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I S Jawahir - One of the best experts on this subject based on the ideXlab platform.
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sustainable Machining of high temperature nickel alloy inconel 718 part 1 predictive performance models
Journal of Cleaner Production, 2014Co-Authors: Franci Pusavec, Ashish Deshpande, S Yang, R Msaoubi, Janez Kopac, O W Dillon, I S JawahirAbstract: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.
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Sustainable Machining of high temperature Nickel alloy – Inconel 718: part 1 – predictive performance models
Journal of Cleaner Production, 2014Co-Authors: Franci Pusavec, Ashish Deshpande, S Yang, Janez Kopac, O W Dillon, R. M'saoubi, I S JawahirAbstract: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.
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a comprehensive tool wear tool life performance model in the evaluation of ndm near dry Machining for sustainable manufacturing
International Journal of Machine Tools & Manufacture, 2008Co-Authors: P W Marksberry, I S JawahirAbstract:Traditionally, metal working fluids (MWF) are known to improve Machining performance despite poor ecological and health side effects. A new sustainable process that has minimized the use and application of MWFs is NDM (near dry Machining). Although there is much controversy on the effectiveness of NDM, it is agreed that a lack of science-based modeling prevents its widespread use. This paper presents a new method to predict tool-wear/tool-life performance in NDM by extending a Taylor speed-based dry Machining equation. Experimental work and validation of the model was performed in an automotive production environment in the Machining of steel wheel rims. Machining experiments and validation of the new equation reveal that tool-wear can be predicted within 10% when the effect of NDM is statistically different than dry Machining. Tool-wear measurements obtained during the validation of the model showed that NDM can improve tool-wear/tool-life over four times compared to dry Machining which underlines the need to develop sustainable models to match current practices.
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A comprehensive tool-wear/tool-life performance model in the evaluation of NDM (near dry Machining) for sustainable manufacturing
International Journal of Machine Tools & Manufacture, 2008Co-Authors: P W Marksberry, I S JawahirAbstract:Traditionally, metal working fluids (MWF) are known to improve Machining performance despite poor ecological and health side effects. A new sustainable process that has minimized the use and application of MWFs is NDM (near dry Machining). Although there is much controversy on the effectiveness of NDM, it is agreed that a lack of science-based modeling prevents its widespread use. This paper presents a new method to predict tool-wear/tool-life performance in NDM by extending a Taylor speed-based dry Machining equation. Experimental work and validation of the model was performed in an automotive production environment in the Machining of steel wheel rims. Machining experiments and validation of the new equation reveal that tool-wear can be predicted within 10% when the effect of NDM is statistically different than dry Machining. Tool-wear measurements obtained during the validation of the model showed that NDM can improve tool-wear/tool-life over four times compared to dry Machining which underlines the need to develop sustainable models to match current practices.
P W Marksberry - One of the best experts on this subject based on the ideXlab platform.
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a comprehensive tool wear tool life performance model in the evaluation of ndm near dry Machining for sustainable manufacturing
International Journal of Machine Tools & Manufacture, 2008Co-Authors: P W Marksberry, I S JawahirAbstract:Traditionally, metal working fluids (MWF) are known to improve Machining performance despite poor ecological and health side effects. A new sustainable process that has minimized the use and application of MWFs is NDM (near dry Machining). Although there is much controversy on the effectiveness of NDM, it is agreed that a lack of science-based modeling prevents its widespread use. This paper presents a new method to predict tool-wear/tool-life performance in NDM by extending a Taylor speed-based dry Machining equation. Experimental work and validation of the model was performed in an automotive production environment in the Machining of steel wheel rims. Machining experiments and validation of the new equation reveal that tool-wear can be predicted within 10% when the effect of NDM is statistically different than dry Machining. Tool-wear measurements obtained during the validation of the model showed that NDM can improve tool-wear/tool-life over four times compared to dry Machining which underlines the need to develop sustainable models to match current practices.
