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1 – 10 of over 4000
Article
Publication date: 10 February 2021

Vaibhav Sidraya Ganachari, Uday Chate, Laxman Waghmode, Prashant Jadhav and Satish Mullya

Many engineering applications in this era require new age materials; however, some classic alloys like spring steel are still used in critical applications such as aerospace…

Abstract

Purpose

Many engineering applications in this era require new age materials; however, some classic alloys like spring steel are still used in critical applications such as aerospace, defense and automobile. To machine spring steel material, there exist various difficulties such as rapid tool wear rate, the rough surface formation of a workpiece and higher power consumption. The purpose of this paper is to address these issues, various approaches in addition to electrical discharge machines (EDM) are used such as dry EDM (DEDM) and near dry EDM (NDEDM).

Design/methodology/approach

This study focuses on these two approaches and their comparative analysis with respect to tool wear during machining of spring steel material. For this study, current, gap voltage, cycle time and dielectric medium pressure are considered input variables. This study shows that the near dry EDM approach yields better results. Hence, the thermo-electrical model for this approach is developed using ANSYS workbench, which is further validated by comparing with experimental results. This thermo-electrical model covers spark radius variation and formation of temperature profile due to electric discharge. Transient thermal analysis is used to simulate the electric discharge machining.

Findings

It is observed from this study that discharge environment parameters such as debris concentration and fluid viscosity largely influences the dielectric fluid pressure value. Experimental results revealed that NDEDM yields better results in comparison with DEDM as it shows a 25% lesser tool wear rate in NDEDM.

Originality/value

The range of predicted results and the experimental results are in close agreement, authenticating the model.

Details

World Journal of Engineering, vol. 18 no. 5
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 26 September 2023

Talwinder Singh, Chandan Deep Singh and Rajdeep Singh

Because many cutting fluids contain hazardous chemical constituents, industries and researchers are looking for alternative methods to reduce the consumption of cutting fluids in…

145

Abstract

Purpose

Because many cutting fluids contain hazardous chemical constituents, industries and researchers are looking for alternative methods to reduce the consumption of cutting fluids in machining operations due to growing awareness of ecological and health issues, government strict environmental regulations and economic pressures. Therefore, the purpose of this study is to raise awareness of the minimum quantity lubrication (MQL) technique as a potential substitute for environmental restricted wet (flooded) machining situations.

Design/methodology/approach

The methodology adopted for conducting a review in this study includes four sections: establishment of MQL technique and review of MQL machining performance comparison with dry and wet (flooded) environments; analysis of the past literature to examine MQL turning performance under mono nanofluids (M-NF); MQL turning performance evaluation under hybrid nanofluids (H-NF); and MQL milling, drilling and grinding performance assessment under M-NF and H-NF.

Findings

From the extensive review, it has been found that MQL results in lower cutting zone temperature, reduction in cutting forces, enhanced tool life and better machined surface quality compared to dry and wet cutting conditions. Also, MQL under H-NF discloses notably improved tribo-performance due to the synergistic effect caused by the physical encapsulation of spherical nanoparticles between the nanosheets of lamellar structured nanoparticles when compared with M-NF. The findings of this study recommend that MQL with nanofluids can replace dry and flood lubrication conditions for superior machining performance.

Practical implications

Machining under the MQL regime provides a dry, clean, healthy and pollution-free working area, thereby resulting the machining of materials green and environmentally friendly.

Originality/value

This paper describes the suitability of MQL for different machining operations using M-NF and H-NF.

Peer review

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2023-0131/

Details

Industrial Lubrication and Tribology, vol. 75 no. 9
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 31 December 2018

Talwinder Singh, J.S. Dureja, Manu Dogra and Manpreet S. Bhatti

The purpose of this paper is to investigate the influence of turning parameters such as cutting speed, feed rate and depth of cut on tool flank wear and machined surface quality…

Abstract

Purpose

The purpose of this paper is to investigate the influence of turning parameters such as cutting speed, feed rate and depth of cut on tool flank wear and machined surface quality of AISI 304 stainless steel during environment friendly turning under nanofluid minimum quantity lubrication (NMQL) conditions using PVD-coated carbide cutting inserts.

Design/methodology/approach

Turning experiments are conducted as per the central composite rotatable design under the response surface methodology. ANOVA and regression analysis are employed to examine significant cutting parameters and develop mathematical models for VB (tool flank wear) and Ra (surface roughness). Multi-response desirability optimization approach is used to investigate optimum turning parameters for simultaneously minimizing VB and Ra.

