Improving machining performance of Ti-6Al-4V through multi-point minimum quantity lubrication method

2018 ◽  
Vol 233 (1) ◽  
pp. 321-336 ◽  
Author(s):  
Nilanjan Banerjee ◽  
Abhay Sharma
Keyword(s):  
Scientific Evidence ◽  
Minimum Quantity Lubrication ◽  
Experimental System ◽  
Shear Zones ◽  
Lubrication System ◽  
Distribution Factor ◽  
Machining Performance ◽  
Machined Surface ◽  
Minimum Quantity ◽  
Flank Face

This article provides an improved lubrication system for minimum quantity lubrication machining wherein oil is locally supplied and individually controlled at different heating zones during machining operation. The proposed lubrication method, that is, a multi-point minimum quantity lubrication system, is aimed at improving energy efficiency and environmental friendliness of cutting process. An experimental system is devised in which process parameters, such as air pressure, stroke volume (i.e. amount of oil in one stroke of pump), stroke frequency, and oil distribution factor (i.e. proportion of oil at rake and flank face), are individually controlled for each supply system. The devised system is demonstrated through machining of Ti-6Al-4V. The results of the experimental study on effects of oil quantity and supply method on specific cutting energy, tool wear, and machined surface quality are presented and discussed and corroborated with scientific evidence. The study suggests that distributing oil at the rake face and the flank face in unequal proportions can be more beneficial than injecting it solely at a single location. The investigation also provides mechanism of multi-point minimum quantity lubrication machining through analysis of adiabatic shear zones, observed in scanning electron microscope images of chips.

Experimental investigation to study the effect of synthesized and characterized monotype and hybrid nanofluids in minimum quantity lubrication assisted turning of bearing steel

2021 ◽  
pp. 135065012110381
Author(s):  
Anup A Junankar ◽  
Yashpal Yashpal ◽  
Jayant K Purohit
Keyword(s):  
Zinc Oxide ◽  
Copper Oxide ◽  
Minimum Quantity Lubrication ◽  
Bearing Steel ◽  
Hybrid Nanofluid ◽  
Machining Performance ◽  
Minimum Quantity ◽  
Cutting Zone ◽  
Cutting Zone Temperature ◽  
Zone Temperature

A minimum quantity lubrication system using biodegradable cutting fluids has facilitated the excellent machining performance and is observed as more sustainable. In the view of enhancement of machining performance, the utilization of nanofluids with a minimum quantity lubrication system as a cutting fluid delivered noteworthy outcomes. For the present experimental investigation, the monotype nanofluids (copper oxide and zinc oxide) and a hybrid nanofluid (copper oxide/zinc oxide) were synthesized by using a two-step method. Scanning electron microscopy and energy dispersive X-ray analysis were performed to characterize the synthesized nanoparticles. A vegetable oil was utilized as a base fluid and three types of nanofluids were prepared by the addition of a surfactant (butenol). Also, ultrasonication has been performed to avoid the agglomeration of nanoparticles into the base fluid. The thermal conductivity evaluation of prepared nanofluids was carried out by using a hot wire method. The effects of three nanofluids were investigated by considering three machining input variables (cutting speed, feed rate and depth of cut) on response variables (surface roughness and cutting zone temperature) during bearing steel turning under nanofluid minimum quantity lubrication cooling conditions. The multi-objective optimization was performed by using grey relational analysis and found that the hybrid nanofluid (copper oxide/zinc oxide) was noted as the highly effective cooling condition as equated to copper oxide and zinc oxide monotype nanofluid. The hybrid nanofluid (copper oxide/zinc oxide) shows a 65% and 60% reduction in surface roughness on comparing with copper oxide and zinc oxide nanofluids, respectively. Also, the minimization of cutting zone temperature was observed under the hybrid nanofluid (copper oxide/zinc oxide) by 11% and 13% on equating with copper oxide and zinc oxide nanofluids, respectively.

scholarly journals Towards Sustainable Machining of Inconel 718 Using Nano-Fluid Minimum Quantity Lubrication

2018 ◽  
Vol 2 (3) ◽  
pp. 50 ◽  
Author(s):  
Hussien Hegab ◽  
Hossam Kishawy
Keyword(s):  
Inconel 718 ◽  
Government Regulation ◽  
Effective Properties ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Al2o3 Nanoparticles ◽  
Machining Performance ◽  
Multi Wall Carbon Nanotubes ◽  
Minimum Quantity ◽  
Cooling And Lubrication

