Conventional machining

1. Experimental investigation of micro-pillar textured WC inserts during turning of Ti6Al4V under various cutting fluid strategies

A comparative study is made for tool wear, forces, surface roughness, and chip morphology using textured and plain tools.
Turning is performed under four strategies, namely, dry, compressed air, minimum quantity lubrication, and wet.
Reduced tool-chip contact area due to tighter chip curling, and better heat dissipation due to enhanced CF penetration using the textured tool are observed.

2. Novel texture pattern on WC inserts fabricated using reverse-μEDM for enhanced cutting of Ti6Al4V

Textured rake and flank surfaces of a cutting tool exhibit promising results in machining performances.
This work proposes a novel texture pattern to mitigate the disadvantages of the existing textures.
Experiments are performed to check the fabrication feasibility of the proposed pattern on the rake face of Tungsten Carbide (WC) inserts using Reverse-micro Electrical Discharge Machining (R-μEDM) process.
In order to investigate the advantage of the proposed pattern, orthogonal machining of Titanium alloy is conducted. A significant reduction of 25.77% is obtained in the measured temperature and 11.1% in the friction coefficient compared to the plain insert.

3. Sustainable approach for machining of Ti6Al4V using micro-pillar textured turning tool insert

The use of cutting fluids (CF) in metal cutting is questioned due to environmental and biological impacts, encouraging the adoption of dry machining to minimize these effects.
This study explored the impact of an innovative micro-pillar texture pattern fabricated using a combination of Laser Beam Micro Machining (LBμM) and Reverse Micro Electrical Discharge Machining (RμEDM) for the dry machining of Ti6Al4V.
The investigation considers various parameters, including tool wear, contact length, titanium adhesion, cutting forces, cutting temperature, and chip morphology .

Fabrication of novel micro-pillar textures on tungsten carbide inserts using RμEDM
Machining under dry, compressed air, minimum quantity lubrication, and wet conditions.
Investigation of forces, surface roughness, tool wear, and chip morphology is performed.
Enhanced machinability of SLM Ti6Al4V due to micro-texturing of the rake face.
Reduced tool-chip contact and enhanced CF penetration are witnessed in textured tools.

- Novel combination of eco-friendly cooling and lubrication techniques i.e., MQL, LCO2 and ultrasonic vibration is used for machining Ti-6Al-4V.
- Tool wear, power consumption, surface roughness and specific cutting energy are compared under dry, wet MQL and LCO2.
- Comparative performance of Ti-6Al-4V is analysed in ultrasonic assisted and conventional turning.
- The LCO2 considerably reduces the tool wear, specific cutting energy without compromising the surface quality.
- The LCO2 along with ultrasonic assisted turning is attained the sustainability in machining Ti-6Al-4V.

This paper deals with the concerns of industrial demand for enhancing the machinability of Inconel 718.
In this regard, sustainable cooling strategies, i.e., minimum quantity lubrication (MQL), electrostatic minimum quantity lubrication (EMQL), and liquid carbon dioxide (LCO2), in combination with ultrasonic-assisted turning, are used to reduce the tool wear in the machining of Inconel 718.
Six different combinations of cooling strategies are used to perform the experiments. These cooling strategies are LCO2 +MQL (in this case LCO2 is used on the rake face and MQL on the flank face of the tooling), MQL+LCO2, EMQL+LCO2, LCO2+EMQL, EMQL+MQL, and MQL+EMQL.

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