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22. Comparison of dry and liquid carbon dioxide cutting conditions based on machining performance and life cycle assessment for end milling GFRP

Author

Ingeniería mecánica, Ingeniaritza mekanikoa, Khanna, Navneet, Rodríguez Ezquerro, Adrián, Shah, Prassan, Pereira Neto, Octavio Manuel, Rubio Mateos, Antonio, López de Lacalle Marcaide, Luis Norberto, Ostra Beldarrain, Txomin, Ingeniería mecánica, Ingeniaritza mekanikoa, Khanna, Navneet, Rodríguez Ezquerro, Adrián, Shah, Prassan, Pereira Neto, Octavio Manuel, Rubio Mateos, Antonio, López de Lacalle Marcaide, Luis Norberto, and Ostra Beldarrain, Txomin

Abstract

In the present scenario, citizens' concern about environment preservation creates a necessity to mature more ecological and energy-efficient manufacturing processes and materials. The usage of glass fiber reinforced polymer (GFRP) is one of the emerging materials to replace the traditional metallic alloys in the automotive and aircraft industries. However, it has been comprehended to arise a sustainable substitute to conventional emulsion-based coolants in machining processes for dropping the destructive effects on the ecosystem without degrading the machining performance. So, in this study, the comparison of the two sustainable cutting fluid approaches, i.e., dry and LCO2, has been presented based on machining performance indicators like temperature, modulus of cutting force, tool wear, surface roughness, power consumption, and life cycle assessment (LCA) analysis for end milling of GFRP. The cutting condition of LCO2 has been found to be superior in terms of machining performance by providing 80% of lower cutting zone temperature, tool wear, 5% lower modulus of cutting force, and reduced surface roughness with 9% lower power consumption that has been observed in the case of LCO2 in comparison with dry machining. However, to compress the CO2 for converting in liquid form, a higher amount of energy and natural resources is consumed resulting in a higher impact on the environment in comparison with dry machining. Considering the 18 impact categories of ReCiPe midpoint (H) 2016, 95% higher values of impacts have been observed in the case of LCO2 in comparison with dry machining.

Published
2022

25. Comparison of LN2and LCO2based on machining performance indicators for drilling Inconel 718

Author

Shah, Prassan, Khanna, Navneet, Arora, Amit, and Srivastava, Nishkarsh

Abstract

In the present scenario, global concern about the preservation of environment creates a necessity to mature more ecological manufacturing processes. In this context, cryogenic coolants i.e., liquid nitrogen (LN2) and liquid carbon dioxide (LCO2) are proved to be the prominent alternatives to conventional carbon-based flood coolant pollutants. However, the comparison of these cryogenic coolants based on machining performance is still lacking to cut the materials having low machinability like Inconel 718 at various cutting speeds (vc). In this context, thrust force, tool wear, and hole quality indicators using field emission scanning electron microscopy (FE-SEM) and Energy Dispersive X-ray Spectroscopy (EDS) analysis, microhardness, chip morphology for drilling Inconel 718 utilizing cryogenic fluids i.e., LCO2and LN2are extensively explored. Holes are drilled at three values of vcfor both cooling conditions. By analyzing the mean of thrust force, 14 %, 9 %, and 31 % reduced values of it have been observed for LCO2as compared to LN2when the same quantity of holes are considered for vcas 10, 15, and 20 m/min correspondingly. Both cryogenic coolants reveal abrasion and chipping wear mechanisms on tools as significant at all vc. However, a higher worn region on the rake and flank face of drills was found for LN2. A superior machining performance was observed for LCO2in comparison with LN2at all vc. The superiority of LCO2over LN2makes it suitable for high-value machining industries.

Published
2022
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29. Energy Consumption and Lifecycle Assessment Comparison of Cutting Fluids for Drilling Titanium Alloy.

Author

Khanna, Navneet, Shah, Prassan, Wadhwa, Jwalant, Pitroda, Anjali, Schoop, Julius, and Pusavec, Franci

Abstract

This study analyzes four cutting conditions (dry, flood, Liquid CO 2 (LCO 2), and Liquid N 2 (LN 2)) based on energy consumption and ecological impacts for drilling VT-20, a Titanium alloy. The lower cutting and total energy have been consumed for LCO 2 as compared to others. The Life Cycle Assessment (LCA) analysis has been performed using ReCiPe 2016 midpoint (H) to identify the impact of cutting conditions on ecosystem, human health, and natural resources. Cryogenic environment with LN 2 has been found as the most ecological cutting condition next to dry machining, while flood coolant has 94-99% of total impact considering all cutting conditions. [ABSTRACT FROM AUTHOR]

Published
2020
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