Papers by Keyword: Near-Dry Cutting

Abstract: Recently, high-combustion-efficiency jet engines have become required in the aircraft industry. High burning temperatures are necessary to maximize the combustion efficiency of jet engines. Inconel 718, which has excellent mechanical and chemical properties, has been selected for use in many jet engine parts. However, Inconel 718 is a difficult material to cut because of its low thermal conductivity. Consequently, wet cutting is typically used to reduce the heat generated in cutting Inconel 718. Wet cutting, which uses a large amount of cutting fluid, is costly and requires considerable energy for maintenance and disposal of the cutting fluid, making this cutting method environmentally unfriendly. To reduce the associated cost and environmental load, the near-dry cutting method, which uses a very small amount of cutting fluid, may be preferable for cylindrical cutting of Inconel 718. However, this method has some drawbacks, such as the cutting stock removal rate and the wear on cemented carbide tools. For example, the cutting stock removal rate is lower than with wet cutting because cutting edge fracture occurs easily in near-dry cutting. In this study, we conducted experiments to examine the relationships between the tool materials, cutting speed and tool fracture in near-dry cutting and wet cutting, and we compared the results obtained using the two cutting methods. We found that an S05-type cemented carbide coating can reduce tool wear. We also found that in the early stages of cutting, between cutting speeds of V = 50 and 90 m/min, the tool wear can be comparatively reduced.

Abstract: In recent years, high-combustion-efficiency jet engines are required in the aircraft industry. Inconel 718, which has excellent mechanical and chemical characteristics. However, Inconel 718 is difficult to cut material because of its low-thermal conductivity. Consequently, Wet cutting is ordinarily adopted to reduce the heat on cutting heat edge in Inconel 718 cutting. Wet cutting which uses large amount of cutting fluid requires much cost and energy on maintenance or disposal of cutting fluid, and this method is environmentally-unfriendly. From the view point of reducing cost and environmental load, we examined the method of Near-Dry cutting which uses very small amount of cutting fluid for the cylindrical cutting of Inconel 718. However, this method has some problems, such as tool wear and cutting stock removal rate. In this report, we experimentally examined the relationship between cutting speed, tool materials, and tool fracture of near-dry cutting of Inconel 718. We compared these results with those of wet cutting, a method which is more expensive, requires significantly greater amounts of energy, and is less environment-friendly. The results indicate that when cutting speed is 100 m/min, tool fracture occurs at a cutting distance of 200 m. When cutting speed is 50 m/min, tool fracture does not occur and near-dry cutting distances can continue beyond 600 m. Moreover, tool wear could be reduced when S05 tool material, which has high bending strength, was used.

Abstract: Dry cutting technology is a new environmentally friendly green process technology. Based on the characteristics of dry cutting and deep-hole processing, a deep-hole processing solution by means of dry cutting technology is presented, that is the near-dry deep hole processing system. Combination of the characteristics of near-dry deep hole processing, we improve the design of tool structure and the selection of blade material, and find the blade material of near-dry deep hole processing by processing testing. Analyzing and testing the cutting performance and processing effect by comparing near-dry and traditional oil processing methods, we achieve a satisfactory result and confirm that the near-dry processing is a green processing technology which has a good processing effect and applying prospect.

Abstract: The traditional cast-type method of BTA deep-hole drilling(such as BTA or DF) has cutting fluid consumption of the existence of large, high production costs, pollution of the environment and endangering the health of the operator and other problems. In this paper, the MQL technology (minimum lubrication technology) is applied to the method of BTA deep-hole machining (ie, near-dry deep-hole processing), we also analyzed the function and effect of MQL machining cutting fluid. Through the near-dry deep-hole drilling experiment, we find that a water-soluble cutting fluid has good atomization effect and the processing system also has fine effect of cooling and chip evacuation. We proposed mixed-use oil and the low-temperature cold spray methods to improve the tool lubrication and cooling effect for some great issues such as tool wear.

Abstract: Based on the characteristics of near-dry cutting and BTA deep-hole drilling, this paper presented design method of near-dry deep-hole processing system, and then studied on it through experiments. The results show that the near-dry deep-hole processing system has better effects on discharge chips and coolant. At the same time, near-dry cutting function was better than BTA cutting with appropriate cutting parameters through comparing with BTA cutting machining.

Abstract: Near-dry deep hole processing technology is a kind of technology which dry cutting technology is applied to deep hole processing to save energy and decrease environmental pollution. In this paper, the structure and work principle of near-dry deep-hole drilling system were introduced and the cutting mechanism of near-dry deep-hole drilling was analyzed which include the mechanism of cutting fluid atomization and flow, the mechanism of atomized cutting fluid cool and lubricate, and the mechanism of separating chips into short pieces and discharge chips by air stream, etc. The mathematical mode of gas-liquid two-phase flow of atomized cutting fluid in drilling shaft and the cooling and lubrication mechanism of the capillary in cutting zone were introduced. It is found that near-dry deep hole processing has better cooling and lubrication effect through experiments.

Abstract: The near-dry deep hole drilling system was taken as object in this study，and the contrast experiment between the deep hole drilling system and the traditional（wet）deep-hole drilling system，including the cutting force，the tool wear，the surface quality and the chip-break have been done. The results show that the near-dry system drill stability and have better effort in cooling，lubrication，chip removal effective. The tool life and surface quality within the hole are better，at the same time，it can greatly reducing the amount of cutting fluid，the costs and the pollution of the environment. So we can get a conclusion that it is an ideal system in green drilling process.

Abstract: This paper depicts a boring and trepanning association (BTA) deep-hole drilling system with near-dry cutting technique. The cutting tests are carried out in view of the machining performances under the condition of applying the compressed air and atomized cutting fluid for drilling deep holes on titanium alloy which is difficult to cut. Several cutter materials have been utilized in the tests. The reasonable material of the deep-hole drilling cutter has been determined by analyzing the cutting force, the cutter wear and the surface finish. Environmental pollution decreases owing to little cutting fluid consumption in near-dry cutting system.