Cooling techniques for improved productivity in turning

Vishal S. Sharma1, Manu Dogra2, N.M. Suri3
1Department of Industrial Engineering, Dr. B.R. Ambedkar NIT Jalandhar, Punjab, India
2Department of Mechanical Engineering, SSG Panjab University Regional Centre, Punjab, India
3Department of Production Engineering, Punjab Engineering College, Chandigarh, India

Tài liệu tham khảo

Childs, 2001 Trent, 2000 Ueda, 2006, Effect of oil mist on tool temperature in cutting, Journal of Manufacturing Science and Engineering, 128, 130, 10.1115/1.2039099 Boothroyd, 2005 Zhao, 2002, A study of flank wear in orthogonal cutting with internal cooling, Wear, 253, 957, 10.1016/S0043-1648(02)00248-X Rahmath Zareena, 2005, Binderless CBN tools, a breakthrough for machining titanium alloys, Journal of Manufacturing Science and Engineering, 127, 277, 10.1115/1.1852570 Barrow, 1973, A review of experimental and theoretical techniques for assessing cutting temperatures, Annals of the CIRP, 22, 203 Silva, 1999, Cutting temperature: prediction and measurement methods—a review, Journal of Material Processing Technology, 88, 195, 10.1016/S0924-0136(98)00395-1 Shaw, 1996, Energy conversion in cutting and grinding, Annals of the CIRP, 45, 101, 10.1016/S0007-8506(07)63025-X Stephenson, 1995, Thermal expansion of the workpiece in turning, ASME Journal of Engineering for Industry, 117, 542, 10.1115/1.2803532 Tuholski, 1993, Don’t forget the cutting fluid, Journal of Industrial Technology, Fall, 2 K.L. Yerkes, J. Dorian, Micro-cooler for chip-level temperature control, in: Aero System Power Conference, Arizona, 1401–1404, 1999, pp. 1–9. Taylor, 1907, On the art of cutting metals, Transactions of the ASME, 28, 31 Liu, 2007, On temperatures and tool wear in machining hypereutectic Al–Si alloys with vortex-tube cooling, International Journal of Machine Tools & Manufacture, 47, 635, 10.1016/j.ijmachtools.2006.04.008 Hong, 2001, Economical and ecological cryogenic machining, Journal of Manufacturing Science and Engineering, 12, 331, 10.1115/1.1315297 Klocke, 1997, Dry cutting, CIRP Annals—Manufacturing Technology, 46, 519, 10.1016/S0007-8506(07)60877-4 J.D. Silliman, R. Perich, Cutting and grinding fluids: selection and application, second ed., Society of Manufacturing Engineers, Dearbornr, Michigan, 1992, 216pp. Bienkowski, 1993, Coolants & lubricants—staying pure, Manufacturing Engineering, March, 55 Chiffre, 2002, Investigation of cutting fluid performance using different machining operations, Lubrication Engineering, 58, 22 Baradie, 1996, Cutting fluids, Part I. Characterisation, Journal of Materials Processing Technology, 56, 787, 10.1016/0924-0136(95)01892-1 Jen, 2002, Investigation of heat pipe cooling in drilling application, Part 1: preliminary numerical analysis and verification, International Journal of Machine Tools & Manufacture, 43, 634 Evans, 1991, Cryogenic diamond turning of stainless steel, Annals of the CIRP, 40, 571, 10.1016/S0007-8506(07)62056-3 Hong, 2001, Friction and cutting forces in cryogenic machining of Ti–6Al–4V, International Journal of Machine Tools & Manufacture, 41, 2271, 10.1016/S0890-6955(01)00029-3 Wang, 2000, Cryogenic machining of hard-to-cut materials, Wear, 239, 168, 10.1016/S0043-1648(99)00361-0 S.Y. Hong, Economical cryogenic machining high speed cutting of difficult-to-machine materials, in: Proceedings of First International Conference on Manufacturing Technology, Hong Kong, 27–29 December 1991. Khan, 2008, Improving tool life using cryogenic cooling, Journal of Materials Processing Technology, 196, 149, 10.1016/j.jmatprotec.2007.05.030 Dhar, 2002, Role of cryogenic cooling on cutting temperature in turning steel, Transactions of the ASME, 124, 146 S. Hong, Conclusion report, Phase I, economical cryogenic machining for high speed cutting of difficult-to-machine materials, Technical Project Report to EMTEC, 1993. Venugopal, 2007, Growth of tool wear in turning of Ti–6Al–4V alloy under cryogenic cooling, Wear, 262, 1071, 10.1016/j.wear.2006.11.010 Wang, 1997, Wear of CBN tools in turning of silicon nitride with cryogenic cooling, International Journal of Machine Tools & Manufacture, 37, 319, 10.1016/S0890-6955(96)00037-5 Mirghani, 2007, Effectiveness