Experimental assessment of thermal and rheological properties of coconut oil-silica as green additives in drilling performance based on minimum quantity of cutting fluids

Conventional metal working fluids are prepared from petroleum based mineral oils with toxic, carcinogenic, non- biodegradable and unsustainable additives, which can cause serious environmental contamination and health risks to operators. Formulations with non-toxic emulsifiers and natural additives such as vegetable oils are currently being considered for further development and use of non-toxic tribological products. This study is concerned with the thermal and flow properties of a cutting fluid (taladrine, T) mixed with a phase change material (PCM) coconut oil (CO) in a proportion of 1:9 (CO-0.1T) and hydrophilic silica in 0.01, 0.03 and 0.05 vol fractions. The thermal properties were evaluated by differential scanning calorimetry (DSC) and thermal conductivity measurements while the flow properties were assessed by viscosity temperature curves. The addition of solid particles has demonstrated an enhancement of the thermal conductivities with small differences in the latent heat. The microstructure of the suspensions was established from the DSC cooling dynamic ther- mogram and the rheological measurements. These results were confirmed by the images of optical polarized microscopy in which plate-like needles were observed. The suspension of 0.03 silica in CO-0.1T demonstrated an adequate gel strength and produced a reduction of 11 ◦C in drilling performance. A Minimum Quantity of Cutting Fluid (MQCF) of 2 g as an alternative for dry machining and flood cooling. It also prevented evaporative loss and removed metal chips, as a high viscosity complex fluid. In this work the use of phase change materials filled with solid particles as a way of sustainable eco-friendly toxic waste removal in drilling was justified.Funding for open access charge: Universidad de Málag

Progressing towards sustainable machining of steels : a detailed review

Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production

Advanced Powder Metallurgy Technologies

Powder metallurgy is a group of advanced processes used for the synthesis, processing, and shaping of various kinds of materials. Initially inspired by ceramics processing, the methodology comprising the production of a powder and its transformation to a compact solid product has attracted attention since the end of World War II. At present, many technologies are availabe for powder production (e.g., gas atomization of the melt, chemical reduction, milling, and mechanical alloying) and its consolidation (e.g., pressing and sintering, hot isostatic pressing, and spark plasma sintering). The most promising methods can achieve an ultra-fine or nano-grained powder structure, and preserve it during consolidation. Among these methods, mechanical alloying and spark plasma sintering play a key role. This book places special focus on advances in mechanical alloying, spark plasma sintering, and self-propagating high-temperature synthesis methods, as well as on the role of these processes in the development of new materials

CPM LCA Database – Life Cycle Inventory Datasets

This report contains all 748 complete LCI datasets in the CPM LCA Database as published in 2020-11-20. Contents:Table 1 (pp 3-23) lists all LCI process names in alphabetical order.Table 2 (pp 24-2543) lists all complete LCI datasets in alphabetical order.For information about the database please refer to the Swedish Life Cycle Center, lifecyclecenter.se

Ultra-high precision machining of rapidly solidified aluminium (RSA) alloys for optics

The advancement of ultra-precision is one of the most adaptable machining processes in the manufacturing of very complex and high-quality surface structures for optics, industrial, medical, aerospace and communication applications. Studies have shown that single-point diamond turning has an outstanding ability to machine high-quality optical components at a nanometric scale. However, in a responsive cutting process, the nanometric machinability of these optical components can easily be affected by several factors. The call for increasing needs of optical systems has recently led to the development of newly modified aluminium grades of non-ferrous alloys characterized by finer microstructures, defined mechanical and physical properties. To date, there has been a lack of sufficient research into these new aluminium alloys. In modern ultra-precision machining, the high demands for smart and inexpensive cutting tools are becoming more relevant in recent precision machines. In monitoring and predicting high-quality surface, cutting forces in single point diamond turning are believed to be as critical as other machining processes due to their potential effects on the quality of surface roughness. Undermining such an important factor is a compromise between the machining process's efficiency and the increased cost of production. Therefore, a comprehensive scientific understanding of the Nano-cutting mechanics is critical, particularly on modelling and analysis of cutting force, surface roughness, chip vii formation, acoustic emission, material removal rates, and molecular dynamic simulation of the rapidly solidified aluminium alloys to bridge the gap between fundamentals and industrial-scale application. The study is divided into three essential sections. First, the development of a force sensor. Secondly, investigation of the effect of cutting parameters (i.e., cutting speed, feed rate, and cutting depth) on cutting force, acoustic emission (AE), material removal rate (MRR), chip formation, Nose radius, and surface roughness (Ra), which play a leading role in the determination of machine productivity and efficiency of single-point diamond turning of rapidly solidified aluminium alloys. Thirdly, a 3-D molecular dynamic (MD) simulation of RSA 6061 is also carried out to further understand the nanometric mechanism and characterization of the alloy. The experiment was mainly conducted using Precitech Nanoform ultra-grind 250 lathe machines on three different advanced optical aluminium alloys materials; these are RSA 443, RSA 905, and RSA 6061.Thesis (PhD) -- Faculty of Engineering, the Built Environment and Information Technology, School of Engineering, 202

Ultra-high precision machining of rapidly solidified aluminium (RSA) alloys for optics

