1. A novel empirical modeling approach for energy and resource efficiency in low carbon machining of Ti6Al4V.
- Author
-
Khan, Aqib Mashood, Zhao, Wei, Hu, Jue, Merschroth, Holger, He, Ning, Jamil, Muhammad, and Iqbal, Asif
- Subjects
SUSTAINABILITY ,ENVIRONMENTAL engineering ,ENVIRONMENTAL impact analysis ,CARBON emissions ,CUTTING fluids - Abstract
The metal processing industry faces significant environmental and energy consumption challenges, which are increasingly important in global sustainability initiatives. Traditional metal-cutting methods, which involve substantial quantities of cutting fluids and generate considerable waste and emissions, are now considered unsustainable. The sustainability assessment and environmental impacts of cooling-lubricating assisted machining of Ti-6Al-4V alloys have not been studied holistically. This research aims to develop a new empirical model for the comprehensive understanding of the energy consumption and carbon emissions associated with clean-cutting processes. To achieve this, a series of milling tests were conducted using different clean-cutting techniques, including green wet cutting (pouring), Minimum Quantity Lubrication (MQL), Cryogenic CO
2 cooling and hybrid CO2 mixed with minimum quantity lubrication (CO2 -MQL). The CO2 -MQL technique stood out among the tested methods, showing a remarkable improvement in energy efficiency and carbon emissions reduction. Specifically, this method demonstrated up to 30% better energy efficiency than traditional methods. Additionally, it significantly reduced carbon emissions, supporting the premise that integrating CO2 with minimal quantity lubrication could offer a dual benefit of enhanced cooling and lubrication while minimizing environmental impact. The success of the CO2 -MQL technique highlights the potential for scalable improvements in energy and emissions reductions across the metal processing industry, suggesting a viable pathway toward greener manufacturing practices. This study provides fundamental knowledge about the environmental impact of machining processes used in metal processes industry and reduce waste related pollution. [ABSTRACT FROM AUTHOR]- Published
- 2025
- Full Text
- View/download PDF