Papers by Keyword: MQL

Abstract: Because of their extraordinary qualities, titanium alloys are very sought-after materials that can be applied to a wide range of sectors. Excellent mechanical and chemical qualities, including a high strength-to-weight ratio and resistance to corrosion, are present in it. The special properties of these alloys make machining them extremely difficult. As frequent tool wear occurs throughout the machining process, Computer Numerical Control (CNC) milling has become a potential method for machining titanium alloys due to its precision and versatility. This review article provides a comprehensive overview of the development of titanium alloy CNC milling, with an emphasis on the effects of cutting tool geometries and materials on machining efficiency. The process examines several aspects of cutting circumstances, including depth of cut, speed, feed rate, and lubrication techniques, and optimizes machining parameters and procedures to achieve the best results. Surface integrity and quality, surface roughness, residual stresses, and microstructural changes brought about by CNC milling are the main points of evaluation.

Abstract: The cutting fluid plays a significant role in minimizing heat generation and chip removal process during the machining of materials, hence improving tool life and surface finish of the workpiece. Many researchers have focused on minimum quantity lubrication (MQL) among the existing methods on the application of the coolant as it reduces the usage of coolant by spurting a mixture of compressed air and cutting fluid in an improved way instead of flood cooling. The MQL method has demonstrated to be appropriate as it fulfills the necessities of ‘green’ machining. Additionally, considering current environmental issues and provisions for safe healthy working conditions at the workplace, it is important to divert machining processes towards an eco-friendly path. Hence, the focus of research has been shifted to MQL using eco-friendly lubricants for green and sustainable manufacturing processes. In this review paper, the effect of different vegetable oil-based biodegradable coolants like castor oil, coconut oil, palm oil, etc. for different machining process parameters like cutting force, cutting temperature, surface finish, tool wear, etc. has been reviewed. It is observed that proper selection of cutting parameters along with lubricant through MQL can provide enhanced machinability to get desired outputs.

Abstract: In the present study, feasibility of micro-plasma transferred arc (M-PTA) for flank surface treatment of gears has been explored. 20MnCr5 spur gears manufactured by sustainable technique minimum quantity lubrication assisted hobbing (MQLAH) were subjected to M-PTA-based heat treatment for further improving the surface properties of flank surface and comparisons were made with respect to M-PTA treated gears machined by conventional flood lubrication assisted hobbing (FLAH). The results revealed that M-PTA enhanced flank surface hardness of all the gears without deteriorating the gear accuracy. However, flank hardness increment was observed to be almost 18% in case of MQLAH gears as compared to 15% for FLAH gears. This study proves that M-PTA based heat treatment after MQLAH can result in superior surface hardness along with better gear accuracy and can improve the sustainability of overall process chain involved in machining-based gear manufacturing.

Abstract: Application of cutting fluids in machining can improve machinability but it may danger to the environment. An alternative to reduce this bad effect is by using minimum quantity lubrication (MQL). This study aims to determine the most optimal parameters in the AISI 4340 steel turning machining process to produce the best surface roughness with MQL conditions. The design method used is the Taguchi orthogonal array L9 ). The combined parameters are depth of cut, cutting speed, method of giving cutting fluid and feed rate. Based on the mean response value, it can be concluded that to get the most optimal results of surface roughness, the parameters are depth of cut 1.8 mm, cutting speed 120.89 m/min, method of giving cutting fluid by MQL method and feed rate 0.122 mm/rev. While the percentage contribution of the feed rate has the largest percentage, namely 57,02% and the cutting fluid method 41,33%.

Abstract: Study of input factors play a vital role in controlling of process responses such as surface finish, cutting temperature, energy consumption etc. in machining process. Design of Experiment (DOE) is one such tool used by researchers to identify the key factors and levels and optimize the process.An attempt was made to identify and experiment turning of AISI 4340 steel using 6 factors viz. cutting speed, feed rate, depth of cut, MQL nozzle orientations (distance from the cutting tool-chip interface, nozzle angle) and different cutting fluid (Coolant). The response variable selected for study was surface roughness of the work-piece which needed to fit criteria smaller-the-better. L₂₅ Orthogonal Array-OA design was selected for 6 factors and 5 levels. Comparison of results of average responses of different levels of factors, analysis of variance (ANOVA) of the process is detailed. Experimental results showed that the key contributors in the turning process are due to cutting speed, feed and depth of cut covering from 12% to 40%. The major contributor to the process was the cutting speed. Selection of MQL fluids and nozzle orientation contributed to 10% showing least significance.This experiment helps us to understand the importance of machine cutting conditions as key success factors which can be assisted with MQL fluids and other input factors.

