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Advance cooling/lubrication (lubricooling) approaches are getting fame in industry and academia due to their excellent performance. A significant amount of work has been conducted to investigate the effect of various lubricooling approaches on the machinability of the hardened steel. However, sustainability-based performance evaluation of lubricooling assisted machining is missing. Thus, this paper presents 3E-based (Energy, Economics, Environment) analysis to compare the performance of various lubricooling approaches. Initially, preliminary experiments were performed to achieve optimal flow rates of various cutting fluids used in Minimum Quantity Lubrication (MQL), cryogenic cooling, and conventional emulsion (Flood) approaches. Later, optimal flow rates were used to achieve equal cutting-tool life under all machining environments. Results showed that with the same tool life method (STLM), Cryogenic-MQL(CryoMQL) could withstand aggressive cutting speeds and produce the highest productivity among all lubricooling approaches. In addition, it yielded 50% lower-priced specific production cost as compared to dry machining. However, 44.3% more specific-CO2 emitted in CryoMQL as compared with dry machining. In summary, the hybrid CryoMQL assisted machining process is sustainable economically but not environmentally. The outcomes of the present study provide useful information, and it can help machinist to enhance the process performance.
Aqib Mashood Khan; Mohammed Alkahtani; Shubham Sharma; Muhammad Jamil; Asif Iqbal; Ning He. Sustainability-based holistic assessment and determination of optimal resource consumption for energy-efficient machining of hardened steel. Journal of Cleaner Production 2021, 319, 128674 .
AMA StyleAqib Mashood Khan, Mohammed Alkahtani, Shubham Sharma, Muhammad Jamil, Asif Iqbal, Ning He. Sustainability-based holistic assessment and determination of optimal resource consumption for energy-efficient machining of hardened steel. Journal of Cleaner Production. 2021; 319 ():128674.
Chicago/Turabian StyleAqib Mashood Khan; Mohammed Alkahtani; Shubham Sharma; Muhammad Jamil; Asif Iqbal; Ning He. 2021. "Sustainability-based holistic assessment and determination of optimal resource consumption for energy-efficient machining of hardened steel." Journal of Cleaner Production 319, no. : 128674.
Distribution of temperature during the welding process is essential for predicting and realizing some important welding features such as microstructure of the welds, heat-affected zone (HAZ), residual stresses, and their effects. In this paper, a numerical model was developed using COMSOL Multiphysics of dissimilar laser welding (butt joint) of AISI 316L and Ti6Al4V thin sheet of 2.5 mm thickness. A continuous mode (CW) fiber laser heat source of 300 W laser power was used for the present study. A time-dependent prediction of temperature distributions was attempted. The heat source was assumed as a Hermit–Gaussian analytical function with a moving velocity of 120 mm/min. Both convective and radiant heat loss and phase change of the materials were considered for the analysis. In addition, variation of temperature-dependent material properties was also considered. The maximum and minimum temperature for the two materials at different times and the temperature in the different penetration depths were also predicted. It was found that the average temperature that can be achieved in the bottom-most surface near the weld line was more than 2400 K, which justifies the penetration. Averages of maximum temperatures on the weld line at different times at the laser spot irradiation were identified near 3000 K.The temperature fluctuation near the weld line was minimal and decreased more in the traverse direction. Scanning with a displaced laser relative to the interface toward the Ti6Al4V side reduces the maximum temperature at the interface and the HAZ of the 316L side. All of these predictions agree well with the experimental results reported in current literature studies.
Partha Ghosh; Abhishek Sen; Somnath Chattopadhyaya; Shubham Sharma; Jujhar Singh; Shashi Dwivedi; Ambuj Saxena; Aqib Khan; Danil Pimenov; Khaled Giasin. Prediction of Transient Temperature Distributions for Laser Welding of Dissimilar Metals. Applied Sciences 2021, 11, 5829 .
AMA StylePartha Ghosh, Abhishek Sen, Somnath Chattopadhyaya, Shubham Sharma, Jujhar Singh, Shashi Dwivedi, Ambuj Saxena, Aqib Khan, Danil Pimenov, Khaled Giasin. Prediction of Transient Temperature Distributions for Laser Welding of Dissimilar Metals. Applied Sciences. 2021; 11 (13):5829.
Chicago/Turabian StylePartha Ghosh; Abhishek Sen; Somnath Chattopadhyaya; Shubham Sharma; Jujhar Singh; Shashi Dwivedi; Ambuj Saxena; Aqib Khan; Danil Pimenov; Khaled Giasin. 2021. "Prediction of Transient Temperature Distributions for Laser Welding of Dissimilar Metals." Applied Sciences 11, no. 13: 5829.
Application of cryogenic fluids for efficient heat dissipation is gradually becoming part and parcel of titanium machining. Not much research is done to establish the minimum quantity of a cryogenic fluid required to sustain a machining process with respect to a given material removal rate. This article presents an experimental investigation for quantifying the sustainability of milling a commonly used titanium alloy (Ti–6Al–4V) by varying mass flow rates of two kinds of cryogenic coolants at various levels of cutting speed. The three cooling options tested are dry (no coolant), evaporative cryogenic coolant (liquid nitrogen), and throttle cryogenic coolant (compressed carbon dioxide gas). The milling sustainability is quantified in terms of the following metrics: tool damage, fluid cost, specific cutting energy, work surface roughness, and productivity. Dry milling carried out the at the highest level of cutting speed yielded the worst results regarding tool damage and surface roughness. Likewise, the evaporative coolant applied with the highest flow rate and at the lowest cutting speed was the worst performer with respect to energy consumption. From a holistic perspective, the throttle cryogenic coolant applied at the highest levels of mass flow rate and cutting speed stood out to be the most sustainable option.
