Effects of Minimum Quantity Lubrication (MQL) on Chip Formation Mode, Tool Wear, and Surface Roughness in Turning AISI-1040 Steel with Uncoated Carbide Tool

2008 ◽  
Vol 9 (1-2) ◽  
pp. 107-118 ◽  
Author(s):  
M.A.H. Mithu, ◽  
M.M.A. Khan, ◽  
N R. Dhar,
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Chip Formation ◽  
Minimum Quantity Lubrication ◽  
Carbide Tool ◽  
Minimum Quantity ◽  
Formation Mode ◽  
On Chip

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.

Evaluation and comparison of lubrication methods in finish machining of hardened steel mould inserts

2015 ◽  
Vol 231 (14) ◽  
pp. 2458-2467 ◽  
Author(s):  
Yuk Lun Chan ◽  
Xun Xu
Keyword(s):  
Surface Roughness ◽  
Tool Wear ◽  
Feed Rate ◽  
Minimum Quantity Lubrication ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Machining Time ◽  
Minimum Quantity ◽  
Step Over ◽  
Steel Mould

Traditionally, metal cutting fluid or lubricant is used in finishing operations of high-speed machining process to reduce the rate of tool wear, which in turn will improve surface quality. In automobile and aerospace industries, minimum quantity lubrication technique is considered to provide the same level of performance as the flood coolant method and offers financial benefits by saving coolant direct and associated costs. However, scant research work has been done on minimum quantity lubrication applications in the die and mould manufacturing industry. In this study, the effects of dry, flood and minimum quantity lubrication machining on surface roughness, tool wear, dimensional accuracy and machining time of hardened steel mould inserts were compared. The results revealed that there were no significant differences between these three lubrication methods. More in-depth experimental study of dry and minimum quantity lubrication machining was then carried out using the design of experiments technique. In terms of surface roughness and tool wear, there were again no significant differences. Nevertheless, minimum quantity lubrication machining produced more accurate results than dry machining in dimensional deviation. The regression models show that feed-rate ( fz) has a larger effect on surface roughness and machining time than step-over ( ae), while depth of cut ( ap) has no significant effect on surface roughness. Based on the test piece shape, a shortest possible machining time of 3.55 h and a good surface finish of 0.28 µm can be achieved using a small feed-rate (0.03 mm/tooth), a large step-over (0.1 mm) and a large depth of cut (0.2 mm). This work shows that when combining the minimum quantity lubrication technique with the right cutting conditions in modern die and mould manufacturing, machining time and polishing time can be saved, which leads to an overall saving in production cost. Using the dry and minimum quantity lubrication techniques for different finish machining situations can therefore be a good economical solution.

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.

Machinability investigation and sustainability assessment in hard turning of AISI D3 steel with coated carbide tool under nanofluid minimum quantity lubrication-cooling condition

2021 ◽  
pp. 095440622199384
Author(s):  
Lalatendu Dash ◽  
Smita Padhan ◽  
Anshuman Das ◽  
Sudhansu Ranjan Das
Keyword(s):  
Surface Roughness ◽  
Power Consumption ◽  
Sustainability Assessment ◽  
Flank Wear ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Carbide Tool ◽  
Minimum Quantity ◽  
Coated Carbide Tool ◽  
Coated Carbide

The present research addresses the machinability of hardened die steel (AISI D3, 61HRC) in hard turning using multilayer (TiCN/Al2O3/TiN) coated carbide tool under nanofluid based minimum quantity lubrication-cooling condition, where no previous data are available. Power consumption, flank wear, chip morphology and surface integrity (microhardness, residual stress, white layer formation, machined surface morphology, and surface roughness) are considered as technological performance characteristics to evaluate the machinability. Combined approach of central composite design - analysis of variance, response surface methodology and desirability function analysis have been employed respectively for experimental investigation, predictive modelling and multi-response optimization. With a motivational philosophy of “Go Green-Think Green-Act Green”, the work also deals with energy saving carbon footprint analysis and sustainability assessment to recognize the green manufacturing in the context of safer and cleaner production. under environmental-friendly nanofluid assisted minimum quantity lubrication condition. The quantitative analysis revealed that the cutting speed influenced the power consumption during hard machining (75.78%) and flank wear of coated carbide tool (45.67%); feed rate impacted the surface finish of the machined part (68.8%) significantly. Saw tooth shapes of chip produced due to cyclic cracking. Due to low percentage contribution of error (5.32% to Ra, 6.64% to VB, and 7.79% to Pc), a higher correlation coefficient (R2) was obtained with the quadratic regression model, which showed values of 0.9, 0.88 and 0.92 for surface roughness, flank wear, and power consumption, respectively. Optimization with the highest desirability (0.9173) resulted the optimum machining conditions under NFMQL at the cutting speed of 57 m/min, depth of cut 0.1 mm, feed of 0.07 mm/rev, and insert’s nose radius of 0.4 mm. As a result, under NFMQL tool life was improved by 30.8% and 22.6% in respect of flank wear and surface roughness respectively than when machining with MQL technique by adapting the optimum machining condition. Therefore, using hard nanoparticles-reinforced cutting fluid under minimum quantity lubrication condition in practical manufacturing becomes very promising to improve sustainability.

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.

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