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Hybrid cooling-lubrication strategies to improve surface topography and tool wear in sustainable turning of Al 7075-T6 alloy

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Abstract

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 (N2), as well as hybrid C/L strategies, i.e., nitrogen minimum quantity lubrication (N2MQL) and Ranque–Hilsch vortex tube (RHVT) N2MQL 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-N2MQL 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-N2MQL is more attractive for cleaner manufacturing system due to a higher recyclability, remanufacturing, and lower disposal of chips.

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Authors and Affiliations

  1. Mechanical Engineering, NIT Hamirpur, Hamirpur, India

    Munish Kumar Gupta

  2. Department of Mechanical Engineering, Chandigarh University, Gharuan, Punjab, India

    Munish Kumar Gupta

  3. Mechanical & Production Engineering, Ahsanullah University of Science and Technology, Dhaka, 1208, Bangladesh

    Mozammel Mia

  4. School of Mechanical Engineering, Lovely Professional University, Phagwara, Punjab, India

    GurRaj Singh

  5. Automated Mechanical Engineering, South Ural State University, Lenin Prosp. 76, Chelyabinsk, 454080, Russia

    Danil Yu Pimenov

  6. Mechanical Engineering, Sinop University, 57030, Sinop, Turkey

    Murat Sarikaya

  7. Industrial & Production Engineering, Dr B R Ambedkar National Institute of Technology, Jalandhar, 144011, India

    Vishal S. Sharma

Authors
  1. Munish Kumar Gupta
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  2. Mozammel Mia
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  6. Vishal S. Sharma
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Correspondence to Mozammel Mia.

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Gupta, M.K., Mia, M., Singh, G. et al. Hybrid cooling-lubrication strategies to improve surface topography and tool wear in sustainable turning of Al 7075-T6 alloy. Int J Adv Manuf Technol 101, 55–69 (2019). https://doi.org/10.1007/s00170-018-2870-4

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  • DOI: https://doi.org/10.1007/s00170-018-2870-4

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