Performance evaluation of minimum quantity lubrication by vegetable oil in terms of cutting force, cutting zone temperature, tool wear, job dimension and surface finish in turning AISI-1060 steel

2006 ◽  
Vol 7 (11) ◽  
pp. 1790-1799 ◽  
Author(s):  
M. M. A. Khan ◽  
N. R. Dhar
Keyword(s):  
Performance Evaluation ◽  
Tool Wear ◽  
Cutting Force ◽  
Vegetable Oil ◽  
Surface Finish ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
Cutting Zone ◽  
Cutting Zone Temperature ◽  
Zone Temperature

Experimental investigation to study the effect of synthesized and characterized monotype and hybrid nanofluids in minimum quantity lubrication assisted turning of bearing steel

2021 ◽  
pp. 135065012110381
Author(s):  
Anup A Junankar ◽  
Yashpal Yashpal ◽  
Jayant K Purohit
Keyword(s):  
Zinc Oxide ◽  
Copper Oxide ◽  
Minimum Quantity Lubrication ◽  
Bearing Steel ◽  
Hybrid Nanofluid ◽  
Machining Performance ◽  
Minimum Quantity ◽  
Cutting Zone ◽  
Cutting Zone Temperature ◽  
Zone Temperature

A minimum quantity lubrication system using biodegradable cutting fluids has facilitated the excellent machining performance and is observed as more sustainable. In the view of enhancement of machining performance, the utilization of nanofluids with a minimum quantity lubrication system as a cutting fluid delivered noteworthy outcomes. For the present experimental investigation, the monotype nanofluids (copper oxide and zinc oxide) and a hybrid nanofluid (copper oxide/zinc oxide) were synthesized by using a two-step method. Scanning electron microscopy and energy dispersive X-ray analysis were performed to characterize the synthesized nanoparticles. A vegetable oil was utilized as a base fluid and three types of nanofluids were prepared by the addition of a surfactant (butenol). Also, ultrasonication has been performed to avoid the agglomeration of nanoparticles into the base fluid. The thermal conductivity evaluation of prepared nanofluids was carried out by using a hot wire method. The effects of three nanofluids were investigated by considering three machining input variables (cutting speed, feed rate and depth of cut) on response variables (surface roughness and cutting zone temperature) during bearing steel turning under nanofluid minimum quantity lubrication cooling conditions. The multi-objective optimization was performed by using grey relational analysis and found that the hybrid nanofluid (copper oxide/zinc oxide) was noted as the highly effective cooling condition as equated to copper oxide and zinc oxide monotype nanofluid. The hybrid nanofluid (copper oxide/zinc oxide) shows a 65% and 60% reduction in surface roughness on comparing with copper oxide and zinc oxide nanofluids, respectively. Also, the minimization of cutting zone temperature was observed under the hybrid nanofluid (copper oxide/zinc oxide) by 11% and 13% on equating with copper oxide and zinc oxide nanofluids, respectively.

A Critical Factor in Enhancement of MQL Lubricants: Platelet Thickness

2013 ◽  
Author(s):  
Trung Kien Nguyen ◽  
Patrick Y. Kwon ◽  
Kyung-Hee Park
Keyword(s):  
Tool Wear ◽  
Vegetable Oil ◽  
Ball Mill ◽  
Minimum Quantity Lubrication ◽  
Critical Factor ◽  
Solid Lubricants ◽  
Minimum Quantity ◽  
Lamellar Type

The lamellar-type solid lubricants are readily available in a form of platelets. The diameter and thickness of these platelets are typically up to tens of microns and few microns, respectively, which are classified as micro-platelets. Some of these platelets are also available as nano-platelets whose thickness is well below a micron (even to few nanometers). In the previous work, the vegetable oil mixed with nano-platelets was enormously effective for Minimum Quantity Lubrication (MQL) machining. Clearly, the micro-platelets are not as inexpensive. In addition, the mixtures with the micro-platelets are not as stable as those with the nano-platelets. This paper intends to find the effect of the thickness differential on these platelets in MQL machining. The tribometer test shows that the nano-platelets are much more effective than the micro-platelets in reducing wear without changing the friction. With the MQL ball mill experiment, the micro-platelets present in MQL oil increased the tool wear, even compared to the traditional MQL with pure oil only. Thus, the thickness of the nano-platelets holds an important characteristic to enhance MQL-based machining.

Machinability investigation and sustainability analysis of minimum quantity lubrication–assisted micro-milling process

2020 ◽  
Vol 234 (11) ◽  
pp. 1388-1401
Author(s):  
Xueming Yang ◽  
Xiang Cheng ◽  
Yang Li ◽  
Guangming Zheng ◽  
Rufeng Xu
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Sustainability Assessment ◽  
Minimum Quantity Lubrication ◽  
Production Quality ◽  
Milling Process ◽  
Micro Milling ◽  
Cutting Fluids ◽  
Thin Wall ◽  
Minimum Quantity

Machining conditions such as cutting fluids exert a crucial function in micro-milling, which removes chips from the cutting area and lubricates the interface between the tool and workpiece. Therefore, it is necessary to identify suitable cutting fluids for processing different materials. In this article, the effects of cutting fluids (dry, flood cooling, minimum quantity lubrication, and jet cold air) on tool wear, surface roughness, and cutting force were studied. The Pugh matrix environmental approach was used to compare different cutting fluids in terms of sustainable production. In addition, a curved thin wall was processed to demonstrate the value of minimum quantity lubrication in industry. The experimental results illustrated that the minimum quantity lubrication can not only effectively reduce tool wear and cutting force but also improve the finished surface quality. According to the sustainability assessment results, minimum quantity lubrication was superior to other cutting fluids in terms of environmental impact and production quality. The curved thin wall size error was only 2.25% under minimum quantity lubrication condition. This indicated minimum quantity lubrication was particularly suitable for micro-milling of H59 brass and 6061 aluminum compared to other cutting fluids.