Asif Iqbal; Guolong Zhao; Hazwani Suhaimi; Malik Nauman; Ning He; Juliana Zaini; Wei Zhao. On Coolant Flow Rate-Cutting Speed Trade-Off for Sustainability in Cryogenic Milling of Ti–6Al–4V. Materials 2021, 14, 3429 .
AMA StyleAsif Iqbal, Guolong Zhao, Hazwani Suhaimi, Malik Nauman, Ning He, Juliana Zaini, Wei Zhao. On Coolant Flow Rate-Cutting Speed Trade-Off for Sustainability in Cryogenic Milling of Ti–6Al–4V. Materials. 2021; 14 (12):3429.
Chicago/Turabian StyleAsif Iqbal; Guolong Zhao; Hazwani Suhaimi; Malik Nauman; Ning He; Juliana Zaini; Wei Zhao. 2021. "On Coolant Flow Rate-Cutting Speed Trade-Off for Sustainability in Cryogenic Milling of Ti–6Al–4V." Materials 14, no. 12: 3429.
Titanium, being a structural material, undergoes drilling process frequently for its engineering applications. The superior mechanical properties of titanium alloys make hole-making a highly unsustainable process. The process is marred by high cutting forces, intense tool damage, high energy consumption, poor hole quality, and high process cost. The work presents an approach for viable and cleaner drilling of the difficult-to-cut material by investigating the effects of micro-lubrication and the following two options of cryogenic cooling: (1) evaporative cooling using liquid nitrogen and (2) throttle cooling using compressed carbon dioxide gas. Additionally, the effects of cutting speed and pecking – a technique actualized by rapidly retracting the twist drill by 2 mm at two levels of depth during thru-cutting of the holes – are also quantified. Pecking is not found to be favorable to any of the evaluated sustainability measures. Of the three cutting fluids testes, throttle cryogenic cooling yielded the most advantageous results. The coolant, because of its effective heat dissipation capability, yielded superior outcomes with respect to all the sustainability measures except surface quality. Micro-lubrication proved to be beneficial, at the low level of cutting speed, to specific cutting energy, surface quality, and process cost. Evaporative cryogenic cooling did not yield promising results. The runs employing evaporative coolant or the high level of cutting speed experienced thicker tool adhesions whereas those utilizing pecking showed signs of intense progressive wear. Moreover, the thrust force data indicated occurrence of thermal softening of the work material as the drills progressed through the hole-cutting process. From the holistic perspective of sustainability, it is recommended to adopt throttle cryogenic cooling, a medium-to-high level of cutting speed, and no-pecking for hole-making in the titanium alloy.
Asif Iqbal; Guolong Zhao; Juliana Zaini; Ning He; Malik M. Nauman; Muhammad Jamil; Hazwani Suhaimi. Sustainable hole-making in a titanium alloy using throttle and evaporative cryogenic cooling and micro-lubrication. Journal of Manufacturing Processes 2021, 67, 212 -225.
AMA StyleAsif Iqbal, Guolong Zhao, Juliana Zaini, Ning He, Malik M. Nauman, Muhammad Jamil, Hazwani Suhaimi. Sustainable hole-making in a titanium alloy using throttle and evaporative cryogenic cooling and micro-lubrication. Journal of Manufacturing Processes. 2021; 67 ():212-225.
Chicago/Turabian StyleAsif Iqbal; Guolong Zhao; Juliana Zaini; Ning He; Malik M. Nauman; Muhammad Jamil; Hazwani Suhaimi. 2021. "Sustainable hole-making in a titanium alloy using throttle and evaporative cryogenic cooling and micro-lubrication." Journal of Manufacturing Processes 67, no. : 212-225.
Hole-making in CFRP plates has been unsustainable due to poor hole quality, high specific energy consumption, a trade-off between shortened drill life and low productivity, and high processing cost. This experimental study investigates the effects of using throttle and evaporative cryogenic fluids, actualized by applying compressed carbon dioxide and liquid nitrogen, respectively, and micro-lubrication on hole quality (roughness, coaxiality, and circularity), production economy (tool damage and process cost), structural intactness (delamination and uncut fibers), energy consumption, and machining forces. Additionally, the effects of applying drill pecking and cutting speed are also quantified. Based on the experimental results, micro-lubrication is found to have outperformed dry drilling and the two cryogenic coolants regarding the measures associated with process viability, such as tool wear, process cost, energy consumption, and machining forces. Throttle cryogenic cooling, on the other hand, yielded the best results in respect of the work quality measures, which includes hole quality and structural intactness. Pecking yielded disappointing results regarding most of the measures, whereas the high level of cutting speed yielded favorable results in respect of specific cutting energy and process cost.
Asif Iqbal; Guolong Zhao; Juliana Zaini; Muhammad Jamil; Malik M. Nauman; Aqib M. Khan; Wei Zhao; Ning He; Hazwani Suhaimi. CFRP drilling under throttle and evaporative cryogenic cooling and micro-lubrication. Composite Structures 2021, 267, 113916 .
AMA StyleAsif Iqbal, Guolong Zhao, Juliana Zaini, Muhammad Jamil, Malik M. Nauman, Aqib M. Khan, Wei Zhao, Ning He, Hazwani Suhaimi. CFRP drilling under throttle and evaporative cryogenic cooling and micro-lubrication. Composite Structures. 2021; 267 ():113916.
Chicago/Turabian StyleAsif Iqbal; Guolong Zhao; Juliana Zaini; Muhammad Jamil; Malik M. Nauman; Aqib M. Khan; Wei Zhao; Ning He; Hazwani Suhaimi. 2021. "CFRP drilling under throttle and evaporative cryogenic cooling and micro-lubrication." Composite Structures 267, no. : 113916.
