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Lubricants
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New Technologies to Improve Machining Performance from a Tribological Viewpoint
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New Technologies to Improve Machining Performance from a Tribological Viewpoint

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: 15 May 2024 | Viewed by 3498

Special Issue Editors

Prof. Dr. Carlos Eiji Hirata Ventura

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Federal University of São Carlos, São Carlos 13565-905, SP, Brazil
Interests: machining processes; cutting tools; tribology; surface integrity; tool wear
Prof. Dr. Alexandre Mendes Abrão

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Universidade Federal de Minas Gerais, Belo Horizonte 31270-901, MG, Brazil
Interests: metal cutting; abrasive processes; non-conventional machining; surface integrity

Special Issue Information

Dear Colleagues,

Machining processes are widely used in the manufacturing industry, given their flexibility to generate different geometries and ability to provide excellent surface finishes. Within this context, the interactions between the cutting tool and machined surface and the cutting tool and chip have received great attention from the community since the first studies for the optimization of material removal processes.

New technologies have been proposed in order to reduce friction and thermal and mechanical loads in the cutting tool/machined surface/chip interfaces. Tool texturing, application of different types of cutting fluid, as well as the development of new coatings have been investigated to increase tool life and process productivity.

Thus, this Special Issue aims to share the latest advances that focus on improving machining performance, based on the existing tribological phenomena in the contact regions. The issue will cover cooling–lubricant techniques, coatings, tool surface treatment and geometry, and modern methods for wear analysis. Both theoretical and experimental investigations are highly welcome.

Prof. Dr. Carlos Eiji Hirata Ventura
Prof. Dr. Alexandre Mendes Abrão
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • machining
  • tool wear
  • friction
  • cutting force
  • temperature
  • surface integrity
  • textured cutting tool
  • cutting fluid
  • MQL
  • cryogenic cooling
  • tool material
  • coating
  • cutting-edge geometry
  • tool geometry
  • chip flow

Published Papers (3 papers)