of cryogenic machining with modified tool holder, Journal of Materials Processing Technology, 185, 91, 10.1016/j.jmatprotec.2006.03.123 Dhar, 2007, Cutting temperature, tool wear, surface roughness and dimensional deviation in turning AISI-4037 steel under cryogenic condition, International Journal of Machine Tools & Manufacture, 47, 754, 10.1016/j.ijmachtools.2006.09.018 Paul, 2001, Beneficial effects of cryogenic cooling over dry and wet machining on tool wear and surface finish in turning AISI 1060 steel, Journal of Materials Processing Technology, 116, 44, 10.1016/S0924-0136(01)00839-1 Ding, 1998, Improvement of chip breaking in machining low carbon steel by cryogenically pre-cooling the workpiece, Transaction of ASME, Journal of Manufacturing Science and Engineering, 120, 76, 10.1115/1.2830113 Wang, 1996, Cryogenic PCBN turning of ceramic (S&N), Wear, 195, 1, 10.1016/0043-1648(95)06645-4 Kalyan Kumar, 2008, Investigation of tool wear and cutting force in cryogenic machining using design of experiments, Journal of Materials Processing Technology, 203, 95, 10.1016/j.jmatprotec.2007.10.036 Dhar, 2002, The influence of cryogenic cooling on tool wear, dimensional accuracy and surface finish in turning AISI 1040 and E4340C steels, Wear, 249, 932, 10.1016/S0043-1648(01)00825-0 Chiffre, 2007, Performance testing of cryogenic CO2 as cutting fluid in parting/grooving and threading austenitic stainless steel, Annals of the CIRP, 56, 10.1016/j.cirp.2007.05.026 Zbigniew Zurecki, Ranjit Ghosh, Jhon H. Frey, Finish turning of hardened powder metallurgy steel using cryogenic cooling, in: International Conference on Powder Metallurgy and Particulate Material, Las Vegas, NV, June 2003. Yildiz, 2008, A review of cryogenic cooling in machining processes, International Journal of Machine Tools & Manufacture, 48, 947, 10.1016/j.ijmachtools.2008.01.008 A.S. Varadharajan, P.K. Philip, B. Ramamoorthy, Investigations on hard turning with minimal pulsed jet of cutting fluid, in: Proceedings of the International Seminar on Manufacturing Technology Beyond 2000, Bangalore, India, November 17–19, 1999, pp. 173–179. Philip, 2001, Influences of cutting fluid composition and delivery variables on performance in hard turning using minimal fluid in pulsed jet form, Journal of the Institution of Engineers India, 82, 12 Wertheim, 1992, Influence of high pressure flushing through the rake face of the cutting tool, Annals of the CIRP, 41, 101, 10.1016/S0007-8506(07)61162-7 Chepe, 1994, Cutting fluid injection at tool–chip interface to improve machining performance, Journal of the Institution of Engineers India, 75, 25 Mazurkiewicz, 1989, Metal machining with high pressure water jet cooling assistance—a new possibility, Journal of Engineering for Industry, 111, 7, 10.1115/1.3188736 Bennett, 1987, Minimizing human exposure to chemicals in metal working fluids, Lubrication Engineering, 43, 169 Kendall, 1998, Friction and wear of cutting tools and cutting tool materials, vol. 18, 609 Attanasio, 2006, Minimal quantity lubrication in turning: effect on tool wear, Wear, 260, 333, 10.1016/j.wear.2005.04.024 Kamata, 2007, High speed MQL finish-turning of Inconel-718 with different coated tools, Journal of Materials Processing Technology, 192–193, 281, 10.1016/j.jmatprotec.2007.04.052 Dhar, 2006, Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI-4340 steel, Journal of Materials Processing Technology, 172, 299, 10.1016/j.jmatprotec.2005.09.022 Vikram, 2007, Performance of coated tools during hard turning under minimum fluid application, Journal of Materials Processing Technology, 185, 210, 10.1016/j.jmatprotec.2006.03.148 Varadarajan, 2002, Investigations on hard turning with minimal cutting fluid application (HTMF) and its comparison with dry and wet turning, International Journal of Machine Tools & Manufacture, 42, 193, 10.1016/S0890-6955(01)00119-5 Diniz, 2003, Influence of refrigeration/lubrication condition on SAE 52100 hardened steel turning at several cutting speeds, International Journal of Machine Tools & Manufacture, 43, 317, 10.1016/S0890-6955(02)00186-4 Chen, 2001, A study of turning operation by oil–water combined mist lubrication machining method, Key Engineering Materials, 