Effect of Cooling Coherent Nozzle Orientation on the Machinability of Ti-6Al-4V in Step Shoulder Milling
In this work, a cooling coherent round nozzle was developed and the impact of nozzle placement (i.e. nozzle angle and stand-off/impinging distance) on the machinability of Ti-6Al-4V was evaluated. Key process measures were cutting force, workpiece temperature, tool wear, burr formation and average surface roughness (Ra). Experimental results showed that nozzle position at a 15° angle in the feed direction and 45°/60° against feed direction assisted in minimising workpiece temperature. A stand-off distance of 55 and 75 mm is also necessary to control burr formation, workpiece temperature and Ra, but coherent nozzle orientation has no statistically significant impact on the mean values of cutting force and tool wear. It can be concluded that stand-off distance is more substantially significant than nozzle angles when step shoulder milling Ti-6Al- 4V using vegetable oil-based cutting fluid.
[1] R. Revuru, N. Posinasetti, V. Ramana, and M. Amrita, "Application of cutting fluids in machining of titanium alloys—a review," The International Journal of Advanced Manufacturing Technology, vol. 91, no. 5-8, pp. 2477-2498, 2017.
[2] P. Priarone, M. Robiglio, L. Settineri, and V. Tebaldo, "Effectiveness of minimizing cutting fluid use when turning difficult-to-cut alloys," Procedia CIRP, vol. 29, no. Supplement C, pp. 341-346, 2015/01/01/ 2015.
[3] A. Iturbe, E. Hormaetxe, A. Garay, and P. J. Arrazola, "Surface Integrity analysis when machining Inconel 718 with conventional and cryogenic cooling," Procedia CIRP, vol. 45, pp. 67-70, 2016/01/01 2016.
[4] N. Madanchi, S. Thiede, and C. Herrmann, "Functional and environmental evaluation of alternative disinfection methods for cutting fluids," Procedia CIRP, vol. 61, pp. 558-563, // 2017.
[5] S. Debnath, M. Reddy, and Q. Yi, "Environmental friendly cutting fluids and cooling techniques in machining: a review," Journal of Cleaner Production, vol. 83, no. 0, pp. 33-47, 11/15/ 2014.
[6] E. Vazquez, J. Gomar, J. Ciurana, and C. Rodríguez, "Analyzing effects of cooling and lubrication conditions in micromilling of Ti6Al4V," Journal of Cleaner Production, vol. 87, no. 0, pp. 906-913, 1/15/ 2015.
[7] E. Benedicto, D. Carou, and E. M. Rubio, "Technical, economic and environmental review of the lubrication/cooling systems used in machining processes," Procedia Engineering, vol. 184, pp. 99-116, // 2017.
[8] G. Chetan, S. Ghosh, and P. Venkateswara Rao, "Application of sustainable techniques in metal cutting for enhanced machinability: a review," Journal of Cleaner Production, vol. 100, pp. 17-34, 2015/08/01/ 2015.
[9] R. Katna, M. Suhaib, N. J. M. Agrawal, and M. Processes, "Nonedible vegetable oil-based cutting fluids for machining processes–a review," vol. 35, no. 1, pp. 1-32, 2020.
[10] S. Lawal, I. Choudhury, I. Sadiq, and A. Oyewole. Vegetable-oil based metalworking fluids research developments for machining processes: survey, applications and challenges [Online].
[11] S. Kolawole and J. Odusote, "Performance evaluation of vegetable oil-based cutting fluids in mild steel machining," Chemistry and Materials Research, vol. 3, no. 9, pp. 35-45, 2013.
[12] M. Mahadi, I. Choudhury, M. Azuddin, N. Yusoff, A. Yazid, and A. Norhafizan, "Vegetable oil-based lubrication in machining: issues and challenges," in IOP Conference Series: Materials Science and Engineering, 2019, vol. 530, no. 1, p. 10: IOP Publishing, 2019.
