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

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.

Surface integrity and Flank wear response under Pure coconut oil-Al2O3 nano MQL turning of Al-7079/7wt.%-TiC in-situ metal matrix composites

Major cooling and lubricating properties such as conduction, convection and lubricant stability at higher temperature are improvised by the addition nano particle into metal cutting fluids. The present investigation is mainly focused into the effects of pure coconut oil (PC) based nano-fluids through minimum quantity lubrication (MQL) on oblique cutting performance of Al-7079/7wt.%-TiC in-situ reinforced metal matrix composites (MMCs). The machining performance has been evaluated under dry machining, pure coconut oil (PC)-MQL and MQL by varying 0.1 % to 0.6 vol. % nano particles into PC. The performance of nano cutting fluids were compared to dry machining and PC machining in terms of cutting forces, tool wear, cutting zone temperature, and surface roughness respectively. It has found that, compared to dry and PC-MQL machining, the performance of nano MQL machining was superior among all cutting conditions. However, above 0.4 % nano particles, the nano MQL performance was degraded drastically which leads to the substantial increment in cutting forces, tool wear, surface roughness and cutting zone temperature respectively.

The Effects of Cooling Applications on Tool Life, Surface Quality, Cutting Forces and Cutting Zone Temperature in Turning of Ni-Based Inconel 625

Nickel-based super alloys are used in many fields, especially in the aviation and aerospace industries, due to their high temperature resistance. Besides these advantages, there are some machining difficulties. Some cooling methods are used to minimize the machining difficulties of these materials. For this purpose, in this study, tool life, tool wear (Vb), surface roughness (Ra), cutting forces (Fc) and cutting zone temperature (T) were investigated in turning Inconel 625 super alloys under different cooling conditions. Experiments were carried out under three different cutting conditions (Dry, minimum quantity lubrication (MQL) and Vortex cooling methods). Three feed rates (0.08, 0.1 and 0.12 mm/rev) and three cutting speeds 60, 80, 100 m/min) were used. Tool wear tests were carried out at average cutting speed and feed rate (80 m/min and 0,1 mm/rev). After the experiments, it was concluded that the cooling application affects positively in terms of tool life, cutting zone temperature and surface roughness.

The Experimental Investigation of Using Thermography Inspection for Dry Turning Process Diagnosis

Increasing the productivity and the quality of the machined parts are the main challenges of metal-based industry. There has been increased interest in monitoring all aspects of the machining process. When cutting metals and alloys most of the energy required to form the chips is converted into heat. Therefore, the temperatures generated in the cutting zone are an important factor to take into consideration. This factor is of a major importance to the performance of the cutting tool and quality of the work piece. Temperature at the cutting point of the tool is then a crucial parameter for controlling the course of turning process.Temperature monitoring by used of thermovision cameras provides a lot of information about thermal behavior of machines, tools and processes since they monitor large areas during normal operation. The article presents the research results referring to the observation of changes of cutting zone temperature with cutting parameters during turning of AW-7020.

The Influence of Tool Stiffness on the Dimensional Accuracy in Titanium Alloy Milling

The paper presents the simulation model of down milling process of titanium alloy (Ti6Al4V) with a tool made of sintered carbides, considering a tool stiffness. A finite element method, applied for numerical computations was experimentally verified with the help of force dynamometer, thermo-vision and high-speed video cameras. Differences between measured and simulated values were less than 22 % for cutting forces and about 8% for maximum cutting zone temperature and about 5% for tool deflection in the active part of the cutting edge.

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

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.

LN2 Grinding of Ti 6Al-4V Using Novel Bondless Diamond Grinding Wheel

Titanium alloys are extremely difficult to machining and economically it’s very expensive, so that to minimize the machining cost using the novel bondless diamond grinding wheel, analyze the performance of nanometric finishing in grinding operation. While machining the Ti alloys, the cutting zone temperature is too high, so that to reduce the temperature of cutting zone and favorable change in the chip-grinding using liquid nitrogen (LN2) coolant for good surface finish.

Applying Genetic Algorithm and BP Neural Network Model to Predict Cutting Area Temperature Distribution in the Laser-Assisted Milling

Laser assisted milling(LAM) can change the cutting processability of the workpiece, which is evaluated by the temperature of cutting zone. Therefore, the prediction of cutting zone temperature in LAM has an important practical meaning. There is a kind of complicated nonlinear relation between the cutting zone temperature and its adjacent temperature. Meanwhile the BP neural network (BP NN)can truly elaborate the nonlinear relation. In this paper, a new kind of algorithm combined the advantages of genetic algorithm (GA) and BP neural network is introduced to predict the temperature correctly. GA is used to train connection weights and biases of BP neural network. According to the characteristics of cutting area temperature distribution, the adjacent temperature and time are selected as the judging indexes. Then the model of predicting the cutting zone temperature is built. Practical application reveals that the model is a very efficient method.