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A comprehensive tool-wear/tool-life performance model in the evaluation of NDM (near dry Machining) for sustainable manufacturing
International Journal of Machine Tools & Manufacture, 2008Co-Authors: P W Marksberry, I S JawahirAbstract:Traditionally, metal working fluids (MWF) are known to improve Machining performance despite poor ecological and health side effects. A new sustainable process that has minimized the use and application of MWFs is NDM (near dry Machining). Although there is much controversy on the effectiveness of NDM, it is agreed that a lack of science-based modeling prevents its widespread use. This paper presents a new method to predict tool-wear/tool-life performance in NDM by extending a Taylor speed-based dry Machining equation. Experimental work and validation of the model was performed in an automotive production environment in the Machining of steel wheel rims. Machining experiments and validation of the new equation reveal that tool-wear can be predicted within 10% when the effect of NDM is statistically different than dry Machining. Tool-wear measurements obtained during the validation of the model showed that NDM can improve tool-wear/tool-life over four times compared to dry Machining which underlines the need to develop sustainable models to match current practices.
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micro flood mf technology for sustainable manufacturing operations that are coolant less and occupationally friendly
Journal of Cleaner Production, 2007Co-Authors: P W MarksberryAbstract:Abstract 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/m 3 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/m 3 concentration as much as 4–5 mg/m 3 for water-miscible MWFs and 15–22 mg/m 3 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/m 3 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/m 3 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.
Domnita Fratila - One of the best experts on this subject based on the ideXlab platform.
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Research of Environment-Friendly Techniques Influence on Accuracy of Gear Processing in Context of Sustainable Machining by Near Dry Machining
Acta Mechanica Slovaca, 2012Co-Authors: Domnita FratilaAbstract:This paper highlights the importance of the sustainable Machining technologies in achieving sustainable development objectives. The Machining processes constitute a major manufacturing activity that contributes to the growth of the global economy. The research and the development in the Machining processes have improved Machining performances through advanced tool materials, higher productivity and quality, while the environmentally and the health-friendly technologies are becoming increasingly important for achieving cleaner, healthier, and safer Machining. In the context of the sustainable Machining, the case study presents the influence of the environment-friendly techniques use on the accuracy of 16MnCr5 gear with small modulus, manufactured by milling.
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Assessment of Cutting Area Temperature to the Face Milling using Several Cooling Methods
Acta Mechanica Slovaca, 2011Co-Authors: Domnita FratilaAbstract:This paper analyzes the temperature variations in the cutting zone under flood cooling (FC), near dry Machining (NDM) and dry cutting (DC) conditions. The research compares the dual effects of air-oil mixture in near-Dry Machining with the cooling effect to dry cutting and flood cooling in terms of the reduction of cutting temperature through the cooling effect, as well as the reduction of heat generation through the lubricating effect to face milling.
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macro level environmental comparison of near dry Machining and flood Machining
Journal of Cleaner Production, 2010Co-Authors: Domnita FratilaAbstract:Abstract 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.
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evaluation of near dry Machining effects on gear milling process efficiency
Journal of Cleaner Production, 2009Co-Authors: Domnita FratilaAbstract:Abstract One of the main environmental pollution sources related to machine building industry is the huge amount of cutting fluids which are supplied during the Machining processes. In order to avoid the problems induced by cutting fluids' usage, considerable progress has been recently made in the field of near-Dry Machining (NDM). Converting conventional processes to minimal quantity lubrication (MQL) methods imposes new tasks' classification within the tribiological system in order to guarantee the process safety and product quality. This paper gives an overview on some requirements to be considered for a successful MQL application into industrial practice. Its last part is focused on the evaluation of NDM effects on the gear milling process efficiency, with respect to hob wear, surface quality, cooling effect, and environment protection.
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Minimization of cutting fluids ecological impact by near dry Machining.
