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Different cooling strategies applied during the process of aluminum alloy boring

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Abstract

Aluminum alloys are applied in large volumes to various mechanical components. However, during the boring process of such alloys, it becomes necessary that H7 tolerances be obtained. Additionally, when machining aluminum alloys, adhesion problems are often noted due to ductility. Furthermore, owing to the high cutting speeds used in this process, the need arises for the utilization of a cutting fluid, in order to reduce adhesion. Other cooling techniques are used worldwide to replace, reduce, or eliminate cutting fluids. In this study, three factorial designs were used to verify performance and compare cutting fluid abundance (CFA), dry machining (DM), and minimum quantity lubrication (MQL) during the boring process, while using polycrystalline diamond (PCD) tools. The input variables were cutting speed (Vc), feed per tooth (fz), and depth of cut (doc), while the output variables were diameter, roundness, and tool wear mechanism analysis. In total, forty-eight experiments were performed. The results presented for MQL were noted as showing similarity with those for CFA. These results indicated that MQL can replace the CFA technique, thus improving process sustainability.

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The datasets obtained during the current work are available from the corresponding author upon request.

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Acknowledgements

The authors would like to thank the Federal University of Minas Gerais, Belo Horizonte, Brazil, Stellantis Latam Brazil. The authors would also like to thank the Grupo de Manufatura Sustentável — GMS (Group of Manufacture Sustainable — GMS) of the Laboratório de Ensino e Pesquisa em Usinagem — LEPU at the Federal University of Uberlandia — Brazil.

Funding

This work was supported by the following Brazilian research agencies: the Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) (grant number 001, 2019) and Fundação de Amparo à Pesquisa do Estado de Minas Gerais — FAPEMIG (grant number 001, 2019). This work was also supported by the CEFET-MG Research Promotion Agency in the Master’s Program/CEFET-MG for the Postgraduate Program in Materials Engineering and the Coordination for the Improvement of Higher Education Personnel — Brazil (CAPES) — Finance Code 001.

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Authors and Affiliations

  1. Manufacturing Engineering, Stellantis LATAM, Av. do Contorno da Fiat, 3455, Betim, MG, CEP: 32530-490, Brazil

    Paulo Paiva de Carvalho & Paulo Sérgio Martins

  2. Mechanical Engineering Graduate Program, Universidade Federal de Uberlândia, Av. João Naves de Ávila Avenue, 2121, Uberlândia, MG, CEP 38408-100, Brazil

    Gustavo Henrique Nazareno Fernandes, Lucas Melo Queiroz Barbosa, Elhadji Cheikh Talibouya Ba & Álisson Rocha Machado

  3. Mechanical Engineering, Universidade Tecnológica Federal do Paraná, Av. dos Pioneiros, 3131, Londrina, PR, CEP: 86036-370, Brazil

    José Aécio Gomes de Sousa

  4. Materials Engineering, Centro Federal de Educação Tecnológica de Minas Gerais, Av. Amazonas, 5253, Nova Suíça, Belo Horizonte, MG, CEP: 30421-169, Brazil

    Elhadji Cheikh Talibouya Ba

  5. Mechanical Engineering Graduate Program, Pontifícia Universidade Católica do Paraná - PUCPR, Rua Imaculada Conceição, 1155, Prado Velho, Curitiba, PR, CEP: 80215-901, Brazil

    Álisson Rocha Machado

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  1. Paulo Paiva de Carvalho
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Contributions

Paulo Paiva de Carvalho: conceptualization, methodology, formal analysis, investigation, data curation, and writing — original draft. Gustavo Henrique Nazareno Fernandes: writing — review and editing. Lucas Melo Queiroz Barbosa: writing — review and editing. José Aécio Gomes de Sousa: writing — review and editing. Paulo Sérgio Martins: supervision, writing — review and editing and visualization. Elhadji Cheikh Talibouya Ba: writing — review and editing and visualization. Álisson Rocha Machado: writing — review and editing and visualization.

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Correspondence to Paulo Sérgio Martins.

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de Carvalho, P.P., Fernandes, G.H.N., Barbosa, L.M.Q. et al. Different cooling strategies applied during the process of aluminum alloy boring. Int J Adv Manuf Technol 128, 563–579 (2023). https://doi.org/10.1007/s00170-023-11840-0

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