Wet Machining Research Articles

Experimental analysis on Feed force reduction performance by Nanofluid of Graphene Nano platelets enriched Waste Coconut Oil in wet Machining of SAE 1045 Steel Shaft

The Waste utilization is one of the prime importance and possess good social impacts. Here the used coconut oil which disposal as waste at Kerala chips shop is utilized for preparing a novel Nano fluid for machining purposes. Such Nano fluid can be alternatively used for lubricating purpose for machining the precision shaft. This piece of research work prepared Nano fluid by concentrating Graphene Nanoplatelets with used coconut oil (waste). The synthesized nanofluid used as coolant in machining SAE1045 steel work material. The range of inputs were adapted from the conventional dry machining practices and manufacturer catalogue of the material. As planned to investigate the three key input variables at 4 levels from minimum to maximum in the selected range, the Taguchi L16 orthogonal array was preferred to design the experiments. The t-test employed for comparing the machining environment (a kind of input variable) performance through 16 different input combinations and found that the proposed intervention is outperformed significantly. So, the parameters for the proposed machining practice was optimized and input factors’ contributions were analyzed by means of Taguchi analysis and ANOVA.

Reconnoitering the influence of nanofluid of Nano- alumina particles enriched waste coconut oil in Machining SAE 1045 shaft on modification Surface finish

Nanofluids plays critical role in thermal engineering. In this research prepare nanofluid for improving the thermal as well as tribological properties for shaft manufacturing. The surface quality is a prime factor in the failures of shaft by fatigue load. Here used coconut oil or waste coconut oil from Kerala chips shop for base fluid. This study looked into the effect of a Nano fluid containing Nano-alumina particles which float on the base fluid ofcoconut oil for the purpose of act as coolant and therebyreducing surface roughness on machined surface. The samples in this study were divided into two groups: group I was the control group, and group II was the experimental group, in which the samples were machined (turned) on a heavy-duty lathe using the green machining process. The intervention group's sample was machined using a clean technology approach using 0.3 percent Nano-alumina particles enriched waste coconut oil based wet machining process. The sample size was estimated to be 12 per group using G-Power 80 percent, while 16 samples observationswere examined tooptimizeprocess parameters using Taguchi analysis and analysing further using ANOVA to validate the statistical model, observation fits, and mathematical model creation. The Surface Roughness encountered under various combinations of similar input conditions for both green machining and Nano- alumina particles enriched waste coconut oil based wet machining methods were compared, and it was discovered that material processing of AE 1045 shaft by graphite enriched waste coconut oil based wet machining method significantly reduced Surface Roughness. 0.006 (p 0.05) is indicated that observation are significant. According to the results of the experimental investigation, the proposed Nano-alumina particles concentrated waste coconut oil based wet machining method reduces Surface Roughness by 39.95% on average and ensures that the results do not violate the statistical assumption, it can be recommended to process SAE 1045 material for shaft manufacturing.

Novel application of SiO2 nanofluid coolant for enhancing machinability over inconel 706 CNC end milling with conventional coolant

This comparative experimental study aims to improve machinability in terms of machining rate by novelly applying SiO2 nanofluid in the palace of conventional coolant for CNC end milling of Inconel 706. Two groups considered in this study are SiO2 nanofluid (CN) and Conventional Coolant (CC) based wet machining of Inconel 706 work material. The carbide end mill cutter of four flute, square end type used. Nanofluid with SiO2 concentration 4 wt% with less 5 nm sized particles considered. Sample size calculated 16 per group with G-power 80 % and alpha 0.05 settings. The key factors of cutting velocity, cutter feed rate, and depth of cut are varied by four levels. Material Removal Rate was calculated from the experimental observations and compared group wise in SPSS software. The test result shows a significance value of 0.015 (p less than 0.05), which reveals that observed results are significant. Novel application of SiO2 nanofluid in CNC end milling of Inconel 706 yielded 44.71 % higher material removal rate than conventional coolant.

