The cooling applications in machining operations play a very important role and many operations cannot be carried out efficiently without cooling. Application of a coolant in a cutting process can increase tool life and dimensional accuracy, decrease cutting temperatures, surface roughness and the amount of power consumed in a metal cutting process and thus improve the productivity. In this review, liquid nitrogen, as a cryogenic coolant, was investigated in detail in terms of application methods in material removal operations and its effects on cutting tool and workpiece material properties, cutting temperature, tool wear/life, surface roughness and dimensional deviation, friction and cutting forces. As a result, cryogenic cooling has been determined as one of the most favourable method for material cutting operations due to being capable of considerable improvement in tool life and surface finish through reduction in tool wear through control of machining temperature desirably at the cutting zone.

A review of cryogenic cooling in machining processes

Cryogenically assisted manufacturing processes are emerging as environmentally-benign, toxic-free, hazardless operations, producing functionally superior products. This paper presents an overview of major cryogenic manufacturing processes, summarizing the state-of-the-art and significant developments during the last few decades. It begins with a summary of historic perspectives, including definitions, scope, and proceeds to analysis of process mechanics and material performance covering tribological and thermo-mechanical interactions, followed by surface integrity, product quality and performance in cryogenic manufacturing. Process analysis and applications includes machining, forming and grinding. Economic, safety and health issues are then discussed. Finally, progress in developing predictive performance models and future outlook are presented.

Cryogenic manufacturing processes

Today, hybrid manufacturing technology has drawn significant interests from both academia and industry due to the capability to make products in a more efficient and productive way. Although there is no specific consensus on the definition of the term ‘hybrid processes’, researchers have explored a number of approaches to combine different manufacturing processes with the similar objectives of improving surface integrity, increasing material removal rate, reducing tool wear, reducing production time and extending application areas. Thus, hybrid processes open up new opportunities and applications for manufacturing various components which are not able to be produced economically by processes on their own. This review paper starts with the classification of current manufacturing processes based on processes being defined as additive, subtractive, transformative, joining and dividing. Definitions of hybrid processes from other researchers in the literature are then introduced. The major part of this paper reviews existing hybrid processes reported over the past two decades. Finally, this paper attempts to propose possible definitions of hybrid processes along with the authors’ classification, followed by discussion of their developments, limitations and future research needs.

/pdf/a-review-of-hybrid-manufacturing-processes-state-of-the-art-2sia0d73cv.pdf

A review of hybrid manufacturing processes – state of the art and future perspectives

In modern days, the conception of sustainability has progressively advanced and has begun receiving global interest. Thus, sustainability is an imperative idea in modern research. Considering the recent trend, this review paper presents a summary of the previously published research articles on minimum quantity lubrication (MQL) assisted machining. The requirement to stir towards sustainability motivated the researchers to revise the effects of substitute lubrication methods on the machining. Conventional lubri-cooling agents are still extensively employed when machining of engineering alloys, but the majority of the recent papers have depicted that the utilization of vegetable oil, nanofluids, and nanoplatelets in MQL system confers superior machining performances as compared to conventional lubrication technology. In actual, the definite principle of this manuscript is to re-examine modern advancements in the MQL technique and also explore the benefits of the vegetable oil and nanofluid as a lubricant. In brief, this paper is a testimony to the advancing capabilities of eco-friendly MQL technique which is a viable alternative to the flood lubrication technology, and the outcomes of this review work can be contemplated as a movement towards sustainable machining.

/pdf/eco-friendly-cutting-fluids-in-minimum-quantity-lubrication-1r11c2o191.pdf

Eco-Friendly Cutting Fluids in Minimum Quantity Lubrication Assisted Machining: A Review on the Perception of Sustainable Manufacturing

The process of cryogenic machining, due to increased demand for environmentally friendly manufacturing processes, has seen a growing interest in the machining community. This article presents an overview of cryogenic machining and its induced surface integrity characteristics such as surface roughness, topography, grain refinement and machining-induced layer, microhardness, phase transformation, residual stress and fatigue life in machining of various materials including difficult-to-machine materials, aerospace alloys, lightweight materials, etc. The effect of cryogenic machining on surface integrity characteristics is discussed, and compared with dry, Minimum Quantity Lubrication (MQL), and flood-cooled machining processes. In addition to being an environmentally friendly process, this study shows that cryogenic machining significantly contributes to improved functional performance of machined components through its superior and more desirable surface integrity characteristics.