Difficult-to-cut materials have been widely employed in many engineering applications, including automotive and aeronautical designs because of their effective properties. However, other characteristics; for example, high hardness and low thermal conductivity has negatively affected the induced surface quality and tool life, and consequently the overall machinability of such materials. Inconel 718, is widely used in many industries including aerospace; however, the high temperature generated during machining is negatively affecting its machinability. Flood cooling is a commonly used remedy to improve machinability problems; however, government regulation has called for further alternatives to reduce the environmental and health impacts of flood cooling. This work aimed to investigate the influence of dispersed multi-wall carbon nanotubes (MWCNTs) and aluminum oxide (Al2O3) gamma nanoparticles, on enhancing the minimum quantity lubrication (MQL) technique cooling and lubrication capabilities during turning of Inconel 718. Machining tests were conducted, the generated surfaces were examined, and the energy consumption data were recorded. The study was conducted under different design variables including cutting speed, percentage of added nano-additives (wt.%), and feed velocity. The study revealed that the nano-fluids usage, generally improved the machining performance when cutting Inconel 718. In addition, it was shown that the nanotubes additives provided better improvements than Al2O3 nanoparticles.

scholarly journals Effects of the Tribological Behaviour of h-BN MQL Nano Cutting Fluid (NCF-MQL) on Turning Inconel 625

2019 ◽  
Vol 11 (4) ◽  
pp. 107-121 ◽  
Author(s):  
Chinmaya PADHY ◽  
Pariniti SINGH
Keyword(s):  
Optimization Technique ◽  
Minimum Quantity Lubrication ◽  
Chip Morphology ◽  
Machining Process ◽  
Cutting Fluid ◽  
Inconel 625 ◽  
Machining Parameters ◽  
Machining Performance ◽  
Tribological Behaviour ◽  
Machined Surface

Minimum quantity lubrication (MQL) is currently a widely used lubricating technique during machining, in which minimum amount of lubricant in the form of mist is delivered to the machining interface, thus helps to reduce the negative effects caused to the environment and human health. Further, to enhance the productivity of machining process specifically for hard-to-cut materials, nano cutting fluid (suitably mixed nano materials with conventional cutting fluid) is used as an alternative method to conventional lubrication (wet) in MQL. In this study, h-BN nano cutting fluid was formulated with 0.1% vol. concentration of h-BN in conventional cutting fluid (Servo- ‘S’) for NCF-MQL technique and its tribological behaviors on machining(turning) performance of Inconel 625 were studied and compared with other lubricating conditions (dry, wet, MQL conventional). The tribological effects were analyzed in terms of tool wear analysis, chip morphology along with statistical analysis for machined surface and evolved cutting forces during machining. The optimal input machining parameters for experiments were defined by the use of Taguchi and Grey relational based multi response optimization technique. Finally, the tribological study shows that the use of h-BN NCF-MQL is a viable and sustainable option for improving machining performance of hard- to- cut material like Inconel 625.

Experimental investigation of nanofluids in minimum quantity lubrication during turning of EN-24 steel

2019 ◽  
Vol 234 (5) ◽  
pp. 712-729
Author(s):  
Archana Thakur ◽  
Alakesh Manna ◽  
Sushant Samir
Keyword(s):  
Comparative Analysis ◽  
Desirability Function ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Hybrid Nanofluid ◽  
Machining Performance ◽  
Optimization Of Parameters ◽  
Minimum Quantity ◽  
Response Optimization ◽  
Hybrid Nanofluids

The present work evaluates the performance of different machining environments such as dry, wet, minimum quantity lubrication, Al2O3 nanofluids based minimum quantity lubrication, CuO nanofluids based minimum quantity lubrication and Al–CuO hybrid nanofluids based minimum quantity lubrication on machining performance characteristics during turning of EN-24. The nanofluids and hybrid nanofluids were prepared by adding the Al2O3, CuO and Al2O3/CuO to the soluble oil with different weight percentages (0.5 wt.%, 1 wt.%, 1.5 wt.%). The thermal and tribological properties of hybrid nanofluid and nanofluids were analyzed. The comparative analysis of different turning environments has been done. From comparative analysis it is clearly observed that the nanofluids and hybrid nanofluid shows better performance during turning of EN-24 steel. So there is a need for optimization of parameters during turning of EN-24 under Al2O3 nanofluids based minimum quantity lubrication, CuO nanofluids based minimum quantity lubrication and Al–CuO hybrid nanofluids based minimum quantity lubrication. The optimization of parameters has been done by response surface methodology. The significance of developed model was identified from analysis of variance. Multi-response optimization was done using desirability function approach. To verify the accuracy of developed models, confirmatory experiments were performed. The experimental results reveal that Al–CuO hybrid nanofluids based minimum quantity lubrication significantly improves surface quality, reduces cutting temperature and cutting forces.

Wear behavior of textured tools under graphene-assisted minimum quantity lubrication system in machining Ti-6Al-4V alloy

2020 ◽  
Vol 145 ◽  
pp. 106183 ◽  
Author(s):  
Rupinder Singh ◽  
J.S. Dureja ◽  
Manu Dogra ◽  
Munish Kumar Gupta ◽  
Mozammel Mia ◽  
...  
Keyword(s):  
Wear Behavior ◽  
Minimum Quantity Lubrication ◽  
Lubrication System ◽  
Minimum Quantity
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