Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel

Cooling fluids have been used successfully in machining processes to suppress tool wear, enhance surface quality, and reduce the cutting forces and temperature. However, cooling fluids have negative effects on the cost of handling and the environment. Furthermore, under Minimum Quantity Lubrication...

Full description

Saved in:

Bibliographic Details
Main Author:	Majeed, Faraj Saeid Adrees
Format:	Thesis
Language:	English
Published:	2022
Subjects:	TJ Mechanical engineering and machinery
Online Access:	http://eprints.utm.my/id/eprint/99330/1/FarajSaeidPSKM2022.pdf
Tags:	Add Tag No Tags, Be the first to tag this record!

id	my-utm-ep.99330
record_format	uketd_dc
spelling	my-utm-ep.993302023-02-22T08:20:38Z Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel 2022 Majeed, Faraj Saeid Adrees TJ Mechanical engineering and machinery Cooling fluids have been used successfully in machining processes to suppress tool wear, enhance surface quality, and reduce the cutting forces and temperature. However, cooling fluids have negative effects on the cost of handling and the environment. Furthermore, under Minimum Quantity Lubrication (MQL) conditions, the usage of mineral oil-based cooling fluid for hard turning is found to be unsatisfactory. The aim of this study was to evaluate the performance of titanium aluminium nitride (TiAlN) coated carbide cutting tool (KC5010) when turning martensitic stainless steel (AISI 420) with hardness of 48±1 HRC under MQL conditions. The cooling fluid flow rate and air pressure were employed at 50 ml/h and 5 bar, respectively. In the first Phase, seven experiments were conducted at medium cutting speed and medium feed (135 m/min, 0.20 mm/rev) (MM), under MQL using different cooling fluids. The cooling fluids used were paraffin oil and nanofluids consisting of the mixtures of paraffin oil with iron oxide (γ-Fe2O3) nanoparticles as well as with nano graphene (xGnP). The concentration of nanofluids were 0.40% (1.6g), 0.80% (3.2g), and 1.20% (6.4g) by weight of γ-Fe2O3 and xGnP. The sizes of γ-Fe2O3 and xGnP nanoparticles were ≤10 nm, and these were separately added to 400g of paraffin oil. Among others, the evaluation was in terms of tool life, surface roughness, cutting forces and vibration. Based on the result of Phase 1, different cutting parameters were investigated in Phase 2, where MQL using cooling fluid consisting of a mixture of paraffin oil and 0.80% wt γ-Fe2O3 was selected for further investigation. This concentration of nanofluid performed best in terms of tool life, surface roughness, vibration and cutting forces when compared to the other cooling fluids investigated in Phase 1. The tool life improvement was 47.5% and 46.8% compared to paraffin oil and xGnP nanofluid, respectively. Surface roughness was enhanced by 83.3% and 44.4% compared to paraffin oil and xGnP nanofluid conditions, respectively. The vibration level decreased by 33.5% when using 0.80% wt γ-Fe2O3 compared to 0.40% wt xGnP, and cutting forces (feed force) were reduced by 4.6% and 46.2% compared to paraffin oil and xGnP nanofluid conditions, respectively. The cutting conditions investigated in Phase 2 were low (L), medium (M) and high (H) combinations of cutting speeds (100, 135 and 170 m/min) and feed rates (0.16, 0.20 and 0.24 mm/rev). This involved a further eight experimental conditions (i.e. LL, LM, LH, ML, MH, HL, HH, and HM). The eight experimental conditions, when combined with the MM condition of Phase 1 results in a two-factor, three-level full factorial design with two center points. In Phase 2, better surface roughness and lower cutting forces were obtained at LH. However, the longest tool life and the highest material removal rate were obtained at a low cutting speed and feed rate. A combination of adhesion wear and abrasion wear was the dominant wear mechanisms. Catastrophic failure occurred at high cutting speed and feed rate, resulting in the shortest tool life among all experiments. The flank and crater wears were dominant at low and medium cutting speeds and feed rates. Continuous chips were observed at low speed and saw tooth chip at high feed rate. Empirical models for the various machining responses were developed and these were used to determine the optimum process parameters within the limits investigated. 2022 Thesis http://eprints.utm.my/id/eprint/99330/ http://eprints.utm.my/id/eprint/99330/1/FarajSaeidPSKM2022.pdf application/pdf en public http://dms.library.utm.my:8080/vital/access/manager/Repository/vital:149282 phd doctoral Universiti Teknologi Malaysia, Faculty of Engineering - School of Mechanical Engineering Faculty of Engineering - School of Mechanical Engineering
institution	Universiti Teknologi Malaysia
