Flank Wear Characterization in Aluminum Alloy (6061 T6) With Nanofluid Minimum Quantity Lubrication Environment Using an Uncoated Carbide Tool

2015 ◽  
Vol 137 (6) ◽  
Author(s):  
M. S. Najiha ◽  
M. M. Rahman ◽  
A. R. Yusoff
Keyword(s):  
Aluminum Alloy ◽  
Wear Mechanisms ◽  
Flank Wear ◽  
Volume Fraction ◽  
End Milling ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
Water Based ◽  
Flank Surface ◽  
Conventional Oil

This study is focused on the categorical analysis of flank wear mechanisms in end milling of aluminum alloy AA6061 with minimum quantity lubrication (MQL) conditions using nanofluid. Wear mechanisms for the water-based TiO2 nanofluid with a nanoparticle volume fraction of 1.5% are compared with conventional oil-based MQL (0.48 ml/min and 0.83 ml/min) using an uncoated cemented carbide insert. Micro-abrasion, micro-attrition, and adhesion wear leading to edge chipping are identified as the main wear mechanisms. Aluminum deposits on the tool flank surface are observed. Results show that the water-based nanofluid shows potential as a capable MQL cutting media, in terms of tool wear, replacing the conventional oil-based MQL.

Swarm intelligence based selection of optimal end-milling parameters under minimum quantity nano-green lubricating environment

2021 ◽  
pp. 095440622110127
Author(s):  
Binayak Sen ◽  
Syed Abou Iltaf Hussain ◽  
Munish Kumar Gupta ◽  
Mozammel Mia ◽  
Uttam Kumar Mandal
Keyword(s):  
Palm Oil ◽  
Volume Fraction ◽  
End Milling ◽  
Cutting Speed ◽  
Minimum Quantity Lubrication ◽  
Cumulative Distribution ◽  
Depth Of Cut ◽  
Minimum Quantity ◽  
Milling Operations ◽  
Inconel 690

With the development of ideas such as green and sustainable processing, recently evolved lubrication methods are commonly used to resolve the disadvantages of the flood lubrication approach. In the minimum quantity lubrication (MQL) technology, a small lubricant mist is inserted into the tool-workpiece interface to achieve better lubrication. The present study, therefore, explored the viability of alumina-reinforced palm oil as a lubricant in the MQL environment. A diverse volume fraction of aluminium (0-1.4%) was mixed with palm oil, and the optimal concentration of nanoparticles (0.8%) was chosen through spectroscopic analysis. Subsequently, twenty-seven milling operations were carried out on Inconel 690 material under the best lubricating medium. Statistical analysis of the machining values was conducted using the main effect plot (MEP), empiric cumulative distribution (ECD), and analysis of variance (ANOVA). Besides, Response surface methodology (RSM) was used to create a mathematical equation between input and machining responses. Finally, the Particle Swarm Optimization (PSO) approach was applied to achieve an optimal machining environment: cutting speed = 88.348 m/min, feed rate = 0.108 mm/tooth, and depth of cut = 1 mm. The optimal machining conditions were confirmed by functional experimentation, which has shown that the mean error between the experimental and the predictive outputs is minimal (less than 2%).

Experimental Evaluation on the Effect of the Position of the Nozzle in End Milling under Minimum Quantity Lubrication Condition

2012 ◽  
Vol 155-156 ◽  
pp. 42-46 ◽  
Author(s):  
Song Mei Yuan ◽  
Si Liu ◽  
Lu Tao Yan ◽  
Qing Chun Xiong
Keyword(s):  
Negative Impact ◽  
End Milling ◽  
Minimum Quantity Lubrication ◽  
Experimental Investigations ◽  
Promising Alternative ◽  
Minimum Quantity ◽  
Milling Tool ◽  
Nozzle Position ◽  
Lubrication Condition ◽  
Oil Mist

Stricter environmental regulations are making the use of an ample amount of conventional coolant impossible because of its negative impact on the environment. Consequently, the use of minimum quantity lubrication (MQL) has been regarded as an promising alternative to conventional fluid coolant applications. Despite several studies, there have been a few investigations about the influence of the MQL nozzle position, such as distance from tool-workpiece contact zone, elevation angles, the included angle between jet direction and feed direction. The current study presents experimental investigations on influences of the above parameters on performance in end milling. Tool wear and surface roughness are experimentally studied to compare the effects of different positions. The results show that the setting location of the nozzle is an important factor regarding the effective application of MQL oil mist.

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