[13] A. Mohsan, Z. Liu, and G. Padhy, "A review on the progress towards improvement in surface integrity of Inconel 718 under high pressure and flood cooling conditions," The International Journal of Advanced Manufacturing Technology, journal article vol. 91, no. 1, pp. 107-125, July 01 2017.
[14] G. Gaurav, A. Sharma, G. Dangayach, and M. Meena, "Assessment of jojoba as a pure and nano-fluid base oil in minimum quantity lubrication (MQL) hard-turning of Ti–6Al–4V: A step towards sustainable machining," Cleaner Production, Journal vol. 272, p. 39, 2020.
[15] P. Priarone, M. Robiglio, L. Settineri, and V. Tebaldo, "Milling and turning of titanium aluminides by using minimum quantity lubrication," Procedia CIRP, vol. 24, no. 0, pp. 62-67, // 2014.
[16] G. Singh et al., "Investigations of machining characteristics in the upgraded MQL-assisted turning of pure titanium alloys using evolutionary algorithms," MDPI: Materials, vol. 12, no. 6, p. 999, 2019.
[17] N. Madanchi, M. Winter, S. Thiede, and C. Herrmann, "Energy Efficient Cutting Fluid Supply: The Impact of Nozzle Design," Procedia CIRP, vol. 61, pp. 564-569, 2017.
[18] A. Lopez-Arraiza, G. Castillo, H. Dhakal, and R. Alberdi, "High performance composite nozzle for the improvement of cooling in grinding machine tools," Composites Part B: Engineering, vol. 54, no. 0, pp. 313-318, 11// 2013.
[19] M. Morgan and V. Baines-Jones, "On the coherent length of fluid nozzles in grinding," Key Engineering Materials, vol. 404, pp. 61-67, 2009.
[20] C. Wang, M. Chen, Q. An, M. Wang, and Y. Zhu, "Tool wear performance in face milling Inconel 182 using minimum quantity lubrication with different nozzle positions," International journal of precision engineering and manufacturing, vol. 15, no. 3, pp. 557-565, 2014.
[21] F. Rabiei, A. Rahimi, M. Hadad, and M. Ashrafijou, "Performance improvement of minimum quantity lubrication (MQL) technique in surface grinding by modeling and optimization," Journal of Cleaner Production, vol. 86, no. 0, pp. 447-460, 1/1/ 2015.
[22] A. Yassin and C. Teo, "Effect of pressure and nozzle angle of minimal quantity lubrication on cutting temperature and tool wear in turning," Applied Mechanics & Materials, Journal vol. Vol. 695, pp 676-679, no. 695, p. 4, 2015.
[23] J. Webster, "Improving surface integrity and economics of grinding by optimum coolant application, with consideration of abrasive tool and process regime," Proceedings of the institution of mechanical engineers, Part B: journal of engineering manufacture, vol. 221, no. 12, pp. 1665-1675, 2007.
[24] R. Irani, R. Bauer, and A. Warkentin, "A review of cutting fluid application in the grinding process," International Journal of Machine Tools and Manufacture, vol. 45, no. 15, pp. 1696-1705, 12// 2005.
[25] W. B. Rowe and M. Hitchnier, Handbook of Machining with Grinding, 2 nd edition ed. USA: CRC Press, 2007.
[26] S. Gariani, I. Shyha, F. Inam, and D. Huo, "Evaluation of a Novel Controlled Cutting Fluid Impinging Supply System When Machining Titanium Alloys," Applied Sciences, vol. 7, no. 6, p. 560, 2017.
[27] S. Gariani, I. Shyha, F. Inam, and D. Huo, "Experimental analysis of system parameters for minimum cutting fluid consumption when machining Ti-6Al-4V using a novel supply system," The International Journal of Advanced Manufacturing Technology, vol. 95:2795–2809, pp. 1-15, 2017.
