A comprehensive tool-wear/tool-life performance model in the ...

Recommendations

Info

ARTICLE IN PRESS P.W. Marksberry, I.S. Jawahir / International Journal of Machine Tools & Manufacture 48 (2008) 878–886 885 1.00 Predicted Tool-wear Value using Dry Equation 0.90 Straight MWF Width of Groove Backwall Wear (mm) 0.80 0.70 0.60 0.50 0.40 0.30 Predicted Tool-wear Value using New NDM Equation Tool-wear Repeatability Results Shown with 95% confidence interval Soluble MWF Semi-Syn. MWF Synthetic MWF 0.20 0 50 100 150 200 MWF Volumetric Flow Rate (ml/hr) Fig. 5. Tool-wear varying MWF type for rake face nozzle position. Modification of the ASTM Tapping Torque Test can be used as a technique to characterize cooling and lubricity behaviors in MWFs while altering the reamed hole size. The new approach in assessing tool-wear/tool-life remains useful for characterizing tool-wear patterns in NDM that cannot be described by traditional standards. It is proposed to validate the new tool-wear/tool-life equation for a wider range of conditions including atomization type, chip form/flow interference with spray mist field, cutting geometry and work materials. Acknowledgments The author would like to thank the two anonymous reviewers for their comments. Very special thanks to Bob Gregory for suggestions for improving the draft. I would also like to thank the participants of the spring 2006, Sustainability Seminar Series (coordinated by Dr. I.S. Jawahir at the University of Kentucky, College of Mechanical Engineering) for their comments. References [1] T. Brockhoff, A. Walter, Fluid minimization in cutting and grinding, abrasives, Journal for the Abrasive Engineering Society, Butler, PA, October–November 1998. [2] E.S. Nachtman, S. Kalpakjian, Lubricants and Lubrication in Metalworking Operations, Marcel Dekker, Inc., New York, NY, 1985. [3] NIOSH, National Occupational Exposure Survey (NOES), 1981 B83, US Department of Health and Human Services, Cincinnati, OH, 1983. [4] I.A. Greaves, E.A. Eisen, T.J. Smith, L.J. Pothier, D. Kriebel, S.R. Woskie, et al., Respiratory health of automobile workers exposed to metal-working fluid aerosols. II. Respiratory symptoms, Final Draft, Harvard School of Public Health, Occupational Health Program, Boston, MA, 1995. [5] K. Kreiss, J. Cox-Ganser, Metalworking fluid-associated hypersensitivity pneumonitis: a workshop summary, American Journal of Industrial Medicine 32 (4) (1997) 423–432. [6] N. Sprince, P. Thome, W. Popendorf, C. Zwerling, E. Miller, J. DeKoster, Respiratory symptoms and lung function abnormalities among machine operators in automobile production, American Journal of Industrial Medicine 31 (4) (1997) 403–404. [7] J. Fuchs, B. Burg, J. Hengsder, U. Bolm-Audorff, F. Oesch, DNA damage in mononuclear blood cells of metal workers exposed to N-nitrosodiethanolamine in synthetic cutting fluids, Mutation Research 342 (2) (1995) 95–102. [8] M. Chan-Yeung, J.-L. Malo, Compendium I: table of the major inducers of occupational asthma, in: I.L. Bernstein, M. Chan-Yeung, J.-L. Malo, D.I. Bernstein (Eds.), Asthma in the Workplace, Marcel Dekker, Inc., New York, NY, 1993, pp. 595–623. [9] C. Zugerman, Cutting fluids. Their use and effects on the skin, Occupational Medicine: State of the Art Review 1 (2) (1986) 245–258. [10] E. Brinksmeier, T. Brockhoff, Minimum quantity lubrication in grinding, Society of Manufacturing Engineers, Dearborn, MI, Technical Paper, 1997. [11] U. Heisel, M. Lutz, D. Spath, D. Wassmer, U. Walter, Application of minimum quantity cooling lubrication technology in cutting processes, Production Engineering, vol. II/1, Annals of the German Academic Society for Production Engineering, 1994. [12] T. Wakabayashi, H. Sato, I. Inasaki, Turning using extremely small amounts of cutting fluids, JSME International Journal, Series C 41 (1) (1998) 43–148.
