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.

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 Investigation on Surface Roughness during Milling of AL-61 Machining under Minimum Quantity Lubrication (MQL)

2021 ◽  
Vol 9 (VII) ◽  
pp. 1059-1064
Author(s):  
Er. Sher Singh
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Surface Finish ◽  
Feed Rate ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Dry Machining ◽  
Minimum Quantity

In modern production industries, main focus is on high productivity with best surface finish. For this purpose use of cutting fluid in machining of component plays major role in controlling the surface finish of components. The cutting fluids are generally applied continually during machining i.e. wet or flooded machining. The dry machining yields poor surface finish and less tool life whereas wet machining results in better surface finish as well as longer tool life. But continuous lubrication involves very large amount of consumption of cutting fluids which cause health hazards of machining operator and ill effects on environment. Moreover, continuous lubrication contributes to increase in total production cost of product. Hence, the Minimum Quantity Lubrication(MQL) is needed nowadays which works with less amount of cutting fluid (100-1000ml/hr) with pressurized air (as mist form) as compare wet machining (amount of cutting fluid 400-500L/hr approx.). The study focus on comparison of surface roughness behavior of AL-6061 under different lubrication conditions i.e. Dry, Wet and MQL. The experimental work performed on CNC milling machine involving cutting parameters feed rate, spindle speed and depth of cut as input parameters, where surface roughness and microstructure of specimens were observed as output parameters in the experiment. The machined components under different conditions i.e. DCM (dry cutting machining), MQL (minimum quantity lubrication), WCM (wet cutting machining) were examined for surface roughness using R-10 surface roughness tester whereas microstructure analysis was done using optical microscope. For given cutting parameters at 2000RPM spindle speed, 200mm/min. feed rate and it is found that better result of MQL from the dry machining and nearest of wet machining.

Machining parameters effect in dry turning of AISI 316L stainless steel using coated carbide tools

2015 ◽  
Vol 231 (4) ◽  
pp. 676-683 ◽  
Author(s):  
Rusdi Nur ◽  
MY Noordin ◽  
S Izman ◽  
D Kurniawan
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Power Consumption ◽  
Cutting Force ◽  
Tool Life ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Machining Parameters ◽  
Aisi 316L ◽  
Coated Carbide

Austenitic stainless steel AISI 316L is used in many applications, including chemical industry, nuclear power plants, and medical devices, because of its high mechanical properties and corrosion resistance. Machinability study on the stainless steel is of interest. Toward sustainable manufacturing, this study also includes the power consumption during machining along with other machining responses of cutting force, surface roughness, and tool life. Turning on the stainless steel was performed using coated carbide tool without using cutting fluid. The turning was performed at various cutting speeds (90, 150, and 210 m/min) and feeds (0.10, 0.16, and 0.22 mm/rev). Response surface methodology was adopted in designing the experiments to quantify the effect of cutting speed and feed on the machining responses. It was found that cutting speed was proportional to power consumption and was inversely proportional to tool life, and showed no significant effect on the cutting force and the surface roughness. Feed was proportional to cutting force, power consumption, and surface roughness and was inversely proportional to tool life. Empirical equations developed from the results for all machining responses were shown to be useful in determining the optimum cutting parameters range.

scholarly journals Effect of Minimum Quantity Lubrication System for Improving Surface Roughness in Turning Operation

2021 ◽  
Vol 6 (1) ◽  
pp. 50-59
Author(s):  
Shazzad Hossain ◽  
Mohammad Zoynal Abedin
Keyword(s):  
Surface Roughness ◽  
Minimum Quantity Lubrication ◽  
Numerical Data ◽  
Cutting Parameters ◽  
Cutting Fluid ◽  
Turning Operation ◽  
Minimum Quantity ◽  
Dimensional Deviation ◽  
Optimum Cutting ◽  
Cutting Zone

Due to increase in temperature at the cutting zone, the tool wear and surface roughness along with the non-uniform chip formation and the dimensional deviation of the job by using the conventional cutting fluid, the machining operation experts have directed their concentrations in order to achieve a smooth machining operation by using minimum quantity lubrication (MQL). As a consequence, numerous efforts can be seen for not only having the optimum cutting parameters but also other parameters that enhance the product quality and the surface roughness. In this regard, relevant experimental and numerical data outcomes not only MQL but also conventional cutting fluid (CCF) in the turning operation of 50HRC steel has been investigated experimentally. It is revealed that the surface roughness becomes optimal and significantly reduced for the condition of MQL with that of dry and conventional flood lubrication.

