The effects of liquid-CO2 cooling, MQL and cutting parameters on drilling performance

An investigation is made into the effects of liquid carbon dioxide (LCO2) cooling, minimum-quantity lubrication (MQL) and cutting speed in drilling. Experimental measurements of torque, thrust force and temperature are made over a wide range of process and operating conditions. The resulting empirical models are used to quantify the individual contributions of the controlled parameters on drilling performance, and to facilitate temperature-based process optimization. Of particular interest is the need to carefully adjust the LCO2 flow rate for any combination of MQL flow rate and cutting speed. The optimization is validated both in simulation and actual drilling tests

On assessing grindability of recycled and ore-based crankshaft steel: an approach combining data analysis with material science

Material-related grindability variations when grinding recycled and ore-based steel can significantly impair the process efficiency during finishing of automotive crankshafts. To address this problem and to achieve more robust grinding processes, the underlying causes of variation need to be understood. The present work investigates the feasibility of using quality data obtained during production to study grindability variations and identify material-related effects. Analysis of non-destructive inspection protocols indicates steel supplier-dependent differences in grindability. However, no systematic grindability differences between recycled and ore-based steel could be identified. Possible correlations between grindability and material characteristics obtained from supplied steel certificates are discussed

Method of grinding a workpiece having a cylindrical bearing surface and method for determining processing parameters

The present disclosure relates in general to a method of grinding a workpiece by means of a grinding wheel, the workpiece comprising a cylindrical bearing surface, a radially extending sidewall extending outward from the cylindrical bearing surface, and a curved transition portion connecting the cylindrical bearing surface with the sidewall. The present disclosure also relates to a method for determining processing parameters of such a grinding method

Evaluation of subcooled MQL in cBN hard turning of powder-based Cr-Mo-V tool steel using simulations and experiments

Metal cutting fluids for improved cooling and lubrication are an environmental risk and a health risk for workers. Minimizing water consumption in industry is also a goal for a more sustainable production. Therefore, metal cutting emulsions that contain hazardous additives and consume considerable amounts of water are being replaced with more sustainable metal cutting fluids and delivery systems, like vegetable oils that are delivered in small aerosol droplets, i.e., via minimum quantity lubrication (MQL). Since the volume of the cutting fluid in MQL is small, the cooling capacity of MQL is not optimal. In order to improve the cooling capacity of the MQL, the spray can be subcooled using liquid nitrogen. This paper investigates subcooled MQL with machining simulations and experiments. The simulations provide complementary information to the experiments, which would be otherwise difficult to obtain, e.g., thermal behavior in the tool-chip contact and residual strains on the workpiece surface. The cBN hard turning simulations and experiments are done for powder-based Cr-Mo-V tool steel, Uddeholm Vanadis 8 using MQL subcooled to −10 \ub0C and regular MQL at room temperature. The cutting forces and tool wear are measured from the experiments that are used as the calibration factor for the simulations. After calibration, the simulations are used to evaluate the thermal effects of the subcooled MQL, and the surface residual strains on the workpiece. The simulations are in good agreement with the experiments in terms of chip morphology and cutting forces. The cutting experiments and simulations show that there is only a small difference between the subcooled MQL and regular MQL regarding the wear behavior, cutting forces, or process temperatures. The simulations predict substantial residual plastic strain on the workpiece surface after machining. The surface deformations are shown to have significant effect on the simulated cutting forces after the initial tool pass, an outcome that has major implications for inverse material modeling

Application of the dimensionless Aggressiveness number in abrasive processes

The chip thickness is often used to characterize abrasive processes, particularly grinding. Unfortunately, because of the seemingly random nature of the geometrically undefined cutting points and difficulty in estimating the cutting-point density, chip thickness is notoriously difficult to quantify. Recently, the dimensionless Aggressiveness number has gained popularity because it circumvents the need to quantify the wheel topography and is applicable to any geometry in abrasive contact. This paper shows how the concept of dimensionless Aggressiveness number applies to the most common abrasive geometries and how it can be used to achieve practical results in a variety of applications

Verification of electric steel punching simulation results using microhardness

One of the most dominant manufacturing methods in the production of electromechanical devices from sheet metal is punching. In punching, the material undergoes plastic deformation and finally fracture. Punching of an electrical steel sheet causes plastic deformation on the edges of the part, which affects the magnetic properties of the material, i.e., increases iron losses in the material, which in turn has a negative effect on the performance of the electromagnetic devices in the final product. Therefore, punching-induced iron losses decrease the energy efficiency of the device. FEM simulations of punching have shown significantly increased plastic deformation on the workpiece edges with increasing tool wear. In order to identify the critical tool wear, after which the iron losses have increased beyond acceptable limits, the simulation results must be verified with experimental methods. The acceptable limits are pushed further in the standards by the International Electrotechnical Commission (IEC). The new standard (IEC TS 60034-30-2:2016) has much stricter limits regarding the energy efficiency of electromechanical machines, with an IE5 class efficiency that exceeds the previous IE4 class (IEC 60034-30-1:2014) requirements by 30%. The simulations are done using Scientific Forming Technologies Corporation Deform, a finite element software for material processing simulations. The electrical steel used is M400-50A, and the tool material is Vanadis 23, a powder-based high-speed steel. Vanadis 23 is a high alloyed powder metallurgical high-speed steel with a high abrasive wear resistance and a high compressive strength. It is suitable for cold work processing like punching. In the existing literature, FEM simulations and experimental methods have been incorporated for investigating the edge deformation properties of sheared surfaces, but there is a research gap in verifying the simulation results with the experimental methods. In this paper, FEM simulation of the punching process is verified using an electrical steel sheet from real production environment and measuring the deformation of the edges using microhardness measurements. The simulations show high plastic deformation 50\ua0μm into the workpiece edge, a result that is shown to be in good agreement with the experimental results

