Investigation to Study the Applicability of Solid Lubricant in Turning AISI 1040 steel (original) (raw)
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Experimental investigation to study the performance of solid lubricants in turning of AISI1040 steel
Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 2010
Machining is one of the most fundamental and indispensable processes of the manufacturing industry. The heat generated in the cutting zone during machining is critical in deciding the workpiece quality. Though cutting fluids are widely employed to carry away the heat in machining, their usage poses threat to ecology and the health of workers. Hence, there arises a need to identify eco-friendly and user-friendly alternatives to conventional cutting fluids. Modern tribology has facilitated the use of solid lubricants. The present work features a specific study of the application of solid lubricants in turning of AISI1040 steel with carbide tool. Results show considerable improvement in reducing the cutting forces, coefficient of friction between chip and tool interface, average tool flank wear, and the surface roughness of the machined surface with solid lubricants. Among the selected lubricating conditions boric acid performed well compared to graphite. Chip thickness ratio is also e...
Feasibility of Application of Solid Lubricants in Machining Process: A review
To control the high heat generation and its effects during machining, the liquid lubrication has been used traditionally; but there are more problems associated with the health of person and environmental pollution with the use of cutting fluids. So now it is the demand of time and situation that the use of cutting fluid should be minimize or if possible eliminate its use and find out some other means or alternative instead of cutting fluid can be a topic of research in machining. To overcome the difficulties with the cutting fluids one concept is use of solid lubricants while machining and it will control the process temperature and so as heat generated. Solid lubricant, if employed properly, could control the machining zone temperature effectively by intensive removal of heat from the machining zone.
Journal of Engineering, Design and Technology, 2011
Cutting fluids of various types are usually employed to control the heat generated in machining. The continued application of conventional petroleum based metal working fluids is being challenged by the need to reduce overall volume of fluids, minimize health risks and bio-contamination. Bio-oils assisted machining is an environmental bio-compatible technology for desirable control of temperature. This paper investigates the effect of some vegetable based oils on cutting force during cylindrical machining of mild steel, aluminium and copper.
Improvement in Surface Quality with Solid Lubrication in Turning AISI 4340 steel
Hard turning is characterized by development of high temperatures at the cutting zone, which impairs the surface quality of the final product. Thus, an effective control of heat generated at the cutting zone is essential to ensure workpiece surface quality. Cutting fluids are generally used to avoid this. However, cutting fluids are being restricted due to their direct influence to human health and environment. New alternative approaches are in process to alleviate the problems associated with dry and wet hard turning. This study deals with an investigation of molybdenum disulphide as a solid lubricant as an alternative to the cutting fluids to reduce friction and thereby improve the surface finish of bearing steels. Experiments have been conducted using central composite rotatable design, to study the effect of molybdenum disulphide lubricant on surface roughness while hard turning bearing steel. Results indicate that there is a considerable improvement in the performance of hard turning of bearing steels using molybdenum disulphide as a solid lubricant when compared with dry hard turning in terms of surface roughness
Journal of Materials Processing Technology, 2006
Minimum quantity of lubrication (MQL) is an efficient practice in machining of soft materials. Its application during machining of hard materials has not yet been completely explored in scientific research. This work evaluates the wear process of PCBN cutting tools, as well as machining forces, workpiece surface roughness and white layer depth, chip morphology, and chip microstructure in hard turning of induction hardened SAE1045 steel using MQL and compared to dry machining. Results demonstrated that for all the experiments (MQL and dry machining), the abrasive wear was the prevailing mechanism, where the tool wear modes were flank wear and crater wear. Notch wear was observed on both at the end of contact in the secondary cutting edge and at the end of the depth of cut. Secondary notch wear affects the white layer formation and increases the workpiece surface roughness. After a certain period along the cutting time, a reduction in the roughness with an increase in the average flank wear was also observed when using MQL. The use of MQL, despite reducing the average flank wear, increased the notch wear at the secondary cutting edge, and consequently increased the surface roughness. In regard to crater wear, the MQL reduced its occurrence. MQL provided better results than dry machining concerning the machining forces, as well as reduced the white layer occurrence.
gazi university journal of science, 2010
In all machining processes, tool wear is a natural phenomenon and it leads to tool failure. The growing demands for high productivity of machining need use of high cutting velocity and feed rate. Such machining inherently produces high cutting temperature, which not only reduces tool life but also impairs the product quality. Metal cutting fluids changes the performance of machining operations because of their lubrication, cooling, and chip flushing functions but the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. The use of cutting fluid generally causes economy of tools and it becomes easier to keep tight tolerances and to maintain workpiece surface properties without damages. Due to these problems, some alternatives has been sought to minimize or even avoid the use of cutting fluid in machining operations. Some of these alternatives are dry machining and machining with minimum quantity lubrication (MQL). This paper deals with the experimental investigation on the role of MQL on cutting temperature, tool wear, surface roughness and dimensional deviation in turning of AISI-4340 steel at industrial speed-feed combinations by uncoated carbide insert. The encouraging results include significant reduction in tool wear rate, dimensional inaccuracy and surface roughness by MQL mainly through reduction in the cutting zone temperature and favorable change in the chip-tool and work-tool interaction.