Experimentally exploring nano-fluid of alumina nano-particles enriched waste coconut oil effects in cutting zone temperature reduction in motor shaft manufacturing process

Metal cutting, in general, produces heat, which has an impact on the machining quality of the final job. The surface quality of the shaft is a major factor in fatigue stress shaft failures. Coconut oil or leftover coconut oil from Kerala chips was utilized here. shop The cutting zone temperature response is utilized to optimize the metal removal process's parameters. The cutting speed was changed from 40 to 190 m/min, the tool feed rate was varied from 0.05 to 0.20 mm/rev, and the CVD coated tool was employed with four different nose radius 0.3 mm, 0.6 mm, 0.9 mm, and 1.2 mm, and an L16 orthogonal array was used to generate the minimal experimental combinations. The results were compared to current dry machining procedures. According to the results of the experimental investigation, the proposed Alumina Nanoparticles enriched waste coconut oil based wet machining method reduces the Cutting zone temperature by 27.36 percent on average and ensures that the results do not violate the statistical assumption, it can be recommended for processing SAE 1045 material for shaft manufacturing.

Influence of molybdenum disulfide particles’ concentration on waste cooking oil nano fluid coolant in cutting force reduction on machining SAE 1144 steel

Utilization of waste cooking oil to develop a Nanofluid with Molybdenum disulfide Nanoparticles for a metal machining application is focused in this research. Based on the nature of lubricating, non-corrosive and biodegradable properties the waste cooking oil and nano Molybdenum disulfide combination is preferred in this research. Molybdenum disulfide Nano-particles enriched waste cooking oil in minimizing cutting forces. This investigation involved 2 group of samples the group-I is control group in which the samples machined (turning) in heavy duty lathe by green machining method. The sample of intervention group machined Nanofluids with variable concentration of Molybdenum disulfide between 0.1 and 0.25 wt%. The sample size estimated with G-Power 80% and was 12 per group but 16 samples group considered to conducting experiments and optimizing the process parameters by means of Taguchi analysis. The results of cutting forces encountered were measured under various combinations of similar input conditions for both green machining and Molybdenum disulfide Nano-particles enriched waste cooking oil based wet machining method for lathe machining of AE 1144 shaft. The statistical test reveals that Molybdenum disulfide Nano-particles enriched waste cooking oil based wet machining method averagely reduced the cutting force 27.53% than green machining method. The significant value is 0.001 (p < 0.05). It was ensured that the results did not violate the statistical assumption.

Influence of SiO2, MgO, and Fe2O3 metallic nano cutting fluids of AA6061 in MQL environment

Metallic nano-lubricant tri-hybridization was used to study the mechanical and process of machining analysis for metallic nano-lubricant utilizing a predetermined volumetric ratio of SiO2, MgO, and Fe2O3 metallic nanoparticles in cold-pressed coconut oil. For aluminium end milling, an alternative to dry and wet machining processes is needed because of the high productivity and surface quality requirements.As a result, the produced nanofluids were examined for rheological behaviour before being used in the milling of AA6061 to solve the problem. When compared to traditional approaches, the nanofluids performed admirably. Results show that trio-hybridized lubricant reduces cutting force, tool wear and surface roughness more effectively than monotype nano fluids. With nano fluids and low quantities of lubricant, the interaction between process variables can be studied using response surface methods. All three of these metrics were reduced while using hybrid cutting fluids and the results were within acceptable parameters.

Preparation and characterization of nanoparticles mixed cutting fluids

Health and environmental concerns about the use of excessive conventional cutting fluids during conventional machining has led to the development of a new type of cutting fluid. Inefficient disposal of industrial cutting fluids during wet machining also reduces the use of conventional cutting fluid. Nano-material mixed cutting fluids have shown superior thermal properties and tribological properties. In the present work, different nanofluids are prepared by suspension of Titanium dioxide (TiO2), Silicon oxide (SiO2) and Aluminum oxide (Al2O3) nanoparticles in vegetable oil and water-based emulsion at room temperature in different volumetric concentrations. The viscosity and density of the developed nanofluids are measured at different temperatures for different nanoparticle volumetric concentrations. From the experimental results, it has been found that with the increase of nanoparticle concentration in base fluid, enhanced the its viscosity and density. Furthermore, addition of nanoparticles at 25 ºC enhances viscosity more compared to its addition at higher temperatures. For an increase of concentration from 0.25% to 3%, enhancement in viscosity of Al2O3, SiO2 and TiO2 nanofluids is observed as 41.6%, 43.75% and 35.55%, respectively, while for higher temperatures almost constant improvement of 25%, 24% and 30% is observed for Al2O3, SiO2 and TiO2 nanofluids, respectively. The viscosity and density of three different nanofluids are also compared. Results showed that newly prepared Al2O3 based nanofluid exhibits better properties than TiO2 and SiO2 based nanofluids. Copyright © 2017 VBRI Press.

