Comparative Study of Rheological Effects of Vegetable Oil-Lubricant, TiO2, MWCNTs Nano-Lubricants, and Machining Parameters’ Influence on Cutting Force for Sustainable Metal Cutting Process (original) (raw)
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The International Journal of Advanced Manufacturing Technology, 2020
Aluminium 8112 alloy has become a leading material in the aluminium family and currently used in the aerospace and automobile industries due to its excellent chemical and mechanical properties. However, during machining of aluminium alloy, one of the challenges faced by the manufacturing industry is the material adhesion, which increases the rate of chips discontinuity at the machining region and leads to a high surface roughness of the workpiece. The focus of this research is to proffer solutions to this material adhesion by implementing vegetable oil that is copra oil-lubricant, titanium dioxide (TiO 2) and multi-walled carbon nanotube (MWCNTs) nano-lubricants during endmilling of AA8112 alloy. Also, using quadratic rotatable central composite design (QRCCD) to study the effects of the machining parameters under minimum quantity lubrication condition, this research used the two-step method to synthesise the nano-lubricants and carried out the homogenisation using the magnetic stirrer and ultrasonic cleaner machine. The study considered five machining factors, including spindle speed, feed rate, length of cut, depth of cut and helix angle. The result from the surface roughness shows that the TiO 2 nano-lubricant reduces the surface roughness with 10% and 17% when compared with the MWCNTs nano-lubricant and copra oil. The minimum surface roughness of 1.15 μm, 1.16 μm and 1.35 μm, for the three machining environments, was achieved, respectively. Spindle speed is the most influential machining parameter, followed by the feed rate. The result of this study will aid the manufacturing industry to produce an excellent quality product for a cleaner manufacturing system. This is a preview of subscription content, access via your institution. Article Google Scholar 2. 2. Okokpujie IP, Bolu CA, Ohunakin OS, Akinlabi ET, Adelekan DS (2019) A review of recent application of machining techniques, based on the phenomena of CNC machining operations. Procedia Manuf 35:1054-1060 3. 3. Lawal SA, Choudhury IA, Nukman Y (2013) A critical assessment of lubrication techniques in machining processes: a case for minimum quantity lubrication using vegetable oil-based lubricant. J Clean Prod 41:210-221 Article Google Scholar 4. 4.
Journal of Measurements in Engineering, 2021
Difficult-to-machine materials, e.g., Titanium alloys, are highly applicable in diverse industries that yield strength and wear resistance. However, they prove difficult to machine due to high vibration, leading to high cutting forces during the machining process. This vibration occurs from chip discontinuity and thereby leads to high friction between the cutting tool and workpiece. In order to minimize these challenges, lubricants are employed in machining operations to reduce frictional and other unnecessary cutting forces and improve surface finish. This research focuses on studying the nano-lubricant effects in reducing cutting forces in the machining of TI-6AL-4V-ELI alloy. Also, carry out a comparative study of dry, mineral oil, and TiO2 nano-lubricant during face-milling machining for optimal performance. Additionally, the study develops a predictive mathematical model for cutting force using a Taguchi L9 orthogonal array. A two-step approach was employed to develop the nano-...
Procedia Manufacturing, 2019
Increasing production quality and minimizing costs in machining process have become an important aspect for green machining. In order for this to be sustained, high concern towards human health and high environmental awareness has resulted to the minimization and elimination of cutting fluids. Therefore, this research project aims at investigating the feasibility of some selected nano-particles dispersed in water as the base fluids. This is deemed a promising solution due to cooling and lubricating attributes of nano-fluids. In this case Al2O3, TiO2 and SiO2 nanoparticles were individually dispersed in water and then used to determine the variation of temperature with machining time and also the surface morphology of chip formation observed from mild steel subjected to an end milling operation in a vertical milling machine. Two pass end milling operation was carried out on the work piece while monitoring temperature response at 30 seconds interval for each trial of experiment with K thermocouple. The mean temperature distribution result obtained were 65.977ºC, 37.542ºC, 36.868ºC and 36.5796ºC for dry, TiO2, SiO2 and Al2O3 water based nano-fluids. The results showed that Al2O3 water base nano-coolant performed better in all the 5g/L nanoparticle concentration, nano-fluids in terms of heat transfer because it had the least mean temperature when compared to dry machining. In conclusion, 5g/L concentration of nano-coolants were efficient in machining but can be improved further by optimization.
