Effect of tri-hybridized metallic nano cutting fluids in end milling of AA7075 in minimum quantity lubrication environment

2021 ◽  
pp. 095440892110037
Author(s):  
S Vignesh ◽  
U Mohammed Iqbal
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
End Milling ◽  
Coconut Oil ◽  
Minimum Quantity Lubrication ◽  
Machining Process ◽  
Nano Particles ◽  
Cutting Fluids ◽  
Minimum Quantity ◽  
Nano Fluids

The current paper is concentrated on the mechanical and machining process exploration of metallic nano-lubricant with the concept of tri-hybridization with improved lubricative and cooling properties by using TiO2, ZnO and Fe2O3 metallic nano particles with neat cold-pressed coconut oil in a fixed volumetric proportion (10:90). End milling of gummy material like aluminium requires a solution to the conventional dry and wet machining due to high productivity requirement and to obtain good surface quality. So, the prepared nanofluids were tested for their rheological behavior and latter introduced into milling of AA7075 as a solution to the above stated problem. Overall, the nanofluids gave good performance when compared to conventional methods. Furthermore, the results obtained from the experiments confirm that the trio-hybridized lubricant has reduced the cutting force, tool wear and surface roughness in an improved way when related to monotype nano fluids. The response surface methodology is performed to evaluate the interaction of process parameters in minimum quantity lubrication environment with nano fluids. The results show that the cutting forces, surface roughness, tool wear was minimized while machining with hybrid cutting fluids and well within the desirability.

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.

scholarly journals Application of Eco-Friendly Cutting Fluids Through Small Quantity Lubrication Technique: A Study

2018 ◽  
Vol 7 (2) ◽  
pp. 116-120
Author(s):  
Amrit Pal ◽  
Hazoor Singh Sidhu
Keyword(s):  
Minimum Quantity Lubrication ◽  
Colloidal Suspensions ◽  
Nano Particles ◽  
Cutting Fluid ◽  
Superior Performance ◽  
Cutting Fluids ◽  
Machining Performance ◽  
Machining Processes ◽  
Minimum Quantity ◽  
Nano Fluids

Owing to environmental concerns and growing regulations over contamination and pollution, the demand for renewable and biodegradable cutting fluids is rising. The aim of this paper is to review the eco-friendly and user-friendly minimum quantity lubrication (MQL) technique using vegetable-based oil and solid lubricant in different machining processes. It has been reported in various literature that the minimum quantity lubrication (MQL) method using vegetable oil-based cutting fluid shows superior performance as compared to dry and wet machining. The major benefits of MQL are reduction of consumption of cutting fluid, cost saving, reduction of impact to the environment and improved overall performances in cutting operation and the surface quality. To achieve improved thermal conductivity researchers focused attention on nano fluids. Nano fluids are nano-metered sized colloidal suspensions in the base fluid like water, oil, glycol, etc. The application of nano fluid controls the tool wear by reducing the temperature. Impingement of the nano-particles with high pressure in MQL enables entry of nano-particles at the tool chip interface. Thus it reduces the coefficient of friction and improves machining performance significantly.

scholarly journals Experimental Investigation on Properties and Machining Performance of CNT Suspended Vegetable oil Nanofluids

2018 ◽  
Vol 15 (4) ◽  
pp. 5957-5975
Author(s):  
P. V. Krishna ◽  
R. R. Srikant ◽  
N. Parimala
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Cutting Forces ◽  
Microbial Contamination ◽  
Cutting Temperature ◽  
Coconut Oil ◽  
Minimum Quantity Lubrication ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Machining Performance

This work is motivated by environmentally conscious machining and focus on the basic properties and applicability of nano cutting fluids in machining. Cutting fluids are formulated by dispersing carbon nanotubes (CNT) in coconut oil (CC) with varying percentage of nanoparticle inclusions (NPI). The properties such as density, heat transfer coefficient, dynamic viscosity and thermal conductivity are determined before their application. The formulated nanofluids are applied during machining through minimum quantity lubrication (MQL) technique. Microbial contamination and biodegradability tests are conducted to assess the quality of nanocutting fluids. Viscosity is found to decrease with increase in temperature where, as specific heat slightly decreased with an increase in NPI for CNT dispersed fluids. It is observed that nanofluids in MQL upshot in the reduction of cutting force, cutting temperature, tool wear and surface roughness. CNT dispersed cutting fluids at 0.5% NPI and speed of 60 m/min, 0.131 mm/rev feed and 0.5 mm depth of cut (DOC) shown better performance in the selected range of parameters. Machining performance is more influenced by the percentage of nanoparticles and then the depth of cut, speed and feed respectively. For the cutting conditions, the influence of DOC in obtaining minimum cutting forces and reducing cutting temperatures is found to be 85% and 45% respectively for nBA dispersed fluids. The extent of influence of %NPI is found to be 35.19% for CNT dispersed fluids to obtain reduced cutting forces, cutting temperatures, tool wear and surface roughness according to GRA analysis. Microbial contamination is observed to be the least for 0.5% NPI dispersed fluids. It is also identified that nano cutting fluids used in this work are biodegradable and biologically treatable for disposal as well.

