Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester
Predicting the tribological behaviour in the secondary shear zone in the metal-cutting processes is considered a significant challenge in contemporary research. This work investigated the frictional performance in the secondary shear zone of a planing process using a modified ball-on-disc open tribo...
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| Format: | Article |
| Language: | English |
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MDPI AG
2024-02-01
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| Series: | Lubricants |
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| Online Access: | https://www.mdpi.com/2075-4442/12/3/77 |
| _version_ | 1797240294468485120 |
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| author | Belal G Nassef Florian Pape Gerhard Poll Jan Schenzel Benjamin Bergmann Berend Denkena |
| author_facet | Belal G Nassef Florian Pape Gerhard Poll Jan Schenzel Benjamin Bergmann Berend Denkena |
| author_sort | Belal G Nassef |
| collection | DOAJ |
| description | Predicting the tribological behaviour in the secondary shear zone in the metal-cutting processes is considered a significant challenge in contemporary research. This work investigated the frictional performance in the secondary shear zone of a planing process using a modified ball-on-disc open tribometer. The values of the coefficient of friction (COF) were tracked between an AISI4140 + QT disc (chip) and a cemented carbide ball (cutting tool) coated with TiAlN under three contact pressures of 0.5, 1, and 2 GPa at a range of sliding speeds starting from 0.2 m/s to 1.6 m/s. The tests were conducted under both dry and lubricated conditions using three commercial cutting fluids of CSF 35 straight oil, Vasco 6000, and Zubora 67H emulsions. Also, the MWFs were tested for their rheological properties and wettability. The tribometer results validated the same COF trend as that in the actual metal-cutting experiments, particularly at 0.5 and 1 GPa in dry conditions. Moreover, Zubora 67H emulsion is proven to be the optimal choice due to it reducing the COF between the rubbing contacts by up to 78%. Furthermore, it showed the lowest contact angle and viscosity index, revealing its ability to easily penetrate, especially at higher temperatures, within the secondary cutting zone. |
| first_indexed | 2024-04-24T18:05:09Z |
| format | Article |
| id | doaj.art-b5a108af958347939049868843e9cbcb |
| institution | Directory Open Access Journal |
| issn | 2075-4442 |
| language | English |
| last_indexed | 2024-04-24T18:05:09Z |
| publishDate | 2024-02-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Lubricants |
| spelling | doaj.art-b5a108af958347939049868843e9cbcb2024-03-27T13:51:41ZengMDPI AGLubricants2075-44422024-02-011237710.3390/lubricants12030077Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open TribotesterBelal G Nassef0Florian Pape1Gerhard Poll2Jan Schenzel3Benjamin Bergmann4Berend Denkena5Institute of Machine Design and Tribology, Leibniz University of Hanover, 30823 Hannover, GermanyInstitute of Machine Design and Tribology, Leibniz University of Hanover, 30823 Hannover, GermanyInstitute of Machine Design and Tribology, Leibniz University of Hanover, 30823 Hannover, GermanyInstitute for Production Engineering and Machine Tools, Leibniz University of Hanover, 30823 Hannover, GermanyInstitute for Production Engineering and Machine Tools, Leibniz University of Hanover, 30823 Hannover, GermanyInstitute for Production Engineering and Machine Tools, Leibniz University of Hanover, 30823 Hannover, GermanyPredicting the tribological behaviour in the secondary shear zone in the metal-cutting processes is considered a significant challenge in contemporary research. This work investigated the frictional performance in the secondary shear zone of a planing process using a modified ball-on-disc open tribometer. The values of the coefficient of friction (COF) were tracked between an AISI4140 + QT disc (chip) and a cemented carbide ball (cutting tool) coated with TiAlN under three contact pressures of 0.5, 1, and 2 GPa at a range of sliding speeds starting from 0.2 m/s to 1.6 m/s. The tests were conducted under both dry and lubricated conditions using three commercial cutting fluids of CSF 35 straight oil, Vasco 6000, and Zubora 67H emulsions. Also, the MWFs were tested for their rheological properties and wettability. The tribometer results validated the same COF trend as that in the actual metal-cutting experiments, particularly at 0.5 and 1 GPa in dry conditions. Moreover, Zubora 67H emulsion is proven to be the optimal choice due to it reducing the COF between the rubbing contacts by up to 78%. Furthermore, it showed the lowest contact angle and viscosity index, revealing its ability to easily penetrate, especially at higher temperatures, within the secondary cutting zone.https://www.mdpi.com/2075-4442/12/3/77open tribometerball-on-discrheologywettabilitymetal cutting fluidtribology |
| spellingShingle | Belal G Nassef Florian Pape Gerhard Poll Jan Schenzel Benjamin Bergmann Berend Denkena Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester Lubricants open tribometer ball-on-disc rheology wettability metal cutting fluid tribology |
| title | Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester |
| title_full | Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester |
| title_fullStr | Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester |
| title_full_unstemmed | Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester |
| title_short | Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester |
| title_sort | evaluating the tribological behaviour in cutting operations using a modified ball on disc open tribotester |
| topic | open tribometer ball-on-disc rheology wettability metal cutting fluid tribology |
| url | https://www.mdpi.com/2075-4442/12/3/77 |
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