Grantee Research Project Results
Environmentally Benign Machining Processes
EPA Grant Number: GR833357Alternative EPA Grant Number: R833357
Title: Environmentally Benign Machining Processes
Investigators: Jen, Tien-Chien , Chen, Junhong
Institution: University of Wisconsin - Milwaukee
EPA Project Officer: Hahn, Intaek
Project Period: September 1, 2007 through August 31, 2010
Project Amount: $349,978
RFA: Greater Research Opportunities: Environmentally Benign Manufacturing and Processing (2006) RFA Text | Recipients Lists
Research Category: Pollution Prevention/Sustainable Development , Sustainable and Healthy Communities , Nanotechnology
Description:
This research will focus on removing heat from the cutting zone of two major machining processes—drilling and milling. A 3-D model for a heat pipe under rotation will be developed and a solution obtained. Experiments will be performed under actual drilling and milling conditions. The results will be used to quantify the efficiency of the heat pipe cooling effect and provide the data needed as input to, and validation of, the model. This information will enable U.S. machining companies to become more competitive by reducing environmental remediation costs.
Objective:
In many machining processes, a metalworking fluid serves many system functions such as lubrication, thermal sink, corrosion inhibitor, chip control and washing. These fluids could adversely affect the health of the personnel in the machine room. Metal chips (solid waste) in used cutting fluid are a source of pollution and must be disposed of in an appropriate manner. Contaminants retained in the scrap usually mean that the scrap cannot be recycled for application similar to the original application. The cost for recovery for these contaminated materials consists of nearly 30% of the total operational cost of the machining processes. The main objective of this project is to demonstrate the feasibility of running the machining operation completely dry, thus not only completely eliminating the use of the metalworking fluid, but also eliminating the solid waste (chips, swarfs and scraped parts). All these can then be fully recycled.
In any materials removal process, however, most of the input energy is converted into heat in the cutting zone. The generated heat is then transferred to the tool and workpiece and carried away by the machining fluid and the chips. The absence of the metalworking fluid reduces the amount of heat carried away, resulting in an increase in tool and workpiece temperatures. Elevated temperature can significantly shorten the tool life. Excessive heat accumulated in the tool and workpiece can contribute to thermal distortion and poor dimensional control of the workpiece. The innovative concept behind this proposed research is to demonstrate that an internally-cooled machining tool can perform at the same level as a conventional externally-cooled machining tool and thus eliminate the use of metalworking fluids.
Approach:
In this project, heat pipe technology will be applied as a method of removing heat from the cutting zone in two major machining processes, namely drilling and end milling processes, to demonstrate its feasibility. A three-dimensional model for a heat pipe under rotation will be developed and a solution will be obtained either analytically or numerically. These results will then be coupled with the transient temperature model to predict the tool temperature in the vicinity of the cutting tip. Experiments will be performed under actual drilling and end milling conditions.
Expected Results:
The results of the experiments will be used to (a) quantify the efficiency of the heat pipe cooling effect, and (b) provide the data needed as input to, and validation of, the model. A better understanding of internal cooling of end mills will help to advance greener manufacturing practices and enable US machining companies to become more competitive, particularly with increasing environmental remediation costs.
Publications and Presentations:
Publications have been submitted on this project: View all 2 publications for this projectSupplemental Keywords:
Cutting fluids, aerosol, environmentally conscious manufacturing, factory worker health, clean technology, innovative technology, heat pipe technology, thermal management, machining processes, modeling, measurement, tool wear reduction, Midwest, machining-related industry,, RFA, Scientific Discipline, Sustainable Industry/Business, Sustainable Environment, Technology for Sustainable Environment, Engineering, milling, pollution control, machining, pollution prevention design, pollution preventionProgress and Final Reports:
The perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.