Elsevier

Journal of Cleaner Production

Volume 218, 1 May 2019, Pages 601-615
Journal of Cleaner Production

Review
Ecological trends in machining as a key factor in sustainable production – A review

https://doi.org/10.1016/j.jclepro.2019.02.017Get rights and content

Highlights

  • Review of ecological trends in machining of hard to-cut-materials.

  • Discussion on improvement of machining, regarding the reduction of pollution.

  • Development of ring of sustainable machining.

  • Implementation of discussed methods in cleaner and effective production.

Abstract

A comprehensive analysis of literature pertaining to ecological trends in machining processes of difficult-to-cut materials (e.g. hard steels, Ti-based alloys, Ni-based alloys) has been performed. The paper focuses on the improvement of machining processes with a balanced attention onthe reduction of pollution generated by coolants and emulsions. Here, the specific areas of interest are: Dry cutting; Minimum Quantity Lubrication/Minimum Quantity Cooling Lubrication; Cryogenic Cooling; High-Pressure Coolant and Biodegradable Vegetable Oils. The proposed approach of sustainable and cleaner production for the above-mentioned areas involves the minimized use of coolant/lubricants, employment of appropriate cutting tool's grade and machining conditions that leads to the reduction of total cost, cutting force, energy consumption, temperature but improvements of surface quality, volume of material removed, as well as the prolongation of tool life. In addition, the qualitative judgments like impact on human operator's health, atmospheric air, chip removal from machining area etc. are taken into account. The study presented in the paper is such a vast compendium of knowledgeregarding multi-directional critical analysis of machined parts, tools, chips under state-of-art cooling/lubrication systems that it will help the next generation scientists to find recent advances as well as future avenues of research on ecological aspects of machining for sustainability.

Introduction

The present paradigm shift in manufacturing is moving toward the economically justified green technologies. The following trends are being investigated:

  • Prolongation of cutting tool life,

  • Sustainable cooling/lubricating condition, and

  • Determination of functional parameters of manufactured surfaces.

The objective of machining technology is to manufactureatthe lowest possible cost, but simultaneously with highest dimensional accuracy. Concurrently, the machining process should be eco-friendly, clean and sustainable. Sustainable production is an action which is not representing the threat for the future generations and is not carried out at the expense of future generations. Clean production must not stand for the increased financial investment.

The alloys, which mainly consist of titanium, nickel and chromium,are usually applied in the production of parts that are usually used in automotive, energy, medical and chemical industries. The numerous specific properties (Singh et al., 2018), as high strength, chemical degradation resistance or very good corrosion resistance – especially stress corrosion, predestinate the use of high-performance alloyin heat exchangers, water heaters, pressure vessels or orthopedic implants. However, their ability to maintaining these properties in the elevated temperatures significantly inhibits the machinability, and thus these alloys are usually considered as difficult-to-cut. Notable such materials are stainless steel, hardened steels, alloy steels, Ti-alloys, Ni-alloys etc.

During the machining of these alloys, temperature present in vicinity of contact point of the tool-material grows severely, because of low heat conductivity connected with the high chemical reactivity. Consequently it affects the rapid tool wear (Gupta and Sood, 2017). The chemical reactivity of the difficult-to-cut alloys with tool materials leads to the premature tool damage and poor surface finish (Jianxin et al., 2011). To improve this state, the oils and liquids provided to the cutting zone act like a lubricant which reduces the contact area between the chip and tool, and form a relatively thin film. Moreover, it acts indirectly as a coolant, because it reduces the heat generation and thereby decreases the temperature. In this context, the advantages of machining with the use of coolant/lubricant are obvious. Nevertheless, the use of coolant/lubricant possesses serious treats to human as well as to environment. Therefore, one should attempt to reduce the negative industrial effect on the environment and human's health:this requires a study of ecological trends in machining.

The investigations currently carried out by many of researchers, concerning the ecological trends in machining processes, allowed the formulation of research assumption which will be verified in this paper. This assumption has the following content: “the evaluation of physical phenomena and technological effects of machining for the various cooling/lubrication techniques allows the selection of rational solutions in ecologic and technological aspects”.

Section snippets

Ecological aspects of cooling/lubrication

To maintain the trends of machining productivity improvement, the various methods of substituting the “conventional process” are being developed (Pusavec et al., 2010). The increase of global production volume and therefore the growth of cooling-lubricating fluids and oils' application induced a large number of negative environmental effects and significant threat for the employees' health. This fact urges for intensive research concerning the ecological aspects of cooling/lubrication.

Dry cutting

Dry condition, as it lacks the use of cooling/lubricating agent, is not always a performance improver, hence the sustainable machinability can be achived by two alternatives approaches: (a) use of coated tool to endow withreduced-friction that would be provided by the coolant-lubricant, (b) optimization of process parameters so that desired machining characteristics are achieved at optimum parameters level – not by the implementation of menacing cutting fluids.

Extreme thermal condition due to

Summary of review and scope of future research

On the light of the knowledge available on the practicing cooling-lubrication strategies in machining, the authors have summarized the comparative performances of five studied environments. This comparison is performed for machining operations and shown in Table 6. Here, the scores are done in a scale of 1–5, 1 being the worst performance and 5 is the best performance.

Conclusions

The ecologic awareness of companies operating on the international competitive market forces the machine parts’ manufacturers to adopt the efficient, economically and ecologically justified manufacturing methods. In this paper the state-of-the-art of ecological methods in machining processes, the current technological status, as well as the characteristics of cutting tools applied in the development of sustainable production methods were presented. The cutting parameters and cutting tool

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