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 Evaluation of MQL with Graphene Mixed Nano Fluids prepared at different Concentrations in Turning of Pure Titanium (TI6Al4V) Alloy

2021 ◽  
Vol 309 ◽  
pp. 01041
Author(s):  
S. Suresh ◽  
N. Sateesh ◽  
Ramsubbiah ◽  
B. Ch Nookaraju ◽  
D. Sivanagaraju ◽  
...  
Keyword(s):  
Experimental Design ◽  
Minimum Quantity Lubrication ◽  
Ti6al4v Alloy ◽  
Cutting Conditions ◽  
Nano Particles ◽  
Cutting Fluids ◽  
Machining Parameters ◽  
Minimum Quantity ◽  
Mql System ◽  
Nano Fluids

This paper presents an investigation into the minimum quantity lubrication mode with Nano fluid during turning of titanium (TI6AL4V) alloy. In heavy cutting conditions, minimum quantity lubrication (MQL) has been observed, that, Nano-cutting fluids which have enrich thermal conductivity than base fluid, are begun to be used in MQL system. The addition of the required nano particle ratio to the base liquid is one of the most important issues that arise in this method. Therefore, this study aimed to find the optimum distribution rate of graphene nano particles having excellent properties and machining parameters. To do this, graphene nano particles were added to a vegetable-based cutting solution. Nano-cutting fluids were prepared in different volumetric concentrations. When turning of titanium (TI6AL4V) alloy, these Nano fluids were used in the MQL system. Three different parameters were added to the experimental design to study the performance of Nano fluids under several cutting conditions. i.e., speed, feed rate and depth off cut. Apart from this experimental design, three tests were carried out at each concentration ratio while keeping the machining parameters constant to clearly see the impact of concentration rates on surface roughness, flank wear. And crater wear. In addition, while chipping/fracture, were observed under all cutting conditions

Effect of Minimum Quantity Lubrication on Tool Wear and Surface Roughness in Micro-Milling

2009 ◽  
Author(s):  
Kuan-Ming Li ◽  
Shih-Yen Chou
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Machine Tools ◽  
Minimum Quantity Lubrication ◽  
Micro Milling ◽  
Burr Formation ◽  
Cutting Fluids ◽  
Electronic Components ◽  
Minimum Quantity ◽  
Aspect Ratios

Micro-milling is a suitable technique for manufacturing of microstructures with high aspect ratios and intricate geometries. The application of the micro-milling process in cutting hardened tool steel is particularly challenging. The low strength of the miniaturized end mills implies accurate control of the chip load in order to prevent the tool break and product dimension errors, which requires high positioning accuracy. It is known that the application of cutting fluids can improve the performance of machining operations. However, the supply of cutting fluids in a conventional way is not appropriate for miniature machine tools due to the plentiful electronic components used to construct micro-scale machine tools. Minimum quantity lubrication (MQL) presents itself as a possible alternative for micro-cutting with respect to the minimum impact on the electronic components as well as low tool wear, better heat dissipation, and machined surface quality in metal cutting. This study compares the mechanical performance of MQL to completely dry condition for the micro-milling of SKD 61 steel based on experimental measurements of tool wears and surface finish. The effect of MQL on the burr formation is also observed. Results indicate that the use of MQL leads to reduced tool wears, better surface roughness, and less burr formation.

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.

Experimental Study on Micro End-Milling Process of Ti-6AL-4V Using Nanofluid Minimum Quantity Lubrication (MQL)

2014 ◽  
Author(s):  
Dae Hoon Kim ◽  
Pil-Ho Lee ◽  
Jung Sub Kim ◽  
Hyungpil Moon ◽  
Sang Won Lee
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
End Milling ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Minimum Quantity ◽  
Nanofluid Minimum Quantity Lubrication ◽  
Micro End Milling ◽  
Milling Forces ◽  
End Milling Process

This paper investigates the characteristics of micro end-milling process of titanium alloy (Ti-6AL-4V) using nanofluid minimum quantity lubrication (MQL). A series of micro end-milling experiments are conducted in the meso-scale machine tool system, and milling forces, burr formations, surface roughness, and tool wear are observed and analyzed according to varying feed per tooth and lubrication conditions. The experimental results show that MQL and nanofluid MQL with nanodiamond particles can be effective to reduce milling forces, burrs and surface roughness during micro end-milling of titanium alloy. In particular, it is demonstrated that smaller size of nanodiamond particles — 35 nm — can be more effective to decrease burrs and surface roughness in the case of nanofluid MQL micro end-milling.

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