Performance evaluation of textured carbide tools under environment-friendly minimum quantity lubrication turning strategies

Rupinder Singh1, J. S. Dureja2, Manu Dogra3
1Department of Mechanical Engineering, University School of Engineering and Technology, Rayat Bahra University, Mohali, India
2Department of Mechanical Engineering, Punjabi University, Patiala, India
3Department of Mechanical Engineering, Panjab University SSG Regional Centre, Hoshiarpur, India

Tóm tắt

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 (VBmax), 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.

Tài liệu tham khảo

Lawal SA, Choudhury IA, Nukman Y (2013) A case for minimum quantity lubrication using vegetable oil-based lubricant. J Clean Prod 41:210–221 Carou D, Rubio EM, Davim JP (2015) A note on the use of the minimum quantity lubrication (MQL) system in turning. Ind Lub Tribol 67(3):256–261 Makhesana MA et al (2016) Investigation to study the applicability of solid lubricants in machining for green manufacturing. Ind Lub Tribol 68(5):591–596. https://doi.org/10.1108/ilt-03-2015-0037 Sharma VS, Dogra M, Suri NM (2009) Cooling techniques for improved productivity in turning. Int J Mach Tools 49(6):435–453. https://doi.org/10.1016/j.ijmachtools.2008.12.010 Chetan J, Narasimhulu A, Ghosh S, Rao PV (2014) Study of tool wear mechanisms and mathematical modeling of flank wear during machining of Ti Alloy (Ti6Al4V). J Inst Eng India Ser C 96(3):279–285 Wójcik R, Nadolny K (2017) Effects of a variety of cutting fluids administered using the minimum quantity lubrication method on the surface grinding process for nickel-based alloys. J Zhejiang Univ Sci A 18(9):728–740 Khan MMA, Dhar NR (2006) Performance evaluation of minimum quantity lubrication by vegetable oil in terms of cutting force, cutting zone temperature, tool wear, job dimension and surface finish in turning AISI-1060 steel. J Zhejiang Univ Sci A 7:1790–1799 Chetan J, Behera BC, Ghosh S, Rao PV (2016) Application of nanofluids during minimum quantity lubrication: a case study in turning process. Tribol Int 101:234–246. https://doi.org/10.1016/j.triboint.2016.04.019 Srikant R, Prasad M, Amrita M et al (2014) Nanofluids as a potential solution for minimum quantity lubrication: a review. Proc Inst Mech Eng Part B J Eng Manuf 228(1):3–20. https://doi.org/10.1177/0954405413497939 Hadad M, Sadeghi B (2013) Minimum quantity lubrication-MQL turning of AISI 4140 steel alloy. J Clean Prod 54:332–343 Mia M, Dhar NR (2018) Effects of duplex jets high-pressure coolant on machining temperature and machinability of Ti–6Al–4V superalloy. J Mater Process Technol 252:688–696 Sharma V, Pandey PM (2016) Recent advances in turning with textured cutting tools: a review. J Clean Prod 137:701–715 Arslan A, Masjuki HH, Kalam MA et al (2016) Surface texture manufacturing techniques and tribological effect of surface texturing on cutting tool performance: a review. Crit Rev Solid State Mater Sci 8436:1–35 Lei Shuting, Devarajan Sasikumar, Chang Zenghu (2009) A comparative study on the machining performance of textured cutting tools with lubrication. Int J Mechatron Manuf Syst 2(4):401–413 Kawasegi N, Sugimori H, Morimoto H, Morita N, Hori I (2009) Development of cutting tools with microscale and nanoscale textures to improve frictional behavior. Precis Eng 33(3):248–254 Kiyota H, Itoigawa F, Nakamura T (2014) Mechanism of reduction in cutting force with micro textured tool. Key Eng Mater 612:489–490 Obikawa T, Kamio A, Takaoka H, Osada A (2011) Micro-texture at the coated tool face for high performance cutting. Int J Mach Tools Manuf 51(12):966–972 Orra K, Sounak C (2018) Tribological aspects of various geometrically shaped micro-textures on cutting insert to improve tool life in hard turning process. J Manuf Proc 31:502–513 Su Y, Gong L, Li B et al (2016) Performance evaluation of nanofluid MQL with vegetable-based oil and ester oil as base fluids in turning. Int J Adv Manuf Technol 83(9–12):2083–2089. https://doi.org/10.1007/s00170-015-7730-x Singh RK, Sharma AK, Dixit AR et al (2017) Performance evaluation of alumina-graphene hybrid nano-cutting fluid in hard turning. J Clean Prod 162:830–845 Sharma V, Pandey PM (2016) Geometrical design optimization of hybrid textured self-lubricating cutting inserts for turning 4340 hardened steel. Int Adv Manuf Technol 89:1575–1589 Bagchi SN, Parkash Kuldip (1979) Industrial steel reference book. Wiley, Calcutta, pp 145–146 WIDIA (2017) Master