Improving Process And Cooling/Lubrication Conditions Through Modeling And Experimental Investigation Of Deformation, Thermal, And Tribology Mechanisms In Hybrid Manufacturing Processes

Official URL: https://risc01.sabanciuniv.edu/record=b3205835

Traditional cutting fluids are known to pose environmental and health concerns, and dry machining is not efficient for difficult-to-cut materials. Therefore, it is important to identify green cutting solutions for such materials, including titanium and nickel alloys. Alternative green solutions, such as vegetable oil using minimum quantity lubrication, cryogenics, and hybrid methods, can be explored and developed. The performance of these methods was evaluated by measuring tool wear, temperature, cutting forces and surface integrity. The primary objective of this study is to demonstrate the feasibility and determine the performance of these alternative methods on hard-to-cut materials. Subsequently, the aim is to apply the best-performing solutions to enhance the hybrid additive/subtractive processes. While the combination of additive and machining processes can lead to sustainable and cleaner production, there is a lack of literature on material deformation and friction behavior in hybrid additive/subtractive manufacturing, which hinders the ability to effectively model and optimize the process. To address this gap, the study investigates the material deformation behavior using parameters such as shear stress, shear angle, and friction. A dual-zone thermomechanical model approach is proposed to modify the commonly used Johnson-Cook model for hybrid manufacturing under both dry and different cooling/lubrication conditions. This approach significantly reduces the experimental effort required for material model and friction identification, as only a few orthogonal cutting tests are needed. In addition, the JC parameters are adjusted for selective laser melting (SLM), directed energy deposition (DED), and wrought materials in various cooling/lubrication conditions to cater to the requirements of hybrid manufacturing modeling.