Evaluation of mist flow characteristic and performance in Minimum Quantity Lubrication (MQL) machining

Minimum Quantity Lubrication (MQL) is an alternative method to supply the cutting fluid in the formation of mist. MQL has proven to reduce machining cost and increase machining performance. The effectiveness and the working principle of MQL are still questionable with very few explanations provided. The present study is conducted to investigate the performance of MQL technique with different combination of spray and machining parameters. The Phase Doppler Anemometry (PDA) was used to characterize the lubricant spray under different input pressure for various nozzle outlet diameter of 2.5 mm (OD25) and 3.0 mm (OD30). This device can measure the amount of droplet and size. From these results, the distance of the nozzle to the cutting tip can be estimated. The turning performance in terms of cutting force and cutting temperature was evaluated under three levels of cutting speed and two levels of feed rate and at a constant depth of cut. The result shows that the most suitable mist flow pattern during machining was the largest spray cone angle supplied under 0.4 MPa input air pressure. In addition, significant reduction of cutting force and cutting temperature were obtained when using OD30 nozzle at the nozzle distances of 6–9 mm and the input air pressure of 0.4 MPa

Human machine interface design analysis of defect detection prototype by wonderware intouch software

Human Machine Interface (HMI) serves as a bridge for operators to understand the processes that occur on the machine. Without HMI, operators will have difficulty in monitoring and controlling the machine. HMI used in this study using Wonderware InTouch software. The HMI design that is used, displays the home button, as the start screen. There are two options in the home menu, which is the option to login as an identification and classification operator. To start operation and enter the monitoring window, any operator that uses this HMI must login using a username and password. The function of HMI in this research is as a connector between operators with machine. In this paper we have presented the human machine interface design of defect detection prototype by wonderware intouch software. Based on the tested results can be concluded that the designed is successfully

Three dimensional finite element modeling, when drilling of Ti-6Al-4V

Finite element modeling (FEM) is widely used to optimize machining processes, to predict and analyze the cutting force, cutting temperature and other related responses. Most of the FEM studies were conducted under the two dimensional orthogonal cutting. Drilling process, which involves oblique cutting is not suitable for orthogonal cutting modelling. Therefore, an attempt to simulate a three dimensional simulation of the drilling process is required. A commercially available software called DEFORM is used to accomplish the task. The value of thrust force from the simulation is compared with the experimental results and they are both in a good agreement. Comparison of the drill temperature at TC1 and TC2 are within an error margin of 12%

Machining performance of vegetable oil with phosphonium- and ammonium-based ionic liquids via MQL technique

Thermo-mechanical loads are the main factor that influences the tool wear and product surfaces during machining processes. Lubrication in metal cutting is an effective medium to reduce frictional forces and wear on the tool-workpiece interfaces. On this regards, the advantages of using refined bio-based metalworking fluids (MWFs) with the presence of low toxic, biocompatible and oil-miscible ionic liquids (ILs) additives ([N1,8,8,8][NTf2] (AIL) & [P6,6,6,14][(iC8)2PO2] (PIL)) at nominal weight concentrations of 1, 5 and 10% are explored during orthogonal cutting of AISI 1045 steel. Accordingly, the lubricants are supplied via minimum quantity lubrication (MQL) technique and comparative studies are conducted against the performance of the neat modified Jatropha-based lubricant (MJO) and commercially available synthetic ester-based MQL cutting fluid (SE). The combination of mist supply of the MJOs during machining have a great impact on cleaner production that eliminates the excessive usage of fluids and supports the utilization of environmentally friendly chemicals. This work extends the application of a minute quantity of fully miscible ILs in polar vegetable-based MWF which proven to provide a significant improvement on the lubrication effect of the MJO. MJOþAIL10% and MJOþPIL1% showed the best cutting performance amongst all lubricant mixtures with reduction of cutting forces and specific cutting energy by 4 to 5%, cutting temperatures by 7 to 10%, friction coefficient by 2 to 3%, tool-chip contact length by 8 to 11%, chip thickness by 22 to 25%, friction angle by 1 to 2% and increased shear angle by 25 to 29% compared to the SE. Besides, the effect of low friction and reduced cutting forces produced lower specific cutting energy that promotes “greener” and more sustainable working environment

Tribological performance of modified jatropha oil containing oil-miscible ionic liquid, for machining applications

Modifying physicochemical and tribological properties of a bio-based lubricant is essential in improving its lubrication performances. This paper presents the effectiveness of a fully oil-miscible Ionic liquid (IL) as lubricant additive into a bio-based lubricant. Methyltrioctylammonium bis(trifluoromethylsulfonyl)imide (AIL) was selected as IL additive to improve the tribological performance of the bio- based lubricant. Additive was mixed into the bio-based lubricant at three levels of mass concentrations (1 wt.%, 5 wt.% & 10 wt.%). Tribology tests on steel/steel contacts were conducted to evaluate the lubricant samples. Test outputs were benchmarked against the neat bio-based lubricant. Results revealed good synergistic effect of the AIL additive blended into the bio-based lubricant. MJO+AIL10 % has shown good corrosion inhibition, superior friction reduction (48 %), lower worn surface area (23 %), excellent surface finish (46 %) and increased tapping torque efficiency (8 %). MJO+AIL10 % provided excellent tribological performances which corresponds to the energy saving and environmental benefit for sustainable machining applications

