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Experimental analysis of system parameters for minimum cutting fluid consumption when machining Ti-6Al-4V using a novel supply system

Lookup NU author(s): Dr Islam Shyha, Dr Dehong Huo

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This work is licensed under a Creative Commons Attribution 4.0 International License (CC BY 4.0).

Abstract

© 2017 The Author(s) 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 (Ra) 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.

Publication metadata

Author(s): Gariani S, Shyha I, Inam F, Huo D

Publication type: Article

Publication status: Published

Journal: International Journal of Advanced Manufacturing Technology

Year: 2018

Volume: 95

Issue: 5-8

Pages: 2795-2809

Print publication date: 01/03/2018

Online publication date: 29/11/2017

Acceptance date: 13/10/2017

Date deposited: 14/12/2017

ISSN (print): 0268-3768

ISSN (electronic): 1433-3015

Publisher: Springer London

URL: https://doi.org/10.1007/s00170-017-1216-y

DOI: 10.1007/s00170-017-1216-y

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