Investigation of the Effects of CNC Nanoparticle-Added Nanofluids on the Machinability of Cupral 4M Alloy

Abstract

The machinability of copper-nickel-based alloys, such as Cupral 4M, is known to be quite challenging in the manufacturing industry due to their high thermal conductivity, sticky chip formation, and susceptibility to tool wear. Conventional cooling and lubrication methods are insufficient for improving the machinability of these materials, resulting in a negative impact on machinability metrics such as production quality and tool life. In this study, the effects of adding 0.5 wt% CNC nanopowder to the MQL fluid on the milling process of Cupral 4M material were investigated. The experiments were conducted under two different cutting speeds (125-150 m/min), two different feed rates (0.04-0.06 mm/rev), and three different cooling/lubrication conditions (dry, pure MQL, and CNC nanoparticle MQL). As a result of the experiment, surface roughness, tool wear, and energy consumption were measured, and the obtained data were compared. The addition of CNC nanopowder to MQL fluid provided significant improvements (up to 66% in surface quality, 39% in tool wear, and 10% in energy consumption) in all three results compared to dry and MQL conditions. These results indicate that the addition of CNC nanoparticles has a friction-reducing and tribofilm-protecting effect in the cutting zone. This study fills one of the essential gaps in the literature on improving the sustainable millability of Cupral 4M material and reveals the effectiveness of nanoparticle-added MQL fluids.

Keywords

• Cupral 4M
• Nanofluid
• Minimum quantity lubrication
• Crystalline nano cellulose

CNC Nanopartikül Katkılı Nanoakışkanların Cupral 4M Alaşımının İşlenebilirliği Üzerine Etkilerinin Araştırılması

Abstract

Cupral 4M gibi bakır-nikel esaslı alaşımların işlenebilirliği, yüksek termal iletkenlik, yapışkan talaş oluşumu ve takım aşınmasına yatkınlık nedeniyle imalat endüstrisinde oldukça zorlu işlenebilirliğe sahip olarak bilinir. Geleneksel soğutma ve yağlama yöntemleri bu malzemelerin işlenebilirliğinde yetersiz kalmakla birlikte, üretim kalitesi ve takım ömrü gibi işlenebilirlik metrikleri üzerinde olumsuzluğa neden olmaktadır. Bu çalışmada, ağırlıkça %0.5 CNC nanotozu katkılı MQL sıvısının Cupral 4M malzemesinin frezeleme işlemi üzerindeki etkileri incelenmiştir. Deneyler iki farklı kesme hızı (125-150 m/dk), iki farklı ilerleme hızı (0.04-0.06 mm/dev) ve üç farklı soğutma/yağlama koşulu (kuru, saf MQL, CNC nano parçacık MQL) altında gerçekleştirilmiştir. Deney sonucu olarak yüzey pürüzlülüğü, takım aşınması ve enerji tüketimi ölçülmüş, elde edilen veriler karşılaştırmalı olarak irdelenmiştir. CNC nanotoz ilaveli MQL sıvısı, kuru ve MQL ortamına göre her üç sonuçta da anlamlı iyileşmeler (yüzey kalitesinde %66’ya, takım aşınmasında %39’a, enerji tüketiminde ise %10’a kadar) sağlamıştır. Bu sonuçlar, CNC nano partikül ilavesinin kesme bölgesinde sürtünme azaltıcı ve tribo-film koruyucu bir etki oluşturduğunu göstermiştir. Bu çalışma, Cupral 4M malzemesinin sürdürülebilir frezelenebilirliğini artırmaya yönelik literatürdeki önemli boşluklardan birini doldurmakla birlikte ve nano partikül katkılı MQL sıvılarının etkinliğini ortaya çıkarmıştır.

Keywords

• Cupral 4M
• Nanosıvı
• Minimum miktarda yağlama
• Kristalin Nano Selüloz

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