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Advances in Sustainable Machining and Manufacturing Processes
Kishor Kumar Gajrani, Arbind Prasad, Ashwani Kumar, Kishor Kumar Gajrani, Arbind Prasad, Ashwani Kumar
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eBook - ePub
Advances in Sustainable Machining and Manufacturing Processes
Kishor Kumar Gajrani, Arbind Prasad, Ashwani Kumar, Kishor Kumar Gajrani, Arbind Prasad, Ashwani Kumar
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About This Book
This text provides an in-depth overview of sustainability in machining processes, challenges during machining of difficult-to-cut materials and different ways of green machining in achieving sustainability.It discusses important topics including green and sustainable machining, dry machining, textured cutting coated tools for machining, solid lubricants-based machining, gas-cooled machining, cryogenic cooling for intelligent machining, artificial neural network for machining, big data based machining, and hybrid intelligent machining.
This book-
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- Covers advances in sustainable machining such as gas-cooled machining, near dry machining, and minimum quantity lubrication.
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- Explores use of big data, machine learning and artificial intelligence for machining processes.
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- Provides case studies and experimental design as well as results with analysis focusing on achieving sustainability.
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- Discusses artificial intelligence and machine learning based machining processes.
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- Cover the latest applications of sustainable manufacturing for a better understanding of the concepts.
The text is primarily written for senior undergraduate, graduate students, and researchers in the fields of mechanical, manufacturing, industrial, production engineering and materials science.
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Information
Part I Sustainable Machining
1 Challenges in Machining of Advanced Materials
M. N. Mathabathe and A. S. Bolokang
Council for Scientific and Industrial Research, Manufacturing Cluster, Advanced Materials Engineering, Pretoria, South Africa
DOI: 10.1201/9781003284574-2
Contents
- 1.1 Introduction
- 1.2 Machining Process and Materials
- 1.2.1 Cutting Tool
- 1.2.2 Material Selection
- 1.2.3 Types of Machining Techniques
- 1.3 Tool Wear/Life Span and Commercial Metal Cutting
- 1.4 Machinability
- 1.5 Machining Process Selection
- 1.5.1 Challenges Related to Machining
- 1.5.2 Practical Aspects and Developments
- 1.6 Conclusion
- References
1.1 Introduction
The fuel efficiency and performance improvement in the aerospace application has led to the development of advanced materials, namely, from steel to nickel to titanium alloys; materials with lower density, for example, aluminum to carbon fiber composites; and ceramic and metal matrix composites (CMCs and MMCs, respectively), which are restituting part of elevated temperature alloys subject to engine application en route to the end of the 20th century [1].
Advanced structural materials can be defined as complex shapes or materials combinations to attain properties linking to functionality, for example, smart materials. These are materials designed for good mechanical, electrical, or thermal properties; high-efficiency energy conversion; materials with embedded sending systems for reliability and safety; and smart materials vehicles and large space structures are subject to a high-strength-per-mass ratio [2]. Researchers studied the design and fabrication of specific structures to enhance materials property three-dimensional (3D) printed structures, such as curved [3], honeycomb [4], cell shapes [5] or hexachirales [6].
The thermal, mechanical and electrical properties, which also enhance the performance of polymer matrix composites, make carbon nanotubes (CNTs) attractive for industry use. However, identifying prospective applications for space use is a challenge for these materials [7]. On one hand, the chief challenges formed by today’s establishments involve comprehending and assimilating the rapidly advancing technological machining methods fabricated by industry. The integration and application of these advances prepare the industry for the next set of leading technical improvements. The present work focuses on a vast area of machining techniques and their challenges faced by advanced materials.
1.2 Machining Process and Materials
1.2.1 Cutting Tool
Advanced materials, such as superalloys, are a challenge for machining due to their inherent high hardness, low thermal conductivity, and great resistance to shearing. However, they require elevated cutting temperatures and high cutting forces to avoid severe tool wear [8].
