gurraj Singh, Munish Kumar Gupta, Danil Yu. Pimenov
    Abstract:

    Extreme thermal conditions in machining of hardened steel impair the overall performance especially the tool life and surface quality. Although, the cutting fluids are known for improving the tool life and surface quality, yet they have adverse effects on the human health as well as environment because of the presence of potentially harmful chemical ingredients. Hence, in view of the above problems associated with the cutting fluids, the implementation of sustainable methods is advantageous which further reduces the use of cutting fluids i.e. dry, minimum quantity Lubrication (MQL) spray system and solid lubricant with compressed air Cooling system. In this paper, the effect of three sustainable techniques, along with the traditional flood Cooling system, on prominent machining indices such as cutting temperature, surface roughness, chip characteristics and tool wear in plain turning of hardened AISI 1060 steel has been investigated. In the end, the Pugh matrix environmental approach has been used to establish the sustainability assessment model (in terms of environmental effect, operator health, coolant cost, recycling cost and disposal, part cleaning and selected machining responses) among the used Cooling/Lubrication conditions. The research findings show that use of MQL system can ameliorate the heat transfer problem, and divulge quite promising results. Therefore, it is suggested that MQL system, provides environment friendliness, cleaner production and helps to improve the desirable machinability characteristics.

Grzegorz Krolczyk - One of the best experts on this subject based on the ideXlab platform.

  • ecological trends in machining as a key factor in sustainable production a review
    Journal of Cleaner Production, 2019
    Co-Authors: Grzegorz Krolczyk, Radoslaw W Maruda, P Nieslony, Szymon Wojciechowski, Jolanta B Krolczyk, G Budzik
    Abstract:

    Abstract A comprehensive analysis of literature pertaining to ecological trends in machining processes of difficult-to-cut materials (e.g. hard steels, Ti-based alloys, Ni-based alloys) has been performed. The paper focuses on the improvement of machining processes with a balanced attention onthe reduction of pollution generated by coolants and emulsions. Here, the specific areas of interest are: Dry cutting; Minimum Quantity Lubrication/Minimum Quantity Cooling Lubrication; Cryogenic Cooling; High-Pressure Coolant and Biodegradable Vegetable Oils. The proposed approach of sustainable and cleaner production for the above-mentioned areas involves the minimized use of coolant/lubricants, employment of appropriate cutting tool's grade and machining conditions that leads to the reduction of total cost, cutting force, energy consumption, temperature but improvements of surface quality, volume of material removed, as well as the prolongation of tool life. In addition, the qualitative judgments like impact on human operator's health, atmospheric air, chip removal from machining area etc. are taken into account. The study presented in the paper is such a vast compendium of knowledgeregarding multi-directional critical analysis of machined parts, tools, chips under state-of-art Cooling/Lubrication systems that it will help the next generation scientists to find recent advances as well as future avenues of research on ecological aspects of machining for sustainability.

  • effects of extreme pressure and anti wear additives on surface topography and tool wear during mqcl turning of aisi 1045 steel
    Journal of Mechanical Science and Technology, 2018
    Co-Authors: Radoslaw W Maruda, Szymon Wojciechowski, Grzegorz Krolczyk, Krzysztof Zak, Witold Habrat, P Nieslony
    Abstract:

    The paper presents an original study of the influence of extreme pressure and anti-wear (EP/AW) additives on the surface topography of double-phase steel during turning with different Cooling media and variable flow rates. The obtained surface topographies were compared using frequency and fractal analyses for dry, minimum quantity Cooling Lubrication (MQCL), and MQCL + EP/AW methods. Results showed that the addition of phosphate ester-based additives to an active medium caused the formation of tribofilm on the tool-chip interface and thus a change in the lubricating properties by reducing friction. The tool wear and the formation of the thin-layered tribofilm were also incorporated. The application of the MQCL method with the EP/AW additives led to a decrease in particular surface topography parameters from 8 % to 38 % in comparison with the effects of dry cutting and from 6 % to 35 % in comparison with the effects of machining under MQCL conditions. An exception was the result obtained for the surface roughness height parameter Sp, which was higher than that obtained after the MQCL + EP/AW process for the lowest investigated feed per revolution f = 0.1 mm/rev. This observation was correlated with the uneven formation of the tribofilm on the machined surface. The phosphate ester-based additive used in the MQCL + EP/AW method contributed to achieving tool wear that was less than that obtained by the processes conducted under dry and MQCL conditions.

