Swarm intelligence based selection of optimal end-milling parameters under minimum quantity nano-green lubricating environment

2021 ◽  
pp. 095440622110127
Author(s):  
Binayak Sen ◽  
Syed Abou Iltaf Hussain ◽  
Munish Kumar Gupta ◽  
Mozammel Mia ◽  
Uttam Kumar Mandal
Keyword(s):  
Palm Oil ◽  
Volume Fraction ◽  
End Milling ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cumulative Distribution ◽  
Depth Of Cut ◽  
Minimum Quantity ◽  
Milling Operations ◽  
Inconel 690

With the development of ideas such as green and sustainable processing, recently evolved lubrication methods are commonly used to resolve the disadvantages of the flood lubrication approach. In the minimum quantity lubrication (MQL) technology, a small lubricant mist is inserted into the tool-workpiece interface to achieve better lubrication. The present study, therefore, explored the viability of alumina-reinforced palm oil as a lubricant in the MQL environment. A diverse volume fraction of aluminium (0-1.4%) was mixed with palm oil, and the optimal concentration of nanoparticles (0.8%) was chosen through spectroscopic analysis. Subsequently, twenty-seven milling operations were carried out on Inconel 690 material under the best lubricating medium. Statistical analysis of the machining values was conducted using the main effect plot (MEP), empiric cumulative distribution (ECD), and analysis of variance (ANOVA). Besides, Response surface methodology (RSM) was used to create a mathematical equation between input and machining responses. Finally, the Particle Swarm Optimization (PSO) approach was applied to achieve an optimal machining environment: cutting speed = 88.348 m/min, feed rate = 0.108 mm/tooth, and depth of cut = 1 mm. The optimal machining conditions were confirmed by functional experimentation, which has shown that the mean error between the experimental and the predictive outputs is minimal (less than 2%).

Optimization of Cutting Parameters of Multiple Performance Characteristics in End Milling of AlSi/AIN MMC – Taguchi Method and Grey Relational Analysis

2014 ◽  
Vol 68 (4) ◽  
Author(s):  
S. H. Tomadi ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim ◽  
A. R. Daud
Keyword(s):  
Taguchi Method ◽  
Grey Relational Analysis ◽  
Volume Fraction ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Performance Characteristics ◽  
Depth Of Cut ◽  
Relational Analysis ◽  
Grey Relational

The main objective of this paper is to investigate and optimize the cutting parameters on multiple performance characteristics in end milling of Aluminium Silicon alloy reinforced with Aluminium Nitride (AlSi/AlN MMC) using Taguchi method and Grey relational analysis (GRA). The fabrication of AlSi/AlN MMC was made via stir casting with various volume fraction of particles reinforcement (10%, 15% and 20%). End milling machining was done under dry cutting condition by using two types of cutting tool (uncoated & PVD TiAlN coated carbide). Eighteen experiments (L18) orthogonal array with five factors (type of tool, cutting speed, feed rate, depth of cut, and volume fraction of particles reinforcement) were implemented. The analysis of optimization using GRA concludes that the better results for the combination of lower surface roughness, longer tool life, lower cutting force and higher material removal could be achieved when using uncoated carbide with cutting speed 240m/min, feed 0.4mm/tooth, depth of cut 0.3mm and 15% volume fraction of AlN particles reinforcement. The study confirmed that with a minimum number of experiments, Taguchi method is capable to design the experiments and optimized the cutting parameters for these performance characteristics using GRA for this newly develop material under investigation.

scholarly journals Nanofluid-based Minimum Quantity Lubrication (MQL) Face Milling of Inconel 625

2019 ◽  
Vol 16 (3) ◽  
pp. 6874-6888
Author(s):  
P. Singh ◽  
J. S. Dureja ◽  
H. Singh ◽  
M. S. Bhatti
Keyword(s):  
Negative Impact ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Face Milling ◽  
Cutting Fluid ◽  
Inconel 625 ◽  
Depth Of Cut ◽  
Base Oil ◽  
Minimum Quantity ◽  
Milling Parameters

Machining with minimum quantity lubrication (MQL) has gained widespread attention to boost machining performance of difficult to machine materials such as Ni-Cr alloys, especially to reduce the negative impact of conventional flooded machining on environment and machine operator health. The present study is aimed to evaluate MQL face milling performance of Inconel 625 using nano cutting fluid based on vegetable oil mixed with multi-walled carbon nanotubes (MWCNT). Experiments were designed with 2-level factorial design methodology. ANOVA test and desirability optimisation method were employed to arrive at optimised milling parameters to achieve minimum tool wear and machined surface quality. Experiments were performed under nanoparticles based minimum quantity lubrication (NMQL) conditions using different weight concentrations of MWCNT in base oil: 0.50, 0.75, 1, 1.25 and 1.5 wt. %; and pure MQL environment (without nanoparticles). The optimal MQL milling parameters found are cutting speed: 47 m/min, table feed rate: 0.05 mm/tooth and depth of cut: 0.20 mm. The results revealed improvement in the surface finish (Ra) by 17.33% and reduction in tool flank wear (VB) by 11.48 % under NMQL face milling of Inconel 625 with 1% weight concentration of MWCNT in base oil compared to pure MQL machining conditions.