Air-leakage detection is among the most important processes at the assembly stage of unclosed components, especially for large aircraft. A series of air-leakage detecting methods are generally applied during the final assembly, nevertheless, many of them are less effective to detect the leakage at the assembly stage. The present study aims to discuss the principles of ultrasonic generation in negative pressure conditions to detect the air-leakage. An ultrasonic-based detection method is proposed and designed to detect the air-leakage of unclosed components for aircraft. A relationship between the acoustic power, sound pressure, and the leak aperture detection distance was identified and discussed. A leakage rate model related to leakage rate, leak aperture, and system pressure was implemented and confirmed through experiments. Findings have indicated that the air-leakage can be detected effectively within a detection distance of 0.8 m and a leak aperture greater or equal to 0.4 mm with this method. Besides, the leak location, leak aperture, and leakage rate was acquired in an accurate and fast way. It is an effective method of detecting the air-leakage of unclosed components at the aircraft assembly stage reducing the testing time, energy consumption, and cost for the air-leakage detection in the final assembly stage of large aircraft.
Yanlin Lyu; Muhammad Jamil; Pengfei Ma; Ning He; Munish Gupta; Aqib Khan; Danil Pimenov. An Ultrasonic-Based Detection of Air-Leakage for the Unclosed Components of Aircraft. Aerospace 2021, 8, 55 .
AMA StyleYanlin Lyu, Muhammad Jamil, Pengfei Ma, Ning He, Munish Gupta, Aqib Khan, Danil Pimenov. An Ultrasonic-Based Detection of Air-Leakage for the Unclosed Components of Aircraft. Aerospace. 2021; 8 (2):55.
Chicago/Turabian StyleYanlin Lyu; Muhammad Jamil; Pengfei Ma; Ning He; Munish Gupta; Aqib Khan; Danil Pimenov. 2021. "An Ultrasonic-Based Detection of Air-Leakage for the Unclosed Components of Aircraft." Aerospace 8, no. 2: 55.
The management of a controllable production in the manufacturing system is essential to achieve viable advantages, particularly during emergency conditions. Disasters, either man-made or natural, affect production and supply chains negatively with perilous effects. On the other hand, flexibility and resilience to manage the perpetuated risks in a manufacturing system are vital for achieving a controllable production rate. Still, these performances are strongly dependent on the multi-criteria decision making in the working environment with the policies launched during the crisis. Undoubtedly, health stability in a society generates ripple effects in the supply chain due to high demand fluctuation, likewise due to the Coronavirus disease-2019 (COVID-19) pandemic. Incorporation of dependent demand factors to manage the risk from uncertainty during this pandemic has been a challenge to achieve a viable profit for the supply chain partners. A non-linear supply chain management model is developed with a controllable production rate to provide an economic benefit to the manufacturing firm in terms of the optimized total cost of production and to deal with the different situations under variable demand. The costs in the model are set as fuzzy to cope up with the uncertain conditions created by lasting pandemic. A numerical experiment is performed by utilizing the data set of the multi-stage manufacturing firm. The optimal results provide support for the industrial managers based on the proactive plan by the optimal utilization of the resources and controllable production rate to cope with the emergencies in a pandemic.
Mohammed Alkahtani; Muhammad Omair; Qazi Salman Khalid; Ghulam Hussain; Imran Ahmad; Catalin Pruncu. A COVID-19 Supply Chain Management Strategy Based on Variable Production under Uncertain Environment Conditions. International Journal of Environmental Research and Public Health 2021, 18, 1662 .
AMA StyleMohammed Alkahtani, Muhammad Omair, Qazi Salman Khalid, Ghulam Hussain, Imran Ahmad, Catalin Pruncu. A COVID-19 Supply Chain Management Strategy Based on Variable Production under Uncertain Environment Conditions. International Journal of Environmental Research and Public Health. 2021; 18 (4):1662.
Chicago/Turabian StyleMohammed Alkahtani; Muhammad Omair; Qazi Salman Khalid; Ghulam Hussain; Imran Ahmad; Catalin Pruncu. 2021. "A COVID-19 Supply Chain Management Strategy Based on Variable Production under Uncertain Environment Conditions." International Journal of Environmental Research and Public Health 18, no. 4: 1662.
Lightweight materials are finding plentiful applications in various engineering sectors due to their high strength-to-weight ratios. Hole-making is an inevitable requirement for their structural applications, which is often marred by thermal damages of the drill causing unacceptable shortening of tool life. Efficient cooling of the tool is a prime requirement for enhancing the process viability. The current work presents a novel technique of cooling only the twist drill between drilling of holes with no effect of the applied cryogenic coolant transferred to the work material. The technique is applied in the drilling of two commonly used high-strength lightweight materials: carbon fibers reinforced polymer (CFRP) and an alloy of titanium (Ti-6Al-4V). The efficacy of the cooling approach is compared with those of conventionally applied continuous cryogenic cooling and no-cooling. The effectiveness is quantified in terms of tool wear, thrust force, hole quality, specific cutting energy, productivity, and consumption of the cryogenic fluid. The experimental work leads to a finding that between-the-holes cryogenic cooling possesses a rich potential in curbing tool wear, reducing thrust force and specific energy consumption, and improving hole quality in drilling of CFRP. Regarding the titanium alloy, it yields a much better surface finish and lesser consumption of specific cutting energy.
Asif Iqbal; Guolong Zhao; Juliana Zaini; Munish Gupta; Muhammad Jamil; Ning He; Malik Nauman; Tadeusz Mikolajczyk; Danil Pimenov. Between-the-Holes Cryogenic Cooling of the Tool in Hole-Making of Ti-6Al-4V and CFRP. Materials 2021, 14, 795 .
AMA StyleAsif Iqbal, Guolong Zhao, Juliana Zaini, Munish Gupta, Muhammad Jamil, Ning He, Malik Nauman, Tadeusz Mikolajczyk, Danil Pimenov. Between-the-Holes Cryogenic Cooling of the Tool in Hole-Making of Ti-6Al-4V and CFRP. Materials. 2021; 14 (4):795.
