Minimum Quantity Lubrication Research Papers (original) (raw)
Recently all environmental worries are calling for reducing the usage of fluids in machining operations. One of the promising solutions that appeared lately is minimum quantity lubrication (MQL). This research aimed to develop an... more
Recently all environmental worries are calling for reducing the usage of fluids in machining operations. One of the promising solutions that appeared lately is minimum quantity lubrication (MQL). This research aimed to develop an eco-friendly cooling system for a lathe machine and assess its performance. After considering the customer needs, the needs were translated into engineering specifications in the conceptual design phase, and then the quality function deployment was developed. Three concepts were generated and evaluated considering the selection criteria, and a final concept was selected using the decision matrix method. Following this, a detailed design and fabrication of the subsystems such as the oil tank and a structure accommodate all the components. The developed system was tested on six different workpiece samples to compare the MQL system with the conventional one. In general, the MQL system resulted in lower surface roughness values as well as lower tool wear.
In this study, a review of the available literature on lubrication techniques during machining processes was conducted. Factors such as workpiece material, tool material and machining conditions were observed to be vital to the... more
In this study, a review of the available literature on lubrication techniques during machining processes was conducted. Factors such as workpiece material, tool material and machining conditions were observed to be vital to the performance of any of the techniques. The performance and drawback of each technique were highlighted based on the machining conditions. It concludes by making a case for minimum quantity lubrication (MQL) method using vegetable oil-based lubricant in different machining processes, as a way of addressing the environmental health issues and cost associated with the application of lubricant in machining processes.
Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems.... more
Machining operations are very common for the production of auto parts, i.e., connecting rods, crankshafts, etc. In machining, the use of cutting oil is very necessary, but it leads to higher machining costs and environmental problems. About 17% of the cost of any product is associated with cutting fluid, and about 80% of skin diseases are due to mist and fumes generated by cutting oils. Environmental legislation and operators’ safety demand the minimal use of cutting fluid and proper disposal of used cutting oil. The disposal cost is huge, about two times higher than the machining cost. To improve occupational health and safety and the reduction of product costs, companies are moving towards sustainable manufacturing. Therefore, this review article emphasizes the sustainable machining aspects of steel by employing techniques that require the minimal use of cutting oils, i.e., minimum quantity lubrication, and other efficient techniques like cryogenic cooling, dry cutting, solid lubricants, air/vapor/gas cooling, and cryogenic treatment. Cryogenic treatment on tools and the use of vegetable oils or biodegradable oils instead of mineral oils are used as primary techniques to enhance the overall part quality, which leads to longer tool life with no negative impacts on the environment. To further help the manufacturing community in progressing towards industry 4.0 and obtaining net-zero emissions, in this paper, we present a comprehensive review of the recent, state of the art sustainable techniques used for machining steel materials/components by which the industry can massively improve their product quality and production.
The quality of machined components is currently of high interest, for the market demands mechanical components of increasingly high performance, not only from the standpoint of functionality but also from that of safety. Components... more
The quality of machined components is currently of high interest, for the market demands mechanical components of increasingly high performance, not only from the standpoint of functionality but also from that of safety. Components produced through operations involving the removal of material display surface irregularities resulting not only from the action of the tool itself, but also from other factors that contribute to their superficial texture. This texture can exert a decisive influence on the application and performance of the machined component. This article analyzes the behavior of the minimum quantity lubricant (MQL) technique and compares it with the conventional cooling method. To this end, an optimized fluid application method was devised using a specially designed nozzle, by the authors, through which a minimum amount of oil is sprayed in a compressed air flow, thus meeting environmental requirements. This paper, therefore, explores and discusses the concept of the MQL in the grinding process. The performance of the MQL technique in the grinding process was evaluated based on an analysis of the surface integrity (roughness, residual stress, microstructure and microhardness). The results presented here are expected to lead to technological and ecological gains in the grinding process using MQL. r
The machining parameters of any machining operation highly affect the surface quality of a component. The objective of this investigation was to find the best possible machining parameters in order to obtain better surface quality. CNC... more
The machining parameters of any machining operation highly affect the surface quality
of a component. The objective of this investigation was to find the best possible machining
parameters in order to obtain better surface quality. CNC turning was carried out with titanium nitride-coated carbide insert on hardened C45 medium carbon steel. The turning parameters, namely spindle speed, feed rate, depth of cut and nose radius were chosen to conduct the experiments based on L9(3)4 orthogonal array. Surface roughness of the machined specimens was measured with a surface roughness tester. A mathematical model representing average surface roughness was developed using regression analysis with the help of MINITAB software. The optimum machining conditions for minimum surface roughness were determined through Taguchi technique and genetic algorithm and verified with confirmation experiments.
