Long Sump Life Effects of a Naturally Aged Bio-Ester Oil Emulsion on Tool Wear in Finish Turning a Ni-Based Superalloy
Abstract
:1. Introduction
Overview of the Approach Taken
2. Materials and Methods
2.1. Workpieces
2.2. Machine Tool
2.3. Cutting Fluid
2.4. Tool Holder and Tip Insert
2.5. Set-Up and Method for Experiments
2.6. Turning Parameters for This Study
2.7. Instruments
3. Results and Discussion
3.1. Stability of Machine Tool and Workpiece, Using Turning Protocol
3.2. Comparing Aged and Unaged Coolant Performance
3.2.1. Flank Wear
3.2.2. Effect of Workpiece Diameter on Tool Flank Wear Measurement
3.2.3. Cutting Forces
3.2.4. Surface Work Hardening
3.2.5. Chip Forms
3.2.6. Temperature
4. Analysis of Coolant Samples
4.1. Element Analysis
4.2. Contamination
4.3. Chemistry
4.4. Microorganism Effects
4.5. Nonwater Hardening Ions
5. Conclusions
- o
- The flank wear profile was shown to be the maximum on the tool nose midway between the major and minor flank edges.
- o
- The measured radial force (Fr) on the tool increased at a much faster rate than the main cutting (Fc) and feed (Fa) forces, confirming a higher sensitivity to the flank wear. Moreover, the nonlinear trend in the flank wear before VBzmax stabilised correlated well with Fr.
- o
- The measured wear rate results were unable to show dependency on the bar hardness, which was attributed to the low hardness range of the bar stock from 339 to 344 HB, which was sourced from a single batch.
- o
- Although the aged and unaged CFs were tested on the same bar piece, there was high variability in the difference in the flank wear between the aged and unaged CFs. Nevertheless, there was confidence that the flank wear for the aged CF suggested reduced performance in a qualitative way. Consequently, the wear results obtained from the five different bars for the aged CF were grouped at each measurement stage, and similarly for the unaged CF, enabling a quantitative statistical comparison of the wear results at each stage.
- o
- Irregular saw tooth features on a chip form obtained from the aged CF on reaching VBz0.2 could be attributed to vibration. Feathering along one edge was also visible for the aged CF on reaching VBz0.2 and could be attributed to the reduced lubricity of the aged CF.
- o
- The flank wear on the turning tool which often appears to be tilted slightly inwards was explained by the arc of contact that develops between the bar diameter and the flank wear on the tool. More material is lost through the wear at the top of the flank than at the bottom of the flank, and it was shown that the smaller the bar diameter, the greater the difference. This could explain the findings of Boud [42] who found that the tool temperature increased in turning a smaller diameter bar at the same surface-cutting speed.
- o
- Turning down the bar workpiece with multiple passes of the cutting tool at a small depth of cut could accelerate the notch wear at the leading edge of the tool as shown for the aged CF, which could be attributed to higher surface and subsurface hardness that develops on the workpiece through reduced lubricity.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
BUE | Built-up edge |
CE | Chip entanglement |
CF | Cutting fluid |
X, Y, Z | Axes of global coordinate system |
Fc (N) | Main cutting force on Z-axis |
Fa (N) | Axial force on X-axis |
Fr (N) | Radial force on Y-axis |
dc | Depth of cut (mm) |
f | Feed rate (mm/rev) |
Rn | Tool nose radius (mm) |
tc | Cut time |
V | Cutting surface speed (mm/min) |
LE | Tool leading edge |
TE | Tool trailing edge |
PPM | Parts per million |
Rb | Bar workpiece radius |
VBz | Tool flank wear |
VBz0.1 | Flank wear limit 0.1 mm |
VBz0.2 | Flank wear limit 0.2 mm |
VBz0.3 | Flank wear limit 0.3 mm |
VBzmax | Maximum flank wear measured on tool nose |
VBzmaxdiff | Flank wear difference [VBzmax (unaged CF) − Vbzmax (aged CF)] |
Y3 | Loss of tool material from flank wear in the radial direction |
(n) | Stage number to suspend job and measure flank wear |
β | Tool tip clearance angle |
k1,2 | Constants in equations. |
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Speed (mm/min) | Depth of Cut (mm) | Feed (mm/rev) | Tool Nose Radius (mm) | Tool Material | Lubricant Condition | Measures | |
---|---|---|---|---|---|---|---|
30–70 | 1 | 0.168–0.393 | 0.8 | TiAlN PVD coated | Dry, vegetable emulsion | Tool wear, surface roughness | [7] |