[28] C. Sandvik. (2021, Accessed on 06/01/2021). Cutting tool materials. Available: https://www.sandvik.coromant.com
[29] K. Park, G. Yang, M. Lee, H. Jeong, S. Lee, and D. Lee, "Eco-friendly face milling of titanium alloy," International Journal of Precision Engineering and Manufacturing, vol. 15, no. 6, pp. 1159-1164, 2014.
[30] V. Krishnaraj, S. Samsudeensadham, R. Sindhumathi, and P. Kuppan, "A study on High Speed End Milling of Titanium Alloy," Procedia Engineering, vol. 97, pp. 251-257, 2014/01/01 2014.
[31] I. Mulyadi, "Improving the performance of minimum quantity lubrication in high speed milling and environmental performance analysis," Ph.D Doctor of Philosphy, School of Mechanical, ASerospace and Civil Engineering, University of Manchester Manchester, UK, 2013.
[32] Z. Liu, X. Cai, M. Chen, and Q. An, "Investigation of cutting force and temperature of end-milling Ti–6Al–4V with different minimum quantity lubrication (MQL) parameters," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 225, no. 8, pp. 1273-1279, 2011.
[33] U. Heisel, M. Schaal, and G. Wolf, "Burr formation in milling with minimum quantity lubrication," Production Engineering, vol. 3, no. 1, pp. 23-30, 2009.
[34] X. Cai, Z. Liu, M. Chen, and Q. An, "An experimental investigation on effects of minimum quantity lubrication oil supply rate in high-speed end milling of Ti–6Al–4V," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 266:1784, p. 10, 2012.
[35] M. Chen, H. Ni, Z. Wang, and Y. Jiang, "Research on the modeling of burr formation process in micro-ball end milling operation on Ti–6Al–4V," The International Journal of Advanced Manufacturing Technology, vol. 62, no. 9-12, pp. 901-912, 2012.
[1] R. Revuru, N. Posinasetti, V. Ramana, and M. Amrita, "Application of cutting fluids in machining of titanium alloys—a review," The International Journal of Advanced Manufacturing Technology, vol. 91, no. 5-8, pp. 2477-2498, 2017.
[2] P. Priarone, M. Robiglio, L. Settineri, and V. Tebaldo, "Effectiveness of minimizing cutting fluid use when turning difficult-to-cut alloys," Procedia CIRP, vol. 29, no. Supplement C, pp. 341-346, 2015/01/01/ 2015.
[3] A. Iturbe, E. Hormaetxe, A. Garay, and P. J. Arrazola, "Surface Integrity analysis when machining Inconel 718 with conventional and cryogenic cooling," Procedia CIRP, vol. 45, pp. 67-70, 2016/01/01 2016.
[4] N. Madanchi, S. Thiede, and C. Herrmann, "Functional and environmental evaluation of alternative disinfection methods for cutting fluids," Procedia CIRP, vol. 61, pp. 558-563, // 2017.
[5] S. Debnath, M. Reddy, and Q. Yi, "Environmental friendly cutting fluids and cooling techniques in machining: a review," Journal of Cleaner Production, vol. 83, no. 0, pp. 33-47, 11/15/ 2014.
[6] E. Vazquez, J. Gomar, J. Ciurana, and C. Rodríguez, "Analyzing effects of cooling and lubrication conditions in micromilling of Ti6Al4V," Journal of Cleaner Production, vol. 87, no. 0, pp. 906-913, 1/15/ 2015.
[7] E. Benedicto, D. Carou, and E. M. Rubio, "Technical, economic and environmental review of the lubrication/cooling systems used in machining processes," Procedia Engineering, vol. 184, pp. 99-116, // 2017.
[8] G. Chetan, S. Ghosh, and P. Venkateswara Rao, "Application of sustainable techniques in metal cutting for enhanced machinability: a review," Journal of Cleaner Production, vol. 100, pp. 17-34, 2015/08/01/ 2015.
