Subjects: Mechanical Engineering >> Machine Tool submitted time 2024-05-14
Abstract： In-process detection of cutting forces, temperature, roughness, wear etc. during machining of titanium alloys are very important. The Finite element (FE) analysis plays an important role in monitoring and detection of machining responses. It offers a high accuracy in modeling of dry cutting processes and its performance in modeling of cryogenic machining process is a matter of interest. In this context, current investigation focuses on the dry turning and LN2/CO2 cooling assisted turning process of commonly used Ti6Al4V alloy. It is very useful material in the biomedical sector, and the simulation of cutting forces and cutting temperature via finite element method (FEM) has been performed. In addition, the simulation results are validated with experimental work. The results show that the deviations between FE modeling and experimental results for the cutting temperature are the average of 5.54%, 5.18% and 8.42% for the dry, LN2 and CO2 cooling conditions, respectively. On the other hand, the deviations from FE modeling and cutting force test results were 3.74%, 3.358%, and 3.03% under dry, LN2 and CO2 cooling conditions, respectively.
Subjects: Mechanical Engineering >> Machinofacture Technique and Equipment submitted time 2024-05-12
Munish Kumar Gupta
Hamza El Etri
Mehmet Erdi Korkmaz
Nimel Sworna Ross
Grzegorz M. Krolczyk
Józef Gawlik
Nafiz Yaşar
Danil Yu Pimenov
Abstract： Being easily fabricated, welded, biocompatible, having a high strength-to-weight ratio, withstanding comparatively high temperatures up to 800 °C and low modulus of elasticity make grade titanium and its alloys an important choice for automotive, biomedical and aerospace industries. In contempt of the different pleasant assets of Ti–6Al–4V alloy, the operation of this alloy is restricted especially when it comes to tribological and surface morphological characteristics. Enhancing these properties is important, for this purpose, a diversity of attempts and studies have been conducted. This paper mounts a review of morphological and tribological behaviors of titanium alloys including Ti–6Al–4V against different materials counting with carbide tools and other types of materials under dry and lubricated sliding conditions. The surface morphological, wear, and other properties have been discussed in this review article.
Subjects: Mechanical Engineering >> Machine Tool submitted time 2024-05-10
Grzegorz M. Krolczyk
Ça#1;grı Vakkas Yıldırım
Murat Sarikaya
Munish Kumar Gupta
Italo Tomaz
Danil Yu Pimenov
Mustafa Kunto#1;glu
Navneet Khanna
Abstract： Today, superalloys (also known as hard-to-cut materials) such as nickel, titanium and cobalt based cover a wide range of areas in engineering applications. At the same time, challenging material properties namely high strength and low thermal conductivity cause low quality in terms of cutting tool life and surface integrity of the machined part. It is important to improve the machinability of this type of materials by applying various methods in the perspective of sustainability. Therefore, current study presents surface integrity, tool wear characteristics and initiatives to improve them during the machining of superalloys. In this manner, it is outlined the surface integrity characteristics containing surface defects, surface roughness, microstructure alterations and mechanical properties. Also, tool wear mechanisms for example abrasive, adhesive, oxidation, diffusion and plastic deformation are investigated in the light of literature review. Finally, possible improvement options for tool wear and surface integrity depend on machining parameters, tool modifications, cooling methods and trade-off strategies are highlighted. The paper can be a guide for the researchers and manufacturers in the area of sustainable machining of hard-to-cut materials as explaining the latest trends and requirements.
Subjects: Mechanical Engineering >> Machinofacture Technique and Equipment submitted time 2024-05-10
Abstract： In this work, the sustainable machining approach is promoted by implementing the dry and minimum quantity lubrication (MQL) cooling conditions in the turning of duplex stainless steel. Initially, the turning experiments were performed under dry as well as MQL conditions and then, the influence of different positions of MQL nozzles on tribological and machining performance of 2205 duplex steel was investigated. The cutting parameters were kept fixed and the performance is evaluated in terms of surface roughness, micro-hardness, energy consumption, tool wear, machined surface microstructure and chips morphology. The results demonstrated that the highest average surface roughness values were obtained under dry conditions, with a value of 2.20 μm while MQL (flank + rake directions) produces the lowest surface roughness value of 1.55 μm with an improvement of 30%. Moreover, dual-jet MQL gives the lowest energy consumption (229 kJ) and tool wear (0.15 mm) with 23.67% and 52.38% enhancement, respectively.
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