In this paper, experimental investigations are carried out by end milling process on hardened tool steel, Impax Hi Hard (Hardness 55 HRC) a newly developed tool steel material used by tool and die making industries. Experiments are... more
In this paper, experimental investigations are carried out by end milling process on hardened tool steel, Impax Hi Hard (Hardness 55 HRC) a newly developed tool steel material used by tool and die making industries. Experiments are performed with an aim to study performance investigations of machining parameters such as cutting speed, feed, depth of cut and width of cut with consideration of multiple responses viz. volume of material removed, tool wear, tool life and surface finish to evaluate the performance of PVD coated carbide inserts and ball end mill cutters. It has been observed through scanning electron microscope, X-ray diffraction technique (EDX) that chipping and adhesion are active tool wear mechanisms and saw-toothed chips are formed while machining of Impax Hi Hard steel. It is also noticed out that tool life is not enhanced while machining with minimum quantity lubricant than dry machining. From the investigations, it is observed that hard machining can be considered as an alternative to grinding and EDM, traditional methods of machining difficult-to-machine materials i.e. hardened steel with hardness greater than 50 HRC with a scope of improved productivity, increased flexibility, decreased capital expenses and reduced environmental waste.
In recent years, going green has become a strategic priority in manufacturing which has evolved from the growing awareness of the need for environmentally friendly processes and products. Recent trends in developing new machining... more
In recent years, going green has become a strategic priority in manufacturing which has evolved from the growing awareness of the need for environmentally friendly processes and products. Recent trends in developing new machining strategies able to support environmental protection and prevention of pollution in balance with socioeconomic needs and technical requirements inevitably require significant efforts in fundamental understanding of the actual energy and material flows needed to meet the machining requirements. This paper describes the methodology and software, Global Reasoning for Eco-Evaluation of Machining, developed to evaluate the use phase of a machine tool system with respect to a consistent set of technical, economical, and environmental criteria, as a part of the NEXT European project. The evaluation, based on the analytic hierarchy process, is conducted at two levels: (a) the process/part level which considers the local cutting environment along with the "actors" that are directly involved in the cutting area, their relationships, and the phenomena that occur from their interactions and (b) the system level which gathers together the main specifications of the machine tool system and the energy requirements associated with various activities performed in order to support the material removal processes. Two database structures were defined in order to store the entire amount of data needed to perform the analysis at each level. A detailed example of the evaluation carried out at the first level demonstrated the superior performance of the dry and minimum quantity lubrication alternatives over their wet machining counterpart when cutting power, cutting fluid consumption, and the machining time were considered as criteria for the performance evaluation of various milling tests.
The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace industry as it is efficient for energy and has excellent properties. In this paper, the experimental studies of tool wear mechanism and tool... more
The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace industry as it is efficient for energy and has excellent properties. In this paper, the experimental studies of tool wear mechanism and tool life in ball nose end milling of Inconel 718 is presented under minimum quantity lubricant (MQL) condition. The evaluations of the results are focusing on the comparison of up-milling and down-milling operations using physical vapor deposition (PVD) - coated carbide inserts. Machining parameters; depth of cut, feed rate and cutting speed are considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear than up-milling operation. Chipping on cutting tool edge was the primary reason that responsible to notch wear with prolong machining.
