An experimental investigation on the effects of combined application of ultrasonic assisted milling (UAM) and minimum quantity lubrication (MQL) on cutting forces and surface roughness of Ti-6AL-4V

2021 ◽  
Vol 25 (5) ◽  
pp. 738-775
Author(s):  
Ramazan Hakkı Namlu ◽  
Bahram Lotfi Sadigh ◽  
Sadık Engin Kiliç
Keyword(s):  
Surface Roughness ◽  
Experimental Investigation ◽  
Cutting Forces ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
Combined Application ◽  
Ultrasonic Assisted

scholarly journals An Experimental Investigation on Vegetable Oils as a Cutting Fluid under Minimum Quantity Lubrication: A Sustainable Machining Approach

2021 ◽  
Vol 23 (04) ◽  
pp. 143-155
Author(s):  
Shrikant U. Gunjal ◽  
◽  
Sudarshan B. Sanap ◽  
Nilesh C. Ghuge ◽  
Satish Chinchanikar ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Vegetable Oils ◽  
Cutting Forces ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Fluid ◽  
Interface Temperature ◽  
Cutting Fluids ◽  
Minimum Quantity

Cutting fluid is a vital part of the machining process. Cutting fluid is significantly applied tolower the friction and heat generated in the machining zone. It also helps in easy chip removal, protection against oxidation, tool life improvement, and an overall improvement in the quality of the product. The current industrial practices are majorly emphasized on mineral-based oil application under flood lubrication to achieve superior quality. However, these oils and techniques are toxic and environmentally unfriendly. Machining under dry or with minimum quantity lubrication (MQL) has been mostly preferred to eliminate the use of abundant oil. The current research work has established the promising potential for vegetable oils as a cutting fluid under MQL during turning of AISI 4130 steel. The results inferred that vegetable-based cutting fluids performed better over mineral-based cutting fluids in terms of lower values of machined surface roughness, tool wear, cutting forces, and chip-tool interface temperature. The MQL machining performance in terms of cutting forces, surface roughness and tool life has been observed better in comparison to machining under flood and dry cutting conditions.

scholarly journals Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools

2017 ◽  
Vol 9 (7) ◽  
pp. 168781401771061 ◽  
Author(s):  
Duc Tran Minh ◽  
Long Tran The ◽  
Ngoc Tran Bao
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Minimum Quantity Lubrication ◽  
High Hardness ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Hard Milling ◽  
Minimum Quantity ◽  
Coated Carbide ◽  
Lubrication Conditions

In this article, an attempt has been made to explore the potential performance of Al2O3 nanoparticle–based cutting fluid in hard milling of hardened 60Si2Mn steel (50-52 HRC) under different minimum quantity lubrication conditions. The comparison of hard milling under minimum quantity lubrication conditions is done between pure cutting fluids and nanofluids (in terms of surface roughness, cutting force, tool wear, and tool life). Hard milling under minimum quantity lubrication conditions with nanofluid Al2O3 of 0.5% volume has shown superior results. The improvement in tool life almost 177%–230% (depending on the type of nanofluid) and the reduction in surface roughness and cutting forces almost 35%–60% have been observed under minimum quantity lubrication with Al2O3 nanofluids due to better tribological behavior as well as cooling and lubricating effects. The most outstanding result is that the uncoated cemented carbide insert can be effectively used in machining high-hardness steels (>50 HRC) while maintaining long tool life and good surface integrity (Ra = 0.08–0.35 µm; Rz = 0.5–2.0 µm, equivalent to finish grinding) rather than using the costlier tools like coated carbide, ceramic, and (P)CBN. Therefore, using hard nanoparticle–reinforced cutting fluid under minimum quantity lubrication conditions in practical manufacturing becomes very promising.

Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

2020 ◽  
Vol 997 ◽  
pp. 85-92
Author(s):  
Abang Mohammad Nizam Abang Kamaruddin ◽  
Abdullah Yassin ◽  
Shahrol Mohamaddan ◽  
Syaiful Anwar Rajaie ◽  
Muhammad Isyraf Mazlan ◽  
...  
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Low Cost ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Tool Performance

One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

Effect of minimum quantity lubrication and vortex tube cooling on laser-assisted micromilling of a difficult-to-cut steel

2020 ◽  
Vol 234 (11) ◽  
pp. 1422-1432 ◽  
Author(s):  
Pushparghya Deb Kuila ◽  
Shreyes Melkote
Keyword(s):  
Tool Wear ◽  
Cutting Forces ◽  
Vortex Tube ◽  
Minimum Quantity Lubrication ◽  
Dimensional Accuracy ◽  
Burr Formation ◽  
Workpiece Material ◽  
Minimum Quantity ◽  
Tool Condition ◽  
Cooling Methods

Laser-assisted micromilling is a promising micromachining process for difficult-to-cut materials. Laser-assisted micromilling uses a laser to thermally soften the workpiece in front of the cutting tool, thereby lowering the cutting forces, improving the dimensional accuracy, and reducing the tool wear. Thermal softening, however, causes the workpiece material to adhere to the tool and form a built-up edge. To mitigate this problem and to enhance micromachinability of the workpiece in laser-assisted micromilling, this article investigates the following lubrication and cooling methods: (1) minimum quantity lubrication and (2) vortex tube cooling. Experiments utilizing the two methods are carried out on a difficult-to-cut stainless steel (A286), and the surface morphology, tool condition, burr formation, groove dimensional accuracy, surface finish, and cutting forces are analyzed. Results show that the combination of laser-assisted micromilling and minimum quantity lubrication yields the least amount of tool wear, lower resultant force, better groove dimensional accuracy, and no built-up edge. While vortex tube cooling with laser-assisted micromilling produces smaller burrs compared to minimum quantity lubrication, it yields larger changes in groove dimensions and is characterized by built-up edge formation. Possible physical explanations for the experimental observations are given.

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