60, 180 | 0.25 | 0.1 | 0.8 | Carbide, CBN | Emulsion, dry, cryogenic, CMQL | Tool wear, surface roughness | [23] |
50–100 | 0.4–1.2 | 0.1–0.2 | 0.8 | Coated carbide | Emulsion | Surface roughness | [11] |
45, 90 | 1 | 0.2 | Tool diameter 12 | Carbide | Emulsion | Chip form | [6] |
65, 84 | 0.2, 0.5 | 0.1 | 0.8 | Uncoated WC | Dry | Tool flank wear, cutting forces, chip form | [24] |
100 | 0.2–0.6 | 0.12 | 0.8 | Carbide | Dry | Chip form | [15] |
60 | 0.4 | 0.08–0.2 | - | - | Dry and cold air | Surface roughness, XRD analysis | [25] |
65–125 | 0.25 | 0.1 | 0.8, 1.2 | Carbide | Emulsion | Tool wear | [5] |
40–70 | 0.2–0.8 | 0.1–0.25 | 0.8, 1.2 | Carbide, ceramic | Emulsion | Cutting force | [26] |
30, 80 | 0.1, 0.5 | 0.15 | 0.4 | Carbide | Coolant | Residual stress | [27] |
60, 120 | 0.8 | 0.075 | 0.8 | Uncoated 890 grade carbide | Dry, MQL | Tool wear, cutting forces, surface roughness, chip | [18] |
50, 70 | 0.5 | 0.1 | 0.4 | Carbide | Dry | Tool wear and surface roughness | [19] |
50–300 | 0.25 | 0.1–0.15 | 0.4–0.8 | PCBN-Carbide | Emulsion | Forces and surface damage | [20] |
40–120 | 0.25 | 0.15, 0.25 | 0.4 | K10 coated and uncoated, WC substrate | Emulsion | Residual stress | [21] |
30–50 | 2 | 0.2–0.4 | - | Carbide | Wet | Tool life and forces | [22] |
Yield Strength (Mpa) | Tensile Strength (Mpa) | Elongation (%) | Reduction in Area (%) | Brinell Hardness | |
---|---|---|---|---|---|
862–1000 | ≥1034 | ≥20 | ≥35 | 314–360 | |
ASTM E 23-18 (2018) [34] | 889 | 1220 | 32 | 52 | 341 1 |
Element | C | Si | Mn | Cr | Mo | Fe | Al | Co | Cu | Ti | Ni | Nb |
---|---|---|---|---|---|---|---|---|---|---|---|---|
Wt % | 0.014 | 0.05 | 0.06 | 18.9 | 3.00 | 18.57 | 0.53 | 0.42 | 0.03 | 0.95 | 53.1 | 5.05 |
Stage Number for Measurement | 1 | 2 | 3 | 4 | 5 | 6 | 7 |
---|---|---|---|---|---|---|---|
Accumulated cut time (min) | 1.75 | 3.4 | 4.98 | 6.48 | 11.7 | 16.5 | 19.3 |
Number of tool passes per stage | 3 | 3 | 3 | 3 | 12 | 12 | 12 |
Cut length per stage (mm) | 206 | 200 | 198 | 194 | 727 | 696 | 662 |
Nominal bar diameter at start (mm) | 50.0 | 48.5 | 47.0 | 45.5 | 44.0 | 38.0 | 32.0 |
Nominal bar diameter at finish (mm) | 48.5 | 47.0 | 45.5 | 44.0 | 38.0 | 32.0 | 26.0 |
VBz0.1 | VBz0.2 | |||||||
---|---|---|---|---|---|---|---|---|
α1 | α2 | tc (min) | Goodness of Fit (R2) | α1 | α2 | tc (min) | Goodness of Fit (R2) | |
Unaged | 51.3 | 0.0831 | 8.03 | 0.87 | 52.1 | 0.0787 | 17.1 | 0.94 |
Aged | 52.9 | 0.0987 | 6.45 | 0.91 | 55.7 | 0.0869 | 14.7 | 0.91 |
Absolute difference (%) | 21.8 | 15.1 |
Bar Diameter (mm) | VBz (mm) | Y1 (mm) | Y2 (mm) | Y3 (mm) | Y2/Y3 (%) |
---|---|---|---|---|---|
100 | 0.2000 | 49.9996 | 0.0004 | 0.0210 | 1.9% |
50 | 0.2000 | 24.9992 | 0.0008 | 0.0210 | 3.8% |
26 | 0.2000 | 12.9985 | 0.0015 | 0.0210 | 7.3% |
10 | 0.2000 | 4.9960 | 0.0040 | 0.0210 | 19.0% |
Test | Unit | Limits | Unaged | Aged | |
---|---|---|---|---|---|
Contamination | FW index | Comparative | 13.2 | 13 | |
Colour | Yellowish | Brownish | |||
Emulsion condition | Fine dispersion | Fine dispersion | |||
Chemistry | pH | 8.7–9.3 | 9 | 8.9 | |
Conductivity | mS/cm | <7.0 | 4.7 | 4.6 | |
Nitrate | mg/L | <150 | 8 | 26 | |
Total hardness | °dH | <70 | 11 | 19 | |
Chloride | mg/L | <150 | 57 | 84 | |
Sulphate | mg/L | <400 | 111 | 200 | |
Supplementary | Average droplet size | μm | <0.700 | 0.122 | 0.113 |
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Wood, P.; Mantle, A.; Boud, F.; Carter, W.; Gunputh, U.; Pawlik, M.; Lu, Y.; Díaz-Álvarez, J.; Miguélez Garrido, M.H. Long Sump Life Effects of a Naturally Aged Bio-Ester Oil Emulsion on Tool Wear in Finish Turning a Ni-Based Superalloy. Metals 2023, 13, 1610. https://doi.org/10.3390/met13091610
Wood P, Mantle A, Boud F, Carter W, Gunputh U, Pawlik M, Lu Y, Díaz-Álvarez J, Miguélez Garrido MH. Long Sump Life Effects of a Naturally Aged Bio-Ester Oil Emulsion on Tool Wear in Finish Turning a Ni-Based Superalloy. Metals. 2023; 13(9):1610. https://doi.org/10.3390/met13091610
Chicago/Turabian StyleWood, Paul, Andrew Mantle, Fathi Boud, Wayne Carter, Urvashi Gunputh, Marzena Pawlik, Yiling Lu, José Díaz-Álvarez, and María Henar Miguélez Garrido. 2023. "Long Sump Life Effects of a Naturally Aged Bio-Ester Oil Emulsion on Tool Wear in Finish Turning a Ni-Based Superalloy" Metals 13, no. 9: 1610. https://doi.org/10.3390/met13091610