Modeling of micro-grinding forces considering dressing parameters and tool deflection

The prediction of cutting forces is critical for the control and optimization of machining processes. This paper is concerned with developing prediction model for cutting forces in micro-grinding. The approach is based on the probabilistic distribution of undeformed chip thickness. This distribution is a function of the process kinematics, properties of the workpiece, and micro-topography of the grinding tool. A Rayleigh probability density function is used to determine the distribution of the maximum chip thickness as an independent parameter. The prediction model further includes the effect of dressing parameters. The integration of the dressing model enables the prediction of static grain density of the grinding tool at various radial dressing depths. The tool deflection is also considered in order to account for the actual depth of cut in the modeling process. The dynamic cutting-edge density as a function of the static grain density, the local tool deflection, elastic deformation, and process kinematics can hence be calculated. Once the chip thickness is calculated, the single-grain forces for individual abrasive grains are predicted and the specific tangential and normal grinding forces simulated. The simulation results are experimentally validated via cutting-force measurements in micro-grinding of Ti6Al4V. The results show that the model can predict the tangential and normal grinding forces with a mean accuracy of 10% and 30%, respectively. The observed cutting forces further imply that the flow stress of the material did not change with changing the cutting speed and the cutting strain rate. Moreover, it was observed that the depth of cut and grinding feed rate had the same neutral effect on the resultant grinding forces

The influence of single-channel liquid CO2 and MQL delivery on surface integrity in machining of Inconel 718

Sustainable machining of difficult-to-cut materials requires effective cooling and lubrication techniques. To substitute conventional flood cooling and lubrication, different techniques such as cryogenic cooling and/or minimum quantity lubrication (MQL) can be used. Liquid carbon dioxide (LCO2) can be pre-mixed with different lubricants before its delivery to the cutting zone. This article investigates the influence of this recently developed cooling and lubrication method on surface integrity characteristics in milling of Inconel 718. Surface roughness, surface topography and microstructure were evaluated for flood lubrication, dry cutting and LCO2 machining using a single-channel LCO2 and MQL strategy. Moreover, two different lubricants were evaluated for MQL: (i) conventional MQL oil and (ii) solid lubricant molybdenum di-sulphide (MoS2). In addition to being environmentally friendly, MoS2 lubricated LCO2 showed comparable surface characteristics to flood lubrication. Also, the use of lubricated LCO2 resulted in higher part surface cleanliness compared to flood lubrication

On geometry and kinematics of abrasive processes: The theory of aggressiveness

Due to the stochastic nature of the abrasive-tool topography, abrasive processes are difficult to model and quantify. In contrast, their macro geometry and kinematics are usually well defined and straightforwardly controlled on machine tools. To reconcile this seeming contradiction, a novel unifying modelling framework is defined through the theory of aggressiveness. It encompasses the arbitrary geometry and kinematics of a workpiece moving relative to an abrasive surface. The key parameter is the point-aggressiveness, which is a dimensionless scalar quantity based on the vector field of relative velocity and the vector field of abrasive-surface normals. This fundamental process parameter relates directly to typical process outputs such as specific energy, abrasive-tool wear and surface roughness. The theory of aggressiveness is experimentally validated by its application to a diverse array of abrasive processes, including grinding, diamond truing and dressing, where the aggressiveness number is correlated with the aforementioned measured process outputs

The role of resource efficiency in engineering education

Part of: Seliger, Günther (Ed.): Innovative solutions : proceedings / 11th Global Conference on Sustainable Manufacturing, Berlin, Germany, 23rd - 25th September, 2013. - Berlin: Universitätsverlag der TU Berlin, 2013. - ISBN 978-3-7983-2609-5 (online). - http://nbn-resolving.de/urn:nbn:de:kobv:83-opus4-40276. - pp. 90–95.The purpose of this paper is to address various issues of resource efficiency in the perspective of engineering education in the Middle East and North Africa (MENA) region, with particular focus on Occupied Palestinian Territory (Palestine). First, the paper reviews the concept of resource efficiency from several perspectives including energy, electricity and water related challenges, material management and solid waste management. Then the current state of the education and training is discussed along with some details regarding the developed resource accounting perspective for engineering education. Open knowledge platform is foreseen to aid the transition from problem to solution, bringing engineering education up front to tackle the resource efficiency challenges in the MENA region. Finally, capacity building through university graduates is considered as an important mechanism for raising awareness in resource efficiency