Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea...
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![Page 1: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/1.jpg)
Green Cutting using Supersonic Air Jets as Coolant and
Lubricant during Turning
Authors Andrea Bareggi (presenter) Andrew TorranceGarret O’Donnell
ICM
R 2
006
Department of Mechanical and Manufacturing Engineering
The University of Dublin
Trinity College
Trinity College Dublin
![Page 2: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/2.jpg)
Introduction
Difficult-to-cut materials• Heat resistant alloys• Hard materials• Super stainless alloys (or
super-alloys)
Trinity College Dublin
ICM
R 2
006
![Page 3: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/3.jpg)
Introduction
Difficult-to-cut materials• Heat resistant alloys• Hard materials• Super stainless alloys (or
super-alloys)
Trinity College Dublin
ICM
R 2
006
• Nickel base alloys• Cobalt base alloys• Titanium alloys• Iron base (high chromium
stainless steel) 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
![Page 4: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/4.jpg)
CoolantsTrinity College Dublin
ICM
R 2
006
• Thermal damage
After P. Dahlman, M. Escursell / International Journal of Machine Tools & Manufacture vol.44 (2004) pp.109–115
![Page 5: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/5.jpg)
CoolantsTrinity College Dublin
ICM
R 2
006
• Thermal damage• Wearing by friction
After P. Dahlman, M. Escursell / International Journal of Machine Tools & Manufacture vol.44 (2004) pp.109–115
![Page 6: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/6.jpg)
CoolantsTrinity College Dublin
ICM
R 2
006
• Thermal damage• Wearing by friction• Built up edges
After P. Dahlman, M. Escursell / International Journal of Machine Tools & Manufacture vol.44 (2004) pp.109–115
![Page 7: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/7.jpg)
CoolantsTrinity College Dublin
ICM
R 2
006
• Thermal damage• Wearing by friction• Built up edges
• Sweeping and cleaning the chip-tool interface
![Page 8: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/8.jpg)
Improving cooling techniquesTrinity College Dublin
ICM
R 2
006
• Reducing cutting forces
• Reducing tool wearing
• Reducing workpiece temperature
• Reducing costs
• Reducing environmental impact
![Page 9: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/9.jpg)
Using air jets: why?Trinity College Dublin
ICM
R 2
006
• 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
![Page 10: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/10.jpg)
Experimental apparatusTrinity College Dublin
ICM
R 2
006
• Ursus 225 Centre Lathe
• Kistler piezoelectric tool-force dynamometer
• WC inserts with different nose radius
• Supersonic nozzle Silvent 1011
• Hommel roughness tester
• Infrared camera
![Page 11: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/11.jpg)
Test setupTrinity College Dublin
ICM
R 2
006
• 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
![Page 12: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/12.jpg)
Experimental ResultsTrinity College Dublin
ICM
R 2
006
• Force
Small reduction of forces, when using air jets
![Page 13: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/13.jpg)
Experimental ResultsTrinity College Dublin
ICM
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• Force
• Finishing
Without jet Ra = 0.83μm
With jet Ra = 0.75 μm
![Page 14: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/14.jpg)
Experimental ResultsTrinity College Dublin
ICM
R 2
006
• Force
• Finishing• Chip shape
and colour
Air jet on
Air jet off
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Experimental ResultsTrinity College Dublin
ICM
R 2
006
• Force
• Finishing• Chip shape
and colour• Thermo-
CameraAir jet on Air jet off
![Page 16: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/16.jpg)
Finite Element ModelTrinity College Dublin
ICM
R 2
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• Deform-3D™• Arbitrary Lagragian
Eulerian formulation• adaptive non-linear
remeshing algorithm• fully coupled
thermo-mechanical analysis
![Page 17: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/17.jpg)
Finite Element ModelTrinity College Dublin
ICM
R 2
006
Finite Element ModelTrinity College Dublin
ICM
R 2
006
• Deform-3D™• Arbitrary Lagragian
Eulerian formulation• adaptive non-linear
remeshing algorithm• fully coupled
thermo-mechanical analysis
• Force prediction
![Page 18: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/18.jpg)
Finite Element ModelTrinity College Dublin
ICM
R 2
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• Femlab3.1™• Frictional power• Estimated specific
cutting energy• Heat transfer by
formed chip• Thermal power
generation in the chip-tool interface area
![Page 19: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/19.jpg)
Conclusions & Further ResearchTrinity College Dublin
ICM
R 2
006
• Heat transfer by impinging jet
1. Fluid-dynamic data
2. Estimated Nusselt number
3. Temperature measurement with hot-spot radiometer
![Page 20: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/20.jpg)
Conclusions & Further ResearchTrinity College Dublin
ICM
R 2
006
• Heat transfer by impinging jet
• Chip shape and shear plane investigation
1. Beneficial effect of the force applied on the chip by the air jet
2. Quick-stop tests
![Page 21: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/21.jpg)
Conclusions & Further ResearchTrinity College Dublin
ICM
R 2
006
• Heat transfer by impinging jet
• Chip shape and shear plane investigation
• Improve the FE modeling
1. Modeling the air jet effect (Deform)
2. Improving the friction model (Deform)
3. Improve heat transfer model in chip-tool interface (Femlab)
4. Develop a fluid-structure interaction model (Femlab)
![Page 22: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/22.jpg)
Conclusions & Further ResearchTrinity College Dublin
ICM
R 2
006
• Heat transfer by impinging jet
• Chip shape and shear plane investigation
• Improve the FE modeling
• Testing
1. Cutting parameters
2. Workpiece and insert standard materials
3. Air jet positioning
4. Investigating the use of atomized fluids
5. Investigating the use of two nozzles: overhead and flank configuration
![Page 23: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/23.jpg)
Conclusions & Further ResearchTrinity College Dublin
ICM
R 2
006
• Heat transfer by impinging jet
• Chip shape and shear plane investigation
• Improve the FE modeling
• Testing• Advanced testing
1. Nickel base alloys cutting
2. Other machining applications
![Page 24: Green Cutting using Supersonic Air Jets as Coolant and Lubricant during Turning Authors Andrea Bareggi (presenter) Andrew Torrance Garret O’Donnell ICMR.](https://reader030.fdocuments.net/reader030/viewer/2022033107/56649daa5503460f94a984dc/html5/thumbnails/24.jpg)
Conclusions & Further ResearchTrinity College Dublin
ICM
R 2
006
Thank you for the attention