Journal of Materials Processing Technology, 2009
This paper presents the effects of minimum quantity lubrication (MQL) by vegetable oil-based cutting fluid on the turning performance of low alloy steel AISI 9310 as compared to completely dry and wet machining in terms of chip-tool interface temperature, chip formation mode, tool wear and surface roughness. The minimum quantity lubrication was provided with a spray of air and vegetable oil. MQL machining was performed much superior compared to the dry and wet machining due to substantial reduction in cutting zone temperature enabling favorable chip formation and chip-tool interaction. It was also seen from the results that the substantial reduction in tool wears resulted in enhanced the tool life and surface finish. Furthermore, MQL provides environment friendliness (maintaining neat, clean and dry working area, avoiding inconvenience and health hazards due to heat, smoke, fumes, gases, etc. and preventing pollution of the surroundings) and improves the machinability characteristics.
This paper elucidates the effect of mineral oil based cutting fluid such as Servocut 'S' grade oil emulsified with water and used edible vegetable oil based cutting fluids such as, Palm Oil and Peanut Oil emulsified with water on the surface quality of AISI 1045 cylindrical steel components. The turning operation is carried out with three TiN coated carbide inserts of different nose radius on AISI 1045 steel using Minimum Quantity Lubrication system. The machining parameters, namely spindle speed, feed rate, depth of cut, tool nose radius and cutting fluids are decided for the lead of trials. The 5 trials are designed based on Taguchi's L (3) orthogonal array. The surface roughness of the turned samples is measured 27 with a surface roughness analyzer and in this manner; a scientific model representing the average surface roughness is created through regression examination. The results revealed that the surface quality of the turned samples using vegetable based cutting fluids are equivalence with the components machined using mineral oil based cutting fluid.
Investigation of lubricant condition and machining parameters while turning of AISI 4340
The International Journal of Advanced Manufacturing Technology, 2014
Metal cutting fluids change performance of machining operations because of their lubrication, cooling, and chip flushing functions. But the use of cutting fluid has become more problematic in terms of both employee health and environmental pollution. The minimization of cutting fluid also leads to economical benefits by way of saving lubricant costs and workpiece/tool/machine cleaning cycle time. Hence, the concept of minimum quantity lubrications (MQL) has been proposed a decade ago to solve problems of environmental intrusiveness and occupational hazards associated with the airborne cutting fluid particles on factory shop floors. The present work contains an experimental investigation to study the effect of various lubrication and machining parameters on tool wear and surface roughness in turning of AISI 4340. Firstly, 12 exploratory experiments have been carried out under 3 different machining regimes and 4 strategies of lubrication namely dry (without any lubricant), air cool (with gaseous lubricant), wet (with pure liquid lubricant), and MQL (mixture of air and liquid). The results indicated that in all cases, the MQL strategy ensures lowest surface roughness and tool wear. Hence, it was selected as the main cooling strategy for the next stage of experiments. In the second stage of experiments, 27 experiments have been designed based on L 27 orthogonal arrays to investigate the influences of feed rate, spindle speed, depth of cut, cutting angle, and mist inlet pressure on surface roughness and tool wear (R a and V B). Then, analysis of variances (ANOVA) has been performed to study the influence of each factor on R a and V B. In order to correlate the relationship between turning parameters and responses, an adaptive neuro-fuzzy system (ANFIS) has been employed. In order to select the optimal solutions for simultaneous minimization of R a and V B , a Grey relational analysis has been applied. The results indicated that cutting speed and feed rate are the most important factors which have major effect on the tool wear and surface roughness. Also, increasing in mist inlet pressure leads to lower surface roughness and tool wear due to cooling and flushing of damaging chips from cutting zone. Also, feed rate of 0.2 mm/rev, spindle speed of 250 RPM, depth of cut of 0.5 mm, cutting angle of 90°, and mist pressure of 3 bar are the optimal combination of turning factors which cause lowest R a and V B , simultaneously. This result has been experimentally verified to prove the effectiveness of the proposed method.