Wear behavior of textured tools while turning Ti–6Al–4V under dry, minimum quantity lubrication (MQL) using canola oil and MQL using graphene blended in canola oil environment was discussed in this ...work. The tool wear and surface roughness were characterized to evaluate the textured tool's performance. It was revealed that the MQL (graphene mixed in canola oil) showed better results followed by MQL (only canola oil) and then dry condition. The excellent performance of graphene based MQL was mostly due to high thermal conductivity and shearing behavior of graphene. An increased shear angle (11–30%) and reduced coefficient of friction (16–39%) under graphene environment have contributed for enhanced performance of graphene-based MQL.
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•Wear behavior of textured tools during machining of titanium alloy has been investigated.•Texturing on tools improved the tribological behavior of cutting tool.•The use of graphene mixed canola oil resulted in better wear performance and lower roughness.•Increase of shear angle (11–30%) and reduction of friction (16–39%) using graphene mixed with canola oil.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UILJ, UL, UM, UPCLJ, UPUK, ZAGLJ, ZRSKP
Present investigation is focused to study the impact of different lubricating environments using pure canola oil and graphene mixed in canola oil, on the performance of uncoated carbide textured ...tools in minimum quantity lubrication (MQL) turning of AISI 4340 hardened steel. The influence of using twin jet and single jet was also studied under MQL. The turning performance was evaluated in terms of flank wear (VB
max
), cutting forces, cutting temperature, and chip morphology. The results showed that MQL mist supplied simultaneously on rake and flank face of the textured tool by twin-jet nozzle performed better than MQL mist supplied on the rake face of textured tool by the single-jet nozzle. Out of all the tested lubricating environments, best tool life was achieved with nanoparticle minimum quantity lubrication (NMQL) using the twin jet followed by only oil using twin jet as compared to all other conditions tested in this study. The outcome of the study illustrates that MQL mist of graphene which is mixed in canola oil on a textured tool with the twin-jet nozzle can be successfully applied for finish turning of hardened steel.
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EMUNI, FIS, FZAB, GEOZS, GIS, IJS, IMTLJ, KILJ, KISLJ, MFDPS, NLZOH, NUK, OBVAL, OILJ, PNG, SAZU, SBCE, SBJE, SBMB, SBNM, UKNU, UL, UM, UPUK, VKSCE, ZAGLJ
In this study, turning of titanium (Ti-6Al-4V) alloy under four different environments as dry, vegetable oil under minimum quantity lubrication (MQL), texture on the rake face filled with graphene ...particles, and graphene-mixed vegetable oil under nanoparticle-based minimum quantity lubrication (NMQL) with textured carbide tools is investigated. Results shows that maximum tool life, lower cutting forces, and minimum cutting temperature generated are with NMQL followed by MQL, texture filled with graphene, and dry turning. The tool life under NMQL is improved by 178 to 190%, main cutting force minimized by 36 to 40%, and cutting temperature reduced by 31 to 42% as compared with dry condition at various cutting speeds. The best turning performance is achieved under NMQL which is mainly due to higher thermal conductivity of MQL fluid mixture and shearing action imparted by graphene on different contact surfaces of tool. Further, the phenomena of improved thermal conductivity and shearing action imparted by graphene are explained by using transient hot-wire/SEM/Raman spectroscopy in this study. Finally, it is concluded that graphene has potential to act as lubricant/coolant in turning processes.
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DOBA, EMUNI, FIS, FZAB, GEOZS, GIS, IJS, IMTLJ, IZUM, KILJ, KISLJ, MFDPS, NLZOH, NUK, OBVAL, OILJ, PILJ, PNG, SAZU, SBCE, SBJE, SBMB, SBNM, SIK, UILJ, UKNU, UL, UM, UPUK, VKSCE, ZAGLJ
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.
The benefits of cutting fluids in machining are well known, but their use is accompanied by health and environment hazards. Moreover, strict environmental regulations make the manufacturers to switch ...over to dry turning, which is not feasible during machining of sticky material like stainless steel and Inconel etc. Therefore, the use of minimal quantities of lubricant (MQL) can be regarded as an alternative solution and a step towards green machining. In the present investigation an attempt has been made to explore the potential of MQL turning of stainless steel with coated carbide cutting tool. Turning under MQL conditions has shown superior results (in terms of flank wear and machined surface roughness) over wet and dry turning. Signal to noise (S/N) ratio as per Taguchi design revealed speed and MQL as significant parameters for minimizing flank wear and surface roughness, whereas feed can be set within range. The optimum combination of parameters are cutting speed (58 m/min), feed rate (0.06 mm/rev.) and MQL flow rate (100 mL/h) for flank wear and cutting speed (23 m/min), feed rate (0.07 mm/rev.) and MQL flow rate (150 mL/h) for surface roughness. Taguchi optimized conditions were validated through multiple response optimization using desirability function.