  • An approach to cleaner production for machining hardened steel using different Cooling-Lubrication conditions
    Journal of Cleaner Production, 2018
    Co-Authors: Mozammel Mia, Grzegorz Krolczyk, Gurraj Singh, Munish Kumar Gupta, Danil Yu. Pimenov
    Abstract:

    Extreme thermal conditions in machining of hardened steel impair the overall performance especially the tool life and surface quality. Although, the cutting fluids are known for improving the tool life and surface quality, yet they have adverse effects on the human health as well as environment because of the presence of potentially harmful chemical ingredients. Hence, in view of the above problems associated with the cutting fluids, the implementation of sustainable methods is advantageous which further reduces the use of cutting fluids i.e. dry, minimum quantity Lubrication (MQL) spray system and solid lubricant with compressed air Cooling system. In this paper, the effect of three sustainable techniques, along with the traditional flood Cooling system, on prominent machining indices such as cutting temperature, surface roughness, chip characteristics and tool wear in plain turning of hardened AISI 1060 steel has been investigated. In the end, the Pugh matrix environmental approach has been used to establish the sustainability assessment model (in terms of environmental effect, operator health, coolant cost, recycling cost and disposal, part cleaning and selected machining responses) among the used Cooling/Lubrication conditions. The research findings show that use of MQL system can ameliorate the heat transfer problem, and divulge quite promising results. Therefore, it is suggested that MQL system, provides environment friendliness, cleaner production and helps to improve the desirable machinability characteristics.

  • tool wear characterizations in finish turning of aisi 1045 carbon steel for mqcl conditions
    Wear, 2017
    Co-Authors: Radoslaw W Maruda, Eugene Feldshtein, P Nieslony, Grzegorz Krolczyk, Bozena Tyliszczak, Franci Pusavec
    Abstract:

    Abstract This study presents analysis of tool wear of P25 cemented carbide inserts in finish turning of AISI 1045 carbon steel for different Cooling conditions: dry cutting, minimum quantity Cooling-Lubrication (MQCL) and MQCL with phosphate ester-based EP/AW additive. It was proven that the wear of the inserts using MQCL + EP/AW method is reduced by about 40% compared to dry cutting and about 25% compared with MQCL. The improvement was proved to be a consequence of phosphate ester-based tribofilm formation. Additionally, SEM analysis revealed that active compounds contained in this tribofilm reduce the rate of adhesion and diffusion of tool wear processes. Further, analyzed is also the droplet diameter which has turned out to also have significant impact on wear. It was shown that droplet diameter has the greatest effect on the wear rate. Smaller droplets provide the better penetration into the cutting zone, especially for micro-machining applications. Thus, this work shows that MQCL medium as well as its proper application via generation of controllable mist can provide significant improvements in cutting tool wear rate and/or productivity of cutting tool.

  • structural and microhardness changes after turning of the aisi 1045 steel for minimum quantity Cooling Lubrication
    Journal of Materials Engineering and Performance, 2017
    Co-Authors: Radoslaw W Maruda, M Michalski, P Nieslony, Grzegorz Krolczyk, Szymon Wojciechowski
    Abstract:

    This work presents the Cooling effect under minimum quantity Cooling Lubrication and dry cutting on structural changes and microhardness of the ferritic-pearlitic AISI 1045 steel after turning. Due to the fact that the AISI 1045 steel has a two-phase structure, microhardness tests using the Vickers method were conducted with a load of 0.05 HV separately for ferrite and pearlite grains. The tests showed that Cooling of the cutting zone under minimum quantity Cooling Lubrication (MQCL) condition decreased the depth of the hardened layer compared to dry cutting by approximately 40% for both pearlite and ferrite. Scanning electron microscopy analysis revealed that applying MQCL limits the formation of plastic deformations, among others, by reducing the surface crumple zone by approximately 50% compared to dry cutting. As a result of Cooling being applied to the cutting zone using the MQCL method, the average diameter of ferrite grains has been decreased in the entire surface area compared to dry cutting. When using dry cutting, clear structural changes of the surface layer were also observed. This may be the result of sulfide inclusions which have formed, causing microcracks on the edge of the hardened layer and surface deformation visible as notches.

Franci Pusavec - One of the best experts on this subject based on the ideXlab platform.

