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    Comprehensive analysis of tool wear, tool life, surface roughness, costing and carbon emissions in turning Ti-6Al-4V titanium alloy: Cryogenic versus wet machining
    (Elsevier Sci Ltd, 2021) Agrawal, Chetan; Wadhwa, Jwalant; Pitroda, Anjali; Pruncu, Catalin Iulian; Sarikaya, Murat; Khanna, Navneet
    Cryogenic machining has emerged as a sustainable technique that reflects in terms of reduced environmental effects, superior part quality, and lesser resource consumption. However, further exploration of machinability and sustainability improvements using this technique will help the manufacturing industry to adopt it as an alternative to conventional techniques. In this government-supported work, the machinability of Ti-6Al-4V is assessed at five different cutting speeds (70, 80, 90, 100, and 110 m/min) under wet and cryogenic environments. This article presents a detailed analysis of tool wear (flank and crater wear), power consumption, and surface roughness to seek improvements in machinability of Ti-6Al-4V using cryogenic turning in comparison to wet turning. To investigate the sustainability aspects of cryogenic and wet turning, results are also analyzed in terms of total machining cost and carbon emissions that remain relatively less explored in literature. The results show higher crater wear under a wet environment relative to the cryogenic environment at most of the cutting speeds. However, tool life is improved (by up to 125%) using cryogenic turning in comparison to wet turning exclusively at higher cutting speeds (100 and 110 m/min). Reduced power consumption (by up to 23.4%) and surface roughness (by up to 22.1%) are obtained using cryogenic turning than wet turning at all cutting speeds. It is noted that machining cost is reduced (by up to 27%) using cryogenic turning in comparison to wet turning, especially at higher cutting speeds. Cryogenic turning is proved to be better in terms of environmental aspects as it enables a reduction in overall carbon emissions (by up to 22%) at higher cutting speeds.
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    Life cycle assessment of environmentally friendly initiatives for sustainable machining: A short review of current knowledge and a case study
    (Elsevier, 2022) Khanna, Navneet; Wadhwa, Jwalant; Pitroda, Anjali; Shah, Prassan; Schoop, Julius; Sarikaya, Murat
    The establishment of energy and resource-efficient machining processes is key for achieving more sustainable production in the manufacturing industries. However, accomplishing the eco-efficiency goal for machining high strength materials used in the automotive and aerospace industry is challenging, because a trade-off must be achieved between energy consumption and economical productivity. To address this challenge from an ecological perspective, this study focuses on a detailed literature review of Life Cycle Assessment (LCA) analysis made on machining processes considering the comparison of cutting fluid strategies. Along with this, the present study also provides an extensive elucidation regarding the steps required to analyze LCA. Besides, this study aim to analyze LCA analysis in machining processes, and present the case study about macro-level comparative LCA of turning in-house cast AXZ911/10SiC metal matrix composites (MMCs) for three levels of cutting speed (v(c)), longitudinal feed rate (f), and axial depth of cut (a(p)). Each condition was subjected to three different cutting fluid approaches i.e., Dry, Liquid Carbon Dioxide (LCO2), and Liquid Nitrogen (LN2). Streamlined LCA (SLCA) was performed for 18 environmental impact categories using the Ecochain Mobius platform, connected to ReCiPe midpoint (H) and normalized with World (H) method. The findings showed that for all the levels of a(p & nbsp;)and the same cutting strategy, the lower v(c & nbsp;)and lower f result in a higher environmental impact. The comparison of the cutting fluid approach in terms of their correspondent normalized impact score reveals that machining in the cryogenic environment of LN2 with higher v(c) and higher f is the most sustainable and economical approach.