In this study, a review of the available literature on lubrication techniques during machining processes was conducted. Factors such as workpiece material, tool material and machining conditions were observed to be vital to the... more
In this study, a review of the available literature on lubrication techniques during machining processes was conducted. Factors such as workpiece material, tool material and machining conditions were observed to be vital to the performance of any of the techniques. The performance and drawback of each technique were highlighted based on the machining conditions. It concludes by making a case for minimum quantity lubrication (MQL) method using vegetable oil-based lubricant in different machining processes, as a way of addressing the environmental health issues and cost associated with the application of lubricant in machining processes.
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... more
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.
Nowadays, the challenge in machining industries is focused on achieving high-quality product on component accuracy, and high production rate. It is necessary to enhance existing technology and develop the product with reasonable cost.... more
Nowadays, the challenge in machining industries is focused on achieving high-quality product on component accuracy, and high production rate. It is necessary to enhance existing technology and develop the product with reasonable cost. Thus, researchers have developed advanced technology such as high-speed machining. High-speed machining plays a very important role in achieving cost and time savings together with better surface finish and dimensional accuracy. High-speed machining is being widely employed in the aerospace industry. Aluminum 7075-T6 is one of the popular materials with attractive properties such as high tensile strength, toughness and high corrosion resistance. Minimum quantity lubrication is known as a technique to provide the best cutting performances. This paper provides the recent studies in minimum quantity lubrication and high-speed machining of aluminum 7075-T6. The influence of high-speed machining process parameters in term the surface roughness and relevant cutting fluid technique have been discussed based on the findings of the recent studies.
Modeling and optimization of cutting parameters are one of the most important elements in machining processes. The present study focused on the influence machining parameters on the surface roughness obtained in drilling of AISI 1045. The... more
Modeling and optimization of cutting parameters are one of the most important elements in machining processes. The present study focused on the influence machining parameters on the surface roughness obtained in drilling of AISI 1045. The matrices of test conditions consisted of cutting speed, feed rate, and cutting environment. A mathematical prediction model of the surface roughness was developed using response surface methodology (RSM). The effects of drilling parameters on the surface roughness were evaluated and optimum machining conditions for minimizing the surface roughness were determined using RSM and genetic algorithm. As a result, the predicted and measured values were quite close, which indicates that the developed model can be effectively used to predict the surface roughness. The given model could be utilized to select the level of drilling parameters. A noticeable saving in machining time and product cost can be obtained by using this model.
Many scientists are working in the field of machining fluids to reduce its usage while machining for economic and environmental benefits. Near Dry Machining (NDM) is a new machining technique in which an oil mist in a compressed air... more
Many scientists are working in the field of machining fluids to reduce its usage while machining for economic and environmental benefits. Near Dry Machining (NDM) is a new machining technique in which an oil mist in a compressed air stream, rather than a flood coolant is applied to the machining interface. There are three types of NDM systems exist today internal, external and single channels. Mist is supplied to the machining area according to machining operation. However, there is no proper approach to this technique. Some studies have stated that NDM results in zero airborne mist levels since the oil mist vaporizes. In this review, an effort is made to study the NDM advantage over the conventional dry and flooded machining application.
The paper presents a study of the effect of operating variable parameter; cutting speed, feed rate, depth of cut and width of cut on heat being generated when end milling under MQL condition. The response surface methodology (RSM) was... more
The paper presents a study of the effect of operating variable parameter; cutting speed, feed rate, depth of cut and width of cut on heat being generated when end milling under MQL condition. The response surface methodology (RSM) was employed in the experiment, and a Box–Behnken design was used to determine the cause and effect of the relationship between the input variables and response. The investigated milling parameters were cutting speed (100 - 140 m/min), feed rate (0.1 - 0.2 mm/tooth), depth of cut (0.5-1.0 mm) and width of cut (0.2 -1.8 mm). Result of this study show ball nose end milling generates low temperature ranging from 69°C to 359°C. Experimental data and statistical analysis showed that heat generation was dominated by radial depth of cut, followed by axial depth of cut. Feed rate and cutting speed were found statistically not significant. The linear models were developed with a 92% confidence level. The optimum condition required for minimum heat generated include...
