Specific cutting energy modeling for turning nickel-based Nimonic 90 alloy under MQL condition

Abstract

The energy utilized during the cutting process at the cutting edge can be modeled as the specific cutting energy (SCE). It is essential to study the SCE during the machining because of its direct effect on work surface integrity. The direct relation of SCE with electrical energy further increases its importance from sustainability viewpoint as to date most of the electrical energy sources are from non-sustainable resources. Till now, only a few authors have modeled the SCE and that too under dry machining environment. Therefore, this paper deals with the development of a mathematical model for predicting the SCE during the machining of a nickel-based alloy under sustainable MQL mode. The model takes into consideration both the shearing and frictional energy components. The specific frictional energy at the rake face has been modeled by considering sticking and sliding regions at the secondary shear zone (SSZ). The coefficient of friction in the sliding zone for the frictional energy has been obtained using the unique approach of open tribo meter tests. The results obtained from the analytical model developed for the SCE have been found to be in good agreement with the experimental results. The increase in flow rate and pressure during the application of MQL reduced the SCE by reducing the chip-tool contact length and shear flow stress over the rake face.