Abstract: One of the most significant factors in machining process or metal cutting is the cutting tool performance. The rapid wear rate of cutting tools and cutting forces expend due to high cutting temperature is a critical problem to be solved in high-speed machining process, milling. Near-dry machining such as minimum quantity lubrication (MQL) is regarded as one of the solutions to solve this problem. However, the function of MQL in milling process is still uncertain so far which prevents MQL from widely being utilized in this specific machining process. In this paper, the mechanism of cutting tool performance such as tool wear and cutting forces in MQL assisted milling is investigated more comprehensively and the results are compared in three different cutting conditions which is dry cutting, wet cutting (flooding) and MQL. The MQL applicator is constructed from a household grade low-cost 3D printing technique. The chips surface of chips formation in each cutting condition is also observed using Scanning Electron Microscopy (SEM) machine. It is found out that wet cutting (flooding) is the best cutting performance compare to MQL and dry cutting. However, it can also be said that wet cutting and MQL produced almost the same value of tool wear and cutting forces as there is negligible differences in average tool wear and cutting forces between them based on the experiment conducted.

Abstract: In today’s industrial scenario, the requisite for elevated efficiency, better economic viability and higher quality asks for immense improvements in the cutting process stability. Such machining at higher cutting speeds and cutting depths causes an immense amount of heat generation at the work tool interface. The industry makes utilization of cooling techniques to contravene these ill-effects. These techniques make utilization of chemical coolants which are non-biodegradable in nature and consumed in immense quantities. In this study the role of minimum quantity lubrication (MQL) or green machining was experimentally evaluated when utilizing nanoparticle enriched coolants. The effect on the wear and roughness values while turning commercially pure Titanium (Grade 3) was analyzed. Experimentation was performed in two phases. In the first phase, the comparison in dry, flood and MQL process was made. The experimental design was composed factorially and 16 experiments were performed. Analysis was carried out utilizing ANOVA and the results were compared. In the second phase, a graphical cognation was established between the coolant application rate with both surface roughness and flank wear values. It was concluded that the nanoparticle enriched coolant i.e. the “eco nanomist”technique was more efficacious when machining the biocompatible Titanium grade 3.

Abstract: In metal cutting, surface roughness plays an important role in assessing the quality of processed products. The roughness depends greatly on the selection of machining parameters such as cooling conditions and cutting parameters. For this purpose, cooling conditions including dry, MQL, and Silica-based nanofluid MQL as well as cutting parameters including cutting speed, depth-of-cut and feed-rate were investigated to determine their influence on machining roughness during hard milling of AISI H13 steel. The DOE method developed by G. Taguchi was used to design the experiments. An analysis of the signal-to-noise response and ANOVA were carried to obtain the optimal values of cutting parameters for minimizing surface roughness. The results of the present study show that Silica-based nanofluid MQL, minimum feed-rate, minimum depth-of-cut, and maximum cutting speed is an optimal cutting condition for reducing machining roughness.

Abstract: Aluminum-based metal matrix composites (MMCs) have been suggested due to intense interest from automobile, marine, aerospace and other structural applications owing to their balanced mechanical, physical and chemical properties. MMCs are manufactured in order to meet present demand such as low material density, high mechanical strength and higher wear resistance of the component. Generally,MMCs tend to form rougher surface during machining because of the abrasive nature of hard ceramic particles present in them. Stir casting technique was used for fabrication of this composite which ensures better homogeneity.Furthermore, an attempt has been made in this paper to examine the results on the surface roughness of Al-6082/SiC metal matrix composites (containing 0%, 5% and 10% SiC particles).Focus was spent on parametric optimization of these composites in order to achieve cost-effective machining limits. The machining parameter studies have been carried out through the design of experiments (DoE) under minimum quantity lubrication (MQL) condition and effect of machining parameters such as spindle speed, feed rate and depth of cut on surface roughness was investigated to analyze the influence of reinforcement on surface roughness. In addition, analysis of variance was studied to obtain percentage contribution of machining parameters involved. Also, the surface morphology of the machined surface was studied through a scanning electron microscope (SEM). Distribution of SiC in aluminum alloy is fairly uniform with few clusters. Results of the experiments revealed that most significant turning parameter for surface roughness was spindle speed followed by feed rate and depth of cut. Furthermore, an optimal setting parameter for getting lower surface roughness was presented in confirmation table.

Abstract: The turning Process is the main processes used in automotive parts from more productivity, it requires the cutting velocity and feed rate high. And from those cutting, it causes high temperatures on cutting and a tool life of cutting tools decreased. Therefore using of cutting fluid (Coolant) is one of the commonly used methods to reduce temperatures that occur while cutting, reducing the wear of cutting tool and helps extend the tool life of the cutting tool. However, cutting fluid it's not always a good way, from the high cost and environmental problems issues. Using the MQL technique is one of the alternatives that using more nowadays to solve the above mentioned problems. This research proposed a MQL technique substitution of cutting fluid that using in the current process by applying in order to obtain the proper cutting condition for carbon steel material grade SAPH370 with the carbide cutting tool. The cutting conditions will acceptable from the minimum quantity of lubricant and the maximum of tool life of cutting tool under surface roughness (Ra) is less than 1.2 μm. The proper cutting condition determined at a feed rate of 0.10 mm/rev, a cutting speed of 300 m/min and a flow rate of 5ml/hr.