  • Influence of rake face texturing on machining performance of carbide tools
    Procedia CIRP, 2019
    Co-Authors: Damir Grguraš, Franci Pusavec
    Abstract:

    Abstract Controlled surface texture of cutting tools has potential to reduce cutting forces, tool wear, etc. Even though several different textured cutting tools have been identified and tested in machining of various workpiece materials, it is difficult to conclude the most effective surface texture for machining performance improvement. Therefore, in this paper, 8 carbide tools with different rake face texturing have been tested and evaluated over following estimators: (i) cutting force, (ii) chip shape and (iii) surface roughness. Results are showing that texturing of carbide tools can improve machining performance if the orientation of texturing is parallel to the main cutting edge. In such cases, the texturing form offers better penetration of the Cooling-Lubrication fluid into the cutting zone and can serve as a micro-reservoir for constant emulsion replenishment. This results in better Cooling and Lubrication, which reflects on lower cutting force. On the other hand, no major differences in chip shape and surface roughness have been observed between texturing.

  • tool wear characterizations in finish turning of aisi 1045 carbon steel for mqcl conditions
    Wear, 2017
    Co-Authors: Radoslaw W Maruda, Eugene Feldshtein, P Nieslony, Grzegorz Krolczyk, Bozena Tyliszczak, Franci Pusavec
    Abstract:

    Abstract This study presents analysis of tool wear of P25 cemented carbide inserts in finish turning of AISI 1045 carbon steel for different Cooling conditions: dry cutting, minimum quantity Cooling-Lubrication (MQCL) and MQCL with phosphate ester-based EP/AW additive. It was proven that the wear of the inserts using MQCL + EP/AW method is reduced by about 40% compared to dry cutting and about 25% compared with MQCL. The improvement was proved to be a consequence of phosphate ester-based tribofilm formation. Additionally, SEM analysis revealed that active compounds contained in this tribofilm reduce the rate of adhesion and diffusion of tool wear processes. Further, analyzed is also the droplet diameter which has turned out to also have significant impact on wear. It was shown that droplet diameter has the greatest effect on the wear rate. Smaller droplets provide the better penetration into the cutting zone, especially for micro-machining applications. Thus, this work shows that MQCL medium as well as its proper application via generation of controllable mist can provide significant improvements in cutting tool wear rate and/or productivity of cutting tool.

  • a study on droplets sizes their distribution and heat exchange for minimum quantity Cooling Lubrication mqcl
    International Journal of Machine Tools & Manufacture, 2016
    Co-Authors: Radoslaw W Maruda, Eugene Feldshtein, Stanislaw Legutko, Grzegorz Krolczyk, Franci Pusavec, Michal Szydlowski, Agnieszka Sobczakkupiec
    Abstract:

    Abstract The paper analyses the influence of emulsion mist formation parameters and the nozzle distance from the tool–chip interface, on the droplet velocity at the nozzle outlet, on active medium atomization angle as well as on the diameter and number of droplets supplied to the cutting zone. The deformation coefficient of the droplets falling on the surface and the wetting angle have also been determined. In the work it has been proved that the strongest influence on the droplets diameter have the air flow and the distance of the nozzle from the cutting zone. It has been shown that larger angle of the stream splitting ensures that the droplets do not join each other in the air, and consequently assures small diameter on the surface. Additionally, the results show that the emulsion mass flow does not change the droplets diameters by more than 12%. It has been determined that smaller the droplets diameter is, higher content of active compounds in the tribofilms formed on the machined surface is present. In this way the paper presents the analysis and directions of MQCL adjustment trends needed to improve the machining performance.

  • sustainable machining of high temperature nickel alloy inconel 718 part 2 chip breakability and optimization
    Journal of Cleaner Production, 2015
    Co-Authors: Franci Pusavec, Ashish Deshpande, S Yang, R Msaoubi, Janez Kopac, O W Dillon, I S Jawahir
    Abstract:

