Feasibility of Supercritical Carbon Dioxide Based Metalworking Fluids in Micromilling

S. D. Supekar; B. A. Gozen; B. Bediz; O. B. Ozdoganlar; S. J. Skerlos

doi:10.1115/1.4023375

Journal of Manufacturing Science and Engineering | Volume 135 | Issue 2 | Technical Brief

< Previous Article Next Article >

Technical Briefs

Feasibility of Supercritical Carbon Dioxide Based Metalworking Fluids in Micromilling

S. D. Supekar, B. A. Gozen, B. Bediz, O. B. Ozdoganlar and S. J. Skerlos

[+] Author and Article Information

S. D. Supekar

Department of Mechanical Engineering,
The University of Michigan at Ann Arbor,
Ann Arbor, MI 48109-2122

O. B. Ozdoganlar

Department of Mechanical Engineering,
Carnegie Mellon University,
Pittsburgh, PA 15213-3815

S. J. Skerlos

Department of Mechanical Engineering,
The University of Michigan at Ann Arbor,
Ann Arbor, MI 48109-2122
e-mail: skerlos@umich.edu

¹Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received May 17, 2011; final manuscript received October 17, 2012; published online March 22, 2013. Assoc. Editor: Patrick Kwon.

J. Manuf. Sci. Eng 135(2), 024501 (Mar 22, 2013) (6 pages) Paper No: MANU-11-1175; doi: 10.1115/1.4023375 History: Received May 17, 2011; Revised October 17, 2012

Article

References

Figures

Tables

Abstract

This article investigates the feasibility of using supercritical carbon dioxide based metalworking fluids (scCO₂ metalworking fluids (MWFs)) to improve micromachinability of metals. Specifically, sets of channels were fabricated using micromilling on 304 stainless steel and 101 copper under varying machining conditions with and without scCO₂ MWF. Burr formation, average specific cutting energy, surface roughness, and tool wear were analyzed and compared. Compared to dry machining, use of scCO₂ MWF reduced burr formation in both materials, reduced surface roughness by up to 69% in 304 stainless steel and up to 33% in 101 copper, tool wear by up to 20% in 101 copper, and specific cutting energy by up to 87% in 304 stainless steel and up to 40% in 101 copper. The results demonstrate an improvement in micromachinability of the materials under consideration and motivate future investigations of scCO₂ MWF-assisted micromachining to reveal underlying mechanisms of functionality, as well as to directly compare the performance of scCO₂ MWF with alternative MWFs appropriate for micromachining.

FIGURES IN THIS ARTICLE

Purchase this Content

$25.00

Purchase

Learn about subscription and purchase options

Your Session has timed out. Please sign back in to continue.

References

Liow, J. L., 2009, “Mechanical Micromachining: A Sustainable Micro-Device Manufacturing Approach?,” J. Cleaner Prod., 17, pp. 662–667. [CrossRef]

Dornfeld, D. A., Min, S., and Takeuchi, Y., 2006, “Recent Advances in Mechanical Micromachining,” CIRP Ann., 55, pp. 745–768. [CrossRef]

Ehmann, K. F., Bourell, D., Culpepper, M. L., Hodgson, T. J., Kurfess, T. R., Madou, M., Rajurkar, K., and De Vor, R. E., 2005, “International Assessment of Research and Development in Micromanufacturing,” World Technology Evaluation Center, Baltimore, MD.

