Abstract
Cutting fluids have been widely used in machining processes because of their favourable lubrication and cooling properties. However, their high costs, the risk to worker’s health and environmental concerns have necessitated the development of alternative methods of cooling and lubricating that eliminate or, reduce such drawbacks. In this study, a comparative analysis of two sustainable cooling systems (dry machining and minimum quantity lubrication (MQL) system) in intermittent turning of UNS M11917 magnesium pieces was performed. To analyse the influence of the cooling system on intermittent cutting, the surface roughness was selected as the response variable. In addition to the cooling system, other parameters such as the feed rate, spindle speed, tool type, interruption type and measurement zone (defined by the length and the generatrix) were taken into account. A combined L4 x32 experimental design with three nested replications was carried out. The obtained data were analysed using the analysis of variance (ANOVA) method. Main conclusions include the identification of the feed rate and interruption type as the most important sources of surface roughness variability. In addition, it is possible to affirm that, in general, increases in the coolant flow rate, within the range studied, lead to slightly poorer surface roughness results.
Similar content being viewed by others
Abbreviations
- C :
-
coolant flow rate (ml/h)
- d :
-
depth of cut (mm)
- f :
-
feed rate (mm/rev)
- G :
-
measuring generatrix (○)
- I :
-
interruption type
- L :
-
measuring length (mm)
- N :
-
spindle speed (rpm)
- Ra :
-
average surface roughness (μm)
- Rae :
-
estimated average surface roughness (μm)
- Rt :
-
tool nose radius
- T :
-
tool type
References
Diniz, A. E. and José de Oliveira, A., “Optimizing the Use of Dry Cutting in Rough Turning Steel Operations,” International Journal of Machine Tools and Manufacture, Vol. 44, No. 10, pp. 1061–1067, 2004.
Peloubet, J. A., “Machining Magnesium-a Study of Ignition Factors,” Fire Technology, Vol. 1, No. 1, pp. 5–14, 1965.
Park, C. W., Kwon, K. S., Kim, W. B., Min, B. K., Park, S. J., and et al., “Energy Consumption Reduction Technology in Manufacturing-A Selective Review of Policies, Standards, and Research,” Int. J. Precis. Eng. Manuf., Vol. 10, No. 5, pp. 151–173, 2009.
Nouari, M., List, G., Girot, F., and Coupard, D., “Experimental Analysis and Optimisation of Tool Wear in Dry Machining of Aluminium Alloys,” Wear, Vol. 255, No. 7, pp. 1359–1368, 2003.
Avallone, E. A. and Baumeister, T., “Marks’ Standard Handbook for Mechanical Engineers,” McGraw Hill, 10th Ed., pp. 13–50, 1996.
Hwang, Y. K., Lee, C. M., and Park, S. H., “Evaluation of Machinability according to the Changes in Machine Tools and Cooling Lubrication Environments and Optimization of Cutting Conditions using Taguchi Method,” Int. J. Precis. Eng. Manuf., Vol. 10, No. 3, pp. 65–73, 2009.
Klocke, F. and Eisenblätter, G., “Dry Cutting,” CIRP Annals-Manufacturing Technology, Vol. 46, No. 2, pp. 519–526, 1997.
Marksberry, P. W. and Jawahir, I. S., “A Comprehensive Tool-Wear/Tool-Life Performance Model in the Evaluation of NDM (Near Dry Machining) for Sustainable Manufacturing,” International Journal of Machine Tools and Manufacture, Vol. 48, No. 7, pp. 878–886, 2008.
Adler, D. P., Hii, W. W. S., Michalek, D. J., and Sutherland, J. W., “Examining the Role of Cutting Fluids in Machining and Efforts to Address Associated Environmental/Health Concerns,” Machining Science and technology, Vol. 10, No. 1, pp. 23–58, 2006.
De Chiffre, L. and Belluco, W., “Comparison of Methods for Cutting Fluid Performance Testing,” CIRP Annals-Manufacturing Technology, Vol. 49, No. 1, pp. 57–60, 2000.