The major tools employed in the fabrication of Ni-based superalloys are ceramic, carbide tools, and polycrystalline cubic boron nitride (PCBN). The latter is commonly used due to its superior machining capabilities for “difficult to cut” materials [9]. The PCBN is designed without a chip breaker, which is a flat rake, resulting in more resistance to breaking the chip during the cutting process. However, its shortcomings are that the surface of the workpiece is effortlessly damaged by the chip winding workpiece [9]. It was suggested that applying high-pressure cooling may overcome these drawbacks [10–11], while the importance of tool failure is attributed to analyzing the damage of tool material [12].
1.2.2 Material Selection
Advanced ceramic materials, for example, are clustered into two groups, that is, (1) conductive—such as the typical zirconium diboride (ZrB2), metal nitrides (TiN/ZrN), boron carbide (B4C), titanium diboride (TiB2), and other similar materials—and (2) nonconductive silicon nitride (Si3N4), alumina (Al2O3), zirconia (ZrO2), and silicon carbide (SiC). However, adding advanced ceramic materials or conductive particles to the latter, such as B4C, TiC, Si, CaO, TiB2, Si3N4 + TiC, Si3N4 + TiN, ZrO2 + Cao, Al2O3 + TiC, ZrO2 + Y2O3 + TiN, and Al2O3 + TiN, makes them conductive advanced materials [13–14]. However, the conventional machining shortcomings of advanced ceramic materials are attributable to their elevated hardness and brittleness [13]. Additionally, their processing/manufacturing performance is not cost-effective, particularly the expense incurred during the polishing stage [13]. Therefore, the surface of advanced materials may suffer damage during machining, resulting in stress concentration and cracks, thus affecting the mechanical strength of components [14].
Ceramic phases, that is, Al2O3/Al2O3 or SiC/SiC, in the same structure of CMCs mitigate the aggregate residual stresses emanating from the manufacturing process. Further, the coefficient of thermal expansion (CTE) mismatch and processing temperature affects the residual stresses amid matrix and fibers, characterized by X-ray diffraction (XRD), Raman spectroscopy, or micro-hardness tests [15].
1.2.3 Types of Machining Techniques
Many machining techniques effectuated unrelenting tool wear associated with longer cutting time, the high cutting force resulting in higher machining cost, thus bearing machining challenges of advanced materials [12]. Furthermore, when processing advanced ceramics, for example, by abrasive machining and grinding, the product components experience plastic deformation and considerable residual stress, friable layers, and surface cracks [16, 17]. Table 1.1 outlines some machining techniques, both conventional and nonconventional.
| Machining Techniques | Information Machined | Challenges | Concluding Remarks | References |
|---|---|---|---|---|
| Conventional | ||||
| Orthogonal cutting |
| Ductile and brittle behavior transpire due to ceramic machining at small uncut chip thickness leading to grain fracture and slip-plane mechanisms | Roughness/coarseness of machined surface is susceptible to microcracking mechanisms of the particles, leading to residual stress as the scratch load increases | [22] |
| Milling |
| Observed ductile to brittle transition in the matrix during machining. Fiber removal due to pullout mechanism. | Concluded that surface roughness increased at a penetration depth of >4 μm, resulting in larger grooves due to brittle fracture | [23] |
| Drilling | The tool rotates along its axis | Entry and exit delaminations are induced machining damage due to high thrust forces employed-conventional drilling (CD) | Rotary ultrasonic machining (RUM) had an average reduced thrust force (~10%–15%), resulting in less significant exit delamination than CD | [24] |
| Grinding | Favored finishing operation for hard/brittle materials to achieve dimensional accuracies | Three grinding methods showed different results performed on C/Si materials CG provided a surface roughness (Ra) ~2–4 times lower than IG, while the UAG produced much higher values of Ra, as a result of the induced impact on the abrasive grains -caused cracks to propagate | Grinding holes >1-mm diameter are useful for successful machining of slots and surface finish employing the typical conventional mechanical techniques using cubic boron nitride and diamond tools | [25] |
| Nonconventional | ||||
| Abrasive waterjet (AWJ) | Cut and shape hard metals | Reduced surf... | ||