Abstract
Minimum quantity lubrication (MQL) is a sustainable method that has been efficiently applied to achieve machinability improvements with various materials in recent years, such as hardened steels, superalloys, soft metals, and composites. This study is the first to focus on the performance evaluation of MQL and dry milling environments with AISI 1040 steel. The tool wear, cutting temperature, and power consumption were considered as the quality responses while cutting speed, feed rate and machining environment are taken as input parameters. The effects of the influential factors are analyzed using analysis of variance (ANOVA) and bar charts. Additionally, Taguchi signal-to-noise (S/N) ratios are utilized in order to determine the optimum parameters for the best quality responses. The results show that the MQL system provides better performance compared to dry milling by reducing the tool wear, cutting temperature, and power consumption. According to the ANOVA results, the cutting environment affects the cutting temperature (37%) and power consumption (94%), while cutting speed has importance effects on the tool wear (74%). A lower cutting speed (100 m/min) and feed rate (0.10 mm/rev) should be selected under MQL conditions to ensure minimum tool wear and power consumption; however, a higher feed rate (0.15 mm/rev) needs to be selected along with a low cutting speed and MQL conditions to ensure better temperatures. A comparative evaluation is carried out on the tool wear, cutting temperature, and power consumption under MQL and dry environments. This investigation is expected to contribute to the current literature, highlighting the superiority of sustainable methods in the milling of industrially important materials.
Highlights
Three indicators are used to identify the significance of the cutting parameters, namely parameters, namely and the Fpercent value, contribution p-value, and percent contribution (PC)
The tool wear progressions clearly showed that MQLassisted milling provided better flank wear results than dry cutting under the same cutting conditions
For higher cutting speeds especially (150 m/min), the differences were much greater than for lower cutting speeds (10 m/min); When Minimum quantity lubrication (MQL) and dry environments were compared in terms of flank wear, peak temperature, and power consumption, improvements of 30.9%, 32.5%, and 16.9%
Summary
The primary aim is to cut the material into small pieces to ensure good workpiece quality, dimensions, and geometry Such processes require huge amounts of energy owing to the large amount of plastic deformation [1]. The negative effects of the excessive temperature are damaging to the material properties, shortening the tool life and increasing the tool wear progression [2,3] Depending on these developments, the cutting forces can increase and mechanical vibrations can be triggered, which causes poor surface roughness and leads to high power consumption as a result of losing the cutting ability of the cutting tool [4,5]. This situation has been questioned by many researchers and promising results have been found in the past
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