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Öğe Cooling techniques to improve the machinability and sustainability of light-weight alloys: A state-of-the-art review(Elsevier Sci Ltd, 2021) Sarikaya, Murat; Gupta, Munish Kumar; Tomaz, Italo; Danish, Mohd; Mia, Mozammel; Rubaiee, Saeed; Jamil, MohdA well-acknowledged role of cutting fluids in any cutting operation has made them inevitable to utilize regarding the provision of adequate cooling and lubrication. Mineral-based cutting fluids are common practice in the industry; however, they are not suitable for our ecology and health. Therefore, there is a need to implement sustainable cooling/lubrication system that helps the environment and improves the machinability of light weight alloys. This review is presenting the machining and sustainability characteristics of minimum quantity lubrication (MQL), nanofluids-MQL, Ranque-Hilsch vortex tube MQL (RHVT + MQL), cryogenic-MQL as alternative to flood cooling applications in the cutting of light-weight materials. It can be stated that MQL advancements can offer clear guidelines to implement hybrid cooling techniques to improve heat transfer, lubrication, and sustainable implementations.Öğe Correction to: Parametric optimization and process capability analysis for machining of nickel-based superalloy(Springer London Ltd, 2023) Gupta, Munish Kumar; Mia, Mozammel; Pruncu, Catalin I.; Kaplonek, Wojciech; Nadolny, Krzysztof; Patra, Karali; Mikolajczyk, Tadeusz[No abstract available]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 Evaluation of machinability-based sustainability indicators in the eco-benign turning of Ti3Al2.5V alloy with textured tools(Springer London Ltd, 2021) Singh, Rupinder; Gupta, Munish Kumar; Sarikaya, Murat; Mia, Mozammel; Garcia-Collado, A.The recent step towards Sustainable Manufacturing (SM) and efforts to reduce the consumption of cutting fluids have become the hot topic of research these days. Various efforts and strategies have been employed in the modern manufacturing sector to control the environmental pollutions generated from the application of cutting fluids. Therefore, in this holistic work, one such effort of reducing the consumption of cutting fluid is employed with the application of minimum quantity lubrication (MQL) and tool texturing. The turning trials were made on titanium alloy:Ti3Al2.5V alloy under dry and MQL conditions using textured and non-textured tools. The tool life, average surface roughness, specific cutting energy, air quality, and chip morphology were studied with the aid of the above-subjected conditions. In the end, the socio-economic aspects of all cooling conditions were studied and analyzed in the context of sustainable manufacturing. The outcomes of this study reveal that the combination of textured tools and minimum quantity lubrication considerably enhance the machining and sustainability performance as contended with other conditions. However, the air quality factor, i.e., PM2.5 particle generation, was less in the case of a textured tool with MQL conditions. Overall, it is worthy to mention that the combination of tool texturing and MQL cooling conditions has been considered as one of the potential combinations in the area of green machining.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 Hybrid cooling-lubrication strategies to improve surface topography and tool wear in sustainable turning of Al 7075-T6 alloy(Springer London Ltd, 2019) Gupta, Munish Kumar; Mia, Mozammel; Singh, GurRaj; Pimenov, Danil Yu; Sarikaya, Murat; Sharma, Vishal S.In machining of soft alloys, the sticky nature of localized material instigated by tool-work interaction exacerbates the tribological attitude and ultimately demeans it machinability. Moreover, the endured severe plastic deformation and originated thermal state alter the metallurgical structure of machined surface and chips. Also, the used tool edges are worn/damaged. Implementation of cooling-lubrication (C/L) agents to reduce friction at faying surfaces can ameliorate overall machinability. That is why, this paper deliberately discussed the influence of pure C/L methods, i.e., such as dry cutting (DC) and nitrogen cooling (N-2), as well as hybrid C/L strategies, i.e., nitrogen minimum quantity lubrication (N(2)MQL) and Ranque-Hilsch vortex tube (RHVT) N(2)MQL conditions in turning of Al 7075-T6 alloy, respectively. With respect to the variation of cutting speed and feed rate, at different C/Ls, the surface roughness, tool wear, and chips are studied by using SEM and 3D topographic analysis. The mechanism of heat transfer by the cooling methods has been discussed too. Furthermore, the new chip management model (CMM) was developed under all C/L conditions by considering the waste management aspects. It was found that the R-N(2)MQL has the potential to reduce the surface roughness up to 77% and the tool wear up to 118%. This significant improvement promotes sustainability in machining industry by saving resources. Moreover, the CMM showed that R-N(2)MQL is more attractive for cleaner manufacturing system due to a higher recyclability, remanufacturing, and lower disposal of chips.