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Understanding the machining characteristics of Al6082 hybrid metal matrix composites milled under cryogenic cooling conditions

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Abstract

Cutting fluid used in machining is under investigation to check the achievement of sustainability and the cleaner process by the machining process. Many attempts were made to find new cooling strategies as an alternative to the existing cooling methods. Cryogenic cooling was an efficient method to move towards sustainability for machining any materials and to ensure green machining. Machining of Al6082 HMMC has been carried out under distinct cutting environments. The fallout of these cutting environments was studied based on parameters like surface roughness, cutting temperature, chip morphology, and tool wear. The application of cryogenic CO2 substantially reduced the tool wear by 37% and 48% when compared to MQL and wet conditions. The SEM image of the worn tool disclosed that adopting the cryogenic cooling technique led to less crater wear and prevented the peeling of the tool layer to some extent. The impressive cooling effect of cryogenic cooling also produced a good surface finish on the machined surface compared to the other cooling environments. Thus, cryogenic cooling proved to be trustworthy in all the output parameters.

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Abbreviations

AMMCs:

Aluminium metal matrix composites

HMMCs:

Hybrid metal matrix composites

UTS:

Ultimate Tensile Strength

RSM:

Response surface methodology

GRA:

Grey relational analysis

MWCNTs:

Multi-walled carbon nanotubes

BN:

Boron nitride

B4C:

Boron carbide

MoS2 :

Molybdenum disulphide

Mo:

Molybdenum

Ti:

Titanium

Si3N4 :

Silicon nitride

WC:

Tungsten carbide

SiC:

Silicon carbide

Al2O3 :

Aluminium oxide

HBN:

Hexagonal boron nitride

Gr:

Graphite

Mg:

Magnesium

Cu:

Copper

Ni:

Nickel

RHA:

Rice husk ash

MCDM:

Multi-criteria decision making

CF:

Cutting force

CT:

Cutting temperature

TW:

Tool wear

wt.%:

Weight percentage

PVD:

Physical vapour deposition

TiAlN:

Titanium aluminium nitride

v c :

Cutting speed (m/min)

F :

Feed rate (mm/min)

a p :

Depth of cut (mm)

R a :

Surface roughness (μm)

S :

Spindle speed (rpm)

MQL:

Minimum Quantity Lubrication

LN2 :

Liquid nitrogen

CO2 :

Carbon dioxide

L:

Length of cut (mm)

BUE:

Built-up edge

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Funding

This work is supported by the Future for Young Scholars of Shandong University, China (31360082064026, 31360082164007) and by Fundamental Research Funds of Shandong University (2019HW040).

Author information

Authors and Affiliations

  1. School of Mechanical Engineering, Key Laboratory of High-Efficiency and Clean Mechanical Manufacture, National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, Shandong, China

    Vinothkumar Sivalingam, Qian Zhou & Jie Sun

  2. Research Center for Aeronautical Component Manufacturing Technology & Equipment, Shandong University, Jinan, 250061, Shandong, China

    Vinothkumar Sivalingam, Qian Zhou & Jie Sun

  3. Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha Institute of Medical and Technical Sciences (SIMATS), Chennai, 602105, India

    Vinothkumar Sivalingam

  4. Department Department of Mechanical Engineering, St. Joseph’s College of Engineering, Tamilnadu, India

    Ganesh Manickajothi

  5. Department of Mechanical and Industrial Engineering Technology, University of Johannesburg, Johannesburg, South Africa

    Nimel Sworna Ross

  6. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St., 45‑758, Opole, Poland

    Munish Kumar Gupta

  7. Department of Mechanical Engineering, Graphic Era (Deemed to Be University), Dehradun, Uttrakhand, India

    Munish Kumar Gupta

  8. Department of Mechanical Engineering, Karabük University, Karabük, Turkey

    Mehmet Erdi Korkmaz

  9. Department of Mechanical Engineering, St. Joseph’s Institute of Technology, Chennai, 600 119, India

    Thangapandian Nagamalai

Authors
  1. Vinothkumar Sivalingam
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  2. Qian Zhou
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  3. Ganesh Manickajothi
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  4. Nimel Sworna Ross
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  5. Jie Sun
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  6. Munish Kumar Gupta
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  7. Mehmet Erdi Korkmaz
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  8. Thangapandian Nagamalai
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Contributions

Vinothkumar Sivalingam: conceptualization, supervision, experimental work, funding and data curation, writing—review and editing, and technical validation. Qian Zhou: experimental work and data curation. Ganesh Manickajothi: formal analysis and writing—review and editing. Nimel Sworna Ross: writing—review and editing. Jie Sun: project administration, resources, and supervision. Munish Kumar Gupta: writing—review and editing. Mehmet Erdi Korkmaz: writing—review. Thangapandian Nagamalai: diagram and writing—review.

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Correspondence to Vinothkumar Sivalingam or Munish Kumar Gupta.

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Sivalingam, V., Zhou, Q., Manickajothi, G. et al. Understanding the machining characteristics of Al6082 hybrid metal matrix composites milled under cryogenic cooling conditions. Int J Adv Manuf Technol 129, 3387–3402 (2023). https://doi.org/10.1007/s00170-023-12534-3

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