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Öğe Implementation of green cooling/lubrication strategies in metal cutting industries: A state of the art towards sustainable future and challenges(Elsevier, 2023) Korkmaz, Mehmet Erdi; Gupta, M. K.; Ross, Nimel Sworna; Sivalingam, VinothkumarWhile the metal cutting industrial sector is essential for global economic growth, it also has a major impact, such as cutting tools, cooling and lubrication environments, improved cutting parameters, etc., on the world's natural resources and ecosystems. The increasing demand for goods and services has resulted in a paradigm of linear production and consumption that cannot be maintained over the long term. The need to transition towards green or sustainable manufacturing is necessary for a variety of reasons, including issues relating to occupational health, legislation governing the environment, and hazardous or dirty working conditions for employees. However, the most important reason is the waste cost associated with utilising an excessive amount of cutting fluid in metal cutting sectors. As a result, this article examines a sustainable manufacturing system built in the metal cutting sector and offers a comprehensive guide for the industrial sector. Organisational tactics, indications, and potential roadblocks to execution are all given special attention in this review article. Further, the review article investigates the obstacles that stand in the way of environmentally friendly production. In addition to this, it investigates the criteria that are used to quantify development towards more sustainable production techniques and provides a new strategy for evaluating initiatives of this nature. It has been concluded that this indepth analysis helps academics and researchers by detailing the green machining techniques that have been put into practise in many machining domains to ensure a clean and secure working environment.Öğe A mathematical approach of evaluating sustainability indicators in milling of aluminium hybrid composite by different eco-friendly cooling strategies(Elsevier, 2023) Sivalingam, Vinothkumar; Zhou, Qian; Selvam, Baskaran; Sun, Jie; Pandiyan, Karthik; Gupta, M. K.; Korkmaz, Mehmet ErdiThe purpose of this study is to evaluate the sustainability indicators of aluminium hybrid composite material (AA6082 + 3wt%SiC+1wt .%MoS2) under different eco-friendly cooling strategies such as dry, MQL, LCO2, MQL + LCO2. A variety of social, economic, and environmental aspects of sustainability indicators such as Total cycle time (TTCT), productivity, Total machining cost (CT) Energy consumption (Ec), Carbon emission analysis (Cee), Cutting force (CF) and Surface Roughness (Ra) are considered in this study. A novel sustainable approach of overall equipment effectiveness (OEE) is included to evaluate the true productivity under different cooling en-vironments. By comparing all the machining conditions, it was found that hybrid (CO2 + MQL) resulted the highest OEE as 95.63% and very low carbon emission of 0.6 kg-CO2 under higher cutting speed of 120 m/min and feed rate of 0.1 mm/rev at 1 mm depth of cut.Öğe Towards sustainability assessment, energy consumption, and carbon emissions in cryogenic drilling of Alloy 20: a new approach towards sustainable future and challenges(Springer London Ltd, 2024) Sivalingam, Vinothkumar; Liu, Haochen; Selvam, Baskaran; Kai, Guo; Kumar, Poongavanam Ganesh; Gupta, Munish Kumar; Korkmaz, Mehmet ErdiBoth the product and the manufacturing process must be sustainable in today's modern world. Traditional machining methods are undesirable when working with heat-resistant alloys. These methods could be more efficient and can be maintained over time. As the world progresses to sustainability, many people are working to integrate this concept into the industrial process. In the manufacturing industry, the evaluation of sustainability carries immense significance in ensuring product quality, promoting operators' safety and well-being, and preventing any form of environmental degradation or pollution. Concerning this regard, the main objective of the present study is to assess the sustainability parameters during the drilling of Alloy 20 material under different environmental conditions such as minimum quantity lubrication (MQL) and cryogenic and hybrid methods. The study is conducted in two stages, and in the first stage, the most impactful sustainable indicators, i.e., energy consumption, carbon emissions, total cycle time, and cost, have been evaluated. In the second phase of the investigation, the machining analysis of surface roughness, cutting forces, and circularity was determined under different conditions. The results showed that the hybrid cooling condition exhibited better technical, quality, and economic sustainability. Thus, it is important to note that selecting appropriate cooling conditions can contribute to achieving sustainability in manufacturing processes and that the hybrid cooling method aids industries in moving towards sustainable production systems that, in turn, contribute to a more environmentally conscious and efficient economy.Öğe Understanding the machining characteristics of Al6082 hybrid metal matrix composites milled under cryogenic cooling conditions(Springer London Ltd, 2023) Sivalingam, Vinothkumar; Zhou, Qian; Manickajothi, Ganesh; Ross, Nimel Sworna; Sun, Jie; Gupta, Munish Kumar; Korkmaz, Mehmet ErdiCutting fluid used in machining is under investigation to check the achievement of sustainability and the cleaner process by the machining process. Many attempts were made to find new cooling strategies as an alternative to the existing cooling methods. Cryogenic cooling was an efficient method to move towards sustainability for machining any materials and to ensure green machining. Machining of Al6082 HMMC has been carried out under distinct cutting environments. The fallout of these cutting environments was studied based on parameters like surface roughness, cutting temperature, chip morphology, and tool wear. The application of cryogenic CO2 substantially reduced the tool wear by 37% and 48% when compared to MQL and wet conditions. The SEM image of the worn tool disclosed that adopting the cryogenic cooling technique led to less crater wear and prevented the peeling of the tool layer to some extent. The impressive cooling effect of cryogenic cooling also produced a good surface finish on the machined surface compared to the other cooling environments. Thus, cryogenic cooling proved to be trustworthy in all the output parameters.Öğe Understanding the machining induced tribological mechanism of Hastelloy-X under sustainable cooling/lubrication conditions(Springer London Ltd, 2022) Zhou, Qian; Sivalingam, Vinothkumar; Sun, Jie; Murugasen, Pradeep Kumar; Gupta, Munish Kumar; Korkmaz, Mehmet ErdiDespite the recent developments in non-conventional manufacturing approaches, machining is still a prominent technique for the mass production of metallic components. However, given the difficult-to-machine nature and high heat generation during machining of Hastelloy-X, there is a lack of comparative investigations that can provide basics for sustainable process management in machining of Hastelloy-X. Different sustainable cooling approaches (dry, minimum quantity lubrication (MQL), cryogenic) and their impact on Hastelloy-X machining process behavior have been investigated in this study. Machining parameters such as constant cutting speed of 124 mm/min, feed rate of 0.15 mm/min, and cutting depth of 0.1 mm and cutting force, cutting temperature, and surface roughness were consider as output responses. It was observed that with the adaptation of cryogenic conditions, cutting forces can be reduced 5 to 14% in comparison with MQL and dry conditions. Cutting temperature and surface roughness values were however observed to be largely reduced with cryogenic cooling. The chipping and adhesion were found to be reduced with cryogenic cooling due to the reduction in workpiece softening behavior and increase in hardness to cutting tool.