Chicago/Turabian StyleAsif Iqbal; Guolong Zhao; Juliana Zaini; Munish Gupta; Muhammad Jamil; Ning He; Malik Nauman; Tadeusz Mikolajczyk; Danil Pimenov. 2021. "Between-the-Holes Cryogenic Cooling of the Tool in Hole-Making of Ti-6Al-4V and CFRP." Materials 14, no. 4: 795.
The manufacturing industries consume one-third of global energy. Intensive use of electrical energy in industries provides the researchers and experts strong reasons to develop and propose strategies to minimize energy consumption. Evidently, the advanced technologies such as nanofluid minimum quantity lubrication in machining and process optimization accompanied by holistic models can eliminate the use of conventional fluids to reduce production cost and to cope up with environmental issues of global warming and climate change. This study investigates the holistic analysis of four metrics, i.e., surface quality, energy, cost, and carbon emission that influence the impact of the machining process on the environment of China. Al2O3 based nanofluid was prepared and used in the external turning of Haynes 25 alloys to improve the machining and to promote sustainability. Multi-objective optimization was performed to find out a trade-off relation for product quality, energy consumption and production cost. Results showed that the minimum levels of energy consumption and carbon emission were obtained at the high levels of feed rate and cutting speed. The Carbon Emission Factors (CEF) of used resources have the most significant effects on CO2 emissions. Furthermore, the feed rate was found to be the most significant parameter on the machining performance indices. The application of nanoparticles helped to reduce the cutting energy and CO2 emission, which are proportional to electricity consumption. A holistic component activity-based cost model was developed, and it was noted that the overhead and workpiece cost shared more than 95% of the total cost. Multi-objective optimization reduced specific energy by 18.10%, carbon emission by 22.17% and product cost by 16.25%. Moreover, the present study deals with 3E, i.e., Energy, Environment, and Economy. The optimum cutting parameters obtained from the concept of 3E at the machine shop level can significantly improve efficiency of nanofluid MQL assisted machining (NFMQL) process, reduce cost per unit of product, and achieve the low carbon manufacturing goal.
A.M. Khan; L. Liang; M. Mia; M.K. Gupta; Z. Wei; M. Jamil; H. Ning. Development of process performance simulator (PPS) and parametric optimization for sustainable machining considering carbon emission, cost and energy aspects. Renewable and Sustainable Energy Reviews 2021, 139, 110738 .
AMA StyleA.M. Khan, L. Liang, M. Mia, M.K. Gupta, Z. Wei, M. Jamil, H. Ning. Development of process performance simulator (PPS) and parametric optimization for sustainable machining considering carbon emission, cost and energy aspects. Renewable and Sustainable Energy Reviews. 2021; 139 ():110738.
Chicago/Turabian StyleA.M. Khan; L. Liang; M. Mia; M.K. Gupta; Z. Wei; M. Jamil; H. Ning. 2021. "Development of process performance simulator (PPS) and parametric optimization for sustainable machining considering carbon emission, cost and energy aspects." Renewable and Sustainable Energy Reviews 139, no. : 110738.
China’s manufacturing sector accounts for more than half of the country’s total energy demand, and specifically, metal processing is one of the manufacturing sectors that consume significant energy. However, reducing the electrical energy consumption of the machine tool, improving productivity, and ultimately increasing profit is a challenge while machining difficult-to-cut materials. To mitigate these challenges, advanced hybrid lubri-cooling machining is gaining attention in modern manufacturing. This paper aims to explore a holistic sustainability evaluation of advanced machining technologies specifically, the evaluation of a hybrid cryogenic-LN2 and minimum quantity lubrication (MQL) – named ‘CryoMQL’. In Addition, a comparison of CryoMQL with flood machining of Ti–6Al–4V has been performed. The machining power, specific cutting energy, specific electrical energy consumption, Cumulative Energy Demand (CED), carbon emission per part, energy cost, and production cost are considered the key sustainable performance measures. The research findings have shown that the CryoMQL approach is sustainable only when employed at high cutting conditions. Also, sustainable production of LN2 is inevitable to reduce the CED per part in CryoMQL assisted machining. In addition, the environmental cost considering Chinese manufactured products could be an effective way to reduce carbon emissions since it shares 10.9% of the total cost of the product. The present study is applicable to implement 3E (i.e., Energy, Environment, and Economy) concepts for the Chinese Manufacturing Industry.
Aqib Mashood Khan; Wei Zhao; Liang Li; Mohammed Alkahtani; Saqib Hasnain; Muhammad Jamil; Ning He. Assessment of cumulative energy demand, production cost, and CO2 emission from hybrid CryoMQL assisted machining. Journal of Cleaner Production 2021, 292, 125952 .
AMA StyleAqib Mashood Khan, Wei Zhao, Liang Li, Mohammed Alkahtani, Saqib Hasnain, Muhammad Jamil, Ning He. Assessment of cumulative energy demand, production cost, and CO2 emission from hybrid CryoMQL assisted machining. Journal of Cleaner Production. 2021; 292 ():125952.
Chicago/Turabian StyleAqib Mashood Khan; Wei Zhao; Liang Li; Mohammed Alkahtani; Saqib Hasnain; Muhammad Jamil; Ning He. 2021. "Assessment of cumulative energy demand, production cost, and CO2 emission from hybrid CryoMQL assisted machining." Journal of Cleaner Production 292, no. : 125952.
