Abstract
The requirement of cost-effective and ecological production systems is crucial in the competitive market. In this regard, the focus is shifted towards sustainable and cleaner machining processes. Besides the clean technologies, effective parametric control is required for machining materials (such as High Strength Low Alloy Steels) specifically designed for high strength applications having superior physio-chemical properties. Therefore, the machinability complexities require optimized solutions to reduce temperature elevation and tooling costs and improve machining of these materials. Complying to the market needs, this research examines the effectiveness of nanofluid on tool life, wear mechanisms, surface roughness (Ra), surface morphology, and material removal rate (MRR) in turning of 30CrMnSiA (HSLA) using minimum quantity lubrication (MQL) and SiO2-H2O nanofluids (NF-MQL). A systematic investigation based on physical phenomena involved is carried out considering four process parameters (cutting speed (VC), feed rate (Fr), depth of cut (DOC), and mode of lubrication for machining. Fr is found as the vital parameter for surface roughness while MRR is highly influenced by DOC regardless of lubrication approach. One-step sustainability technique is applied, in which process variables used for roughing conditions are analogous to attain surface comparable to finished machining without compromising process efficiency and demonstrate its feasibility through optimal settings under NF-MQL. Multi-response optimization proved the NF-MQL machining condition as the best alternative which result in 28.34% and 5.09% improvements for surface roughness and MRR, respectively. Moreover, the use of SiO2 is recommended over MQL due to lower energy consumption, low tool wear, and better surface integrity, sustainable liquid, and related costs.
Highlights
In the modern industry, High Strength Low Alloy (HSLA) steel has gained attention due to high strength, toughness, and wear resistance
Quality and productivity are the essential requirements for these industrial products, are defined mainly by two attributes such as surface roughness (Ra) and material removal rate (MRR) [3]
minimum quantity lubrication (MQL), maximum MRR is obtained at the high level of both process parameters by keeping depth of cut (DOC) constant 0.6 mm whereas similar trends are obtained for NFMQL mode
Summary
High Strength Low Alloy (HSLA) steel has gained attention due to high strength, toughness, and wear resistance. No cutting liquid is used which results in a rise in temperature that affects the thermal damage to the process surface which increases the work roughness [5] To overcome these challenges, there should be lubrication between workpiece and tool. Jeevan et al [22] inspected surface roughness during the turning of AA6061 by using different environmentallyfriendly cutting fluids Jatropha and Pongamia oil, by using MQL method According to their results, good quality surface was achieved at Fr of 0.1 mm/rev, DOC of 0.5 mm, and VC of 1600 rpm. Nanolubrication containing nano sized particles in the base fluid could be effective method to reduce the friction between tool-workpiece interface as it plays sliding and rolling role at the point of interaction of both surfaces which results in improving the machining performance [27]. Desirability technique is utilized to get the optimal set of variables for multi-objective optimization which leads to a sustainable process
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