202–203, 47, 10.4028/www.scientific.net/KEM.202-203.47 Su, 2007, Refrigerated cooling air cutting of difficult-to-cut materials, International Journal of Machine Tools & Manufacture, 47, 927, 10.1016/j.ijmachtools.2006.07.005 Li, 2007, Performance profiling of minimum quantity lubrication in machining, International Journal of Advance Manufacturing Technology, 35, 226, 10.1007/s00170-006-0713-1 Obikawa, 2008, Micro-liter lubrication machining of Inconel 718, International Journal of Machine Tools & Manufacture, 48, 1605, 10.1016/j.ijmachtools.2008.07.011 Wertheim, 1992, Influence of high pressure flushing through the rake face of the cutting tool, Annals of the CIRP, 41, 101, 10.1016/S0007-8506(07)61162-7 Anselom, 2007, Influence of the direction and flow rate of the cutting fluid on tool life in turning process of AISI 1045 steel, International Journal of Machine Tools & Manufacture, 47, 247, 10.1016/j.ijmachtools.2006.04.003 Ezugwu, 2005, Finish machining of nickel base Inconel-718, alloy with coated carbide tool under conventional and high pressure coolant supplies, Tribiology Transaction, 48, 76, 10.1080/05698190590899958 Trent, 1988, Metal cutting and the tribology of seizure: III temperatures in metal cutting, Wear, 128, 65, 10.1016/0043-1648(88)90253-0 Ezugwu, 2005, Key improvements in the machining of difficult-to-cut aerospace superalloys, International Journal of Machine Tools & Manufacture, 1353, 10.1016/j.ijmachtools.2005.02.003 Ezugwu, 2007, Surface integrity of finished turned Ti–6Al–4V alloy with PCD tools using conventional and high pressure coolant supplies, International Journal of Machine Tools & Manufacture, 47, 884, 10.1016/j.ijmachtools.2006.08.005 Ezugwu, 2004, Effect of high-pressure coolant supply when machining nickel base Inconel-718 alloy with coated carbide tools, Journal of Materials Processing Technology, 153–154, 1045, 10.1016/j.jmatprotec.2004.04.329 Ezugwu, 2005, Machining of nickel base Inconel-718 alloy with ceramic tools under finishing conditions with various coolant supply pressure, Journal of Materials Processing Technology, 162–163, 609, 10.1016/j.jmatprotec.2005.02.144 Lopez de Lacalle, 2000, Using high pressure coolant in the drilling and turning of low machinability alloys, International Journal of Advance Manufacturing Technology, 16, 85, 10.1007/s001700050012 A.K. Nandy, M.C. Gowrishankar, S. Paul, Some studies on high pressure cooling in turning of Ti–6Al–4V, International Journal of Machine Tools & Manufacture, doi:10.1016/j.ijmachtools.2008.08.008. A.R. Zarena, M. Rahman, Y.S. Wong, High speed machining of aerospace alloy Ti–6Al–4V, in: Proceedings of the 33rd International SAMPE Technical Conference, Seattle, USA, 2001. Tan, 2002, A decision-making framework model of cutting fluid selection for green manufacturing and a case study, International Journal of Machine Tools & Manufacture, 129, 467 Sreejith, 2000, Dry machining: machining of the future, Journal of Materials Processing Technology, 101, 287, 10.1016/S0924-0136(00)00445-3 Shaji, 2003, Analysis of process parameters in surface grinding with graphite as lubricant based on the Taguchi method, Journal of Materials Processing Technology, 141, 51, 10.1016/S0924-0136(02)01112-3 Lathkar, 2000, Clean metal cutting process using solid lubricants, 15 Singh, 2008, Performance improvement of hard turning with solid lubricants, International Journal of Advance Manufacturing Technology, 38, 529, 10.1007/s00170-007-1079-8 Vamsi Krishna, 2008, Performance evaluation of solid lubricants in terms of machining, International Journal of Machine Tools & Manufacture, 48, 1131, 10.1016/j.ijmachtools.2008.01.012 Nageswara, 2008, The influence of solid lubricant particle size on machining parameters in turning, International Journal of Machine Tools & Manufacture, 48, 107, 10.1016/j.ijmachtools.2007.07.007 Mukhopadhyay, 2007, Investigation to study the applicability of solid lubricant in turning AISI 1040 steel, Journal of Manufacturing Science and Engineering, 129, 520, 10.1115/1.2716743 V.A. Godlevski, Water steam lubrication during machining, Tribologia, 162(6) 11 (1998) 890–901. Sandvik Coromant documentation (2006), Tooling Catalogues. Çakır, 2004, Comparison of gases