Wilson, M. E., Kota, N., Kim, Y., Wang, Y., Stolz, D., LeDuc, P. R., and Ozdoganlar, O. B., 2011, “Fabrication of Circular Microfluidic Channels by Combining Mechanical Micromilling and Soft Lithography,” Lab Chip, 11(8), pp. 1550–1555. [CrossRef]

Filiz, S., Xie, L., Weiss, L., and Ozdoganlar, O. B., 2008, “Micromilling of Microbarbs for Medical Implants,” Int. J. Mach. Tools Manuf., 48(1), pp. 459–472. [CrossRef]

Kim, C. J., Mayor, J. R., and Ni, J., 2004, “A Static Model of Chip Formation in Microscale Milling,” ASME J. Manuf. Sci. Eng., 126(4), pp. 710–718. [CrossRef]

Lucca, D. A., and Seo, Y. W., 1993, “Effect of Tool Edge Geometry on Energy Dissipation in Ultraprecision Machining,” CIRP Ann., 42, pp. 83–86. [CrossRef]

Liu, X., DeVor, R. E., Kapoor, S. G., and Ehmann, K. F., 2004, “The Mechanics of Machining at the Microscale: Assessment of the Current State of the Science,” ASME J. Manuf. Sci. Eng., 126(4), pp. 666–678. [CrossRef]

Vogler, M. P., DeVor, R. E., and Kapoor, S. G., 2004, “On the Modeling and Analysis of Machining Performance in Micro-Endmilling, Part I: Surface Generation,” ASME J. Manuf. Sci. Eng., 126(4), pp. 685–694. [CrossRef]

Liu, X., DeVor, R. E., and Kapoor, S. G., 2006, “An Analytical Model for the Prediction of Minimum Chip Thickness in Micromachining,” ASME J. Manuf. Sci. Eng., 128(2), pp. 474–481. [CrossRef]

Filiz, S., Conley, C. M., Wasserman, M. B., and Ozdoganlar, O. B., 2007, “An Experimental Investigation of Micro-Machinability of Copper 101 Using Tungsten Carbide Micro-Endmills,” Int. J. Mach. Tools Manuf., 47, pp. 1088–1100. [CrossRef]

Bissacco, G., Hansen, H. N., and De Chiffre, L., 2005, “Micromilling of Hardened Tool Steel for Mould Making Applications,” J. Mater. Process. Technol., 167, pp. 201–207. [CrossRef]

Ng, C. K., Melkote, S. N., Rahman, M., and Kumar, A. S., 2006, “Experimental Study of Micro- and Nano-Scale Cutting of Aluminum 7075-T6,” Int. J. Mach. Tools Manuf., 46, pp. 929–936. [CrossRef]

Lee, K., and Dornfeld, D. A., 2002, “An Experimental Study on Burr Formation in Micro Milling Aluminum and Copper,” Trans. NAMRI/SME, 30, pp. 1–8. Available at http://sme.org/ProductDetail.aspx?id=16354&terms=An%20Experimental%20Study%20on%20Burr%20Formation%20in%20Micro%20Milling%20Aluminum%20and%20Copper

Egashira, K., and Mizutani, K., 2002, “Micro-Drilling of Monocrystalline Silicon Using a Cutting Tool,” Precis. Eng., 26, pp. 263–268. [CrossRef]

Weinert, K., and Petzoldt, V., 2008, “Machining NiTi Micro-Parts by Micro-Milling,” Mater. Sci. Eng.: A, 481–482 , pp. 672–675. [CrossRef]

Arif, M., Rahman, M., and San, W. Y., 2011, “Ultraprecision Ductile Mode Machining of Glass by Micromilling Process,” J. Manuf. Process., 13, pp. 50–59. [CrossRef]

Kakinuma, Y., Yasuda, N., and Aoyama, T., 2008, “Micromachining of Soft Polymer Material Applying Cryogenic Cooling,” J. Adv. Mech. Des., Syst., Manuf., 2, pp. 560–569. [CrossRef]

Jun, M. B. G., Joshi, S. S., DeVor, R. E., and Kapoor, S. G., 2008, “An Experimental Evaluation of an Atomization-Based Cutting Fluid Application System for Micromachining,” ASME J. Manuf. Sci. Eng., 130(3), p. 031118. [CrossRef]

Li, K.-M., and Chou, S.-Y,2010, “Experimental Evaluation of Minimum Quantity Lubrication in Near Micro-Milling,” J. Mater. Process. Technol., 210, pp. 2163–2170. [CrossRef]