[9] R. Katna, M. Suhaib, N. J. M. Agrawal, and M. Processes, "Nonedible vegetable oil-based cutting fluids for machining processes–a review," vol. 35, no. 1, pp. 1-32, 2020.
[10] S. Lawal, I. Choudhury, I. Sadiq, and A. Oyewole. Vegetable-oil based metalworking fluids research developments for machining processes: survey, applications and challenges [Online].
[11] S. Kolawole and J. Odusote, "Performance evaluation of vegetable oil-based cutting fluids in mild steel machining," Chemistry and Materials Research, vol. 3, no. 9, pp. 35-45, 2013.
[12] M. Mahadi, I. Choudhury, M. Azuddin, N. Yusoff, A. Yazid, and A. Norhafizan, "Vegetable oil-based lubrication in machining: issues and challenges," in IOP Conference Series: Materials Science and Engineering, 2019, vol. 530, no. 1, p. 10: IOP Publishing, 2019.
[13] A. Mohsan, Z. Liu, and G. Padhy, "A review on the progress towards improvement in surface integrity of Inconel 718 under high pressure and flood cooling conditions," The International Journal of Advanced Manufacturing Technology, journal article vol. 91, no. 1, pp. 107-125, July 01 2017.
[14] G. Gaurav, A. Sharma, G. Dangayach, and M. Meena, "Assessment of jojoba as a pure and nano-fluid base oil in minimum quantity lubrication (MQL) hard-turning of Ti–6Al–4V: A step towards sustainable machining," Cleaner Production, Journal vol. 272, p. 39, 2020.
[15] P. Priarone, M. Robiglio, L. Settineri, and V. Tebaldo, "Milling and turning of titanium aluminides by using minimum quantity lubrication," Procedia CIRP, vol. 24, no. 0, pp. 62-67, // 2014.
[16] G. Singh et al., "Investigations of machining characteristics in the upgraded MQL-assisted turning of pure titanium alloys using evolutionary algorithms," MDPI: Materials, vol. 12, no. 6, p. 999, 2019.
[17] N. Madanchi, M. Winter, S. Thiede, and C. Herrmann, "Energy Efficient Cutting Fluid Supply: The Impact of Nozzle Design," Procedia CIRP, vol. 61, pp. 564-569, 2017.
[18] A. Lopez-Arraiza, G. Castillo, H. Dhakal, and R. Alberdi, "High performance composite nozzle for the improvement of cooling in grinding machine tools," Composites Part B: Engineering, vol. 54, no. 0, pp. 313-318, 11// 2013.
[19] M. Morgan and V. Baines-Jones, "On the coherent length of fluid nozzles in grinding," Key Engineering Materials, vol. 404, pp. 61-67, 2009.
[20] C. Wang, M. Chen, Q. An, M. Wang, and Y. Zhu, "Tool wear performance in face milling Inconel 182 using minimum quantity lubrication with different nozzle positions," International journal of precision engineering and manufacturing, vol. 15, no. 3, pp. 557-565, 2014.
[21] F. Rabiei, A. Rahimi, M. Hadad, and M. Ashrafijou, "Performance improvement of minimum quantity lubrication (MQL) technique in surface grinding by modeling and optimization," Journal of Cleaner Production, vol. 86, no. 0, pp. 447-460, 1/1/ 2015.
[22] A. Yassin and C. Teo, "Effect of pressure and nozzle angle of minimal quantity lubrication on cutting temperature and tool wear in turning," Applied Mechanics & Materials, Journal vol. Vol. 695, pp 676-679, no. 695, p. 4, 2015.
[23] J. Webster, "Improving surface integrity and economics of grinding by optimum coolant application, with consideration of abrasive tool and process regime," Proceedings of the institution of mechanical engineers, Part B: journal of engineering manufacture, vol. 221, no. 12, pp. 1665-1675, 2007.
[24] R. Irani, R. Bauer, and A. Warkentin, "A review of cutting fluid application in the grinding process," International Journal of Machine Tools and Manufacture, vol. 45, no. 15, pp. 1696-1705, 12// 2005.
