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.

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 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 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.

Effect of Cutting Fluid Supply Strategies on Surface Finish of Turned Parts

2011 ◽  
Vol 383-390 ◽  
pp. 4576-4584 ◽  
Author(s):  
M.N. Islam ◽  
N. H. Rafai ◽  
B. C. Heng
Keyword(s):  
Surface Roughness ◽  
Surface Finish ◽  
Negative Impact ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Anova Analysis ◽  
Fluid Supply ◽  
Steel Aisi ◽  
Turned Parts

This paper presents the experimental and analytical results of different cutting fluid supply strategies—dry, minimum quantity lubrication (MQL) and flood turning in terms of the surface finish of turned parts. Subsequently, the influence of independent input parameters on surface finish is investigated in order to optimize their effects. Three techniques—traditional analysis, Pareto ANOVA analysis, and the Taguchi method—are employed. Initially mild steel AISI 1030 has been selected as the work material. The results indicate that the cutting fluid supply strategy has insignificant influence on the surface finish of turned parts. However, the amount of cutting fluid in MQL showed some influence. Further research on two additional materials, aluminum 6061 and alloy steel AISI 4340, reveals that the surface roughness for different work materials is influenced differently by the cutting fluid supply strategies and there is a scope for optimizing the cutting fluid supply strategy in terms of both method and the amount of cutting fluid. This will reduce the amount of cutting fluids used and consequently, their negative impact on the environment, by avoiding unnecessary applications.

scholarly journals EXPERIMENTAL ANALYSIS AND OPTIMIZATION OF THE CONTROLLABLE PARAMETERS IN TURNING OF EN AW-2011 ALLOY; DRY MACHINING AND ALTERNATIVE COOLING TECHNIQUES

2020 ◽  
Vol 18 (1) ◽  
pp. 013
Author(s):  
Sonja Jozić ◽  
Ivana Dumanić ◽  
Dražen Bajić
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Material Removal Rate ◽  
Material Removal ◽  
Removal Rate ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Dry Machining ◽  
Cold Air ◽  
Minimum Quantity

The latest trends in machining research show that great efforts are being made to understand the impact of different cooling and lubrication techniques as well as cutting parameters on machining performances. This paper presents the investigation results of different cutting parameters and different cutting environments such as dry machining, minimum quantity lubrication (MQL) and minimum quantity lubrication with compressed cold air (MQL+CCA) on average surface roughness, cutting force and material removal rate. The experiments were designed based on three input parameters and three different cutting environments when turning of EN AW-2011 alloy. Taguchi-based grey relational analysis was used to identify the optimal process parameters by which minimum values of surface roughness, minimum value of cutting force and maximum value of material removal rate will be achieved. The results showed that minimum quantity lubrication in the stream of compressed cold air, in comparison to dry and minimum quantity lubrication machining, gives the best machining performances. Therefore, the use of MQL + CCA method, which reduces the amount of lubricant may represent in the described extent of turning operations an alternative to turning processes most often carried out by wet method that causes considerable costs for purchasing, maintaining and using cutting fluids.

scholarly journals Study of a Multicriterion Decision-Making Approach to the MQL Turning of AISI 304 Steel Using Hybrid Nanocutting Fluid

Materials ◽  
2021 ◽  
Vol 14 (23) ◽  
pp. 7207
Author(s):  
Vineet Dubey ◽  
Anuj Kumar Sharma ◽  
Prameet Vats ◽  
Danil Yurievich Pimenov ◽  
Khaled Giasin ◽  
...  
Keyword(s):  
Decision Making ◽  
Surface Roughness ◽  
Feed Rate ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Aisi 304 ◽  
Minimum Quantity ◽  
Aisi 304 Steel ◽  
Multicriterion Decision Making

