Impact of Cutting Environments on Sustainable Machining of H13 Tool Steel Alloy

Vincent A Balogun, Isuamfon F Edem, Etimbuk B Bassey

Abstract


The use of electrical energy and coolants/lubricants has been widely reported in mechanical machining. However, increased research and process innovation in high speed machining has brought about optimised manufacturing cycle times. This has promoted dry machining and the use of minimum quantity lubrication (MQL). This work understudies the impact of different cutting environments in machining H13 tool steel alloys at transition speed regime with emphasis on sustainable machining of the alloy. To achieve this, end milling tests were performed on AISI H13 steel alloy (192 BHN) on a MIKRON HSM 400 high speed machining centre using milling inserts. After each cutting pass, the milling insert was removed for tool wear measurement on the digital microscope. The electrical power consumed was measured with the Fluke 435 power clamp meter mounted on the three phase cable at the back of the machine. It was discovered that MQL has a promising advantage in terms of tool life with 25 minutes of machining, net power requirement of 10% when compared to dry cutting, and environmental benefits when machining H13 tool steel alloy. This work is fundamentally important in assessing the environmental credentials and resource efficiency regime for green machining of H13 tool steel alloys

Keywords— H13 tool steel, green machining, process optimization, tool life, cutting environments, energy consumption 


Full Text:

PDF

References


Adler, D., Hii, W.S., Michalek, D., & Sutherland, J., (2006).

Examining the role of cutting fluids in machining and

efforts to address associated environmental/health

concerns, Mach. Sci. Technol. 10: 23–58.

Anuj, K.S., Arun, K.T., & Amit, R.D., (2016). Effects of

Minimum Quantity Lubrication (MQL) in machining

processes using conventional and nanofluid based

cutting fluids: A comprehensive review. Journal of

Cleaner Production. 127: 1-18.

Balogun, V.A., Edem, I.F., Gu, H., Mativenga P. T., (2018).

Energy centric selection of machining conditions for

minimum cost. Energy 164: 655-663.

Balogun, V.A., Edem, I.F., Mativenga, P.T., (2015). The

effect of auxiliary units on the power consumption.

International Journal of Scientific & Engineering Research, 6(2).

Balogun, V.A., Edem, I.F., Mativenga, P.T., (2019). Process

Mechanisms and their Relevance for Sustainable

Machining Processes. Procedia Manufacturing 35: 361-366.

Balogun, V.A., Mativenga, P.T., (2013). Modelling of direct

energy requirements in mechanical machining processes. Journal of Cleaner Production 41 (0): 179-186.

Buranska, E., Buransky, I., (2018). Cutting environment

impact on the aluminium alloy machining. Proceedings of the 29th DAAAM International Symposium, pp.1158-1163, B. Katalinic (Ed.), Published by DAAAM International, ISBN 978-3-902734-20-4, ISSN 1726-9679.

Campatelli, G.,( 2009). Analysis of the environmental

impact for a turning operation of AISI 1040 steel,

IPROMS Conference. pp. 6-17.

Edem, I.F., Balogun, V.A., (2017). Sustainability analyses of

cutting edge radius on specific cutting energy and surface finish in side milling processes. International Journal of Advanced Manufacturing Technology, 95:3381–3391

Edem, I.F., Balogun, V.A., Nkanang, B.D., Mativenga, P.T.,

(2019). Software analyses of optimum toolpath strategies

from computer numerical control (CNC) codes. The

International Journal of Advanced Manufacturing Technology, DOI: https://doi.org/10.1007/s00170-019-03604-6

Gajrani, K.K., Sankar, M.R., (2020). Role of Eco-friendly

Cutting Fluids and Cooling Techniques in Machining,

Materials Forming, Machining and Post Processing.

Springer, pp. 159-181.

Howard, M.C., (2014). Sustainable Manufacturing Initiative

(SMI): A true Public-Private Dialogue, Available from:

https://www.oecd.org/sti/ind/45010349.pdf, Accessed

on: 16 August, 2014.

Hsu, Q.-C., Do, T.-V., Nguyen, T.-N., (2019). Minimum

quantity lubricant: A beneficial application in hard-

milling of AISI H13 steel. Universal Journal of Mechanical

Engineering 7(6): 411-423.

ISCAR, (2014). Grade: IC928. (Accessed 16th March 2020).

Klocke, F., Kuchle, A., (2011). Cutting fluids, Manufacturing

Processes 1. Springer, pp. 219-236.

Liew, P.J., Shaaroni, A., Sidik, N.A.C., Yan, J., (2017). An

overview of current status of cutting fluids and cooling

techniques of turning hard steel. International Journal of

Heat and Mass Transfer 114: 380–394.

Mondal, P., Samanta, S., (2020). Surface Roughness

Characteristics of MS Rod Using Different Cutting Fluids

During Turning Operation, Advances in Materials and

Manufacturing Engineering. Springer, pp. 135-141.

Mulyadi, I., (2013). Improving the performance of

minimum quantity lubrication in high speed milling and

environmental performance analysis.

Mulyadi, I.H., Balogun, V.A., Mativenga, P.T., (2015).

Environmental performance evaluation of different

cutting environments when milling H13 tool steel.

Journal of Cleaner Production, 108: 110-120.

Narita, H., Desmira, N., Fujimoto, H., (2008).

Environmental burden analysis for machining operation

using LCA method, Manufacturing Systems and

Technologies for the New Frontier. Springer, pp. 65-68.

Pervaiz, S., Deiab, I., Darras, B., (2013). Power consumption and tool wear assessment when machining titanium alloys. International journal of precision engineering and manufacturing 14(6): 925-936.

Pusavec, F., Krajnik, P., Kopac, J., (2010). Transitioning to

sustainable production - Part I: application on machining

technologies. Journal of Cleaner Production 18(2): 174-184.

Rotella, G., Priarone, P.C., Rizzuti, S., Settineri, L., (2011).

Evaluation of the environmental impact of different

lubrorefrigeration conditions in milling of γ-TiAl alloy,

Glocalized Solutions for Sustainability in Manufacturing.

Springer, pp. 365-370.

Sen, B., Mia, M., Krolczyk, G., Mandal, U.K., Mondal, S.P.,

(2019). Eco-friendly cutting fluids in minimum quantity

lubrication assisted machining: a review on the

perception of sustainable manufacturing. International

Journal of Precision Engineering and Manufacturing-Green Technology, 1-32.

Standard, I., 8688-2 (1989). International Standard For Tool Life Testing In End Milling.

Steel, O.S., (2013). AISI H13. (Accessed 14th February 2020).

Taktak, S., (2007). Some mechanical properties of borided

AISI H13 and 304 steels. Materials & design 28(6): 1836- 1843.

Verma, J.K., Bartarya, G., Bhaskar, J., (2019). Effect of

Minimum Quantity Lubrication on Tool Wear and

Surface Integrity During Hard Turning of EN31 Steel, Advances in Forming, Machining and Automation. Springer,

pp. 205-218.




DOI: http://dx.doi.org/10.46792/fuoyejet.v5i2.497

Refbacks

  • There are currently no refbacks.


Copyright (c) 2020 The Author(s)

Creative Commons License
This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

Powered by ICT and Faculty of Engineering, FUOYE

Copyright © 2020 The Author(s). Published by Faculty of Engineering, FUOYE

image The FUOYEJET website and her metadata are licensed under CC BY-NC