Cryogenic Machining-Induced Surface Integrity: A Review and Comparison with Dry, MQL, and Flood-Cooled Machining

TiB2 is a relatively new coating material used on carbide cutting tool inserts and is useful owing to its high hardness and chemical inertness. In the present investigation, TiB2-coated carbide inserts were used to machine titanium alloy (Ti-5Al-5Mo-2Sn-V) under dry as well as cryogenic cooling conditions. The cutting forces, surface quality, surface roughness and tool wear were studied in detail. Although beneficial effects of machining under cryogenic cooling, reported in previous investigations, were observed in the present investigation, TiB2 as a coating material on carbide inserts was found to be unsuitable for machining titanium alloys. Removal of coating followed by severe abrasion, adhesion and diffusion was found to be the main reason for tool failure.

Turning of titanium alloy with TiB2-coated carbides under cryogenic cooling:

In the recent past, the importance of geopolymer concrete as an eco-friendly product to replace portland cement concrete is continuously increasing over time. Yet less research effort has been invested in this area compared with some topical issues in civil engineering. Thus, the objective of this article is to analyse the mechanical properties of geopolymer concrete where the cement is replaced by fly ash and ground granulated blast-furnace slag (GGBS). Sodium silicate and sodium hydroxide 8 molarity solution was used. The compressive strength of a cube in an 8 molarity solution was measured for various mixtures (i.e. G50F50 where G and F stand for GGBS and flyash, respectively while the numerical value denotes the cement percentage) and the cement contents (i.e. 0, 10, 20, 30, 40%). The cube specimens are 100mmx100mmx100mm with the ambient curing at 35- 400C. In total, 9 cubes, 3 beams and 3 cylinders are cast at 7days, 14days and 28days while the compressive strengths of different mixes and cubes are calculated. For 28days, beams and cylinders are measured for flexural and tensile strength. The compressive strength at 7,14 and 28 days nearly doubled the target strength by using geopolymer concrete instead of normal concrete. Compressive strength is about 10% higher at 7 and 14days and 20% higher at 28days after replacing 40% of the cement. Flexural strength increased by 50% when 40% of the cement was replaced but split tensile strength only increased by 1%.

/pdf/mechanical-properties-of-geopolymer-concrete-with-varying-24dfi4rv.pdf

Mechanical properties of geopolymer concrete with varying cement content using flyash and ground granulated blast furnace slag

Forming process plays a significant role in manufacturing a product. Deep drawing among the forming process is considered superior because of its low wastage. The appropriate parameters to have an optimized drawing process must be found. A slight change in these parameters will cause major change on positive or negative side. In this, the punch forces mainly focused. This is the force used to draw the object. An experiment by varying punch force is made and investigate what happens in that resulting product. During the application of excessive force some failure like fracture thinning and cracks would occur. Experiment by varying load is done, and the outcomes are observed. The outcome of the experiment was noted. From this experiment it’s found that the optimistic load to draw the object and to improve the processing speed. By this, the productivity and accuracy is improved. By doing this for various loads, many results were obtained which gave reliability of the results. These findings are also theoretically and analytically examined.

https://iopscience.iop.org/article/10.1088/1742-6596/2272/1/012015/pdf

Effect on the product finish in deep drawing process due to supremacy of punch force

Experimental and predictive modelling in dry micro-drilling of titanium alloy using Ti–Al–N coated carbide tools

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Turning of titanium alloy with TiB2-coated carbides under cryogenic cooling:

Mechanical properties of geopolymer concrete with varying cement content using flyash and ground granulated blast furnace slag

Effect on the product finish in deep drawing process due to supremacy of punch force

Experimental and predictive modelling in dry micro-drilling of titanium alloy using Ti–Al–N coated carbide tools