Öğe Improvement of machinability of Ti and its alloys using cooling-lubrication techniques: a review and future prospect(Elsevier, 2021) Pimenov, Danil Yu; Mia, Mozammel; Gupta, Munish K.; Machado, Alisson R.; Tomaz, Italo, V; Sarikaya, Murat; Wojciechowski, SzymonProducts made of titanium and its alloys are widely used in modern areas like the mechanical engineering, instrument making, aerospace and medical sector. High strength and low thermal conductivity are the causes of difficulties with the machinability of these alloys. It is important to find ways to increase machinability by cutting titanium alloys. One way to implement this is to apply various methods of cooling on workpieces of titanium alloys and on cutting tools during machining. In this review article, an extensive analysis of the literature on such cooling techniques as dry, conventional cooling system, minimum quantity of lubricant (MQL), minimum quantity cooling lubrication (MQCL), cryogenic lubrication, and high-pressure cooling (HPC) is performed. The following groups of Ti alloys are considered: high-strength structural and high-temperature Ti alloys, intermetallic compounds, pure titanium, as well as composites CFRPs/Ti alloys. For the processes of turning, milling, drilling, and grinding, etc. it is shown how the type of cooling affects the surface integrity include surface roughness, tool wear, tool life, temperature, cutting forces, environmental aspects, etc. The main advantages, disadvantages and prospects of different cooling methods are also shown. The problems and future trends of these methods for the machining of Ti and its alloys are indicated. (c) 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Products made of titanium and its alloys are widely used in modern areas like the mechanical engineering, instrument making, aerospace and medical sector. High strength and low thermal conductivity are the causes of difficulties with the machinability of these alloys. It is important to find ways to increase machinability by cutting titanium alloys. One way to implement this is to apply various methods of cooling on workpieces of titanium alloys and on cutting tools during machining. In this review article, an extensive analysis ofÖğe Investigation into the surface quality and stress corrosion cracking resistance of AISI 316L stainless steel via precision end-milling operation(Springer London Ltd, 2021) Yasir, Muhammad; Danish, Mohd; Mia, Mozammel; Gupta, Munish Kumar; Sarikaya, MuratThis study presents a two-fold investigation on precision end-milling of stainless steel (AISI 316L). First, the impact of end-milling variables (cutting speed and feed rate) on the surface quality (surface roughness, microhardness, and surface morphology) was analyzed. The best surface quality with surface roughness (R-a) 0.65 +/- 0.02 mu m was observed for cutting speed of 140 m/min and 0.025 mm/tooth of feed rate. Microhardness was increased with increment in cutting speed. Second, the impact of surface roughness (R-a) on the stress corrosion cracking under two different mediums, i.e., body solutions (Hank's solution) and 1 M hydrochloric acid solution, was studied. The investigations showed that the samples with higher surface roughness values were more prone to stress corrosion cracking.