collection	UTM Institutional Repository
language	English
topic	TJ Mechanical engineering and machinery
spellingShingle	TJ Mechanical engineering and machinery Majeed, Faraj Saeid Adrees Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel
description	Cooling fluids have been used successfully in machining processes to suppress tool wear, enhance surface quality, and reduce the cutting forces and temperature. However, cooling fluids have negative effects on the cost of handling and the environment. Furthermore, under Minimum Quantity Lubrication (MQL) conditions, the usage of mineral oil-based cooling fluid for hard turning is found to be unsatisfactory. The aim of this study was to evaluate the performance of titanium aluminium nitride (TiAlN) coated carbide cutting tool (KC5010) when turning martensitic stainless steel (AISI 420) with hardness of 48±1 HRC under MQL conditions. The cooling fluid flow rate and air pressure were employed at 50 ml/h and 5 bar, respectively. In the first Phase, seven experiments were conducted at medium cutting speed and medium feed (135 m/min, 0.20 mm/rev) (MM), under MQL using different cooling fluids. The cooling fluids used were paraffin oil and nanofluids consisting of the mixtures of paraffin oil with iron oxide (γ-Fe2O3) nanoparticles as well as with nano graphene (xGnP). The concentration of nanofluids were 0.40% (1.6g), 0.80% (3.2g), and 1.20% (6.4g) by weight of γ-Fe2O3 and xGnP. The sizes of γ-Fe2O3 and xGnP nanoparticles were ≤10 nm, and these were separately added to 400g of paraffin oil. Among others, the evaluation was in terms of tool life, surface roughness, cutting forces and vibration. Based on the result of Phase 1, different cutting parameters were investigated in Phase 2, where MQL using cooling fluid consisting of a mixture of paraffin oil and 0.80% wt γ-Fe2O3 was selected for further investigation. This concentration of nanofluid performed best in terms of tool life, surface roughness, vibration and cutting forces when compared to the other cooling fluids investigated in Phase 1. The tool life improvement was 47.5% and 46.8% compared to paraffin oil and xGnP nanofluid, respectively. Surface roughness was enhanced by 83.3% and 44.4% compared to paraffin oil and xGnP nanofluid conditions, respectively. The vibration level decreased by 33.5% when using 0.80% wt γ-Fe2O3 compared to 0.40% wt xGnP, and cutting forces (feed force) were reduced by 4.6% and 46.2% compared to paraffin oil and xGnP nanofluid conditions, respectively. The cutting conditions investigated in Phase 2 were low (L), medium (M) and high (H) combinations of cutting speeds (100, 135 and 170 m/min) and feed rates (0.16, 0.20 and 0.24 mm/rev). This involved a further eight experimental conditions (i.e. LL, LM, LH, ML, MH, HL, HH, and HM). The eight experimental conditions, when combined with the MM condition of Phase 1 results in a two-factor, three-level full factorial design with two center points. In Phase 2, better surface roughness and lower cutting forces were obtained at LH. However, the longest tool life and the highest material removal rate were obtained at a low cutting speed and feed rate. A combination of adhesion wear and abrasion wear was the dominant wear mechanisms. Catastrophic failure occurred at high cutting speed and feed rate, resulting in the shortest tool life among all experiments. The flank and crater wears were dominant at low and medium cutting speeds and feed rates. Continuous chips were observed at low speed and saw tooth chip at high feed rate. Empirical models for the various machining responses were developed and these were used to determine the optimum process parameters within the limits investigated.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Majeed, Faraj Saeid Adrees
author_facet	Majeed, Faraj Saeid Adrees
author_sort	Majeed, Faraj Saeid Adrees
title	Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel
title_short	Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel
title_full	Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel
title_fullStr	Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel
title_full_unstemmed	Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel
title_sort	performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of aisi420 stainless steel
granting_institution	Universiti Teknologi Malaysia, Faculty of Engineering - School of Mechanical Engineering
granting_department	Faculty of Engineering - School of Mechanical Engineering
publishDate	2022
url	http://eprints.utm.my/id/eprint/99330/1/FarajSaeidPSKM2022.pdf
_version_	1776100590788542464

Performance of minimum quantity lubrication using paraffin based nanofluids during hard turning of AISI420 stainless steel

Similar Items