Design and development of SQL system in sustainability issues of machining

Abstract

Machining is an important part of any production industry. During machining operation, large amount of heat is generated between contact of tool and work piece which is not desirable because it increases power consumption, affects product quality and also results in early failure of cutting tool. Cutting fluids are applied to avoid the heat generated during machining to ensure good quality of the workpiece. But, conventional cutting fluids are harmful to human health. Adopting sustainable machining offers a cost-effective route to improve economic, environmental and social performance of any manufacturing industry. Small Quantity Lubrication (SQL) machining is a sustainable cooling technology that ensures green machining. SQL refers to the use of cutting fluids typically of a flow rate of less than 50 ml/hour. The main objective of the research is to develop and demonstrate an innovative and viable SQL system to reduce chip-tool interface temperature, provide an ergonomic working atmosphere, achieve better part quality, tool life and experimentally investigate the roles of SQL by vegetable oil-based cutting fluid on chip–tool interface temperature, chip color and shape, chip reduction coefficient and surface roughness in turning AISI 1060 steel by the industrially used uncoated tungsten carbide tool (SNMG 120408 TTS) at different cutting velocities and feeds combinations as compared to dry machining. SQL provided significant improvements expectedly; in terms of chip formation modes and surface finish throughout the range of cutting velocity and feed rate undertaken mainly due to reduction in the average chip–tool interface temperature and also the cutting performance is also improved ensuring sharpness of the cutting edges. Therefore, it appears that SQL can provide sustainable machining environment.