Exploratory data analysis & EDS analysis on tool chip adhesion under dry and nano minimum quantity lubrication machining environment

Abstract

Adhesion, abrasion, plowing and transverse displacement are the major causes of origin of friction. During dry machining of ductile materials, chips are fused with the rake face of the cutting tool and contribute to the formation of the built up edge. Built up edge protects the rake face of the tool from wear, but makes the machined surface rough. To improve the tribological properties and to decrease the tool-chip adhesion, cutting fluids are used. Cutting fluids are added to the machining zone to minimise cutting temperature and friction, but they result in environmental and health degradation. Surface texturing of tools is a potential way to modify the tribological properties of mating surfaces in order to increase the tribological qualities and decrease the tool-chip adhesion. The performance of surface textured tools depends upon orientation, dimple depth, width and pattern. Under lubrication regime, microholes in surface textured tools acts both as lubrication reservoir and traps wear debris to reduce abrasive wear. Nano Minimum Quantity Lubrication (nano-MQL) is an advanced lubrication technique used in machining processes, specifically designed to minimize the use of lubricants while maintaining effective lubrication. This method involves delivering an extremely small amount of high-performance lubricant directly to the cutting zone. The MoS2 lubricant with sunflower oil is typically in the form of nanodroplets, which are much smaller than conventional minimum quantity lubrication (MQL) droplets. The Exploratory Data Analysis (EDA) methodology enables the identification of patterns, trends, and outliers within the collected data, offering insights into the complex interplay of factors affecting the machining of Aluminium Alloy AA2024. At a spindle speed of 3500 rpm the feed force decreases by 37% under dry environment when compared with nano-MQL environment. Under dry environment average surface roughness reduces by 27% when compared with nano-MQL environment.