Replacement of Hazard Lubricants by Green Coolant in Machining of Ti6Al4V: A 3D FEM Approach

Abstract

Metalworking fluids (MWF's) are frequently used for cooling and lubrication during machining processes in manufacturing industries. MWF's such as soluble straight oils, synthetic oils, solid lubricants, bio lubricants contain a mix of water and mineral oil with some percentage of vegetable oils and petroleum. These MWF's are hazardous for the environment and for human health. After using, the lubricants are disposed into the environment by burning or by dumping on the ground or in the sea water. Burning the lubricant creates pollution and airborne disease. To avoid these harmful effects of the lubricants sustainable machining technique is implemented in machining processes. In the present study, liquid nitrogen (green coolant) is used as a sustainable machining technique for cooling and lubrication. Finite element modeling is used to simulate the micro-end milling at different conditions of the workpiece (cryogenic plus preheated and cryogenic). The analysis of chip morphology and cutting forces measurement were done by applying these conditions. The predicted model is validated with the experimental results. It was observed that cryogenic with preheated workpiece (473K) is the optimum condition with the application of green coolant. This study will clarify the behavior of cryogenic on the machining conditions and will solve the environmental problems.