An Experimental Investigation on Vegetable Oils as a Cutting Fluid under Minimum Quantity Lubrication: A Sustainable Machining Approach

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.

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

International Journal for Research in Applied Science and Engineering Technology ◽

10.22214/ijraset.2021.36483 ◽

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.

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Performance of Al2O3 nanofluids in minimum quantity lubrication in hard milling of 60Si2Mn steel using cemented carbide tools

Advances in Mechanical Engineering ◽

10.1177/1687814017710618 ◽

2017 ◽

Vol 9 (7) ◽

pp. 168781401771061 ◽

Cited By ~ 15

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.

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Performance of Synthetic and Mineral Soluble Oil When Turning AISI 8640 Steel

Journal of Manufacturing Science and Engineering ◽

10.1115/1.2831190 ◽

1997 ◽

Vol 119 (4A) ◽

pp. 580-586 ◽

Cited By ~ 7

Author(s):

A. R. Machado ◽

M. F. Motta ◽

M. B. da Silva

Keyword(s):

Surface Roughness ◽

Comparative Study ◽

Tool Life ◽

Cutting Forces ◽

Flank Wear ◽

Interface Temperature ◽

Cutting Fluids ◽

Dry Cutting ◽

Steel Bars ◽

Cemented Carbide Tools

The present work shows a comparative study of the application of synthetic and semi synthetic, mineral soluble oil (at concentrations of 3 and 10 percent) as well as dry cut when turning AISI 8640 steel bars with triple coated (TiC,Al2O3,TiN) P35 grade of cemented carbide tools. Tool lives, cutting forces, cutting temperatures and surface roughness were considered to evaluate the cutting fluids. Generally, the semi-synthetic gave longer tool life based on flank wear parameter VB. The surface roughness was not sensitive to the lubrication quality, if wear effects are not considered. Mean tool-chip interface temperature was lower with the synthetic fluid, followed by the semi-synthetic, mineral soluble oils and dry cutting, respectively. The inverse of this order was true for the cutting forces.

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

JOURNAL OF MECHANICAL ENGINEERING AND SCIENCES ◽

10.15282/jmes.15.2.2021.09.0634 ◽

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

Proceedings of the Institution of Mechanical Engineers Part E Journal of Process Mechanical Engineering ◽

10.1177/09544089211003730 ◽

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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Studying The Effect of a New Mixed Cutting Fluid on Surface Roughness

Engineering and Technology Journal ◽

10.30684/etj.v38i11a.1516 ◽

2020 ◽

Vol 38 (11A) ◽

pp. 1593-1601

Author(s):

Mohammed H. Shaker ◽

Salah K. Jawad ◽

Maan A. Tawfiq

Keyword(s):

Surface Roughness ◽

Stainless Steel ◽

Cutting Parameters ◽

Machining Process ◽

Cutting Fluid ◽

Depth Of Cut ◽

Cutting Fluids ◽

Machining Processes ◽

Dry Cutting ◽

Cutting Speeds

This research studied the influence of cutting fluids and cutting parameters on the surface roughness for stainless steel worked by turning machine in dry and wet cutting cases. The work was done with different cutting speeds, and feed rates with a fixed depth of cutting. During the machining process, heat was generated and effects of higher surface roughness of work material. In this study, the effects of some cutting fluids, and dry cutting on surface roughness have been examined in turning of AISI316 stainless steel material. Sodium Lauryl Ether Sulfate (SLES) instead of other soluble oils has been used and compared to dry machining processes. Experiments have been performed at four cutting speeds (60, 95, 155, 240) m/min, feed rates (0.065, 0.08, 0.096, 0.114) mm/rev. and constant depth of cut (0.5) mm. The amount of decrease in Ra after the used suggested mixture arrived at (0.21µm), while Ra exceeded (1µm) in case of soluble oils This means the suggested mixture gave the best results of lubricating properties than other cases.

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A Review of Minimum Quantity Lubrication (MQL) based on Bibliometry

Current Materials Science ◽

10.2174/2666145413999201222104811 ◽

2020 ◽

Vol 13 ◽

Author(s):

Gaurav Gaurav ◽

Abhay Sharma ◽

G S Dangayach ◽

M L Meena

Keyword(s):

