Experimental Analysis of System Parameters for Minimum Cutting Fluid Consumption when Machining Ti-6Al-4V Using a Novel Supply System

Gariani, Salah, Shyha, Islam, Inam, Fawad and Huo, Dehong (2018) Experimental Analysis of System Parameters for Minimum Cutting Fluid Consumption when Machining Ti-6Al-4V Using a Novel Supply System. International Journal of Advanced Manufacturing Technology, 95 (5-8). pp. 2795-2809. ISSN 0268-3768

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Official URL: http://dx.doi.org/10.1007/s00170-017-1216-y

Abstract

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.

Item Type: Article
Uncontrolled Keywords: Fluid consumption; Coherent nozzle, vegetable oil-based; Cutting fluid; Shoulder milling; Ti-6Al-4V
Subjects: H300 Mechanical Engineering
Department: Faculties > Engineering and Environment > Mechanical and Construction Engineering
Depositing User: Ellen Cole
Date Deposited: 17 Oct 2017 08:47
Last Modified: 15 Apr 2018 16:13
URI: http://nrl.northumbria.ac.uk/id/eprint/32332

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