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Öğe A review on conventional and advanced minimum quantity lubrication approaches on performance measures of grinding process(Springer London Ltd, 2021) Gupta, Munish Kumar; Khan, Aqib Mashood; Song, Qinghua; Liu, Zhanqiang; Khalid, Qazi Salman; Jamil, Muhammad; Kuntoglu, MustafaGrinding is one of the important machining processes that are widely applied in precision manufacturing. In the beginning, studies mostly focused on dry machining. In time, emerging technologies have led to change in the development of the machining process. New techniques and tools have been developed over the last decade that has brought the process to an advanced place. At first, flood cooling has removed the burning problems in the grinding process. After that, a new technique was developed which is known as minimum quantity lubrication (MQL). This technique is a recognized opportunity to eliminate environmental concerns. This paper reviews some of the common as well as advanced MQL systems specifically used in grinding operations. The effect of MQL and other cutting parameters on cutting forces, surface roughness of the machined workpiece, tool wear, temperature, specific cutting energy, and residual stress is outlined. This paper also addressees the recent trend of cooling systems in the grinding process. After reading this research paper, one can easily get an overview of the previously conducted research to find the output parameter trends in MQL condition. The reader can infer from this paper in which direction the development trend in grinding is in the machining process.Öğe Ecological, economical and technological perspectives based sustainability assessment in hybrid-cooling assisted machining of Ti-6Al-4 V alloy(Elsevier, 2020) Gupta, Munish Kumar; Song, Qinghua; Liu, Zhanqiang; Sarikaya, Murat; Jamil, Muhammad; Mia, Mozammel; Kushvaha, VinodTi-6Al-4 V alloy is a well-acknowledged standard material for the application of modern aerospace, surgical equipment, and prosthetic body parts owing to its stable thermo-physical properties at elevated temperature. However, this structure stability imparts its low thermal conductivity that leads to buildup of heat at toolworkpiece interface during machining which subsequently has a damaging effect on the tool cutting edge. Several biodegradable cutting fluids have already been attempted controlling the heat generation, environmental footprints to improve the overall machinability. In this endeavor, the effectiveness of dry, liquid nitrogen (LN2) and hybrid cryogenic and minimum quantity lubrication (LN2 + MQL) conditions was evaluated in terms of important machinability indicators for instance surface roughness, cutting forces and temperature. The environmental parameters such as total cycle time, productivity, economic analysis, energy consumption and carbon emissions were also analyzed under these cooling conditions. Lastly, the sustainability assessment of process parameters was calculated with the help of the Analytic Hierarchy Process (AHP) coupled with the Technique for Order Preference Based on Similarity to Ideal Solution (TOPSIS) techniques. Findings have exhibited superior cooling/lubrication effect under LN2 + MQL conditions lowering the machining as well as environmental indices. The improvement in cycle time and productivity of LN2 and LN2 + MQL was appeared to be 29.01% and 34.21% as compared with dry turning. The sustainability assessment results also revealed that the lower cutting parameters under LN2 + MQL produced best results to achieve the overall sustainability index. (C) 2020 Elsevier B.V. All rights reserved.Öğe Environment and economic burden of sustainable cooling/lubrication methods in machining of Inconel-800(Elsevier Sci Ltd, 2021) Gupta, Munish Kumar; Song, Qinghua; Liu, Zhanqiang; Sarikaya, Murat; Jamil, Muhammad; Mia, Mozammel; Singla, Anil KumarThe present work deals with the machining application of one of the aerospace material i.e., Inconel-800 alloy by considering the social, economic and environmental effects. The turning tests were done under four sustainable machining conditions i.e., dry, vegetable oil with minimum quantity lubrication (MQL) system, graphene nanofluid plus vegetable oil with MQL (NMQL) system and liquid nitrogen (N-2) cooling. Then, the energy consumption, carbon emissions, cost per part, average surface roughness and cutting tool wear have been measured for varied cutting speed and feed rate under selected sustainable environments. The outcomes of this study revealed that the N-2 cooling conditions reduced the total machining cost up to 9.3%, total energy consumption up to11.3%, carbon emissions up to 49.17% and tool wear up to 46.6% as compared to other cooling conditions. Significant improvement in surface roughness and tool wear have also been noticed from the outcomes of N-2 cooling conditions. Hence, it is worthy to mention that these cooling conditions promote sustainability in the aerospace sector by saving resources and extending environmental benefits. (C) 2020 Elsevier Ltd. All rights reserved.