Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy
Abstract
:1. Introduction
2. Literature Review
2.1. Energy Consumption
2.2. Environmental Burden
2.3. Production Cost
2.4. Cooling and Lubrication Approaches
3. Empirical Models for Sustainable Indicators
4. Experimentation
4.1. Work Material and Tooling
4.2. Hybrid Cooling and Lubrication Approaches
4.3. Experimental Procedure and Measurements
4.4. Data Inventory
5. Results and Discussion
5.1. Selection of Optimal Levels of Input Parameters
5.2. Mechanism of Nanofluid and Cryogenic Cooling
- Hybrid nanofluids (variable-sized nano-additives) enhanced the performance of nanofluids behaving as spacers between the tool–workpiece contact interface.
- Hybrid nanofluids atomized through the MQL mist containing nano-additives and air mixture formed a thin tribo-film on the tool and workpiece surface to enhance the tribological characteristics.
- Hybrid nanofluids have the capability to penetrate well inside narrow surfaces, preventing rubbing of two surfaces [44].
- Fine dissolution of nano-additives is a challenging task.
- Nanoparticles enter our skin, cause allergies, and have a negative impact on plant growth and seeds.
- Nanoparticles are difficult to detect if opened in the air. Therefore, a hazard appraisal should also be reported to underscore the danger associated with the particles.
- Cryogenic materials having extremely low temperature touch the workpiece and evaporate without leaving a residue.
- The self-generated high pressure does not require external pressure.
- Quick evaporation also keeps the workpiece cold and does not affect the surrounding, creating space for the new coolant.
- Furthermore, cryogenic coolants are sustainable in machining and also improve machining under harsh cutting conditions [45].
- The Leidenfrost effect of cryogenic nitrogen also helps to improve the process efficiency.
5.3. Surface Quality
5.4. Power and Energy Consumption
5.5. Environmental Impacts
5.6. Production Cost
6. Overall Comparison of Cooling/Lubrication Approaches
7. Conclusions
- The results showed that the flow rate of cryogenic LN2 has a significant effect on energy consumption and a flow rate of more than 0.3 L/min is not sustainable economically and environmentally. Similarly, the optimal flow rate of MQL mist is also essential for economical production.
- Owing to effective cooling effects, the cryogenic LN2-assisted turning process produced a better surface quality of the workpiece. However, the hybrid Al-GnP produced only a few microns more than that of the cryogenic LN2 approach.
- At the lowest cutting parameters, the cryogenic cooling approach consumed more power. However, at very high cutting conditions, the Al-GnP approach consumed more power. The specific cumulative energy demand was very high in the cryogenic cooling approach and makes this cooling approach not sustainable. The higher CO2 emissions in the cryogenic cooling approach are due to the high embodied energy of liquid nitrogen.
- Procurement of liquid nitrogen is expensive as compared to MQL oil. Thus, the application of the cryogenic coolant is only economical at the highest cutting condition. The Al-GnP approach incurred less specific production cost at low, medium, and high MRRs. However, at very high MRR (3000 mm3/min), cryogenic LN2-assisted machining produced 4.14% lower price products.
- In conclusion, the cryogenic LN2 cooling approach enhanced the tool life and reduced cutting power, SEC, the tool chip temperature, and specific production cost. At the same time, higher CO2 emissions are associated with the energy-intensive non-sustainable production of LN2.
- At cutting speed , the cryogenic approach outperformed in all sustainable metrics except specific cumulative energy demand and specific carbon emission. This was due to the extremely high embodied energy and carbon footprints associated with the production of liquid nitrogen.
8. Future Recommendation
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Nomenclature
Symbols | |||
Cycle time (s) | Standby time (s) | ||
Idle time (s) | Cutting time (s) | ||
Air-cutting time (s) | Lubrication/coolant time (s) | ||
Cutting length (mm) | Air-cutting length (mm) | ||
Tool change time (s) | Tool life (s) | ||
MRV | Material Removal Volume (mm3) | Standby power (W) | |
Total power (W) | Setup power (W) | ||
Idle power(W) | Power during cutting (W) | ||
Air-cutting power (W) | Compressor/coolant pump power (W) | ||
Tool change power(W) | Machining energy (J) | ||
Embodied energy of MQL oil (kJ) | Embodied energy of LN2 (MJ) | ||
cost of MQL oil (kJ) | cost of LN2 (MJ) | ||
Carbon footprints of MQL oil (kg-CO2) | Carbon footprints of LN2 (kg-CO2) | ||
Cumulative energy demand (J) | Specific cumulative energy demand (J/mm3) | ||
Carbon emission per part (kg-CO2) | Specific carbon emission per part (kg CO2/mm3) | ||
Total cost per part (CNY) | Total cost per part (CNY/mm3) | ||
Environmental cost (CNY) | Overhead costs (CNY) | ||
Flow rate of MQL oil (mL/hr | Flow rate of LN2 (L/min) | ||
Idle energy consumption (J) | Setup energy consumption (J) | ||
Air-cutting energy consumption (J) | Tool-change energy consumption (J) | ||
Cooling energy consumption (J) | Lubrication energy consumption (J) |
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Ti | V | Al | C | Fe | H | N | Y |
---|---|---|---|---|---|---|---|
Balance | 4.02 | 5.85 | 0.01 | 0.20 | 0.0023 | 0.007 | <0.0048 |
Parameter (s) | Units | Value | Reference/Remarks |
---|---|---|---|
W | 350 | Idle power (measured) | |
W | 800 | MQL system power (measured) | |
s | 30 | Idle time | |
s | 20 | Air cutting time | |
s | 60 | Tool change time per part | |
s | Lubrication time | ||
L/min | 0.4 | LN2 flow rate | |
mL/s | 300 | Consumption rate of MQL oil | |
MJ/L | 2.6 | Embodied energy LN2 [31]. | |
kJ/L | 1.37 | Embodied energy (MQL oil) [32] | |
kg-CO2/GJ | 258.2 | CES of Nanjing electric grid [33] | |
kg-CO2/L | 0.11 | Carbon footprints of MQL oil [34] | |
kg-CO2/L | 1.30 | Carbon footprints of LN2 [35] | |
CNY/kWh | 0.723 | Cost of electricity [12] | |
CNY/L | 100 | Cost of the cutting fluid | |
CNY/L | 1 | Cost of the LN2 |
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Khan, A.M.; Anwar, S.; Jamil, M.; Nasr, M.M.; Gupta, M.K.; Saleh, M.; Ahmad, S.; Mia, M. Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy. Metals 2021, 11, 88. https://doi.org/10.3390/met11010088
Khan AM, Anwar S, Jamil M, Nasr MM, Gupta MK, Saleh M, Ahmad S, Mia M. Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy. Metals. 2021; 11(1):88. https://doi.org/10.3390/met11010088
Chicago/Turabian StyleKhan, Aqib Mashood, Saqib Anwar, Muhammad Jamil, Mustafa M. Nasr, Munish Kumar Gupta, Mustafa Saleh, Shafiq Ahmad, and Mozammel Mia. 2021. "Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy" Metals 11, no. 1: 88. https://doi.org/10.3390/met11010088