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Research

16 pages, 4761 KiB  
Article
Comparison of Machining Performance of Ti-6Al-4V under Dry and Cryogenic Techniques Based on Tool Wear, Surface Roughness, and Power Consumption
by Dhvanil Chauhan, Mayur A. Makhesana, Rizwan Abdul Rahman Rashid, Vivek Joshi and Navneet Khanna
Lubricants 2023, 11(11), 493; https://doi.org/10.3390/lubricants11110493 - 15 Nov 2023
Cited by 2 | Viewed by 1445
Abstract
The machining of Ti-6Al-4V alloys is challenging due to their high strength, poor thermal conductivity, and high chemical reactivity. When used in traditional machining, cryogenic coolants can reduce tool wear, thus extending tool life, improving surface finish, and requiring less power with reduced [...] Read more.
The machining of Ti-6Al-4V alloys is challenging due to their high strength, poor thermal conductivity, and high chemical reactivity. When used in traditional machining, cryogenic coolants can reduce tool wear, thus extending tool life, improving surface finish, and requiring less power with reduced environmental effects. In this context, this study aimed to perform a machinability analysis of the surface roughness, power consumption, tool wear, and specific energy consumption of a Ti-6Al-4V titanium alloy and to comprehend the performance of dry and cryogenic machining in turning operations. A comprehensive analysis of tool wear and specific cutting energy (SCE) under dry and cryogenic machining was conducted. It was found that the machining time under a cryogenic environment was increased by 83% and 39% at 80 and 90 m/min compared to a cutting speed at 100 m/min. The higher cutting speed (100 m/min) in cryogenic environments produced an improved surface finish. Compared to dry machining, the cooling effect of liquid CO2 helped dissipate heat and reduce thermal damage, improving surface finish. The findings revealed that in dry conditions, approximately 5.55%, 26.45%, and 27.61% less power was consumed than in cryogenic conditions at 80, 90, and 100 m/min cutting speeds, respectively. Based on the outcomes of the work, the application of cryogenic cooling can be considered an alternative to dry and flood cooling for improving the machinability of Ti-6Al-4V alloys. Full article
(This article belongs to the Special Issue New Technologies to Improve Machining Performance from a Tribological Viewpoint)
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20 pages, 16158 KiB  
Article
An Investigation of the Sequential Micro-Laser Drilling and Conventional Re-Drilling of Angled Holes in an Inconel 625 Ni-Based Alloy
by Krzysztof Szwajka, Joanna Zielińska-Szwajka, Krzysztof Żaba and Tomasz Trzepieciński
Lubricants 2023, 11(9), 384; https://doi.org/10.3390/lubricants11090384 - 08 Sep 2023
Cited by 1 | Viewed by 918
Abstract
The conventional (mechanical) micro-drilling of Inconel 625 alloys suffers from premature breakage of the drill bit due to its brittle nature and limited cutting tool life. Even greater problems are encountered when micro-drilling holes at an acute angle to the machining plane. In [...] Read more.
The conventional (mechanical) micro-drilling of Inconel 625 alloys suffers from premature breakage of the drill bit due to its brittle nature and limited cutting tool life. Even greater problems are encountered when micro-drilling holes at an acute angle to the machining plane. In such a process, there are great difficulties associated with the low stiffness of the tool, which leads to the frequent breakage of the drill during machining. Therefore, in this type of mechanical drilling operation, the hole surface is usually milled with an end mill to provide a flat surface on the entry side of the drill bit. The aim of this article is to recognise the process of sequential micro-drilling and to assess the possibility of its use as an effective and efficient method of micro-drilling in hard-to-cut metals. The paper describes the process of initial laser drilling followed by final mechanical micro-drilling. Inconel 625 Ni-based alloy sheets were used as the test material. The shape and microstructure of pre-holes made with a laser, the volumetric efficiency of laser processing, the energy in the mechanical drilling process, and tool wear were analysed. The research results show that in the sequential drilling process, mechanical re-drilling eliminates the geometrical discrepancies resulting from the laser pre-drilling. In addition, it was found that, compared to mechanical micro-drilling, the use of sequential micro-drilling resulted in a two-fold increase in drill life. It has been also observed that sequential machining reduces the energy demand by 60% compared to mechanical micro-drilling. In addition, it was found that the edge of the drill bit is a key factor in deciding the target diameter of the laser-drilled pilot hole, and thus in selecting the micro-drilling parameters. Full article
(This article belongs to the Special Issue New Technologies to Improve Machining Performance from a Tribological Viewpoint)
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10 pages, 3092 KiB  
Article
Revisiting the Influence of Contact Length and Surrounding Medium on Metal Cutting Tribology
by Carlos E. H. Ventura, Afonso V. L. Gregório, Lara S. M. Fernandes, Alexandre M. Abrão and Pedro A. R. C. Rosa
Lubricants 2023, 11(8), 342; https://doi.org/10.3390/lubricants11080342 - 11 Aug 2023
Viewed by 725
Abstract
Metal cutting processes involve severe frictional conditions at the tool-chip contact interface, physico-chemical phenomena that are not fully understood and theoretical models with a strong empirical basis. In the literature, it is common to find values for the friction coefficient which are higher [...] Read more.
Metal cutting processes involve severe frictional conditions at the tool-chip contact interface, physico-chemical phenomena that are not fully understood and theoretical models with a strong empirical basis. In the literature, it is common to find values for the friction coefficient which are higher than the unit, despite the inconsistency of these findings with the mathematical theory of plasticity used for accurate modelling of the chip formation mechanics. Thus, the present work seeks to contribute to a better understanding of metal cutting tribology based on well-controlled and specially designed experimental conditions. To enable the stress state at the contact interface to be determined and to provide a known real contact area, polished cutting inserts with prepared rake faces were used to restrict the contact length in orthogonal cutting tests under controlled atmospheres. These conditions also allowed the contribution of the sticking mechanisms to be minimized. Cutting tools of restricted contact lengths have been found to reduce process forces and the friction coefficient, while industrial standard inserts make cutting operation sensitive to the chemical composition of the surrounding atmosphere. Full article
(This article belongs to the Special Issue New Technologies to Improve Machining Performance from a Tribological Viewpoint)
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