A colloidal mixture of metallic or non-metallic nano meter sized particles in a base fluid is called nanofluid (NF). In the present work, a nanofluid with superior thermal and tribological properties is developed by mixing TiO 2 nanoparticles in vegetable oilwater emulsion in different concentrations. The developed nanofluid is characterized for its thermal conductivity and viscosity for various nanoparticle concentrations at different temperatures. Furthermore, its machining performance is examined in turning of AISI 1040 steel using minimum quantity lubrication (MQL) technique. The obtained results are also compared with that of dry machining and wet/MQL machining using conventional cutting fluid. The experimental study clearly reveals that performance of TiO 2 nanofluid in terms of surface roughness, tool wear, cutting force and chip morphology is found to be better compared to dry machining, wet/MQL machining with conventional cutting fluid.
A Review on Minimum Quantity Lubrication for Machining Processes
Materials and Manufacturing Processes, 2014
Presently, nanoparticles are mixed into lubricants to enhance the lubricating and cooling properties. Some research works are available on minimum quantity lubrication (MQL) machining performance of nanofluids suspended with MoS2, Al2O3 and xGnP nanoparticles. However, the deficiency has been found in applying of metal particles like copper (Cu) nanoparticles. In this research, nanofluids have been prepared by mixing four types of nanoparticle (Cu, Graphite, MoS2 and Al2O3) into natural-77 vegetable oil with two concentrations (1 % and 2 %). Taguchi's orthogonal array has used for experimental design. The machining performance of nanofluids are evaluated with regard to the reduction in cutting force and surface roughness during MQL milling of Ti-6Al-4V alloys. Analysis of variance (ANOVA) has carried out to investigate the relative influence of machining parameters. From the analysis, Cu and Graphite nanoparticles have shown higher effects for reducing cutting force and surface roughness. The results of ANOVA have shown that the type and concentration of nanoparticles influence the cutting force significantly. The confirmation tests have carried out and found that copper-nanofluid reduced cutting force and surface roughness by 8.84 % and 14.74 %, respectively. Graphite-nanofluid reduced cutting force and surface roughness by 5.51 % and 21.96 %, respectively.
IAEME PUBLICATION, 2020
This paper focuses on the mechanical and machining process exploration of metallic and carbonaceous nanocutting lubricants with neat cold-pressed canola oil in a fixed volumetric proportion (1%wt). The idea of tri-hybridization with improved lubricative and cooling properties is achieved by using TiO2, Al2O3, and MOS2 metallic nanoparticles and MWCNT, h-BN, and graphite carbonaceous particles. A solution to the traditional dry and wet machining methods is needed for end milling slippery materials like 7011 H aluminum because of the high productivity requirements and the need for good surface quality. In order to address the aforementioned issue, the produced nanofluids were first evaluated for their rheological behavior before being added to the 7011H milling process. In comparison to conventional approaches, the performance of the nanofluids was good overall. Additionally, the experiment results show that, in comparison to monotype nano fluids, the trio-hybridized lubricants have better cutting force, tool wear, and surface roughness reduction. The response surface methodology is used to assess how process factors interact with nanofluids in a minimum quantity lubrication environment. The findings demonstrate that when using hybrid cutting fluids during machining, cutting forces, surface roughness, and tool wear were all reduced and remained well within desirable bounds.
Performance Evaluation of Vegetable-Oil Based Cutting Fluids in Mild Steel Machining
Recently, the application of nano-cutting fluids has gained much attention in the machining of nickel-based super alloys due their good lubricating/cooling properties including thermal conductivity, viscosity, and tribological characteristics. In this study, a set of turning experiments on new nickel-based alloy i.e., Inconel-800 alloy, was performed to explore the characteristics of different nano-cutting fluids (aluminum oxide (Al 2 O 3), molybdenum disulfide (MoS 2), and graphite) under minimum quantity lubrication (MQL) conditions. The performance of each nano-cutting fluid was deliberated in terms of machining characteristics such as surface roughness, cutting forces, and tool wear. Further, the data generated through experiments were statistically examined through Box Cox transformation, normal probability plots, and analysis of variance (ANOVA) tests. Then, an in-depth analysis of each process parameter was conducted through line plots and the results were compared with the existing literature. In the end, the composite desirability approach (CDA) was successfully implemented to determine the ideal machining parameters under different nano-cutting cooling conditions. The results demonstrate that the MoS 2 and graphite-based nanofluids give promising results at high cutting speed values, but the overall performance of graphite-based nanofluids is better in terms of good lubrication and cooling properties. It is worth mentioning that the presence of small quantities of graphite in vegetable oil significantly improves the machining characteristics of Inconel-800 alloy as compared with the two other nanofluids.