A predictive model is presented to optimize deep drilling operations under high speed conditions for the manufacture of steel components such as moulds and dies. The input data include cutting parameters and axial cutting forces measured... more
A predictive model is presented to optimize deep drilling operations under high speed conditions for the manufacture of steel components such as moulds and dies. The input data include cutting parameters and axial cutting forces measured by sensors on the milling centres where the tests are performed. The novelty of the paper lies in the use of Bayesian Networks that consider the cooling system as an input variable for the optimization of roughness quality in deep drilling operations. Two different coolant strategies are tested: traditional working fluid and MQL (Minimum Quantity Lubrication). The model is based on a machine learning classification method known as Bayesian networks. Various measures used to assess the model demonstrate its suitability to control this type of industrial task. Its ease of interpretation is a further advantage in comparison with other artificial intelligence tools, which makes it a user-friendly application for machine operators.
Turning operations are a versatile secondary metal cutting process. In metal cutting industry, manufacturing processes are designed to attain minimum manufacturing cost, best quality and improved cutting tool's performance. Nonetheless,... more
Turning operations are a versatile secondary metal cutting process. In metal cutting industry, manufacturing processes are designed to attain minimum manufacturing cost, best quality and improved cutting tool's performance. Nonetheless, the deterioration of cutting tools, occupational diseases amongst the workers and environmental aspects are increasingly becoming a major issue. Therefore, one alternative to reduce the impact of metal cutting activity in term of cutting tool, the health and environment is Portable MQL Applicator. The portable MQL applicator is an equipment that equipped with pneumatic system to deliver a small amount of fluid in the form of aerosol into the cutting zone. The effect of the portable MQL applicator was investigated and compared with the results from dry machining in terms of tool life and material removal rate in turning of Inconel 718 using carbide tool. The results showed that the applications of the portable MQL applicator have successfully resulted in better tool life and improved material removal rate.
The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace industry as it is efficient for energy and has excellent properties. In this paper, the experimental studies of tool wear mechanism and tool... more
The demand for the use of nickel-based superalloy such as Inconel 718 is increasing in aerospace industry as it is efficient for energy and has excellent properties. In this paper, the experimental studies of tool wear mechanism and tool life in ball nose end milling of Inconel 718 is presented under minimum quantity lubricant (MQL) condition. The evaluations of the results are focusing on the comparison of up-milling and down-milling operations using physical vapor deposition (PVD) -coated carbide inserts. Machining parameters; depth of cut, feed rate and cutting speed are considered during the evaluation. The experimental results showed that down-milling operation has better results in terms of tool wear than up-milling operation. Chipping on cutting tool edge was the primary reason that responsible to notch wear with prolong machining.
Nowadays the increasing interest to perform machining operations is in dry/near-dry environments. The reason includes health and safety of operator, cost, ease of chip recyclability, etc. However one important process, which is difficult... more
Nowadays the increasing interest to perform machining operations is in dry/near-dry environments. The reason includes health and safety of operator, cost, ease of chip recyclability, etc. However one important process, which is difficult to perform in dry, is ...
The paper presents a studyof the effect of operating variable parameter; cutting speed, feed rate, depth of cut and width of cut on heat being generated when end milling under MQL condition. The response surface methodology (RSM) was... more
The paper presents a studyof the effect of operating variable parameter; cutting speed, feed rate, depth of cut and width of cut on heat being generated when end milling under MQL condition. The response surface methodology (RSM) was employed in the experiment, and a Box–Behnken design was used to determine the cause and effect of the relationship between the input variables and response. The investigated milling parameters were cutting speed (100 - 140 m/min), feed rate (0.1 - 0.2 mm/tooth), depth of cut (0.5-1.0 mm) and width of cut (0.2 -1.8 mm). Result of this study show ball nose end milling generates low temperature ranging from 69°C to 359°C. Experimental data and statistical analysis showed that heat generation was dominated by radial depth of cut, followed by axial depth of cut. Feed rate and cutting speed were found statistically not significant. The linear models were developed with a 92% confidence level. The optimum condition required for minimum heat generated include cutting speed of 117 m/min, feed rate of 0.11 mm/rev, axial depth of cut of 0.57 mm, and radial depth of cut of 0.21 mm. With this optimum condition, a minimum heat generated of 68°C was obtained.
