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Milling performance evaluation and cooling/lubrication mechanism of Al-50wt% Si alloy based on various environmentally sustainable manufacturing strategies

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Abstract

Silicon aluminum alloy with Si weight percentage in 50% (Al-50wt% Si) is a typical difficult-to-machine composite. In order to improve its machinability, it is necessary to optimize the friction state at the tool-Si-Al alloy interface by cooling/lubrication. Using appropriate cooling and lubricating media can drive machining operations towards cleaner and more sustainable targets. However, the synergy between Si-Al alloy special material structure, material properties, and multiphase coolants/lubricants is still unknown. In this study, the machining performance of Al-50wt% Si alloy under three milling environments (MEs), namely, dry, supercritical carbon dioxide (scCO2), supercritical carbon dioxide–based minimum quantity lubrication (scCO2-MQL), was discussed. The theoretical analysis was made to understand the scCO2-MQL permeation mechanism. The effects of various cutting parameters and MEs on cutting force, cutting temperature, surface roughness, and surface morphology were investigated. The results show that the lowest cutting force and temperature can be found in scCO2-MQL ME owing to its excellent cooling/lubrication and heat transfer performance. The scCO2-MQL coolant/lubricant can inhibit the spalling and crushing of Si particles. Therefore, the lowest surface roughness which is reduced by 32.34% compared with dry milling and the best surface morphology can be obtained in scCO2-MQL milling. An interaction model between tool cutting edge-Si particles in scCO2/scCO2-MQL MEs has also been presented. The results indicate that the performance of scCO2-MQL as a clean and sustainable cooling/lubrication technique can result in an appreciable improvement in milling Al-50wt% Si alloy.

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The data and material in this paper are original, available, and objective.

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Abbreviations

Al-50wt% Si:

Silicon aluminum alloy with Si weight percentage in 50%

ME:

Milling environment

scCO2 :

Supercritical carbon dioxide

MQL:

Minimum quantity lubrication

scCO2-MQL:

Supercritical carbon dioxide based minimum quantity lubrication

LN2 :

Liquid nitrogen

scCO2-WMQL:

ScCO2-based MQL with water-based cutting fluid

scCO2-OoWMQL:

ScCO2-based MQL with oil-on-water droplets cutting fluid

LCO2 :

Liquid carbon dioxide

Q :

Heat transfer quantity per unit time

α :

Convective heat transfer coefficient

S :

Dynamic heat transfer area

Δt :

Temperature difference between the cooling medium and the cutting zone

v c :

Cutting speed, m/min

f z :

Feed rate, mm/z

a p :

Axial cutting depth, mm

ae :

Radial cutting depth, mm

R a :

Arithmetic mean deviation, μm

S :

Total bearing area

F P :

Resistance produced by tiny furrows on the workpiece

F :

Friction between the tool-chip and the tool-workpiece

A :

Total bearing area

β :

Percentage of the direct contact zone to the total bearing area

τ s :

Surface shear strength of Si-Al alloy

τ l :

Surface shear strength of scCO2-MQL fluid

F y :

Feed component of cutting force, N

Q cd :

Conduction

Q nc :

Natural convection

Q cv :

Forced convection

Q su :

Sublimation

Q ev :

Evaporation

r ε :

Tool nose radius, μm

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Funding

This work is supported by the National Natural Science Foundation of China (No. 52075168, 51605161, 51775184), the Project of Department of Education of Hunan Province (No. 19B190), and the Scientific Research Fund of Hunan University of Science and Technology (No. KJ-2042).

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Authors and Affiliations

  1. School of Mechanical Engineering, Hunan University of Science and Technology, Xiangtan, 411201, People’s Republic of China

    Lu Jing, Qiulin Niu, Chunhao Wang, Changping Li, Pengnan Li & Wenhui Yue

  2. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People’s Republic of China

    Jiaqiang Dang, Qinglong An & Fan Zou

  3. School of Mechanical Engineering, Yeungnam University, Gyeongsangbuk-do, Gyeongsan-si, 38541, Republic of Korea

    Tae Jo Ko

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  1. Lu Jing
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Contributions

Lu Jing: Conceptualization, methodology, investigation, data curation, writing—original draft. Qiulin Niu: Conceptualization, methodology, funding acquisition, writing—review and editing. Jiaqiang Dang: Investigation, supervision, writing—review and editing. Qinglong An: Conceptualization, validation. Chunhao Wang: Investigation, supervision. Fan Zou: Investigation, supervision. Changping Li: Methodology, writing—review and editing. Pengnan Li: Supervision, funding acquisition. Wenhui Yue: Supervision. Tae Jo Ko: Funding acquisition, writing—review and editing.

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Correspondence to Qiulin Niu or Tae Jo Ko.

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We would like to submit the manuscript entitled “Milling performance evaluation and cooling/lubrication mechanism of Al-50wt% Si alloy based on various environmentally sustainable manufacturing strategies” by Lu Jing, Qiulin Niu, Jiaqiang Dang, Qinglong An, Chunhao Wang, Fan Zou, Changping Li, Pengnan Li, Wenhui Yue, Tae Jo Ko, and we wish it to be considered for publication in the International Journal of Advanced Manufacturing Technology.

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Jing, L., Niu, Q., Dang, J. et al. Milling performance evaluation and cooling/lubrication mechanism of Al-50wt% Si alloy based on various environmentally sustainable manufacturing strategies. Int J Adv Manuf Technol 122, 1023–1040 (2022). https://doi.org/10.1007/s00170-022-09955-x

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