Sugihara, T and Nomura, T and Enomoto, T and Udupa, A and Viswanathan, K and Mann, J (2022) Exploring the role of mechanochemical effects in cutting of aluminum alloys with alcohols. In: ASME 2022 17th International Manufacturing Science and Engineering Conference, MSEC 2022, 27 June - 1 July 2022, West Lafayette.
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In metal cutting processes, a chemical ambient environment in the cutting zone can be a useful variable for process control and process performance improvement. In this work, we study how mechanochemical effects influence the chip formation process, especially focusing on a specific chemical reaction between aluminum alloys and alcohols as a model system. Using high speed in-situ imaging and particle image velocimetry, we demonstrate that the mechanochemical effect in cutting of annealed Al with use of isopropyl alcohol (IPA) is manifest in two different ways: a lubricating effect at the tool-chip interface and an embrittlement effect at the workpiece free-surface, depending on the undeformed chip thickness and cutting speed. Consequently, the highly unsteady chip flow seen in dry cutting of annealed Al, which is typically seen in cutting of ductile gummy metals, transitions to a laminar-type (smooth) chipflow mode or a segmented, fracture-controlled chip flow, due to the Al-IPA reaction. In both cases, the modified chip flow modes lead to significant reduction in cutting forces and improvement of finished surface quality. The specific manifestation of the mechanochemical effect is found to be principally determined by the penetration capability of the alcohols into the tool-chip interface and the time required for the chemical reaction between aluminum and the alcohols. Also, we discuss some implications for improving the performance of practical Al cutting operations using alcohols as a fluid medium.
| Item Type: | Conference Paper |
|---|---|
| Publication: | Proceedings of ASME 2022 17th International Manufacturing Science and Engineering Conference, MSEC 2022 |
| Publisher: | American Society of Mechanical Engineers |
| Additional Information: | The copyright for this article belongs to American Society of Mechanical Engineers. |
| Keywords: | Aluminum alloys; Chemical reactions; Metal cutting; Process control; Velocity measurement, Ambient environment; Chip flow; Chip formations; Cutting zone; Formation process; Mechanochemical effects; Metal cutting process; Process control performance; Process performance; Tool/chip interface, Tribology |
| Department/Centre: | Division of Mechanical Sciences > Mechanical Engineering |
| Date Deposited: | 18 Nov 2022 05:30 |
| Last Modified: | 18 Nov 2022 05:30 |
| URI: | https://eprints.iisc.ac.in/id/eprint/77907 |
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