Sustainable Manufacturing

and Cutting Techniques

 Contents

• Objectives of Sustainable Manufacturing

• Conventional Machining Methods
• What is the requirement of environmental friendly coolants
• Cutting Parameters, Properties
• Cooling Techniques
• Improved machining performance with Nanoparticle Enriched Cutting Fluids under (MQL) Technique
• Effects of Minimum Quantity Lubrication (MQL) with Conventional and Nanofluid coolants
• Influence of cutting fluids and cutting parameters on surface roughness
• Chip Morphology
• Coated and Uncoated Carbides
Objectives of Sustainable Manufacturing
• Energy consumption reduction
• Waste elimination/reduction.
• Product durability improvement.
• Health hazards and toxic dispersion elimination.
• Higher quality of manufacturing.
• Recycling, reuse, and remanufacturing enhancement.
• Development of renewable energy resources.

Levels of Sustainable Manufacturing

Evolutions of Sustainable Manufacturing

Implementation Steps
Sustainable Manufacturing vs Cutting Process

Sustainable Manufacturing Cutting Process

 Conventional Machining Methods
• In these "traditional" or "conventional" machining processes, machine tools, such as lathes, milling
machines, drill presses, or others, are used with a sharp cutting tool to remove material to achieve a desired
geometry.

 There are many kinds of machining operations, each of which is capable of generating a certain part geometry
and surface texture.
• Turning, a cutting tool with a single cutting edge is used to remove material from a rotating workpiece to
generate a cylindrical shape. The primary motion is provided by rotating the workpiece, and the feed
motion is achieved by moving the cutting tool slowly in a direction parallel to the axis of rotation of the
workpiece.
• Drilling is used to create a round hole. It is accomplished by a rotating tool that typically has two or four
helical cutting edges. The tool is fed in a direction parallel to its axis of rotation into the workpiece to form
the round hole.
• Boring, a tool with a single bent pointed tip is advanced into a roughly made hole in a spinning workpiece
to slightly enlarge the hole and improve its accuracy. It is a fine finishing operation used in the final stages
of product manufacture.
• Reaming is one of the sizing operations that removes a small amount of metal from a hole already drilled.
• Other conventional machining operations include milling, shaping, planing, broaching and sawing. Also,
grinding and similar abrasive operations are often included within the category of machining.
• In milling, a rotating tool with multiple cutting edges is moved slowly relative to the material to generate a
plane or straight surface. The direction of the feed motion is perpendicular to the tool's axis of rotation. The
speed motion is provided by the rotating milling cutter. The two basic forms of milling are:
a)Peripheral milling
b)Face milling
• Other conventional machining operations include shaping, planing, broaching and sawing. Also, grinding and
similar abrasive operations are often included within the category of machining.

 Cutting Parameters
• Cutting velocity (Vc)
• Feed rate (s)
• Depth of cut (t)
 Parameters that measures Efficiency in Machining
• Tool wear/tool Life
• Cutting forces
• Cutting Temperatures
• Surface Roughness
• Chip morphology
Typical End User Machining Cost
• Material Removal rate
• Type of material
 What is the requirement of environmental friendly coolants

 Cutting fluids have been the conventional choice to deal with the generated heat during machining.
 Owing to environmental concerns and growing regulations over contamination and pollution, the demand for
renewable and biodegradable cutting fluids is rising.
 Consequently, during cutting, the coolants and lubricants have to fulfil the following tasks:
Diminish tool wear (longer tool life)
Produce workpieces of accurate size (reduce thermal expansion)
Achieve proper surface quality of the workpieces
Support chip removal
Reduce thermal stress on machine tool
Reduction in Cutting Forces
Reduction in cutting tool Temperature
Material Removal Rate
Applications of Coolants :
Type of oil Appearance Use Dilution
Neat/straight oils Oily, waterless Heavy-duty material, corrosion inhibition Not required
Soluble/emulsifiable oils Milky colour, aqueous Coolant and lubrication, corrosion inhibition Yes, 2-
3% Semi-synthetic oils, soluble Translucent Coolant and less lubrication than for aqueous oils Yes, 1-
3% Synthetic oils Transparent aqueous Excellent coolant, minimal lubrication Yes, 1-
5%
 Cutting fluids/Lubricants Classification

