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Sustainable Advancements and Modeling in Machinability of Difficult-to-Cut Composites and Alloys

A special issue of Sustainability (ISSN 2071-1050). This special issue belongs to the section "Sustainable Engineering and Science".

Deadline for manuscript submissions: 1 December 2024 | Viewed by 2718

Special Issue Editors


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Guest Editor
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Interests: high-performance machining; sustainability; lubricooling; cryogenic machining; energy efficiency
Special Issues, Collections and Topics in MDPI journals

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Guest Editor
Departmental of Mechatronics Engineering, Faculty of Engineering, University of Chakwal, Chakwal 48800, Pakistan
Interests: energy modeling; life-cycle assessment; resource-based energy consumption; nanofluids; hybrid CryoMQL

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Guest Editor
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Interests: finite element analysis (FEA); metal matrix composite (MMC) materials; high-speed machining; artificial neural network; sustainable machining; sustainable cooling/lubrication

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Guest Editor
College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, China
Interests: energy-efficient machining; sustainable manufacturing; high-speed machining; cryogenic cooling

Special Issue Information

Dear Colleagues,

The COVID-19 pandemic has pushed the modern manufacturing sector to seek advancements in machining processes with exceptional product quality, precise tolerances, and eco-friendly manufacturing. As mineral-based emulsion cooling is common practice in the industry to machine difficult-to-cut materials, design and machining using a complicated geometry, the rapidly growing material science, and the efficient cutting of difficult-to-cut aerospace alloys raise the need to develop and implement new sustainable technology solutions for efficient machining with fewer operator health complexities.

With an increased scientific interest in understanding in-depth process mechanisms, research is moving toward numerical modeling, predictive modeling, simulations, experimental studies, new hybrid lubricoolants, heat transfer in machining under sustainable cooling and lubrication, carbon footprints, energy consumption, and machine shop health grades. Multiphysics and multidisciplinary modeling are powerful tools in the efforts to enhance existing machining processes, as well as to develop novel technologies. As they are more widely used by the aerospace industry today, research must be dedicated not only due to their academic importance but also their possible economic benefit.

This Special Issue invites researchers to present recent advances and technologies developed for sustainable machining, modern cooling technologies, lubricoolants with superior heat transfer, FEM, and CFD, indicating future trends for machining processes.

Dr. Muhammad Jamil
Prof. Dr. Aqib Mashood Khan
Dr. Rashid Ali Laghari
Prof. Dr. Ning He
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sustainability is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • sustainable manufacturing
  • sustainable coolants/lubricants
  • surface integrity
  • energy-efficient manufacturing
  • computational fluid dynamics (CFD)
  • finite element analysis (FEM)
  • mathematical modeling
  • cutting simulations
  • hybrid lubricooling
  • heat transfer
  • difficult-to-cut composites materials
  • aerospace alloys

Published Papers (1 paper)

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Research

21 pages, 5157 KiB  
Article
Thermophysical Properties and Heat Transfer Performance of Novel Dry-Ice-Based Sustainable Hybrid Lubri-Coolant
by Muhammad Jamil, Asif Iqbal, Ning He and Quentin Cheok
Sustainability 2022, 14(4), 2430; https://0-doi-org.brum.beds.ac.uk/10.3390/su14042430 - 20 Feb 2022
Cited by 6 | Viewed by 2022
Abstract
It is a well-known fact that the consumption of conventional cutting fluids in metalworking industries leads to severe health and environmental issues. Owing to the EPA (Environmental Protection Agency) increasing regulations regarding pollution and contamination, there is a dire need for a greener [...] Read more.
It is a well-known fact that the consumption of conventional cutting fluids in metalworking industries leads to severe health and environmental issues. Owing to the EPA (Environmental Protection Agency) increasing regulations regarding pollution and contamination, there is a dire need for a greener fluid with excellent cooling and lubrication characteristics to diminish the environmental impact of cutting fluids, as well as to improve machinability. Cryogens are greener and excellent coolants but poor lubricants, while ester oils are excellent lubricants and poor coolants. Therefore, a hybrid lubri-coolant cutting fluid with synergistic cooling and lubrication characteristics could be a desideratum to replace conventional cutting fluid. To investigate a newly proposed hybrid lubri-coolant, thermophysical properties (density, thermal conductivity, specific heat, and viscosity), heat transfer properties (surface temperature, heat flux, and heat transfer coefficient), and machinability properties (tool life, etc.) are key characteristics of the fluids that decide phase change and heat dissipation capabilities during their application in machining. In the current experimental study, hybrid ethanol–ester oils with/without dry ice (−78 °C) are proposed as cutting fluids and holistically investigated in terms of thermo-physical properties, heat transfer properties, and machinability properties under different cutting conditions. Experimental findings have depicted a 20%, 10%, and 5% decrease in density, specific heat, and viscosity, respectively, with a 15% increase in the thermal conductivity of the fluid with the addition of dry ice. The dry-ice-based hybrid lubri-coolant sprayed onto a Ti-6Al-4V plate enhanced the heat transfer coefficient significantly by 17% compared to hybrid lubri-coolant without dry ice. Besides, hybrid ethanol–ester oil dry ice was treated as a trendsetter and indicated an 11% improvement of the tool life at a cutting speed of 75 m/min and a feed rate of 0.04 mm/z. Therefore, dry-ice-based hybrid lubri-coolant can be applied as a cutting fluid by practitioners in aerospace, automotive, prosthetic body parts manufacturing, and manufacturing industries. Full article
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