Experimental Analysis of System Parameters for Minimum Cutting Fluid Consumption when Machining Ti-6Al-4V Using a Novel Supply System

Gariani, Salah; Shyha, Islam; Inam, Fawad; Huo, Dehong

Abstract

This paper presents the development of a new controlled cutting fluid impinging supply system (Cut-list) to deliver an accurate quantity of cutting fluid into machining zones through precisely oriented coherent round nozzles. The performance of the new system was evaluated against a conventional system during the step shoulder milling of Ti-6Al-4V using a water-miscible vegetable oil-based cutting fluid, which was phase 1 in this comprehensive study. The use of Cut-list resulted in a significant reduction up to 42\% in cutting fluid consumption as well as reductions in cutting force, tool flank wear, average surface roughness (R a ) and burr height (Gariani et al. in Appl Sci 7(6):560, 2017). This paper details phase 2 of the study which was aimed to investigate the effects of working conditions, nozzle positions/angles and impinging distances on key process measures including cutting forces, workpiece temperature, tool wear, burr formation and average surface roughness of the machined surface. Feed rate showed a significant effect on mean values of cutting force, burr formation and surface roughness, whereas average workpiece temperature and flank wear values are very sensitive to cutting speed. Nozzle position at a 15? angle in the feed direction and 45?/60? against feed direction assisted in minimising workpiece temperature. An impinging distance of 55/75 mm is also necessary to control burr formation, workpiece temperature and average surface roughness. It can be concluded that Cut-list gave promising results compared to conventional flood cooling systems in terms of the evaluated machining outputs. Therefore, the new system can be considered as a feasible, efficient and ecologically beneficial solution, giving less fluid consumption in machining processes.

Citation

Gariani, S., Shyha, I., Inam, F., & Huo, D. (2018). Experimental Analysis of System Parameters for Minimum Cutting Fluid Consumption when Machining Ti-6Al-4V Using a Novel Supply System. International Journal of Advanced Manufacturing Technology, 95, 2795-2809. https://doi.org/10.1007/s00170-017-1216-y

• Journal Article Type: Article
• Acceptance Date: Oct 13, 2017
• Online Publication Date: Nov 29, 2017
• Publication Date: 2018-03
• Deposit Date: Oct 15, 2020
• Publicly Available Date: Oct 15, 2020
• Journal: International Journal of Advanced Manufacturing Technology
• Print ISSN: 0268-3768
• Electronic ISSN: 1433-3015
• Publisher: Springer
• Peer Reviewed: Peer Reviewed
• Volume: 95
• Pages: 2795-2809
• DOI: https://doi.org/10.1007/s00170-017-1216-y
• Keywords: Fluid consumption; Coherent nozzle, vegetable oil-based; Cutting fluid; Shoulder milling; Ti-6Al-4V
• Public URL: http://researchrepository.napier.ac.uk/Output/2686787