Analysis of MQL Effect on Forces, Friction, and Surface Roughness in Turning of AISI 4140 Steel

2018 ◽  
Author(s):  
Rodrigo Maldonado Mendieta ◽  
Juan de Dios Calderón Nájera
Keyword(s):  
Surface Roughness ◽  
Fluid Flow ◽  
Tool Wear ◽  
Cutting Force ◽  
Flow Rate ◽  
Numerical Control ◽  
Cutting Fluid ◽  
Fluid Flow Rate ◽  
Aisi 4140 ◽  
Fea Simulation

Minimum Quantity Lubrication or MQL is an increasingly used technique for metal cutting operations and it has become an attractive alternative for machining parts at big scale production. However, fully lubricated conditions are still in use for machining special materials so that surface finish, tool wear, and temperature distribution levels remain at optimum levels. On the other hand, dry condition machining is in use as well although with some restraint due to issues with material burr, surface roughness, and tool wear. The main purpose of this work is to analyze the effects of cutting fluid flow rate, its application mechanisms, and cutting speed on surface roughness and establish the lowest possible cutting fluid flow rate that yields to minimum surface roughness (Ra). To achieve the objective, a set of experiments was performed using a Computer Numerical Control (CNC) lathe instrumented with a Kistler 9121 dynamometer and a customized cutting fluid application system to obtain coefficients of friction and cutting forces. Finally, a previously 2D finite element analysis (FEA) simulation from Akbar et al. [1] is applied and compared to experimental results to find out if the cutting force can be predicted. A first regression model that correlates cutting force and surface roughness is posed, so that FEA simulation can be implemented to predict the final surface roughness. AISI 4140 machinery steel in annealed condition is used to carry out the simulated and experimental work.

scholarly journals Influence of Cutting Fluid Flow Rate and Cutting Parameters on the Surface Roughness and Flank Wear of TiAlN Coated Tool In Turning AISI 1015 Steel Using Taguchi Method

2017 ◽  
Vol 62 (3) ◽  
pp. 1827-1832 ◽  
Author(s):  
C. Moganapriya ◽  
R. Rajasekar ◽  
K. Ponappa ◽  
R. Venkatesh ◽  
R. Karthick
Keyword(s):  
Surface Roughness ◽  
Fluid Flow ◽  
Tool Wear ◽  
Flow Rate ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Fluid Flow Rate

AbstractThis paper presents the influence of cutting parameters (Depth of cut, feed rate, spindle speed and cutting fluid flow rate) on the surface roughness and flank wear of physical vapor deposition (PVD) Cathodic arc evaporation coated TiAlN tungsten carbide cutting tool insert during CNC turning of AISI 1015 mild steel. Analysis of Variance has been applied to determine the critical influence of cutting parameters. Taguchi orthogonal test design has been employed to optimize the process parameters affecting surface roughness and tool wear. Depth of cut was found to be the most dominant factor contributing to high surface roughness (67.5%) of the inserts. However, cutting speed, feed rate and flow rate of cutting fluid showed minimal contribution to surface roughness. On the other hand, cutting speed (45.6%) and flow rate of cutting fluid (23%) were the dominant factors influencing tool wear. The optimum cutting conditions for desired surface roughness constitutes the following parameters such as medium cutting speed, low feed rate, low depth of cut and high cutting fluid flow rate. Minimal tool wear was achieved for the following process parameters such as low cutting speed, low feed rate, medium depth of cut and high cutting fluid flow rate.

Effect of Cutting Parameters on the Surface Residual Stress of Face-Milled Pearlitic Ductile Iron

2017 ◽  
Vol 4 (1) ◽  
pp. 38-52
Author(s):  
Olutosin Olufisayo Ilori ◽  
Dare A. Adetan ◽  
Lasisi E. Umoru
Keyword(s):  
Residual Stress ◽  
Fluid Flow ◽  
Flow Rate ◽  
Ductile Iron ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Fluid Flow Rate ◽  
Surface Residual Stress ◽  
Average Surface

The study determined the effect of cutting parameters on the surface residual stress of face-milled pearlitic ductile iron with a view to enhancing surface integrity of machined parts in the manufacturing industries. The pearlitic ductile iron used for this study was prepared and four cutting parameters were considered. The results obtained showed that the average surface residual stress of the machined surfaces was tensile and increased significantly with increase in depth of cut. Feed rate and cutting speed exhibited some effect, though not statistically significant, on average surface residual stress. The average residual stress was found to decrease significantly and drastically from 605.39 MPa to 101.72 MPa as cutting fluid flow rate increased from 0 ?/min to 4 ?/min. The study concluded that out of all four cutting parameters investigated, the cutting fluid flow rate has most considerable influence on the surface residual stress of the machined pearlitic ductile iron.

