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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

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

difficult to cut materials

Trinity College Dublin

Introduction

Difficult-to-cut materials
  • Heat resistant alloys
  • Hard materials
  • Super stainless alloys (or super-alloys)

ICMR 2006

difficult to cut materials3

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

slide4
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

slide5
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

slide6
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

slide7
Thermal damage

Trinity College Dublin

Coolants

  • Wearing by friction
  • Built up edges
  • Sweeping and cleaning the chip-tool interface

ICMR 2006

slide8

Trinity College Dublin

Improving cooling techniques

  • Reducing cutting forces
  • Reducing tool wearing
  • Reducing workpiece temperature
  • Reducing costs
  • Reducing environmental impact

ICMR 2006

slide9

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

slide10
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

slide11

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

slide12
Force

Small reduction of forces, when using air jets

Trinity College Dublin

Experimental Results

ICMR 2006

slide13
Force

Trinity College Dublin

Experimental Results

  • Finishing

Without jet Ra = 0.83μm

With jet Ra = 0.75 μm

ICMR 2006

slide14

Trinity College Dublin

Experimental Results

  • Force
  • Finishing
  • Chip shape and colour

Air jet off

Air jet on

ICMR 2006

slide15
Force

Trinity College Dublin

Experimental Results

  • Finishing
  • Chip shape and colour
  • Thermo-Camera

Air jet on

Air jet off

ICMR 2006

slide16
Deform-3D™

Arbitrary Lagragian Eulerian formulation

adaptive non-linear remeshing algorithm

fully coupled thermo-mechanical analysis

Trinity College Dublin

Finite Element Model

ICMR 2006

slide17
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

slide18
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

slide19
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

slide20
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

slide21
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

slide22
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

slide23
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

slide24
Thank you for the attention

Trinity College Dublin

Conclusions & Further Research

ICMR 2006