Findings

Optimal input turning parameters are observed as follows: cutting speed: 168.06 m/min., feed rate: 0.06 mm/rev. and depth of cut: 0.25 mm with predicted optimal output response factors: VB: 106.864 µm and Ra: 0.571 µm at the 0.753 desirability level. ANOVA test reveals depth of cut and cutting speed-feed rate interaction as statistically significant factors influencing tool flank wear, whereas cutting speed is a dominating factor affecting surface roughness. Confirmation tests show 5.70 and 3.71 percent error between predicted and experimental examined values of VB and Ra, respectively.

Research limitations/implications

AISI 304 is a highly consumed grade of stainless steel in aerospace components, chemical equipment, nuclear industry, pressure vessels, food processing equipment, paper industry, etc. However, AISI 304 stainless steel is considered as a difficult-to-cut material because of its high strength, rapid work hardening and low heat conductivity. This leads to lesser tool life and poor surface finish. Consequently, the optimization of machining parameters is necessary to minimize tool wear and surface roughness. The results obtained in this research can be used as turning database for the above-mentioned industries for attaining a better machined surface quality and tool performance under environment friendly machining conditions.

Practical implications

Turning of AISI 304 stainless steel under NMQL conditions results in environment friendly machining process by maintaining a dry, healthy, clean and pollution free working area.

Originality/value

Machining of AISI 304 stainless steel under vegetable oil-based NMQL conditions has not been investigated previously.

Details

Multidiscipline Modeling in Materials and Structures, vol. 15 no. 3
Type: Research Article
ISSN: 1573-6105

Keywords

Article
Publication date: 7 October 2021

Amrita Maddamasetty, Kamesh Bodduru, Siva Bevara, Rukmini Srikant Revuru and Sanjay Kumar

Inconel 718 is difficult to machine due to its high toughness and study hardenability. Though the use of cutting fluids alleviates the problem, it is not sustainable. So, supply…

Abstract

Purpose

Inconel 718 is difficult to machine due to its high toughness and study hardenability. Though the use of cutting fluids alleviates the problem, it is not sustainable. So, supply of a small quantity of specialized coolant to the machining zone or use of a solid lubricant is a possible solution. The purpose of the present work is to improve machinability of Inconel718 using graphene nanoplatelets.

Design/methodology/approach

In the present study, graphene is used in the machining of Inconel 718 alloy. Graphene is applied in the following two forms: as a solid lubricant and as an inclusion in cutting fluid. Graphene-based self-lubricating tool and graphene added nanofluids are prepared and applied to turning of Inconel 718 at varying cutting velocities. Performances are compared by measuring cutting forces, cutting temperature, tool wear and surface roughness.

Findings

Graphene, in both forms, showed superior performance compared to dry machining. In total, 0.3 Wt.% graphene added nanofluids showed the lowest cutting tool temperature and flank wear with 44.95% and 83.37% decrease, respectively, compared to dry machining and lowest surface roughness, 0.424 times compared to dry machining at 87 m/min.

Originality/value

Graphene could improve the machinability of Inconel 718 when used in tools as a solid lubricant and also when used as a dispersant in cutting fluid. Graphene used as a dispersant in cutting fluid is found to be more effective.

Details

World Journal of Engineering, vol. 19 no. 4
Type: Research Article
ISSN: 1708-5284

Keywords

Article
Publication date: 8 June 2010

Nourredine Boubekri, Vasim Shaikh and Phillip R. Foster

The purpose of this paper is twofold. First review the relevant literature in machining using minimum quantity lubrication (MQL), contrast the economical, environmental, and…

1598

Abstract

Purpose

The purpose of this paper is twofold. First review the relevant literature in machining using minimum quantity lubrication (MQL), contrast the economical, environmental, and technical attributes of this technology to conventional flood‐cooling techniques. Second highlight areas of relevant future research.

Design/methodology/approach

The approach consists of describing the essential elements of MQL as a technology, reviewing the relevant research by focusing on the most frequently used machining processes in this industry, highlighting the findings as they compare to flood cooling, and pointing to directions of required research in this technology.

Findings

The application of MQL in machining has shown better results in some processes; including in drilling, a cleaner environment, and a more cost‐effective machining technology. Further research is required however to better understand the underlying cause an effect phenomena in machining using microlubrication technology including environmental and health effects of this technology.

Practical implications

The paper provides a body of knowledge required for all stakeholders to better use or design machining systems using microlubrications.

Originality/value

This paper focuses on the state of the art of MQL and how it contrasts with conventional methods of machining.

Details

Journal of Manufacturing Technology Management, vol. 21 no. 5
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 30 April 2019

Pragat Singh, J.S. Dureja, Harwinder Singh and Manpreet S. Bhatti

This study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304…

Abstract

Purpose

This study aims to use nanofluid-based minimum quantity lubrication (NMQL) technique to minimize the use of cutting fluids in machining of Inconel-625 and Stainless Steel 304 (SS-304) (Ni-Cr alloys).