Pusavec, F., Hamdi, H., Kopac, J., and Jawahir, I. S., 2011, “Surface Integrity in Cryogenic Machining of Nickel Based Alloy—Inconel 718,” J. Mater. Process. Technol., 211(4), pp. 773–783. [CrossRef]

Su, Y., He, N., Li, L., and Li, X. L., 2006, “An Experimental Investigation of Effects of Cooling/Lubrication Conditions on Tool Wear in High-Speed End Milling of Ti-6Al-4V,” Wear, 261(7–8), pp. 760–766. [CrossRef]

Wang, Z. Y., and Rajurkar, K. P., 2000, “Cryogenic Machining of Hard-to-Cut Materials,” Wear, 239(2), pp. 168–175. [CrossRef]

Clarens, A. F., Hayes, K. F., and Skerlos, S. J., 2006, “Feasibility of Metalworking Fluids Delivered in Supercritical Carbon Dioxide,” J. Manuf. Process., 8(1), pp. 1–7. [CrossRef]

Clarens, A. F., MacLean, D. J., Park, Y.-E., Hayes, K. F., and Skerlos, S. J., 2009, “Solubility of a Metalworking Lubricant in High-Pressure CO₂ and Its Effects in Three Machining Processes,” Trans. NAMRI/SME, 37, pp. 645–652. Available at http://sme.org/ProductDetail.aspx?id=48720&terms=Solubility%20of%20a%20Metalworking%20Lubricant%20in%20High-Pressure%20CO2%20and%20its%20effects

MacLean, D. J., Hayes, K. F., Barnard, T., Hull, T., Park, Y.-E., and Skerlos, S. J., 2009, “Impact of Supercritical Carbon Dioxide Metalworking Fluids on Tool Life in Turning of Sintered Steel and Milling of Compacted Graphite Iron,” Proceedings of the 2009 ASME International Manufacturing Science and Engineering Conference, West Lafayette, IN, Oct. 4–7. [CrossRef]

Clarens, A. F., Park, Y.-E., Temme, J., Hayes, K., Zhao, F., and Skerlos, S. J., 2009, “Evaluation of Cooling Potential and Tool Life in Turning Using Metalworking Fluids Delivered in Supercritical Carbon Dioxide,” Proceedings of the 2009 ASME International Manufacturing Science and Engineering Conference, West Lafayette, IN, Oct. 4–7. [CrossRef]

Stephenson, D. A., and Agapiou, J. S., 2006, Metal Cutting Theory and Practice, 2nd ed., CRC, Boca Raton, FL, Chap. 11.

Aramcharoen, A., and Mativenga, P. T., 2009, “Size Effect and Tool Geometry in Micromilling of Tool Steel,” Precis. Eng., 33, pp. 402–407. [CrossRef]

Pusavec, F., Govekar, E., Kopac, J., and Jawahir, I. S., 2011, “The Influence of Cryogenic Cooling on Process Stability in Turning Operations,” CIRP Ann.—Manuf. Technol., 60(1), pp. 101–104. [CrossRef]

Figures

Fig. 1

High-precision MMT system

View Large | Save Figure | Download Slide (.ppt)

Fig. 2

Delivery nozzle Z and rapidly expanding scCO₂ + oil mixture

Delivery nozzle Z and rapidly expanding scCO2 + oil mixture

View Large | Save Figure | Download Slide (.ppt)