A soft computing system used to optimize deep drilling operations under high-speed conditions in the manufacture of steel components is presented. The input data includes cutting parameters and axial cutting force obtained from the power... more
A soft computing system used to optimize deep drilling operations under high-speed conditions in the manufacture of steel components is presented. The input data includes cutting parameters and axial cutting force obtained from the power consumption of the feed motor of the milling centres. Two different coolant strategies are tested: traditional working fluid and Minimum Quantity Lubrication (MQL). The model is constructed in three phases. First, a new strategy is proposed to evaluate and complete the set of available measurements. The primary objective of this phase is to decide whether further drilling experiments are required to develop an accurate roughness prediction model. An important aspect of the proposed strategy is the imputation of missing data, which is used to fully exploit both complete and incomplete measurements. The proposed imputation algorithm is based on a genetic algorithm and aims to improve prediction accuracy. In the second phase, a bag of multilayer perceptrons is used to model the impact of deep drilling settings on borehole roughness. Finally, this model is supplied with the borehole dimensions, coolant option and expected axial force to develop a 3D surface showing the expected
In the modern manufacturing environment numerous challenges are in front of the manufacturers and researchers, this will lead to advance the various techniques. The present review summarizes the sustainable development in the field of... more
In the modern manufacturing environment numerous challenges are in front of the manufacturers and researchers, this will lead to advance the various techniques. The present review summarizes the sustainable development in the field of coolants and lubricants used in the various metal cutting operations. Cutting fluid used for lessening the warmth, which is produced in the primary and secondary shear zone due to the lapping of tool and work piece throughout the machining operation. Industries are spending nearly quarter of its annual profits in cutting fluids but still there is failure in the work piece quality and surface finish. The large volume of cutting fluids influence on worker’s respiratory system and skin allergies. This paper reviews the recent development of different types of cutting fluids and its applications. The essential function of cutting fluids are its cooling effect and it should be act as a thermal barrier between tool and work piece in the operation. The effective lubrication at cutting zone decreases the coefficient of friction and indirectly reduce the temperature at the mating surfaces of tool and work piece. This review also presents the development of cutting fluid systems in chronological order till the present and also delivers the techniques like coolant less cutting, MQL and cryogenic cooling. These techniques are effectively reducing the quantity of cutting fluid used in machining and also increase the cutting performance.
Hybrid rolling element bearings are being considered for use in flight critical aerospace applications. The following work was undertaken to lay the foundation for future work that would permit the recommendation of appropriate quantities... more
Hybrid rolling element bearings are being considered for use in flight critical aerospace applications. The following work was undertaken to lay the foundation for future work that would permit the recommendation of appropriate quantities of lubrication for these advanced bearing systems. This was accomplished by focusing on the tribological performance of M50/M50 (or AISI M-50) and M50/Si 3 N 4 interfaces with minimum quantities of lubrication at two levels of speed and slide-to-roll ratio (SRR). Ball-on-ring tribological testing was conducted with stepped reductions of lubricant pump rate into the tribological contacts at initial lambda values of approximately 1.7 and 2.5, as calculated from the Hamrock and Dowson film thickness equation and surface finish measurements. Experiments were conducted with 5% and 45% slide-to-roll ratio (or SRR). Starting from these high initial lambda levels, the lubricant flow rate into the contact was reduced until severe damage occurred. Tests were then suspended due to excessive traction (traction coefficient greater than 0.2). The results of this work are in agreement with the starved lubrication literature and the bearing test literature. They provide some solid insight into the minimum quantity of lubrication recommended for M50/M50 and M50/Si 3 N 4 interfaces. In all of the tests conducted there was a clear trend that higher speed and increased sliding both require an increased supply of lubricant to the contact. The M50/M50 interface needed an order of magnitude higher lubricant pump rate into the contact for adequate lubrication as compared to the M50/Si 3 N 4 interface in the initial lambda ∼ 1.7 experiments. At lambda ∼ 2.5 with 5% SRR, the M50/M50 interface needed three times the lubricant pump rate that the M50/Si 3 N 4 interface needed. However, both M50/M50 and M50/Si 3 N 4 needed a similar amount of lubricant at lambda ∼ 2.5 with 45% SRR, in which the interfaces were severely damaged due to the extreme test conditions. These tribological test results are interpreted with an analysis of the wear morphology and surface chemistry of the test articles.