Anomalies in the Geometric Surface Structure of Shaped Elements Composed of Inconel 718 Alloy.

This paper presents the results of investigation that was performed on shafts composed of Inconel 718. Tests were performed in dry and wet conditions. Cutting parameters, such as feed and depth of cut, were constant. The cutting speed was changed. The investigation was performed for various shaft shapes: cylindrical, taper 30°, taper 45°, and sphere. For that reason, the value of the angle between the machined surface and the cutting edge changed. The lowest values of the roughness parameters, Ra and Rz, were obtained for a larger value of the angle between the machined surface and cutting edge. The investigation showed that cutting speed, machining conditions (dry and wet machining), and the variable angle between the machined surface and the cutting edge influenced the surface roughness. Application of a higher cutting speed resulted in lower roughness values. Lower values of roughness parameters were obtained by wet machining.

Experimental Investigation on the Advantages of Dry Machining over Wet Machining during Turning of AISI 1020 Steel

In this study, the experiment was conducted to investigate the advantage of dry machining over wet machining during turning of AISI 1020 steel using cemented carbide tool on a CNC lathe machine. Surface roughness and cutting temperature were measured by VOGEL surface roughness tester and infrared thermometer respectively. The experiments were conducted based on Taguchi L9 orthogonal array design. Surface roughness, cutting temperature, tool life, and machining cost were analyzed graphically. The average surface roughness and cutting temperature achieved with wet machining was 2.01 µm and 26.540C, which was 17.41% and 44.86% respectively, lower than dry machining. The high cutting temperature in dry turning result in short tool life, which was 41.15% shorter than wet turning. The machining cost of wet turning was about 56% greater than the cost of dry turning. The cost of coolant in wet turning is 42.88% greater than that of the cutting tools. The highest cost was shared by tool cost, which was 81.33% of the total cost for dry turning, while 70.00% of the total cost was shared by coolant cost for wet turning. Results revealed that dry turning is more economical than wet turning.

Sustainable machining: environmental performance analysis of turning

ABSTRACT The manufacturing sector accounts for 40% and 25% of global energy and resources consumption respectively. Machining is one of the most power-intense operations in the manufacturing sector making a significant contribution to the environmental footprint. The purpose of this study is to identify the key parameters that contribute towards the environmental impacts of conventional turning. A set of experiments was designed using the Taguchi L9 method. Experiments were performed to analyse the electrical energy consumption, metalworking fluid (MWF) consumption, surface roughness, and material removal rate during turning of AISI P20 with both wet and dry machining. A life cycle assessment (LCA) was conducted to assess the environmental performance of turning. A multi-response optimisation was performed to identify the optimum operating conditions. The results show that turning with wet machining yields better machining and environmental performance compared to dry machining. The LCA results reveal that electrical energy is the highest contributor under most of the impact categories, while the effect of MWF is negligible. The use of workpiece material and cutting insert material contribute significantly to the impacts under aquatic ecosystem and resource depletion damage categories. Further, optimum parameters were proposed considering both machining performance and environmental impact.

CHARACTERIZATION OF METAL WORKING FLUIDS USING TRIBOLOGICAL TESTING METHODS

The objective of this paper is to determine whether it is possible to compare the lubricating properties of different Metal working fluids (MWF) for a defined cutting application using easily reproducible tribological tests. The idea is that this will eventually allow users of MWF to select the most suitable MWF for a specific application without the need to run expensive and time-consuming tests on a machine tool being unavailable for production during that time. The test method chosen is the Pin-on-Disc (PoD) test, as there has been extensive research and an easy setup can be acquired inexpensively, making it more available and attractive for potential users. The PoD-tests were done with two groups of MWF, those for wet machining and those for minimum quantity lubrication (MQL). Additionally, the viscosity of the MQL-MWF has been measured using a capillary viscometer. The evaluation of the wear on the pins and discs with different measuring devices shows consistent and promising results for the comparison of MQL-MWF, while the MWF for wet machining display only limited comparability with the PoD-setup used.