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 Multi-objective optimization of surface roughness, thrust force, and torque produced by novel drill geometries using Taguchi-based GRA(Springer London Ltd, 2019) Meral, Guven; Sarikaya, Murat; Mia, Mozammel; Dilipak, Hakan; Seker, Ulvi; Gupta, Munish K.A significant part of today's chip removal processes are drilling holes. Many parameters such as cutting parameters, material, machine tool, and cutting tool, etc., in the hole-drilling process affect performance indicators such as surface roughness, tool wear, force, torque, energy consumption, and costs etc. While cutting parameters are easily planned by the operator during drilling, the selection and planning of the drill geometry are more difficult. In order to design and produce the new drill geometry, a wide time and engineering research are needed. In this study, the design and fabrication of new drill geometry were performed to improve the hole-drilling performance. The performance of the fabricated drills was judged with regard to surface roughness, thrust force, and drilling torque. In the performance tests, four different drill geometries, four different cutting speed levels, and four different feed rate levels were selected. Holes were drilled on AISI 4140 material. In addition, the optimization was performed in two phases. Firstly, the mono-optimization was carried by using Taguchi's S/N analysis in which each performance output was optimized separately. Secondly, the multi-objective optimization was employed by using Taguchi-based gray relational analysis (GRA). For the purpose of the study, two different drill geometries were designed and fabricated. Experimental results showed that the designed Geometry 4 is superior to other geometries (geometry 1, geometry 2, and geometry 3) in terms of thrust force and surface roughness. However, in terms of drilling torque, geometry 2 gives better results than other drill geometries. It was found that for all geometries, obtained surface roughness values are lower than the surface roughness values expected from a drilling operation and therefore surface qualities (between 1.2 and 2.4m) were satisfactory.Öğe Optimization of hole quality produced by novel drill geometries using the Taguchi S/N approach(Springer London Ltd, 2019) Meral, Guven; Sarikaya, Murat; Mia, Mozammel; Dilipak, Hakan; Seker, UlviReportedly, the drill geometry influences the drilling operation. In fact, the performance of the drill bit is strongly associated with productivity, thus with economy of production. Moreover, the typical performance indicators, i.e., deviation from diameter, cylindricity, perpendicularity, and concentricity, are altered by drill geometry. This fact stresses the need for a novel design of drills with further optimization of performance indicators of hole quality. In that perspective, herein, new drill geometries were designed and fabricated. Afterward, those drills were employed to create holes on AISI 4140 steel, and their performances were investigated and optimized to suggest cutting parameters of best interest. For performance tests, four different drill geometries, four different cutting speeds (90, 100, 110, 120m/min), and four different feeds (0.15, 0.20, 0.25, 0.30mm/rev) were practiced. To measure the performance of the drills, the quality of the drilled holes was studied in terms of the deviation from diameter, cylindricity, perpendicularity, and concentricity. During the experiment, geometry 3 that was developed as the original drill geometry exhibited poor chip evacuation. As such, geometry 4 was developed by considering these negativities, and it was found to demonstrate superior performance compared to other geometries in terms of hole quality. Furthermore, ANOVA revealed that the drill bit flute geometry is the most influential factor. Lastly, the Taguchi S/N approach disclosed that drilling with geometry 4 at the cutting speed of 90m/min and feed rate of 0.15mm/rev produced optimum machining performance.Öğe Parametric optimization and process capability analysis for machining of nickel-based superalloy(Springer London Ltd, 2019) Gupta, Munish Kumar; Mia, Mozammel; Pruncu, Catalin I.; Kaplonek, Wojciech; Nadolny, Krzysztof; Patra, Karali; Mikolajczyk, TadeuszThe manufacturing of parts from nickel-based superalloy, such as Inconel-800 alloy, represents a challenging task for industrial sites. Their performances can be enhanced by using a smart cutting fluid approach considered a sustainable alternative. Further, to innovate the cooling strategy, the researchers proposed an improved strategy based on the minimum quantity lubrication (MQL). It has an advantage over flood cooling because it allows better control of its parameters (i.e., compressed air, cutting fluid). In this study, the machinability of superalloy Inconel-800 has been investigated by performing different turning tests under MQL conditions, where no previous data are available. To reduce the numerous numbers of tests, a target objective was applied. This was used in combination with the response