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EMUNI, FIS, FZAB, GEOZS, GIS, IJS, IMTLJ, KILJ, KISLJ, MFDPS, NLZOH, NUK, OILJ, PNG, SAZU, SBCE, SBJE, SBMB, SBNM, UKNU, UL, UM, UPUK, VKSCE, ZAGLJ
This paper highlights the detailed procedure for preparation of biocompatible sensors and transducers by CAD-CAM assisted investment casting (IC). Along with the properties such as biocompatibility ...and bioactivity, the presented materials possess good surface finish (required for aesthetic sense), acceptable dimensional accuracy (required for assembly purposes) and good surface hardness (required while chewing). In this paper efforts were made for improving surface hardness, finish, and dimensional accuracy of biocompatible materials by controlling composition/proportion of Ni and Cr in IC process. In this case study stir casting (SC) assisted Ni and Cr based metal matrix composites (MMC) has been prepared and composite prepared were poured in the investment mould. The result of study reveals that different material composition influenced the microstructure and the hardness of the MMC prepared. Further with change in weight percentage of Ni and Cr, different microstructures with particle clustering was observed. The employment of nickel and chromium composites for the fabrication of novel sensors and transducers is discussed.
Purpose - The purpose of this paper is to make out a complete solution to logistic outsourcing problem in a medium-scale organization by using consistent fuzzy preference relation (CFPR) and ...vlsekriterijumska optimizacija i kompromisno resenje (VIKOR) method.Design methodology approach - The initial approach to this research was to develop a comprehensive framework for logistic outsourcing problem and selection of most appropriate third party logistic (3PL) provider.Findings - It has been found that the organization should outsource logistic activities. The alternatives (3PL providers) have also been ranked and the fifth 3PL provider has been termed as best third party logistic provider.Research limitations implications - The parameters selected for this study and developed framework are applicable only to a medium-scale organization manufacturing automobile parts in northern India.Originality value - This is probably the first time that an attempt has been made to apply the two-phase methodology approach, using CFPR and VIKOR, to analyze a multi-criteria logistic outsourcing problem. A case is provided which demonstrates how to solve logistic outsourcing, a multi-criteria decision-making problem.
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.
In the present research work dimensional accuracy (Δd) of Al-Al2O3 based metal matrix composite (MMC) developed by combining stir casting with ABS replica based investment casting (IC) process has ...been highlighted. Three controllable factors of the IC process, namely: layer combination (LC), material composition (MC), pouring temperature (PT), were studied at three levels by Taguchi's parametric approach along with fixed parameters of stir casting process and single-response optimization was conducted to identify the main factor controlling Δd. Ceramic shell moulds were made on ABS plastic patterns (prepared by FDM process) using primary slurry and fused-silica sand as stucco. The final MMC prepared by stir casting process has been poured in these moulds. Finally results of study highlights the percentage contribution of different input parameters for Δd of MMC prepared by combined stir casting and IC process.
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GEOZS, IJS, IMTLJ, KILJ, KISLJ, NUK, OILJ, PNG, SAZU, SBCE, SBJE, UL, UM, UPCLJ, UPUK, ZRSKP
Stainless steel 304 (AISI 304), having wide industrial applications, exhibits poor machinability because of rapid work hardening and poor thermal conductivity. Therefore, cutting fluids are utilized ...to remove heat and provide lubrication in the machining zone, but their application pose serious environmental and health hazards, calling to minimize their use for green machining. Nano fluid minimum quantity lubrication (NMQL) technique provides an effective alternative to flooded cooling. Current study evaluates performance of NMQL in terms of tool wear and surface finish during face milling of AISI 304 steel. To enhance thermal conductivity of MQL, soluble multi walled carbon nano tubes (1% wt) were mixed in vegetable oil (cutting fluid). Cutting parameters were optimized to minimize tool wear and surface roughness and validation test also conducted under dry, flooded and pure MQL conditions to compare their performance with NMQL machining. Results revealed superiority of NMQL machining over dry, flooded and pure MQL conditions by 7.45%, 2.08% and 5.15% respectively, in terms of tool wear and 54.10%, 34.43% and 39.34 respectively, in terms of surface finish. Wear characterization of tools indicated less adhesion and abrasion marks on tool flank face during NMQL machining compared to dry and flood conditions.
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