Öğe Experimental characterisation of the performance of hybrid cryo-lubrication assisted turning of Ti-6Al-4V alloy(Elsevier Sci Ltd, 2021) Gupta, Munish Kumar; Song, Qinghua; Liu, Zhanqiang; Sarikaya, Murat; Jamil, Muhammad; Mia, Mozammel; Khanna, NavneetIn this work, sustainable hybrid cryogenic MQL cooling/lubrication techniques viz. Banque- Hilsch Vortex tube plus MQL (RHVT + MQL), liquid nitrogen plus minimum quantity lubrication (N2+MQL), and liquid nitrogen (N2) are presented for turning Ti-6Al-4V utilizing CVD coated carbide insert. The tool wear, surface roughness, micro-hardness, specific cutting energy, and chip morphology are considered under sustainable cooling conditions and compared with the dry condition. The outcome revealed that the N2+MQL reduced the tons of annual coolant consumption attaining smooth surface quality, minimum built-up-edges of chips, and tool wear. Besides, minimum specific cutting energy and surface hardness achieved under N2+MQL among all cooling conditions. This endeavor is peculiar integrating sustainability and machining perspective under advanced cooling techniques for industrial application of Ti-6Al-4V.Öğe Heat Transfer Efficiency of Cryogenic-LN2 and CO2-snow and their application in the Turning of Ti-6AL-4V(Pergamon-Elsevier Science Ltd, 2021) Jamil, Muhammad; He, Ning; Zhao, Wei; Li, Liang; Gupta, Munish Kumar; Sarikaya, Murat; Khan, Aqib MashoodOwing to poor thermal conductivity, and high chemical reactivity of Ti-6Al-4V alloy at elevated temperatures, a lubri-cooling having superior heat transfer is benefic to apply to dissipate cutting heat and to improve the machinability. As conventional coolants are ineffective to prevent thermal damage and tool wear. Therefore, recent advanced cryogenic coolants such as cryogenic-liquid nitrogen (LN2) and carbon dioxide (CO2-snow) are hypothesized to mitigate the set objectives. In this experimental study, a static workpiece plate was sprayed to compare their heat transfer coefficients. Furthermore, the machining performance of cryogenic coolants was evaluated in the turning of Ti-6Al-4V in terms of tool wear, cutting force, surface roughness, and chip curl diameter. For this, experiments are conducted at a constant cutting speed of 120 m/min, a feed rate of 0.1 mm/rev, the coolant injection flow rate of 350, 450g/min, and a depth of cut of 2.5 mm to clarify their effect on the process. The outcome analysis of this work showed the overall less tool wear, cutting forces, surface roughness, with maximum chip curl diameter under CO2-snow cooling followed by cryogenic-LN2 and dry condition. In summary, CO2-snow showed promising outcomes and a superior heat transfer effect warrant its implementation in the aerospace industry. (C) 2020 Elsevier Ltd. All rights reserved.Öğe Machinability investigations of hardened steel with biodegradable oil-based MQL spray system(Springer London Ltd, 2020) Gupta, Munish Kumar; Mia, Mozammel; Jamil, Muhammad; Singh, Rupinder; Singla, Anil Kumar; Song, Qinghua; Liu, ZhanqiangExcessive use of coolant is undesirable in machining due to environmental consciousness; thereby, small but efficacious (improved thermal and tribological properties) amount of coolant has been implemented using minimum quantity lubrication (MQL). In this study, attention was focused on the experimental investigations on tool flank wear, chip morphology, surface roughness (R-a and R-q) and chip-tool interface temperature in the machining of hardened steel (similar to 40 HRC) under olive oil-assisted MQL spray system. As investigating factors, the cutting speed, feed rate, and depth of cut were oriented by following the Taguchi orthogonal array. Then, the cooling and lubrication mechanism of the olive oil-assisted MQL system has been discussed. Outcomes of this study showed that MQL is capable of generating favorable machining outcomes, i.e., lower tool flank wear, reduced temperature, and surface roughness in comparison with dry cutting. The reductions in R-a, R-q, and cutting temperature were about 23.4%, 23.8%, and 24% respectively in terms of mean values. The two types of dominant chip shapes, i.e., (1) continuous tubular and (2) discontinuous small diameter chips, were produced under the dry and MQL-assisted cooling method. In the nutshell, it is appropriate to claim that the overall thermal and tribological properties of olive oil-assisted MQL system are responsible for fruitful results during turning of hardened steel.