886 ARTICLE IN PRESS P.W. Marksberry, I.S. Jawahir / International Journal of Machine Tools & Manufacture 48 (2008) 878–886 [13] P.W. Marksberry, Micro-flood (MF) technology for sustainable manufacturing operations that are coolant less and occupationally friendly, Journal of Cleaner Production 15 (10) (2007) 958–971 Center for Manufacturing, College of Engineering, University of Kentucky, Lexington. [14] P.W. Marksberry, An assessment of tool-life performance in NDM (near dry machining) for sustainable manufacturing of automotive steel components, Dissertation, Department of Mechanical Engineering, College of Engineering, University of Kentucky, 2004. [15] M.G. Gressel, Comparison of mist generation of flood and mist application of metal working fluids during metal cutting, Dissertation, Department of Mechanical, Industrial, and Nuclear Engineering, College of Engineering, University of Cincinnati, 2001. [16] I. Scandiffio, A contribution to dry cutting and to minimum quantity of fluid in steel cutting, M.Sc. Dissertation in Mechanical Engineering, Campinas, SP, Brazil, 2000 (in Portuguese). [17] A. Rahman, S. Kumar, M. Salam, Evaluation of minimal quantities of lubrication in end milling, International Journal of Advance Manufacturing Technologies, Department of Mechanical and Production Engineering, National University of Singapore, Singapore, Springer, 2001. [18] D. Chen, Y. Suzuki, K. Sakai, A study of turning operation by oil–water combined mist lubrication machining method, Key Engineering Materials 202-2 (03) (2001) 47–52. [19] B. Kramer, An analytical approach to tool wear prediction, Ph.D. Thesis, Department of Mechanical Engineering, MIT, USA, 1979. [20] E. Usui, T. Shirakashi, T. Kitagawa, Analytical Prediction of Cutting Tool Wear, 1984, pp. 129–151. [21] V. Venkatesh, Computerized machinability data, in: Proceedings of Automach, 27–29 May 1986, Australia, Sydney, SME, Dearborn, MI, p. 159. [22] W. Lau, P. Venuvinod, C. Rubenstein, The relation between tool geometry and the Taylor tool-life constant, International Journal of Machine Tool Designing and Research 20 (1989) 29–44. [23] P. Dearnley, E. Trent, Wear mechanisms of coated carbide tools, Metals Technology (1982) 60–75. [24] B. Mills, A. Redford, Manufacturing of Engineering Materials, Applied Science, London, 1983, p. 20. [25] J. Schey, Introduction to Manufacturing Processes, second ed., McGraw-Hill, New York, 1987, p. 464. [26] B. Niebel, A. Draper, R. Wysk, Modern Manufacturing Process Engineering, McGraw-Hill, New York, 1989, p. 487. [27] E. Hoffman, Fundamentals of Tool Design, second ed., SME, Dearborn, MI, 1984, p. 83. [28] D.T. Quinto, Mechanical property and structure relationships in hard coated carbide tools, Metals Technology 9 (1988) 60–75. [29] P. Oxley, The Mechanics of Machining—An Analytical Approach to Assessing Machinability, Ellis Horwood, Chichester, 1989, p. 185. [30] H. Wang, R. Wysk, An expert system for machining data selection, Computers and Industrial Engineering 10 (2) (1986) 99. [31] I. Jawahir, P. Li, R. Gosh, E. Exner, A new parametric approach for the assessment of comprehensive tool wear in coated grooved tools, Annals of the CIRP 44 (1995) 49–54. [32] P. Li, D. Stein, R. Gosh, I. Jawahir, Engaged cutting edge effects on tool-wear and tool-life in turning operations using grooved cutting tools, Manufacturing Science and Technology, vol. 2, ASME 1997, pp. 277–284.
Page 1 and 2: ARTICLE IN PRESS International Jour
Page 3 and 4: 880 ARTICLE IN PRESS P.W. Marksberr
Page 5 and 6: 882 ARTICLE IN PRESS P.W. Marksberr
Page 7: 884 ARTICLE IN PRESS P.W. Marksberr

A comprehensive tool-wear/tool-life performance model in the ...

Create successful ePaper yourself

Delete template?

Save as template?