Design/methodology/approach

Machining of Ni-Cr-based alloys is very challenging as these exhibit lower thermal conductivity and rapid work hardening. So, these cannot be machined dry, and a suitable cutting fluid has to be used. To improve the thermal conductivity of cutting fluid, multi-walled carbon nanotubes (MWCNTs) were added to the soybean oil and used with MQL. This study attempts to compare tool wear of coated carbide inserts during face milling of Inconel-625 and SS-304 under dry, flooded and NMQL conditions. The machining performance of both materials, i.e. Inconel-625 and SS-304, has been compared on the basis of tool wear behavior evaluated using scanning electron microscopy-energy dispersive spectroscopy.

Findings

The results indicate higher tool wear and lower tool life during machining of Inconel-625 as compared to SS-304. Machining of Inconel-625 exhibited non-consistent tool wear behavior. The tool failure modes experienced during dry machining are discrete fracture, cracks, etc., which are completely eliminated with the use of NMQL machining. In addition, less adhesion wear and abrasion marks are noticed as compared to dry and flooded machining, thereby enhancing the tool life.

Research limitations/implications

Inconel-625 and SS-304 have specific applications in aircraft and aerospace industry, where sculptured surfaces of the turbine blades are machined. The results of current investigation will provide a rich data base for effective machining of both materials under variety of machining conditions.

Originality/value

The literature review indicated that majority of research work on MQL machining has been carried out to explore machining of Ni-Cr alloys such as Inconel 718, Inconel 800, AISI4340, AISI316, AISI1040, AISI430, titanium alloys, hardened steel alloys and Al alloys. Few researchers have explored the suitability of nanofluids and vegetable oil-based cutting fluids in metal cutting operation. However, no literature is available on face milling using nanoparticle-based MQL during machining Inconel-625 and SS-304. Therefore, experimental investigation was conducted to examine the machining performance of NMQL during face milling of Inconel-625 and SS-304 by using soybean oil (vegetable oil) with MWCNTs to achieve ecofriendly machining.

Article
Publication date: 6 March 2009

Matthew Siniawski and Chris Bowman

The purpose of this paper is to provide a practical review of metal working fluids and their implications to the machining practice. Despite their widespread use and applications…

Abstract

Purpose

The purpose of this paper is to provide a practical review of metal working fluids and their implications to the machining practice. Despite their widespread use and applications, there are several scientific and economic factors that call for an investigation of current practices and development of new approaches.

Design/methodology/approach

There are numerous methods that diverge from traditional “wet” machining, which move towards an environmentally friendly and cost effective machining process. This includes looking at both minimum quantity lubrication and dry machining as methods to reduce recurring costs, lower health care premiums associated to metalworking fluid exposure, and to minimize the environmental footprint attributed to machining.

Findings

Traditional machine lubrication techniques are in use today despite a lack of scientific or economic evidence that they function efficiently. Depending on the machine type and material used, there are several possible methods that can minimize or eliminate metalworking fluids from the machining process.

Practical implications

This paper provides a practical assessment of current industrial practices and offers opportunities for improvement from both an economic and an environmental perspective.

Originality/value

This paper provides an overview of previously conducted research to suggest areas of improvement in manufacturing processes utilizing metalworking fluids.

Details

Industrial Lubrication and Tribology, vol. 61 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 13 April 2015

Diego Carou, Eva M. Rubio and J Paulo Davim

The purpose of this paper is to provide a practical review of the use of the minimum quantity lubrication (MQL) system in turning operations, focussing on the application of the…

Abstract

Purpose

The purpose of this paper is to provide a practical review of the use of the minimum quantity lubrication (MQL) system in turning operations, focussing on the application of the technique in the turning of different kind of materials.

Design/methodology/approach

The use of the MQL system was analysed by several researchers in the past years. Thus, in the present paper, a relevant sample of the main experimental studies that can be found in the literature was analysed to come up with a review with relevant information for researchers and industry.

Findings

The use of the MQL system can help to improve the outcomes of the turning process in several issues like surface quality or tool life. However, it was also recognised that in some cases, other cooling/lubricating methods can provide better results than the MQL system. Thus, the decision, whether to use or not the MQL system in a specific process, is of great importance.

Originality/value

The work is conveniently focussed to serve as a quick reference on the issue. At the same time, the work analysed the use of the turning of some of the main engineering materials that makes it useful for a wider range of researchers and metalworking firms. Finally, the review could be useful to improve the performance of the industry, especially for the metalworking firms in terms of costs, environmental impact and safety.