Fig. 3

scCO₂ MWF delivery system: C. tank of food-grade carbon dioxide; V. gate valve; G. pressure gauge; N. check valve; R. CO₂ compression pump; D. burst disc; P. PLC; S1. hydraulic oil sump; U. hydraulic oil pump; S2. vegetable oil reservoir; F. oil filter; E. oil pump; M. high pressure mixing chamber; L. oil level sensor; T. temperature sensor; O. solenoid valve; Z. spray nozzle

scCO2 MWF delivery system: C. tank of food-grade carbon dioxide; V. gate valve; G. pressure gauge; N. check valve; R. CO2 compression pump; D. burst disc; P. PLC; S1. hydraulic oil sump; U. hydraulic oil pump; S2. vegetable oil reservoir; F. oil filter; E. oil pump; M. high pressure mixing chamber; L. oil level sensor; T. temperature sensor; O. solenoid valve; Z. spray nozzle

View Large | Save Figure | Download Slide (.ppt)

Fig. 4

Cutting forces for Cu-101 when machining with scCO₂ MWF at 3 μm/tooth chip load, 40 μm axial depth of cut, and 100 m/min cutting speed

Cutting forces for Cu-101 when machining with scCO2 MWF at 3 μm/tooth chip load, 40 μm axial depth of cut, and 100 m/min cutting speed

View Large | Save Figure | Download Slide (.ppt)

Fig. 5

Average specific cutting energies for (a) for AISI 304 stainless steel and (b) and Cu-101 with and without scCO₂ MWF under all four machining conditions examined

Average specific cutting energies for (a) for AISI 304 stainless steel and (b) and Cu-101 with and without scCO2 MWF under all four machining conditions examined

View Large | Save Figure | Download Slide (.ppt)

Fig. 6

(a) Wear progression and (b) SEM images of tool nose wear in dry and scCO₂ assisted machining of Cu-101

(a) Wear progression and (b) SEM images of tool nose wear in dry and scCO2 assisted machining of Cu-101

View Large | Save Figure | Download Slide (.ppt)

Fig. 7

Burr formation on AISI 304 and Cu-101 with and without scCO₂ MWF for all machining conditions examined where + and – signs in parentheses represent levels of f_z, a_p, and v_c in that order

Burr formation on AISI 304 and Cu-101 with and without scCO2 MWF for all machining conditions examined where + and – signs in parentheses represent levels of fz, ap, and vc in that order

View Large | Save Figure | Download Slide (.ppt)

Fig. 8

Bottom surface roughness (R_a) for AISI 304 (left) and Cu-101 (right) with and without scCO₂ MWF for all machining conditions examined

Bottom surface roughness (Ra) for AISI 304 (left) and Cu-101 (right) with and without scCO2 MWF for all machining conditions examined

View Large | Save Figure | Download Slide (.ppt)

Tables

Errata

Web of Science® Times Cited: 0

Some tools below are only available to our subscribers or users with an online account.

Sections
PDF
Email

You must be logged in as an individual user to share content.

Return to: Feasibility of Supercritical Carbon Dioxide Based Metalworking Fluids in Micromilling

Copyright in the material you requested is held by the American Society of Mechanical Engineers (unless otherwise noted). This email ability is provided as a courtesy, and by using it you agree that you are requesting the material solely for personal, non-commercial use, and that it is subject to the American Society of Mechanical Engineers' Terms of Use. The information provided in order to email this topic will not be used to send unsolicited email, nor will it be furnished to third parties. Please refer to the American Society of Mechanical Engineers' Privacy Policy for further information.
Share
Get Citation

Supekar SD, Gozen BA, Bediz BB, Ozdoganlar OB, Skerlos SJ. Feasibility of Supercritical Carbon Dioxide Based Metalworking Fluids in Micromilling. ASME. J. Manuf. Sci. Eng. 2013;135(2):024501-024501-6. doi:10.1115/1.4023375.

Download citation file:

RIS (Zotero)

EndNote

BibTex

Medlars

ProCite

RefWorks

Reference Manager

© Copyright
Get Alerts

Processing your request... Please Wait.

Feasibility of Supercritical Carbon Dioxide Based Metalworking Fluids in Micromilling

Abstract

FIGURES IN THIS ARTICLE

References

Figures

Tables

Errata

Related Content

Journals

Conference Proceedings

eBooks