The quest for advanced cooling/lubrication approaches for energy-efficient, eco-benign, and cost-effective sustainable machining processes is garnering attention in academia and industry. Electrical and embodied energy consumption plays an important role in reducing CO2 emissions. In the present study, new empirical models are proposed to assess sustainable indicators. The embodied energy, environmental burden, and cost of coolant/lubricant have been added in the proposed models. Initially, optimal levels of minimum quantity lubrication (MQL) oil flow rate, liquid LN2 flow rate, air pressure, and nanoparticle concentration were found. Based on optimal technological parameters, experiments were performed under the same cutting conditions (machining parameters) for MQL and cryogenic LN2-assisted external turning of Ti6-Al-4V titanium alloy. The electric power and energy consumption, production time/cost, and CO2 emissions were assessed for a unit cutting-tool life. Later, specific responses were measured and compared between both cooling and lubrication approaches. Results showed that hybrid Al-GnP nanofluid consumed 80.6% less specific cumulative energy and emitted 88.7% less total CO2 emissions. However, cryogenic LN2 extended tool life by nearly 70% and incurred 4.12% less specific costs with 11.1% better surface quality. In summary, after Energy–Economy–Ecology–Engineering technology (4E)-based analysis, cryogenic LN2 is sustainable economically but not environmentally and there is a need to improve the sustainable production of LN2 at an industrial scale to achieve environmental sustainability. The present study provides useful information to establish clean machining processes.
Aqib Mashood Khan; Saqib Anwar; Muhammad Jamil; Mustafa M. Nasr; Munish Kumar Gupta; Mustafa Saleh; Shafiq Ahmad; Mozammel Mia. Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy. Metals 2021, 11, 88 .
AMA StyleAqib Mashood Khan, Saqib Anwar, Muhammad Jamil, Mustafa M. Nasr, Munish Kumar Gupta, Mustafa Saleh, Shafiq Ahmad, Mozammel Mia. Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy. Metals. 2021; 11 (1):88.
Chicago/Turabian StyleAqib Mashood Khan; Saqib Anwar; Muhammad Jamil; Mustafa M. Nasr; Munish Kumar Gupta; Mustafa Saleh; Shafiq Ahmad; Mozammel Mia. 2021. "Energy, Environmental, Economic, and Technological Analysis of Al-GnP Nanofluid- and Cryogenic LN2-Assisted Sustainable Machining of Ti-6Al-4V Alloy." Metals 11, no. 1: 88.
Owing to poor thermal conductivity, and high chemical reactivity of Ti-6Al-4V alloy at elevated temperatures, a lubri-cooling having superior heat transfer is benefic to apply to dissipate cutting heat and to improve the machinability. As conventional coolants are ineffective to prevent thermal damage and tool wear. Therefore, recent advanced cryogenic coolants such as cryogenic-liquid nitrogen (LN2) and carbon dioxide (CO2-snow) are hypothesized to mitigate the set objectives. In this experimental study, a static workpiece plate was sprayed to compare their heat transfer coefficients. Furthermore, the machining performance of cryogenic coolants was evaluated in the turning of Ti-6Al-4V in terms of tool wear, cutting force, surface roughness, and chip curl diameter. For this, experiments are conducted at a constant cutting speed of 120 m/min, a feed rate of 0.1 mm/rev, the coolant injection flow rate of 350~450g/min, and a depth of cut of 2.5 mm to clarify their effect on the process. The outcome analysis of this work showed the overall less tool wear, cutting forces, surface roughness, with maximum chip curl diameter under CO2-snow cooling followed by cryogenic-LN2 and dry condition. In summary, CO2-snow showed promising outcomes and a superior heat transfer effect warrant its implementation in the aerospace industry.
Muhammad Jamil; Ning He; Wei Zhao; Liang Li; Munish Kumar Gupta; Murat Sarikaya; Aqib Mashood Khan; Rupinder Singh. Heat Transfer Efficiency of Cryogenic-LN2 and CO2-snow and their application in the Turning of Ti-6AL-4V. International Journal of Heat and Mass Transfer 2020, 166, 120716 .
AMA StyleMuhammad Jamil, Ning He, Wei Zhao, Liang Li, Munish Kumar Gupta, Murat Sarikaya, Aqib Mashood Khan, Rupinder Singh. Heat Transfer Efficiency of Cryogenic-LN2 and CO2-snow and their application in the Turning of Ti-6AL-4V. International Journal of Heat and Mass Transfer. 2020; 166 ():120716.
Chicago/Turabian StyleMuhammad Jamil; Ning He; Wei Zhao; Liang Li; Munish Kumar Gupta; Murat Sarikaya; Aqib Mashood Khan; Rupinder Singh. 2020. "Heat Transfer Efficiency of Cryogenic-LN2 and CO2-snow and their application in the Turning of Ti-6AL-4V." International Journal of Heat and Mass Transfer 166, no. : 120716.
The urgent need for an innocuous and sustainable machining system is essential in this modern manufacturing era. Therefore, a study is devoted to fulfilling a missing bridge between sustainability measures (process time, specific cutting energy, energy efficiency, carbon emissions) and machining characteristics (tool wear, surface roughness, cutting temperature) in the milling of Ti-6Al-4V. The experiments are organized by implementing the minimum quantity lubrication (MQL), CO2-snow, and cryogenic-LN2 under varying end-mill geometries and cutting conditions. The results obtained have underscored the outperformed CO2-snow followed by cryogenic-LN2, MQL, and dry cutting conditions regarding sustainability measures and machining characteristics. The up-milling of 42o helix angle cutter and CO2-snow outperformed by reducing 47% of surface roughness, 50% extended tool life compared to dry cutting. The cryogenic-LN2 provided minimum cutting temperature flowed by CO2-snow, MQL, and dry cutting, respectively. Besides, the up-milling tool of the 42o helix angle provided better machining characteristics than the down-milling tool of the 30o helix angle. The feasibility of CO2-snow was comprehensively expressed and implemented in the milling process to extend the advanced analysis.
