Abstract
Vegetable oils are found as the feasible alternative for conventional minerals oils. There has been many environmental and health issues which are spotted with the use of conventional cutting fluids. There has been a great demand for developing new environmentally friendly vegetable based cutting fluids to reduce these harmful effects. In this present study, vegetable based kapok oil is used as a cutting fluid during milling to study its consequences over other conventional oils. The process parameters such as spindle speed, depth of cut and feed rate were optimized with respect to the flank wear (Vb) and surface roughness (Ra) respectively with the use of central composite design in response surface methodology (RSM). Further an attempt has been made to monitor the tool condition by measuring the cutting force, vibration and sound pressure simultaneously. Three different tool conditions such as dull, fresh and working were analyzed and their consequences were also reported. Also, the performance of the kapok oil is compared with the palm oil and mineral oil (SAE 20W 40). The feed rate has the major contribution for surface roughness and flank wear. It is found that the cutting force (F), sound pressure (p) and vibration (V) increases with the tool wear.
Highlights
Milling is the basic machining process which tends to have high metal removal rate and mostly used for complex machining shapes
The kapok oil is effectively used as a cutting fluid for milling operation and the process parameters were optimized using response surface methodology
This study focuses on the performances of vegetable based oils with respect to commercial mineral oil in terms of cutting force, vibration and sound pressure
Summary
Milling is the basic machining process which tends to have high metal removal rate and mostly used for complex machining shapes. Cutting fluids have been used in the machining process to improve the tribological characteristics of the work piece and tool involved [1]. Cutting fluids improves the efficiency of machining process by enhancing tool life, surface finish of the workpiece, reducing cutting force and vibrations. Many research works have been undertaken on the application of vegetable based cutting fluids for machining applications and most of them were used as a straight cutting oils [5,6]. 14 6 milling [15], grinding and reaming In those investigations, tool life, tool vibration, tool wear, sound pressure, cutting force, torque and surface roughness are considered as parameters [16]. The cutting force, vibration and sound pressure were measured simultaneously for the optimized parameters while using kapok oil as cutting fluid. The obtained results are compared with the results under palm oil and a commercially available branded mineral oil (SAE 20W 40)
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