During metal cutting operation, cutting fluid plays a vital role by cooling and lubricating the tool-work piece interface and removing chips from the cutting zone. As a result, a cutting fluid may significantly affect the tribological conditions at these interfaces. However, human health and environment both are affected negatively by the excessive use of conventional cutting fluid. This has led to the development of a new class of cutting fluid with superior thermal and tribological properties to restrict its extravagant use during machining. A colloidal mixture of metallic or non-metallic nano meter sized particles in a base fluid is called nanofluid. For the last one decade, nanofluids have attracted the attention of researchers due to its improved thermal conductivity and heat extraction capability. In the present work, a new nanofluid is prepared by mixing Al 2 O 3 nanoparticles in conventional cutting fluid at different concentrations. The prepared nanofluid is characterized for its thermal conductivity and viscosity at all nanoparticle concentrations. Furthermore, its machining performance is examined in turning workpiece of AISI 1040 steel using minimum quantity lubrication (MQL) technique. The results are also compared with that of dry machining and wet/MQL machining using conventional cutting fluid. The experimental study clearly reveals that performance of Al 2 O 3 nanofluid in terms of surface roughness, tool wear, cutting force and chip morphology is found to be better compared to dry machining, wet machining with conventional cutting fluid and MQL using conventional cutting fluid.
International Journal on Advanced Science, Engineering and Information Technology, 2017
Minimum quantity lubrication (MQL) technique did not only serve as a better alternative to flood cooling during machining but enhance better surface finish, minimizes the cost, reduces the impact loads on the environment and health hazards on the operation personnel. However, the coolant or lubrication media used in MQL technique posed certain restrictions especially at very high cutting speeds where the lubricating oil tends to evaporates as it strikes the already heated cutting tool at elevated temperature. Desire to compensate for the shortcomings of the lubricating media in the MQL technique led to the introduction of nanoparticles in the cutting fluids for use in the MQL lubrication process. Nanoparticles have much higher and stronger temperature-dependent thermal conductivity and enhanced heat transfer coefficient at very low particle concentration, which are key parameters for their enhanced performance in many of the machining applications. Optimizing the nanoparticles concentration leads to efficiency in most of their application. Their ball bearing effect lubrication at the cutting zone through formation of film layer which reduces friction between the contact surfaces thereby reducing cutting force, temperature and tool wear. It has been reported in various studies that nanoparticles introduction in cutting fluids led to excellent machining performance in reduction of cutting forces, reduced tool wear, reduced cutting temperature and improved surface finish of the work piece thereby increasing productivity and reduction of hazards to the health of personnel and the environment better than the pure or conventional MQL process. Thus, the application of various nanoparticles and its performances in metal cutting operations with respect to the cutting forces, surface finish, tool wear and temperature at the cutting zone are evaluated and highlighted.
Progress in Additive Manufacturing, 2021
The art of nano-additive manufacturing in developing advanced mechanical components via machining cannot be overemphasized when developing mechanical parts for aerospace, automobile, and structural application through the end-milling of aluminum alloys. However, the end-milling process generates heat and friction due to the machining parameter that initiated the contact between the cutting tool and the workpiece. This excess heat leads to high surface roughness (SR), low material removal rate (MRR), and high cutting force (CF). This study aimed to resolve the machining parameters and the material adhesion by carrying out an experimental evaluation with multiobjective optimization of the machining factors on end-milling of AL8112 alloy using copra oil-based multi-walled carbon nanotube (MWCNTs) nanolubricant. The nano-lubricant preparation was done using the two-step method, and nano-lubricants were implemented via the minimum quantity brought to you by CORE View metadata, citation and similar papers at core.ac.uk provided by Covenant University Repository lubrication (MQL) method with the five machining factors. Additionally, the multi-objective optimization and prediction study was achieved using the ramp and desirability bar plot for the three responses, i.e., SR, MRR, and CF under the quadratic rotatable central composite design (QRCCD). The multiobjective optimization result shows that the minimum SR of 1.16 µm, maximum MRR of 52.1 mm 3 /min, and minimum CF of 33.75 N was obtained at the optimized machining factors. Furthermore, the models predicted the experimental results accurately. In conclusion, the multi-objective optimization with copra oil-based MWCNT's-nano-lubricant enhanced machine parts' production for sustainable additive manufacturing. This is a preview of subscription content, access via your institution. Article Google Scholar 2. 2. Okokpujie I, Okonkwo U, Okwudibe C (2015) Cutting parameters effects on surface roughness during end milling of aluminum 6061 alloy under dry machining operation. Internat J Sci Res 4(7):2030-2036 Google Scholar 3. 3. Sharma S, Kumar R, Gaur A (2015) A model for magnetic nanoparticle transport in a channel for targeted drug delivery. Proc Mater Sci 10:44-49 Article Google Scholar 4. 4.