Effect of nozzles on cutting performance when machining with oil-on-water cooling technique
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ORIGINAL ARTICLE
Effect of nozzles on cutting performance when machining with oil-on-water cooling technique Kai Yao 1 & Chengyong Wang 2 & Feng Ding 2 & Jianbo Sui 2 & Suyang Li 2 Received: 9 April 2020 / Accepted: 9 November 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Previous studies identified the oil-on-water (OoW) cooling technique as an effective method to improve the cutting performance when machining compacted graphite iron. The effects of nozzle type, outlet distance, and air pressure were identified by comparing droplet diameters and cutting performances. The results showed that smaller droplets achieved a better penetration ability. In the horizontal and vertical directions, the diameter of OoW droplets increased with increasing distance from the nozzle outlet position. With increasing air pressure, the droplet diameter decreased. At an air pressure of 0.35 MPa, the diameter of OoW droplets of nozzle II decreased by 12%, 34%, and 30% compared with droplets of nozzles I, III, and IV, respectively. Of the four different nozzles, nozzle II had the smallest droplets. Under the spray-to-rake and flank faces external OoW condition, the cutting temperature of nozzle II decreased by 9%, 33%, and 27% compared with those of nozzles I, III, and IV, respectively. The surface roughness of nozzle II decreased by 20%, 27%, and 24% compared with those of nozzles I, III, and IV, respectively. The flank wear width of nozzle II decreased by 2.7%, 13.6%, and 1.4% compared with those of nozzles I, III, and IV, respectively. Moreover, nozzle II showed minimal adhesive wear, abrasive wear, and coating peeling on both rake face and flank face. Therefore, nozzle II had better cooling and lubricating abilities and achieved the best cutting performance. Keywords Compacted graphite iron . Cutting performance . Oil-on-water . Nozzle
1 Introduction Compacted graphite iron (CGI) offers excellent anti-fatigue strength, tensile strength, and wear resistance and is the key material for lightweight and energy-efficient manufacturing of automobiles [1]. However, it is considered to be a difficult-tocut material. Compared with gray iron, CGI has a higher cutting strength and cannot form a MnS lubrication layer to improve the cutting performance of the tool [2]. This leads to a series of issues, such as large cutting force, high cutting temperature, severe abrasive wear, and chip adhesion [3, 4]. Cutting fluid is a conventional cooling method, to improve the machinability of the material and to get good surface
* Chengyong Wang [email protected] 1
College of Mechanical Engineering, Guangxi University, Nanning 530004, China
2
College of Mechanical and Electrical Engineering, Guangdong University of Technology, Guangzhou 510006, China
roughness [5, 6]. However, in high-speed machining, the poor penetration of cutting fluid makes its cooling efficiency significantly reduced. Furthermore, the use of cutting fluid causes environmental pollution, endangers the health of workers, and increases production cost
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