Application of cutting fluids

Classification of Cutting Fluids

Classification of Lubrication Types Advantages and disadvantages of cutting fluid type

An ideal coolant has high thermal capacity, low viscosity, is low-cost, non-toxic, chemically inert and neither causes nor promotes 
corrosion of the cooling system. Some applications also require the coolant to be an electrical insulator.
 Some of key functions of the cutting fluids are as follows:
• To reduce the temperature of the cutting tool so that the mechanical strength and the chemical integrity is retained
• To keep the temperature of the workpiece low to prevent thermal expansion/damage and corrosion
• To reduce energy consumption and tool wear by reducing friction at the tool-chip and toolworkpiece interfaces
• Reduction of built-up edge in the tool and enhancement of tool life
• To improve the finish and surface/subsurface integrity of the machined surface
• To provide assistance in chip formation and flow
• Help in chip removal, especially, from narrow or deep machining, e.g., deep drilling, milling, etc.
• To provide a corrosion-resistant layer on the freshly cut metal surface to prevent oxidation
• To provide lubrication to the machine parts near the machining area
• Improves the accuracy of machining
• Reduces the tool-chip contact length
 There are certain properties that the cutting fluids must possess for proper functionality.
High heat absorption capacity to remove the heat from the tool and the workpiece at a satisfactory rate.
• It should have good lubrication properties. The fluid film should be able to sustain high pressures present at the tool-chip and tool-
workpiece interfaces.
• The coolant should have a high flash point, i.e., it should be nonflammable.
• The cutting fluid should not have solid precipitates at normal working temperatures.
• High-temperature stability is required to prevent the oxidation of the coolant and sticky deposits on the machine of workpiece parts.
• The components of the cutting fluid should not easily become rancid and no unpleasant odor should emanate when heated or used.
• It should not be either toxic or prone to contamination and have a long useful life. • It should be environment friendly to dispose and
should be capable of being recycled.
• A cutting fluid should be inert so that it does not react with the tool, workpiece, or machine parts
 Cooling Techniques
 Many industries started to emphasize a cleaner production on their machining process features and product
life cycle. And the environmental friendly techniques are -
 High Pressure Cooling
• HPC is to inject a high pressure jet of emulsion in the cutting zone.
The lathe should be fitted with high pressure equipment. This
involves a high pressure pump, high pressure tubing, and an outlet
nozzle fixed beside a tool holder. The pump is supplied with filtered
water or emulsion.

• The jet can be applied in two ways:

1)With an external nozzle: The jet is injected directly in between
the rake face and the chip or can be directed to the gap between the
flank face and the workpiece.
2)Through internal channels: The fluid is injected through the tool
using small holes in the insert.
• The supply of high pressure jet between the rake face and the chip decreases the length of their contact. On
the other hand, the cutting zone can be reached by injecting the coolant below the flank face of the tool. The
following procedure is the most efficient in reducing the temperature in the cutting zone, but has no influence
on chip breakability.
  Cryogenic Cooling
• Cryogenic machining is a relatively new technique in
reducing machining temperature by replacing the
conventional cutting fluid with extremely cold or sub-
zero (below −150 ◦C) cutting fluid at the machining
interface.

• Nitrogen (N2), carbon dioxide (CO2), oxygen (O2),

helium (He), etc., in compressed forms, are the potential
liquid cryogens to be used.

• These gases are exist in the atmosphere and can be converted to a liquid form. These liquid cryogens evaporate
in room temperature and convert to gas again. Nevertheless, only liquid carbon dioxide (LCO2) and liquid
nitrogen (LN2) are commonly used in cryogenic machining studies.