surface methodology (RSM) while assuming the cutting force input (F-c), potential of tool wear (VBmax), surface roughness (Ra), and the length of tool-chip contact (L) as responses. Thereafter, the analysis of variance (ANOVA) strategy was embedded to detect the significance of the proposed model and to understand the influence of each process parameter. To optimize other input parameters (i.e., cutting speed of machining, feed rate, and the side cutting edge angle (cutting tool angle)), two advanced optimization algorithms were introduced (i.e., particle swarm optimization (PSO) along with the teaching learning-based optimization (TLBO) approach). Both algorithms proved to be highly effective for predicting the machining responses, with the PSO being concluded as the best amongst the two. Also, a comparison amongst the cooling methods was made, and MQL was found to be a better cooling technique when compared to the dry and the flood cooling.Öğe Parametric Optimization for Improving the Machining Process of Cu/Mo-SiCP Composites Produced by Powder Metallurgy(Mdpi, 2021) Sap, Emine; Usca, Usame Ali; Gupta, Munish Kumar; Kuntoglu, Mustafa; Sarikaya, Murat; Pimenov, Danil Yurievich; Mia, MozammelThe features of composite materials such as production flexibility, lightness, and excellent strength put them in the class of materials that attract attention in various critical areas, i.e., aerospace, defense, automotive, and shipbuilding. However, the machining of composite materials displays challenges due to the difficulty in obtaining structural integrity. In this study, Cu/Mo-SiCP composite materials were produced by powder metallurgy with varied reinforcement ratios and then their machinability was investigated. In machinability experiments, the process parameters were selected as cutting speed (v(C)), feed rate (f), depth of cut (a(P)), and reinforcement ratio (R-R). Two levels of these parameters were taken as per the Taguchi's L8 orthogonal array, and response surface methodology (RSM) is employed for parametric optimization. As a result, the outcomes demonstrated that R-R = 5%, f = 0.25 mm/rev, a(P) = 0.25 mm, v(C) = 200 m/min for surface roughness, R-R = 0%, f = 0.25 mm/rev and a(P) = 0.25 mm and v(C) = 200 m/min for flank wear and R-R = 0%, f = 0.25 mm/rev, a(P) = 0.25 mm, v(C) = 150 m/min for cutting temperature for cutting temperature and flank wear should be selected for the desired results. In addition, ANOVA results indicate that reinforcement ratio is the dominant factor on all response parameters. Microscope images showed that the prominent failure modes on the cutting tool are flank wear, built up edge, and crater wear depending on reinforcement ratio.Öğe Progress for sustainability in the mist assisted cooling techniques: a critical review(Springer London Ltd, 2020) Singh, Gurraj; Gupta, Munish Kumar; Hegab, Hussein; Khan, Aqib Mashood; Song, Qinghua; Liu, Zhanqiang; Mia, MozammelThe proper implementation of sustainable manufacturing processes is an effective step towards a clean environment. The modern cooling strategies applied in the manufacturing sector have presented promising solutions that enable economic growth and ecological environment. In machining operations, cryogenic cooling and minimum quantity lubrication (MQL) have been extensively utilized to replace conventional cooling techniques. Thus, this work offers a detailed review of major works focused on manufacturing processes that use some of these sustainable cooling/lubrication modes (i.e., MQL, nanocutting fluids, nanofluid-based MQL strategy, and other miscellaneous MQL upgrades). The main driver of this study is to create a bridge between the past and present studies related to MQL and MQL upgrades. In this way, a new guideline can be established to offer clear directions for a better economic vision and a cleaner manufacturing process. Thus, this review has mainly focused on the machining of the most commonly used materials under MQL-related methods in conventional operations including turning, milling, drilling, and grinding. Current work provides a detailed insight into the major benefits, limitations, as well as mechanisms of cooling strategies that directly affects the machinability performance from a sustainable point of view. In summary, further potential upgrades are indicated so that it will help to drive more sustainable approaches in terms of cooling and lubrication environment during machining processes.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.
