The Impact of Cooling System on Surface Quality in Milling

Abstract:

In the last years there has been an increased demand to lower the impact of industrial activities on environment quality. Cutting fluids, among other products, are an important pollutant but they have often been associated with the need for a higher productivity of machining processes. Cutting fluids are a mean of reducing temperature in the cutting area, friction and tool wear but they also represent 7% to 17% of the production costs. Other problems raised by cutting fluids are: microorganism infestation, which can cause pulmonary and dermatological diseases and poor lubrication or corrosion caused by some of the chemicals. Dry cutting is regarded as the cleanest cooling method, but it has a reduced heat dissipation efficiency and practically there is no lubrication. Other relatively new green solutions concern the use of minimum quantity lubrication (MQL) and cryogenic machining.

• Periodical: Applied Mechanics and Materials (Volumes 809-810)
• Pages: 135-140
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.809-810.135
• Online since: November 2015
• Authors: Bogdan Alexandru Chirita*, Nicolae Catalin Tampu
• Keywords: Cooling System, Green Machining, Milling, Surface Quality

References

[1] M. Kutz, Environmentally Conscious Manufacturing, Wiley, Hoboken, New Jersey, (2007).

[2] F. Klocke, Manufacturing Processes 1: Turning, Milling, Drilling, Springer, New York, (2011).

[3] U.S. Dixit, D.K. Sarma, J.P. Davim, Environmentally Friendly Machining, Springer, New York, (2012).

[4] A. Shokrani, V. Dhokia, S.T. Newman, Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids, Int. J. Mach. Tool. Manu. 57 (2012) 83-101.

DOI: 10.1016/j.ijmachtools.2012.02.002

[5] D.P. Adler, W.W.S. Hii, D.J. Michalek, J.W. Sutherland, Examining the role of cutting fluids in machining and efforts to address associated environmental/health concerns, Mach. Sci. Technol. 10 (2006) 23-58.

DOI: 10.1080/10910340500534282

[6] S.A. Lawal, I.A. Choudhury, Y. Nukman, A critical assessment of lubrication techniques in machining processes: a case for minimum quantity lubrication using vegetable oil-based lubricant, J. Clean. Prod. 41 (2013) 210-221.

DOI: 10.1016/j.jclepro.2012.10.016

[7] F. Pusavec, P. Krajnik, J. Kopac, Transitioning to sustainable production – Part I: application on machining technologies, J. Clean. Prod. 18 (2010) 174-184.

DOI: 10.1016/j.jclepro.2009.08.010

[8] F. Pusavec, D. Kramar, P. Krajnik, J. Kopac, Transitioning to sustainable production – part II: evaluation of sustainable machining technologies, J. Clean. Prod. 18 (2010) 1211-1221.

DOI: 10.1016/j.jclepro.2010.01.015

[9] M. Helu, B. Behmann, H. Meier, D. Dornfeld, G. Lanza, V. Schulze, Impact of green machining strategies on achieved surface quality, CIRP Ann-Manuf. Techn. 61 (2012) 55-58.

DOI: 10.1016/j.cirp.2012.03.092

[10] I.H. Mulyadi, P.T. Mativenga, Random or intuitive nozzle position in high-speed milling using minimum quantity lubricant, P. I. Mech. Eng. B-J. Eng. 228 (2013) 21-30.

DOI: 10.1177/0954405413495536

[11] A. Attanasio, M. Gelfi, C. Giardini, C. Remino, Minimal quantity lubrication in turning: Effect on tool wear, Wear. 260 (2006) 333-338.

DOI: 10.1016/j.wear.2005.04.024

[12] S. Bhowmick, M.J. Lukitsch, A.T. Alpas, Dry and minimum quantity lubrication drilling of cast magnesium alloy (AM60), Int. J. Mach. Tool. Manu. 50 (2010) 444-457.

DOI: 10.1016/j.ijmachtools.2010.02.001

[13] D.F. Frăţilă, C. Caizar, Assessment of cooling effect and surface quality to face milling of AlMg3 using several cooling lubrication methods, Mater. Manuf. Process. 27 (2011) 291-296.

DOI: 10.1080/10426914.2011.577864

[14] J.P. Davim, P.S. Sreejith, R. Gomes, C. Peixoto, Experimental studies on drilling of aluminium (AA1050) under dry, minimum quantity of lubricant, and flood-lubricated conditions, P. I. Mech. Eng. B-J. Eng. 220 (2006) 1605-1611.

DOI: 10.1243/09544054jem557

[15] V.N. Gaitonde, S.R. Karnik, J.P. Davim, Optimal MQL and cutting conditions determination for desired surface roughness in turning of brass using genetic algorithms, Mach. Sci. Technol. 16 (2012) 304-320.

DOI: 10.1080/10910344.2012.673976

[16] D. Umbrello, Z. Pu, S. Caruso, J.C. Outeiro, A.D. Jayal, O.W. Dillon, I.S. Jawahir, The effects of cryogenic cooling on surface integrity in hard machining, Procedia. Eng. 19 (2011) 371-376.

DOI: 10.1016/j.proeng.2011.11.127

[17] D. Umbrello, F. Micari, I.S. Jawahir, The effects of cryogenic cooling on surface integrity in hard machining: a comparison with dry machining, CIRP Ann-Manuf. Techn. 61 (2012) 103-106.

DOI: 10.1016/j.cirp.2012.03.052

[18] Y. Kaynak, T. Lu, I.S. Jawahir, Cryogenic machining-induced surface integrity: a review and comparison with dry, MQL, and flood-cooled machining, Mach. Sci. Technol. 18 (2014) 149-198.

DOI: 10.1080/10910344.2014.897836

[19] D. Carou, E.M. Rubio, C.H. Lauro, J.P. Davim, Experimental investigation on surface finish during intermittent turning of UNS M11917 magnesium alloy under dry and near dry machining conditions, Measurement 56 (2014) 136-154.

DOI: 10.1016/j.measurement.2014.06.020