- by Gary Doll and +1
- •
- Materials Engineering, Mechanical Engineering, Wear, Surface Chemistry
In conventional or macroscale milling, appropriate physical vapour deposition (PVD) coatings can be used to improve machining performance, promote the use of higher cutting speeds and facilitate dry machining or the use of minimum... more
In conventional or macroscale milling, appropriate physical vapour deposition (PVD) coatings can be used to improve machining performance, promote the use of higher cutting speeds and facilitate dry machining or the use of minimum quantity lubrication (MQL). When micro ...
Hybrid rolling element bearings are being considered for use in flight critical aerospace applications. The following work was undertaken to lay the foundation for future work that would permit the recommendation of appropriate quantities... more
Hybrid rolling element bearings are being considered for use in flight critical aerospace applications. The following work was undertaken to lay the foundation for future work that would permit the recommendation of appropriate quantities of lubrication for these advanced bearing systems. This was accomplished by focusing on the tribological performance of M50/M50 (or AISI M-50) and M50/Si 3 N 4 interfaces with minimum quantities of lubrication at two levels of speed and slide-to-roll ratio (SRR). Ball-on-ring tribological testing was conducted with stepped reductions of lubricant pump rate into the tribological contacts at initial lambda values of approximately 1.7 and 2.5, as calculated from the Hamrock and Dowson film thickness equation and surface finish measurements. Experiments were conducted with 5% and 45% slide-to-roll ratio (or SRR). Starting from these high initial lambda levels, the lubricant flow rate into the contact was reduced until severe damage occurred. Tests were then suspended due to excessive traction (traction coefficient greater than 0.2). The results of this work are in agreement with the starved lubrication literature and the bearing test literature. They provide some solid insight into the minimum quantity of lubrication recommended for M50/M50 and M50/Si 3 N 4 interfaces. In all of the tests conducted there was a clear trend that higher speed and increased sliding both require an increased supply of lubricant to the contact. The M50/M50 interface needed an order of magnitude higher lubricant pump rate into the contact for adequate lubrication as compared to the M50/Si 3 N 4 interface in the initial lambda ∼ 1.7 experiments. At lambda ∼ 2.5 with 5% SRR, the M50/M50 interface needed three times the lubricant pump rate that the M50/Si 3 N 4 interface needed. However, both M50/M50 and M50/Si 3 N 4 needed a similar amount of lubricant at lambda ∼ 2.5 with 45% SRR, in which the interfaces were severely damaged due to the extreme test conditions. These tribological test results are interpreted with an analysis of the wear morphology and surface chemistry of the test articles.
In this study, a review of the available literature on lubrication techniques during machining processes was conducted. Factors such as workpiece material, tool material and machining conditions were observed to be vital to the... more
In this study, a review of the available literature on lubrication techniques during machining processes was conducted. Factors such as workpiece material, tool material and machining conditions were observed to be vital to the performance of any of the techniques. The performance and drawback of each technique were highlighted based on the machining conditions. It concludes by making a case for minimum quantity lubrication (MQL) method using vegetable oil-based lubricant in different machining processes, as a way of addressing the environmental health issues and cost associated with the application of lubricant in machining processes.