• Cryogenic machining with liquid nitrogen LN2 reduces cutting forces and improved tool life and surface finish
of the machined parts. However, the usage of cryogenic technology in early days was limited by the high cost.
 Flood cooling
• In the flood cooling method, conventional soluble oil is made to flood over the cutting area, in order to
remove the heat generated in the cutting zone. The cutting fluid helps to improve the surface finish as well as
to facilitate chip flushing.

• The major disadvantage of this method is that the coolant will never be allowed to penetrate properly into the
actual chip-tool contact area, due to the high speed of the chip flowing at high cutting speeds. Moreover, the
wastage of the coolant oil will be large as it is made to flood. The conventional emulsion (or) flood cooling.

• Several environmentally conscious cooling and

lubrication technologies during machining
processes have been presented such as dry cutting,
minimum quantity lubrication (MQL).

• It is a typical cooling strategy used in industry to

reduce the high temperature generated during
machining. The use of flood coolant raised
environmental and health concerns which call for
different alternatives.
 Improved machining performance with Nanoparticle Enriched Cutting
Fluids under (MQL) Technique

• In MQL/NDM technique, a very small amount of lubricant/

coolant is mixed with air to form aerosol, which is sprayed at a
high pressure in the cutting zone with the help of a nozzle.

• MQL technology is close to dry cutting technique, which is

between dry and wet machining. Its principle is to mix a small
quantity of cutting fluid with compressed air and access the
contact zone between tool and chip.

• Nanofluids are colloidal mixtures of nanometer-sized particles (1-100 nm) in a base fluid. The mixing of nano
particles with base fluid may alter the thermo-physical properties of fluids as the nanoparticles possess higher
thermal conductivity than base fluids.

• Apart from the cost aspects, cutting fluids pose a serious problem to the preservation of the environment and to
human health. Therefore, Minimum Quantity Lubrication (MQL) may represent a compromise between the
advantages and disadvantages of completely dry cutting and cutting with abundant soluble oil.
• The machining of hardened steel is almost done using dry
cutting, because the increase of the temperature makes chip
deformation and shearing of the hardened material, easier.
The use of abundant cutting fluid (wet condition) has the
advantages of providing chip transportation, reducing
friction and cooling the workpiece.

• Addition of graphite nanoparticles improves the lubricating

property of conventional lubricants due to reduction in the
friction coefficient. Because of their low friction behavior,
the graphite and MoS2 solid lubricants may contribute in the
reduction of cutting force and reduce the surface roughness
in machining.

• Also, the addition of nanoparticles into base fluid can

enhance their convective heat transfer coefficient, lubricating
properties, wettability. On the other hand, it can reduce tool
wear, surface roughness, cutting force and chip thickness
compared with dry machining and conventional fluid
machining.
 Nano lubricant is a novel type of engineering system consisting of nano-sized particles dispersed
in base oil. Physical analysis of nano-lubricants shows that dispersed nanoparticles can easily
penetrate into the rubbing surfaces and have a great elasto-hydrodynamic lubrication effect.
 Therefore, due to the high performance of Nano based lubricants productivity in the machining
industry could be increased through cost reduction by abandoning cutting fluid, saving the
environment and at the same time machining performance would be improved.
 With the help of additives, the cutting fluids should have the following additional qualities:
Physiological harmlessness for the operating personnel, Environmental compatibility and
biodegradability, Corrosion protection of workpiece and machine, Formation of the lubricant film,
Ability to be flooded and wetted (reducing the liquid’s surface tension), Resistance to
microorganisms, Resistance to paints and varnishes, Filterability.
 Nanofluid as coolant for machining processes

• The addition of metallic nanoparticles into conventional cutting fluid enhances its thermal conductivity
significantly. Being expansive, the nanofluid is not advisable to use as cutting fluid in wet machining.
However, its application with MQL technique makes it as a viable alternative to the wet machining.

• The role of nanoparticles in nano oil lubrication on machining performance parameters in various
machining processes, such as, turning, grinding, milling, drilling etc. using MQL technique.