    Abstract Global competition, stricter environmental legislation and demands for fulfilling sustainability initiatives, are increasing the pressure on the manufacturing industry, to develop and implement in their production alternative sustainable machining processes. This work focuses on sustainability evaluation and comparison in machining of high-temperature Nickel-based alloy (Inconel 718). Four sustainable machining alternatives (dry, near-dry (MQL), cryogenic and cryo-Lubrication (cryogenic + near-dry)) to conventional machining, are evaluated based on the performance models from the Part 1 of the paper and used in the optimization procedure for determining the overall optimum machining conditions. As chip breakability is important machining characteristic, performance-based models of sustainable machining processes, developed in Part 1, are upgraded in this Part 2 of the paper with an additional model for chip breakability. Updated models are used as inputs to the optimization procedure developed, based on the combined overall desirability function. Genetic algorithms (GA) are used to evaluate and optimize the machining process for each Cooling/Lubrication (C/L) application. Results of the work show that machining performance optimization, when including beside machining parameters also the sustainable alternative Cooling/Lubrication conditions, can provide further improvement of the processes through tool-life, machined surface quality, chip breakability, productivity and nevertheless power consumption.

  • sustainable machining of high temperature nickel alloy inconel 718 part 1 predictive performance models
    Journal of Cleaner Production, 2014
    Co-Authors: Franci Pusavec, Ashish Deshpande, S Yang, R Msaoubi, Janez Kopac, O W Dillon
    Abstract:

    This two-part paper presents the results from modeling and optimization of alternative sustainable machining processes of Inconel 718. Nickel and Titanium, as representatives of high temperature alloys, with their specific thermo-mechanical properties, pose significant difficulties in machining. The high temperature and the consequent work hardening of these materials during the machining processes adversely affect cutting forces, tool-wear, surface integrity and chip breakability. This first part (Part 1) of the paper presents the experimental study of sustainable high performance machining of Inconel 718 with the development of performance-based predictive models for dry, near-dry (MQL), cryogenic and cryo-Lubrication (cryogenic + near-dry) machining processes using response surface methodology (RSM). The robustness of these models was verified using the ANOVA. Cutting forces, surface roughness and tool-wear were measured, analyzed and modeled. The results show that the Cooling/Lubrication condition has an influence on machining performance and that optimum machining conditions have to be determined, at which an improved overall machining performance can be achieved, while sustainability directions are followed in terms of reducing cutting forces/power consumption, the prolonging of tool-life, and increasing productivity. The models developed in the first part of the paper are used for process evaluation and optimization in the second part, to determine optimum machining conditions for an overall process performance improvement.

Radoslaw W Maruda - One of the best experts on this subject based on the ideXlab platform.

  • ecological trends in machining as a key factor in sustainable production a review
    Journal of Cleaner Production, 2019
    Co-Authors: Grzegorz Krolczyk, Radoslaw W Maruda, P Nieslony, Szymon Wojciechowski, Jolanta B Krolczyk, G Budzik
    Abstract:

    Abstract A comprehensive analysis of literature pertaining to ecological trends in machining processes of difficult-to-cut materials (e.g. hard steels, Ti-based alloys, Ni-based alloys) has been performed. The paper focuses on the improvement of machining processes with a balanced attention onthe reduction of pollution generated by coolants and emulsions. Here, the specific areas of interest are: Dry cutting; Minimum Quantity Lubrication/Minimum Quantity Cooling Lubrication; Cryogenic Cooling; High-Pressure Coolant and Biodegradable Vegetable Oils. The proposed approach of sustainable and cleaner production for the above-mentioned areas involves the minimized use of coolant/lubricants, employment of appropriate cutting tool's grade and machining conditions that leads to the reduction of total cost, cutting force, energy consumption, temperature but improvements of surface quality, volume of material removed, as well as the prolongation of tool life. In addition, the qualitative judgments like impact on human operator's health, atmospheric air, chip removal from machining area etc. are taken into account. The study presented in the paper is such a vast compendium of knowledgeregarding multi-directional critical analysis of machined parts, tools, chips under state-of-art Cooling/Lubrication systems that it will help the next generation scientists to find recent advances as well as future avenues of research on ecological aspects of machining for sustainability.