Comparison between Dry, MQL, and Cryogenic Cooling Technique on Surface Integrity of Burnished Surface

Environmental concerns has contributed towards higher demands for green products. Therefore, various machining conditions, such as dry and near dry machining have been introduced to resolve the cutting fluid problem. However, the application of cryogenic cooling still not well understood especially for burnishing process. It is essential to initiate a study on the effect of cryogenic cooling technique to substitute other techniques to improvement burnishing process. Carbon dioxide is used as the cryogenic gas under supercritical state, and compare with dry and minimal quantity lubricant. Solid carbide burnishing tool is used with a diameter and corner radius of 16 mm and 1 mm, respectively. The result shows that burnishing process under cryogenic condition recorded less burn mark and better tool wear than dry and MQL conditions. In addition, cryogenic condition exhibits significant grain refinement and surface hardness. In conclusion, the performance of carbon dioxide gas under supercritical state outperformed other coolant conditions

Tribological Interaction of Bio-Based Metalworking Fluids in Machining Process

Metalworking fluids were applied during the machining process to lubricate and cool the machine tool in order to reduce wear, friction, and heat generated. The increasing attention to the environment and health impacts leads to the formulation of eco-friendly metalworking fluids derived from vegetable oils (Jatropha and palm oils) to substitute the use of mineral-based oil. The present work focuses on the performance of refined bio-based metalworking fluids during tapping torque and orthogonal cutting processes. Bio-based metalworking fluids were formulated using 0.05 wt.% of hexagonal boron nitride (hBN) and 1 wt.% of phosphonium-based ionic liquid [P66614][(iC8)2PO2] in a modified Jatropha and palm olein oils and were examined for their rheological properties in comparison with a commercially obtained synthetic ester (SE)-based cutting fluid. The tapping torque performance of the refined bio-based metalworking fluids was evaluated for their torque and efficiency. In addition, the performance of these bio-based metalworking fluids on orthogonal cutting parameters such as cutting force, cutting temperature, chip thickness, tool-chip contact length, and specific cutting energy was highlighted. The results obtained revealed that the rheological properties of the newly formulated bio-based metalworking fluids were improved. From the tapping torque and orthogonal cutting performances, it was proven that the modified palm and Jatropha oils possess good anti-wear and anti-friction behavior compared to SE. In conclusion, the newly formulated bio-based metalworking fluids are suitable for the use as a new advanced renewable metalworking fluid for machining processes that correspond to the energy-saving benefits and environmental concerns

A performance of 2 dimensional ultrasonic vibration assisted milling in cutting force reduction, on aluminium AL6061

This paper were investigate a performance of 2 Dimensional Ultrasonic Vibration assisted Milling (UVAM) toward Aluminium Al 6061. The focus is to find the performance of reduction of cutting force compared to the conventional machining in the industries shop floor. Due to the major effect of cutting force of production in industries, the excessive cutting force problem must be investigated deeply as it will cause shortens tool life and reduces the production rate. A scientific approach has been found in order to reduce the cutting force during machining which is integrating the ultrasonic concept into workpiece. The modelling of vibration cutting ratio has been simulated to find the time force contact and non-contact. Thus, less cutting force could be found. The ultrasonic vibration platform that generated by XY25XS from Cedrat Technologies is travelled in X direction as a feed movement. Thus, the X and Y axis vibration actuate along the workpiece for the machining process. The performance of UVAM in cutting force reduction found the superior benefits of UVAM is come from the alternating cycle’s between tool and workpiece. The comparison between UVAM and conventional machining in reduction of cutting force is 32%. The potential of the UVAM tool wear and tool life will be discussed deeply in finding and next in the conclusion section

A study on cryogenic supercritical carbon dioxide coolant delivery technique when machining of AISI 1045 steel

The machining operation involves a material removal process and develop high temperature due to the friction force. The heat generated at the region of cutting edge has critical influences on machining process. It can increase cutting tool wear, reduce tool life, get rise to thermal deformation and might consequence to microcracks. The application of cutting fluid at the cutting zone by conventional process could overcomes the aforementioned problems to some extent via cooling and lubrication process. However, the waste of cutting fluid might be profuse and its impact on the environment. A new efficient process, cryogenic cooling using carbon dioxide gas (CO2) has been introduced on improving the cooling process. This technique is more economical in coolant usage while maintaining significant performance including cutting temperature, cutting force and surface roughness. The pulse mode of CO2 cooling spray under supercritical state has been used to corroborate the machining process by reducing the cutting zone temperature as to reducing coolant usage