Abstract
In this study, an attempt is made to examine the machining response parameters in turning of AISI 1040 steel under different lubrication environment. Subsequently, design of experiment technique Response surface methodology (RSM) is used for analyzing machining performance by varying cutting conditions with the use of 2wt% of CNT/MoS2(1:2) HNCF. Regression models are developed for multiple machining responses. Optimization is performed for these models by using desirability function, which converts multi-objective into single objective. Then the optimal setting parameters for single objective is found. Significant reduction in main cutting force (Fz), cutting temperature (T), surface roughness(Ra) and tool flank wear (Vb) are found with the use of 2wt% of CNT/MoS2(1:2) HNCF compared to other lubrication environment. Significant factors that affect the main cutting force (Fz), the temperature in the cutting zone are cutting speed, feed rate and depth of cut. Parameter depth of cut has an insignificant effect on tool flank wear and surface roughness (Ra). The optimal cutting conditions for four multi-objective optimization of main cutting force (Fz), cutting temperature, surface roughness (Ra) and tool flank wear are found to be cutting speed 70.25 m/min, feed 0.13 mm/rev and doc 0.5mm at desirability value of 0.907.
Highlights
Turning is one of the widely used machining operations in production industries
The outputs are attained from the well-designed regression analysis that is based on independently controllable input factors
Surface roughness (Ra) value is found to reduce by 28.5%, 18.3%, 13% and 9% with the use of 2wt% of CNT/MoS2 (1:2) Hybrid Nano Cutting Fluid (HNCF) compared to dry condition, CCF, pure CNT and pure MoS2 nanofluids
Summary
Turning is one of the widely used machining operations in production industries. Cutting conditions, which include cutting speed (CS), feed rate (FR), and depth of cut (DOC) play a key role for improving productivity. Besides cooling and lubrication, cutting fluids performs other functions such as flushing the chips away from cutting area, protects the part against oxidation, provides longer life of the tool and improves the surface quality of the machined part (Amrita et al, 2014). Marques et al, (2016) reported the enhancement in surface integrity of workpiece and life of cutting tool with the inclusion of graphite nanoparticle in neat oil compared to MoS2 (Molybdenum di sulfide) in turning of Inconel 718 using MQL mode. It was reported that MQL, solid lubricants and vegetable oil based nanofluid has improved the surface finish of the machined component. Workpiece material used for machining in the current study is chosen from the literature (Krishna and Rao, 2008)
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