  • effects of extreme pressure and anti wear additives on surface topography and tool wear during mqcl turning of aisi 1045 steel
    Journal of Mechanical Science and Technology, 2018
    Co-Authors: Radoslaw W Maruda, Szymon Wojciechowski, Grzegorz Krolczyk, Krzysztof Zak, Witold Habrat, P Nieslony
    Abstract:

    The paper presents an original study of the influence of extreme pressure and anti-wear (EP/AW) additives on the surface topography of double-phase steel during turning with different Cooling media and variable flow rates. The obtained surface topographies were compared using frequency and fractal analyses for dry, minimum quantity Cooling Lubrication (MQCL), and MQCL + EP/AW methods. Results showed that the addition of phosphate ester-based additives to an active medium caused the formation of tribofilm on the tool-chip interface and thus a change in the lubricating properties by reducing friction. The tool wear and the formation of the thin-layered tribofilm were also incorporated. The application of the MQCL method with the EP/AW additives led to a decrease in particular surface topography parameters from 8 % to 38 % in comparison with the effects of dry cutting and from 6 % to 35 % in comparison with the effects of machining under MQCL conditions. An exception was the result obtained for the surface roughness height parameter Sp, which was higher than that obtained after the MQCL + EP/AW process for the lowest investigated feed per revolution f = 0.1 mm/rev. This observation was correlated with the uneven formation of the tribofilm on the machined surface. The phosphate ester-based additive used in the MQCL + EP/AW method contributed to achieving tool wear that was less than that obtained by the processes conducted under dry and MQCL conditions.

  • tool wear characterizations in finish turning of aisi 1045 carbon steel for mqcl conditions
    Wear, 2017
    Co-Authors: Radoslaw W Maruda, Eugene Feldshtein, P Nieslony, Grzegorz Krolczyk, Bozena Tyliszczak, Franci Pusavec
    Abstract:

    Abstract This study presents analysis of tool wear of P25 cemented carbide inserts in finish turning of AISI 1045 carbon steel for different Cooling conditions: dry cutting, minimum quantity Cooling-Lubrication (MQCL) and MQCL with phosphate ester-based EP/AW additive. It was proven that the wear of the inserts using MQCL + EP/AW method is reduced by about 40% compared to dry cutting and about 25% compared with MQCL. The improvement was proved to be a consequence of phosphate ester-based tribofilm formation. Additionally, SEM analysis revealed that active compounds contained in this tribofilm reduce the rate of adhesion and diffusion of tool wear processes. Further, analyzed is also the droplet diameter which has turned out to also have significant impact on wear. It was shown that droplet diameter has the greatest effect on the wear rate. Smaller droplets provide the better penetration into the cutting zone, especially for micro-machining applications. Thus, this work shows that MQCL medium as well as its proper application via generation of controllable mist can provide significant improvements in cutting tool wear rate and/or productivity of cutting tool.

  • structural and microhardness changes after turning of the aisi 1045 steel for minimum quantity Cooling Lubrication
    Journal of Materials Engineering and Performance, 2017
    Co-Authors: Radoslaw W Maruda, M Michalski, P Nieslony, Grzegorz Krolczyk, Szymon Wojciechowski
    Abstract:

    This work presents the Cooling effect under minimum quantity Cooling Lubrication and dry cutting on structural changes and microhardness of the ferritic-pearlitic AISI 1045 steel after turning. Due to the fact that the AISI 1045 steel has a two-phase structure, microhardness tests using the Vickers method were conducted with a load of 0.05 HV separately for ferrite and pearlite grains. The tests showed that Cooling of the cutting zone under minimum quantity Cooling Lubrication (MQCL) condition decreased the depth of the hardened layer compared to dry cutting by approximately 40% for both pearlite and ferrite. Scanning electron microscopy analysis revealed that applying MQCL limits the formation of plastic deformations, among others, by reducing the surface crumple zone by approximately 50% compared to dry cutting. As a result of Cooling being applied to the cutting zone using the MQCL method, the average diameter of ferrite grains has been decreased in the entire surface area compared to dry cutting. When using dry cutting, clear structural changes of the surface layer were also observed. This may be the result of sulfide inclusions which have formed, causing microcracks on the edge of the hardened layer and surface deformation visible as notches.

  • analysis of contact phenomena and heat exchange in the cutting zone under minimum quantity Cooling Lubrication conditions
    Arabian Journal for Science and Engineering, 2016
    Co-Authors: Radoslaw W Maruda, Eugene Feldshtein, Stanislaw Legutko, Grzegorz Krolczyk
    Abstract:

    The paper critically investigates about the influence of emulsion mist Cooling on the conditions of heat absorption from the machining zone. The Cooling conditions under which the total number of drops falling on the hot surfaces of the machining zone evaporate have been studied. The state of cutting wedges made of P25 sintered carbide after finish turning of two-phase pearlite-ferrite AISI 1045 steel with the presence of an anti-seizure and anti-wear additive has been subjected to scanning inspection. In the contact area, the content of surface active compounds is much larger as compared to the areas beyond the contact. It has been observed that the concentration of active compounds on the surface grows by about three times. This phenomena provides confirmatory evidences of favourable machining conditions.