The enormous use of cutting fluid in machining leads to an increase in machining costs, along with different health hazards. Cutting fluid can be used efficiently using the MQL (minimum quantity lubrication) method, which aids in improving the machining performance. This paper contains multiple responses, namely, force, surface roughness, and temperature, so there arises a need for a multicriteria optimization technique. Therefore, in this paper, multiobjective optimization based on ratio analysis (MOORA), VIseKriterijumska Optimizacija I Kompromisno Resenje (VIKOR), and technique for order of preference by similarity to ideal solution (TOPSIS) are used to solve different multiobjective problems, and response surface methodology is also used for optimization and to validate the results obtained by multicriterion decision-making technique (MCDM) techniques. The design of the experiment is based on the Box–Behnken technique, which used four input parameters: feed rate, depth of cut, cutting speed, and nanofluid concentration, respectively. The experiments were performed on AISI 304 steel in turning with minimum quantity lubrication (MQL) and found that the use of hybrid nanofluid (Alumina–Graphene) reduces response parameters by approximately 13% in forces, 31% in surface roughness, and 14% in temperature, as compared to Alumina nanofluid. The response parameters are analyzed using analysis of variance (ANOVA), where the depth of cut and feed rate showed a major impact on response parameters. After using all three MCDM techniques, it was found that, at fixed weight factor with each MCDM technique, a similar process parameter was achieved (velocity of 90 m/min, feed of 0.08 mm/min, depth of cut of 0.6 mm, and nanoparticle concentration of 1.5%, respectively) for optimum response. The above stated multicriterion techniques employed in this work aid decision makers in selecting optimum parameters depending upon the desired targets. Thus, this work is a novel approach to studying the effectiveness of hybrid nanofluids in the machining of AISI 304 steel using MCDM techniques.

Application of Minimum Quantity Lubrication for Drum High Clutch in Turning Process

2019 ◽  
Vol 947 ◽  
pp. 160-166
Author(s):  
Nutrada Khumjeen ◽  
Somkiat Tangjitsitcharoen
Keyword(s):  
Tool Life ◽  
Feed Rate ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Condition ◽  
Turning Process ◽  
Minimum Quantity

The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.

The Influence of the Lubrication Method and the Cutting Regime on the Surface Roughness when Milling 7175 Aluminum Alloy

2013 ◽  
Vol 371 ◽  
pp. 28-32 ◽  
Author(s):  
Vlad Diciuc ◽  
Mircea Lobonțiu ◽  
Gheorghe Bran ◽  
Vasile Lazar
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Feed Rate ◽  
Ecological Impact ◽  
Minimum Quantity Lubrication ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Dry Cutting ◽  
Lubrication Conditions

In the current paper, some aspects regarding the quality of the surface machined under different lubrication conditions is being assessed: cutting under a jet of cutting fluid, minimum quantity lubrication cutting, dry cutting. The objective was to assess the results obtained after MQL cutting in comparison with dry cutting and cutting under a jet of cutting fluid. The variables of the cutting regime were the feed rate and the type of milling (climb and conventional). This study has an important ecological impact over the use of cutting fluids.

Experimental investigation of cutting temperature and surface roughness for different cutting fluids during turning of Duplex stainless steel-2205 under minimum quantity lubrication technique

2021 ◽  
Vol 15 (2) ◽  
pp. 8042-8056
Author(s):  
Prashantha Kumar S T ◽  
Thirtha Prasada HP
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Duplex Stainless Steel ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Deionized Water ◽  
Cutting Fluid ◽  
Depth Of Cut ◽  
Cutting Fluids ◽  
Minimum Quantity

Duplex stainless steel (DSS)-2205 comes under hard to machine material owing to its inherent properties but more applications in severe working conditions hence, selection of turning process parameters and suitable cutting fluids of DSS-2205 is essential. In the present work, investigate the performance of Deionized water, neat cut oil, and emulsified fluid on cutting temperature and surface roughness during turning of duplex stainless steel-2205 under minimum quantity lubrication technique. Based on a face-centered composite design, 20 experiments were conducted with varying speed, feed, and depth of cut in three levels for three different fluids. Analysis of variance (ANOVA) is used to identify significant parameters that affect the response. Numerical optimization was carried out under Desirability Function Analysis (DFA) for cutting temperature during deionized water cutting fluid for surface roughness during emulsified cutting fluid. Depth of cut is the significant factor for cutting temperature contribution is 74.83% during Deionized water as a fluid, and feed is the significant factor for surface roughness contribution is 93.57% during emulsified fluid. The optimum cutting parameters were determined for speed (50m/min), feed (0.051mm/rev) and depth of cut (0.4mm). Experimental results revealed that Deionized water gives better results for reduced the cutting temperature and emulsified fluid for surface roughness reduction.

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