[25] W. B. Rowe and M. Hitchnier, Handbook of Machining with Grinding, 2 nd edition ed. USA: CRC Press, 2007.
[26] S. Gariani, I. Shyha, F. Inam, and D. Huo, "Evaluation of a Novel Controlled Cutting Fluid Impinging Supply System When Machining Titanium Alloys," Applied Sciences, vol. 7, no. 6, p. 560, 2017.
[27] S. Gariani, I. Shyha, F. Inam, and D. Huo, "Experimental analysis of system parameters for minimum cutting fluid consumption when machining Ti-6Al-4V using a novel supply system," The International Journal of Advanced Manufacturing Technology, vol. 95:2795–2809, pp. 1-15, 2017.
[28] C. Sandvik. (2021, Accessed on 06/01/2021). Cutting tool materials. Available: https://www.sandvik.coromant.com
[29] K. Park, G. Yang, M. Lee, H. Jeong, S. Lee, and D. Lee, "Eco-friendly face milling of titanium alloy," International Journal of Precision Engineering and Manufacturing, vol. 15, no. 6, pp. 1159-1164, 2014.
[30] V. Krishnaraj, S. Samsudeensadham, R. Sindhumathi, and P. Kuppan, "A study on High Speed End Milling of Titanium Alloy," Procedia Engineering, vol. 97, pp. 251-257, 2014/01/01 2014.
[31] I. Mulyadi, "Improving the performance of minimum quantity lubrication in high speed milling and environmental performance analysis," Ph.D Doctor of Philosphy, School of Mechanical, ASerospace and Civil Engineering, University of Manchester Manchester, UK, 2013.
[32] Z. Liu, X. Cai, M. Chen, and Q. An, "Investigation of cutting force and temperature of end-milling Ti–6Al–4V with different minimum quantity lubrication (MQL) parameters," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 225, no. 8, pp. 1273-1279, 2011.
[33] U. Heisel, M. Schaal, and G. Wolf, "Burr formation in milling with minimum quantity lubrication," Production Engineering, vol. 3, no. 1, pp. 23-30, 2009.
[34] X. Cai, Z. Liu, M. Chen, and Q. An, "An experimental investigation on effects of minimum quantity lubrication oil supply rate in high-speed end milling of Ti–6Al–4V," Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, vol. 266:1784, p. 10, 2012.
[35] M. Chen, H. Ni, Z. Wang, and Y. Jiang, "Research on the modeling of burr formation process in micro-ball end milling operation on Ti–6Al–4V," The International Journal of Advanced Manufacturing Technology, vol. 62, no. 9-12, pp. 901-912, 2012.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:80872", author = "Salah Gariani and Islam Shyha and Osama Elgadi and Khaled Jegandi", title = "Effect of Cooling Coherent Nozzle Orientation on the Machinability of Ti-6Al-4V in Step Shoulder Milling", abstract = "In this work, a cooling coherent round nozzle was developed and the impact of nozzle placement (i.e. nozzle angle and stand-off/impinging distance) on the machinability of Ti-6Al-4V was evaluated. Key process measures were cutting force, workpiece temperature, tool wear, burr formation and average surface roughness (Ra). Experimental results showed that nozzle position at a 15° angle in the feed direction and 45°/60° against feed direction assisted in minimising workpiece temperature. A stand-off distance of 55 and 75 mm is also necessary to control burr formation, workpiece temperature and Ra, but coherent nozzle orientation has no statistically significant impact on the mean values of cutting force and tool wear. It can be concluded that stand-off distance is more substantially significant than nozzle angles when step shoulder milling Ti-6Al- 4V using vegetable oil-based cutting fluid. ", keywords = "Coherent round nozzle, step shoulder milling, Ti-6Al-4V, vegetable oil-based cutting fluid.", volume = "16", number = "7", pages = "174-8", }