Sharma, V. S., Dogra, M., and Suri, N., “Cooling Techniques for Improved Productivity in Turning,” International Journal of Machine Tools and Manufacture, Vol. 49, No. 6, pp. 435–453, 2009.
Nguyen, T. K., Do, I., and Kwon, P., “A Tribological Study of Vegetable Oil Enhanced by Nano-Platelets and Implication in MQL Machining,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 7, pp. 1077–1083, 2012.
Hwang, Y. K., Lee, C. M., and Park, S. H., “Evaluation of Machinability according to the Changes in Machine Tools and Cooling Lubrication Environments and Optimization of Cutting Conditions using Taguchi Method,” Int. J. Precis. Eng. Manuf., Vol. 10, No. 3, pp. 65–73, 2009.
Gariboldi, E., “Drilling a Magnesium Alloy using PVD Coated Twist Drills,” Journal of Materials Processing Technology, Vol. 134, No. 3, pp. 287–295, 2003.
Bhowmick, S., Lukitsch, M. J., and Alpas, A. T., “Dry and Minimum Quantity Lubrication Drilling of Cast Magnesium Alloy (AM60),” International Journal of Machine Tools and Manufacture, Vol. 50, No. 5, pp. 444–457, 2010.
Bhowmick, S. and Alpas, A., “The Role of Diamond-like Carbon Coated Drills on Minimum Quantity Lubrication Drilling of Magnesium Alloys,” Surface and Coatings Technology, Vol. 205, No. 23, pp. 5302–5311, 2011.
Balout, B., Songmene, V., and Masounave, J., “An Experimental Study of Dust Generation during Dry Drilling of Pre-Cooled and Pre-Heated Workpiece Materials,” Journal of Manufacturing Processes, Vol. 9, No. 1, pp. 23–34, 2007.
Wang, J., Liu, Y. B., An, J., and Wang, L. M., “Wear Mechanism Map of Uncoated HSS Tools during Drilling Die-Cast Magnesium Alloy,” Wear, Vol. 265, No. 5, pp. 685–691, 2008.
Tönshoff, H. K. and Winkler, J., “The Influence of Tool Coatings in Machining of Magnesium,” Surface and Coatings Technology, Vol. 94, No. pp. 610–616, 1997.
Pu, Z., Outeiro, J., Batista, A., Dillon Jr, O., Puleo, D., and Jawahir, I., “Enhanced Surface Integrity of AZ31B Mg Alloy by Cryogenic Machining Towards Improved Functional Performance of Machined Components,” International Journal of Machine Tools and Manufacture, Vol. 56, No. pp. 17–27, 2012.
Rubio, E. M., Valencia, J. L., Saá, A. J., and Carou, D., “Experimental Study of the Dry Facing of Magnesium Pieces based on the Surface Roughness,” Int. J. Precis. Eng. Manuf., Vol. 14, No. 6, pp. 995–1001, 2013.
Fang, F. Z., Lee, L. C., and Liu, X. D., “Mean Flank Temperature Measurement in High Speed Dry Cutting of Magnesium Alloy,” Journal of Materials Processing Technology, Vol. 167, No. 1, pp. 119–123, 2005.
Mordike, B. L. and Ebert, T., “Magnesium: Properties-Applications-Potential,” Materials Science and Engineering: A, Vol. 302, No. 1, pp. 37–45, 2001.
Funatani, K., “Emerging Technology in Surface Modification of Light Metals,” Surface and Coatings Technology, Vol. 133, No. pp. 264–272, 2000.
Kleiner, M., Geiger, M., and Klaus, A., “Manufacturing of Lightweight Components by Metal Forming,” CIRP Annals-Manufacturing Technology, Vol. 52, No. 2, pp. 521–542, 2003.
Gray, J. E. and Luan, B., “Protective Coatings on Magnesium and its Alloys-a Critical Review,” Journal of Alloys and Compounds, Vol. 336, No. 1, pp. 88–113, 2002.
