Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester

Research output: Contribution to journalArticleResearchpeer review

Authors

  • Belal G. Nassef
  • Florian Pape
  • Gerhard Poll
  • Jan Schenzel
  • Benjamin Bergmann
  • Berend Denkena

External Research Organisations

  • Alexandria University
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Details

Original languageEnglish
Article number77
Number of pages17
JournalLubricants
Volume12
Issue number3
Publication statusPublished - 28 Feb 2024

Abstract

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.

Keywords

    ball-on-disc, metal cutting fluid, open tribometer, planing process, rheology, tribology, wettability

ASJC Scopus subject areas

Cite this

Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester. / Nassef, Belal G.; Pape, Florian; Poll, Gerhard et al.
In: Lubricants, Vol. 12, No. 3, 77, 28.02.2024.

Research output: Contribution to journalArticleResearchpeer review

Nassef, B. G., Pape, F., Poll, G., Schenzel, J., Bergmann, B., & Denkena, B. (2024). Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester. Lubricants, 12(3), Article 77. https://doi.org/10.3390/lubricants12030077
Nassef BG, Pape F, Poll G, Schenzel J, Bergmann B, Denkena B. Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester. Lubricants. 2024 Feb 28;12(3):77. doi: 10.3390/lubricants12030077
Nassef, Belal G. ; Pape, Florian ; Poll, Gerhard et al. / Evaluating the Tribological Behaviour in Cutting Operations Using a Modified Ball-on-Disc Open Tribotester. In: Lubricants. 2024 ; Vol. 12, No. 3.
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AU - Poll, Gerhard

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N1 - Funding Information: The authors appreciate the funding of this work within the Priority Program 2231 “Efficient cooling, lubrication and transportation—coupled mechanical and fluid-dynamical simulation methods for efficient production processes (FLUSIMPRO)” by the German Research Foundation (DFG)—project number 439904924. The publication of this article was funded by the Open Access Fund of Leibniz Universität Hannover.

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