Effect of High-Pressure Coolant on Temperature, Chip, Force, Tool Wear, Tool Life and Surface Roughness inTurning AISI 1060 Steel
Öz Metal cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions. The use of cutting fluid generally causes economy of tools and it becomes easier to keep tight tolerances and to maintain workpiece surface properties without damages. However, the conventional types and methods of application of cutting fluid have been found to become less effective with the increase in cutting speed and feed when the cutting fluid cannot properly enter the chip-tool interface to cool and lubricate due to bulk plastic contact of the chip with the tool rake surface. Besides that, often in high production machining the cutting fluid may cause premature failure of the cutting tool by fracturing due to close curling of the chips and thermal shocks. Because of them some alternatives has been sought to minimize these problems. Some of these alternatives are cryogenic machining, minimum quantity lubricant machining and machining with high-pressure coolant jet. This paper deals with experimental investigation on the role of high-pressure coolant on cutting temperature, chips, cutting forces, tool wear, tool life and surface finish in turning of AISI 1060 steel at industrial speed-feed combinations by uncoated carbide inserts. The encouraging results include significant reduction in cutting forces, tool wear, surface roughness and significant improvement in tool life by high-pressure coolant jet mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction. Key Words: High-pressure coolant, Temperature, Chip reduction coefficient, Force, Tool wear, Tool life and Surface roughness.
___
Tonshoff H. K., Brinkomeier, E., “Determination of the mechanical and thermal influences on machined surface by microhardness and residual stress analysis”, Anns. of CIRP, 29/2: 519-532 (1986).Sales W.F., Guimaraes G., Machado A.R., Ezugwu E.O., “Cooling ability of cutting fluids and measurement temperatures”, Ind. Lub. Tribol., 54(2): 57-68 (2002). chip-tool interface
Merchant M.E., “The physical chemistry of cutting fluid action”, Am. Chem. Soc., Preprint 3, 4A: 179-189 (1958).
Grzesik W., Bartoszuk M., Nieslony P., “Finite difference analysis of the thermal behaviour of coated tools in orthogonal cutting of steels”, Int. J. Machine Tools & Manuf., 44: 1451–1462 (2004).
Cassin C., Boothroyed G., “Lubrication action of cutting fluids”, J. Mech. Eng. Sci., 7(1): 67-81 (1965).
Farook A., Varadarajan A.S., Philip P.K., “Machinability studies on steel using hard metal inserts with soft material deposit”, Proc. of the 18th AIMTDR, 152-155 (1998).
Ramaiyengar H. S., Salmon R., Rice W. B., “Some effects of cutting fluids on chip formation in metal cutting “, Trans. ASME, 86: 36-38 (1964).
Dawson T.G., Kurfess T.R., "An investigation of tool wear and surface quality in hard turning," Trans. North American Manuf. Research Institution of SME, 28: 215-220 (2000).
Zoya Z.A., Krishnamurthy R., “The performance of CBN tools in the machining of titanium alloys”, J. Mater. Process. Technol., Elsevier Science S.A., 100 80–86 (2000).
Evans C., “Cryogenic diamond turning of stainless steel”, Anns. of CIRP, 40/1: 571-575 (1991).
Dhar N.R., Paul S., Chattopadhyay A.B., "Role of cryogenic cooling on cutting temperature in turning steel", Trans. of the ASME, 123:146-154 (2002).
Dhar N.R., Paul S., Chattopadhyay A.B., "The effects of cryogenic cooling on chips and cutting forces in turning of AISI 1040 and AISI 4320 steels", J. Eng. Mannuf. (IMechE-2002), .216(B):713-724 (2002).
Dhar N.R., Kamruzzaman M., Ahmed Mahiuddin, “Effect of minimum quantity lubrication (MQL) on tool wear and surface roughness in turning AISI- 4340 steel”, J. Mater. Process. Technol., 172: 299-304 (2006).
Dhar N. R., Islam M. W., Islam S., Mithu M. A. H., “The influence of minimum quantity of lubrication (MQL) on cutting temperature, chip and dimensional accuracy in turning AISI 1040 steel”, J. Mater. Process. Technol., 171:.93-99 (2006).
Senthil Kumar A., Rahman M., Ng. S. L.; “Effect of performance”, Int. J. Adv. Manuf. Technol., 20: 83–91 (2002). on machining
Mazurkiewicz M., Kubala Z., Chow J., “Metal machining with high-pressure water-jet cooling assistance- A New Possibility”, J. Eng. Ind., 111: 7-12 (1989).
Lopez L. N., Lacalle de., Perez-Bilbatua J., Sanchez J. A., Llorente J. I., Gutierrez A., Alboniga J., “Using high pressure coolant in the drilling and turning of low machinability alloys”, Int. J. Adv. Manuf. Technol., 16:.85–91 (2000).
Wrethim R., Rotberg J., Ber A., “Influence of high pressure flushing, through the rake face cutting tool”, Anns. of CIRP, 41 (1): 101-106 (1992).
Ezugwu E.O., Bonney J.; “Effect of high-pressure coolant supply when machining nickel-base, Inconel 718, alloy with coated carbide tools”, J. Mater. Process. Technol., 153–154:.1045–1050 (2004).
Ezugwua E.O., Da Silva R.B., Bonneya J., Machado A.R.; “Evaluation of the performance of CBN tools when turning Ti–6Al–4V alloy with high pressure coolant supplies”, Inter. J. Mach. Tools Manuf., 45:1009–1014 (2005).
Manouchehr Vosough, “A literature study of high pressure cooling “jet break” and turning in titanium”, Department of Applied Physics and Mechanical Manufacturing Systems Engineering, The Cirius Laboratory, 17 (2002). Division of
Kovacevic R., Cherukuthota C., Mazurkiewicz M.; “High pressure waterjet cooling/lubrication to improve machining efficiency in milling”, Int. J. Mach. Tools Manuf., 35(10): 1459-1473 (1995).
Kaminski J., Alvelid B., “Temperature in the cutting zone in water-jet assisted turning”, J. Mater. Process. Technol., 106: 68–73 (2000).
Kamruzzaman M., “Effect of high pressure coolant on machinability of steel”, Ph.D. dissertation (continuing), Engineering & Technology, (2008). University of
- Yayın Aralığı: Yılda 4 Sayı
- Başlangıç: 1988
- Yayıncı: Gazi Üniversitesi, Fen Bilimleri Enstitüsü