Investigation on effect of TiN, TiAlN & DLC-triple layer coated carbide tool in machining of Al-Si 4032 alloy

Aluminium is a widely used metal in the world due to its abundance and easy to work with properties. One of the major users of aluminium are the auto and aero industries, since it reduces the weight of the vehicle significantly. The properties of aluminium can be customized with certain alloying components and there are plenty of combinations, among which Aluminium 4032 alloy is taken for this investigation. This Al -Si 4032 alloy is enriched in silicon content up to 13%. High presence of silicon leads to more amount of friction in machining hence the machining of this particular alloy has to be done with coated materials for enhanced results. The machining is carried out with the carbide inserts triple layer coated with Titanium Nitride (TiN), Titanium Aluminium Nitride (TiAlN) and Diamond like Carbon (DLC). These coated inserts are used to machine Al-Si alloy workpiece under various machining variables of speed, feed, depth of cut as well as in both dry and wet environments. Various parameters are premeditated from the experiments like surface roughness, tool wear, tool life and material removal rate. And the responses were recorded, optimization process is carried out with Minitab software tool to find the finest combinations for machining. The better results are found to be in wet environment machining condition.

Optimization of Process Parameters for Turning Hastelloy X under Different Machining Environments Using Evolutionary Algorithms: A Comparative Study

In this research work, the machinability of turning Hastelloy X with a PVD Ti-Al-N coated insert tool in dry, wet, and cryogenic machining environments is investigated. The machinability indices namely cutting force (CF), surface roughness (SR), and cutting temperature (CT) are studied for the different set of input process parameters such as cutting speed, feed rate, and machining environment, through the experiments conducted as per L27 orthogonal array. Minitab 17 is used to create quadratic Multiple Linear Regression Models (MLRM) based on the association between turning parameters and machineability indices. The Moth-Flame Optimization (MFO) algorithm is proposed in this work to identify the optimal set of turning parameters through the MLRM models, in view of minimizing the machinability indices. Three case studies by considering individual machinability indices, a combination of dual indices, and a combination of all three indices, are performed. The suggested MFO algorithm’s effectiveness is evaluated in comparison to the findings of Genetic, Grass-Hooper, Grey-Wolf, and Particle Swarm Optimization algorithms. From the results, it is identified that the MFO algorithm outperformed the others. In addition, a confirmation experiment is conducted to verify the results of the MFO algorithm’s optimal combination of turning parameters.

Analysis of Machining Operation using Vegetable Oil and Nano Fluids

The influence of the hybrid additives of alumina and titanium oxide on varied lubricant characteristics as a cut fluid in steel turning. In varied volumetric concentrations, the hybrid nano lubricant has to evolve. The mixture of alumina and titanium oxide improved its tribology. The new nano-lubricant reduces the wear and nodal temperature of the tool&amp;#39;s flank substantially. The application of hybrid nano-particles rather than nano-particles is among the most significant jobs in improving the heat transfer of fluids. We saw several sorts of pairs used to cut fluid and their effects on machining (turning).A potential MQL approach can be tested to limit the excessive use of traditional cutting fluid. The minimum amount of any cutting fluid in this approach is sprayed into the cutting zone at high pressure to improve its penetration into the machining area. Using MQL enhances surface quality and the life of the tool. MQL is a feasible alternative to wet machining. In their perspective. Therefore, both production costs and environmental dangers may be minimized through MQL..

Investigation on Surface Roughness during Milling of AL-61 Machining under Minimum Quantity Lubrication (MQL)