catalogue. https://www.widia.com/en/featured/widia-master-catalog-2017. Accessed 28 Mar 2018 Yu H, Deng H, Huang W, Wang X (2011) The effect of dimple shapes on friction of parallel surfaces. Proc Inst Mech Eng Part J J Eng Tribol 225:693–703. https://doi.org/10.1177/1350650111406045 Stoeterau RL, Janssen A, Mallmann G (2016) Friction analyses of dimple-structured surface. J Mech Eng Autom 6:269–276. https://doi.org/10.17265/2159-5275/2016.06.001 Sharma V, Pandey PM (2016) Comparative study of turning of 4340 hardened steel with hybrid textured self-lubricating cutting inserts. Mater Manuf Proc 31(14):1904–1916 Singh T, Singh P, Dureja JS (2016) A review of near dry machining/minimum quantity lubrication machining of difficult to machine alloys. Int J Mach Mach Mater 18(3):213–251 Kuram E, Ozcelik B, Demirbas E (2012) Environmentally friendly machining: vegetable based cutting fluids. In: Davim J (ed) Green manufacturing processes and systems. Materials forming, machining and tribology. Springer, Berlin, pp 23–47. https://doi.org/10.1007/978-3-642-33792-5_2 Whitener KE, Sheehan PE (2014) Graphene synthesis. Diam Relat Mater 46:25–34 Zhong Y, Zhen Z, Zhu H (2017) Graphene: fundamental research and potential applications solution phase methods. Flat Chem 4:20–32. https://doi.org/10.1016/j.flatc.2017.06.008 Lee Gwan, Hyoung Cooper, Ryan C et al (2013) High strength chemical-vapor-deposited graphene and grain boundaries. Science 340:1073–1076 Kim H, Seo K, Kim D (2016) Investigation of mechanical behavior of single- and multi-layer graphene by using molecular dynamics simulation. Int J Precis Eng Manuf 17(12):1693–1701. https://doi.org/10.1007/s12541-016-0196-4 Kumar P, Wani MF (2017) Synthesis and tribological properties of graphene: a review. J Tribol Malays Tribol Soc 13:36–71 Berman D, Erdemir A, Sumant AV (2014) A new emerging lubricant. Mater Today 17(1):31–42 Wu L, Gu L, Xie Z, Zhang C, Song B (2017) Improved tribological properties of Si 3N 4/GCr15 sliding pairs with few layer graphene as oil additives. Ceram Int 43(16):14218–14224 Arao Y, Kubouchi M (2015) High-rate production of few-layer graphene by high-power probe sonication. Carbon 95:802–808 Chu B, Singh E, Koratkar N, Samuel J (2013) Graphene-enhanced environmentally-benign cutting fluids for high-performance micro-machining applications. J Nanosci Nanotechnol 13(8):5500–5504 Przybylski R, Mag T, Eskin NAM, McDonald BE (2015) Canola oil. Bailey’s Ind Oil Fat Prod 6:61–121 Johnson DW, Dobson BP, Coleman KS (2015) A manufacturing perspective on graphene dispersions. Curr Opin Colloid Interface Sci 20(5–6):367–382 Dogra M, Sharma VS, Dureja J (2011) Effect of tool geometry variation on finish turning—a review. J Eng Sci Technol Rev 4(1):1–13 International Organization for Standardization. Tool-life testing with single point turning tools, ISO 3685–1993 (E), 2nd edn. Geneva 20, Switzerland ASTM International (2014) Standard test method for calibration and accuracy verification of wideband infrared thermometers. ASTM International, West Conshohocken (ASTM E2847-14) Chinchanikar S, Choudhury SK (2014) Hard turning using HiPIMS-coated carbide tools: wear behavior under dry and minimum quantity lubrication (MQL). J Int Meas Confed 55:536–548 Wu Z, Deng J, Su C et al (2014) Performance of the micro-texture self-lubricating and pulsating heat pipe self-cooling tools in dry cutting process. Int J Ref Met Hard Mater 45:238–248 Roy S, Ghosh A (2013) High speed turning of AISI 4140 steel using nanofluid through twin jet SQL system. In: ASME, conference on systems; micro and nano technologies, sustainable manufacturing, USA, 2. https://doi.org/10.1115/msec2013-1067 Berman D, Erdemir A, Sumant AV (2013) Reduced wear and friction enabled by graphene layers on sliding steel surfaces in dry nitrogen. Carbon 59:167–175 Groover MP (2002) Fundamentals of modern manufacturing, 2nd edn. Wiley, New York Stoeterau Rodrigo L, Andreas Janssen, Guilherme Mallmann (2016) Analysis of dimple textured surfaces on cutting tools. DOI, J Braz Soc Mech Sci Eng. https://doi.org/10.1007/s40430-016-0692-6 Williams J, Tabor D (1977) The role of lubricants in machining. Wear 43(3):275–292 Uysal Alper (2016) Investigation of flank wear in MQL milling of ferritic stainless steel by using nano graphene reinforced vegetable cutting fluid. Ind Lub Tribol 68(4):446–451 Berman D, Erdemir A, Sumant AV (2013) Few layer graphene to reduce wear and friction on sliding steel surfaces. Carbon 54:454–459