ABSTRACT

We primarily need to reduce the consumption of metalworking fluid to ensure sustainable and eco-friendly machining of aerospace alloys. The present study was planned to determine the efficiency of various eco-friendly metalworking fluid strategies for the sustainable turning of aerospace aluminium alloy (Al7075-T6) coated carbide tools under different eco-friendly metalworking fluid strategies namely dry machining, minimum quantity lubrication (MQL), Ranque-Hilsch vortex tube (RHVT), and compressed air. Machining performance was investigated in terms of micro-hardness, tool tip temperature, tool wear, cutting forces, work surface roughness, chip morphology, and energy consumed. Results manifested that MQL and tool coatings can significantly lower tool tip temperature by up to 16%, tool wear by up to 102–106%, average cutting forces by 17–21%, and surface roughness reduced from 11–21% as compared to dry conditions.

Abbreviations: BUE, built-up edge; CVD, chemical vapour deposition; CrN, chromium nitride; DCR, disposed chip ratio; DLC, diamond like carbon; DSPR, disposal scrap part ratio; EDS, energy dispersive X-ray spectroscopy; MF, metalworking fluid; MoS2, molybdenum disulphide; MQL minimum quantity lubrication; PVD, physical vapour deposition; RHVT, Ranque-hilsch vortex tube; RPSR, recycled part scrap ratio; RSPR, remanufacturing scrap part ratio; SEM, scanning electron microscopy; SDSS, super duplex stainless steel; TiAlN, titanium aluminium nitride

摘要

我们主要需要减少金属加工液的消耗，以确保航空航天合金的可持续和环保加工。本研究计划确定在不同的环保金属加工液策略（即干式加工、微量润滑（MQL）下）可持续车削航空航天铝合金（Al7075-T6）涂层硬质合金刀具的各种环保金属加工液策略的效率）、Ranque-Hilsch 涡流管 (RHVT) 和压缩空气。加工性能的研究包括显微硬度、刀尖温度、刀具磨损、切削力、工作表面粗糙度、切屑形态和能量消耗。结果表明，MQL 和刀具涂层可显着降低刀尖温度高达 16%，刀具磨损高达 102–106%，平均切削力降低 17–21%，

缩写： BUE，积屑瘤；CVD、化学气相沉积；CrN，氮化铬；DCR，处置芯片比率；DLC，类金刚石碳；DSPR，处置报废部分比例；EDS，能量色散X射线光谱仪；MF，金属加工液；MoS2，二硫化钼；MQL微量润滑；PVD，物理气相沉积；RHVT，Ranque-hilsch 涡流管；RPSR，回收零件报废率；RSPR，再制造废品率；SEM，扫描电子显微镜；SDSS，超级双相不锈钢；TiAlN、氮化钛铝