Munish Kumar Gupta - One of the best experts on this subject based on the ideXlab platform.

  • investigation of surface modification and tool wear on milling nimonic 80a under hybrid Lubrication
    Tribology International, 2021
    Co-Authors: Nimel Sworna Ross K, Munish Kumar Gupta, G Manimaran, Saqib Anwar, Azizur M Rahman, Mehmet Erdi Korkmaz, Abdullah Alfaify, Mozammel Mia
    Abstract:

    Abstract Friction at cutting interfaces deteriorates the nascent surfaces and influences the wear of tool (tool life) that causes the cost of manufacturing. Hybrid Cooling/Lubrication has been used to machine Nimonic 80A which is challenging to machine conventionally due to its poor heat diffusivity and superior chemical attraction. The focus was on the surface modification (roughness, topography, residual stress, microhardness) and wear phenomenon of the tools under the hybrid cryogenic minimum quantity Lubrication (CMQL) approach. Compressive residual stress, increased microhardness (4–9%), and less tool wear (22–71%) were few benefits of CMQL compared to the traditional approach. Concurrent action of chilling and Lubrication enabled lower temperatures, higher compressive residual stress, microhardness, and surface quality. Abrasion and adhesion were dominant wear modes.

  • Influence of MoS2 based nanofluid-MQL on tribological and machining characteristics in turning of AA 2024 T3 aluminum alloy
    'Elsevier BV', 2021
    Co-Authors: Ayşegül Yücel, Cagri Vakkas Yildirim, Turgay Kivak, Munish Kumar Gupta, Murat Sarikaya, şenol şirin, Ítalo V. Tomaz
    Abstract:

    Aluminum (Al) alloys are of particular importance to the aerospace industry owing to the combination of characteristics including strength, ductility, toughness, fatigue life and oxidation resistance as a light metal. This is the case of AA 2024 T3 Al alloy. In particular, machining of these alloys has similar importance for productivity and part quality. Recently, the use of nanofluids, which have various advantages in terms of both Cooling ability and tribological aspects, has become popular for the efficient machining of such alloys. In this context, guiding data are needed that enable industry and researchers to machine these types of alloys with high efficiency. Taking these into account, in this study, AA 2024 T3 Al alloy was machined and various machinability indicators such as surface roughness, surface topography, maximum temperature and dominant tool wear mechanism under different Cooling/Lubrication strategies i.e., dry cutting, base fluid minimum quantity Lubrication (MQL) and mineral oil based MoS2 nanofluid MQL (NFMQL) were investigated. As a results, significant improvements have been achieved in surface roughness, surface topography, and maximum temperature with help of NFMQL application. The intensive built-up edge (BUE) and built-up layer (BUL) formations are produced on the cutting tool when machining AA 2024 T3 Al alloy under dry cutting. On the other hand, BUE formation has been significantly eliminated thanks to NFMQL. Moreover, a less damaged cutting edge was obtained when machining Al alloy under NFMQL compared to both dry cutting and MQL environments

  • evaluating the sustainability pillars of energy and environment considering carbon emissions under machining ofti 3al 2 5 v
    Sustainable Energy Technologies and Assessments, 2020
    Co-Authors: Rupinder Singh, Munish Kumar Gupta, J S Dureja, Manu Dogra, Muhammad Jamil, Mozammel Mia
    Abstract:

    Abstract This paper investigates the turning of Ti-3Al-2.5 V with coated carbide tools under different Cooling/lubricating environments to identify the sustainable and improved Cooling/Lubrication technology. Five different Cooling/Lubrication conditions (dry, pressurized compressed air-assisted wet Cooling, Cooling with Ranque-Hilsch-vortex-tube (RHVT), conventional MQL, and wet oil Cooling) were selected and turning performance was evaluated in terms of air quality of the worker’s breathable/working zone, energy consumption, carbon emissions, tool wear, surface roughness, and chips analysis. From experimentation, it was found that under MQL the value of tool wear and surface roughness was lowest as compared to other Cooling/lubricating conditions. But the generation of particulate matter of PM2.5 (150–305 mg/m3) under MQL was on alarming scale as compared to other Cooling/lubricating environments. Further, energy consumption and carbon emissions with MQL was found to be lowest followed by RHVT, which was mainly due to effective Cooling/Lubrication provided by the lubricant in MQL and chilled air under RHVT. The comparison of RHVT and MQL environments indicate just 1.6–1.4% increment in energy consumed with the use of RHVT under both tested speeds. Further, under RHVT state 45%–56% reduction in carbon emission (at both MRR) in contrast to dry turning was observed. The generation trend of average PM2.5 particles under RHVT was comparable with that achieved under dry conditions. Results of the study clearly indicates that RHVT can act as sustainable Cooling/Lubrication techniques in terms of environmental, economic and technological aspects for turning of Ti-3Al-2.5 V.