In this study, the surface integrity of nickel-titanium (NiTi) shape memory alloys (SMAs) was investigated after face milling processes with cryogenically treated/untreated cemented carbide cutting tools at the conditions of dry cutting... more
In this study, the surface integrity of nickel-titanium (NiTi) shape memory alloys (SMAs) was investigated after face milling processes with cryogenically treated/untreated cemented carbide cutting tools at the conditions of dry cutting and minimum quantity lubrication (MQL) of cutting fluids depending on the changing cutting parameters. The integrity of surface layer of the workpiece material was evaluated according to the mean surface roughness, microstructure and hardness, as well as according to the resultant cutting force and flank wear of inserts. Cutting tests were carried out at three different cutting speeds (20, 35 and 50 m/min), feed rates (0.03, 0.07 and 0.14 mm/tooth) and a constant axial cutting depth (0.7 mm). The influence of these parameters on the surface integrity was extensively investigated. The face milling tests of NiTi SMA at optimal cutting parameters show that the surface integrity enhanced at a cutting speed of 50 m/min and feed rate of 0.03 mm/tooth using boron-added cutting fluid (EG + %5BX) with deep cryogenic heat treated (2 196°C) CVD coated S40T grade cutting tool. Under MQL conditions, the minimum mean surface roughness (0.278 lm), resultant cutting force (268.2 N) and flank wear (0.18 mm) were obtained due to the high thermal conductivity and lubrication property of EG + %5BX cutting fluid. The highest hardness values (343 HV) were measured at the zone subjected to the highest deformation, while the lowest one (316 HV) was measured at the zone at the least deformation.
Coolants and lubricants for machining can improve the machinability of the workpiece, increase productivity, and extend tool life by reducing tool wear. However, for environmental and economic reasons, recent research in industry and... more
Coolants and lubricants for machining can improve the machinability of the workpiece, increase productivity, and extend tool life by reducing tool wear. However, for environmental and economic reasons, recent research in industry and academia has sought ways to reduce the use of machining fluids. This paper reports the use of dry and minimum quantity lubrication (MQL) to drill austempered ductile iron (ADI), a new class of materials used for light weight automotive components like connecting rods and crankshafts. In this study, ADI is produced by a novel processing technique known as continuous castingheat treatment process. The novel technique is developed by the integration of casting (in die casting) and heat treatment processes in the foundry to save energy and time. This paper deals with an experimental investigation on the role of MQL drilling on the cutting forces, tool wear and surface roughness of newly produced ADI at industrial speed-feed combinations by TiAlN-coated tungsten carbide tool. MQL drilling, performance is then compared with the dry and conventional drilling process under the same experimental conditions and environment. The results include significant reduction in tool wear, cutting forces and surface roughness by MQL drilling, mainly through reduction in the cutting zone temperature.
A better understanding in the application of minimum quantity lubrication (MQL) or near dry machining (NDM) is needed for its effective use in practical industrial applications. This paper presents the combination of confocal laser... more
A better understanding in the application of minimum quantity lubrication (MQL) or near dry machining (NDM) is needed for its effective use in practical industrial applications. This paper presents the combination of confocal laser scanning microscopy (CLSM) and image processing ...
The paper presents a studyof the effect of operating variable parameter; cutting speed, feed rate, depth of cut and width of cut on heat being generated when end milling under MQL condition. The response surface methodology (RSM) was... more
The paper presents a studyof the effect of operating variable parameter; cutting speed, feed rate, depth of cut and width of cut on heat being generated when end milling under MQL condition. The response surface methodology (RSM) was employed in the experiment, and a Box-Behnken design was used to determine the cause and effect of the relationship between the input variables and response. The investigated milling parameters were cutting speed (100-140 m/min), feed rate (0.1-0.2 mm/tooth), depth of cut (0.5-1.0 mm) and width of cut (0.2-1.8 mm). Result of this study show ball nose end milling generates low temperature ranging from 69°C to 359°C. Experimental data and statistical analysis showed that heat generation was dominated by radial depth of cut, followed by axial depth of cut. Feed rate and cutting speed were found statistically not significant. The linear models were developed with a 92% confidence level. The optimum condition required for minimum heat generated include cutting speed of 117 m/min, feed rate of 0.11 mm/rev, axial depth of cut of 0.57 mm, and radial depth of cut of 0.21 mm. With this optimum condition, a minimum heat generated of 68°C was obtained.
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... more
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 ...
