Thesis supervisor: Gyula Varga
Location of studies (in Hungarian): Gyártástudományi Intézet Abbreviation of location of studies: GYT
Description of the research topic:
For decades in cutting processes, in order to achieve the proper chip removing performance, a significant amount of coolants and lubricants has often been used to achieve the following tasks:
a) chip removal, b) cooling, and c) lubrication.
In addition to their favourable properties, however, the used coolants and lubricants, which leaves the process with the chips, evaporates, or improperly handled, can damage the environment significantly.
After a detailed examination of the conventional machining, a detailed examination of the low environmental load machining (executed on dry or using minimal quantity lubrication) is also required.
Once the mechanical, tribological models have been set up, the use of dry or minimally lubricated industrial machining will result in a machining with less burdensome to the environment.
Tasks to be solved:
1. Establishing a mechanical model, creating a tribological model, finite element tests
a) Set up theoretical models
Comprehensive analysis of literature on environmentally friendly machining, summarizing lessons learned. Theoretical tribological examinations and tool wear tests. Studying different wear models. Energy-based analysis of dry machining: 2D examination of contact surfaces, Fourier analysis of surface geometry, development of existing wear models (e.g. Archard, Mulhearn, Samuels, Murray, Mutton, Wattson, Moore, etc.), creating new wear models.
b) Finite element examinations.
Modelling of environmentally friendly machining using 2D analysis. Upgrading the 2D model to 3D. Several sophisticated machining processes can also be examined. The aim is to apply a finite element program which can deal with high strains and to evaluate the results. As a result of the modelling, the heat load of the tool, the stresses in the tool, the surface pressures of the tool and the workpiece, the degree of residual stresses are determined. In addition, it is possible the examination of the process of chip removal.
2. Experimental examinations.
To complete or validate the theoretical studies, making experimental examinations are justified. Experimental examinations of low-environmental-load machining’s (e.g. drilling, turning, milling) for different cooling lubrication: (e.g. making dry machining or using minimal quantity lubrication for example using Bio-lubricants).
a) Examination (calculation, measurement) of cutting force and torque required for cutting, analysis of tribological tests, analysis of tool wear, examination of existing and new tool life criteria,
b) Examination of surface roughness, shape error and structure of the machined surface.
Institute that cares about the subject: Institute of Manufacturing Science
Supervisor: Dr. Gyula Varga associate professor
Industrial background of the theme: Various automotive companies are significantly involved in the use of environmentally friendly machining technologies.
Foreign Relations:
1. Otto-von-Guericke-University of Magdeburg, Institute of Manufacturing Technology und Quality Management,
Literature:
1. Dudás I., Lierath F., Varga G., Environmentally friendly technologies in production engineering, Műszaki Kiadó, (2010), pp. 308. (in Hungarian)
2. Ophey L., Trockenbearbeitung, Bearbeitung metallischer Werkstoffe ohne Kühlschmierstoffe, Expert Verlag, (1998), pp. 190.
3. Weinert, K.: Trockenbearbeitung und Minimalmengekühlschmierung, Einsatz in der spanenden Fertigungstechnik, Springer-Verlag, Berlin-Heidelberg-New York, 1998
4. Shaw, M. C.: Metal Cutting Principles, Oxford Science Publications, Clarendon Press, 1984, pp.: 423.
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