Descriptive Analysis ◽

Minimum Quantity Lubrication ◽

Citation Network ◽

Machining Process ◽

Cutting Fluid ◽

Future Research ◽

Research Directions ◽

Minimum Quantity ◽

Research Areas ◽

Future Research Directions

Background: Minimum quantity lubrication (MQL) is one of the most promising machining techniques that can yield a reduction in consumption of cutting fluid more than 90 % while ensuring the surface quality and tool life. The significance of the MQL in machining makes it imperative to consolidate and analyse the current direction and status of research in MQL. Objective: This study aims to assess global research publication trends and hot topics in the field of MQL among machining process. The bibliometric and descriptive analysis are the tools that the investigation aims to use for the data analysis of related literature collected from Scopus databases. Methods: Various performance parameters are extracted, such as document types and languages of publication, annual scientific production, total documents, total citations, and citations per article. The top 20 of the most relevant and productive sources, authors, affiliations, countries, word cloud, and word dynamics are assessed. The graphical visualisation of the bibliometric data is presented in terms of bibliographic coupling, citation, and co-citation network. Results: The investigation reveals that the International Journal of Machine Tools and Manufacture (2611 citations, 31 hindex) is the most productive journal that publishes on MQL. The most productive institution is the University of Michigan (32 publications), the most cited country is Germany (1879 citations), and the most productive country in MQL is China (124 publications). The study shows that ‘Cryogenic Machining’, ‘Sustainable Machining’, ‘Sustainability’, ‘Nanofluid’ and ‘Titanium alloy’ are the most recent keywords and indications of the hot topics and future research directions in the MQL field. Conclusion: The analysis finds that MQL is progressing in publications and the emerging with issues that are strongly associated with the research. This study is expected to help the researchers to find the most current research areas through the author’s keywords and future research directions in MQL and thereby expand their research interests.

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Performance of Low Cost 3D Printed Minimum Quantity Lubrication Applicator Using Palm Oil in Milling Steel

Materials Science Forum ◽

10.4028/www.scientific.net/msf.997.85 ◽

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.

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Experimental Determination of Cutting Power for Turning and Material Removal Rate for Drilling of AA 6061-T6 Using Vegetable Oils as Cutting Fluid

Advances in Tribology ◽

10.1155/2013/362931 ◽

2013 ◽

Vol 2013 ◽

pp. 1-7 ◽

Cited By ~ 10

Author(s):

Y. M. Shashidhara ◽

S. R. Jayaram

Keyword(s):

Vegetable Oils ◽

Material Removal Rate ◽

Cutting Forces ◽

Material Removal ◽

Removal Rate ◽

Mineral Oil ◽

Cutting Fluid ◽

Cutting Fluids ◽

Cutting Power ◽

Thrust Forces

The raw and modified versions of two nonedible vegetable oils, Pongam (Pogammia pinnata) and Jatropha (Jatropha curcas), and a commercially available branded mineral oil are used as straight cutting fluids for turning AA 6061 to assess cutting forces. Minimum quantity lubrication is utilized for the supply of cutting fluids. Cutting and thrust forces are measured. Cutting power is determined for various cutting speeds, depths of cut, and feed rates. Also, drilling is performed on the material to understand the material removal rate (MRR) under these oils. The performances of vegetable oils are compared to mineral oil. A noticeable reduction in cutting forces is observed under the Jatropha family of oils compared to mineral oil. Further, better material removal rate is seen under both the vegetable oils and their versions compared to under petroleum oil for the range of thrust forces.

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The Effect of Cutting Force Vibration on Machining Quality for Reaming ZL102 Alloy with PCD Step Reamer

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.764.279 ◽

2018 ◽

Vol 764 ◽

pp. 279-290

Author(s):

X.D. Wang ◽

W.L. Ge ◽

Y.G. Wang

Keyword(s):

Surface Roughness ◽

Cutting Force ◽

Cutting Forces ◽

Thrust Force ◽

Maximum Amplitude ◽

Spindle Speed ◽

Machining Process ◽

Cutting Fluid ◽

Hole Quality ◽

Force Vibration

The characteristics of cutting forces vibration and its effects to the hole quality in reaming aluminum cast alloy using a poly-crystalline diamond (PCD) step reamer in dry and wet conditions were studied. First, centrifugal force vibration model of the PCD step reamer during machining process was established and through the analysis of the model, it can be concluded that the maximum amplitude of the vibration is positively related to the angular velocity of the reamer. Then, thrust force and cutting torque were measured by a Kistler Dynamometer during reaming process and these vibration frequency and amplitude were analyzed by fast Fourier transformation (FFT). Hole quality was evaluated by hole diameter and surface roughness. Results show that, as the spindle speed increases, the stability of thrust force and cutting torque deteriorates gradually, and there was a severe vibration in the cutting force and the surface roughness when the spindle speed reached 10000 rpm in wet and 7000 rpm in dry cutting conditions. Compared the variation of hole surface roughness and vibration characteristic of cutting forces, it can be observed that the trends are very consistent, the surface roughness deteriorates when cutting forces become unstable. Therefore,the cutting forces stability was an important factor that influence the hole quality. Cutting fluid has a positive effect to stabilize the reaming process and was beneficial to improve the hole quality.

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