Experimental Research on Minimum Quantity Lubrication Surface Grinding With Different Cooling and Lubrication Conditions

2021 ◽  
pp. 1052-1079
Author(s):  
Changhe Li ◽  
Hafiz Muhammad Ali
Keyword(s):  
Surface Roughness ◽  
Experimental Research ◽  
Temperature Rise ◽  
Minimum Quantity Lubrication ◽  
Environmentally Friendly ◽  
Grinding Force ◽  
Minimum Quantity ◽  
Urgent Task ◽  
Cooling And Lubrication ◽  
Lubrication Conditions

Given the increasing attention to environmental and health problems caused by machining, the development of an environmentally friendly grinding fluid has become an urgent task. The cooling and lubricating properties of different cooling and lubricating conditions were analyzed. The influence mechanism of nanofluids minimum quantity lubrication (NMQL) on cooling and lubricating effect was revealed with different nanoparticles (MoS2, CNT, ZrO2) and different volume concentrations of MoS2 nanofluids (1%, 2%, 3%). The experimental results showed that the temperature rise (258 °C) and grinding force (Fn=70 N, Ft=27 N) obtained under NMQL grinding were the closest to the flood grinding. The specific grinding energy of MoS2 nanofluids was the lowest, which was 47 J/mm3. When the volume concentration was 2%, the best cooling and lubricating effect was obtained. The surface roughness of the workpiece was the lowest (Ra = 0.283 μm; Rz = 0.424 μm).

The Influence of Spray Characteristics on Surface Roughness in Minimum Quantity Lubrication Turning

2010 ◽  
Vol 97-101 ◽  
pp. 1906-1909
Author(s):  
Chun Yan Zhang ◽  
Gui Cheng Wang ◽  
Hong Jie Pei ◽  
Chun Gen Shen
Keyword(s):  
Surface Roughness ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Mathematics Model ◽  
Particle Dynamic ◽  
Spray Characteristics ◽  
Proper Position ◽  
3 Dimensional ◽  
Minimum Quantity ◽  
Set Up

In Minimum Quantity Lubrication machining, cutting fluid is provided as mist. Mist with different velocity and diameter may lead to different cooling, lubrication effect and cutting quality. Thus, cutting quality is highly influenced by spray characteristics in MQL machining. In this study, the mathematics model of mist flow was set up first. Then spray characteristics were tested by a 3-Dimensional Particle Dynamic Analyzer. In order to study the influence of spray characteristics on cutting quality, precision turning of 45 steel was performed by a CNC Super Precision Machine Tool. The results indicate that the lowest surface roughness was obtained by supplying more cutting fluid at proper position for spraying distance of 20mm.

scholarly journals Pengaruh Metode Minimum Quantity Lubrication (MQL) Terhadap Nilai Kekasaran Permukaan

Rekayasa ◽  
2020 ◽  
Vol 13 (2) ◽  
pp. 125-129
Author(s):  
Dicky Aprilian Nugraha ◽  
Rika Dwi Hidayatul Qoryah ◽  
Mahros Darsin
Keyword(s):  
Surface Roughness ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Fluid Composition ◽  
Machined Surface ◽  
Minimum Quantity ◽  
Flood Depth ◽  
Roughness Analysis ◽  
Machined Surface Roughness