Öğe Sustainable milling of Ti-6Al-4V: A trade-off between energy efficiency, carbon emissions and machining characteristics under MQL and cryogenic environment(Elsevier Sci Ltd, 2021) Jamil, Muhammad; Zhao, Wei; He, Ning; Gupta, Munish Kumar; Sarikaya, Murat; Khan, Aqib Mashood; Sanjay, M. R.The urgent need for an innocuous and sustainable machining system is essential in this modern manufacturing era. Therefore, a study is devoted to fulfilling a missing bridge between sustainability measures (process time, specific cutting energy, energy efficiency, carbon emissions) and machining characteristics (tool wear, surface roughness, cutting temperature) in the milling of Ti-6Al-4V. The experiments are organized by implementing the minimum quantity lubrication (MQL), CO2-snow, and cryogenic-LN2 under varying end-mill geometries and cutting conditions. The results obtained have underscored the outperformed CO2-snow followed by cryogenic-LN2, MQL, and dry cutting conditions regarding sustainability measures and machining characteristics. The up-milling of 42 degrees helix angle cutter and CO2-snow outperformed by reducing 47% of surface roughness, 50% extended tool life compared to dry cutting. The cryogenic-LN2 provided minimum cutting temperature flowed by CO2-snow, MQL, and dry cutting, respectively. Besides, the up-milling tool of the 42 degrees helix angle provided better machining characteristics than the down-milling tool of the 30 degrees helix angle. The feasibility of CO2-snow was comprehensively expressed and implemented in the milling process to extend the advanced analysis. (C) 2020 Elsevier Ltd. All rights reserved.Öğe Tool wear patterns and their promoting mechanisms in hybrid cooling assisted machining of titanium Ti-3Al-2.5V/grade 9 alloy(Elsevier Sci Ltd, 2022) Gupta, Munish Kumar; Nieslony, P.; Sarikaya, Murat; Korkmaz, Mehmet Erdi; Kuntog, Mustafa; Krolczyk, G. M.; Jamil, MuhammadHybrid lubri-cooling is a latest technology that provides synergistic cooling and lubrication effect in the machining area especially in the cutting of titanium and its alloys. In this current study, cryogenic-LN2, minimum quantity lubrication (MQL), and hybrid cryogenic LN2-MQL are applied and compared against dry medium in perspective of in-depth analysis of tool flank wear, EDS mapping, and intensity of tool wear. Experimental results showed that in comparison with dry, hybrid LN2-MQL substantially reduced the tool flank and rake wear fol-lowed by LN2, MQL, and dry conditions, respectively. Additionally, the SEM and EDS analysis depicted relatively less severe wear and chemical elements adhesion on the tool's main cutting edge, while turning titanium alloy under a hybrid LN2-MQL lubri-cooling environment. In addition, the dry condition has maximum value of tool wear progressions i.e., 1.04 mm and hybrid LN2-MQL have 0.06 mm while machining titanium alloys. When tool wear is evaluated from a tribological point of view, the reduction in flank wear value compared to dry machining is 89.4 %, 92.3 % and 94.2 % owing to MQL, LN2, MQL and hybrid LN2-MQL cutting strategies. In terms of crater wear, the improvement was 87.7 %, 90.4 % and 90.8 % thanks to MQL, LN2, MQL and hybrid LN2-MQL.Öğe Tribological performance based machinability investigations in cryogenic cooling assisted turning of α-β titanium Alloy(Elsevier Sci Ltd, 2021) Gupta, Munish Kumar; Song, Qinghua; Liu, Zhanqiang; Sarikaya, Murat; Mia, Mozammel; Jamil, Muhammad; Singla, Anil KumarMachining of titanium is considered as a challenging process due to its ability to interact with various tool materials when critical cutting temperature is exceeded, resulting in excessive tool wear and poor surface finish, etc. To exhibit an efficient machining process, this research study has experimentally investigated the key quality indicators of machinability, namely surface roughness, cutting temperature, tool wear, in-depth analysis of worn tool and cutting force in the machining process of alpha-beta titanium alloy, which used in critical applications, under three sustainable cooling environments i.e., dry, liquid nitrogen (LN2) and carbon dioxide (CO2). The effect of cutting speed and feed rate on such performance measures were examined under a function of cooling strategy as the best substitute in machining. As a result, the feasibility of LN2 cooling has been confirmed to be more significant for the machining of alpha-beta titanium alloy when compared to dry and CO2 machining strategies. To sum up, cryogenic cooling (LN2 cooling) assisted machining of alpha-beta titanium has acquiesced as a sustainable strategy in the context of environmental consciousness.