Muhammad Jamil; Wei Zhao; Ning He; Munish Kumar Gupta; Murat Sarikaya; Aqib Mashood Khan; Sanjay M. R; Suchart Siengchin; Danil Yu Pimenov. Sustainable milling of Ti–6Al–4V: A trade-off between energy efficiency, carbon emissions and machining characteristics under MQL and cryogenic environment. Journal of Cleaner Production 2020, 281, 125374 .
AMA StyleMuhammad Jamil, Wei Zhao, Ning He, Munish Kumar Gupta, Murat Sarikaya, Aqib Mashood Khan, Sanjay M. R, Suchart Siengchin, Danil Yu Pimenov. Sustainable milling of Ti–6Al–4V: A trade-off between energy efficiency, carbon emissions and machining characteristics under MQL and cryogenic environment. Journal of Cleaner Production. 2020; 281 ():125374.
Chicago/Turabian StyleMuhammad Jamil; Wei Zhao; Ning He; Munish Kumar Gupta; Murat Sarikaya; Aqib Mashood Khan; Sanjay M. R; Suchart Siengchin; Danil Yu Pimenov. 2020. "Sustainable milling of Ti–6Al–4V: A trade-off between energy efficiency, carbon emissions and machining characteristics under MQL and cryogenic environment." Journal of Cleaner Production 281, no. : 125374.
Great biocompatibility and superior mechanical properties of titanium alloys (Ti6Al4V) stimulate the use of this material frequently in biomedical, defence, and aeronautical industries. In these applications the end parts generally have complex curved profiles. Through conventional means of machining, complex profiles with high dimensional accuracy are not easily achievable due to difficult-to-cut nature of Ti6Al4V. Wire Electric Discharge Machining (WEDM) is a promising alternative to cut the complex features like angular and curved features. In this research, convex and concave profiles are machined in Ti6Al4V through WEDM. The influence of four machining parameters, namely servo voltage, wire feed, pulse On- and Off-time, over the geometrical accuracies of convex and concave profiles along with corner radii have been comprehensively investigated. L27 orthogonal array was taken as the design of the experiment, and the results are evaluated in terms of statistical (ANOVA and signal-to-noise ratio) and microscopic morphology by Scanning Electron Microscopy (SEM). Optimized combination of machining parameters are sought capable of result in minimum geometric deviations (0.250% overcut in convex and 0.236% undercut in concave profiles) and corner radii of 0.106 mm. Moreover, the SEM analysis has confirmed that the discharge energy and erosion phenomenon significantly affect the profile accuracy as well as the surface integrity. In addition to optimized parameters the provision of wire offset, ranging within 0.169-0.173 mm, can further mitigate the geometric deviations of the actual machined profiles from the designed geometries.
Muhammad Umar Farooq; Muhammad Asad Ali; Yong He; Aqib Mashood Khan; Catalin Iulin Pruncu; Muhammad Kashif; Naveed Ahmed; Noman Asif. Curved profiles machining of Ti6Al4V alloy through WEDM: investigations on geometrical errors. Journal of Materials Research and Technology 2020, 9, 16186 -16201.
AMA StyleMuhammad Umar Farooq, Muhammad Asad Ali, Yong He, Aqib Mashood Khan, Catalin Iulin Pruncu, Muhammad Kashif, Naveed Ahmed, Noman Asif. Curved profiles machining of Ti6Al4V alloy through WEDM: investigations on geometrical errors. Journal of Materials Research and Technology. 2020; 9 (6):16186-16201.
Chicago/Turabian StyleMuhammad Umar Farooq; Muhammad Asad Ali; Yong He; Aqib Mashood Khan; Catalin Iulin Pruncu; Muhammad Kashif; Naveed Ahmed; Noman Asif. 2020. "Curved profiles machining of Ti6Al4V alloy through WEDM: investigations on geometrical errors." Journal of Materials Research and Technology 9, no. 6: 16186-16201.
Sustainability assessments of cooling/lubrication-assisted advanced machining processes has been demanded by environment control agencies because it is an effective management tool for improving process sustainability. To achieve an effective and efficient sustainability evolution of machining processes, there is a need to develop a new method that can incorporate qualitative indicators to create a quantifiable value. In the present research work, a novel quantifiable sustainability value assessment method was proposed to provide performance quantification of the existing sustainability assessment methods. The proposed method consists of three steps: establishing sustainable guidelines and identifying new indicators, data acquisition, and developing an algorithm, which creates the Overall Performance Assessment Indicator (OPAI) from the sustainability assessment method. In the proposed algorithm, initially, both quantitative and qualitative sustainability indicators are normalized. After weight assignment and aggregation, the OPAI is obtained. The developed algorithm was validated from three literature case studies, and optimal cutting parameters were obtained. The present methodology provides effective guidelines for a machinist to enhance process performance and achieve process optimization. The study also offers a relationship between sustainable and machining metrics for the support of industrial sustainability.
Aqib Mashood Khan; Saqib Anwar; Munish Kumar Gupta; Abdullah AlFaify; Saqib Hasnain; Muhammad Jamil; Mozammel Mia; Danil Yurievich Pimenov. Energy-Based Novel Quantifiable Sustainability Value Assessment Method for Machining Processes. Energies 2020, 13, 6144 .
AMA StyleAqib Mashood Khan, Saqib Anwar, Munish Kumar Gupta, Abdullah AlFaify, Saqib Hasnain, Muhammad Jamil, Mozammel Mia, Danil Yurievich Pimenov. Energy-Based Novel Quantifiable Sustainability Value Assessment Method for Machining Processes. Energies. 2020; 13 (22):6144.
Chicago/Turabian StyleAqib Mashood Khan; Saqib Anwar; Munish Kumar Gupta; Abdullah AlFaify; Saqib Hasnain; Muhammad Jamil; Mozammel Mia; Danil Yurievich Pimenov. 2020. "Energy-Based Novel Quantifiable Sustainability Value Assessment Method for Machining Processes." Energies 13, no. 22: 6144.