The advancement of ultra-precision is one of the most adaptable machining processes in the manufacturing of very complex and high-quality surface structures for optics, industrial, medical, aerospace and communication applications. Studies have shown that single-point diamond turning has an outstanding ability to machine high-quality optical components at a nanometric scale. However, in a responsive cutting process, the nanometric machinability of these optical components can easily be affected by several factors. The call for increasing needs of optical systems has recently led to the development of newly modified aluminium grades of non-ferrous alloys characterized by finer microstructures, defined mechanical and physical properties. To date, there has been a lack of sufficient research into these new aluminium alloys. In modern ultra-precision machining, the high demands for smart and inexpensive cutting tools are becoming more relevant in recent precision machines. In monitoring and predicting high-quality surface, cutting forces in single point diamond turning are believed to be as critical as other machining processes due to their potential effects on the quality of surface roughness. Undermining such an important factor is a compromise between the machining process's efficiency and the increased cost of production. Therefore, a comprehensive scientific understanding of the Nano-cutting mechanics is critical, particularly on modelling and analysis of cutting force, surface roughness, chip vii formation, acoustic emission, material removal rates, and molecular dynamic simulation of the rapidly solidified aluminium alloys to bridge the gap between fundamentals and industrial-scale application. The study is divided into three essential sections. First, the development of a force sensor. Secondly, investigation of the effect of cutting parameters (i.e., cutting speed, feed rate, and cutting depth) on cutting force, acoustic emission (AE), material removal rate (MRR), chip formation, Nose radius, and surface roughness (Ra), which play a leading role in the determination of machine productivity and efficiency of single-point diamond turning of rapidly solidified aluminium alloys. Thirdly, a 3-D molecular dynamic (MD) simulation of RSA 6061 is also carried out to further understand the nanometric mechanism and characterization of the alloy. The experiment was mainly conducted using Precitech Nanoform ultra-grind 250 lathe machines on three different advanced optical aluminium alloys materials; these are RSA 443, RSA 905, and RSA 6061.Thesis (PhD) -- Faculty of Engineering, the Built Environment and Information Technology, School of Engineering, 202

Advances in the utilization of waste materials and alternative sources of energy in clay brick making : a South Tyrolean case study investigating environmental and financial impacts

The background to this research program was the need to investigate novel technologies and their application to fired ceramic processes that would facilitate the return to profitability for a small size brick maker. The company, Gasser Brick Company. Ziegel Gasser Mattoni GmbH S.r.l., in Natz-Schabs (Naz-Sciaves) in the north of Italy, is a relatively small manufacturer producing < 20,000 metric tons of brick per year. In this thesis the economic, environmental and social advantages consequent to a complete review of the approach to the company’s manufacture of cored clay bricks are discussed, including energy saving measures and the use of novel fuel and clay body supplements. A number of wide ranging novel technical modifications to the production processes of the Gasser Brick company have been tested, evaluated, reviewed, compared, and critically evaluated. The approach includes the utilization of a substantial percentage of various wastes as part-substitution of, or as an addition to, quarried raw materials and also the use of renewable and alternative fuels as a substitute for fossil fuels. A number of these modifications have resulted in beneficial changes to the product and the efficiency of the production process and considerably reduced the environmental footprint of the operation. Process modifications and the technological improvements to production equipment are explained and discussed along with detailed information about the measures that enabled the Gasser Brick company to return the profitability. The modifications resulted in a substantial increase of income. Revenues from waste gate fees are about 30% of the total turnover of the company. Costs for thermal energy dropped by 2/3: A ton of boiler oil commanded a price of 220 - 245 €/ton versus the around 80 €/ton of rendering fat.EThOS - Electronic Theses Online ServiceGBUnited Kingdo

Advances in the utilization of waste materials and alternative sources of energy in clay brick making : a South Tyrolean case study investigating environmental and financial impacts

The background to this research program was the need to investigate novel technologies and their application to fired ceramic processes that would facilitate the return to profitability for a small size brick maker. The company, Gasser Brick Company. Ziegel Gasser Mattoni GmbH S.r.l., in Natz-Schabs (Naz-Sciaves) in the north of Italy, is a relatively small manufacturer producing < 20,000 metric tons of brick per year. In this thesis the economic, environmental and social advantages consequent to a complete review of the approach to the company’s manufacture of cored clay bricks are discussed, including energy saving measures and the use of novel fuel and clay body supplements. A number of wide ranging novel technical modifications to the production processes of the Gasser Brick company have been tested, evaluated, reviewed, compared, and critically evaluated. The approach includes the utilization of a substantial percentage of various wastes as part-substitution of, or as an addition to, quarried raw materials and also the use of renewable and alternative fuels as a substitute for fossil fuels. A number of these modifications have resulted in beneficial changes to the product and the efficiency of the production process and considerably reduced the environmental footprint of the operation. Process modifications and the technological improvements to production equipment are explained and discussed along with detailed information about the measures that enabled the Gasser Brick company to return the profitability. The modifications resulted in a substantial increase of income. Revenues from waste gate fees are about 30% of the total turnover of the company. Costs for thermal energy dropped by 2/3: A ton of boiler oil commanded a price of 220 - 245 €/ton versus the around 80 €/ton of rendering fat.EThOS - Electronic Theses Online ServiceGBUnited Kingdo