• Role of nanoparticles in nanofluid machining : Reduction in friction and an increment in load bearing
capacity of friction parts by adding nanoparticles into conventional fluid. The nanofluid exhibits better
tribological and thermophysical properties relative to its base fluid and reduced the cutting forces,
surface roughness, cutting zone temperature and tool wear.

• An increase of nanoparticle volume concentration increases thermal conductivity, viscosity and density
of fluid, which, in turn, increases the heat extraction capability of cutting fluid and reduces the cutting
zone temperature.
 Effects of Minimum Quantity Lubrication (MQL)

• Misuse of the cutting fluid and wrong methods of its disposal can affect human health and the
environment badly. Also, it accounts for 16-20% of the total cost of manufacturing in the production
industry. Among various techniques available on application of the coolant, Near Dry Machining (NDM)
or Minimum Quantity Lubrication (MQL) as it minimizes the use of coolant by spraying the mixture of
compressed air and cutting fluid in an optimized manner instead of flood cooling.

a) MQL using Conventional cutting fluids :

• For turning process MQL produces the best surface finish over a wide range of machining time as
compared to the wet and dry turning. MQL plays a vital role in reducing the dimensional deviation of
a finished job due to removal of heat to a large extent and reduction of temperature.
• In drilling process MQL uses coolant with high water content and low viscosity has a beneficial effect
in deep-hole drilling as the coolant of lower viscosity can reach the cutting zone easily as compared to
highly viscous coolant.
• In grinding process, MQL was more effective for grinding hardened steel as compared to soft steel in
terms of surface roughness and grinding forces. The MQL grinding could be used in higher metal
removal rates with enhanced surface finish and lower grinding forces.
 • In milling process, MQL improves the tool life and reduces flank wear by about 60%
compared to dry milling under all machining conditions and also alleviated the burr
formation. MQL generated a surface roughness less than 0.2 mm and did not change
much with the variation of feeds and cutting speed. MQL has the better cutting life for all
the cutting speeds.

b) MQL using Nano cutting fluids :

• In turning process the use of MQL improves the cutting fluid's performance in comparison with
conventional flood machining by reducing the surface roughness by 30%, cutting forces 54%, cutting
temperature 25% and tool wear 71%. It also improves chip morphology. The dispersion of silver nano
particle enriched the cutting fluid and the cutting forces were reduced up to 8.8% and surface
roughness up to 7.5% by the use of nanofluid.
• In milling process, the effect of nano cutting fluid during MQL have better result for the chipping, at
the cutting edge and central wear ,a reduced power and lubricant consumption by using SiO2 based
nanofluid during milling performed on a vertical milling machine.
• In grinding process, the mechanism of nanofluid impingement in MQL effects on specific energy,
surface temperature, wheel wear and force ratio and found that the use of nanofluid reduced the
abrasive wheel wear to 48-55% and force ratio and specific energy to 45-50%. A CNT based nano
cutting fluid reduced micro-cracks on machined surface and also generated better surface finish as
compared to grinding with conventional cutting fluid.
The best nano particles added to base fluids
Oxide ceramics- Al2O3,CuO
Metal carbides –SiC
Nitrides-AlN, SiN
Metals – Al, Cu
Nonmetals – Graphite, carbon nanotubes
Layered – Al+Al2O3, +C
Functionalized nanoparticles
cBN(cubic boron nitride)
 Chip Morphology

• The chip morphology examination was carried out to provide details

about the effects of dispersed MWCNTs/Al2O3 nanoparticles on chip–
tool interface temperature.

• For tests performed without nano-additives, the continuous helical chips

were generated as the material becomes much softer compared to the
cutting tool material due to the high generated temperature in the
cutting shear zone.