Sebuah alat kendali semprotan cutting fluid pada minimum quantity lubrication (MQL) telah berhasil dibuat. Alat yang bekerja dengan sistem Arduino ini dihubungkan dengan sensor suhu yang diletakkan pada sisi pahat dan berhasil mengendalikan kapan cutting fluid harus disemprotkan dan kapan harus berhenti. Tujuan dari penelitian ini adalah untuk mempelajari efek penggunaan alat kendali ini terhadap kekasaran permukaan pada pembubutan baja AISI 4340. Metode Taguchi L9 digunakan untuk menyusun desain eksperimen dengan variasi parameter: metode pemberian cutting fluid, kedalaman permukaan dan komposisi campuran cutting fluid. Pahat sisipan berbahan karbida digunakan untuk memesin lurus dan roughness tester digunakan untuk mengukur kekesaran permukaan hasil pembubutan. Analisis S/N ratio dilanjutkan dengan analisis varians (ANAVA) membuktikan bahwa metode MQL yang dilengkapi sistem kendali ini mampu menghasilkan rata-rata permukaan paling halus dibandingkan metode lain. Nilai kekasaran optimum sebesar 1,941 µm diperoleh pada kombinasi permesinan dengan MQL dengan sistem kendali, depth of cut 2,0 mm, dan komposisi air terhadap minyak pada cutting fluid 7:3Effect of Minimum Quantity Lubrication (MQL) Method on Surface RoughnessA device to control the spraying of cutting fluid in minimum quantity lubrication (MQL) has been initiated. This device was programmed with Ardunio and connected to a thermal sensor which is stick on the flank face of the tool. It succeeded in controlling when the cutting fluid should be sprayed and stopped. This research aim is to investigate the effect of using this device to the machined surface roughness. The Taguchi method L9 was used for designing the experiments. Variations were made on the method of applying cutting flood, depth of cut, and cutting fluid composition. Carbide insert tools were used and roughness tester was employed to measure the machined surface roughness. Analysis of S/N ratio following with analysis of variance (ANOVA) revealed that the controlled MQL cooling application results in the minimum surface roughness. The optimum surface roughness would be achieved when using MQL with temperature controller, depth of cut of 2.0 mm, and composition between water and oil for cutting fluid of 7:3.

Wear Characteristics of Cutting Tools in Turning of Sintered Steel under Different Lubrication Conditions

2012 ◽  
Vol 523-524 ◽  
pp. 13-18
Author(s):  
Toshiyuki Obikawa ◽  
Tatsumi Ohno ◽  
Masashi Yamaguchi ◽  
Toshio Maetani ◽  
Shigeru Unami ◽  
...  
Keyword(s):  
Cutting Tools ◽  
Cemented Carbide ◽  
Cutting Fluid ◽  
Manufacturing Cost ◽  
Sintered Steel ◽  
Wear Characteristics ◽  
Finish Machining ◽  
Air Jet ◽  
Coated Carbide ◽  
Lubrication Conditions

Finish machining of sintered steel is increasingly important for near net shape technology. However, the life of a cutting tool for machining sintered steel is generally much shorter than for carbon steel and thus, finish machining increases the manufacturing cost of sintered products. For this reason, wear characteristics of several grades of cutting tools in turning sintered steel were investigated under different lubrication conditions. As a result, it is found that a P10 grade of cermet and an S01 grade of AlTiN coated carbide are recommended for dry machining. When cutting fluid is necessary for chip control and disposal, air jet assisted wet machining with a K10 uncoated cemented carbide and wet machining with a P10 cermet are recommended. It is also found that a small amount of cutting fluid remained in the workpiece during wet machining caused an intense thermal impact to a P10 uncoated cemented carbide leading to short tool life.

Experimental Research on Minimum Quantity Lubrication Surface Grinding With Different Cooling and Lubrication Conditions

2020 ◽  
pp. 132-159
Keyword(s):  
Surface Roughness ◽  
Experimental Research ◽  
Temperature Rise ◽  
Minimum Quantity Lubrication ◽  
Environmentally Friendly ◽  
Grinding Force ◽  
Minimum Quantity ◽  
Urgent Task ◽  
Cooling And Lubrication ◽  
Lubrication Conditions

Given the increasing attention to environmental and health problems caused by machining, the development of an environmentally friendly grinding fluid has become an urgent task. The cooling and lubricating properties of different cooling and lubricating conditions were analyzed. The influence mechanism of nanofluids minimum quantity lubrication (NMQL) on cooling and lubricating effect was revealed with different nanoparticles (MoS2, CNT, ZrO2) and different volume concentrations of MoS2 nanofluids (1%, 2%, 3%). The experimental results showed that the temperature rise (258 °C) and grinding force (Fn=70 N, Ft=27 N) obtained under NMQL grinding were the closest to the flood grinding. The specific grinding energy of MoS2 nanofluids was the lowest, which was 47 J/mm3. When the volume concentration was 2%, the best cooling and lubricating effect was obtained. The surface roughness of the workpiece was the lowest (Ra = 0.283 μm; Rz = 0.424 μm).

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