  • ecological economical and technological perspectives based sustainability assessment in hybrid Cooling assisted machining of ti 6al 4 v alloy
    Sustainable Materials and Technologies, 2020
    Co-Authors: Munish Kumar Gupta, Mozammel Mia, Murat Sarikaya, Muhammad Jamil, Qinghua Song, Zhanqiang Liu, Vinod Kushvaha, Anil Kumar Singla
    Abstract:

    Abstract Ti-6Al-4 V alloy is a well-acknowledged standard material for the application of modern aerospace, surgical equipment, and prosthetic body parts owing to its stable thermo-physical properties at elevated temperature. However, this structure stability imparts its low thermal conductivity that leads to buildup of heat at tool-workpiece interface during machining which subsequently has a damaging effect on the tool cutting edge. Several biodegradable cutting fluids have already been attempted controlling the heat generation, environmental footprints to improve the overall machinability. In this endeavor, the effectiveness of dry, liquid nitrogen (LN2) and hybrid cryogenic and minimum quantity Lubrication (LN2 + MQL) conditions was evaluated in terms of important machinability indicators for instance surface roughness, cutting forces and temperature. The environmental parameters such as total cycle time, productivity, economic analysis, energy consumption and carbon emissions were also analyzed under these Cooling conditions. Lastly, the sustainability assessment of process parameters was calculated with the help of the Analytic Hierarchy Process (AHP) coupled with the Technique for Order Preference Based on Similarity to Ideal Solution (TOPSIS) techniques. Findings have exhibited superior Cooling/Lubrication effect under LN2 + MQL conditions lowering the machining as well as environmental indices. The improvement in cycle time and productivity of LN2 and LN2 + MQL was appeared to be 29.01% and 34.21% as compared with dry turning. The sustainability assessment results also revealed that the lower cutting parameters under LN2 + MQL produced best results to achieve the overall sustainability index.

  • Hybrid Cooling-Lubrication strategies to improve surface topography and tool wear in sustainable turning of Al 7075-T6 alloy
    The International Journal of Advanced Manufacturing Technology, 2019
    Co-Authors: Munish Kumar Gupta, Danil Yu. Pimenov, Gurraj Singh, Murat Sarikaya, Vishal S. Sharma
    Abstract:

    In machining of soft alloys, the sticky nature of localized material instigated by tool-work interaction exacerbates the tribological attitude and ultimately demeans it machinability. Moreover, the endured severe plastic deformation and originated thermal state alter the metallurgical structure of machined surface and chips. Also, the used tool edges are worn/damaged. Implementation of Cooling-Lubrication (C/L) agents to reduce friction at faying surfaces can ameliorate overall machinability. That is why, this paper deliberately discussed the influence of pure C/L methods, i.e., such as dry cutting (DC) and nitrogen Cooling (N_2), as well as hybrid C/L strategies, i.e., nitrogen minimum quantity Lubrication (N_2MQL) and Ranque–Hilsch vortex tube (RHVT) N_2MQL conditions in turning of Al 7075-T6 alloy, respectively. With respect to the variation of cutting speed and feed rate, at different C/Ls, the surface roughness, tool wear, and chips are studied by using SEM and 3D topographic analysis. The mechanism of heat transfer by the Cooling methods has been discussed too. Furthermore, the new chip management model (CMM) was developed under all C/L conditions by considering the waste management aspects. It was found that the R-N_2MQL has the potential to reduce the surface roughness up to 77% and the tool wear up to 118%. This significant improvement promotes sustainability in machining industry by saving resources. Moreover, the CMM showed that R-N_2MQL is more attractive for cleaner manufacturing system due to a higher recyclability, remanufacturing, and lower disposal of chips.