In modern production industries, main focus is on high productivity with best surface finish. For this purpose use of cutting fluid in machining of component plays major role in controlling the surface finish of components. The cutting fluids are generally applied continually during machining i.e. wet or flooded machining. The dry machining yields poor surface finish and less tool life whereas wet machining results in better surface finish as well as longer tool life. But continuous lubrication involves very large amount of consumption of cutting fluids which cause health hazards of machining operator and ill effects on environment. Moreover, continuous lubrication contributes to increase in total production cost of product. Hence, the Minimum Quantity Lubrication(MQL) is needed nowadays which works with less amount of cutting fluid (100-1000ml/hr) with pressurized air (as mist form) as compare wet machining (amount of cutting fluid 400-500L/hr approx.). The study focus on comparison of surface roughness behavior of AL-6061 under different lubrication conditions i.e. Dry, Wet and MQL. The experimental work performed on CNC milling machine involving cutting parameters feed rate, spindle speed and depth of cut as input parameters, where surface roughness and microstructure of specimens were observed as output parameters in the experiment. The machined components under different conditions i.e. DCM (dry cutting machining), MQL (minimum quantity lubrication), WCM (wet cutting machining) were examined for surface roughness using R-10 surface roughness tester whereas microstructure analysis was done using optical microscope. For given cutting parameters at 2000RPM spindle speed, 200mm/min. feed rate and it is found that better result of MQL from the dry machining and nearest of wet machining.

Machining Temperature and Accuracy of Magnesium Alloy AZ31 with Deep-Hole Small Drilling

In recent years, magnesium-based materials have become expected to replace conventional engineering plastics as next-generation industrial materials to protect the global environment. However, in the production technology, problems of cracking and unstable accuracy in drilled hole shapes persist in plastic molding and machine tool processing; many studies have been conducted to address these problems. In dry machining ignition can be caused by the material, so wet machining is the prevalent method. However, it is necessary to establish a machining method with improved environmental parameters, considering the impact of oil mist and waste oil treatment on woks. In this study, the relationship between machining temperature and the accuracy of hole shapes in magnesium alloy AZ31 is investigated with four types of drills: high-speed steel, cemented carbide (K-Base), diamond-like carbon (DLC; K-Base), and TiN-coated cemented carbide (K-Base). The drill tip angle is set to 116°, 118°, or 120°. The work material used is the extruded AZ31 magnesium alloy. To evaluate the hole shape accuracy, squares of 80 × 80 mm are used. The cutting temperature is measured over an area of 12 × 30 mm. The work material is drilled using a dry method with a 3-mm-diameter drill having the aspect ratio (L/D) of 10. The tool protrusion length of 50 mm and cutting speed of 20 m/min are fixed, and the tool feed rate and drill step amount are changed. The experiment is repeated 3 times. The burr generated around the loophole on the back surface of the test material after the test is evaluated with a criterion burr height H of 0.02 mm. Furthermore, the average roughness (Ra) of the centerline is measured on the inner surface of the hole with a contact-type roughness meter. The results show that when using the three drill point angles of 116°, 118°, and 120° in the drill step, no burrs form at the exit of the drill hole. Carbide tools form burrs when the feed rate exceeds 30 mm/min and the step amount exceeds 20 mm. TiN tools are highly accurate up to a tip angle of 118°, while DLC tools have lower cutting forces and yield better finished surfaces than the other tools.

Theoretical and experimental study of the chatter vibration in wet and MQL machining conditions in turning process

Turning is one of the most commonly used cutting processes for manufacturing components in production engineering. The turning process, in some cases, is accompanied by intense relative movements between tool and workpiece, which is called chatter vibrations. Chatter has been identified as a detrimental problem that adversely impacts surface finish, tool life, process productivity, and dimensional accuracy of the machined part. Cooling/Lubrication in the turning process is normally done for some reasons, including friction and force reduction, temperature decrement, and surface finish improvement. Wet cooling is a traditional cooling/lubrication process that has been used in machining since the past. Besides, a variety of new cooling and lubricating approaches have been developed in recent years, such as the minimum quantity lubrication (MQL), cryogenic cooling, nanolubrication, etc., due to ecological issues. Despite the importance of cooling/lubrication in machining, there is a lack of research on chatter stability in the presence of cutting fluid in cutting processes. In this study, the chatter vibration in turning process for two cooling/lubrication conditions of conventional wet and MQL is investigated. An integrated theoretical model is used to predict both the metal cutting force and the chatter stability lobe diagram (SLD) in turning process. This model involves deriving a math equation for predicting metal cutting force for both wet and MQL conditions using experimental training force data and a Genetic Expression Programming (GEP)-based regression model. Also, the traditional single degree of freedom chatter model is used here for predicting the SLDs. The chatter model is discussed and verified with experimental tests. Then, the experimental results of the tool's acceleration signal, work surface texture, surface roughness, chip shape, and tool wear are presented and compared for wet and MQL conditions. The results of this study show that the cooling/lubrication systems such as wet or MQL have a considerable effect on the SLDs. Also, the predicted results of metal cutting force and SLD for both wet and MQL techniques are in good agreement with the experimental data. Therefore, it is recommended that for each lubrication condition including wet, or MQL, the SLD be determined to achieve higher machinability.