Environmental Engineering and Management Journal, 2009Co-Authors: Domnita FratilaAbstract:This paper analyses a new technology for minimizing the use of metalworking fluids (MWF) during the Machining process. Despite the fact that near dry Machining (NDM) produces almost similar cutting performance to conventional flood supply Machining while using much less MWF, for being fully utilized in industry is necessary to research ecological impact of these Machining techniques. To take full advantage of minimal quantity lubrication (MQL) technique and expand its applicability, an understanding of its environmental consequences is critical. Thus, in this study, the MWF characteristics were analyzed and their changes occurred during the gear milling process were investigated using a multi gas monitor. Emissions composition and component gases concentrations were investigated in dry cutting (DC), MQL via atomized spray mist, in flood cooling (FC), and in open atmosphere.
Franci Pusavec - One of the best experts on this subject based on the ideXlab platform.
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sustainable Machining of high temperature nickel alloy inconel 718 part 1 predictive performance models
Journal of Cleaner Production, 2014Co-Authors: Franci Pusavec, Ashish Deshpande, S Yang, R Msaoubi, Janez Kopac, O W Dillon, I S JawahirAbstract: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.
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Sustainable Machining of high temperature Nickel alloy – Inconel 718: part 1 – predictive performance models
Journal of Cleaner Production, 2014Co-Authors: Franci Pusavec, Ashish Deshpande, S Yang, Janez Kopac, O W Dillon, R. M'saoubi, I S JawahirAbstract: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.
Steven Y. Liang - One of the best experts on this subject based on the ideXlab platform.
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Modeling of cutting forces in near dry Machining under tool wear effect
International Journal of Machine Tools & Manufacture, 2007Co-Authors: Steven Y. LiangAbstract:Abstract A predictive model for the cutting forces in near dry Machining, in which only a small amount of cutting fluid is used, is developed based on considerations of both the lubricating effect and the cooling effect. For the lubricating effect, with the material properties, lubricating parameters, and cutting conditions, the friction coefficient in near dry Machining is calculated based on the boundary lubrication model for use in a modified Oxley's approach to determine the cutting forces. For the cooling effect in near dry Machining, a moving heat source method is pursued to quantify the primary-zone shear deformation heating, the secondary-zone friction heating, and flank face air–oil mixture cooling. These two effects are considered collectively to estimate cutting forces under the condition of sharp tools. The predicted variables of flow stress, contact length, and shear angle obtained from the model are used to predict the cutting forces due to the tool flank wear effect based on Waldorf's model. Comparisons are made between predicted and experimental cutting forces for sharp tools and worn tools in the cutting of AISI 1045 with uncoated carbide tools. The results show that the proposed model provides average prediction errors of 14% in the tangential cutting force direction, 21% in the axial directions, and 30% in the radial directions within the experimental test condition range (cutting speeds of 45.75–137.25 m/min, feeds 0.0508–0.1016 mm/rev, and depth of cuts 0.508–1.016 mm). It is also found that the cutting forces in near dry Machining are generally lower than those under dry Machining condition. Under cutting speeds of 91.5 and 137.25 m/min, the deviations of the predicted forces between near dry Machining and dry Machining range from 5% to 39% for axial cutting forces, 3% to 36% for radial cutting forces, and 1% to 32% for tangential cutting forces. It suggests that the lubricating mechanism has a stronger effect on cutting forces than the cooling mechanism when cutting AISI 1045 with uncoated carbide tools.