Investigation of Machinability in Minimum Quantity Lubrication Milling of GH4169 Aerospace Superalloy

2010 ◽  
Vol 34-35 ◽  
pp. 666-670 ◽  
Author(s):  
Song Mei Yuan ◽  
Lu Tao Yan ◽  
Wei Dong Liu ◽  
Qiang Liu
Keyword(s):  
Cutting Force ◽  
Surface Finish ◽  
Cooling System ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Minimum Quantity ◽  
Cooling Method ◽  
Conventional Cooling ◽  
Cooling Air

Due to environmental concerns and the coming legislations, pollution-free and eco-friendly minimum quantity lubrication (MQL) technology has become focus of attention in manufacture field. The MQL and cooling system in this work has been designed, fabricated and used. The cutting performance of MQL with cooling air compare with the conventional cooling method in milling of GH4169 aerospace superalloy is evaluated based on analysis of cutting force and surface finish. The effect of cutting parameters (depth of cut, feed rate) on machining performances is analyzed. The experimental results show that, the application of MQL and cooling air brings about a lower cutting force, better surface finish compared to conventional coolant environment.

Effect of Minimum Quantity Lubrication when Turning a Steel Grade

2014 ◽  
Vol 541-542 ◽  
pp. 392-396
Author(s):  
K. Abou-El-Hossein
Keyword(s):  
Surface Finish ◽  
Metal Cutting ◽  
Minimum Quantity Lubrication ◽  
Steel Grade ◽  
Dry Cutting ◽  
Minimum Quantity ◽  
Minimum Quantity Lubricant ◽  
Steel Grades ◽  
Cutting Zone ◽  
Cutting Modes

In turning operations a coolant is usually introduced to the cutting zone to reduce the friction developed at the tool-workpiece contact area and remove heat generated because of this rubbing action. Conventionally, a coolant is introduced into the cutting zone in excessive quantities. However, a lot of concern has been raised recently as a result of the uncontrolled using of coolants in the metal cutting industry. Therefore, the concept of minimum quantity lubricant (MQL) has been introduced recently. In this paper, the principle of MQL is utilised in machining of a steel grade. The performance of MQL in terms of surface finish is evaluated against both, the flood coolant and dry cutting modes. The results obtained show that MQL produces acceptable surface finish. Therefore, it is highly recommended to consider the application of MQL instead of flood cooling when turning steel grades.

Effect of hBN Solid Lubricant Concentration on Machinability of Titanium (Ti-6Al-4V) Alloy

2015 ◽  
Vol 830-831 ◽  
pp. 87-90 ◽  
Author(s):  
S. Santosh ◽  
K. Rajkumar ◽  
A. Gnanavelbabu
Keyword(s):  
Solid Lubricant ◽  
Hexagonal Boron Nitride ◽  
Sustainable Manufacturing ◽  
Minimum Quantity Lubrication ◽  
Solid Lubricants ◽  
Aerospace Applications ◽  
Dry Conditions ◽  
Cutting Zone ◽  
Cutting Zone Temperature ◽  
Zone Temperature

The prime rationale for designers to choose titanium in their designs for aerospace applications is its relative low weight for a given strength level and its relative resistance to high temperature. Excellent biocompatibility makes titanium as ideal material for many biomedical applications. Even though the titanium products are either sintered or cast into required shape, there is a need for machining in order to produce intricate shapes. However machining of titanium alloys poses many serious problems owing to the reactivity of titanium at high cutting temperatures and rapid tool wear. An alternative method to overcome this is by reducing the cutting zone temperature. This can be achieved by the addition of solid lubricants to regular cutting liquids and using it as minimum quantity lubrication (MQL) strategy. In this study, hexagonal boron nitride (hBN) powder with different concentrations (5, 10, 15 wt %) was mixed with water and used as a lubricant. Turning experiments were performed with TiAlN coated Tungsten carbide insert for a constant speed and variable feed rates. For comparison purpose, machining was carried out under dry conditions. Results indicate that the cutting zone temperature reduced drastically on addition of solid lubricant hBN with water. MQL conditions showed that cutting zone temperature decreased by several folds when compared to dry machining. However there was no significant decrease in temperature between 10 and 15 wt% hBN additions which indicates that 10% hBN addition proves to be optimal. This type of machining thereby paves way for sustainable manufacturing.

Multi-Point Injection Minimum Quantity Lubrication Machining

2015 ◽  
Vol 830-831 ◽  
pp. 108-111 ◽  
Author(s):  
Nilanjan Banerjee ◽  
Abhay Sharma
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Minimum Quantity Lubrication ◽  
Working Fluid ◽  
Multiple Points ◽  
Minimum Quantity ◽  
Special Attachment ◽  
Point Injection ◽  
Cutting Zone

This paper presents a study on minimum quantity lubrication wherein the metal working fluid is injected individually at multiple points in cutting zone, namely, rake face, back of chip and at flank face. A special attachment is developed for injecting aerosol at all possible combinations of one, two, or three forgoing points of injection. A case study on machining of Ti-6Al-4V showing effect of injection schemes on cutting force and surface roughness is presented. Comparison of multi-point injection with dry and flood cooling indicates reduction in cutting force and surface roughness while using different combinations of fluid injection.

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