Shan, Z., Qin, S., Liu, Q., and Liu, F., “Key Manufacturing Technology & Equipment for Energy Saving and Emissions Reduction in Mechanical Equipment Industry,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 7, pp. 1095–1100, 2012.
Lee, E. S., Won, J. K., Shin, T. H., and Kim, S. H., “Investigation of Machining Characteristics for Electrochemical Micro-Deburring of the AZ31 Lightweight Magnesium Alloy,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 3, pp. 339–345, 2012.
Park, C. W. and Kim, Y. H., “A Study on the Manufacturing of Digital Camera Barrel using Magnesium Alloy,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 7, pp. 1047–1052, 2012.
Shin, H. W., “A Feasibility Study to Replace Steel made Hood Panels by Magnesium Alloy made Hood Panels,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 11, pp. 2011–2016, 2012.
Danilenko, B., “Selecting the Initial Cutting Parameters in Machining Magnesium Alloys,” Russian Engineering Research, Vol. 29, No. 3, pp. 316–318, 2009.
Polmear, I., “Light Alloys: from Traditional Alloys to Nanocrystals,” Butterworth-Heinemann, 4th Ed., Paper No. 291, 2005.
Weinert, K., Inasaki, I., Sutherland, J. W., and Wakabayashi, T., “Dry Machining and Minimum Quantity Lubrication,” CIRP Annals-Manufacturing Technology, Vol. 53, No. 2, pp. 511–537, 2004.
Tomac, N., Tonnessen, K., and Rasch, F. O., “Formation of Flank Build-up in Cutting Magnesium Alloys,” CIRP Annals-Manufacturing Technology, Vol. 40, No. 1, pp. 79–82, 1991.
Diniz, A. E., Gomes, D. M., and Braghini Jr, A., “Turning of Hardened Steel with Interrupted and Semi-Interrupted Cutting,” Journal of Materials Processing Technology, Vol. 159, No. 2, pp. 240–248, 2005.
Oliveira, A. J. D., Diniz, A. E., and Ursolino, D. J., “Hard Turning in Continuous and Interrupted Cut with PCBN and Whisker-Reinforced Cutting Tools,” Journal of Materials Processing Technology, Vol. 209, No. 12, pp. 5262–5270, 2009.
Gwynne, B. and Lyon, P., “Magnesium Alloys in Aerospace Applications, Past Concerns, Current Solutions,” Proc. of 5th Triennial International Aircraft Fire and Cabin Safety Research Conference, pp. 1–59, 2007.
Chandrasekaran, H. and Thoors, H., “Tribology in Interrupted Machining: Role of Interruption Cycle and Work Material,” Wear, Vol. 179, No. 1, pp. 83–88, 1994.
Tönshoff, H. K., Kaestner, W., and Schnadt, R., “Machinability of Forged Steels in Interrupted Cutting,” Journal of Materials Processing Technology, Vol. 21, No. 2, pp. 219–236, 1990.
Beswick, J.M., “STP 1419 Bearing steel technology,” Astm International, pp. 75–76, 2002.
Taguchi, G., “System of Experimental Design: Engineering Methods to Optimize Quality and Minimize Costs,” UNIPUB/Kraus International Publications, pp. 531, 1987.
Montgomery, D. C., “Design and Analysis of Experiments,” John Wiley & Sons, 6th Ed., pp. 643, 2004.
Rubio, E., Camacho, A., Sánchez-Sola, J., and Marcos, M., “Surface Roughness of AA7050 Alloy Turned Bars: Analysis of the influence of the Length of Machining,” Journal of Materials Processing Technology, Vol. 162, No. pp. 682-689, 2005.
Sáenz de Pipaón, J. M., “Diseño y fabricación de probetas de componentes híbridos con aleaciones de magnesio para ensayos de mecanizado,” Tesis Doctoral, E.T.S. Ingenieros Industriales de la UNED, Madrid, 2013.
