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Recent Trends of Cutting Fluids and Lubrication Techniques in Machining
Published in Yashvir Singh, Nishant K. Singh, Mangey Ram, Advanced Manufacturing Processes, 2023
Machining is an essential process in the manufacturing cycle of a product. It is a process of removing unwanted material from the workpiece through chip formation. This is generally performed at the later stage of the manufacturing cycle, which can put forward its significance for the life of the machined components. The machining process is used extensively for the production of necessary component size and shape. The component could be machined at high speed for improving productivity. However, a lot of heat is produced during machining because of the friction at the tool and workpiece contact pairs. This, in turn, results in high temperature, high pressure, friction, and considerable tool wear. Also, it results in the creation of tensile residual stresses and chip segmentation and affects the workpiece’s surface integrity. Hence, there is a need of cutting fluid to reduce the temperature of the cutting zone and provide sufficient lubrication to reduce the friction and for evacuation of chips from the machining zone [1–4].
Mechanics of Chip Formation
Published in Zainul Huda, Machining Processes and Machines, 2020
We have learnt in the preceding chapter that conventional machining processes involve removal of material from a workpiece in the form of chips. The chip formation, in machining, is a localized shear deformation process that involves the removal of material from workpiece in the form of chip. The main cutting action in a conventional machining process involves shear deformation of the work material in a narrow region where the material is plastically deformed and slides off along the rake face of the cutting edge in the form of a chip (see Figure 2.1). As the chip is removed, a new surface is exposed. A chip consists of two sides: (a) the shiny side (flat and uniform side) that is in contact with the tool, due to frictional effects, and (b) the jagged side, which is the free workpiece surface, due to shear. The chip formation affects the surface finish, cutting forces, temperature, tool life, and dimensional tolerance (Liang and Shih, 2016; Huda, 2018).
Process Monitoring and Control of Machining Operations
Published in Osita D. I. Nwokah, Yildirim Hurmuzlu, The Mechanical Systems Design Handbook, 2017
Robert G. Landers, A. Galip Ulsoy, Richard J. Furness
The three major chip formation types are discontinuous, continuous, and continuous with built-up edge (BUE).30 Discontinuous chips arise when the operation continuously forms and fractures chips because of the workpiece’s inability to undergo large amounts of plastic deformation, while continuous chips do not fracture but form continuous ribbons. Continuous chips with BUE form when part of the chip welds to the tool due to high cutting temperatures and pressures. Continuous chips (with and without BUE) will interfere with the normal interaction between the tool and workpiece and cause poor surface finish, as will discontinuous chips that do not clear the cutting zone. Therefore, chip control is the proper formation of chips that clear the cutting zone and are directed toward the chip conveyor system for efficient removal.
Turning of Al 7075-T6 aerospace alloy under different sustainable metalworking fluid strategies by coated carbide tools
Published in Surface Engineering, 2023
Jasjeevan Singh, Simranpreet Singh Gill
The investigation of chip morphology is critical for any unknowable work-tool combination in machining conditions. The chip formation has an impact on machining dynamics, surface quality, cutting speed, and insert life. The foremost problems encountered in the machining of aluminium alloys are chip breakability; in reality, protracted chips can damage the machine’s evacuation system, the tool, and machined surface. Consequently, to attain sustainable machinability of Al7075-T6 alloy as one of the objectives of this work, the chips were considered to examine the variation in the generation of chip beneath different MF strategies. Hence, the chips were collected and both photographic and optical images were obtained (Table 3) for all the four MF strategies that is, dry cutting, MQL, RHVT, and compressed air.
Development and performance of non-edible oil based green cutting fluid in manufacturing
Published in Materials and Manufacturing Processes, 2023
Rahul Katna, Mohd Suhaib, Narayan Agrawal
The cutting force reduces upon an increase in the cutting speed. This is because at higher cutting speeds higher temperature is attained which causes thermal softening of the workpiece and hence cutting force reduced. This is in line with previous investigations that reported reduction in the cutting force due to increased cutting speed.[85] Increase in cutting force was also observed when the feed and depth of cut were increased as yields higher chip load and increased chip thickness are encountered which results in difficulty in chip formation thereby a higher cutting force is required. Main effect plots of means and SN ratio (considering minimum is better) of cutting force is shown in Fig. 10. The experiment results show that the factor cutting fluid environment in the experiment with the lowest cutting force corresponds to the cutting fluid CF-NENO.
The effect of machining parameters on the surface quality of 3D printed and cast polyamide
Published in Machining Science and Technology, 2021
When discussing chip type results, it is necessary to determine the type of machining created by the chip to examine the chip properties. In this study, an orthogonal cutting process has been performed; this cutting is a type of cutting of the wedge-shaped cutting tool where the cutting edge is radial to the tool movement direction. Tribological conditions at the tool-chip interface can cause the material to be macroscopically welded to the cutting tool. For this reason, microscope images before and after tool wear were included in the study. In cutting operations at relatively low cutting speeds, chip formation depends on the cutting conditions, the cutting tool, and to a large extent, on the material being processed. This information can support the resulting variable chip sizes. Besides, since the depth of cut affects the radius of curvature of the chip, changes in the radius of chip curvature are expected. Again, this expectation is met by continuous and discontinuous chip results. The differences in the production method in this study have also led to different chip types. In AM, the joints and separations between layers affected the chip type (Patel, 2008; Monkova et al., 2019).