There is a need to replace non-sustainable conventional coolant (emulsion) with eco benign high-performance cutting fluids such as biodegradable nanofluids that exhibit sufficient lubrication and cooling properties. Also, the sustainability performance of titanium-based alloys can be improved with the geometric alteration on the tool rake zone and by the proper cooling-lubrication mechanism. In the present study, the holistic sustainability of external turning of titanium (Ti–6Al–4V) alloy under two different cutting environments (Al–GnP nanoparticle–based minimum quantity lubrication (MQL) with textured carbide tools and conventional emulsion) is investigated. Novel empirical models for cycle time, machining power, embodied and electrical energy consumption carbon emission, and production cost were developed. For both environments, machining experiments were performed until the cutting tool reaches its life. All sustainable indicators were measured and compared with the conventional process. Results showed that textured carbide cutting tools in the presence of Al–GnP nanoparticle–based MQL-assisted machining (hybrid process) are sustainable environmentally and economically. At the very-high (130 m/min) cutting speed, the sustainable hybrid machining process consumed 1.50% less specific cumulative energy (S_CEC), emitted 5.96% less specific CO2, and incurred 4.33% less specific production cost (S_PC) compared with flood-assisted machining. Finally, it is concluded that the presence of hybrid Al–GnP nanofluids in line texture has the potential to act as lubricant/coolant in turning processes.
Aqib Mashood Khan; Ghulam Hussain; Mohammed Alkahtani; Ayoub Alzabidi; Mustufa Haider Abidi; Ning He. Holistic sustainability assessment of hybrid Al–GnP-enriched nanofluids and textured tool in machining of Ti–6Al–4V alloy. The International Journal of Advanced Manufacturing Technology 2020, 112, 731 -743.
AMA StyleAqib Mashood Khan, Ghulam Hussain, Mohammed Alkahtani, Ayoub Alzabidi, Mustufa Haider Abidi, Ning He. Holistic sustainability assessment of hybrid Al–GnP-enriched nanofluids and textured tool in machining of Ti–6Al–4V alloy. The International Journal of Advanced Manufacturing Technology. 2020; 112 (3-4):731-743.
Chicago/Turabian StyleAqib Mashood Khan; Ghulam Hussain; Mohammed Alkahtani; Ayoub Alzabidi; Mustufa Haider Abidi; Ning He. 2020. "Holistic sustainability assessment of hybrid Al–GnP-enriched nanofluids and textured tool in machining of Ti–6Al–4V alloy." The International Journal of Advanced Manufacturing Technology 112, no. 3-4: 731-743.
To achieve an excellent workpiece surface quality and longer tool life in the machining of hardened steel is an excessive challenge. Recently, conventional emulsion cooling assisted machining processes are being used to address this problem. However, such traditional processes have adverse effects on the environment as well as on the machine shop worker’s health. Hence, in this study, the effects of emulsion cooling and sustainable Cryo-LN2 cooling approach on sustainable metrics, such as surface roughness, energy consumption, tool life, and production cost in the external turning of AISI-52100 have been investigated and compared. The comparative results showed that the Cryo-LN2 technique outperformed emulsion cooling for all measured indices. The Cryo-LN2 assisted turning process not only improved surface quality but also consumed 18% less energy consumption and produced 70.9% low-priced products at aggressive cutting parameters as compared to the emulsion. The findings of the current study encourage metal processing industries to use such type of sustainable techniques at a machine shop. This study is based on the “ Think Green, Plan Green and Execute Green” strategy.
Aqib Mashood Khan; Ning He; Wei Zhao; Muhammad Jamil; Hongjun Xia; Longhui Meng; Munish Kumar Gupta. Cryogenic-LN2 and conventional emulsion assisted machining of hardened steel: Comparison from sustainability perspective. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture 2020, 1 .
AMA StyleAqib Mashood Khan, Ning He, Wei Zhao, Muhammad Jamil, Hongjun Xia, Longhui Meng, Munish Kumar Gupta. Cryogenic-LN2 and conventional emulsion assisted machining of hardened steel: Comparison from sustainability perspective. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 2020; ():1.
Chicago/Turabian StyleAqib Mashood Khan; Ning He; Wei Zhao; Muhammad Jamil; Hongjun Xia; Longhui Meng; Munish Kumar Gupta. 2020. "Cryogenic-LN2 and conventional emulsion assisted machining of hardened steel: Comparison from sustainability perspective." Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture , no. : 1.
The present work deals with the machining application of one of the aerospace material i.e., Inconel-800 alloy by considering the social, economic and environmental effects. The turning tests were done under four sustainable machining conditions i.e., dry, vegetable oil with minimum quantity lubrication (MQL) system, graphene nanofluid plus vegetable oil with MQL (NMQL) system and liquid nitrogen (N2) cooling. Then, the energy consumption, carbon emissions, cost per part, average surface roughness and cutting tool wear have been measured for varied cutting speed and feed rate under selected sustainable environments. The outcomes of this study revealed that the N2 cooling conditions reduced the total machining cost up to 9.3%, total energy consumption up to11.3%, carbon emissions up to 49.17% and tool wear up to 46.6% as compared to other cooling conditions. Significant improvement in surface roughness and tool wear have also been noticed from the outcomes of N2 cooling conditions. Hence, it is worthy to mention that these cooling conditions promote sustainability in the aerospace sector by saving resources and extending environmental benefits.
Munish Kumar Gupta; Qinghua Song; Zhanqiang Liu; Murat Sarikaya; Muhammad Jamil; Mozammel Mia; Anil Kumar Singla; Aqib Mashood Khan; Navneet Khanna; Danil Yu Pimenov. Environment and economic burden of sustainable cooling/lubrication methods in machining of Inconel-800. Journal of Cleaner Production 2020, 287, 125074 .