Corrosion Behavior of Engineering Materials in Flow Field

2014 ◽  
Vol 922 ◽  
pp. 722-727 ◽  
Author(s):  
Yuki Soya ◽  
Shoichiro Yoshihara ◽  
Yuki Ohmura ◽  
Bryan J. Mac Donald ◽  
Emmet Galvin
Keyword(s):  
Surface Roughness ◽  
Fluid Flow ◽  
Mass Loss ◽  
Corrosion Behavior ◽  
Flow Rate ◽  
Body Fluid ◽  
Test Bench ◽  
Fluid Flow Rate ◽  
Magnesium Alloy Az31 ◽  
Diamond Paste

In this study, the effect of fluid flow rate, surface roughness and strain level on the corrosion behavior of magnesium alloy AZ31 was characterized in a custom test bench. Specimens were prepared by mechanical polishing and subject to flow in a simulated body fluid at 37°C for 24 hrs. Compared to a specimen pre-strain of 0%, mass loss was shown to increase by approximately 6% with a specimen pre-strain of 10%. Similarly, mass loss increased by approximately 13% when the fluid flow rate was increased from 250ml/min to 500ml/min. Surface roughness had a significant influence on corrosion behavior. Compared to a specimen polished with a 1 µm diamond paste, the mass loss for a specimen polished with #600 sandpaper was 28% greater.

Effect of coating on tool inserts and cutting fluid flow rate on the machining performance of AISI 1015 steel

2018 ◽  
Vol 60 (12) ◽  
pp. 1202-1208
Author(s):  
Chinnasamy Moganapriya ◽  
Rathanasamy Rajasekar ◽  
Kannayiram Ponappa ◽  
Palaniappan Sathish Kumar ◽  
Samir Kumar Pal ◽  
...  
Keyword(s):  
Fluid Flow ◽  
Flow Rate ◽  
Cutting Fluid ◽  
Fluid Flow Rate ◽  
Machining Performance

Ultrasonic Vibration-Assisted Cutting of Titanium Alloy

2008 ◽  
Vol 389-390 ◽  
pp. 277-282 ◽  
Author(s):  
Shigeomi Koshimizu
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Cutting Fluid ◽  
Dry Cutting ◽  
Interrupted Cutting ◽  
Fluid Supply

Although titanium is a very useful material and becoming more in demand, we are faced with difficulties in machining the material. By applying ultrasonic vibration to the tool tip, interrupted cutting can be applied. Using ultrasonic vibration-assisted cutting of titanium alloy, we succeeded in reducing the cutting force. This technology enables us to improve tool wear and surface roughness of the workpiece. In regards to cutting fluid supply methods, it was found that semi-dry cutting was the most suitable for ultrasonic vibration-assisted cutting of titanium alloy.

Application of Cross-correlation Analysis Method for Measurement of the Fluid Flow Rate Based on X-ray Radiation

2019 ◽  
Vol 11 (1) ◽  
pp. 01025-1-01025-5 ◽  
Author(s):  
N. A. Borodulya ◽  
◽  
R. O. Rezaev ◽  
S. G. Chistyakov ◽  
E. I. Smirnova ◽  
...  
Keyword(s):  
Fluid Flow ◽  
Correlation Analysis ◽  
Flow Rate ◽  
Cross Correlation ◽  
Fluid Flow Rate ◽  
Analysis Method ◽  
X Ray ◽  
Cross Correlation Analysis ◽  
Correlation Analysis Method

A Suction Device Using Air Under Pressure

1956 ◽  
Vol 23 (2) ◽  
pp. 269-272
Author(s):  
L. F. Welanetz
Keyword(s):  
Fluid Flow ◽  
Flow Rate ◽  
Fluid Flows ◽  
Central Hole ◽  
Fluid Flow Rate ◽  
Circular Plates ◽  
Suction Device ◽  
Holding Power ◽  
Plate Separation

Abstract An analysis is made of the suction holding power of a device in which a fluid flows radially outward from a central hole between two parallel circular plates. The holding power and the fluid flow rate are determined as functions of the plate separation. The effect of changing the proportions of the device is investigated. Experiments were made to check the analysis.

scholarly journals Estimation of Flow Rate Through Analysis of Pipe Vibration

2018 ◽  
Vol 12 (4) ◽  
pp. 294-300 ◽  
Author(s):  
Santhosh K. Venkata ◽  
Bhagya R. Navada
Keyword(s):  
Neural Network ◽  
Fluid Flow ◽  
Flow Rate ◽  
Back Propagation ◽  
Vibration Signal ◽  
Vibration Sensor ◽  
Percentage Error ◽  
Fluid Flow Rate ◽  
Bee Colony ◽  
Neural Network Algorithm

Abstract In this paper, implementation of soft sensing technique for measurement of fluid flow rate is reported. The objective of the paper is to design an estimator to physically measure the flow in pipe by analysing the vibration on the walls of the pipe. Commonly used head type flow meter causes obstruction to the flow and measurement would depend on the placement of these sensors. In the proposed technique vibration sensor is bonded on the pipe of liquid flow. It is observed that vibration in the pipe varies with the control action of stem. Single axis accelerometer is used to acquire vibration signal from pipe, signal is passed from the sensor to the system for processing. Basic techniques like filtering, amplification, and Fourier transform are used to process the signal. The obtained transform is trained using neural network algorithm to estimate the fluid flow rate. Artificial neural network is designed using back propagation with artificial bee colony algorithm. Designed estimator after being incorporated in practical setup is subjected to test and the result obtained shows successful estimation of flow rate with the root mean square percentage error of 0.667.

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