Chip Morphological Behaviour During Machining Of Ti-6Al-4V Using Refrigerated Soluble Oil

Chips formed during machining are a vital instrument for the assessment both of machinability of material and the effectiveness of the machining method adopted. Various approaches have been proposed by researchers to make machining Ti-6Al-4V easier, ranging from reduction of cutting speed and feed rate to the use of coolant during machining. In this study, investigatation of the effect of refrigerated soluble oil on machinability of Ti-6Al-4V via monitoring of the chips formed during the various machining processes was carried out. The chips formed for various machining conditions were collected using a designed chip receptor medium and was analyzed using a metallographic microscope with an attached stylus. The experiment was planned using central composite designs (CCD) of the Response Surface Methodology (RSM) resulting in a 20 experimental run plan for dry and wet machining. Machining factors considered were cutting speed, feed rate, depth of cut and coolant temperature with corresponding values 40-120 m/min, 0.05-0.20 mm/rev, 0.2-1.0 mm and 5-11°C respectively. Responses monitored chip thickness, tooth profile and peak height. The effect of various factors on responses were discussed. Basically, results show that chip diameter increased with an increase in cutting speed. However, the sawtooth profile on chip reduced with an increase in cutting speed. It was therefore concluded that coolant temperature has an effect on chip morphology during machining of Ti-6Al-4V using refrigerated coolant.

Effect of tri-hybridized metallic nano cutting fluids in end milling of AA7075 in minimum quantity lubrication environment

The current paper is concentrated on the mechanical and machining process exploration of metallic nano-lubricant with the concept of tri-hybridization with improved lubricative and cooling properties by using TiO2, ZnO and Fe2O3 metallic nano particles with neat cold-pressed coconut oil in a fixed volumetric proportion (10:90). End milling of gummy material like aluminium requires a solution to the conventional dry and wet machining due to high productivity requirement and to obtain good surface quality. So, the prepared nanofluids were tested for their rheological behavior and latter introduced into milling of AA7075 as a solution to the above stated problem. Overall, the nanofluids gave good performance when compared to conventional methods. Furthermore, the results obtained from the experiments confirm that the trio-hybridized lubricant has reduced the cutting force, tool wear and surface roughness in an improved way when related to monotype nano fluids. The response surface methodology is performed to evaluate the interaction of process parameters in minimum quantity lubrication environment with nano fluids. The results show that the cutting forces, surface roughness, tool wear was minimized while machining with hybrid cutting fluids and well within the desirability.

Machinability analysis of nickel-based superalloy Nimonic 90: a comparison between wet and LCO2 as a cryogenic coolant

The usage of cryogenic fluid is increasing in the machining industries especially to cut the materials having a lower machinability like Nimonic 90, a nickel-based alloy. However, the comparison of flood coolant and LCO2 as a cryogenic fluid based on machining performance has not been found for machining Nimonic 90. In this regard, this study compares LCO2 and conventional mineral oil-based flood coolant on the basis of machining performance while turning Nimonic 90. The effect of turning process parameters (cutting speed (vc), feed (f), and depth of cut (ap)) and cutting fluids has been identified by analyzing machinability indicators like cutting force, flank tool wear, power consumption, surface roughness in terms of Ra, and chip morphology. Increment of 34%, 25%, and 24% in cutting forces has been observed for cryogenic turning using LCO2 in comparison with wet machining when the values of ap are 0.75, 0.50, and 0.25 mm, respectively. A decrement of 63% tool wear has been seen in LCO2 cryogenic fluid in contrast to wet machining at higher values of vc, f, and ap. The superior surface finish has been found in wet machining, while lesser power consumption was recorded for LCO2 as a cutting fluid. Cryogenic machining provided better chip breakability in comparison with wet machining.