Details

Industrial Lubrication and Tribology, vol. 67 no. 3
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 10 December 2018

Aqib Mashood Khan, Muhammad Jamil, Ahsan Ul Haq, Salman Hussain, Longhui Meng and Ning He

Sustainable machining is a global consensus and the necessity to cope up the serious environmental threats. Minimum quantity lubrication (MQL) and nanofluids-based MQL(NFMQL) are…

Abstract

Purpose

Sustainable machining is a global consensus and the necessity to cope up the serious environmental threats. Minimum quantity lubrication (MQL) and nanofluids-based MQL(NFMQL) are state-of-the-art sustainable lubrication modes. The purpose of this study is to investigate the effect of process parameters, such as feed rate, depth of cut and cutting fluid flow rate, on temperature and surface roughness of the manufactured pieces during face milling of the AISI D2 steel.

Design/methodology/approach

A statistical technique called response surface methodology with Box–Behnken Design was used to design experimental runs, and empirical modeling was presented. Analysis of variance was carried out to evaluate the model’s accuracy and the validation of the applied technique.

Findings

A comprehensive analysis revealed the superiority of implementing NFMQL in comparison to MQL within the levels of process parameters. The comparison has shown a significant reduction of temperature under NFMQL at the tool-workpiece interface from 16.2 to 34.5 per cent and surface roughness from 11.3 to 12 per cent.

Practical implications

This research is useful for practitioners to predict the responses in workshop and select appropriate cutting parameters. Moreover, this research will be helpful to reduce the resource which will ultimately save energy consumption and cost.

Originality/value

To cope with the industrial challenges and tribological issues associated with the milling of AISI D2 steel, experiments were conducted in a distinct machining mode with innovative cooling/lubrication. Until now, few studies have addressed the key lubrication effects of Al2O3-based nanofluid on the machinability of D2 steel under NFMQL lubrication condition.

Details

Industrial Lubrication and Tribology, vol. 71 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

Article
Publication date: 13 December 2018

Yusuf S. Dambatta, Mohd Sayuti, Ahmed A.D. Sarhan, Hamdi Bin Ab Shukor, Nur Aqilah binti Derahman and Sunusi Marwana Manladan

Optimisation of grinding processes involves enhancing the surface quality and reducing the cost of manufacturing through reduction of power consumptions. Recent research works…

292

Abstract

Purpose

Optimisation of grinding processes involves enhancing the surface quality and reducing the cost of manufacturing through reduction of power consumptions. Recent research works have indicated the minimum quantity lubrication (MQL) system is used to achieve near dry machining of alloys and hard materials. This study aims to provide an experimental analysis of the grinding process during machining of aluminium alloy (Al6061-T6). MQL nanofluid was used as the lubricant for the grinding operations. The lubricant was formed by suspending silicon dioxide nanoparticles in canola vegetable oil. The effect of input parameters (i.e. nanoparticle concentration, depth of cut, air pressure and feed rate) on the grinding forces and surface quality was studied. Adaptive neuro-fuzzy inference system (ANFIS) prediction modelling was used to predict the specific normal force, specific tangential force and surface quality, the ANFIS models were found to have prediction accuracies of 97.4, 96.6 and 98.5 per cent, respectively. Further study shows that both the specific grinding forces and surface roughness are inversely proportional to the nanofluid concentration. Also, the depth of cut and table feed rate were found to have a directly proportional relationship with both the grinding forces and surface roughness. Moreover, higher MQL air pressure was found to offer better delivery of the atomised nanofluid into the grinding region.

Design/methodology/approach

Grinding experiments were performed using MQL nanofluid as the lubricant. The lubricant was formed by suspending silicon dioxide nanoparticles in canola vegetable oil. The effect of input parameters (i.e. nanoparticle concentration, depth of cut, air pressure and feed rate) on the grinding forces and surface quality has been studied.

Findings

The grinding process parameters were optimised using Taguchi S/N ratio analysis, whereas the prediction of the response parameters was done using ANFIS modelling technique. The developed ANFIS models for predicting the specific normal force, specific tangential force and surface quality were found to have prediction accuracies of 97.4, 96.6 and 98.5 per cent, respectively. Further findings show that both the specific grinding forces and surface roughness are inversely proportional to the percentage of nanoparticle concentration in the lubricant. Also, the depth of cut and table feed rate were found to exhibit a direct proportional relationship with both the grinding forces and surface roughness, while high MQL air pressure was observed to offer more efficient delivery of the atomised nanofluid into the grinding region.

Practical implications

The work can applied into manufacturing industries to prevent unnecessary trials and material wastages.

Originality/value

The purpose of this study is to develop an artificial intelligent model for predicting the outcomes of MQL grinding of the aluminium alloy material using ANFIS modelling technique.

Details

Industrial Lubrication and Tribology, vol. 71 no. 2
Type: Research Article
ISSN: 0036-8792

Keywords

1 – 10 of over 4000