TY - JOUR
T1 - Experimental Analysis of System Parameters for Minimum Cutting Fluid Consumption when Machining Ti-6Al-4V Using a Novel Supply System
AU - Gariani, Salah
AU - Shyha, Islam
AU - Inam, Fawad
AU - Huo, Dehong
PY - 2018/3/1
Y1 - 2018/3/1
N2 - This paper presents the development of a new controlled cutting fluid impinging supply system (Cut-list) to deliver an accurate quantity of cutting fluid into machining zones through precisely oriented coherent round nozzles. The performance of the new system was evaluated against a conventional system during the step shoulder milling of Ti-6Al-4V using a water-miscible vegetable oil-based cutting fluid, which was phase 1 in this comprehensive study. The use of Cut-list resulted in a significant reduction up to 42% in cutting fluid consumption as well as reductions in cutting force, tool flank wear, average surface roughness (R a ) and burr height (Gariani et al. in Appl Sci 7(6):560, 2017). This paper details phase 2 of the study which was aimed to investigate the effects of working conditions, nozzle positions/angles and impinging distances on key process measures including cutting forces, workpiece temperature, tool wear, burr formation and average surface roughness of the machined surface. Feed rate showed a significant effect on mean values of cutting force, burr formation and surface roughness, whereas average workpiece temperature and flank wear values are very sensitive to cutting speed. Nozzle position at a 15° angle in the feed direction and 45°/60° against feed direction assisted in minimising workpiece temperature. An impinging distance of 55/75 mm is also necessary to control burr formation, workpiece temperature and average surface roughness. It can be concluded that Cut-list gave promising results compared to conventional flood cooling systems in terms of the evaluated machining outputs. Therefore, the new system can be considered as a feasible, efficient and ecologically beneficial solution, giving less fluid consumption in machining processes.
AB - This paper presents the development of a new controlled cutting fluid impinging supply system (Cut-list) to deliver an accurate quantity of cutting fluid into machining zones through precisely oriented coherent round nozzles. The performance of the new system was evaluated against a conventional system during the step shoulder milling of Ti-6Al-4V using a water-miscible vegetable oil-based cutting fluid, which was phase 1 in this comprehensive study. The use of Cut-list resulted in a significant reduction up to 42% in cutting fluid consumption as well as reductions in cutting force, tool flank wear, average surface roughness (R a ) and burr height (Gariani et al. in Appl Sci 7(6):560, 2017). This paper details phase 2 of the study which was aimed to investigate the effects of working conditions, nozzle positions/angles and impinging distances on key process measures including cutting forces, workpiece temperature, tool wear, burr formation and average surface roughness of the machined surface. Feed rate showed a significant effect on mean values of cutting force, burr formation and surface roughness, whereas average workpiece temperature and flank wear values are very sensitive to cutting speed. Nozzle position at a 15° angle in the feed direction and 45°/60° against feed direction assisted in minimising workpiece temperature. An impinging distance of 55/75 mm is also necessary to control burr formation, workpiece temperature and average surface roughness. It can be concluded that Cut-list gave promising results compared to conventional flood cooling systems in terms of the evaluated machining outputs. Therefore, the new system can be considered as a feasible, efficient and ecologically beneficial solution, giving less fluid consumption in machining processes.
KW - Fluid consumption
KW - Coherent nozzle, vegetable oil-based
KW - Cutting fluid
KW - Shoulder milling
KW - Ti-6Al-4V
U2 - 10.1007/s00170-017-1216-y
DO - 10.1007/s00170-017-1216-y
M3 - Article
SN - 0268-3768
VL - 95
SP - 2795
EP - 2809
JO - International Journal of Advanced Manufacturing Technology
JF - International Journal of Advanced Manufacturing Technology
IS - 5-8
ER -