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Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning

Trinity College Dublin. Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning. Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell. Department of Mechanical and Manufacturing Engineering The University of Dublin Trinity College. ICMR 2006.

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Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning

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  1. Trinity College Dublin Green Cutting using Supersonic Air Jets as Coolant andLubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell Department of Mechanical and Manufacturing Engineering The University of Dublin Trinity College ICMR 2006

  2. Trinity College Dublin Introduction Difficult-to-cut materials • Heat resistant alloys • Hard materials • Super stainless alloys (or super-alloys) ICMR 2006

  3. Trinity College Dublin Introduction Difficult-to-cut materials • Heat resistant alloys • Hard materials • Super stainless alloys (or super-alloys) • Nickel base alloys • Cobalt base alloys • Titanium alloys • Iron base (high chromium stainless steel) ICMR 2006 after Seco Technical Guide, Turning Difficult-To-Machine Alloy, S. Miller, Advanced materials means advanced engines, Interdisciplinary Science Review, vol.21 (2) (1996) pp.117-129

  4. Thermal damage Trinity College Dublin Coolants After P. Dahlman, M. Escursell / International Journal of Machine Tools & Manufacture vol.44 (2004) pp.109–115 ICMR 2006

  5. Thermal damage Trinity College Dublin Coolants • Wearing by friction After P. Dahlman, M. Escursell / International Journal of Machine Tools & Manufacture vol.44 (2004) pp.109–115 ICMR 2006

  6. Thermal damage Trinity College Dublin Coolants • Wearing by friction • Built up edges After P. Dahlman, M. Escursell / International Journal of Machine Tools & Manufacture vol.44 (2004) pp.109–115 ICMR 2006

  7. Thermal damage Trinity College Dublin Coolants • Wearing by friction • Built up edges • Sweeping and cleaning the chip-tool interface ICMR 2006

  8. Trinity College Dublin Improving cooling techniques • Reducing cutting forces • Reducing tool wearing • Reducing workpiece temperature • Reducing costs • Reducing environmental impact ICMR 2006

  9. Trinity College Dublin Using air jets: why? • Good for environment • Not toxic for the operator • Cheap • Good for chip sweeping • More likely to penetrate into the chip-tool interface • Capable of accelerating fluid particles to give better heat transfer ICMR 2006

  10. Ursus 225 Centre Lathe Kistler piezoelectric tool-force dynamometer WC inserts with different nose radius Supersonic nozzle Silvent 1011 Hommel roughness tester Infrared camera Trinity College Dublin Experimental apparatus ICMR 2006

  11. Trinity College Dublin Test setup • Cutting speed: 270 m/min • Depth of cut: 0.5 mm • Feed: 0.095 mm/rev • Insert nose radius: 0.4 mm • Rake angle: 5° • Air jet pressure (nozzle inlet): 6 bar • Insert material: WC • Workpiece material: AISI1020 steel ICMR 2006

  12. Force Small reduction of forces, when using air jets Trinity College Dublin Experimental Results ICMR 2006

  13. Force Trinity College Dublin Experimental Results • Finishing Without jet Ra = 0.83μm With jet Ra = 0.75 μm ICMR 2006

  14. Trinity College Dublin Experimental Results • Force • Finishing • Chip shape and colour Air jet off Air jet on ICMR 2006

  15. Force Trinity College Dublin Experimental Results • Finishing • Chip shape and colour • Thermo-Camera Air jet on Air jet off ICMR 2006

  16. Deform-3D™ Arbitrary Lagragian Eulerian formulation adaptive non-linear remeshing algorithm fully coupled thermo-mechanical analysis Trinity College Dublin Finite Element Model ICMR 2006

  17. Deform-3D™ Arbitrary Lagragian Eulerian formulation adaptive non-linear remeshing algorithm fully coupled thermo-mechanical analysis Force prediction Trinity College Dublin Trinity College Dublin Finite Element Model Finite Element Model ICMR 2006 ICMR 2006

  18. Femlab3.1™ Frictional power Estimated specific cutting energy Heat transfer by formed chip Thermal power generation in the chip-tool interface area Trinity College Dublin Finite Element Model ICMR 2006

  19. Heat transfer by impinging jet Trinity College Dublin Conclusions & Further Research • Fluid-dynamic data • Estimated Nusselt number • Temperature measurement with hot-spot radiometer ICMR 2006

  20. Heat transfer by impinging jet Chip shape and shear plane investigation Trinity College Dublin Conclusions & Further Research • Beneficial effect of the force applied on the chip by the air jet • Quick-stop tests ICMR 2006

  21. Heat transfer by impinging jet Chip shape and shear plane investigation Improve the FE modeling Trinity College Dublin Conclusions & Further Research • Modeling the air jet effect (Deform) • Improving the friction model (Deform) • Improve heat transfer model in chip-tool interface (Femlab) • Develop a fluid-structure interaction model (Femlab) ICMR 2006

  22. Heat transfer by impinging jet Chip shape and shear plane investigation Improve the FE modeling Testing Trinity College Dublin Conclusions & Further Research • Cutting parameters • Workpiece and insert standard materials • Air jet positioning • Investigating the use of atomized fluids • Investigating the use of two nozzles: overhead and flank configuration ICMR 2006

  23. Heat transfer by impinging jet Chip shape and shear plane investigation Improve the FE modeling Testing Advanced testing Trinity College Dublin Conclusions & Further Research • Nickel base alloys cutting • Other machining applications ICMR 2006

  24. Thank you for the attention Trinity College Dublin Conclusions & Further Research ICMR 2006

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