Effect of Surface Texture Tools and Minimum Quantity Lubrication (MQL) on tool Wear and Surface Roughness in CNC Turning of AISI 52100 Steel

This paper is concentrated on the exploration of carbonaceous nanocutting fluids with the concept of tri-hybridization with improved lubricative and cooling properties by using multi-walled carbon nanotubes, hexagonal boron nitride , and graphene nanoparticles with neat cold-pressed coconut oil in a fixed volumetric proportion. The rheological properties of the nanofluids were studied to assess their performance in real-time end milling operations using an AA7075 work piece on a CNC lathe machine under a minimum quantity lubrication environment. At the outset, the carbonaceous nanofluids gave good performance when compared to conventional cutting fluids. Furthermore, the surfaces of the tribo-pairs and the chips formed were analyzed using a profilometer and high-end microscopes. The results obtained from the experiments confirm that the tri-hybridized carbonaceous nanolubricant has reduced the cutting force, tool wear, and surface roughness when correlated to monotype nanofluids. The scanning electron microscope images of the surface and tool were studied and it was found that the surface quality was maintained while end milling with tri-hybridized carbonaceous nanofluid. Improvement of ∼17%, 20% and 25% in cutting forces, surface roughness and tool wear was found in tri-hybrid fluid when compared to other fluids. Thus, the present work indicates that the addition of carbon-based nanoparticles with coconut oil has offered better performance and is found to be a credible alternative to existing conventional cutting fluids.

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Influence of minimum quantity lubrication parameters on tool wear and surface roughness in milling of forged steel

Chinese Journal of Mechanical Engineering ◽

10.3901/cjme.2012.03.419 ◽

2012 ◽

Vol 25 (3) ◽

pp. 419-429 ◽

Cited By ~ 24

Author(s):

Lutao Yan ◽

Songmei Yuan ◽

Qiang Liu

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Minimum Quantity Lubrication ◽

Minimum Quantity

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Evaluation and comparison of lubrication methods in finish machining of hardened steel mould inserts

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/0954405415600683 ◽

2015 ◽

Vol 231 (14) ◽

pp. 2458-2467 ◽

Cited By ~ 4

Author(s):

Yuk Lun Chan ◽

Xun Xu

Keyword(s):

Surface Roughness ◽

Tool Wear ◽

Feed Rate ◽

Minimum Quantity Lubrication ◽

Hardened Steel ◽

Depth Of Cut ◽

Machining Time ◽

Minimum Quantity ◽

Step Over ◽

Steel Mould

Traditionally, metal cutting fluid or lubricant is used in finishing operations of high-speed machining process to reduce the rate of tool wear, which in turn will improve surface quality. In automobile and aerospace industries, minimum quantity lubrication technique is considered to provide the same level of performance as the flood coolant method and offers financial benefits by saving coolant direct and associated costs. However, scant research work has been done on minimum quantity lubrication applications in the die and mould manufacturing industry. In this study, the effects of dry, flood and minimum quantity lubrication machining on surface roughness, tool wear, dimensional accuracy and machining time of hardened steel mould inserts were compared. The results revealed that there were no significant differences between these three lubrication methods. More in-depth experimental study of dry and minimum quantity lubrication machining was then carried out using the design of experiments technique. In terms of surface roughness and tool wear, there were again no significant differences. Nevertheless, minimum quantity lubrication machining produced more accurate results than dry machining in dimensional deviation. The regression models show that feed-rate ( fz) has a larger effect on surface roughness and machining time than step-over ( ae), while depth of cut ( ap) has no significant effect on surface roughness. Based on the test piece shape, a shortest possible machining time of 3.55 h and a good surface finish of 0.28 µm can be achieved using a small feed-rate (0.03 mm/tooth), a large step-over (0.1 mm) and a large depth of cut (0.2 mm). This work shows that when combining the minimum quantity lubrication technique with the right cutting conditions in modern die and mould manufacturing, machining time and polishing time can be saved, which leads to an overall saving in production cost. Using the dry and minimum quantity lubrication techniques for different finish machining situations can therefore be a good economical solution.

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