applications to wet and dry cuttings in turning, Journal of Materials Processing Technology, 153–154, 35, 10.1016/j.jmatprotec.2004.04.190 E. Altan, M. Kıyak, O. Cakır, The effect of oxygen gas application into cutting zone on machining, in: Proceedings of the Sixth Biennial Conference on Engineering Systems Design and Analysis (ESDA2002), Istanbul, 2002, pp. 1–5. Ko, 1999, Air–oil cooling method for turning of hardened material, International Journal of Advance Manufacturing Technology, 15, 470, 10.1007/s001700050091 Junyan, 2007, Study on lubricating characteristic and tool wear with water vapor as coolant and lubricant in green cutting, Wear, 262, 442, 10.1016/j.wear.2006.06.014 Junyan, 2005, Research on experiments and action mechanism with water vapor as coolant and lubricant in Green cutting, International Journal of Machine Tools & Manufacture, 45, 687, 10.1016/j.ijmachtools.2004.09.022 M. Stanford, P.M. Lister, C. Morgan, K.A. Kibble, Investigation into the use of gaseous and liquid nitrogen as a cutting fluid when turning BS 970-80A15 (En32b) plain carbon steel using WC-Co uncoated tooling, Journal of Materials Processing Technology, doi:10.1016/J.J.matprotec.2008.03.003. T.T. Cockerill, Thermodynamics & fluid mechanics of a ranquehilsch vortex tube, Thesis, University of Cambridge, 1998. Sarma, 2007, A comparison of dry and air-cooled turning of grey cast iron with mixed oxide ceramic tool, Journal of Materials Processing Technology, 190, 160, 10.1016/j.jmatprotec.2007.02.049 Su, 2006, An experimental investigation of effects of cooling/lubrication conditions on tool wear in high-speed end milling of Ti–6Al–4V, Wear, 261, 760, 10.1016/j.wear.2006.01.013 Xavior, 2008, Determining the influence of cutting fluids on tool wear and surface roughness during turning of AISI 304 austenitic stainless steel, Journal of Materials Processing Technology Chi, 1976 Haq, 2006, Investigation of the effects of cooling in hard turning operations, International Journal of Advance Manufacturing Technology, 30, 808, 10.1007/s00170-005-0128-4 R.Y. Chiou, J.S.J. Chen, M.T. North, L. Lu, The effect of an embedded heat pipe in a cutting tool on temperature and wear, in: Proceedings of ASME Conference on Mechanical Engineering, 2003, pp. 1–8. Boisse, 2007 Li Kuan-Ming, Predictive modeling of near dry machining: mechanical performance and environmental impact, Ph.D Thesis, School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, 2006. Loewen, 1954, On the analysis of cutting tool temperature, Transactions of the ASME, 217 Strenskovski, 1990, Finite element prediction of chip geometry and tool and workpiece temperature distributions in orthogonal cutting, ASME Journal of Engineering Industry, 112, 313, 10.1115/1.2899593 Hong, 2001, Micro-temperature manipulation in cryogenic machining of low carbon steel, Journal of Material Processing Technology, 116, 22, 10.1016/S0924-0136(01)00836-6 Y. Ding, S.Y. Hong, A study of the cutting temperatures in machining processes cooled by liquid nitrogen, Technical Papers of the North American Research Institution of SME, 1995, pp. 115–119. Baker, 2003, An investigation of chip segmentation process using finite element analysis, Tech. Mech, 23, 1 M. Vosough, V. Kalhori, P. Liu, I. Svenningson, Influence of high-pressure water-jet assisted turning on surface residual stresses on Ti–6Al–4V by measurement and finite element simulation, in: Proceedings of Third International Surface Engineering Congress, Orlando, FL, USA, ASM International, 2004, pp. 107–113. Bell, 1999, Modeling of the environmental effect of cutting fluid, Tribology Transactions, 42, 168, 10.1080/10402009908982204 Chiou, 2007, Investigation of dry machining with embedded heat pipe cooling by finite element analysis and experiments, International Journal of Advance Manufacturing Technology, 31, 905, 10.1007/s00170-005-0266-8 Aggarwal, 2008, Optimization of multiple quality characteristics for CNC turning under cryogenic cutting environment using desirability function, Journal of Materials Processing Technology, 205, 42, 10.1016/j.jmatprotec.2007.11.105 Marksberry, 2008, 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, 48, 878, 10.1016/j.ijmachtools.2007.11.006