AMA StyleMunish Kumar Gupta, Qinghua Song, Zhanqiang Liu, Murat Sarikaya, Muhammad Jamil, Mozammel Mia, Anil Kumar Singla, Aqib Mashood Khan, Navneet Khanna, Danil Yu Pimenov. Environment and economic burden of sustainable cooling/lubrication methods in machining of Inconel-800. Journal of Cleaner Production. 2020; 287 ():125074.
Chicago/Turabian StyleMunish Kumar Gupta; Qinghua Song; Zhanqiang Liu; Murat Sarikaya; Muhammad Jamil; Mozammel Mia; Anil Kumar Singla; Aqib Mashood Khan; Navneet Khanna; Danil Yu Pimenov. 2020. "Environment and economic burden of sustainable cooling/lubrication methods in machining of Inconel-800." Journal of Cleaner Production 287, no. : 125074.
Co-relations of friction factor and Nusselt number for plain tubes have been widely developed, but less analysis has been done for tubes with wavy surfaces. This paper uses the Computational Fluid Dynamics (CFD) tool for the analysis of heat transfer and pressure drop in wavy-walled tubes, which can be utilized as a heating element for fluids. An investigation was done for the effect of Reynolds number (Re) and wavy-walled tube geometry on friction factor and Nusselt number of laminar and turbulent flow inside wavy-walled tubes. The numerical results and experimental comparison indicate that heat transfer and pressure drop for water are significantly affected by wavy-walled tube parameters and flow Reynolds number. These wavy-walled tubes are capable of increasing the heat transfer to or from a fluid by an order of magnitude but at an expense of higher pumping power. This ratio was found to remain at the minimum at a wave factor of 0.83 for 34 < Re < 3500 and maximum at a wave factor of 0.15 for 200 < Re < 17,000. New correlations of friction factor and Nusselt number based on wavy-walled tube parameters are proposed in this paper, which can serve as design equations for predicting the friction factor and heat transfer in wavy-walled tubes under a laminar and turbulent regime with less than 10% error. The quantitative simulation results match the experimental results with less than 15% error. The qualitative comparison with the experiments indicates that the simulations are well capable of accurately predicting the circulation zones within the bulgy part of the tubes.
Malik Muhammad Nauman; Muhammad Sameer; Murtuza Mehdi; Asif Iqbal; Zulfikre Esa. Heat Transfer and Pressure Drop in Wavy-Walled Tubes: A Parameter-BASED CFD Study. Fluids 2020, 5, 202 .
AMA StyleMalik Muhammad Nauman, Muhammad Sameer, Murtuza Mehdi, Asif Iqbal, Zulfikre Esa. Heat Transfer and Pressure Drop in Wavy-Walled Tubes: A Parameter-BASED CFD Study. Fluids. 2020; 5 (4):202.
Chicago/Turabian StyleMalik Muhammad Nauman; Muhammad Sameer; Murtuza Mehdi; Asif Iqbal; Zulfikre Esa. 2020. "Heat Transfer and Pressure Drop in Wavy-Walled Tubes: A Parameter-BASED CFD Study." Fluids 5, no. 4: 202.
The successful realization of Industry 4.0 depends much on how coherently the cyber and physical realms are conjoined in cyber-physical systems. In the context of the fourth industrial revolution, research efforts have mostly been channeled toward the cyber domain, whereas the physical domain has received significantly lesser consideration. A physical domain generally comprises material shaping equipment, work material, tools, working medium, sensors, automation technology, and connectivity mechanisms. The article provides a comprehensive review of the published literature to establish the states of readiness of the two most important manufacturing technologies: subtractive and additive and their sustainable merger from the perspective of Industry 4.0. Rich potentials in the four characteristics at the process level: speed, sustainability, agility, and customer centricity and three at the system level: connectivity, data collection, and automation are required for a manufacturing system (physical domain) to be Industry 4.0 compatible. The review establishes that the subtractive manufacturing domain is nearly compatible regarding speed and agility but needs improvements in respect of sustainability and customer centricity. Additive manufacturing, on the other hand, appears strong on agility and customer-centricity fronts but needs amelioration regarding production speed and sustainability. In respect of the system level characteristics, both technologies seem to be compatible regarding automation, whereas significant improvements are required in connectivity and data sensing and collection. For the sake of raising compatibility levels of the manufacturing systems, subtractive-additive amalgamation is scrutinized. The amalgamation, especially in a done-in-one configuration, has, reportedly, succeeded to retain the favorable traits of the two manufacturing technologies, thus, bringing the merger much closer to the Industry 4.0 requirements. Proper process planning and optimal work distribution between the subtractive and additive modes are critical for operating an amalgamated system at high levels of the key characteristics.
Asif Iqbal; Guolong Zhao; Hazwani Suhaimi; Ning He; Ghulam Hussain; Wei Zhao. Readiness of subtractive and additive manufacturing and their sustainable amalgamation from the perspective of Industry 4.0: a comprehensive review. The International Journal of Advanced Manufacturing Technology 2020, 111, 2475 -2498.
AMA StyleAsif Iqbal, Guolong Zhao, Hazwani Suhaimi, Ning He, Ghulam Hussain, Wei Zhao. Readiness of subtractive and additive manufacturing and their sustainable amalgamation from the perspective of Industry 4.0: a comprehensive review. The International Journal of Advanced Manufacturing Technology. 2020; 111 (9):2475-2498.
Chicago/Turabian StyleAsif Iqbal; Guolong Zhao; Hazwani Suhaimi; Ning He; Ghulam Hussain; Wei Zhao. 2020. "Readiness of subtractive and additive manufacturing and their sustainable amalgamation from the perspective of Industry 4.0: a comprehensive review." The International Journal of Advanced Manufacturing Technology 111, no. 9: 2475-2498.