Abstract: This research deals the experimental works on the effect of minimum quantity lubrication (MQL) and dry cutting towards the cutting tool life and chip morphology in high-speed milling of aluminum alloy 7075-T6 with uncoated... more
Abstract: This research deals the experimental works on the effect of minimum quantity lubrication (MQL) and dry cutting towards the cutting tool life and chip morphology in high-speed milling of aluminum alloy 7075-T6 with uncoated carbide tools. MQL and dry cutting were eco-friendly approaches that highlight essential issues in the field of manufacturing technology. Thus, further investigation required to observe the intensity of those approaches. The experiment was done on computer numerical control (CNC) five axes milling machine at distinct machining parameters, which are cutting speed (500 and 600 m/min), feed rate (0.12 and 0.15 mm/tooth) and axial depth of cut (1.4 and 1.7 mm), while the radial depth of cut restricted to 7 mm. The effect of fluid approaches and machining parameters on eight samples have analyzed the result of the setting of three factors and two levels in accordance with the full factorial design and analyzed further using ANOVA. The MQL flow rate was set ...
Abstract: This research deals the experimental works on the effect of minimum quantity lubrication (MQL) and dry cutting towards the cutting tool life and chip morphology in high-speed milling of aluminum alloy 7075-T6 with uncoated... more
Abstract: This research deals the experimental works on the effect of minimum quantity lubrication (MQL) and dry cutting towards the cutting tool life and chip morphology in high-speed milling of aluminum alloy 7075-T6 with uncoated carbide tools. MQL and dry cutting were eco-friendly approaches that highlight essential issues in the field of manufacturing technology. Thus, further investigation required to observe the intensity of those approaches. The experiment was done on computer numerical control (CNC) five axes milling machine at distinct machining parameters, which are cutting speed (500 and 600 m/min), feed rate (0.12 and 0.15 mm/tooth) and axial depth of cut (1.4 and 1.7 mm), while the radial depth of cut restricted to 7 mm. The effect of fluid approaches and machining parameters on eight samples have analyzed the result of the setting of three factors and two levels in accordance with the full factorial design and analyzed further using ANOVA. The MQL flow rate was set at 100 mL/h. The tool life criterion was determined when the tool wear failure reached 0.30 mm. The chips collected from all machining conditions were taken to be examined using an optical microscope. The empirical model of tool life for the MQL and dry cutting has been developed within the experimental ranges evaluated. The prolonged tool lifespan beyond 20.14 minutes and favorable chip formation were obtained at 500 and 600 m/min, 0.12 mm/tooth, and 1.40 mm, respectively under MQL 100 mL/h. MQL 100 mL/h appeared to be one fit for metal cutting industry that prioritizes clean and green machining as well as the use of appropriate machining parameters as it leads to economic benefits in terms of fluid cost-saving and the better machinability.
A soft computing system used to optimize deep drilling operations under high-speed conditions in the manufacture of steel components is presented. The input data includes cutting parameters and axial cutting force obtained from the power... more
A soft computing system used to optimize deep drilling operations under high-speed conditions in the manufacture of steel components is presented. The input data includes cutting parameters and axial cutting force obtained from the power consumption of the feed motor of the milling centres. Two different coolant strategies are tested: traditional working fluid and Minimum Quantity Lubrication (MQL). The model is constructed in three phases. First, a new strategy is proposed to evaluate and complete the set of available measurements. The primary objective of this phase is to decide whether further drilling experiments are required to develop an accurate roughness prediction model. An important aspect of the proposed strategy is the imputation of missing data, which is used to fully exploit both complete and incomplete measurements. The proposed imputation algorithm is based on a genetic algorithm and aims to improve prediction accuracy. In the second phase, a bag of multilayer perceptrons is used to model the impact of deep drilling settings on borehole roughness. Finally, this model is supplied with the borehole dimensions, coolant option and expected axial force to develop a 3D surface showing the expected borehole roughness as a function of drilling process settings. This plot is the necessary output of the model for its use under real workshop conditions. The proposed system is capable of approximating the optimal model used to control deep drilling tasks on steel components for industrial use.
A better understanding in the application of minimum quantity lubrication (MQL) or near dry machining (NDM) is needed for its effective use in practical industrial applications. This paper presents the combination of confocal laser... more
A better understanding in the application of minimum quantity lubrication (MQL) or near dry machining (NDM) is needed for its effective use in practical industrial applications. This paper presents the combination of confocal laser scanning microscopy (CLSM) and image processing ...