Performance Evaluation of PVD and CVD Coated Inserts during End Milling with DRY and MQL Condition

2017 ◽  
Vol 867 ◽  
pp. 165-170
Author(s):  
Isha Srivastava ◽  
Ajay Batish
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
End Milling ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Sem Analysis ◽  
Depth Of Cut ◽  
High Cutting Speed ◽  
Cutting Operation ◽  
En 31

The aim of this study were to evaluate the performance of PVD (TiAlN+TiN) and CVD (TiCN+Al2O3+TiN) coated inserts in end milling of EN–31 hardened die steel of 43±1 HRC during dry and MQL (Minimum quantity lubrication) machining. The experiments were conducted at a fixed feed rate, depth of cut and varying cutting speed to measure the effect of cutting speed on cutting force and tool wear of CVD and PVD-coated inserts. The performance of CVD and PVD-coated inserts under dry and MQL condition by measuring the tool wear and cutting force were compared. During cutting operation, it was noticed that PVD inserts provide less cutting force and tool wear as compared to the CVD inserts under both dry as well as the MQL condition because PVD inserts have a thin insert coating and CVD inserts have a thick insert coating, but PVD inserts experience catastrophic failure during cutting operation whereas CVD inserts have a capability for continuous machining under different machining. Tool wear has measured by SEM analysis. The result shows that MQL machining provides the optimum results as compared to the dry condition. MQL machining has the ability to work under high cutting speed. As the cutting speed increases the performance of dry machining was decreased, but in MQL machining, the performance of the inserts was increased with increases of cutting speed. MQL machining generates less cutting force on the cutting zone and reduces the tool wear which further increase the tool life.

Experimental Investigation on Turning of Monel K500 Alloy Using Nano Graphene Cutting Fluid Under Minimum Quantity Lubrication

2019 ◽  
Author(s):  
Arul Kulandaivel ◽  
Senthil Kumar Santhanam
Keyword(s):  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
High Strength ◽  
High Heat ◽  
Water Soluble ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Turning Operation ◽  
Minimum Quantity

Abstract Turning operation is one of the most commonly used machining processes. However, turning of high strength materials involves high heat generation which, in turn, results in undesirable characteristics such as increased tool wear, irregular chip formation, minor variations in physical properties etc. In order to overcome these, synthetic coolants are used and supplied in excess quantities (flood type). The handling and disposal of excess coolants are tedious and relatively expensive. In this proposed work, Water Soluble Cutting Oil suspended with nanoparticles (Graphene) is used in comparatively less quantities using Minimum quantity lubrication (MQL) method to improve the quality of machining. The testing was done on Turning operation of Monel K500 considering the various parameters such as the cutting speed, feed and depth of cut for obtaining a surface roughness of 0.462μm and cutting tool temperature of 55°C for MQL-GO (Graphene oxide) process.

Application of tri-hybridized carbonaceous nanocutting fluids in an end milling operation by the minimum quantity lubrication technique

2021 ◽  
pp. 135065012110438
Author(s):  
S. Vignesh ◽  
U. Mohammed Iqbal
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
End Milling ◽  
Hexagonal Boron Nitride ◽  
Coconut Oil ◽  
Minimum Quantity Lubrication ◽  
Work Piece ◽  
Cutting Fluids ◽  
Minimum Quantity ◽  
Milling Operations

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.

Effect of Cryogenic Minimum Quantity Lubrication (CMQL) on Cutting Temperature and Tool Wear in High-Speed End Milling of Titanium Alloys

2010 ◽  
Vol 34-35 ◽  
pp. 1816-1821 ◽  
Author(s):  
Yu Su ◽  
Ning He ◽  
Liang Li
Keyword(s):  
Tool Wear ◽  
Titanium Alloys ◽  
High Speed ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
High Cutting Speed ◽  
Cryogenic Minimum Quantity Lubrication

Cryogenic minimum quantity lubrication (CMQL) is a kind of green cooling/lubrication technique, which consists of the application of a small amount of lubricant (6-100 ml/h), delivered in a refrigerated compressed gas stream to the cutting zone. This paper experimentally investigates the effect of CMQL on cutting temperature and tool wear in high-speed end milling of titanium alloys. Comparative experiments were conducted under different cooling/lubrication conditions, i.e. dry milling, refrigerated air cutting, and CMQL. The refrigerated gas equipment was manufactured based on composite refrigeration method to provide the refrigerated air. The experimental results show that application of CMQL resulted in drastic reduction in cutting temperature and tool wear especially when machining titanium alloys at a high cutting speed.