ISO 4287:1997, “Geometrical Product Specifications (GPS) — Surface Texture: Profile Method — Terms, Definitions and Surface Texture Parameters,” 1997.
Villeta, M., de Agustina, B., de Pipaón, J. M. S., and Rubio, E. M., “Efficient Optimisation of Machining Processes based on Technical Specifications for Surface Roughness: Application to Magnesium Pieces in the Aerospace Industry,” The International Journal of Advanced Manufacturing Technology, Vol. 60, No. 9–12, pp. 1237–1246, 2012.
Sayit, E., Aslantas, K., and Çiçek, A., “Tool Wear Mechanism in Interrupted Cutting Conditions,” Materials and Manufacturing Processes, Vol. 24, No. 4, pp. 476–483, 2009.
Boothroyd, G., “Fundamentos Del Corte De Metales Y De Las Máquinas-Herramienta,” McGraw-Hill Latinoamericana, pp. 352, 1978.
Ståhl, J. E., Schultheiss, F., and Hägglund, S., “Analytical and Experimental Determination of the Ra Surface Roughness during Turning,” Procedia Engineering, Vol. 19, pp. 349–356, 2011.
Hocheng, H. and Hsieh, M., “Signal Analysis of Surface Roughness in Diamond Turning of Lens Molds,” International Journal of Machine Tools and Manufacture, Vol. 44, No. 15, pp. 1607–1618, 2004.
Munawar, M., Chen, J. C. S., and Mufti, N. A., “Investigation of Cutting Parameters Effect for Minimization of Sur Face Roughness in Internal Turning,” Int. J. Precis. Eng. Manuf., Vol. 12, No. 1, pp. 121–127, 2011.
Saini, S., Ahuja, I. S., and Sharma, V. S., “Influence of Cutting Parameters on Tool Wear and Surface Roughness in Hard Turning of AISI H11 Tool Steel using Ceramic Tools,” Int. J. Precis. Eng. Manuf., Vol. 13, No. 8, pp. 1295–1302, 2012.
Seguy, S., Dessein, G., and Arnaud, L., “Surface Roughness Variation of Thin Wall Milling, Related to Modal Interactions,” International Journal of Machine Tools and Manufacture, Vol. 48, No. 3, pp. 261–274, 2008.
Sharma, V. S., Dogra, M., and Suri, N. M., “Cooling Techniques for Improved Productivity in Turning,” International Journal of Machine Tools and Manufacture, Vol. 49, No. 6, pp. 435–453, 2009.
Dhar, N. R., Kamruzzaman, M., and Ahmed, M., “Effect of Minimum Quantity Lubrication (MQL) on Tool Wear and Surface Roughness in Turning AISI-4340 Steel,” Journal of Materials Processing Technology, Vol. 172, No. 2, pp. 299–304, 2006.
Kitagawa, T., Kubo, A., and Maekawa, K., “Temperature and Wear of Cutting Tools in High-Speed Machining of Inconel 718 and Ti-6Al-6V-2Sn,” Wear, Vol. 202, No. 2, pp. 142–148, 1997.
Kamata, Y. and Obikawa, T., “High Speed MQL Finish-Turning of Inconel 718 with Different Coated Tools,” Journal of Materials Processing Technology, Vol. 192, No. pp. 281-286, 2007.
ANSI/ASME B46.1-2009, “Surface Texture, Surface Roughness, Waviness and Lay,” American Society of Mechanical Engineers, pp. 107, 2010.
Armendia, M., Garay, A., Villar, A., Davies, M. A., and Arrazola, P. J., “High Bandwidth Temperature Measurement in Interrupted Cutting of Difficult to Machine Materials,” CIRP Annals — Manufacturing Technology, Vol. 59, No. 1, pp. 97–100, 2010.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Rubio, E.M., Villeta, M., Carou, D. et al. Comparative analysis of sustainable cooling systems in intermittent turning of magnesium pieces. Int. J. Precis. Eng. Manuf. 15, 929–940 (2014). https://doi.org/10.1007/s12541-014-0419-5
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s12541-014-0419-5