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Cutting fluid aerosol generation in near-Dry turning
International Journal of Manufacturing Research, 2006Co-Authors: Steven Y. LiangAbstract:The generation of aerosol using the cutting fluids in Machining processes presents a concern from the standpoint of pollution to the environment. near-Dry Machining, as a method of applying only a minute amount of cutting fluid, has been developed to address the air quality issue. This paper presents the establishment of an analytical method to quantitatively predict the air quality in the near-Dry turning operation. The analytical prediction is based on the modelling of cutting temperature, aerosol generation mechanism and spatial and temporal diffusion. The cutting temperature model is obtained by considering moving and stationary heat sources in the cutting tool. The aerosol generation mechanism model contains two primary parts: the evaporation mechanism due to high temperature in the cutting zone and the air blast splash mechanism due to the kinetic energy of the air-fluid mixture under the near-Dry condition. The diffusion model provides the calculation of the aerosol concentration at a distance from the cutting zone as a function of time due to the concentration gradient. The calibration and validation of the model have been performed experimentally with the use of light-scattering particle counting under various cutting conditions. Results show that the model agrees well with the measurements and that, under normal cutting conditions, the cutting fluid flow rate is the dominant factor for the aerosol generation rate.
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Modeling of Cutting Temperature in Near Dry Machining
Journal of Manufacturing Science and Engineering-transactions of The Asme, 2005Co-Authors: Kuan-ming Li, Steven Y. LiangAbstract:Near dry Machining refers to the condition of applying cutting fluid at relatively low flow rates, on the order of 2-100 ml/h, as opposed to the conventional way of using either a large quantity, typically of about 10 1/min, as in wet Machining; or no fluid at all, as in dry Machining. One important expectation of applying fluids is to control the cutting temperature, which is an important parameter for tool life and part dimensional accuracy in Machining processes. In this context, the understanding of cutting temperature variation corresponding to the near dry cooling and lubrication is of interest. This paper models the temperature distributions in the cutting zone under through-the-tool near dry cooling condition. The heat source method is implemented to estimate the cutting temperatures on the tool-chip interface and the tool-workpiece interface. For the temperature rise in the chip, the effects of the primary heat source and the secondary heat source were modeled as moving heat sources. For the temperature rise in the tool, the effects of the secondary heat source, the heat loss due to cooling, and the rubbing heat source due to the tool flank wear, were modeled as stationary heat sources. For the temperature rise in the workpiece, the primary heat source, the heat loss due to cooling, and the rubbing heat source due to the tool flank wear were modeled as moving heat sources. The model describes the dual effects of air-oil mixture in near dry Machining in terms of the reduction of cutting temperature through the cooling effect, as well as the reduction of heat generation through the lubricating effect. To pursue model calibration and validation, embedded thermocouple temperature measurement in cutting medium carbon steels with uncorted carbide insets were carried out. The model predictions and experimental measurements show reasonable agreement and results suggest that the combination of the cooling and the lubricating effects in near dry Machining reduces the cutting temperatures on the tool-chip interface by about 8% with respect to dry Machining. Moreover, the cutting speed remains a dominant factor in cutting temperature compared with the feed and the depth of cut in near dry Machining processes.
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Predictive Models for Flank Wear in Near Dry Machining
Manufacturing Engineering and Materials Handling Parts A and B, 2005Co-Authors: Kuan-ming Li, Steven Y. LiangAbstract:The objective of this paper is to present a methodology to analytically model the tool flank wear rate in near-Dry turning. The resulting models can serve as a basis to minimize time-consuming Machining tests in predicting tool life. Analytical models, including cutting force model, cutting temperature model, and tool wear model, are presented. The cutting force model was established based on Oxley’s model with modifications for lubricating and cooling effect due to the air-oil mixture in near-Dry Machining. The cutting temperature was obtained by considering a moving or stationary heat source in the tool. The tool wear model contained abrasive mechanism, adhesion mechanism, and diffusion mechanism. The important factors related to this model were contact stresses and temperatures that were obtained from the cutting force model and the cutting temperature model. To develop these models, a set of cutting experiments using carbide tools on AISI 1045 steels were performed to calibrate the coefficients in the models and to verify the proposed flank wear mechanisms. The comparisons between the model-predictive flank wear and experimental results showed that the flank wear in near dry Machining can be estimated well by the proposed models. It was also found that the cutting velocity was a dominant factor among the cutting conditions.Copyright © 2005 by ASME