• Al2O3 nanofluid provides larger chip helix angles (θ) without nano-
additives. It is attributed to forming a hydrodynamic layer between
generated temperature and pressure at the tool tip. On the other hand,
no built-up edge chips were observed when either using MWCNTs or
Al2O3 nano-fluids as they offer promising cooling and lubrication
properties.
 Coated and Uncoated Carbides
• Coated cemented carbide currently represents 80-90% of all cutting tool inserts. Its success as a cutting tool
material is due to its unique combination of wear resistance and toughness, and its ability to be formed into
complex shapes.
• Coated cemented carbide combines cemented carbide with a coating. Together they form a grade which is
customized for its application.
• ​Coated cemented carbide grades are the first choice for a wide variety of tools and applications.
• CVD stands for Chemical Vapor Deposition. The CVD coating is generated by chemical reactions at temperatures
of 700-1050°C.
• CVD coatings have high wear resistance and excellent adhesion to cemented carbide.
• Uncoated cemented carbide grades represent a very small proportion of the total cutting tool assortment. These
grades are either straight WC/Co or have a high volume of cubic carbonitrides.

Applications :
Coated Carbides – They are the first choice in a wide range of applications where wear resistance is important. Such
applications are found in general turning and boring of steel, with crater wear resistance offered by the thick CVD
coatings, general turning of stainless steels and for milling grades in ISO P, ISO M, ISO K.

Uncoated Carbides - Typical applications of this cutting tool material are machining of HRSA (heat resistant super
alloys) or titanium alloys and turning hardened materials at low speed.The wear rate of uncoated cemented carbide
grades is rapid yet controlled, with a self-sharpening action.
 OBJECTIVE 23

To make an experimental Study for Effective Lubrication at

05, 2021
, August
Thursday
Research Plan Presentation
Machining area on CNC Lathe Machine
 Need for Research in the Proposed Area 24

• Link the sustainability aspects with real Manufacturing needs

05, 2021
, August
Thursday
Research Plan Presentation
Reduction of Toxic waste,
energy consumption reduction,
Better Quality environment
• Drop to Drop Lubrication System
• Reduction in Cost of lubrication thus how cost of Production
• High Surface Quality in Machining
• Less Heat Effected Zones-Increased Tool Life
 Literature 25

• It has been proved that flood cooling, though very effective at lower cutting speeds, gets

05, 2021
, August
Thursday
Research Plan Presentation
ineffective at higher speeds because the amount of heat generation is more and the
coolant cannot reach the critical areas (tool workpiece interface); hence the interface
cannot be cooled.
• Controlled flow and pressure through MQL
• Better surface finish can be attained by MQL approach
• Usage of vegetable oils with Nano materials instead of mineral or petroleum based
cutting fluids–reduces toxic waste
 Methodology 26

05, 2021
, August
Thursday
Research Plan Presentation
 To identify the Appropriate material for Machining(Ti alloy or Al alloy)
 To Assess the best way of Machining/Processing(Usage of low cost tool
inserts/uncoated carbon inserts)
 To set up the apparatus
 To Conduct an experimental analysis through MQL and optimizing various
parameters like material removal rate (MRR), temperature, forces
 Experimentation for Usage of Vegetable oils with Nano Particles
 27
Approach

gust 05, 2021

Thursday, Au
Research Plan Presentation
• Optimizing the Parameters like MRR, Temperature,
Forces through DOE Approach

• Interpretation of results through Response Surface Methodology

• Interpretation of results by Experimentation with

different tools on Aluminum alloy and Titanium alloy
 28
Facilities Required

gust 05, 2021

Thursday, Au
Research Plan Presentation
1.CNC Machine
2.MQL setup
3.Tool Inserts
4.MQL Material(Vegetable oils +Nano particles)
5.Dynamometer- force measurement
6.Thermo couples-Temperature measurement
 29

References

gust 05, 2021

Thursday, Au
Research Plan Presentation
1. Nanofluids as potential solution for Minimum Quantity Lubrication: A review
by R.R.Srikanth et al

2. Performance Evaluation and Economic Analysis of Minimum Quantity

Lubrication with Pressurized/Non-Pressurized Air and Nanofluid Mixture by
M.Amrita et al.

3. Review on Application of Minimum Quantity Lubrication (MQL) in Metal

Turning Operations Using Conventional and Nano-Lubricants Based Cutting
Fluids by Siddharth Jeet et al
 Research Plan Presentation
30

Thursday
, August
05, 2021
THANK YOU