Flank Wear Characterization in Aluminum Alloy (6061 T6) With Nanofluid Minimum Quantity Lubrication Environment Using an Uncoated Carbide Tool

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
M. S. Najiha ◽  
M. M. Rahman ◽  
A. R. Yusoff
Keyword(s):  
Aluminum Alloy ◽  
Wear Mechanisms ◽  
Flank Wear ◽  
Volume Fraction ◽  
End Milling ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
Water Based ◽  
Flank Surface ◽  
Conventional Oil

This study is focused on the categorical analysis of flank wear mechanisms in end milling of aluminum alloy AA6061 with minimum quantity lubrication (MQL) conditions using nanofluid. Wear mechanisms for the water-based TiO2 nanofluid with a nanoparticle volume fraction of 1.5% are compared with conventional oil-based MQL (0.48 ml/min and 0.83 ml/min) using an uncoated cemented carbide insert. Micro-abrasion, micro-attrition, and adhesion wear leading to edge chipping are identified as the main wear mechanisms. Aluminum deposits on the tool flank surface are observed. Results show that the water-based nanofluid shows potential as a capable MQL cutting media, in terms of tool wear, replacing the conventional oil-based MQL.

Effect of Cutting Parameters on Minimum Quantity Lubrication Machining of High Strength Steel

2009 ◽  
Vol 626-627 ◽  
pp. 387-392 ◽  
Author(s):  
L.T. Yan ◽  
Song Mei Yuan ◽  
Qiang Liu
Keyword(s):  
Chip Formation ◽  
Feed Rate ◽  
High Strength Steel ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
High Strength ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Work Piece ◽  
Minimum Quantity

The cutting performance (tool wear, surface roughness of machined work-piece and chip formation)of wet, dry and Minimum Quantity Lubrication (MQL) machining when milling of high strength steel (PCrNi2Mo) using cemented carbide tools under different (cutting speed, depth of cut, feed rate) was analyzed. The experimental results showed that as the cutting speed, depth of cut and feed rate changed, MQL conditions provided the lowest flank wear and the highest surface quality. Chip formation produced under MQL conditions become more favorable in terms of color and shape. The results obtained prove the potential of using MQL technique in the milling process of high strength steel (PCrNi2Mo) for high cutting speed, feed rate and depth of cut.

Investigation on Wear Behavior and Chip Formation During Up-Milling and Down-Milling Operations for Inconel 718

2014 ◽  
Vol 66 (3) ◽  
Author(s):  
M. A. Hadi ◽  
J. A. Ghani ◽  
C. H. Che Haron ◽  
M. S. Kasim
Keyword(s):  
Tool Wear ◽  
Chip Formation ◽  
Inconel 718 ◽  
End Milling ◽  
Wear Behavior ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Milling Operations ◽  
Milling Operation ◽  
Coated Carbide

A comprehensive study and FEM simulation of ball nose end milling on tool wear behavior and chip formation had been performed on Inconel 718 (nickle-based superalloy) under minimum quantity lubricant (MQL) condition. In this paper, the investigation was focusing on the comparison of up-milling and down-milling operations using a multi-layer TiAlN/AlCrN-coated carbide inserts. A various cutting parameters; depth of cut, feed rate and cutting speed were considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear compared to up-milling operation. Chipping on cutting tool edge responsible to notch wear with prolong machining. It was observed that the chips formed in up-milling operation were segmented and continuous, meanwhile down-milling operation produced discontinuous type of chips.

scholarly journals Electrohydrodynamic Atomization for Minimum Quantity Lubrication (EHDA-MQL) in End Milling Ti6Al4V Titanium Alloy

2020 ◽  
Vol 4 (3) ◽  
pp. 70
Author(s):  
Andrea De Bartolomeis ◽  
Alborz Shokrani
Keyword(s):  
Titanium Alloy ◽  
Tool Life ◽  
End Milling ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Machine Material ◽  
Minimum Quantity ◽  
Electrohydrodynamic Atomization ◽  
Titanium Alloy Ti6al4v ◽  
Productivity Gains

Titanium alloy Ti6Al4V is a difficult-to-machine material which is extensively used in the aerospace and medical industries. Machining titanium is associated with a short tool life and low productivity. In this paper, a new cooling-lubrication system based on electrohydrodynamic atomization was designed, manufactured and tested and the relevant theory was developed. The major novelty of the system lies within the use of electrohydrodynamic atomization (EHDA) and a three-electrode setup for generating lubricant droplets. The system was tested and compared with that of flood, minimum quantity lubrication (MQL) and compressed air machining. The proposed system can extend the tool life by 6 and 22 times when compared with MQL and flood cooling, respectively. This is equivalent to more than 170 min tool life at 120 m/min cutting speed allowing for significant productivity gains in machining Ti6Al4V.

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