Papers by Keyword: Green Machining

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Authors: Xiao Hong Zhang, Chong Xia, Peng Chen, Guo Fu Yin
Abstract: Gear hobbing in cryogenic air with minimal quantity lubricant (MQL) is a better choice to take place of traditional gear hobbing in oily cutting fluid, in which cryogenic air with pulverized vegetable oil place the great amount of mineral cooling oil, to play the role of lubrication, cooling, chip clearance, and rust prevention. By the comparative experiments, differences on cutter wear are explored, among cryogenic gear hobbing with MQL, gear hobbing in oily cutting fluid, and dry gear hobbing. It indicates that the gear hobbing in cryogenic air with minimal quantity lubricant is practical, and not only a great amount of cooling oil is saved to lower cost and environment pollution, but also life-saving of hobbing cutter reduces production cost.
Authors: Yue Zhang, Li Han, You Jun Zhang, Xi Chuan Zhang
Abstract: The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. The cutting experiments are carried out based on green cooling and lubricating technology. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface. And it can help to chip forming and breaking. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy.
Authors: A.E.I. Elshwain, Norizah Redzuan
Abstract: Advanced materials like nickel and titanium have unique combinations such as low thermal conductivity, high chemical reactivity, and high hardness. Machining these materials requires suitable lubricant and proper cooling technique for increasing tool life, decreasing cutting temperature, and improving surface roughness. This paper presents a brief review done on gas-based coolant-lubricants (CLs) used in the form of either gas or cooled-pressured air and gases. Main gas-based CLs are air, N2, and CO2. Investigations of previous researches include hypered cooled air (at different cooling temperatures), minimum quantity lubrication (MQL), and gases which have been used on machining operation that affect tool life and surface finish. Compresed N2 and cooled air with MQL was identified as the most suitable coolant-lubricants for machining performance. Furthermore, this type of gas-based coolant-lubricant (CLs) is considered as one of the environmentally conscious machining.
Authors: L.T. Yan, Song Mei Yuan, Qiang Liu
Abstract: The cutting performance (tool wear, surface roughness of machined work-piece and chip formation)of wet, dry and Minimum Quantity Lubrication (MQL) machining when milling of high strength steel (PCrNi2Mo) using cemented carbide tools under different (cutting speed, depth of cut, feed rate) was analyzed. The experimental results showed that as the cutting speed, depth of cut and feed rate changed, MQL conditions provided the lowest flank wear and the highest surface quality. Chip formation produced under MQL conditions become more favorable in terms of color and shape. The results obtained prove the potential of using MQL technique in the milling process of high strength steel (PCrNi2Mo) for high cutting speed, feed rate and depth of cut.
Authors: André Marques Riviello, Fernando dos Santos Ortega
Abstract: The growing interesting in the use of silicon carbide in automotive components, biomaterials, energy, among others, which demand the production of parts with complex geometry that are difficult to obtain by conventional compaction techniques, motivates the search for developing new conformation processes. Within this context, this paper investigates the production of pieces of silicon carbide through the gelcasting process and subsequent green machining of these parts. Three systems of monomers were studied: MAM-NVP-MBAM, MAM-PEG (DMA) and MAM-HMAM. The effect of the concentration of monomers, concentration of chemical initiator and the ratio of chain-forming and crosslinker monomers on the cutting force during machining and surface roughness were evaluated. These data are compared with values of flexural strength and hardness of samples produced under the same conditions. Through a statistical analysis it was determined the best formulation for the production of parts of SiC with favorable characteristics of green machining.
Authors: Amad Elddein Issa Elshwain, Norizah Redzuan, Mohd Yusof Noordin
Abstract: Conventional coolant/lubricants have some drawbacks such as high cost, pollution, and unsatisfactory product quality. New cooling approach by using gases to enhance machinability has been investigated. This study presents the finding of nitrogen gas and nitrogen-oil-mist as conditions when turning of hardened stainless tool steel (STAVAX ESR) with hardness 48 HRC. Turning experiments were carried out on CNC turning machine using rhomboid type wiper coated carbide cutting inserts. The result show that better product surface finish and longer tool life, as well as decrease cutting temperatures could be achieved by using nitrogen-oil-mist condition compared to nitrogen gas condition.
Authors: Teng Fei Li, Bo Qiang Shi, Xue Jie Fu
Abstract: Since Green Manufacturing has been becoming the future trend of the manufacturing industries, metal cutting companies are being compelled to reduce their impact on the environment as more international and government environmental protection legislation is introduced. As an important component of Green Manufacturing, Green Machining has been proposed as a new conception and agreed by more and more people. To realize Green Machining, some suggestions are given and some effective methods or technologies are briefly introduced in this paper from two perspectives of reducing environmental pollution and saving natural resources. By comparing these technologies, it is found that the hybrid processing technologies, MQL and Water jet machining are relatively easy to implement.
Authors: Jun Qian, Yao Nan Cheng, Jun Gao, Xiao Chun Ao, Fu Gang Yan
Abstract: In the process of cutting, the problem of flying chips seriously affect the processor’s life safety and the processing environment of workshop. In order to study the characteristics of the chips flying, the authors selected five different kinds of commonly used milling insert, and use these milling insert in the dry milling experiments to study the process of cutting chips flying. In the paper, firstly, carried out flying track analysis on the chips, and concluded the chips flying theory, and then design the cutting experiment, through the statistical analysis of experiments data, to understand the influence of different insert groove chip and cutting parameters to chip flying, and puts forward suggestions on groove development of heavy-duty cutting inserts.
Authors: Hui Wang, Fu Sheng Ni, Xiu Lin Ji
Abstract: The machinability of Titanium alloy Ti6Al4V is poor, so the new green cutting technology with water vapor and ionized air as coolants and lubricants was proposed to achieve the aim of efficient and green cutting for Ti6Al4V. In this paper, the milling formation and milling force were studied in machining Ti6Al4V with application of ionized air and water vapor for cooling lubricants. A set of milling tests using carbide tool YG6 were performed under dry cutting, oil emulsion, water vapor and ionized air, respectively. The results of tests indicated that the milling formation was decreased with increasing feed per tooth and the milling force increased with increasing feed per tooth, the milling formation and milling force were reduced during water vapor and ionized air condition.
Authors: Guang Ju Si, Ming Di Wang, Kang Min Zhong
Abstract: As a new kind of flexible pneumatic actuator using clean compressed air as working medium, pneumatic muscle has many particular characteristics comparing with pneumatic cylinder. It can well accord with the development of green transmission technique. Combing pneumatic muscle with mechanical force amplifier is a practical and creative design method. According to this method, two kinds of green pneumatic clamping devices based on two-step orthogonal toggle force amplifier driven by pneumatic muscle are introduced. Their working principles and characteristic features are analyzed and corresponding mechanics calculating formulae are also given respectively.
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